PURATEK SOLIDIFICATIONpuratek.de/fileadmin/user_upload/009_Verfahren/... · InternatIonal PURATEK®...

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InternatIonalPURATEK®

InternatIonal

SOLIDIFICATION

innovative solutions

PURATEK®

SOLI

DIF

ICAT

ION

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The SOLIDIFICATION, also known under the terms STABILIZATION, IMMOBILIZATION or CONDITIO-NING, encapsulates contaminants non-leachably and permanently and minimizes the risk of environmental hazards.The SOLIDIFICATION is specifically qualified to treat inorganic waste and

contaminants, specifically heavy me-tals, but also organic waste and radio-active waste.Typical types of waste, which are qualified to be treated by SOLIDIFI-CATION are:

> Inorganic waste / solids, e.g. spent catalysts from petrochemical and chemical industry, fly ash and fine slag from incineration plants, spe-cifically municipal waste and ha-zardous waste incineration plants

> Inorganic sludge, e.g. heavy metal containing sludge from galvanizing and leather industry

> Radioactive sludge> Municipal and industrial sewage

sludge> Contaminated soilThe SOLIDIFICATION process is based on the physical encapsulation

of the contaminants and the chemical fi-xation of the conta-minants in the solid matrix of the new ge-nerated product.

Normally cement, limestone or fly ash is used as additives in combination with water. The chemical fixation is caused by additives like sulfides, iron salts, sodium silicate, clay, zeolite etc.

Depending on the specification of the waste to be treated and the specifi-cation of the final product, the final product of the SOLIDIFICATION will be reintegrated at site, disposed and integrated at approved landfills or used for construction e.g. base layer of roads or core of dykes and banks.Furthermore the final product of SOLI-DIFICATION can be casted to molds. The hardened molds can be reused or integrated into a landfill.

1. General 3

2. Process Description SOLIDIFICATION 4

3. Applications SOLIDIFICATION 5

4. Equipment SOLIDIFICATION 64.1. Input Material Feed Hopper 74.2. Conveyors for the Input Material 84.3. Silo Plant(s) for Additives 94.4. Conveyors for Additives 104.5. Dosing Units for Input Material and Additives 114.6. Process Water Tank, Process Water System and 12 Feeding and Dosing Units for Additive Chemicals 4.7. Mixing Equipment 134.8. Conveyor and Loading / Dispatch Equipment for the 14 Final Product4.9. Equipment for Casting, Compaction and Transport 15 of Molds4.10. Process Control System 16

5. References SOLIDIFICATION 17

6. Handling of the Final Product of SOLIDIFICATION 18

7. Scope of Work and Scope of Delivery PURATEK 19

Content

General

skid-mounted unit

Mixer (solidification reactor), inside hardened block after removing the form

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The SOLIDIFICATION process is based on the physical encapsulation of the contaminants and the chemical fixation of the contaminants in the so-lid matrix of the new generated pro-duct.

Normally cement, limestone or fly ash is used as additives in combination

with water. The chemical fixation is caused by additives like sulfides, iron salts, sodium silicate, clay, zeolite etc.

The input material / waste is mixed in continuous or batch wise operated mi-xers with additives like cement, limestone, gypsum, fly ash or blast furnace slag (scoria) and water intensively. In this process the waste and the conta-minants of the waste are encapsula-ted and fixed.

In case of the physical encapsulation,

the input material will be encapsula-ted by the binding material and the additives. Thereby it shall be differen-tiated between micro encapsulation (encapsulation of single particles) and macro encapsulation (encapsulation of agglomerates of particles or the whole waste matter). In case of the physical encapsulation the porosity

will be reduced substantially and the connecting paths to the surface will be blocked and a water infiltration is not possible. The leaching process is limited to the surface or fracture sur-face of the final solidified product.

In case of the chemical fixation of the contaminants, the contaminants will be integrated into the crystal lattice or the solid matrix of the final solidified product.

In case of the treatment of heavy me-tal containing input material frequent-

ly precipitation processes are used to transfer the heavy metals to a non leachable form and to fix the heavy metals in the final solidified product. The alkalinity of cement causes in presence of certain heavy metals the generation of non leachable hydroxi-des and carbonates. To some extent special precipitation chemicals like sulfides or organic sulfur components (e.g. TMT 15) are used to immobilize heavy metals.

Furthermore chemical sorption and physical sorption processes are used for the fixation and immobilization of contaminants. In case of the sorpti-on processes heavy metals and also organic molecules are bonded to electrically charged surfaces of spe-cial substances like clay materials. For sorption of heavy metals clays like bentonite or vermiculite or ion ex-change resins are used.

Depending on the specification of the waste to be treated and the specifi-cation of the final product, the final product of the SOLIDIFICATION will be reintegrated at site, disposed and integrated at approved landfills or used for construction e.g. base layer of roads or core of dykes and banks.Furthermore the final product of SOLI-DIFICATION can be casted to molds. The hardened molds can be reused or integrated into a landfill.

