Meat processing and waste water treatment - example of a treatment plant 1
The waste water treatment plant for a customer producing fresh processed meat, smoked products and specialties and delicatessen products of cold and hot cuisine is being completed these days. It is a smaller work and its primary goal is to pre-treat wastewater to such parameters that water could flow into the public sewer and further to the municipal wastewater treatment plant. The technology is composed of four parts - mechanical pre-treatment, balancing of irregularity in quality and quantity in a balancing tank, flotation, where the largest amount of pollution is removed in the form of sludge and the last stage is sludge treatment.
Period of grape harvest and wine production is approaching – how can be waste water form such an industry treated?
A project for a Czech wine producer was completed last month. It was the installation of a new highly loaded anaerobic reactor and a subsequent aerobic stage, which are protected at the inlet by mechanical pre-treatment. Wastewater production is on average equal to a town with 20,000 inhabitants. A great advantage of this type of treatment is the production of biogas from pollution. The assembly had been already completed, several tanks of granulated anaerobic sludge have been brought in from various sources and the treatment plant is starting its active operation. The treated waste water is discharged into the city sewer and it continues for further processing into a municipal waste water treatment plant.
Bioethanol and wastewater treatment
In the last few days, necessary things are being prepared for pilot plant testing of wastewater from bioethanol production. Testing will take place over several weeks. The goal is to verify the possibility of wastewater processing in anaerobic conditions, in which energy-rich biogas would be produced from the wastewater. Necessary tanks, their connections, necessary chemicals for analysis and other equipment are currently being prepared. All equipment will be sent to the customer, where our process engineers will run the pilot experiment.
Sedimentation tests for waste water with a high content of suspended solids
Tests of sedimentation rates were performed with wastewater generated during paper production and processing of waste paper in our laboratory. Such wastewater is characterized by high content of insoluble substances. One of the first steps of treatment technologies is their separation, most often by sedimentation. To ensure optimal design, tests were performed, based on which the necessary dimensions of the sedimentation tank were specified.
Dry and wet tests in progress
Even during the current situation in our company, we are preparing a wastewater treatment plant launch for a bakery near Dunajská Streda. As usual before putting technology in operation, during complex tests we tested correct electrical connection of all machines and their communication with the control system. We also set parameters of measuring devices (level meters, pH and oxygen probes, flow meters, etc.). For a smoother launch of devices, we invited our delivery partners to start the most important machines.
Sedimentation tank reconstruction in wastewater treatment process
Reconstruction of the settling tank at the WWTP of our customer from petrochemical industry will take place in the next months. Well-functioning sedimentation is one of the key processes for any wastewater treatment plant. This is mainly due to its location, usually as the last stage of process. The project involves minor civil work modifications and installation of a completely new sludge raking device at the bottom of the settling tank.
Increasing of oxygen concentration in the WWTP´s tanks
Hydrotech was awarded with a new project for the reconstruction of a part of a wastewater treatment plant. This is among the most substantial sections of the WWTP and ensures air supply to the biological part. Planned works include aeration system and air distribution pipeline replacement, supply of new blowers with a control program constantly measuring dissolved oxygen concentration in the aerobic tanks. Sufficient oxygen concentration in the system is a necessary condition to ensure sufficient elimination of pollution from wastewater.
Dairy factory, waste water and sludge treatment
A new sludge dewatering device for waste sludge produced at local wastewater treatment plant in dairy factory in Moravian region, Czech Republic was installed. It is a slow-running screw press that also pumps sludge with low concentrations and therefore directly from the tanks. This process efficiency depends on sludge quality entering the technology. Manufacturer declares the ability to achieve a dry matter output concentration from 15 to 30 %. In some cases, this type of dewatering technology costs significantly less than conventional technologies, e.g. centrifuges.
Hydrotech cares about increasing customer safety
Workplace safety is one of the important topics of every employer. Long-time customer of our company asked Hydrotech to design and implement precautions that will increase safety when the chemical – ferric sulphate is supplied to their WWTP. The solution consisted of installing new manual valves with position sensing, safety pneumatic valves were installed, and a new display with level monitoring in the storing tanks was installed at the filling point.
