Water & Wastewater Treatment. Water & Wastewater Treatment.

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1 Water & Wastewater Treatment Water & Wastewater Treatment

2 Water & Wastewater Clarifiers Table of Contents 2 Water & Wastewater Clarifiers 4 Circular Clarifiers 8 Plate Settlers 9 Sludge Collectors 10 Vertical Clarifiers 12 Horizontal Clarifiers 14 API Separators 16 Air Strippers 18 Oil Recovery Units 19 Case Study : Detroit WWTP 20 Air/Gas Cleaning & Odor Control 2 Monroe Environmental designs and manufactures a wide range of water and wastewater clarifiers for municipal and industrial use. All of our equipment utilizes conventional gravitational settling technology, and each system can be customized to meet the specific needs of your application. We ve been in the water and wastewater treatment business for over 40 years, so we know that all water streams are unique. Monroe can provide jar-testing, analysis, and ultimately recommend the correct system to properly treat your specific water or wastewater stream. Clarifier Design Laminar Flow Principle The design of Monroe Clarifiers creates laminar flow conditions and allows gravitational forces to separate the lighter and heavier elements from the fluid. Chemical Treatment Monroe Clarifiers can include a pre-treatment process as an integral part of the system. This aids in the separation of the dissolved solids, fine particles, and emulsified oils that tend to remain suspended in water and process fluids. Separated Solids Removal Monroe offers a wide variety of sludge collection options for all of its clarifier designs, carefully selected for each application. Oil Recovery Separated oils, process fluids, and other floating materials are guided to an accumulation area for easy removal and reclamation. Construction Materials Monroe s manufacturing flexibility includes fabricating with a variety of materials: Mild and stainless steel High-density polyethylene (HDPE) Polypropylene FRP PVC and CPVC And many others Monroe Systems and Services Design and manufacture clarifiers Retrofit existing tanks and clarifiers to improve: Settling efficiency Throughput Sludge collection systems Oil recovery capability Chemical treatment Rebuild worn-out clarifier internals to extend the life of existing units Municipal and industrial applications Turnkey systems available The Monroe Method The Monroe Method is our superior way of doing business that saves our customers time, money, and hassle. It s based upon three main components: In-house Design and Fabrication Shop Assembly and Testing Ongoing Support for the Life of Your Equipment

3 130 ft. diameter Secondary Circular Clarifier operating at a WWTP 70 GPM Vertical Clarifier with flash and flocculation tanks, thickener, and FRP cover for landfill leachate treatment 200 GPM FRP Vertical Clarifier with custom FRP cover operating at industrial wastewater treatment facility Plate Settlers installed and operating at water treatment facility 50 ft. diameter Circular Clarifier with stairway, access walkway, and handrails during installation at steel manufacturing plant 200 GPM Horizontal Clarifier with drag conveyor, truck mounted for portable treatment of hydraulic fracturing water 3

4 Circular Clarifiers Monroe Environmental offers nearly every circular clarifier design preferred by engineers and plant operators for municipal and industrial applications. We will evaluate existing clarifiers and recommend improvements to influent and effluent geometry, feedwell/edi design, weir and launder geometry, skimming and scum baffles, sludge removal systems, and drive equipment, as well as a variety of site-specific design requirements. 50 ft. diameter Circular Clarifier during final assembly Clarifier Designs & Services New, rebuild, and retrofit Primary, secondary, or tertiary treatment Standard scraper Spiral scraper Hydraulic suction tube header Hydraulic suction riser pipes Solids-Contact/Flocculating Thickeners Municipal water and wastewater treatment Industrial waste and process water treatment 46 ft. diameter stainless steel Circular Clarifier fully assembled in Monroe shop 20 ft. diameter Primary Clarifier at a WWTP 4 46 ft. diameter self-supporting Circular Clarifier for separating blast furnace scrubber fines from wastewater at a steel processing plant

