ENVIRONMENTAL SYSTEMS TECHNOLOGY & RESEARCH, Inc.
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Success Stories
Here are a few examples of companies that have successfully installed water treatment technologies from ESTR.
At a cheese factory in central Wisconsin, ESTR provided a solution to the following problem:
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| ESTR technicians construting a treatment facility |
Situation:
- Flow rate of 40,000 gpd
- Aeration Basin Capacity of 97,000 gallons
- DAF Clarifier 400 gallons (13 minutes retention)
- Dissolved Air Re-circulating Pump (5hp) through Dissolving Tube
- Compressed Air Blower (5hp) to Dissolving Tube
- Typical Bubble Size of 30 -70 micron
- BOD removal averaged 81%
- TSS removal averaged 93%
- Discharge Permit limits exceeded nearly every day
Project:
- Replace Dissolved Air Re-circulating Pump
- Remove Compressed Air Blower and Dissolving Tube
- Install ¾ hp Dissolved Air Feed Pump and HYDRO-SPARGER™
- Typical Bubble Size of 0.5 to 5 micron
Results:
- - Increased BOD reduction to 95%
- - Increased TSS reduction to 93%
- - Decreased DAF Re-circulation horsepower by 93%
- - Reduced Polymer consumption by 75%
At a tissue mill in northeast Wisconsin, ESTR provided a solution to the following problem:
Situation:
- Flow rate of 400,000 gpd
- BOD of 12,000 ppm average, 32,000 ppm maximum
- Aeration Basin Capacity of 125,000 gallons (8 hour retention)
- Compressed Air Blower using 200 hp with course bubble distribution piping
- Typical bubble size of 100 - 150 micron
- Average BOD Reduction of 55 %
Project:
- Replace blower with Advanced Aeration Process
- Install Re-circulating Water Pump
- Install HYDRO-SPARGER™
- Install Distribution Piping
Results:
- - Increased Dissolved Oxygen into System from 11,000 ppm to 35,000 ppm
- - Increased BOD reduction to more than 95% every day
- - Reduced horsepower consumption by 40%
Here are descriptions of more successful ESTR water treatment applications.
At a number of paper mills we have retrofitted DAF systems and are monitoring the results. We have successfully completed a pilot project to create a favorable environment to cultivate yeast in the production of ethanol from whey. We are working with Vanderloop Equipment and Skill Associates ESTR in developing a wastewater treatment system for dairy farms with over 2,500 cows. This facility will generate electricity, separate solids and clean the wastewater for use as drinking water for the animals. ESTR has worked with Iowa State University's Department of Agriculture and Bio-systems engineering to improve designs and efficiencies of odor control on manure lagoons. The cooperative effort efficiently reduces odor by treating the entire body of wastewater. The system, including patented ESTR technologies, has a direct impact on microbial interaction with dissolved ammonia providing a reduction in offensive odors. Treatment system operation does produce a layer of foam during start-up, which dissipates after 4 - 6 weeks of operation.
Historical projects of note include our participation in:
The Pactiv Paper project as reported January 2009 where Pactiv Corporation, along with its key project partners successfully completed a grant funded project, titled "The Use Of Pressurized Ozone and Compressed Air Flotation with Membrane Filtration for Industrial Process Water Treatment at a Forest Products Facility". The project was funded in part by the US Department of Energy's State Technology Advancement Collaborative (STAC) program (administered by the National Association of State Energy Officials - NASEO) and New York State Energy Research and Development Authority (NYSERDA) funding as well as Pactiv Corporate funding. The project objective was to design, install and operationally demonstrate a full scale new technology system that used pressurized ozone along with clarification and filtration to effectively remove total dissolved solids (TDS) from mill process water, compile the data and results for evaluation and dissemination to interested water intensive industries. Pactiv's Plattsburgh, New York 40 ton per day molded fiber mill, acting as the host site, has successfully completed an installation and evaluation of the new technology application system for cleaning dirty mill process water and producing both clean process water and a fresh water substitute for mill use. Each day, roughly 10% of the mill's process water is discharged and replaced, the new makeup water entering at city water supply temperature in the range of 55 degrees F and must be warmed to mill operating temperatures (representing approximately a 50 degree F increase). Control of TDS is a crucial step for reducing (or eliminating entirely) the daily purge.NYSERDA, The Energy Office Of Michigan, Cellulose Products and Services LLC, Western Michigan University's Department of Paper and Printing Science and Engineering, have
The LINPAC Paper Project as reported April 2005. "Pressurized Ozone Membrane Ultrafiltration/Nanofiltration Methodology for TDS Removal in Paper Mill Process Water for Energy Savings, Production Efficiency, and Environmental Benefits" LINPAC, along with its project partners, has successfully installed the first full scale commercial pressurized ozone membrane ultrafiltration/nanofiltration system demonstration unit for Total Dissolved Solids (TDS) removal in paper mill process water. The NICE3 project provides a production scale commercial demonstration unit with technology transfer application to the entire Pulp and Paper Industry. LINPAC and its project partners and vendors performed the work and the system is now fully operational. The installed system consists of two major operational systems/processes. First, a pressurized ozone component is used to inject ozone into the process water, improving the chemical rate of reaction that forms oxidized complexes from the TDS in the process water, allowing the TDS to convert to Total Suspended Solids (TSS) and change to a more removable larger particle size. Second an ultrafiltration/nanofiltration component removes the coagulated and precipitated particles as TSS in liquid slurry form. The system is now fully operational and removing TDS from the linerboard mill process water, providing LINPAC with significant production gains and energy savings.
ESTR was also instrumental in the Maraven "F-6" Production Water Treatment Pilot Study. During the period of December, 1995 Blue Diamond Water Treatment Company, of Two Rivers, WI and ESTR Inc. of Brussels, WI in conjunction with their local representatives, Servicios Blue Diamond de Venezuela, conducted a seminar in Caracas, Venezuela for Maraven. This seminar was presented to Mr. Jajime Gutierrez and Mr.Enrique Garcia Asesors de Protection Ambiental. This seminar focused on the recently developed and patented wastewater treatment technologies and their potential application in the treatment of production water and domestic waste from the oil platforms. Based on the response from this seminar, it was decided to do an on-site pilot test of the technologies to see if they are suited to treat these waste streams. ESTR has developed an extensive knowledge base supported by patented technologies for advanced wastewater treatment. When applied to a wide variety of applications, these technologies have been used to significantly improve the efficiency of water treatment facilities. ESTR clients have realized significant reductions in energy consumption, chemical usage and operating costs. In addition, capital investment for facilities using ESTR patented technologies is lower than plants of similar capacity using standard technologies. We are a high tech company that is flexible and responsive to marketplace needs providing high quality products sold at premium prices. The tougher the wastewater problem, the greater our competitive advantage.