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No.

AOS-8G10

VOLUTE
Dewatering Press
Application Information
ES-SA & TA Series
Ver.2.0

2008, June / Hirose


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Table of Contents

Characteristics of ES-SA Series


1. System Outline
1-1 ES Series Model Number Legend
1-2 Structure of The System
1-3 Parts Outline
① Volute Cylinder
② Flow Control Tank
③ Flocculation Tank
④ Control Panel
1-4 Flow Chart

2. Design Criteria
2-1 Suitable Sludge for Volute Process
2-2 Conditions of Pre-Process of Sludge
2-3 Performance
2-4 Control Panel
2-5 Electrical Interfaces
① Electrical Compartment Table
② Block Diagram
③ Skeleton
2-6 Standard Specification
2-7 Nozzle List
2-8 Weight List

3. Criteria for the Dev ices Prepared by Customers


3-1 Sludge Feed Pump
3-2 Polymer Feed Pump
3-3 Water Supply

4. Running Cost
4-1 Calculation for Chemical Cost
4-2 Calculation for Cleaning Water Cost
4-3 Calculation for Power Cost

5. Consumable Parts
5-1 Consumable Parts and Life Span
5-2 How to Exchange

6. Others
6-1 Others

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1. System Outline
1-1 ES Series Model Number Legend (Nomenclature)

ES-202/SA-CE
*ES-202 model with a single Flocculation Tank, Water-Level Adjuster, and with CE
marking.

ES – ( ) ( ) ( ) / ( )-( )
A B C D E F

A: Model Series Name

B: Size of Cylinders
10 100 φ
13 130 φ
20 200 φ
30 300 φ

C: Number of Cylinders
1 One Cylinder
2 Two Cylinders
3 Three Cylinders

D: Motor’s Position “Note: Adapted only for 300 model”


None Inlet Side
F Outlet Side

E: Specifications of Flocculation Tank(s) “Note: TA is adapted only for 300 model”


SA One Flocculation Tank with Water-Level Adjuster Tank
TA Two Flocculation Tank with Water Level Adjuster Tank

F: Conformed Manufacturing Standard

Table-1 Specifications
Throughput (kg-DS/h)
DAF Sludge, D/No. of
Model Waste Activated Sludge
Thickened Sludge Cylinder
2,000~4,000 mg/L
6,000~35,000 mg/L
ES-101SA 2 ~ 3 kg-DS/h 3 ~ 5 kg-DS/h 100 φ ×1
ES-131SA 4 ~ 5 kg-DS/h 6 ~ 9 kg-DS/h 130 φ ×1
ES-132SA 8 ~ 12 kg-DS/h 12 ~ 18 kg-DS/h 130 φ ×2
ES-202SA 12 ~ 18 kg-DS/h 18 ~ 30 kg-DS/h 200 φ ×2
ES-301SA/TA 18 ~ 30 kg-DS/h 36 ~ 50 kg-DS/h 300 φ ×1
ES-302SA/TA 36 ~ 60 kg-DS/h 72 ~ 100 kg-DS/h 300 φ ×2
ES-303SA/TA 54 ~ 90 kg-DS/h 108 ~ 150 kg-DS/h 300 φ ×3

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1-2 Structure of the System
Volute Dewatering Press has been developed mainly for the purpose of dewatering the
organic sludge.

Volute Dewatering Press is the combination of the following devices;


■V o l u t e C yl i n d e r ・・・・・・・・・・・・・・・・ Heart of the system. Thickening and dewatering of sludge.
■Flow Control Tank ・・・・・・・・・・・・・・・・ A necessary amount of sludge is measured by V weir.
■Flocculation Tank ・・・・・・・・・・・・・・・・ The sludge is made to react with chemical in this tank.
■C o n t r o l P a n e l ・・・・・・・・・・・・・・・・ Control Panel includes features of Manual/Auto operation.