5 Clarifier Rebuilds Rebuilding and replacing the internals of a concrete or steel tank clarifier is a quick, cost-effective solution versus constructing an entirely new system. The clarifier tanks often maintain a suitable operating condition while the skimmer arm, center well, drive assembly, and sludge rakes corrode and wear beyond an acceptable level. In this case, a Monroe Environmental Clarifier Rebuild is the perfect solution to restore the clarifier to its peak operating performance level, ensuring several decades of future use. Exact replacement Modified designs to improve performance or maintenance capabilities Variety of construction materials and coatings available Secondary Clarifier before rebuild at a 25 MGD WWTP ft. Clarifier rakes fully assembled in Monroe shop prior to shipment 3 Secondary Clarifier operating after just a three day installation Existing 55 ft. diameter Scraper Clarifier at chemical manufacturing plant 1 New Clarifier internals completely assembled in Monroe shop 2 Installation of new internals as well as drive, bridge, and walkway 3 5

6 Circular Clarifier Designs Primary Clarifier Monroe Environmental s primary circular clarifiers are designed to receive raw wastewater after it has been pre-screened to remove large objects and grit. This primary sedimentation tank will produce a homogeneous liquid capable of being treated biologically and a sludge that can be separately treated or processed. Perimeter Walkway Scum Box with Beach Plate Scum Outlet Skimmer Arm Sludge Rake Sludge Discharge Bridge and Walkway Inlet Well Bridge Supported Drive Assembly Concrete Floor Scum Baffle Influent Effluent Steel Wall Imbedded Steel Channel Sludge Well Secondary Clarifier Monroe Environmental s secondary circular clarifiers for wastewater are designed to provide a high quality effluent suitable for discharge to the environment or further treatment. The Monroe Environmental secondary clarifier effectively separates the biological floc and colloidal solids to produce wastewater with very low levels of organic material and suspended matter. Perimeter Walkway Scum Box with Beach Plate Scum Outlet Skimmer Arm Suction Tube Counter Weight Sludge Discharge Bridge and Walkway Influent Column Supported Drive Assembly Inlet Well Scum Baffle Effluent Sludge Suction Tube/Header Concrete Wall and Floor Influent Solids Contact Clarifier This clarifier combines the functions of chemical treatment, mixing, flocculation, and sedimentation. This clarifier may be used for lime softening, colorant removal, and removal of magnesium and iron. The solids-contact clarifier employs several radial collection and outlet launders. Perimeter Walkway Walkway Influent Sludge Rake Sludge Discharge Radial Launders Imbedded Steel Channel Rake and Turbine Drive Assembly Draft Tube Turbine Sludge Well Baffles Concrete Floor Reaction Well Effluent Flocculation Zone 6

7 18 ft. steel tank Circular Clarifier for an industrial steel manufacturer fully assembled in Monroe shop Skimmer, scum baffle, and launder components Clarifier Features Mechanism Support Bridge supported or center column supported clarifiers and thickeners are available. Influent Center feed or peripheral feed, energy-dissipating inlet and flocculating feed well are available. Sludge Removal Systems Standard scraper Spiral scraper Hydraulic suction tube header Hydraulic suction riser pipes Skimming Systems Floating scum and other material can be removed by a traditional rotating skimmer arm and scum removal box or by a ducking skimmer that feeds a radial scum trough. A scum baffle prevents floating matter from entering the effluent launder. Launder Inboard, outboard, or radial launders available for effluent collection. Weirs A V-notch adjustable weir will be designed to ensure steady overflow rates, even in windy conditions. FRP, stainless steel, and other materials can be used for weir construction. Walkways, Railing, & Stairways Designed and built according to OSHA and API standards. Drives Monroe Environmental uses only the highest quality drives that are conservatively selected to handle even the most demanding loads. Fabricated steel precision gear Cast iron worm gear The unique design of the Monroe 3-axis pivoting scum wiper blade ensures constant contact with the scum beach, ensuring the highest scum removal efficiency possible. 7