Explosive environments seminar
Creation of an explosive environment is also a threat at wastewater treatment plants. This applies more or less to technologies that use anaerobic bacteria producing biogas containing methane. Because of such projects most of our process engineers attended a professional seminar. Content of the training was to assess risks associated with creation of an explosive environment and its prevention or elimination.
Slovak, Czech and Russian met... at Hydrotech teambuilding
At the end of January, Hydrotech organized a meeting of almost every of its branch offices´ employees. This teambuilding was attended by people from the Slovak and Czech Republics, Latvia and the Russian Federation to get to know each other better once again and to enhance the team spirit. We have enjoyed great food, we played pool, bowling and golf on a golf simulator, all this in an informal atmosphere. Some of the employees were having fun until dawn.
Fenton reaction and heavy metal removal in pilot testing
We have been testing wastewater containing resistant organic substances and high heavy metals concentrations for several weeks. As these organic compounds are hardly biodegradable, we decided to use advanced oxidation processes (AOP). Based on laboratory tests we chose just Fenton reaction to be used. The drop in initial COD concentrations (parameter for organic substances) in the inflow to the pilot model is approximately 50%. In the second step, heavy metals are removed from the water with an efficiency of about 90%.
A very simple way to clean 100 cubic meters of wastewater a day
In cooperation with our Czech part of the Hydrotech group, we have started to prepare documentation for two smaller food factories with a daily flow rate of about 100 m3/d. Although, the volume of water is relatively small, water pollution is really high. The designed technology is relatively simple with high treatment efficiencies - COD values can be expected to decrease in the range of 40 to 60%, while TSS and fat parameters can achieve efficiency in decrease of up to 90%. Since the pre-treated water continues to the sewer and to the local sewage treatment plant, such efficiencies should be sufficient.
Malting plant wastewater – completion of WWTP pilot plant model monitoring
Every brewery needs malt from a malt house at the beginning of its production process. For such a food industry, we finished wastewater treatment pilot plant this month. We are extremely satisfied with the results as we managed to lower the organic pollution to 50 mg of COD/l and 5 mg of BOD/l. It is really interesting for the customer to use significant part of the treated water back in the production process, thus approaching the so-called zero liquid discharge factory concept. That is why it will be necessary to treat the effluent using advanced oxidation processes or by reverse osmosis in the tertiary stage.
Hydrotech was awarded with a project involving the WWTP for syrups manufacturing company
Hydrotech has again confirmed its qualities in Russia where we succeeded in being awarded a project which includes execution of the WWTP for a company producing syrups. Wastewater flow is not significantly high (approximately 120 m3/d), but the concentrations reach up to 6 000 mg of COD/l. In the first stage, relatively simple biological aerobic treatment will be performed. If the factory production will be increased in the future, the design of the second stage is already prepared as a biological anaerobic wastewater pre-treatment and the effluent will be post-treated in the aerobic stage.
Progress of the WWTP construction in North Dakota in the U.S.
Our employees came back to Slovakia at the beginning of the December who had finished part of their works in North Dakota, USA. They completed works regarding the wastewater treatment plant especially the high-loaded IC reactor during their stay. In addition, they removed remaining, unused material from the reactor bottom area to be able to seal the reactor´s top. One of the latest tasks was the completion of the odor removal system from wastewater treatment plant´s tanks. At the end of their visit, the pipeline for pH adjustment was installed and pressure tests were carried out.
Hydrotech visited STU university
Hydrotech was invited to two events organized for students by Slovak university of technology. Since we do care about right relationships with professors in the field of wastewater treatment and professional’s community and we also care about new generation of specialists in that field, we attended these events. One of them involved participation in a commission that evaluated the work of university students who presented their science work and calculations. The second of the events was a moderated discussion with university alumni members for high school students from all over Slovak Republic.
Hydrotech attended the international conference of Paques company
Our long-time partner Paques organized the intern conference called Product & Sales conference 2019 at the end of the November and Hydrotech was invited too. Two members of Slovak Hydrotech and two members of Russian Hydrotech met in Zwolle, the Netherlands, where the conference was held. Except highly respected persons such as Mr. Vellinga and Mr. Buisman who have contributed to significant discoveries in the field of wastewater treatment, we met long-time company friends and people who we are cooperating with in the USA or in Russian federation. The whole conference was conducted in a very friendly atmosphere full of inspiration and enthusiasm for the achievements in the field of anaerobic treatment of highly polluted wastewater, biological sulphur removal from biogas or for example of nitrogen biological removal by granular sludge. Beside these more technical aspects, we also dealt with an ability to explain more clearly the way and advantages of anaerobic wastewater treatment...