Process Description SOLIDIFICATION Applications SOLIDIFICATIONTypical input material / type of waste for SOLIDIFICATION:

> Inorganic waste / solids, e.g. spent catalysts from petrochemical and chemical industry, fly ash and fine slag from incineration plants, spe-cifically municipal waste and hazardous waste incineration plants

> Inorganic sludge, e.g. heavy metal containing sludge from galvanizing and leather industry

> Radioactive sludge

> Municipal and industrial sewage sludge

> Contaminated soil

Typical clients for the SOLIDIFICATION:

> Waste treatment facilities

> Landfill facilities, specifically hazardous waste landfill facilities

> Hazardous waste incineration facilities

> Incineration facilities: Municipal waste and ha-zardous waste incineration plants, power plants

> Waste treatment operation companies, also soil treatment companies

> Chemical industry

> Petrochemical industry

> Metal processing industry, like galvanizing industry

> Nuclear power industry and disposal facilities for radioactive waste

user-friendly operation and adjustment of the recipe through touch-panel

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PURATEK SOLIDIFICATION Units consist of the following parts:

> Feed hopper for the waste (inclu-ding grid for the protection of the downstream equipment)

> Conveyor for the waste, e.g. drag chain conveyor, screw conveyor, sludge and slurry pumps etc.

> Silo plant(s) for the additives

> Conveyors for the additives, e.g. screw conveyors, pneumatic con-veyors etc.

> Dosing units for the waste and the additives (gravimetric or volume-tric)

> Process water tank and process water system

> Feeding and dosing units for the additive chemicals

> Mixer (continuous or batch ope-rated)

> Conveyors and loading facilities for the final solidified product

> Alternative:Casting facilities for the produc-tion, compaction and transport of molds

PURATEK SOLIDIFICATION Units are PLC controlled and work fully automatically. The units are opera-ted via touch panel (HMI – human machine interface) and the recipes can be adjusted easily.

According to the applications the SOLIDIFICATION Units are equip-ped with required accessories like air extraction and filter units.

Equipment SOLIDIFICATION Feed Hopper for the Input MaterialPURATEK feed hoppers are designed for the filling via wheel loader. Special design for the filling via truck and skip truck are available also.

The design of the feed hopper avoids bridging, even during handling of very difficult input material, like inorganic sludge or sewage sludge. For the protection of the downstream equip-ment and the retention of bigger par-

ticles like stones the feed hopper can be equipped with a grid.

The discharge of the material from the feed hopper is carried out via a double screw conveyor. The through-put will be adjusted via a manual adjustable gear box or a frequency inverter in accordance with the requi-red throughput and the specification of the input material.

Robust designed feeding screws for various input material

Feed hopper for truck feeding

feed hopper with integrated screen

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Preferably drag chain conveyors are used for the transportation of the in-put material / waste. In accordance to the specification of the waste and the layout of the SOLIDIFICATION unit, specifically the distance between feed hopper and mixer, also screw convey-ors, belt conveyors or sludge or slurry pumps are used.

PURATEK Drag Chain Conveyors ensure the highest flexibility and ro-bustness for the conveying of various input materials considering discre-pancies in the specification of the in-put material and the layout of the SO-

LIDIFICATION plant. PURATEK Drag Chain Conveyors transport reliably either solids / bulk materials or also sludge with a dry substance content more than 15 %. Drag chain convey-ors cause only a low mechanical load on the transported material and there-fore drag chain conveyors work with low abrasion.

The drag chain conveyor consists of a robust steel frame construction with renewable abrasion protection panels at the bottom. The flanged convey-ing elements are connected via flexi-ble fasteners. The one or two string

ground chain consists of C45 steel or 42CrMo4 steel. The ground chain is routed via gears made from low abra-sion manganese steel. The design of the conveying paddles is adjusted to the specification of the input material / waste.

Conveyors for the Input Material / Waste Silo Plant(s) for the Additives

drag chain conveyor, inside production of a drag chain conveyor Loading of a spiral conveyor / screw conveyor in our factory

PURATEK Silo Plants are designed as round silos with conical bottom segment.

The silo plants for the additives are filled pneumatically. A pneumatic pinch valve which is controlled via a level switch protects the silo against over filling.

PURATEK Silo Plants are equipped with automatic pneumatic silo top fil-ters which are activated during the fil-ling process of the silo. The automatic cleaning process is controlled either by time or by differential pressure.

The silo plants are in accordance to the application either equipped with level switches or continuous level mo-nitoring systems.

To avoid bridging in the silo the coni-cal bottom segment is equipped with pneumatic bulking systems, mechani-cal knocking systems or special vib-ration bottoms to avoid bridging in the conical bottom segment of the silo.