8 Parallel Plate Settlers Plate Settlers can greatly increase the effective surface area of the sedimentation tanks at potable water treatment facilities. Monroe Environmental Parallel Plate Settlers can greatly increase the effective surface area of the existing clarifiers and sedimentation basins at water treatment facilities. New tanks can be greatly reduced in size when designed to include plate settlers as well. This is because suspended solids removal in gravity separators and clarifiers depends primarily on the surface area for settling and the multiple parallel plates provide a large surface area in a small space. Monroe features a variety of design improvements over competitive plate settlers. These patent pending designs provide a more equalized flow through the plate sections and also incorporate several features that make inspection, cleaning, and maintenance much easier for plant operators. Plate Settler Design Complete 304 stainless steel construction Increases throughput and capacity Reduces solids loading on final filtration processes More Stable Hydraulic Flow, Which Improves Settling by up to 30% Variably sized influent flow distributors promote better laminar flow across the face of the plates Effluent is collected uniformly at the top of the plates through orifices, unlike inferior full-width slot designs Patent pending design Ease of Maintenance, Improved Operator Capabilities Significantly more open space at top of plates Easy to see and clean the faces of the plates without draining the tank Individual plate sections can be easily removed Operators can walk on the top of the plate sections, even during operation Influent Flow Distributors Effluent Troughs Weir Plates and Effluent Launders Stainless Steel Plate Modules Top view of plate settlers one collection tube per two flow channels 8 Monroe Sludge Collection System Module Support Structure

9 Sludge Collectors The Monroe Sludge Collector is a hoseless, hydraulic suction collector designed to uniformly remove settled solids from the floor of a rectangular sedimentation basin. Monroe s patent pending design improves the flow of sludge through the collector and reduces the chance for in-pipe clogging. Design Features Hoseless, hydraulic pressure suction collector differential head or pump induced All-rigid, 304 stainless steel piping eliminates the problems associated with cumbersome flexible hose designs Pivoting flanges and telescoping sludge pipe rotate and re-align as the sludge cart moves across the tank floor Orifices on collection headers uniformly draw from sludge blanket Positioning winch and cable system drive the collector and ensure smooth movement with no track to install or maintain No submerged electrical components or lubricants required Electrical panel for automatic control Sludge Discharge Pipe Telescoping Pipe Improved Sludge Removal from Basin Sludge collection as cart moves in both directions, reducing the time required for operation Articulating arm configuration does not impede sludge flow through the collector Reduces the chance of clogging and improves sludge flow out of basin For smaller basins, telescoping pipe is not required Articulating Arm Collection Headers Sludge Cart Note: Green arrows indicate sludge flow Sludge Cart Collection Headers 9

10 Vertical Clarifiers Customized Covers, access ladders, and platforms are available in a variety of materials including stainless steel, FRP, aluminum, and many others. The Monroe Vertical Clarifier is designed to provide low cost, efficient solids removal from a wide range of waste and process liquids. The inclined plate design allows the total gravity settling area to be as much as ten times more than the actual floor space occupied by the clarifier. Parallel plate design Efficient removal of solids from liquids Low space requirements Minimum maintenance No moving parts in settling area Single unit capacities from 1 to 2,000 GPM Monroe Vertical Clarifiers are manufactured in two different plate inclinations; the 45 clarifiers are designed for removal of heavy solids while the 55 clarifiers are designed for light solids removal applications. 60 GPM Vertical Clarifier to treat surface/process water at chemical plant 304 stainless steel clarifier cover Optional Flash and Flocculation Tank Modular Laminar Plates Modular Separator Plates Thickener Drive Optional Chemical Mix Tank and Flocculation Tank Inlet Influent Effluent Clean Liquid Outlet 10 Sludge Removal Rake Thickener Sludge Removal Vertical Clarifier with standard pyramid hopper Vertical Clarifier with sludge thickening option

11 1,500 GPM stainless steel Vertical Clarifier with flash and flocculation tanks 200 GPM Vertical Clarifier, FRP construction with mild steel frame Special Features Customized Covers, access ladders, and platforms are available in a variety of materials including stainless steel, FRP, aluminum, and many others. Wide range of construction materials. Mild steel, special coatings, stainless steel, fiberglass, plastics, and other materials are available to meet specific needs. The unique, modular design of the Monroe Vertical Clarifier allows easy removal of individual laminar plate modules from the clarifier for inspection. A flash mixer and flocculator tank are available pretreatment options. A rake thickener with geared drive is available for the bottom of the separator tank to increase solids concentration. Complete electrical controls are available to meet customer requirements. Ideally Suited For Chemical processing Coolant systems Filter backwash clarification Food processing Foundry operations Glass plant operations Industrial waste management Metal working Oil refining Paper making Plastic manufacturing Plating and coating processes Process water treatment Steel processing Storm water systems 8 GPM polypropylene unit with chemical mix tank, flocculator, pyramid sludge hopper, and mild steel support structure 425 GPM stainless steel unit with chemical mix tank, flocculator, and thickener options 11

