This document describes a concept for a 10-25 circulating KASELCO trailer-mounted reaction system followed by dissolved air flotation (DAF). The quotation is based on usage of existing technology designed for testing pig waste. 10-25 means standard 25GPM reactor operated with circulation of a percentage of the through-put such that the total through-put is 10GPM. This effectively allows the waste to be passed through the reactor a couple times.

BACKGROUND
The hog industry is most efficient when the hogs are raised in concentrated feeding operations. However, this concentration results in large volumes of waste generated in a small area, increasing environmental impact. The current practice is to use lagoons to capture the liquid from the barns. The solids load and high nutrient concentration result in anaerobic conditions that cause objectionable odors. There is an interest in reducing or eliminating the lagoons. Fresh waste from barns flushed frequently treats most easily. Either option requires that the waste be treated. Bench-scale pilot testing has shown that the KASELCO electrocoagulation process can remove the solids and reduce some of the nutrient load. After reaction, the insoluble contaminants rise to the surface and remain there, which should make separation by dissolved air flotation very effective. No process has been finalized for the separated solids, but they are expected to be used as a pumpable sludge rather than filtered to dryness. Any system selected must be able to run automatically to minimize labor costs, requiring a PLC for control. The system is expected to require only periodic checks (at least daily) and reactor rebuild (operating-time dependant). The sludge removal method has not been determined. It is expected that this system will be trailer-mounted for demonstration on a number of farms.

CONCEPT
This document describes a basic 10/25 Circulating, trailer-mounted KASELCO electrocoagulation wastewater treatment system with Redux-style dissolved air flotation system.

COLLECTION OF WASTEWATER TO BE TREATED
Waste is accumulated in the barns and is air-sparred so that the dissolved oxygen is at saturated levels. The KASELCO system would be expected to pump directly from the source or from a smaller equalization vessel fed by a sump pump operating from the lagoon or barn. The system requires that all foreign matter greater than 1/8" in diameter be screened prior to the waste feed pumps. Such screening would be by others. The screen must have a working capacity greater than the reaction system to ensure an uninterrupted supply of screened water. The collection and screening systems are not a part of this concept. A level switch will be provided for use in the accumulation vessel that will stop the system in the event fluid is not available.

DELIVERY TO REACTOR
Wastewater will be drawn from the accumulation vessel through a valve tree by a 1” electrically-stroked air diaphragm waste feed pump and fed through the 25gpm KASELCO reactor at 10gpm for treatment. The pump volume will be controllable in the system PLC. The valve tree allows maximum flexibility for flow control providing multiple inputs and outputs for batch treatment as well as continuous flow, reverse flow for reactor flushing, re-circulation, or sampling.

REACTOR AND POWER SUPPLY
The reactor will include an automatic blowdown feature and will be powered by a 200 amp, periodicreversing rectifier. A second AODD pump with pressure/volume controlled stroke will draw 15gpm or greater from the top of the reactor and discharge it into the bottom (inlet) of the reactor. This circulation will provide a total flow of at least 25gpm within the reactor while the throughput is only 10gpm.

SOLIDS SEPARATION
An anionic polymer is added at the exit of the reactor, before the DAF, as the treated wastewater is discharged. A reagent feed pump with electrical supply circuit will be provided for the polymer. After reaction, the waste will flow through a KASELCO de-gassing column to a Redux-style dissolved air flotation clarifier. The DAF will be 48” diameter and will have a 240 volt, single phase direct-air-dissolving pump to boost the solids rise and to ensure clean starts and stops of the system. The DAF will discharge separated solids through a 4” PVC pipe at approximately 2 meters above floor level into a container or handling system provided by others. The water level in the DAF will be controlled using a standpipe in the clean water tank.

TREATED WATER
The clean water tank will overflow back to the original or to another vessel or lagoon by gravity.

PROCESS CONTROL
The entire treatment system will be controlled by a Siemens programmable logic controller with touchscreen annunciation panel mounted in a fiberglass panel. The PLC will monitor level, reactor and other pressures, and will control the waste feed pump stroke frequency, pneumatic valves, and pumps. The program will include startup and shutdown cycles for the DAF with adjustable timers. An air control station will remove condensed water from the compressed air and regulate the pressure for the high (valve) and low (reactor) pressure applications.
The system will have starters, fuses, and breakers for the integral equipment housed in a fiberglass control cabinet. There will not be a main disconnect, which should be provided as part of the electrical utility to the system by the user.

MECHANICAL
The entire KASELCO system except polymer supply vessel will be mounted on an 8’ x 28’ gooseneck trailer.

KASELCO-SUPPLIED EQUIPMENT

REACTOR:
• Three 25-GPM KASELCO Electrocoagulation reactors (05, 07, 011) complete with stands, plumbing, quick-connect leads.

TANKS:
• None. (Tanks are integral to DAF)
• Polymer supply provided by user (usually open-top 55gal plastic drum).

PUMPS:
• 1”, electrically-stroked Yamada air diaphragm waste feed pump with automatic flow monitoring and automatic shutdown complete with hoses and piping to valve tree. Hoses terminate in T-type circulation fittings.
• 1”, electrically-stroked Yamada air diaphragm waste feed pump with automatic flow monitoring and automatic shutdown complete with hoses and piping to valve tree. Hoses terminate in T-type circulation fittings.
• Stroking polymer feed pump with all electrical supply, controls, and mounting.

RECTIFIER:
• 200amp, 48 volt (secondary) air-cooled on 220-volt single-phase supply.

CLARIFIER / SLUDGE THICKENER
• Redux-style 48” dissolved air flotation clarifier complete with controlled start and stop cycle capability. System will use a 3hp Edura, 220VAC air dissolving pump.
• Installation instructions (transported partially disassembled).

CONTROLS:
• Siemens PLC controller with digital modules programmed to monitor and control the KASELCO wastewater treatment system and DAF.
• Touchscreen operator interface panel.
• 2ea Berkert electric/air solenoid valves

SUPPORT:
• 1” Valve Tree with true-union connections, air-operated valve F-1.
• 5 HP air compressor

TRAILER:
• 8.5’ X 28’ double axle tandem wheels or triple axle single wheel gooseneck trailer. Trailer may be used with complete service and new tires.