C r u s h i n g P l a n t s S p A Headquarter Baioni Crushing Plants SpA Via Cesanense 176 61040 Monte Porzio (PU) - Italy tel. +39 071.7950313 - fax +39 071.7950207 e-mail: baioni@baioni.it www.baioni.com - www.baionienvironment.com Foreign branch offices Baioni Algeria 8, Bab Ezzouar Wilaya d'algiers Algeria tel. +213 6 63434480 - fax +213 21.280969 e-mail: baionialgeria@baioni.it Baioni Cuba 5ta Avenida, No. 9208, entre 92 y 94 Miramar Playa La Habana Cuba e-mail: baionicuba@baioni.it Baioni China 1108 Room 1-2# Building Northern Technology Park High-tech Zone Henan Luoyang China tel. +0086 0379 6300 3520 e-mail: baionichina@baioni.com.cn Characteristics, photos and dimensions are not binding. Baioni Crushing Plants SpA reserves the right to modify the specifications herein without prior notice. Copyright2017BaioniCrushingPlants. All rights reserved. Printed in May. Code 046 WATER SLUDGE TREATMENT
Baioni wastewater and sludge treatment system Thanks to the proven experience in the production of crushing and screening equipment, the Baioni company is active with the design and the manufacturing of equipment used in the water clarification and sludge treatment plants: last generation thickeners (tanks), polyelectrolyte dosing system and high performance horizontal centrifuges. Great flexibility to vary their production according to specific customers' needs, combined with a strong experience, allow to enhance innovation and applied technology of an added value always very well appreciated. The Baioni company is able to provide with advice for each application and installation of all the equipment supplied, even for turnkey plants. Baioni BCH clarifiers (thickeners) are designed to adapt to the inevitable qualitative and quantitative variations of the material to be processed; they are sized according to the flow of the slurry and to the concentration of solids. The aim is to clarify the waters coming from quarrying, recycling and industrial operations and recycle them on the same plant, as well as to increase the solids content and reduce the volume of water thereby minimizing the load on downstream processes. FILTERPRESS BaiPress and BaiPress The customization of BaiPress Baioni according to customer's needs is the key feature of the company design and production. Each machine combines widely tested technologies to real innovation, as Baioni is active in the field of filtration of liquids in various fields of application. Filter presses are used today in different industrial sectors: for the sludge dehydration in sewage wastewater treatment p l a n t s / s i t e s a n d i n m a n y aggregate/mineral and chemical processes. The production counts on two kinds of filter presses able to meet every customer requirements: overhead beam type and side beam type. Models range in sizes from 650 x 650 mm up to 2000 x 2000 mm. Differences between the two systems Filterpress The filterpress works discontinuously (2-3 presses/hour). At the end of each press, filters must be perfectly emptied. Operator attendance is always required. Much more space required for installation. Civils works required. Solid cakes are removed/collected with excavators or loaders. Filters are quite delicate, any impurities may easily damage them. Decanter Decanter works continuously. Very little operator attendance required. Fully automatic with PLC. Small footprint. Concret pad or steel structure required. Solid cakes are discharged on a screw conveyor or a conveyor belt. Longlife to components subjected to wear (abrasion-resistant, components in stainless steel, high-performance rotor, Cyclo reducer).