12 Horizontal Clarifiers Ideally Suited For Chemical processing Coolant systems Filter backwash clarification Food processing Foundry operations Glass plant operations Industrial waste management Metal working Oil refining Paper making Plastic manufacturing Plating and coating processes Steel processing Storm water systems The Monroe Parallel Plate Horizontal Clarifier is one of the most versatile clarifiers available on the market. Because the unique Monroe parallel separator plate design effectively separates both settleable solids and floating materials, the Horizontal Clarifier can be used in place of a circular clarifier for nearly any application. This allows for significant cost savings and reduced space requirements versus traditional clarifiers. These advantages have made the Horizontal Clarifier the best-selling clarifier offered by Monroe over the past 40+ years. Broad Range of Capabilities Oil Recovery Separated oils, process fluids, and other floatable materials are guided to an accumulation area for easy removal and reclamation. An adjustable overflow weir or a Monroe Oil Recovery Unit can be included to remove these elements. Separated Solids Removal Where the dirt load is heavy, a drag conveyor or screw conveyor may be included to provide continuous removal of settled solids from the bottom of the clarifier. Chemical Treatment The Monroe Horizontal Clarifier can include a pretreatment process as an integral part of the basic clarifier. This aids in the separation of dissolved solids, very fine particles, and emulsified oils that tend to remain suspended in water or process fluids. A chemical treatment tank and/or flocculation chamber can be added to allow ph control and mixing of emulsion breakers and coagulants into the influent before the laminar flow process. Solids Settling Oils Rising Laminar Flow Principle Modular Laminar Plates Monroe Horizontal Clarifiers In the Monroe Horizontal Clarifier separated particles are required to move only a few inches before reaching an uninterrupted and protected free fall or rise to collection areas. The unique design of the Monroe Horizontal Clarifier creates laminar flow conditions and allows gravitational forces to separate the lighter and heavier elements from the fluid. Normally, industrial laminar flow separation requires settling areas beyond practical space availability in typical manufacturing plants. Monroe s design engineers, however, have eliminated this problem through the unique capabilities of the Horizontal Clarifier GPM Horizontal Clarifier with full polypropylene construction for treating low ph plating wastewater 200 GPM Horizontal Clarifier with drag conveyor option

13 (Left) 300 GPM Horizontal Clarifier for truck wash facility fully assembled in Monroe shop (Below) Top view of a 600 GPM Horizontal Clarifier showing installed parallel plate modules Special Features Wide range of construction materials. Mild steel, special coatings, stainless steel, fiberglass, plastics, and other materials are available to meet specific needs. No moving parts in the clarifier section reduces equipment cost and practically eliminates operating cost when compared with a centrifuge separator. Easily removable laminar plates. The unique, modular design of the Monroe Horizontal Clarifier allows easy removal of individual laminar plate modules from the clarifier for inspection. Complete electrical controls to meet customer requirements are available if required. Optional Flash Mix Tank Influent Optional Flocculation Tank Diffuser Wall Parallel Plate Cartridge Adjustable Pipe Skimmer Adjustable Weir Effluent Stainless steel parallel plate cartridges Clean Liquid Outlet Tramp Oil Outlet HDPE (High-Density Polyethylene) parallel plate packs for low ph and highly corrosive applications Modular Laminar Plates Inlet Solids Discharge Sludge Removal Optional Drag Conveyor Horizontal Clarifier with standard pyramid hopper Horizontal Clarifier with drag conveyor option 13

