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Waste Water Treatment · Water Purification
EISENMANN
This is EISENMANN
Innovations and strategies for the optimization of production, process technology and in-house logistics are what we do best. EISENMANN builds facilities for surface finishing technology, material flow automation,environmental technology, ceramic firing lines and special facilities for coating, recycling, thermal processing and energy recovery.
Approximately 2,500 employees worldwide, half of whom are engineers or technicians, develop new ideasfor future fields of production, painting, assembly ordistribution. Among them are experts and specialistswith well-founded know-how in various areas of expertise and industry sectors. An advantage that is mirrored in tailored concepts with state-of-the-art technology and a high degree of economic efficiency.
Another result of our efficient production and assemblystrategies: Our production centers are tailored to therequirements of individual customers. They allow the production of a system’s configuration specially designed to your requirements at your own site.
EISENMANN technology center in Holzgerlingen
Our unique installation concept offers a significant contribution to increasing quality and on-time deliveryperformance. When delivering complete systems, weassemble the entire system at our facility pre-assemblybuilding in order to conduct a thorough system check.The individual pre-assembled functional units are delivered to the customer. As a result, the customersaves time and money, and installation can proceed without production downtimes.
Needless to say, once the system has been put into operation, we are there to provide you continued support: Our after-sales service provides professionalmaintenance, speedy repairs, and immediate supply of spare parts.
Water treatment from a single source
EISENMANN develops, designs and installs custom-madesystems for water purification, waste water treatmentand water recycling systems for nearly all areas of production and service. This includes a large variety ofindustries such as surface treatment companies, disposaland cleaning plants, the chemical industry, power plants,the printing industry, metal processing plants, the foodindustry, the pharmaceutical industry and many others.
Depending on the desire of our customers, EISENMANN provides not only the planning, design and installationof water treatment systems, but also turnkey total solu-tions, including buildings or even build-operate-transfermodels. For this, EISENMANN can utilise experiencegathered over 25 years of system design and more than800 reference installations for water treatment plants.
ContentsThe best process for every individual case 2
Decontamination, oxidation 3
Precipitation, flocculation, sedimentation 4
Flotation 6
Biology 7
Filtration / membrane processes 8
Ion exchanger 10
Recycling 11
Complete environmental technology from a single source 12
Service and maintenance 13
Complete waste water treatment for a car plant
Desalination plant by ion-exchange for a power station
Turnkey waste water treatment plant in the chemical industry
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Our engineers develop the best water purification or waste water treatment processfor each individual application. EISENMANN is able to do this because we offer allof the important systems.
In accordance with our policy, “avoid – recycle – dispose”, initially the overallsituation of the production process is investigated. The best environmental protection is still to avoid or to reuseemissions. This policy is not only requiredby law, but the proper process design andresource management also reduces invest-ment capital expenditure and associatedoperational costs. Also, when refitting exi-sting plants, it is often possible to achieveconsiderable savings through the utilizationof modern recycling technology.
EISENMANN offers a large number of pro-cesses and combinations of processes whichare specifically adapted to the substancescontained in the raw water or waste water.By means of such custom-made water puri-fication and waste water treatment plants,the undesired substances are removed from the water so that the pure water properties required by the production or the corresponding consent limits for waste water can be fulfilled without difficulty.
The best process for every individual case
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Suspendedsolids
highly recommendedrecommendedapplicable
Heavymetals
Oil / Grease SulphatePhosphate
CN, CrVINitrite,AsIII
PaintInk
OrganicsCOD
AOX Micro-organisms
Ions
Decontamination /Oxidation
Precipitation, Floccu-lation, Sedimentation
Flotation
Filtration/Adsorption
Microfiltration
Ultrafiltration
Nanofiltration
Reverse osmosis
Electrodialysis
Biology
Evaporator
Ion exchanger
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Waste water decontamination is the term for all thoseprocesses in which toxic substances in the water aretransformed into harmless substances that can then beremoved from the water flow.
These are, in particular, waste water flows containing cyanides, chromates, arsenic or nitrite as well as dissolved complex metal compounds.
Around the world, authorities pose increasingly highrequirements on the biodegradability of undesired substances contained in water. In some cases very low COD values are demanded.
Industrial waste waters, in particular, are frequently contaminated with organic substances whose toxicitymakes the biological treatment difficult or even impossi-ble. In such cases, various oxidative treatment processescan solve the problem.
In particular, the Fentox process® patented by EISENMANN is very promising. It is based on the oxidation of organic substances by means of Fenton’sreagent, and in addition to process technology advanta-ges it is also distinguished by low consumption of the oxidation chemical and reduced sludge generation.