The transition to the conveyor is desi-gned as sliding valve and/or star fee-der system depending on the speci-fication of the additives. Star feeders are variable speed controlled.

Cement silo plant, capacity 100 m³

small cement silo integrated in a solidificati-on plant with low capacity

Discharge via powered vibration-bottom

Discharge via pressurized air system Silo plant, capacity 40 m³

spiral conveyor / screw conveyor

chain belt conveyor

spiral conveyor / screw conveyor, inside

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Conveyors for the Additives Dosing Units for the Input Material and the AdditivesIn general the additives are transpor-ted via screw conveyors to the SO-LIDIFICATION unit. According to the application and the specification of the additives screw conveyors with shaft or spiral conveyors without shaft are used.

The screw conveyors are designed either as trough screw conveyors or tube screw conveyors and throughput controlled via manual gear boxes or frequency inverters.

Based on the material selection and the special design, specifically the low rotation speed, PURATEK screw conveyors work with very low abrasi-on. For highly abrasive additives the screw conveyors are equipped with abrasion protection panels.

PURATEK

®

Zur Förderung von PET-Flaschen kommen auch Trogförderschnecken mit einem Schneckenwen-del-Durchmesser von 620 mm zum Einsatz. Gegen Abrieb wird in den Fördertrog ein zusätzliches Har-dox-Verschleißblech oder eine PE-Platte einge-bracht.

special design to operate 2 plants with 1 silo

screw conveyor for additives

Screw conveyor with shaft

screw conveyor for cement shaftless screw conveyor

Input material / waste and additives are dosed via volumetric dosing units or gravimetric weighing drums into the mixer. The selection whether vo-lumetric or gravimetric dosing units are used is based specifically on the required quality of the final solidified product and the selection of the mixer type (continuous or batch wise ope-rated).

Volumetric dosing units consist of a feed hopper and a dosing screw. The type of the dosing screw is adjusted to the specification of the dosing ma-terial. The throughput is controlled eit-her via manual gear boxes or variable speed control via frequency inverter. According to the specification of the dosing material bulking agitators and feeding improvers are installed in the feed hopper to ensure a continuous and homogeneous filling of the do-sing screw and an exact dosing of the material.

In general the gravimetric dosing takes place batch wise via weighing drums, which are located on weighing cells. Continuous weighing systems are used in special applications only, if the specification of the dosing ma-terial enables the use of a continuous weighing system. Specifically for the input material / waste the use of con-tinuous weighing systems is limited because of the specification of the waste and the variation of the specifi-cation of the waste materials.

volumetric dosing device

volumetric dosing device

gravimetric dosing systemload cells at dosing system

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Process Water Tank, Process Water System and Feeding and Dosing Units for additive Chemicals

Mixer

The process water system consist of a process water tank (break tank), which ensures the independence from the local water supply, the pres-sure generation and maintenance system, the flow control system and the required dosing valves.

The chemical additives are dosed via qualified dosing pumps to the process water. Static mixers ensure the requi-red mixing and homogenization with the process water.

In accordance to the application and the required specifications of the final solidified product various mixing de-vices are used:> Continuous operated double shaft mixers with paddles> Continuous operated plough share mixers> Batch plough share mixers

The mixers are the core equipment of the SOLIDIFICATION unit and ensure a proper mixing of the input material / waste with the additives, the process water and the chemical additives and

ensure the required specification of the final solidified product.

The mixing devices are equipped with manual adjustable gear boxes or vari-able speed drive via frequency inver-ter and changeable, adjustable mixing tools. The qualified material selection for the shell of the mixer and the mi-xing tools ensures low abrasion. For abrasive applications renewable ab-rasion protection panels are applied to the mixer shell.The required mixing and the required retention time is controlled via the

size of the mixer or the filling level of the mixer, the rotation speed of the mixer shaft(s) and the adjustment of the mixing tools.

PURATEK Mixers are multiple in ope-ration and proven for various applica-tions and ensure a proper mixing, a high flexibility, low maintenance effort and a long lifespan.

double shaft paddle mixer (continuous mixer) mixer shafts in operation mixer shafts before first operation

continuous mixer, capacity 600 l plough share mixer, interior view with weir mixing tool with wear-protection

plough share mixer designed as a batch mixer plough share mixer designed for continuous operation

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The transport and the loading of the final solidified product are executed via belt conveyors in general. For the homogeneous and complete filling of skips various types of PURATEK belt conveyors are available:

> Belt conveyors and cascades of belt conveyors

> Slidable belt conveyors (also available with reverse transport)

> Swivel-mounted belt conveyors> Telescopic belt conveyors (also

available swivel-mounted)The skip handling is designed as a skip shifting system or skip carrousel systems.