14 API Oil/Water Separators Monroe custom oil/water separators are designed per American Petroleum Institute standards (API) for above and below ground installations. The Monroe API Separator is designed for the removal of free oil and solids. If the removal of soluble substances is required, Monroe can provide additional treatment equipment or will recommend other Monroe Clarifiers. 525 GPM API Separator polypropylene tank with non-metallic internals 900 GPM API Separator, mild steel construction with drag conveyor, screw conveyor, pipe skimmer, and oil roll. The unit, measuring 60 ft. long x 12 ft. wide x 8 ft. high, shipped from our factory fully assembled. Complete covers of various materials are available including the necessary environmental and safety requirements. These provisions may include a nitrogen blanketing system, carbon filtering to remove hydrocarbons from the blanket gas, exhaust flares, and pressure relieving valves and access doors. Existing API Separators can be upgraded with new internal components. In addition, Monroe parallel plate packs can be added to existing API Separators to increase the effective surface area which will provide increased oil removal and increased wastewater flow capacity. Special Features Remove oil from wastewater Separators shipped one piece up to 14 feet wide x 100 feet long Mechanical surface skimmer and pipe skimmer available Mechanical drag conveyor, screw conveyor, and trash screens available Vapor covers available with environmental and safety equipment Retrofit components to upgrade existing separators Monroe Parallel Plate packs available to improve oil removal in existing separators Diffusion Wall Optional Vapor Cover Conveyor Direction Optional Surface Skimmer Underflow Baffle Optional Pipe Skimmer Inlet Outlet Sludge Removal Pipe or Optional Screw Conveyor Optional Drag Conveyor Overflow Weir 14 API Separator standard configuration

15 14 ft. x 90 ft. long 105 GPM API Separator with cover, mineral wool insulation, and aluminum cladding. The unit shipped from our factory fully assembled. (From left): Diffusion chamber with reaction jet baffles, screw conveyor for solids removal, and chain and flight drag conveyor Chain and flight surface skimmer and drag conveyor in separation and settling zone (From left): Automated oil roll, adjustable pipe skimmer, underflow baffle, and adjustable overflow weir 15

16 Air Strippers An air stripper removes volatile gaseous compounds dissolved in a contaminated water stream and transfers them to an air stream. Monroe Environmental designs and manufactures high-efficiency air strippers for industrial and municipal applications. An air stripper removes volatile gaseous compounds dissolved in a contaminated water stream and transfers them to an air stream. Clean water from the Monroe stripper may then be sent to a sump or drain as required. We also manufacture Dry Adsorbers and Packed Bed Scrubbers that can efficiently remove the pollutants transferred to the exhaust air stream by the Air Stripper if necessary. Ideally Suited For Water treatment plant removal of VOCs and odors from potable water Removal of many Volatile Organic Compounds (VOCs) and other compounds with high vapor pressure and low aqueous solubility including: Benzene, toluene, and xylenes (BTX) Ethylbenzene Tetrachloroethylene (PCE) Trichloroethylene (TCE) Methyl tert-butyl ether (MTBE) Ethylenes Ammonia Removal of groundwater contaminants from petroleum fuel leakage Packed Tower Air Stripper The Monroe Environmental Packed Tower Air Stripper typically uses a counter-flow design with a cylindrical tower containing a specially designed packing media that provides a large surface area for air/water contact. Contaminated water flows down through the packing while air flows upward. VOCs or other contaminants are transferred from the contaminated water stream to the air stream, which then flows out through the top of the tower. Clean water flows out at the bottom of the tower. Larger flow rates of contaminated liquid and lower ratio of air flow to liquid flow compared to sieve tray design Lower pressure drop than sieve tray air stripper Capacities up to 5,000 GPM of contaminated liquid for a single tower Efficiencies up to 99.99% Single and multiple tower designs Single-stage or multiple-stage liquid distributors for contaminated water Wide range of packing media including rings, saddles, and structured packing 16

17 Stainless steel Air Stripper during fabrication and pre-assembly in Monroe shop 1,400 GPM Air Stripping Tower installed at a water treatment plant Air Outlet to Carbon or Other Treatment Contaminated Water In Moisture Eliminator Packing Air Inlet Clean Water Out Packed Tower Air Stripper standard configuration 50 ft. x 13 ft. diameter stainless steel stripping tower for VOC removal at a potable water treatment plant 17