EXAMPLE OF A WASHING, CLARIFYING AND DEHYDRATION PLANT Benefits for more Concern for environmental protection and reduction of aggressions is growing. In an attempt to protect our ecological surroundings and minimize the negative effects of industrial process it is necessary to purify and recover the waters used during washing operations. Clarifier tank Clarified water Clean water After having experienced "traditional" plants for many years, the Environment division of the Baioni company has managed to create a new technological solution and develop a series of exclusive innovations which make Baioni water treatment systems: Buffer tank CHEAPER AND QUICK TO SET UP Can be placed on a small concrete pad, no excavation or tunnels. Minimise installation time. EASIER TO INSPECT Each component is easily accessible, maintenance is easier and more accurate. Feeding Polymer flocculant unit Centrate Solids discharge SAFER IN OPERATION The exclusive system of automatic lifting of the bridge during the rotation avoids any possible clogging of solid material. Decanter provides the advantages of high efficiency operation compared to traditional separation system. ADVANTAGES OF BAIONI DECANTER AUTOMATION Polymer pump Dehydration plants is automatically controlled throught inverter with a very little operator attendance. All functions are controlled by a PLC for all power engines and pumps, flocculant dosage, main tank levels. ECONOMY AND QUALITY Very little operator attendance required Hightest cake dryness minimises disposal costs Various wear protection systems for long lifetimes Simple and service-friendly design Low specific power consumption per unit product processed MORE EFFICIENT The concept with 6 rotating rakes and the overflow water chutes reduce the turbulence of the waters and increase the separation of the solid material. EASIER TO EXTEND Thanks to the wide range of modular and coordinated accessorizes. EASIER TO MANAGE Thanks to the computerized system of the flocculant dosing device, the evacuation of solids and all other services. The system can be remotely controlled via internet or another network. EASIER TO MOVE Modular bolted sections ensuring reduced installation time in case tank has to be moved from site. PERFECTLY TESTED TECHNOLOGY WITH A WIDE RANGE OF INSTALLATIONS AVAILABLE. Gearmotor Clear water tank
and BaiDec Standard features Galvanized steel tank. Overflow water chutes mod. "THOMSON". Supporting structure in robust steel profiles. Submersible centrifugal pump for slurry. Rotating Half-Bridge scraper/central Mixer. Fully galvanized stairs with walkway. Hydraulic lifting system for the 6 rotating rakes. Sludge pump. Turbidity monitoring unit for polymer dosing. Automatic polyelectrolyte dosing unit. Polyelectrolyte dosing pump. Clarified water tank. Clear water tank. Centrifugal clarified water pump. Clear water centrifugal pump. PLC control panel, touch-screen. Options Turbidity feed measurement to control polymer dosing. Non-standard pain finish. Application fields The Baioni wastewater treatment system can be used for quarrying, mining and recycling applications as well as for industrial wastewater treatment plants where the following materials are subjected to washing operations: Sands and Gravel Aggregate and Mineral Drilling & Tunnels Soil washing Tannery Agro-industrial Industrial laundry Ceramic industry Industrial processes A decanter centrifuge employs the same principles of gravitational force: it is useful to extract (dewater) solid materials from liquids when they are mixed together in slurry. The process is expedited through the use of continuous rotation, a bowl rotates at high speed and a scroll rotates rotates at a slightly different speed than the bowl and conveys the solids toward the conical end of the bowl. This differential speed determines the residence time of the solids in the bowl. Once inside the bowl, centrifugal force causes the material to separate. The scroll moves the solids to the tapered end where they are discharged on a continuous basis; clear fluid flows out the other end. BOWL The bowl has a conical shape and is in stainless steel to ensure optimal strengh and corrosion resistance. SCROLL The scroll, in stainless steel, rotates at a slightly different speed than the bowl and conveys the deposited solids toward the conical end of the bowl. This differential speed determines the residence time of the solids in the bowl. Residence time is an important variable for the dry solids content. It can be adjusted by changing the differential speed of the scroll thus providing optimal separation. ROTOR BEARINGS Baioni offers a special selection and arrangement of bearings to provide long life and reliability. A central lubrication system supplies grease to bearings. OVERFLOW WEIRS The clarified liquids flow to the cylindrical end of the bowl where they exit over weir plates. Easily adjustable precision weir plates allow for the precise adjustment of the pond depth in the bowl. Overflow is then collected in a centrate chamber and discharged by gravity. Bowl detail Twin motor detail Liquids discharge detail Scroll detail
Baiwash Discharge cone Rotating rakes
Technical specifications D A Model BCH06 BCH08 BCH10 BCH12 BCH14 BCH16 BCH18 feed material flocculent added clean water overflows Diameter D 6 8 10 12 14 16 18 m thickened sludge is discharged rotation of the 6 rakes Height A 5,20 5,40 5,60 5,80 6,00 6,30 6,60 m