Flow Control Tank

Flocculation Tank

Control Panel

Volute Screw Cylinder Dewatering Zone (SUS)

Volute Screw Cylinder Thickening Zone (Resin)

Figure-1 System Structure

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1-3 Parts Outline
① Volute Cylinder
①-1 Structure
The moving rings and fixed rings are arranged in layers one after the other and the
screw pitch narrows from thickening zone towards the dewatering zone.

Screw

Fixed Ring

Moving Ring

Figure-2 Volute Cylinder Structure

①-2 Dewatering Principle


The former part of Volute plays thickening role and the latter part plays dewatering role.
In the thickening zone, the rings are made of resin. Filtration part separates sludge
from filtrate water as it is like a bar screen.
In the dewatering zone, the rings are made of stainless steel. The screw pitch narrows
from thickening zone towards the dewatering zone, thus making the pressure in the
dewatering drum to increase. The End Plate (Figure-2, E) increases the inner pressure
even more, thereby dewatering sludge and discharging the cake with solid content of
approx. 20%.

Figure-3 Volute Cross Section

①-3 Self-Cleaning Structure


The screw passes through the filtration part and continuously pushes the moving rings
up and down with its edge in accordance with its rotation. This causes the moving rings
to move continuously, thereby cleaning the gaps in the filtration part to prevent
clogging.

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② Flow Control Tank
Sludge from a storage tank is regulated to adjust feed sludge volume supplied to the
flow control tank by the sludge feed pump, and constant amount exceeds V weir and it
flows into the focculation tank. The sludge of the remainder returns from the water level
adjustment pipe back to the storage tank.

Water Level Adjuster

V weir

Figure-4 Flocculation Tank

③ Flocculation Tank
In the Flocculation Tank admixing of the chemical substance is carried out in order to
form flock. The flock is then transferred to the Volute drum where instantaneous gravity
thickening takes place at the same time and then the flock moves through the
thickening zone.

④ Control Panel
Control Panel has the function not only for manual operation but also for fully automatic
unattended operation with 24 hours timer for the attached facilities.
Water level control is possible as well by means of receiving operation signal from a
sludge storage tank.

*Circuit of sludge pump and chemical feed pump is included in the Control Panel.

Figure-5 Control Panel

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1-4 Flow Charts

Flocculation Tank
 The sludge is supplied at constant quantity
through V-weir into the Flow Control Tank.
 Admixing of the chemical substance with is N-5 Water supply
Water Supply
carried out in the Flocculation Tank in order to
form flock.

Volute Cylinder N-4 ChemicalInlet


Inlet
 Thickening instantly in the thickening zone. Chemical
 Dewatering occurs in the dewatering zone
N-1 SludgeInlet
Sludge Inlet
due to high pressure inside the drum and
M
pressure from the End Plate. LS

 Discharging sludge cake of solid content


higher than 20%. M

Volute
VoluteDrum
Cylinder
Flocculation
Flocculation Tank
Tank

Model “SA” N-2 Sludge Over Flow N-3 Filtrate


Sludge Over Flow Filtrated Outlet

Figure-7 Flow Charts

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2. Design Criteria
The following Design Criteria should be met when you install Volute
Dewatering Press in your WWTP facility design.

2-1 Suitable Sludge for Volute Process


1) Organic Sludge.
2) Feed sludge concentration should be about 0.2 ~ 3 %.
【Explanation】
1)100% Inorganic Sludge is difficult to dewater due to structural matter of Volute Screw.
In case of high ratio of inorganic sludge among organic sludge is difficult to show good
performance as usual. In such case, please ask us for our free beaker test just before
your design work and procurement.
2) Under the condition of sludge concentration is below 0.2%, process speed tends to
decrease a little and then performance tends to show a worse performance.
In case when sludge concentration is over 3.0%, there is possibility that it could not
show standard performance as well. High concentrated sludge prevents enough
agitation in Flocculation Tank and then enough reaction between sludge and chemical.

