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Wastewater Case Studies·February 5, 2015

Case Study: Greasy “Air-Craft Carriers” Destroyed By Taskmaster®

The Lower Bucks County Joint Municipal Water Works Authority in Levittown, Pennsylvania is an activated sludge primary treatment plant. The facility is responsible for thirteen lift stations in the district and processes 10 million gallons of wastewater per day. One of the stations had chronic problems because it had no catch basin for rags, debris or grease. To make matters worse, it was located directly in the path of two major shopping centers that disgorged massive quantities of all these waste products into the wastewater. “The pieces of grease were so big, we called them aircraft carriers”, said Lift Station Mechanic, Ken Balcom. ” They’d come in and, without a catch basin, would block up the pumps and corrode the valves. We would be down for 8-12 hours of operation because we’d have to clean the pumps.” These rag-laden grease mounds would float downstream and present a menace to the entire system. That was until they installed a TASKMASTER® grinder. Purchasing the TASKMASTER TM8516, a powerful grinding unit, employing counter-rotating banks of intermeshing cutters, made all the difference. The unit was installed right over the influent pipe, negating the need for a bar screen or a catch basin. When the debris entered the station, it passed directly through the grinder where it was ground up into small particles. As a bonus, the “aircraft carriers were completely destroyed and the grease was dispersed. Thereafter, it smoothly and easily passed through the pumps with no difficulties. “We’re very pleased with the unit,” said Mr. Balcom. “It has improved system operations, cut down on maintenance and is very reliable. We maintain it according to the specs and we’ve had no trouble whatsoever.” The TASKMASTER is a rugged workhorse of a grinder. The unit’s twin shaft mechanism is especially rugged due to the use of the CUTTER CARTRIDGE®, instead of standard individual cutter and spacer disks. This design gives it the extra strength needed to successful process these tough rags and grease. ‍ SEE OUR FULL LINE OF WASTEWATER GRINDERS

Wastewater Case Studies·February 5, 2015

Case Study: Grinding Technology Reduces Tough Solids

“In 2007, flushable wipes came on the market and these products did not degrade before they got to the sewer pumps. The wipes tended to bind and clump together, creating huge balls that became tangled in the pumping equipment. The situation worsened as the wipes became more and more popular.” – Bruce Walczyk, Pump Station Foreman Northline Lift Station, Laguna Woods, California For years, three pumps installed at the Laguna Woods, California Northline Station easily handled the 2.5 MGD average flow and even an occasional el Niño deluge. Maintenance was limited to deragging typical solids from the pumps every 3 months. Then, in 2007, flushable wipes changed all that and presented a real problem. Says Bruce Walczyk, Pump Station Foreman, “eventually it was taking two men four hours each, three times a week to de-rag the clogged pumps. They’d often be out at midnight on Sunday fixing a jam.” A unit to pre-shred the debris before it reached the pumps was desperately needed. Dale Gruel of Dudek Consulting engineers, Encinitas California recommended grinding technology to alleviate the problem. After evaluating several units, the pump station chose a Franklin Miller SUPER SHREDDER® SS1200 inline disintegrator. Franklin Miller was the one company that made a heavy duty grinder with a short lay-in length that would fit into the site. The disintegrator was installed at the suction side of the pump. The debris was sucked in, shredded and then easily passed through the treatment plant. This placement avoided the potential for clogs and blockages in the pumps further down the line. Mr. Walczk reports, “Since its installation, the Super Shredder has run flawlessly, saving us countless labor hours.” The problem with wipes is not going away anytime soon. In fact, “flushable” wipes sales are predicted to increase by 6% a year for years to come and the problem is not only in the USA. In London, a lump was discovered that was actually the size of a city bus that consisted of a mixture of cooking grease and wipes. Fortunately, Franklin Miller heavy-duty grinders are playing a critical role in combating this problem in plants nationwide and internationally. Says Franklin Miller President Bill Galanty, “every one of our grinders is certified to reduce tough mops and solids such as flushable wipe products. We’re proud that our grinding equipment is solving this difficult problem that many plant operators are facing nationwide.”