Decontamination · Oxidation
Landfill leachate treatment by the Fentox® process in an industrialpark
Waste water decontamination for a battery manufacturer
COD reduction by the two-step Fentox® process.
FeSO4 NaOH
Sludge thickener
Chamber filter press
Sewer
Belt filter
Preheater
Inlet
Compressed air
Reactor 1 Reactor 2
2-Step Compact clarifier
H2O2
Precipitation is a classic waste water treatment methodused for the removal of dissolved heavy metal ions, fluorides, phosphates and similar substances. By raisingthe pH with neutralization media the harmful substancesare transformed into an insoluble form.
By adding flocculant and polyelectrolyte,large flakes are created, which can beseparated from the water by sedimentat-ion through suitable settling installat-ions. Therefore, EISENMANN developedthe two-step compact clarifier and thehigh-performance sludge clarifier thatare proven technologies in several reference plants.
The separated slurry is concentrated in asludge thickener and drained in a filterpress until it contains approximately 35%dry substance. The water phase from theclarifier is run through sand filters toremove small impurities. Depending onthe quantity of waste water, the processis either designed for batch- or continu-ous operation.
Continuous waste water treatment plant for fluorid removal, preinstalled and commissioned at EISENMANN
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Precipitation · Flocculation · Sedimentation
Waste water treatment using a batch process
Concentrate after thepretreatment
Rinse water from the pre-treatment
Waste waterfrom thecathodicelectro-coatingplant
Batch reactor
Final filter
toSewer
pH finalcontrol
Chamber filter pressStorage tank for water
containing paint
Chemicals fortreatment
Storage tank for wastewater containing oil
Tank for acidic / alkalinewaste water
Waste water treatment for direct discharge in a river: Phosphate precipitation with contactsludge recirculation and a high-performance sludge clarifier for a chemical production plant
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Waste water treatment using a continuous process
Figure, left: Chemical storage, continuous neutralizationwith a clarifier, batch reactor and DI water circulationsystem for an aluminium processor
Final filter
Continuous neutralization system
Waste water tank
High-performancesludge clarifier
toSewer
pH finalcontrol
Sludge thickener
Filter press
Chemicals fortreatment
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Substances that tend to float because of their low densi-ty can be removed from the waste water by flotationtechnology. These are, for instance, substances thatcontain oil, grease and carbohydrates, which are used
in all branches of industry (e.g. the textile industry,laundries, the food processing industry) and waste watercontaining paint.
The flotation of the substances contained in the wastewater is supported by the addition of chemicals and the injection of dispersed air (expansion flotation). The EISENMANN flotation system enables the optimumseparation of the water and the sludge phase. Using the scraper system at the surface of the flotater, the sludgeis separated and drained in subsequent process steps,such as the drainage container, chamber filter press ordecanter.
Paint sludge flotation in an EISENMANN flotator in an automotive plant
Purification of laundry waste water by flotation
Chamber filter press for filtering of slurry
Flotation
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Biological processes use the ability of microorganisms totransform and remove contaminants in the waste water.Many organic contaminants can only be econo-micallyeliminated using biological methods. Therefore, variousanaerobic and aerobic techniques are available. EISEN-MANN is your competent partner for industrial and com-munal waste water treatment in this field, too.
The strength of anaerobic technology is the acidificationand fermentation of organic carbon compounds into theend products methane and carbon dioxide. Anaerobic processes do not require any oxygen, and the quantity ofexcess sludge produced is low. The anaerobic process isparticularly suitable for waste water with a high organicload (COD, BOD).
In aerobic biological processes the effluent is suppliedwith oxygen to grow biomass that degrades the organicsubstances in the waste water. This oxidation processconverts the organics into biomass and mineralized products. Aerobic systems are particularly suitable for achieving very low discharge values of, e.g., COD,BOD, P and N.
Anaerobic and aerobic techniques can be used as singleprocesses or in combination. For example the mainreduction of COD is achieved in an anaerobic reactor by production of a high-energy biogas followed by anaerobic purification process in order to reach the lowdischarge values required. By the additional integrationof membrane techniques, the efficiency of biologicalinstallations can be increased and the space required for them decreased. Here EISENMANN can make use ofconsiderable know-how accumulated in this product area.