Preparation and submission of project documentation for paper mill
Hydrotech submitted the project documentation for a paper industry customer which mainly deals with the addition of a high- loaded IC reactor and its aerobic post-treatment to an existing wastewater treatment plant. Technological design respects BAT conditions (Best available technology). That is why it takes into account the highest possible process efficiency, the lowest built-up area, the highest energy efficiency and the lowest possible level of negative environmental impacts.
An active approach to odor management at a wastewater treatment plant
It is not rare to encounter annoying odor at a WWTP. However, the WWTP manager/process engineer should be prepared to face this problem if necessary. Therefore, we implemented an increase in waste air treatment capacity on existing deodorizing filters for our customer. This includes waste air pipeline split into two separate branches. One of two filters doubled its size and the amount of waste air treated in the filter was increased twofold, too. Another improvement was the replacement of the old peat filling with coconut fibre new one.
Pipeline replacement – just a little job but a professional approach
A new customer from environmental field contacted our company to help them replace several hundreds of meters of their obsolete pipeline. Hydrotechs´ response was a quick design, a quick production and a pipe installation. After that, the entire pipe was thermally isolated as it is located outside. The whole process, from service ordering to completion, took less than 4 weeks.
Few weeks of the wastewater treatment plant operation in RAJO - Bratislava dairy
To help our customer with the wastewater treatment plant operation, Hydrotech ensured daily presence of its technologist at the WWTP for a couple of weeks. We operated the plant as it was our own. The main aim was to fine-tune process technology and it´s operation so that effluent limits of treated water were not exceeded. The second part consisted of taking care of the WWTP operational space, to keep it clean and safe. The third point of our action was to optimise chemical dosage into the system. After several weeks of our technologists’ work, we can be proud of this well-functioning WWTP.
Potato processing industry also requires waste water treatment
One of the biggest potatoes-processors in the Czech Republic has decided to invest effort into its wastewater treatment. The key project idea was to treat whole volume of wastewater and its reuse back in the production process. Wastewater coming from potatoes peels and washing include, in addition to organic pollution (COD), also contamination with undissolved substances in grams or tens of grams per litre. The technology consists of mechanical pre-treatment, biological treatment specifically denitrification and nitrification (nitrogen removal), tertiary treatment involving a sand filtration and water sanitation by UV radiation. The sludge dewatering line involves a centrifuge. Wastewater treatment plant is designed as for 426 PE. The hydraulic capacity is designed for approximately 100 m3/day. The treating efficiency is as follows: COD > 95 %, total phosphorus > 90 %, BOD > 99 %, TSS > 99,99 %.
Laboratory tests of highly polluted waste water using chemostat technology
Chemostat is used as a technology for partial treatment of wastewater, for example prior entering a public sewerage or prior next treatment step. In our laboratory we examined food industry wastewater with COD concentration (parameter representing organic pollution) from 2 000 to 4 000 mg/l. Removal efficiency ranged from 45 to 75 % depending on retention time in the system. Nitrogen (N) and phosphorus (P) removal was observed, too. Conforming to local law, wastewater effluent limits from wastewater treatment plants to watercourses usually cannot exceed tens of milligrams per liter. Therefore, chemostat is basically used as a pre-treatment technology.
Wastewater treatment plant intensification in PIKA Bzenec (CZ) factory
A new IC reactor start-up is planned in PIKA Bzenec cannery in August. The factory is increasing production and the hydraulic loading at WWTP is increasing, too. That is why the customer has decided to intensify their plant, which will include extending the existing anaerobic volume with a new same size IC reactor. Part of the intensification will be the installation of more powerful pumps for IC, new biogas treatment ( gasholder with flare for burning excess biogas), increasing of NaOH preparation unit capacity, waste air treatment and new aeration system in the post-aeration tanks. The WWTP capacity will increase from 733 to 1 100 m3/d. Mass loading will change from 5 000 to 7 500 kg/d with 85 % efficiency of COD removal.
