Tr eatment Pr ocess

Maximum Removal of Soluble Species Using Physical Chemical Treatment

M AX R

TM

What is MaxR ... Improved Process Treatment Technology

Conventional Treatment

The standard method by which dissolved metals and other soluble species involves addition of reagents into the process stream to drive precipitation and form solids. Solids precipitated in this manner form very finely divided particles which settle slowly, forming a low density sludge that is difficult to dewater.

The MaxR Process improves on this basic process by using recycled thickener underflow to serve as precipitation sites for fresh solids. Underflow solids are recycled and mixed with incoming feed reducing chemicals required. Newly precipitated solids grow on top of existing particles forming large crystals that settle rapidly to a higher final density. The ultimate discharge slurry density of a material (solids concentration) can be increased by 5-30 wt% over conventional treatment. In addition, if mechanical dewatering is used, the dewatering rate is greatly increased due to the high density of the feed sludge and improved dewatering characteristics of the solids. Subsequently the size and the cost of the dewatering equipment are reduced.

MaxR Process Treatment Technology

Equipment Required for Con ventional Treatment Flow

Chemical(s) Sludge Filtration

Equipment Required for MaxR Process Treatment Technology

Chemical(s) Sludge Filtration Sedimentation

Sedimentation Precipitation Precipitation

Precipitation Precipitation

Polish Filtration

Sludge Disposal / Transport

Polish Filtration

Sludge Disposal / Transport

Let the MaxR System Work for You

volume/mass

Maximum Rate (Dewatering) Maximum Reaction Rate Maximum Reaction Efficiency Maximum Reaction Stability Maximum Reduction of sludge

Maximum Results Maximum Recovery Maximum Removal Maximum Rho ( density) Maximum Return of Capital
Investment

MaxR System Optimization and Dorr-Oliver Eimco Equipment

Reaction Vessels

Sedimentation Process
Oxallizer Oxidation Reactor

Convention Clarifier with E-DUC Feedwell

Reactor-Clarifier Unit

E-CAT Clarifier

Deep Cone Paste Thickeners

Sludge Disposal

Filtration Process

Rotary Vacuum Filters (EIMCOBelt RVF) Effluent Discharge

Shriver Filter Press

Dorr-Oliver Eimco Horizontal Belt Vacuum Filter

Final Filtration

Vertical Pressure Filter VPF

SBW

Granular Media Filters (OTG, SVG, VPF, SBW Filter Styles)

Complete Project and Process Responsibility

Complete Turnkey Responsibility
Dorr-Oliver Eimco has been a leader in the manufacture of process equipment for the past 50 years. We have successfully integrated this significant process expertise into the service of providing complete project and process responsibility. Specifically, we can offer the following: Bench Scale Testing Pilot Scale Testing (On-site or at our facility) Flow Sheet Development and Optimization Equipment Sizing and Integration Equipment Supply Detail Engineering Construction Management Start-up and Operator training Continued Parts / Service Department COMPLETE Process System Design and Control

Typical Applications
The MaxR Treatment Process can be applied in any application where chemical precipitation occurs and where the process can be modified to control the reaction process. Applications where Dorr-Oliver Eimco has obtained process improvement include: Magnesium Hydroxide Production Acid Mine Drainage (Metal Hydroxides and CaSO4) Steel Mill Acid Pickle (FeCl3, HCl) Water Softening [Ca(HCO3)2, Mg(HCO3)2, SiO2] Rare Earth Oxide Production (Lead Sulfide) Chemical Plant Wastewater (Calcium Fluoride) Agra-Fuel Ethanol Production (CaSO4, Metal Oxides) Phosphate Wastewater Treatment [CaF2, CaSO4, Ca(PO4)3] Mineral Sands Beneficiation (Iron Hydroxide and CaSO4) Brine Treatment in Caustic Chlorine and Food Applications (CaCO3) Mineral Leaching Solution Treatment (Metal Oxides and CaSO4) Ground Water Treatment in Natural Gas Field (Barium Sulfate)
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Ground Water Treatment (Calcium Carbonate, Fluoride and Boron) Titanium Dioxide Wastewater Treatment (Iron/Metal Hydroxides/Calicum Sulfate) Industrial Wastewater from Latex Manufacture (Magnesium Hydroxide) Fluoro-Hydrocarbon Manufacture Wastewater (Calcium Fluoride & Arsenic) Aluminum Reduction Facility Wet Scrubber (Calcium Fluoride and Sulfate) Power Plant Wastewater (Metal Selenium Sulfites)

MaxR Process Portable Pilot Unit

Caustic-Chlorine/Brine Treatment
The MaxR Treatment Process
Dramatically Improves Brine Treatment Performance Maximize treatment capacity with minimized capital/operating costs
No External Reaction Tanks Required Reduced Sludge Filter Size

Maximizes Savings in Sludge Disposal Costs

Filter cake solids increases from 15-40 wt% to 40-70 wt%

Maximizes Dewatering Equipment Performance

Clarifier loading increases from 0.5 m/hr to 1.5 m/hr Clarifier Underflow solids increase from 3-10 wt% to 15-40 wt% Filtration rate increases by 3X-20X compared to Conventional Treatment Processes

Dorr-Oliver Eimco has successfully applied the MaxR Process for use in brine treatment, where removal of soluble magnesium, silica, and other metals as precipitated solids is required. Several installations have enabled us to demonstrate the MaxR Process performance in saturated brine applications. Specifically at the most recent installation in Louisiana, we had the opportunity to compare the MaxR Process versus a Conventional Treatment System that has yet to be upgraded to a MaxR Process. MaxR treatment technology generated superior effluent quality, produced a more dense sludge, and reduced the quantity of chemicals required.