Anaerobic fermentation with production of biogas
Combination of anaerobic and aerobic techniques with membrane filtration
Cross-flow membrane filtration in the bypass to the bioreactor forbiomass concentration and separation
Biology
pH final control
Waste water flow
Primary sludge Secondary sludge
Aerobic reactor
Anaerobic reactor
Air
Membrane sepa-ration step 2
Membraneseparation step 1
Biogas for energyproduction
to sewer
Filtration processes are used to remove fine dispersions or mechanically suspended particles from the water. Theproduct range covers simple candle filters, bag filters orsand filters to more complex filtration layers. In additionto the pore size of these filtration layers, adsorptioneffects are important for the filtration.
The efficiency of these processes can be combined andincreased with appropriate chemicals.
Sand filter installation forsuspended solids removal
Rotor filter for concentrating biomass in highly loaded waste water
Reverse osmosis plant for water desalination
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Filtration · Membrane separation processes
Membrane filtration is the selective separation and con-centration of dissolved as well as non-dissolved sub-stances from the aqueous phase under pressure. The sizeof the particles to be separated determines the pore size(cut-off) of the membrane which has to be chosen forthe optimal process. For example, ultrafiltration is suit-able for retaining paint pigments and/-or oil droplets,but ultrafiltration can’t retain ions. Consequently, theconductivity of the treated water remains the same. Fordesalination of water, reverse osmosis membranes arerequired, which are gaining an increased market share incompetition with the established ion exchange processes.
Most important for the efficiency of the membrane sepa-ration process is among the cut-off and the individualdesign, the choice of membrane material (ceramic ororganic), and module design (hollow fiber, tubular, spiralwound, rotor or plate).
Top: Ultrafiltration system for emulsion splitting at a liquid wastedisposal company.
Left: The modular construction of the membrane filtration system ensures high filtration performance and availability.
Membrane Cut-off Exampleprocess
Microfiltration 0,1 - 0,9 μm MicroorganismsUltrafiltration 0,1 - 0,01 μm Emulsified oil dropletsNanofiltration 0,01 - 0,001 μm Sugar moleculesReverse Osmosis 0,001 - 0,0001 μm Ions
Process diagram of the cross-flow filtration
Ultrafiltrationmodule
Concentrate tank
for utilisation
Filtrate
Concentrate recirculation
Working tank
Waste water flow
Rinsing agenttank
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Ion exchanger
Top: Ion exchanger fluidized bed system for water purification in apower station
Right: Control panel of a power station equipped by EISENMANN
Bottom right: Ion exchanger system for a water circulation systemusing new modular EISENMANN design
Ion exchange is the most versatile and proven separationprocess for water purification and recycling. With thistechnique, it is possible to desalinate fresh water to thepoint that it can be used as boiler water in a power station or in combination with membrane separation processes for chip production.
Ion exchangers are often used for the circulation of rinsing water because of their robustness and economicaladvantages for desalination of low salt-containing water.For the waste water treatment, selective ion exchangersare used for the removal or recovery of metals.
10
Recycling
Two-step membrane separation process for printing ink recycling
Ultrafiltration with tubular modules for printing ink recycling
Because of the EISENMANN policy, reduction and recycling are preferred to disposal, and circulation techniques have priority over waste water treatment. With EISENMANN’s experience in production processes,
all options for water saving and water recycling are checked and already incorporated in the design phase.
By integration of an evaporator in a pretreatment linezero discharge operation can be achieved. Because wastewater no longer discharges into the sewer, a whole seriesof official regulations and controls are eliminated.
Another example of an optimum combination of economyand ecology is the two-step membrane process for prin-ting ink recycling. The wash water from production hastraditionally been treated by coagulation, creating a sludge that had to be disposed of. With the recyclingprocess developed by EISENMANN, the ink containing
Zero discharge pretreatment with evaporator technology
wash water is treated by ultrafiltration so that the prin-ting ink is recovered and can be reused. The second step,the nanofiltration, removes the trace organic substancesand heavy metals from the filtrate of the ultrafiltration.The nanofiltrate can then be reused for cleaning or dis-charged into the sewer.
The example described shows that the combination ofrecovery of valuable substances and waste water treat-ment leads, even for environmental plants, to interestingamortisation periods.
Sludge
Cyclone
Dirty water Evaporator
Ultrafiltration Nanofiltration
Printing ink collection tank
Filtrate tankConcentratetank
Recycling
tosewer
Rinsingwater fromthe produc-tion
Distillate
Fresh water
Pre-degreasing Iron-phosphating
DegreasingIron-phosphating
Rinsing 1 Rinsing 2 DI rinsing
Reverse osmosis
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Complete environmental technology from a single source
EISENMANN’s extensive productrange of environmental technology,with technologies for waste water,exhaust air and waste, enablesEISENMANN to develop complexinstallations and to deliver themfrom a single source supplier. Thisensures optimal process design withminimum operating costs. A typicalexample is the following modulardisposal system.