Wastewater treatment pilot plant for industrial waste water
For several months, Hydrotech has intensively dealt with pilot plant testing of food industry waste water with high concentrations of organic compounds (COD), sulphur and dissolved inorganic salts. In the first phase, aerobic bacteria were applied so oxygen was needed for them to be able to treat them. After several important adjustments of technology, the process began to work perfectly and the system treats the waste water not exceeding required limits. In the second phase, Hydrotech made a decision to try to treat waste water in anaerobic way. The high loaded IC reactor parameters and treating limits are determined by gradual system loading. Pilot testing results seem very promising, so far.
The assembly team has travelled across the Atlantic
A waste water treatment plant construction process in North Dakota for an emerging distillery has reached the point when assembly could begin. The team of Hydrotech´s employees with a chief fitter and technologist left company´s headquarters in Vinosady, Slovakia and started to work on assembly in the USA. The current situation is favourable – the high loaded anaerobic IC reactor has been almost completely finished, as well as the flotation unit for removal of aerobic sludge and the sieve for bigger particles removal at the WWTP inlet.
Hydrotech Slovakia is at the beginning of a new project management system
Our latest Slovak project for bakery is going to be a pilot application of the new project management system. Chief project engineer will be responsible for coordination of processes of design, production and execution itself. Brief meetings intensity has increased pleasantly and internal communication has started to improve significantly. If we´ll succeed improperly implementing this new project management system, we will be able to make our effort much more effective.
Teambuilding of HYDROTECH s. r. o.
A traditional sport and grill afternoon took place on 25th of April 2019. This event started with a favourite game Kubb initiated by one experienced player – our colleague Lenka Silhankova. After that, we were shooting an air rifle and finally we have enjoyed perfectly prepared meat and cold beer. These events always contribute to an informal atmosphere and debates among people. Moreover, our colleagues from Prague also joined us. We are looking forward to next grill afternoon.
Waste treatment tests from dairy industry in anaerobic way
Treatment tests of concentrated waste material from dairy factory are currently being run in our laboratory. Process advantages are as follow: biogas production, transformation and reducing of problematic waste. We do recommend this material as a co-substrate for bigger biogas stations.
We treat waste water from bakery
Because of a new project in Slovakia our technologists and designers are busy these days. This new factory will produce several kinds of bakery products. Therefore, when you enjoy a croissant next time, be aware that perhaps Hydrotech also participated in its production.
It is possible to treat condensates from industrial productions in anaerobic way
If your company produce waste water including condensates, as does our customer in Kaluga (RUS), then be careful in the next steps of treatment. There is lack of salts or ions in condensates. These particles are as important for biological processes as minerals and vitamins for human body. If this problem occurs in your production line be aware that these particles must be dosed into system. This fact was a really essential conclusion after our technologists’ visit in Russia. Their waste water treatment plant equipped with high loaded anaerobic IC reactor was continuously losing its efficiency.
Get rid of heavy metals in your water
Our lab is quite a busy place to be these days. We recently finished an experiment involving heavy metals removal from waste water. Tests were followed by waste water treatment plant designed draft. The results were very satisfactory and we have reached more than 95 % efficiencies in terms of heavy metals´ removal. If you are interested in this topic you can get more information reading our blog.
Hydrotech was awarded for the long-term development of water management in industry
Company Hydrotech has been awarded on the basis of many years of experience and participation in the field of municipal and industrial wastewater treatment and development of industrial water management. The award was taken over by the former director of the Slovak part of Hydrotech group Mr. Dušan Vančo at the 50th Waterworks conference. Our company appreciates the award and continues to strive to further development this field.
Completion of Unipetrol project – Vanadium removal
Hydrotech has completed the project for Unipetrol, which focuses on production of the petrochemical products, agrochemicals and other chemicals. Hydrotech took care of removing vanadium commonly used in production.