2-2 Conditions of Pre-Process of Sludge


1) Always agitate sludge to keep steady solid concentration.
2) pH of the sludge should be in the range of 6 ~ 8.
3) Screen would be required in case when rubbish, dead leaves, fur, straw and fiber
are included in sludge.
【Explanation】
1) and 2) In case of big range of concentration, it is difficult for the system to get steady
performance because frequent adjustment for quantity of chemicals is required.

2-3 Performance
1) Standard Throughput
100 φ × 1 pc ~ 3 kg-DS/h (surplus sludge) ~ 5 kg-DS/h (floating floth)
200 φ × 1 pc ~ 9 kg-DS/h (surplus sludge) ~ 15 kg-DS/h (floating floth)
2) Water content of sludge cake is below 85% in case of dewatering surplus sludge
from biological treatment.
3) Chemicals for the right performance can be selected from Polyferric Sulfate and Polymer
Coagulant depending on sludge property.

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【Explanation】
1) Throughput is influenced by sludge property (quality and concentration).

Table-2 Standard Performance (per one cylinder).


Quality
D Easy Dewatering Difficult Dewatering
Concentration
φ100 3 kg-DS/h 4kg-DS/h
0.6 ~ 1.0 %
φ200 9 kg-DS/h 12kg-DS/h
φ100 4 kg-DS/h 5kg-DS/h
1.0 ~ 3.0 %
φ200 12 kg-DS/h 15kg-DS/h

2) The use of standard polymer coagulant such as Anion and Cation easily achieves 85%
or lower water content of sludge cake. When water content of sludge cake is the highest
priority of a client, it is possible to achieve a better performance by selecting a more
suitable polymer coagulant.
3) In case of flocculated sludge, add Anion 2.5 ~ 3.0%(liquid conversion against DS) and
Cation 2.5 ~ 3.0% (liquid conversion against DS).
In case of activated sludge, add Polyferric Sulfate 15% and in Amphibious 2.5 ~ 3.0%
(liquid conversion).

2-4 Control Panel


1) The speed of Volute motor and Flocculation Tank Agitator is controlled by the
inverter inside the Control Panel.
2) Switch and Indications in Control Panel are for common use up to screw number 1pc ~
5pc.
3) Circuit for a sludge feed pump, a chemical feed pump (Anion, Cation and Polyferric
Sulfate) are pre-installed.
4) 24hr Timer is pre-installed.
5) “Receiver for stop signal from outside” is pre-installed.
6) Dispatch by “Dehydrator collective trouble”
*Motor capacity of each item is referred to the attached Skeleton.

【Explanation】
1) Volute motor speed is controlled by the inverter to adjust a process speed easily. In
case when Volute Screw are more than 2 pieces, thermal switch are equipped at the
secondary inverter.
Flocculation Tank Agitator is controlled with the inverter for correct reaction of sludge
and polymer.
2) For 3),4),5),6), please refer to Figure-8 Electrical Compartment Table, Figure-9 Block
Diagram, Figure-10 Skeleton.

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2-5 Electrical Interfaces
① Electrical Compartment

Solid line AMCON’s arrange


Dotted line Customer’s arrange

Power Supply(200V・Triphase)
Chemical Unit

Power Supply(200V・Triphase) C Volute Control Panel


①Dewatering Press COS Manual・OFF・ON
Control Center A ②Volute CS OFF ・ON
Volute Control Panel ③Agitator CS OFF ・ON
B ④Polymer Pump CS OFF ・ON
Continuing Control Panel (ES-SA Series)
B’ ⑤Sludge Pump CS OFF ・ON

B’ Condition Indication

Main Device Load ①Power Receiving White Pilot Lump


Relation Device Load(B’) Pilot Lump
① Volute Drive ②Trouble Orange
① Sludge Pump ② Flocculation Tank Agitator
③ Electric Valve Content of A is as below
1) Outside starting signal(when required)
Relation Device Detector Detector Contents of B are below
(when required) ① Flocculation Tank-Full 1)Lump sum trouble
① Chemical Tank Level 2)On operating signal
Decreasing Contents of B’are below
・Polymer Coagulant 1)Lump sum trouble
② Sludge Storage Tank 2)On operating signal
※choose one
Level Decreasing 3)Operation order for sludge
① Sludge Pump(B) Pump