Maximizes Utilization of Chemical Additives.

Reactant Chemical Consumption is Reduced by 5-25% Excess Chemical Concentrations Reduced by 25-50% Excess Na2CO3 400-600 ppm Excess NaOH 150-300 ppm

Maximizes System Chemical Stability

Maximizes Metals Removal Producing Lower Effluent Concentration Soluble Calcium from clarifier 0.45-1.25ppm Soluble Magnesium from clarifier 0.025-0.04ppm Soluble Silica reduce to less than 3 ppm as SiO2

Typical MaxR Brine Treatment Process Flowsheet

NaOH Addition Na2CO3 Addition Polymer Treated Effluent Raw Untreated Brine Influent Sludge Recirculation

Vertical Pressure Filter

Effluent Comparison (Settling Time = 5 minutes)

Reactor Clarifier Unit Granular Media Filter (Anthracite)

Soluble Calicum vs. Excess Carbonate Required

10 8
Ca (ppm)
Conventional Treatment MaxR Process Treatment

Thickener Sludge Discharge to Filter

Filter Press

Vacuum Filter

6 4 2 0 200

Filter Cake

Filter Cake Filtrate

Filter Press
Finished Brine

400

600 800 1000 Excess Carbonate (ppm)

1200

MaxR Process requires less excess chemicals to achieve same removal of a soluble species. Shown, in the chart to the left, is the calcium removal versus excess carbonate required in brine treatment.
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Applications
Acid Neutralization and Metal Hydroxide Removal for Water Treatment and Re-use Acid Mine Drainage Treatment

Virginia
Effluent < 15 NTU Sludge thickener underflow 30 - 50 wt% Vacuum filtration solids 70 - 75 wt%

California
Annual operational savings = $1 million Solids concentration doubled in drying ponds to 65 wt% Vacuum filtration rate increased by 20X Center column pumping - no tunnel required

Brine Process Treatment

Super-Phosphate Fertilizer

Louisiana
Silica out < 1 mg/L Sludge thickener underflow = 40 - 60 wt% Excess chemicals decrease by 30 - 50% Water blanket technology utilized

Brazil
Characteristics Inlet (mg/L) Discharge (mg/L) SS 20,000 < 200 F 1,300 <5 PO4 2,500 < 80 Scale formation reduced Sludge thickener underflow = 25 wt%
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Power Plant Wastewater

Steel Mill Wastewater

Pennsylvania
Provided a complete turnkey project MaxR Process which includes:
Reactor Clarifier Unit Thickener EIMCOBELT RVF and SVG Filters used in conjunction with our advanced biological/aeration technology, Advent Integral System

China
Characteristics Inlet (mg/L) Discharge (mg/L) SS 400 < 20 O&G 400 <5 Zn 80 <2 Filtration cake >50 wt% solids versus 35 wt% solids obtained from parallel conventional treatment train

Underflow to vacuum filter is 40 wt%, cake of 65 wt% Influent SS concentration = 70,000 mg/L, final SS effluent averages less than 20 mg/L

Reference Installation List

Application
Process, PbS Brine Treatment (Food Industry) Chemical Plant Wastewater Fertilizer Wastewater HF Wastewater Hydro-Metallurgical Process Acid Wastewater Acid Wastewater Fertilizer Wastewater Acid Mine Drainage Acid/Alkali Wastewater Mine Water Infiltration NaOH-CI2 Brine Treatment Power Plant Wastewater NaOH-CI2 Brine Treatment NaOH-CI2 Brine Treatment TiO2 Acid Neutralization

State/ Country
CA WI MS Brazil LA UT OH OH Thailand CA China NV LA PA LA KY VA

Operation Date Feasibility

1984 1988 1989 1991 1992 1994 1995 1996 1997 1997 1997 1997 2000 2000 2001 2001 2002 X X X X X X X X X X X X X X X X

Pilot Plant
X X X E X X X X E X X X X E E

Equipment Process Equipment Tankage/ Construct. Start-Up Operator Sizing Design Supply Erection Mangmnt. Services Training
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

X X X X X X X X

X X X X X X X

E = Pilot testing results obtained from Experience/Testing from previous similar projects 7

Global Sales, Service and Full Equipment Life Cycle Support

Dorr-Oliver Eimco is here to help you with all your solid/liquid separation needs. Please call us to find out more about how Dorr-Oliver Eimco technology can improve your productivity. In the U.S., please call 1.801.526.2000 and in Canada, call 1.705.325.6181.

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Walluf Milano Beijing

Birmingham

San Luis Potosi

Singapore Lima Sao Paulo Santiago Belmont Gosford

Johannesburg

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For a complete listing of our equipment and to find a regional contact near you, please visit www.glv.com