Our employees took part in cross country skiing competition called „Vodohospodářska třicítka“
The 44th annual winter amateur competition of individuals in cross country skiing – „Vodohospodářska třicítka“ took place on 19th of January 2019 organized by the Association “Zimní vodohospodářská třicítka“. Hydrotech was successfully represented by 5 employees. One of them ranked 5th in his category from overall 93 skiers. Male skiers had to 30 and females 20 kilometres in the vicinity of the small town Rejvíz. This year the weather was extremely favourable, there was enough snow, the track was well prepared and the sun was shining throughout the whole race.
Taking care of our customer Rajo, a.s.
Couple months have passed since Rajo, a.s. dairy waste water treatment plant start-up. We are glad that the required effluent limits are met and the plant works well. Priceless advantage is that Hydrotech and Rajo, a.s. are in a close geographical vicinity and therefore our chemical technologist and our service regularly visit the WWTP. Never-ending will to have good relationships is what our company does constantly.
Trip to Brazil and inspection of IC reactor´s parts preparation
As our company cares about smooth running of the U.S. project, a vice managing director was sent to check the production of parts of the anaerobic IC reactor to Brazil. Along with the excursion in the production, meetings were held with the management of partners – Paques Brazil. Probably anybody would be happy to enjoy Brazilian summer for a couple of days in the middle of Slovak winter.
A friendly visit of our manager to our partners
Our management team travelled across the ocean to visit our partners in North Dakota before technology delivery and start of assembly. The main aim of visit was to improve mutual relationships and planning of the key project point. After pleasant but also tough days the Hydrotech managers came back home.
Preparation for export of technological parts of the wastewater treatment plant to the U.S.
Intensive production, preparations and transportation planning for the U.S. project were taking place during last months in Hydrotech´s production halls. Parts of technology will be transported across Europe, then loaded onto a cargo ship in Polish harbour, subsequently sail across the ocean and travel thousands of kilometres across the USA from the east coast to North Dakota. To make it more “interesting”, one part of technology will be transported from Brazil.
Anaerobic reactor start-up in the starch factory´s wastewater treatment plant
A waste water treatment plant in starch factory was built in Kaluga city (south of Moscow) two years ago. After stabilization of the production processes, a highloaded IC reactor was ready for start-up. Hydrotech technologists from Latvia, Russia and Slovakia faced several difficulties as low quality and activity of granular sludge, sludge washout, etc., but at the end of the day the process was successfully run in.
Hydrotech usual Christmas meeting
Hydrotech employees met at pre-Christmas meeting last December. The official part summarized the last year, plans for the next one was mentioned, some long-time employees were awarded and the company´s management wished merry Christmas to all employees and their families. Informal part followed with tasty food, possibility of leisure activities and a space for personal talks.
Beginning of the construction of a new wastewater treatment plant in the Russian federation
Another project arises from paper form and is becoming a reality. Wastewater treatment plant in the southwest of The Russian Federation is in a process of building and assembling of the technological part. The size of the wastewater treatment plant could be compared to the city with 120 000 inhabitants. The start up of the WWTP is planned for the end of spring 2019. Well, good luck to our employees working during tough Russian winter.
Excel training – 2nd round
There was a Microsoft Excel training early this November which was organized for employees who did not take part in previous summer training. They have been trained in intermediate level and topics such as formatted tables, datasheets, types of formatting, pivot tables etc. were taught. We believe the work and workplace for our employees will be more comfortable and we are glad about development of their skills.
Successful final inspection of WWTP in the Rajo a.s. dairy
Successful final inspection of waste water treatment plant for our customer Rajo a.s. (Meggle group) was completed. The autumn 2018 will be added to the Hydrotech archive with this note. WWTP started to run in automatic mode after more than half a year of planning, building parts and technology assembles. After competent authorities visit the WWTP operation was approved. Next few months it will be run in a trial operation, when the last parameters will be optimally set. Everything takes place in the suppliers´ - Hydrotech and customers´ - Rajo a.s. cooperation.
Hydrotech participated at the Wastewater 2018 conference in the High Tatras
As wastewater and water treatment are fields which are constantly changing, three employees from the Slovak part of Hydrotech and our colleague from Czech Hydrotech attended the conference called „Wastewater 2018“ in the Highs Tatras. The aim was to listen and to discuss various topics connected with wastewater treatment (project realization and operation of WWTP, legislation, research, etc.) in Slovakia, Czech Republic and partly abroad. Maintaining relationships with experts and meeting new people from this field was the second important purpose of the journey.