1st Module: High turbulence reactor(“Turaktor”) for the thermal treat-ment of liquid waste.
2nd Module: Exhaust air purifi-cation system for cleaning the fluegas from the Turaktor.
3rd Module: Waste water treatment plant for the treatment of wash water from the flue gas line.
In these three steps, dangerous, highly toxic substancesare transformed into waste that can be disposed of without a problem. The waste water will be directly dis-charged into the sewer, and the exhaust air can be released into the atmosphere.
EISENMANN waste water treatment of flue gas rinsing water with oxidation, precipitation and sedimentation in the high-performance sludge clarifier(3-dimensional illustration from the CAD design program).
Disposal system for toxic wastes: In the background the thermal treatment and the exhaust air purification, in front of the waste water treatment plant. The total system was completely pre-assembled and commissioned at EISENMANN.
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The EISENMANN Service offers an extensive range of services.These are tailored individually to the customer's needs, there-by taking the know-how of the customer's employees, the coststructure, the processes and the need for expertise into consideration.
Therefore, we regard ourselvesas system providers when itcomes to meeting the individ-ual customer's requirements.
Inspection
We determine the actual stateof your system by conducting inspections and theninform you about the weak spots and possibilities forincreasing your performance, or let you know if there is an urgent need to take action.
Servicing
In order to determine the target state of your system,our specialists not only conduct the servicing, but alsocarry out mechanical and electrical check-ups and safetytests. Routine servicing guarantees an optimum function-ing of your system and increases its service life.
Repair
Our maintenance team also carries out any necessaryrepairs and component replacements of course.
Remote System Diagnosis
Using remote data communication, the remote systemdiagnosis enables our specialists to access your controlsand material-flow computers quickly and easily, and remedy any faults within the shortest time.
On-call Service
We offer you a 24/7, on-call service conducted by our Service specialists, which is based on a mutually agreedresponse time and customised to your own specific shiftoperation and production times.
Maintenance Contracts
You can rely on EISENMANNService. We offer you customised MaintenanceContracts for your system.You are reminded in goodtime of the next routine service which is carried out by qualified engineers.This enables you to plan thecosts on a continuous basisand reduce the system down-times by taking preventativemeasures.
Full Service
Due to our excellent experience gained in the construc-tion and operation of highly automated industrial systems and factories, we are able to take over theentire maintenance of your system, allowing you to fullyconcentrate on the key processes of your business. Weguarantee system availability at all times, and the valueof your systems is preserved long-term through:
• Preventative maintenance• Troubleshooting• Repairs• System Reconstructions and Updates
The EISENMANN Service is your first contact for systemreconstructions or extensions, whether for environmentaltechnology and spray painting, or for process technologyand materials handling. We adapt your systems engineer-ing to new conditions if, for example, you should wish to increase your throughput, or the product dimensionsor weights have changed, or if your space planningnecessitates this. We likewise offer you a first class service where production relocation is concerned.
Service and maintenance
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EISENMANN Corporation150 East Dartmoor DriveCrystal Lake . Illinois 60014 . USAPhone +1 815 4554100Fax +1 815 [email protected]
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OOO EISENMANNUl. Pyatnitskaya 47-1119017 MoscowRussian FederationPhone +7 495 951-6824Fax +7 495 [email protected]
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Daimlerstrasse 571088 Holzgerlingen . Germany
Phone +49 7031 78-0Fax +49 7031 [email protected]
EISENMANN Service GmbH & Co.KGTuebinger Strasse 8171032 Boeblingen . GermanyPhone +49 7031 78-3000 (6.30 - 18.30 h)Fax +49 7031 [email protected]
EISENMANN Ingeniería S.A. Parc de Negocis Mas BlauEdificio Prima Muntadas c/Berguedà, 1 . Barcelona08820 El Prat de LlobregatPhone +34 93 479-6610Fax +34 93 [email protected]
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EISENMANN Italia S.r.l.Via Ferrari, 2121047 Saronno (VA)Phone +39 02 96718-626Fax +39 02 [email protected]
EISENMANN U.K. Ltd.Unit 118 Severn HouseAnson Court Business CentreStaffordshire Technology ParkBeaconside . StaffordStaffordshire ST18 OGBPhone +44 1785 283790Fax +44 1785 [email protected]
www.eisenmann.com
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