Solid Waste Case Studies·February 5, 2015

Case Study: Research Institute Cuts Waste Problem

The Southern Research Institute in Birmingham, Alabama conducts basic research for medical, environmental and engineering companies. The institute was faced with major waste management and disposal problems. The laboratories in the facility produce copious amounts of waste, much of it made of plastic and medical packaging materials. In order to be incorporated into landfills, it was necessary to reduce the waste to an unrecognizable state. The facilities manager considered incinerating the materials but realized that was not a viable disposal method. Clearly, a better alternative was desperately needed. After reviewing a video featuring Franklin Miller TASMASTER® industrial shredders, Facilities Manager, Thomas Hurn, found what he was looking for. ” I saw at once that it had the capacity requirements to manage the waste generated,” he said. “And based on what I saw, it was the best buy for the money.” TASMASTER TM2300 shredders are versatile units with remarkable shredding capabilities on a wide variety of materials. Using counter-rotating banks of intermeshing cutters, they efficiently reduce bulk solids up to 80%. The units cut storage and disposal costs while aiding in the safe disposal of wastes. These units can reduce landfill costs, aid in recycling off-spec materials and waste, and enhance processing. Since installation, the TASMASTER TM2300 industrial shredder has worked exceptionally well. According to Mr. Hurn, “We’ve had no problems. It’s a well-built piece of equipment as far as ruggedness and heavy construction. We’re very satisfied that we made the right decision.” SEE THE FULL LINE OF TASKMASTER INDUSTRIAL SHREDDERS

Wastewater Case Studies·February 5, 2015

DIMMINUTOR Cuts at High Flow; Withstands 125 Year Storm

The Millbury, Massachusetts pumping stations are part of a regionalized consortium of eight communities that discharge their wastewater to the Upper Blackstone Water Pollution Abatement District for treatment. The 56 MGD facility sits at the Headwaters of the Blackstone River, once considered one of the most polluted river ways in the country. As a result of plant upgrades and projects, the water quality was considerably improved, and the river will be swimmable by 2015. “We originally were a secondary trickling filter treatment plant, but were decommissioned after the town of Millbury joined the district,” explained Plant Superintendent, Bradford Lange. “From then on, we were responsible for the maintenance and operation of sixteen pumping stations.” “In 2005, we began a major upgrade of old equipment, including a Worthington comminutor that needed to be taken out of service,” said Lange. “It was very important to have an inline unit that could efficiently grind and screen wastewater solids so they could be easily processed by the pumps.” “On the recommendation of our engineer, we installed a DIMMINUTOR® T20 Channel Disintegrator,” Lange continued. “The unit has an extended shaft and this was a major consideration in our selection. We are located in a flood plain and we needed that shaft to keep the motor up above any flooding that could occur.” According to Lange, purchasing the DIMMINUTOR was a wise decision. “The unit has so many great features. It easily chops up everything in its path, rocks, sticks you name it. In case of a jam, there is a reliable reverse mode. Because of its open design, the unit has a lot less head loss. It takes in as much water as it can get, resulting in a higher velocity of flow. This higher flow speeds the entire process up for us.” “We recently bought another DIMMINUTOR T20.The two units are placed side by side in a channel and are rotated monthly,” said Lange. “The original unit has never been taken out of service. It works as well four years later as the day it was installed. The DIMMINUTOR is a fine rugged piece of equipment. When you’re in the field, you want something dependable. We’re very satisfied.” “Incidentally,” Lange concluded, “shortly after we installed the first unit in 2005, we experienced a tremendous flood, the kind that occurs once in a hundred and twenty five years. We were literally underwater for two day, but the DIMMINUTOR kept right on going.” The DIMMINUTOR offers effective, automatic screening and disintegrating of wastewater solids in straight through channels and wet wells. This powerful unit reduces plastics, wood, rags and other solids to fine bits, enhancing plant operation and improving the reliability of pumps and other downstream equipment. The DIMMINUTOR employs a smooth, continuously rotating design with high torque. As its three bidirectional rotary cutters intermesh at close clearance with stationary cutters, solids are finely reduced to a size small enough to pass through a sizing screen. With no gaps or openings between the screen and cutters, output is controlled and complete reduction assured. The DIMMINUTOR has an intrinsically open design to handle high flow rates with low head-loss. This unit is extremely easy to maintain and features individually replaceable cutters, oil lubrication and a simple rotary design requiring no auxiliary diverter screens. A unique, cantilevered design eliminates seals or bearings near the gritty channel floor. Every component of the unit is constructed for precision and long life.