② Polymer Feed Pump Content of C is below(when AF series adopted)


1)Chemical auto dissolving device interlock signal
Figure-7 Electrical Compartment Table

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② Block Diagram

Figure-9 Block Diagram

Figure-8 Block Diagram

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③ Skeleton

Volute Motor Flocculation Flocculation


Chemical Chemical Sludge Total
Tank Agitator Tank Agitator Pump Pump Feed Pump (kW/h)
No.1 No.2 No.3 Motor Motor
ES-101 0.1 0.1 0.2 + A + C
ES-131 0.1 0.1 0.2 + A + C
ES-132 0.1 0.1 0.1 0.3 + A + C
ES-202 0.2 0.2 0.4 A C 0.8 + A + C
ES-301 0.4 0.4 0.2 0.8(1.0)+A+(B)+C
ES-302 0.4 0.4 0.4 0.2 B 1.2(1.4)+A+(B)+C
ES-303 0.4 0.4 0.4 0.75 0.2 1.95(2.15)+A+(B)+C

Figure-10 Skeleton

.
Figure-9 Skeleton

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2-6 Nozzles
Table-3 Nozzle List
Model
ES-101SA ES-131SA ES-132SA ES-202SA ES-301SA/TA ES-302SA/TA ES-303SA/TA
Items
Caliber 50A 50A 50A 50A 50A 50A 65A
Sludge Inlet Standard Socket Socket Socket Socket Socket Socket Socket
Material SUS SUS SUS SUS SUS SUS SUS
Caliber 80A 80A 80A 100A 125A 150A 150A
Filtrated Water
Standard Socket Socket Socket Socket Socket Socket Socket
Outlet
Material SUS SUS SUS SUS SUS SUS SUS
Caliber 20A 20A 20A 20A 20A 20A 20A
Water Inlet Standard Union Socket Union Socket Union Socket Union Socket Union Socket Union Socket Union Socket
Material PVC PVC PVC PVC PVC PVC PVC
Caliber 20A 20A 20A 25A 25A 40A 40A
Chemical
Standard Union Socket Union Socket Union Socket Union Socket Union Socket Union Socket Union Socket
Inlet
Material PVC PVC PVC PVC PVC PVC PVC
Caliber 20A 20A 20A
Chemical
Standard Union Socket Union Socket Union Socket
Inlet
Material PVC PVC PVC
Caliber 100A 100A 100A 100A 100A 100A 100A
Sludge Over Flow Standard Socket Socket Socket Socket Socket Socket Socket
Material SUS SUS SUS SUS SUS SUS SUS
Caliber 40A 40A 40A 40A 50A 50A 50A
Flocculation Tank
Standard Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve
Drain
Material PVC PVC PVC PVC PVC PVC PVC

2-8 Weight
Table-4 Weight
Model
ES-101SA ES-131SA ES-132SA ES-202SA ES-301SA/TA ES-302SA/TA ES-303SA/TA
Items
840 1370 1620
Empty Weight(kg) 190 205 275 420
900 1420 1900

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3. Criteria of the Devices Prepared by Customers
Volute Dewatering Press needs a “Sludge Feed Pump” and a “Polymer Feed
Pump”.

3-1 Sludge Feed Pump


Sludge Feed Pump shall be out of AMCON’s scope.

The Sludge Feed Pump capacity should be decided by the throughput. Please refer to the
table below.