Autumn informal meeting of Hydrotech employees
It seems that autumn teambuilding with roasted lamb and other tasty dishes is going to become a rule in the Slovak company´s headquarters. There was no lack of good quality homemade wine, hence, the village Vinosady is area filled with vineyards. It is obvious that the company takes care in sustaining of the community spirit at the workplace and creates enough space for informal conversations without business topics. Such an afternoon can never be useless.
Participation at ECWATECH 2018 in Moscow
The Russian Federation is one of the countries where Hydrotech has implemented several projects and others are going to be implemented. Therefore, we have spent several days in Moscow at the international exhibition ECWATECH 2018. Our employees met some well-known customers and discussed with many others who expressed an interest in being informed, consulting or just having an interesting talk about wastewater treatment.
Export of material for the implementation of the freshest project in Russia
Slowly we are getting to the point of assembling the technology of one of our freshest projects in the Russian Federation. Our company´s venue in Vinosady, Slovakia is full of finished or under-construction tanks, electrical switchboards and even imported machinery. Everything is being prepared for export and a long way to the east.
How to become a guru in work with Microsoft Excel
In order to improve the quality and efficiency of our employees' work, two-day training was organized on working with Microsoft Excel, led by a professional trainer. Many employees commended the level, flexibility and practicality of the course. In the near future, we expect another identical training for employees who did not attend the first course.
Sludge dewatering process optimization at our customer with help of our technologists
The main objective of the wastewater treatment plant at the factory for the production of baking additives, confectionery, dairy products and others was to solve the deficient dewatering of excess sludge originating in the flotation unit and in the biological system. After our visit the dewatered sludge was not liquid but had a consistency of a paste. The quality of centrifuged water on the centrifuge - fugate has also improved.
Meeting of Slovak and Russian Hydrotechs in Vinosady
At the beginning of July, we organized a meeting of Slovak and Russian colleagues in Vinosady. The meeting aimed to exchange experience from project implementation in the Russian Federation. At the meeting, besides technical details, topics related to the organization of export, construction and assembly were also discussed. We will organize this meeting regularly. We believe that we will move on to more efficient and higher quality services for our customers.
After a few months, we finished work with a small scale model of high-load anaerobic IC reactor. In the assignment, the customer asked us to investigate the possibility of wastewater treatment in an anaerobic way for the emerging American distillery. It has been confirmed that the water from this production is a good substrate and the treatment efficiency is around 90%. Our company is interested in whether and how the implementation of this project will advance.
Several colleagues from our design department traveled to the Russian Federation. One group to visit customers in Volgograd, where Hydrotech will realize one of the largest and most sophisticated industrial wastewater treatment plants in its history. The second part of the colleagues went to the town of Kozhevnikovo for a local brewery where the membrane filter modules (MBR system) were also installed.
Meeting of all HYDROTECH directors
After a long time, a meeting of all the directors of the HYDROTECH Group was held. Meeting took place at Hotel Zochova Chata in Slovakia. At the meeting, we welcomed the HYDROTECH directors from Russia, Latvia, the Czech Republic, Slovakia and Poland. Meetings were also attended by the President of the Group Mr. Ioannis Hadjivassilis and members of the Board of Directors HYDROTECH, a.s. - Mr Dušan Vančo and Mr Chrysanthos Mavrommatis.
Czecho-Slovak HYDROTECH meeting
Even after a long break, we managed to organize a meeting of our and Czech colleagues. This time the organization of the meeting was in the hands of Slovak Hydrotech, so we organized the meeting in the royal town of Skalica near the Slovak-Czech border. After a tour of the town and the production of the traditional pastry called Skalický trdelník we have followed a cultural program with wine tasting. Despite the rainy weather, the meeting was rated very well. We are looking forward to the next meeting in the Czech Republic.
New organic mowers
After a successful last year's breeding of a small group of lambs, we started again this year. For a few weeks a small herd passes behind our warehouse and lab. In addition to many other benefits, these animals bring finely mowed lawn. With a slight imagination it then reminds us the lawns in Versailles gardens.