Wastewater Case Studies·February 5, 2015

Case Study: Sewage Plant Transformed

The Valley Forge Pump Station receives daily on average 500000 gallon influent. It has been in operation for about 20 years. While visiting Valley Forge Sewage Plant the plant operator, Jim Brennan, informed us that they have a TASKMASTER® TM8500 Grinder installed in front of the pumps, to eliminate the clogging problem. This hydraulically driven TASKMASTER Grinder has been installed for about 4- 1/2 years. “So far it has been a pretty good unit. It has been submerged a few times and no problem whatsoever.” The system is set up so that the stream from two channels goes through the TASKMASTER. There is a mechanical Bar Screen located alongside the grinder to handle the overflow. Since the grinder was installed, the working time for the bar screen has been reduced tremendously. In the previous installation, the bar screen had to be raked at least once a day. Mr. Brennan likes to emphasis the easy aspect of maintenance “It is easy maintenance with the TASKMASTER.” “Twice a year we go over it and other than that, just wash it down. The cartridge part of the cutter is a pretty good idea. If the cutter gets dull (which hasn’t happened yet), restack them for longer life; you could exchange the top with the bottom. We had other units but I like the TM better, no major problem with it. It is a good smooth installation. No more stupid alarms in the middle of the night. I would personally recommend it (the TASKMASTER Grinder unit).”

Wastewater Case Studies·February 5, 2015

Case Study: Sludge Buildup and Aerator Blockage Solved

Case study: The District of Kitimat, British Columbia, a pristine coastal community with 10,000 residents, is located at the head of the Douglas Channel and the Kitimat River. The area is a major salmon spawning corridor, supporting a large sports fishing industry. For both ecological and economic reasons, any facility discharging wastewater into the river must be mindful of strict discharge regulations. No one is more aware of this than the management of the Kitimat Wastewater Treatment Plant. Recently, the plant, which treats 2.6MGD and handles peak flows of 7.3 MGD, was faced with an emergency upgrade. A barminutor, installed in the 1970’s as a bar screen and grinder, had rusted and developed holes, allowing rags, wood, rocks and other debris to pass through unimpeded. The debris not only caused blockages and clogs in the aerators but also contributed to the build up of sludge in the lagoon. The facility’s management was determined to install a more efficient system and end the chronic problems. After carefully reviewing their options, they chose Franklin Miller’s DIMMINUTOR® Turbo Design Channel Disintegrator. “We originally planned to buy one DIMMINUTOR, “said Wayne Sussbauer, Technical Services Manager. “The size of the unit was important because we needed to be sure it could handle peak flows and not require a head differential that would cause the upstream channel to overflow back into the wet well and subsequently untreated effluent into the river. Based on assessment, we decided that two units would do a better job of meeting peak flows and minimizing the probability of an overflow.” The DIMMINUTOR comminutors were placed side by side in two existing channels. “With the supplied frames they were easily installed into the existing headworks units,” commented Sussbauer.” This was a consideration in the purchase.” The DIMMINUTOR offers effective, automatic screening and disintegrating of wastewater solids in straight through channels and wet wells. This powerful unit reduces plastics, wood, rags and other solids to fine bits, improving the reliability of pumps and other downstream equipment. The unit employs a smooth, continuously rotating design with high torque. As its three bi-directional rotary cutters intermesh at close clearance with stationary cutters, solids are finely reduced to a size small enough to pass through a sizing screen. With no gaps or openings between the screen and cutters, output is controlled and complete reduction assured. The DIMMINUTOR has an intrinsically open design to handle high flow rates with low head-loss. This unit is extremely easy to maintain and features individually replaceable cutters, oil lubrication and a simple rotary design requiring no auxiliary diverter screens. A unique, cantilevered design eliminates seals or bearings near the gritty channel floor. Every component of the unit is constructed for precision and long life. The DIMMINUTOR offers effective, automatic screening and disintegrating of wastewater solids in straight through channels and wet wells. This powerful unit reduces plastics, wood, rags and other solids to fine bits, improving the reliability of pumps and other downstream equipment. The unit employs a smooth, continuously rotating design with high torque. As its three bi-directional rotary cutters intermesh at close clearance with stationary cutters, solids are finely reduced to a size small enough to pass through a sizing screen. With no gaps or openings between the screen and cutters, output is controlled and complete reduction assured. The DIMMINUTOR has an intrinsically open design to handle high flow rates with low head-loss. This unit is extremely easy to maintain and features individually replaceable cutters, oil lubrication. A unique, cantilevered design eliminates seals or bearings near the gritty channel floor. Every component of the unit is constructed for precision and long life.