For the skip shifting systems skip trolleys for single or multiple skips, which are moved on rails, are used. Via special turn tables the filled skips are provided for the loading to special skip trucks.

PURATEK Skip Carrousels provide a comfortable skip handling, specifically a smooth dropping of the empty skips and smooth pick-up of the filled skips and provide also a possibility for inter-mediate storage for several skips.

Conveyors and Loading Facilities for the Final Solidified Product

Equipment for Casting, Compaction and Transport of MoldsThe final product of SOLIDIFICATION can also be casted into forms, com-pacted and get hardened to molds. The molds can be removed from the form / shattering after short period already, but the final strength will be achieved after approximately 30 days only. The hardened molds have a very low porosity. A water infiltration is not possible further on. Leaching is limited to the surface of the concrete block.

For the production of molds batch mixers are used. The content of the mixer is adjusted to the size of the molds to be produced. The content of the mixer is emptied after the mi-xing process into the form / shattering completely.

Therefore an empty form / shattering is transported via a roller conveyor system under the mixer. A vibration and compaction unit, which ensu-res the required compaction of the final solidified product and the final strength of the molds, is located un-der the mixer.

The filled forms / shattering are trans-ported via a roller conveyor system out of the SOLIDIFICATION unit. At the end of the roller conveyor system the filled forms are picked up by a fork lift and transported to the hardening area.

fully automatic operated roller conveyor for casting molds

mold feeding processcasting mold and completed blocks, approx. 1 m³

block after removing of the form

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PURATEK SOLIDIFICATION Units are controlled via PLC and operated via Touch Panel (HMI – Human Ma-chine Interface).

The process flow is automatic. The operation software is comfortable for the operators and the operators can adjust the recipes easily.

Beside the program NORMAL OPE-RATION also special programs for START and STOP of the plant and for CLEANING of the plant, specifically of the mixer, are available. In emer-gency case and for maintenance pur-poses also MANUAL OPERATION is foreseen.

Alarms and warnings are provided optically and acoustically to the ope-rators.

For smooth trouble shooting PURA-TEK SOLIDIFICATION Plants are equipped with modems, which enable PURATEK Engineers an online-de-bugging and online-trouble shooting.

Process Control References SOLIDIFICATION

Place of Installation:Landfill Hochhalde Schkopau

Date of Installation:2008 / 2009

Application:Waste Treatment Plant for the production of alternative building materials to use in landfills. For the EU-LIFE-Demonstration-Project ENV/D/000488 CONWASTE

Client: SUC Sächsische Umweltschutz Consulting GmbH

Used Materialt:Inorganic waste form Oil and Gas Refining Company, particularly used catalyzer

Aggregate:Cement, Sand

Capacity:10 t/h end-product

Client: TAKREER(Abu Dhabi Oil Refining Company)

Place of Installation:Ruwais, Abu Dhabi,United Arab Emirates

Date of Installation:2007 / 2008

Place of Installation: Waste Water Treatment Plant Dörentrup, Germany

Date of Installation: 2008

Used Material:Municipal stabilized dewatered sewage sludge

Aggregate: Quicklime

Capacity: Input 15m³/h

Client:City of Dörentrup

Semi Mobile Plant

BeAAT Anlage

Dörentrup

Place of Installation:Brewery Nikolaev, Ukraine

Date of Installation: 2013

Used Material:Dewatered sewage sludge for brewery

Aggregat: QuicklimeClient:CUSS Chriwa Umwelt-Systemtechnik und Service GmbH

Brewery Nikolaev

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Handling of the Fianl product of SOLIDIFICATION PURATEK – EXPERIENCE AND COMPETENCE FROM THE CONSTRUCTION OF SOLIDIFICATION-PLANTS WORLD WIDE

Depending on the specification of the waste to be treated and the specifi-cation of the final product, the final product of the SOLIDIFICATION will be re-integrated at site, disposed and integrated at approved landfills or used for construction e.g. base layer of roads or core of dykes and banks.The re-integration or the integration of the final solidified product in land-fills takes place in layers with qualified compaction. The result is a monolithic block of final solidified product.

Furthermore the final product of SO-LIDIFICATION can be casted to mol-ds. The hardened molds can be reu-sed or integrated into a landfill.

PURATEK Scope of Services:> Concept Studies

> Laboratory Testing

> Basic-Engineering, including Layout

> Detail-Engineering

> Manufacturing of the Equipment of the SOLIDIFIKATION Units

> Delivery at Site and Construction / Erection

> Commissioning

> Optimization of Operation and Troubleshooting

> After–Sales-Service

Solidified waste / concrete blocks before dumping to landfill

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Thölauer Straße 16D - 95615 Marktredwitz / GermanyPhone +49 (0) 92 31 / 98 60 6 - 0 Fax +49 (0) 92 31 / 98 60 6 - 77e-mail: [email protected]

PURATEK ®InternatIonal

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