How to choose a Baioni thickener The range of tanks from 6 to 18 mm in diameter enables to treat a slurry capacity up to 1300 mc/h, with a concentration of solids up to 80g/l. The following graphic shows the general parameters of the most demanded models. For special requirements we are ready to study a specific solution. Selection chart 117,60 80 g/l Process description The BCH clarifiers are devices designed to clarify the washing waters of aggregates. The clarification occurs by decanting the solid particles (silts and clays) which sink to the bottom of the decanter while the clarified water comes out through the dualchannel overflow. The process is continuous and is aimed at the full recovery of the aggregate washing waters to be reused, drastically reducing the consumption of mains water. Inside of the tank perimeter, on the surface are overflow water chutes, installed far from the tank wall. Thanks to this position, overflow water chutes can collect water on either sides, accelerating the drainage. A descharge (drain) pipe finally conveys clear waters towards a storage tank then resued in the process cycle for washing purposes or other. In this storage tank is usually a float valve which provides for the water restore from a well or water supply system. The overflow of the water to be integrated into the compartment of the clarified water allows the maintenance of the water level which is therefore controlled by sensors. SUSPENSION SOLIDS (t/h) TECHNICAL DATA Model Construction material Tank capacity 88,20 73,50 56,50 42,00 30,00 20,30 12,55 6,85 Flow max. turbid 0,0 0 6 8 10 SLURRY FLOW (mc/h) 12 14 137 251 406 600 840 1130 1470 BCH06 BCH08 BCH10 BCH12 BCH14 BCH16 BCH18 Acciaio zincato a caldo 68,5 125,5 203 300 470 565 735 137 251 406 600 840 1130 1470 2280 4180 6760 10000 14000 18830 24500 16 18 50 g/l 20 g/l m3 m3/h Lt/min The slurry coming from washing process or drillings are first conveyed inside a suitable collection tank and then channelized inside the clarification tank through a pump or by gravity. To optimize and speed up the settling process of the solid particles, it is recommended to mix the sludge with appropriate polymer to ease particles agglomeration. Polymer type to use, amount, preparation, depend on the features and composition of the solid part (in the slurry). These additives could be done inside a suitable tank, or directly on the clarifier loading pipe ("cylinder of calm"). Such an additivation can be made inside a tank specific, or directly on the load pipe ("cylinder of calm") of the clarifier. The result is a state of calm both in the liquid mass surface, and in the bottom part, solids fall on the bottom of the clarifier forming a bed of sludge which is necessary to concentrate into the discharging cone: the whole structure of the tank is purposely equipped with six rakes which concentrate sludge into the cone through a very low speed rotation. Rakes rotate along tank floor allowing a high quality sludge and avoiding any clogging. Under the cone, externally and easily accessible, is a pump controlled through a system measuring rake rotation stress, consequently determining the sludge concentration level present in the cone. A pump operates when the sludge achieves the right concentration and is automatically closed when the rake stress gets back under pre-established values. The Baioni water treatment system is fully automatic allowing to adapt the program in function of each installation, as to optimize flocculant dosing and sludge pumping. While the water used for the washing is totally reused, thickened sludge is extracted from the back discharge of the tank and through a pump is sent to the centrifugation step (or pressing). To limit the cost of disposal (by weight) of thickened sludge or limit the amount of material to bring to a landfill, it is necessary to separate the excess of water in the same sludge, making the latter drier. Two methods of mechanical dehydration are available: high performance decanter BaiDec. filterpress BaiPress.
Prpcess description Key features and Benefits Slurry feed direct arrival Turbidity control Clarifier tank Hot-dip galvanized steel tank demountable and totally lifted off the ground. Level of civil requirements reduced. Small footprint. Easy maintenance and quick replacement of spare parts. Slurry feed with pumping Clear water Clarified water tank Modular bolted sections. Minimise installation time. Easy transport and assembly. Clarified water tank Delivery of slurry Sludge pump Clean water centrifugal pump Control panel Centrifugal clarified water pump Fully galvanized stairs with walkway. Optimise control of all operations and maintenance. Connections, pipings Polymer flocculant unit Conical shape in the bottom part. Good flushing of sludge to the centre of the tickener. Direct conveying to the sludge pump. Polymer pump The introduction of Baioni system brings significant cost savings as it reduces the area previously required to accommodate ponds or lagoons, pumps and accessories are outside allowing easy access and maintenance. It also reduces the volume of fresh water required to feed the washing plant by up to 80% as there is a constant water flow during the process, so waters are reused instead of being disposed off. It is a compact design for rapid installation and minimum down time. Six rakes which raise through a hydraulic system while the machine is in operation Avoids any possible clogging of solid material. Excellent push of the sludge towards the centre of the tank. Less water turbulence. Key composition The whole treatment plant consists of two main parts: first part dedicated to the water purification plant with pre-treatment, sludge thickening, flocculation, clear water. second part dedicated to sludge dehydration by using the high performance decanter BaiDec or a filter press BaiPress at the end of the process which include also storage tanks, agitators, pumping. Overflow water chutes "THOMPSON" can collect water on either sides. Decrease the height of the overflow surface favoring the discharge of water more slowly; sludge gets a better sedimentation.