Wastewater Case Studies·February 5, 2015

Case Study: SPIRALIFT® SC Solves Screenings Disposal Problem

The City of Collinsville had a problem. The screenings coming off from their bar screen were odorous, wet and costly to dispose of. Three container loads a week of screenings were very costly to dispose of. Initial tests of a screenings washer were discouraging. Although the unit worked well initially, it quickly broke a shaft on the shredder. That's when the town turned to Franklin Miller Inc. for a better solution. Franklin Miller supplied a SPIRALIFT® SC, screenings conditioner to the town to test in the application. The operators were impressed with the rugged construction of the unit. After installation, the unit quickly went to work grinding and then washing the screenings. The results were excellent. The output was extremely dry and clean and the unit handled the tough screenings without any problem. That's when Collinsville decided to convert the trial into a purchase. Since installation the unit has worked extremely well. What used to require 3 containers now fits in one container per week, resulting in a substantial savings in disposal. Furthermore, odorous screenings are no longer a problem. The output comes out extremely clean, dry and homogeneous for easy disposal. The SPIRALIFT SC consists of two units in one package. First, a rugged 10HP TASKMASTER® TM1600 grinder reduces the screenings to small pieces exposing surface area for thorough subsequent washing. The solids then drop into the wash portion of the unit, which consists of a wash-press. As the unit's auger conveys the solids, they are intensively washed in a water spray. Contaminants are washed down the unit drain and enter the sewage plant for further processing. The solids are de-watered in the SPIRALIFT press zone and ejected into a bin or conveyor. Says the plant operator, "We found no other unit that was as ruggedly constructed and durable as the SPIRALIFT SC."

Wastewater Case Studies·February 5, 2015

Case Study: SPIRALIFT® SL Minimizes Downtime

The Town of San Manuel is located in the heart of the Galiuro Mountains in Arizona. For over fifty years, the town was served by a wastewater treatment plant consisting of primary treatment followed by treatment of the wastewater in oxidation ponds. When a new utility company took over management of the plant, they hired Santec Corporation to design and build a modern water reclamation facility that would meet current standards for wastewater reuse. Santec focused on three key objectives during the design phase of the project; 1) Class B+ reclaimed water quality standards for effluent, 2) Minimization of operating expenses and 3) Maximize value of expenditures. The new facility consists of automated headworks incorporating a spiralift, flow equalization and pumping, 4 stage anoxic/ aeration/ anoxic/ reaeration process, secondary clarifier, disinfection and effluent pumping system. In addition to the typical Fiberglass tank construction utilized in Santec water reclamation facilities, this plant incorporates more traditional, concrete elements such as the circular clarifier and headworks system. This blended approach provides all the benefits of an underground design (noise, odor and aesthetic control) with the open access of standard wastewater treatment systems. According to Marty Zulkoski, Project Manager, Santec Corporation, “A big part of achieving these objectives was the installation of a Franklin Miller® SPIRALIFT® SL. Since its installation, the SPIRALIFT® SL has provided the new facility with a highly effective, low maintenance, automated system for removing solids and debris from the influent wastewater.” “At an average of .350 MGD the facility would quickly run into huge maintenance headaches without proper screening and removal of incoming solids. The simple addition of the SPIRALIFT® SL has minimized solids related maintenance and downtime for the entire system!” he concluded. The SPIRALIFT SL® provides fine screening, washing, transporting and compacting of wastewater solids while leaving essential organics in the flow. The SL is easy to install in existing channels, reduces solids disposal costs and protects downstream equipment. The SPIRALIFT is provided as a fully integrated system including a shaftless screw screen, a powerful TASKMASTER® Grinder and control system which coordinates the system’s normal and special functions. The PLC driven unit uses flow level data to cycle the screw to minimize power and wear. The SPIRALIFT combines the benefits of a rugged grinder with dependable screening technology for a uniquely effective and trouble-free system.