Table-5 Sludge Feed Pump Required Capacity


(Sludge Concentration 1.0%)
ES301SA ES302SA/ ES303SA/
Model ES101SA ES131SA ES132SA ES202SA
/TA TA TA
Items
3 kg-DS/h 4 kg-DS/h 8 kg-DS/h 18 kg-DS/h 27 kg-DS/h 54 kg-DS/h 81 kg-DS/h
Required
Capacity 5 7 14 30 45 90 135
( L / min )

* Calculation Sample
【Conditions】
Volute Model: ES-101SA
Throughput: 3 kg-DS / h
Sludge Concentration: 10,000 mg / L

【Selection Method】
“Throughput (kg-DS / h) ÷ Sludge Concentration (mg / L)”

【Calculation】
Pump Dosage : 3 kg-DS / h ÷ 10,000 mg / L = 0.3 m3 / h
Pump Capacity : 0.3 m3 / h ÷ 60 min = 5.0 L / min

【Required Capacity】
Required pump capacity is 5.0 L / min.

*Note
_Please select a pump which has capacity exceeding the figure described above in the
“Table-5” and the “Calculation Sample”.
_Please select a pump in consideration for pump head.
_For selections and details, please contact pump supplier.

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3-2 Polymer Feed Pump
Polymer Feed Pump shall be out of AMCON’s scope.

The polymer feed pump capacity should be decided by the throughput and addition ratio.
Please refer to the table below.

Table-6 Polymer Feed Pump Required Capacity


(Dilution Rate 0.1 %, Adding Rate 1.0 %)
ES301SA ES302SA/ ES303SA/
Model ES101SA ES131SA ES132SA ES202SA
/TA TA TA
Items
3 kg-DS/h 4 kg-DS/h 8 kg-DS/h 18 kg-DS/h 27 kg-DS/h 54 kg-DS/h 81 kg-DS/h
Required
Capacity 0.5 0.7 1.4 3.0 4.5 9.0 13.5
( L / min )

* Calculation Sample
【Conditions】
Volute Model: ES-101SA
Throughput: 3 kg-DS / h
Sludge Concentration: 10,000 mg / L
Dilution Rate: 0.1 %
Adding Rate: DS of 1.0 %
Polymer Density: 1 g / cm3

【Selection Method】
“Throughput (kg-DS / h) × Adding Rate (%) ÷ Dilution Rate (%) ÷ Density (g / cm3)”

【Calculation】
Polymer Dosage : 3 kg-DS / h × 1.0 % ÷ 0.1 % ÷ 1.0 g / cm3 = 30 L / h
Pump Capacity : 30 L / h ÷ 60 min = 500 ml / min

【Required Capacity】
Required pump capacity is 500 ml / min.

*Note
_Please select the flow adjustable pump or equipment.
_Please select a pump which has capacity exceeding the figure described above in the
“Table-6” and the “Calculation Sample”.
_Please select a pump in consideration for pump head.
_For selections and details, please contact a pump supplier.
_Capacity would be different depending on sludge concentration.
_Adding rate is depending on the kind of sludge. In case of concentrated sludge, add Anion
0.5% ~ 1.0%,Cation 0.5% ~ 1.0% against DS. In case of activated sludge, add Cation 0.5% ~ 1.0%.

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3-3 Water Supply
Necessary water pressure for showering is 0.1 ~ 0.2Mpa. Thus, only normal water pressure is fine.

The filtration part of Volute Dewatering Press is designed as “clog-free”, making rinsing
water unnecessary. However, shower is equipped to clean leaked sludge on the Cylinder by
automatic operation.
Approximate shower water consumption is listed in the Table-7.

Table-7 Shower Water Consumption


(Operating Frequency: 15 second / 15 min)

Model ES301SA ES302SA/ ES303SA/


ES101SA 131SA ES132SA ES202SA
Items /TA TA TA

No. of Head 3 3 6 8 5 10 15
Shower Water
Consumption 24 24 48 64 40 80 120
(L/h)

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4. Running Cost

4-1 Running Cost

【Electric Power Consumption Calculation】


“Volute Model (kW/h) x Operating Cycle (h / day)”

【Polymer Consumption Calculation】


“Throughput (kg DS / h) x Adding Rate (%) x Operating Cycle (h/day)”