Wastewater Case Studies·February 5, 2015

Case Study: SPIRALIFT® SL Solves Headworks Problem

The facility, which handles .55 mgd of wastewater from domestic sources as well as from a Veterans home, was getting deluged with rags and other debris spilling over into various areas of the wastewater treatment process causing frequent maintenance headaches. The debris was constantly clogging up the pumps and had to be removed manually. Of particular concern was the solid waste from the Veterans home, which contained enormous quantities of cooking grease. Once the grease entered the waste stream, it congealed into large blocks that coated and clogged the lines, increasing down time and maintenance headaches. After examining the options with their consulting civil engineer, the facility personnel determined that the best solution would be a screening device to remove the solids. A Franklin Miller SPIRALIFT® Model SL fine screening system was selected for the job. This SPIRALIFT® SL employs a shaftless auger screw and a finely perforated screen that captures debris. The screen is wiped by the auger brushes and conveyed up and out of the system. A TASKMASTER® TITAN® Grinder reduces all the solids assuring a highly dependable system performance. “We immediately saw the difference,” said Don Moore, wastewater system Supervisor. “The combination of SPIRALIFT and grinder virtually eliminated the debris and most of the grease. In our application, it has helped us immensely.” He concluded. The SPIRALIFT® is a versatile screening system that is easy to employ for a variety of channel sizes and capacity requirements. The unit features a built-in washing system to clean the debris before lifting them out of the flow. A special control system integrates and coordinates the system’s normal and special functions. The PLC-based control system uses flow level data to cycle the screw to minimize power and wear. Mr. Moore added, “I am impressed at how the company has always been there when we needed them. Whenever we call them, they get right back to us. I’d definitely recommend the Spiralift System.”

Wastewater Case Studies·February 5, 2015

Spiralift® SLX Defends Prision

First Line of Defense for Prison Effluent For years, Graterford Prison, a maximum security facility in Pennsylvania, experienced continuous problems with their wastewater system. Their antiquated equipment consisted of bar screens, grinders and comminutors which were frequently overwhelmed by the sewage generated daily by 3,600 inmates. To make matters worse, the trash and debris often included full sheets, blankets, clothing, shoes, and plastics which the prisoners stuffed into the toilets in their cells and flushed. The ensuing sewage clogs, backups and flooding created headaches for the maintenance staff and interfered with the institution’s functioning. The crushing load of debris adversely affected downstream equipment. Pumps would often clog and jam, requiring endless maintenance and emergency repairs. Pump bearings and seals would be damaged and need to be replaced, causing frequent system downtime. According to Stan Pace, Utility Supervisor, the main problem was the equipment. “The equipment worked too slowly. We were running 650,000 gallons per day. Our obsolete units could not handle the flow.” A solution was urgently needed and that’s when the prison called on Franklin Miller for help. Franklin Miller engineers evaluated the problems associated with the plant’s wastewater discharge and equipment problems. They suggested one of their SPIRALIFT® SLX auger screening and grinding systems which is part of Franklin Miller's full line of Wastewater Screens. The SPIRALIFT SLX system, specifically designed for screening of heavy prison and institutional effluent, was selected and installed for each channel which was designed to process a maximum flow of 1.5 mgd each. SPIRALIFT Screening systems provide screening, washing, conveying, and compacting of wastewater solids in one integrated, easy to install system. The SLX features a heavy TASKMASTER® TM1630 shredder with a 10 HP motor and drive coupled with an oversized auger style channel screen which removes the solids. Once installed, the TASKMASTER TM1600 Grinder quickly went to work finely shredding all the heavy solids in the flow. The “confetti sized” particles were captured on the screen and intensively washed. As the solids were conveyed up the transport, free water drained back into the channel and the solids were discharged into a bin with moisture reduced by over 50%. “The SPIRALIFT worked,” commented Rusty Brown, Maintenance Operator. “None of us wanted to believe it until we saw it in action.” After only a few weeks in operation, the results were dramatic. Problems with the pumps were eliminated as were maintenance calls in the middle of the night. “SPIRALIFT technology has made our plant run 98% more efficient,” said Mr. Pace. “It’s our first line of defense.”

Wastewater Case Studies·February 5, 2015

Case Study: SPIRALIFT® SR: Solves Major Septage Disposal Problem

Septage haulers in a rural Florida County used to offload their truck’s gooey contents into a large open field. That all changed when the local residents’ complaints about noxious odors led to television and newspaper coverage. That’s when county officials directed the local wastewater treatment facility to come up with a better method of septage disposal. The plant manager researched the available options and spoke to other plants. Based on the information gathered, a decision was made to purchase a SPIRALIFT® SR from Franklin Miller Inc. The SPIRALIFT SR is a complete, turnkey septage receiving system that features dependable operation, easy installation and low operating costs. This system is designed to receive, grind, wash, screen and separate septage solids. A special hauler control station monitors and authenticates haulers for automated access. Once the hauler hooks up to the system, a TASKMASTER® Model TT grinder chews up the incoming septage solids – a key to reliable system performance. The grinder housing has a special built-in tramp trap to collect heavy unshreddable solids. The septage solids are then screened and washed in the unit’s fully enclosed shaftless spiral screen and conveyed to the unit discharge. The screened liquids then pass into the plant headworks. The SPIRALIFT tank and grinder enclosures are constructed of stainless steel.

Wastewater Case Studies·February 5, 2015

Case Study: SUPER SHREDDER® Disintegrators Eliminate Downtime

The Trenton Sewer Utility handles wastewater and sewage generated for the city of Trenton, New Jersey. The utility typically processes 12 mgd, which can quickly rise to 27 mgd during storm events. For the past ten years, the facility has relied upon the powerful grinding capabilities of several strategically placed SUPER SHREDDER Disintegrators to ensure that operations run smoothly. “We have a combined system, which is essentially more complicated,” explains Plant Superintendent, Leigh Jones. “We’re dealing with sewage from homes, businesses, and industries as well as enormous amounts of rocks, trash, grass, wood and other debris that wash in from the streets.” A network of lift stations and gravity collection systems carries effluent into the central pumping station at the plant site where the material is distributed through the treatment processes. Concentrated sewage that has settled out as sludge is collected and sent downstream from the pumps, pulled through a SUPER SHREDDER and ground up. This step prevents the pumps from clogging. The sludge is sent to the primary digester and then transferred to a heat exchanger, where hot water tubes treat the sludge. Before entering the heat exchanger, the sludge passes through another SUPER SHREDDER, effectively preventing residual debris from clogging the tubes. The utility has four SUPER SHREDDER Disintegrators, but only two are in service at any given time. “Most plants have tandem shredding systems so if one unit goes out of service, you can switch to the other one,” explains Jones. “Our spacing doesn’t allow for this configuration. The shredders were an add-on to the original design and there is no room to build in redundancy. The space saving SUPER SHREDDER meets our needs because we can use one shredder at a time. The unit in service can be easily pulled out for repairs and a spare slipped in. Fortunately, we don’t need to use the rebuild services very often, but when we do we’ve been very pleased.” “The units have saved us a lot of maintenance and downtime,” Jones concludes. “They’re well worth the investment.” The SUPER SHREDDER in-line disintegrator easily reduces tough solids directly in sludge or raw sewage lines. The unit combines unsurpassed grinding capabilities with streamlined, easy to maintain features. Its innovative design provides a high level of open area to fluid flow making the SUPER SHREDDER ideal for applications requiring a heavy duty size reduction processor that can handle high flows with minimal headloss. The unit features a patented “spherical shredding” mechanism that cuts and shears tough sewage solids into fine bits. The hard faced stainless steel cutters offer unsurpassed wear resistance. Because of the spherical rotor design, the SUPER SHREDDER has far fewer moving parts and requires much less maintenance than units with banks of cutter disks. With two easily replaceable one-piece cutters, maintenance is convenient and down time is minimal. Included with the SUPER SHREDDER is a S-250 Auto-Reversing control system that senses jam conditions and automatically reverses.

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