【Polymer Dilution Water Consumption Calculation】


“Throughput (kg DS / h) x Adding Rate (%)÷Dilution Rate (%) x Operating Cycle (h/day)”

【Shower Water Consumption Calculation】


“Volute Model (L / h) x Operating Cycle (h / day)”

* Calculation Sample
【Condition】
Volute Model: ES-101SA Throughput : 3 kg-DS / h
Dilution Rate: 0.1 % Adding Rate : DS of 1.0 %
Polymer Gravity: 1 g / cm3 Operating Cycle : 8 h / day

【Electric Power Consumption】


0.2 kW / h x 8 h / day = 1.6 kW / day

【Polymer Consumption】
3 kg DS / h x 1.0 % x 8 h / day = 240 g / day

【Polymer Dilution Water Consumption】


3 kg DS / h x 1.0 % ÷ 0.1 % x 8 h / day = 240 L / day

【Shower Water Consumption】


24 L / h x 8 h /day = 192 L / day

Table-8 Consumption Table


Items Consumptions
Electric Power 1.6 kW / day
Polymer 240 g /day
Polymer Dilution Water 240 L / day
432 L /day
Shower Water 192 L / day

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5. Consumable Parts

5-1 Consumable Parts and Life Span


Consumable parts are Moving Rings and Volute Screw and their approximate life span are
listed in the Table-8.

Table-9 Life Span of Consumable Parts


( Condition : 40 h / week – operation )
Size of D/No. of
Model Moving Ring Volute Screw
Cylinders Cylinder
100 φ ES-101SA 1
ES-131SA 1 2.4 years 4.8 years
130 φ 5,000 h 10,000 h
ES-132SA 2
200 φ ES-202SA 2
ES-301SA/TA 1 4.8 years 14.4 years
300 φ ES-302SA/TA 2 10,000 h 30,000 h
ES-303SA/TA 3

5-2 How to Exchange Consumable


For your convenience, “built-up Volute Drum” is available.
Standard consumable parts “Volute Cylinder”, “Volute Drum”, “Volute Screw”, and “Moving
Ring” in the Table-9 will be delivered. Please exchange these parts accordingly to our manual.
Upon request, AMCON provides skilled engineers for maintenance and services for
exchanging these parts on site.

Table-10 Standard Consumption Parts


Included Parts Note
Parts Volute Volute Moving Fixed
Drum Screw Ring Ring
Volute Cylinder ○ ○ *○ *○ Build-Up Part.
Volute Drum ○ *○ *○ Build-Up Part.
Volute Screw ○
Moving Ring ○ Necessary Pieces.
*A
All m odels are adapted only for Dewatering Zone

Note:
_The life span in the Table-9 is only for your reference, calculated based on the operating
conditions of treating excess sludge from biological treatment, producing 15% DS cake, at 8
hours per day. This data is acquired through a research on wearing of Moving Rings and
Volute Screw, recorded in the Technical Document.
The life span varies depending on types of feed sludge and quality, especially on
inorganic sludge. Moreover, producing sludge cake with solid content higher than
approximately 17% may result in a shorter life span.
_Depending on wearing conditions, Moving Rings at thickening zone may have to be
exchanged.
_As long as Volute continues to operate normally, being confirmed by sludge cake produced
and leakage on the Cylinder, the consumable parts do not have to be replaced even after
the listed life span.

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6. Others
6-1 Others
Data and information described on this document are provided only for your reference.
Please ask us if you have any technical concerns or questions. We will respond to each
question respectively. We will also judge which sludge is suitable or not and select a suitable
model, given appropriate information.

Contact Us…

AMCON INC.
W eb site : http://www.amcon.co.jp
E - m a i l : overseas@amcon.co.jp
volute@amcon.co.jp
TEL : +81(0)45 540 8580
FAX : +81(0)45 540 8588

1926 Nippa-cho, Kohoku-ku, Yokohama, Japan 223-0057

Squeeze Sludge, Squeeze Cost!!

(19/19)

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