18 Oil Recovery Unit Superior belt type oil skimmer Removes tramp oil from process liquids Prevents oil pollution Recovers valuable oil products Minimum maintenance Fully enclosed design The Monroe Oil Recovery Unit is heavily constructed for industrial applications and consists of an endless belt, an electric motor drive unit, and a complete enclosure. The belt is suspended from a specially designed driven pulley, with the lower portion immersed in an oil supporting liquid. As the belt descends into the liquid, the floating oil adheres to both sides of the belt. Self-adjusting wipers mounted in a staggered position wipe the oil from the belt. The recovered oil drains into a trough for deposit into a storage tank or containers. The Monroe Oil Recovery Unit operates unattended in any area of tranquil oil accumulation. It will continuously recover floating oil in a condition that permits disposal or reclaiming for other industrial purposes. Many different industries can prevent water pollution by recovering oily waste with a Monroe Oil Recovery Unit. Even the lightest oils from food processing can be easily removed. Special Features Heavy gauge steel construction with welded seams and lifting hooks provides rugged durability. Special construction materials and coatings are also available. Large, easy to open access doors for all serviceable areas. Heated enclosure. For use in extreme cold, the 12" & 24" models can incorporate insulated panels and an electric infrared or steam heater. An optional controller is available for variable speed operation. Complete electrical controls to meet customer requirements are available. Ideally Suited for Use In Auto manufacturing Chemical processing Food processing Metal processing Oil refineries Steel mills Storm water systems Wastewater treatment Model 8A Oil Recovery Unit with 8 inch wide belt For Recovery of Bunker C oils Cooking oils Hydraulic oils Lubricating oils Skimming Belt Machine oils Mineral seal oils Other organic and synthetic fluids Self-adjusting Wipers Tramp Oil Outlet 18 Oil Recovery Unit standard configuration

19 Case Study City of Detroit Saves Millions of Dollars on WWTP Upgrades Project: Replacement of (4) 250 ft. Diameter Primary Clarifiers Existing 250 ft. diameter clarifiers help treat an average of 707 million gallons per day at the Detroit WWTP, with capacity to treat over 1 billion gallons per day during peak flows Challenge The City of Detroit WWTP needed to upgrade (4) of its 250 ft. primary clarifiers. The plant decided to replace the internal components with a combination of mild, coated steel and noncorrosive stainless steel members. The project included converting the sludge rakes to higher efficiency spiral scrapers and rehabilitating existing drive units, as well as replacing influent wells, column supports, weirs, baffles, and launders. Due to the size of the clarifiers and the amount of steel involved, the budget estimate for the clarifier components and accompanying work was roughly $9,000,000. Solution Monroe was the successful low-bidder and was awarded the project. The city saved several millions of dollars on the total price of the clarifier equipment, with Monroe s contract totaling approximately $5,000,000. Engineering submittals including new spiral scraper rake designs, structural analysis, and related drawings were approved in the 3rd quarter of 2011 and the fabrication of the equipment began shortly thereafter. The project is scheduled to be completed in New stainless steel skimming mechanisms, weirs, baffles, and launders during installation 19

20 Air/Gas Cleaning & Odor Control Monroe Environmental provides air/gas cleaning and odor control equipment for municipal water and wastewater treatment plants as well as industrial manufacturing and processing plants in the following fields: Automotive Manufacturing Chemical Processing Food Processing Glass & Plastics Mining & Metals Oil & Gas Pulp & Paper Steel Processing Utilities/Energy Waste Management Packed Bed Scrubbers Removal of soluble pollutants, odors, and acid gases from municipal and industrial air streams Incinerator, kiln, and RTO exhaust scrubbing Removal of H 2 S, HCl, HF, SOx, NH 3, CO 2, CH 4, formaldehyde, and many other soluble pollutants Venturi Scrubbers Particulate removal from industrial air streams and process gases, including flue exhaust Buffing operations Cast iron machining fines Explosive dusts Fiberglass fines Forging and foundry dust, fines, and fumes Machining and grinding dusts And many others Dust Collectors Removal of airborne dust from manufacturing and processing operations Bulk solids handling Chemical processing Dry machining Grinding Powder coating Shot blast Welding and metal cutting operations Carbon Adsorbers Removal of VOCs, odorous compounds, oil vapors, and gas phase hydrocarbons Municipal water and wastewater treatment odors Industrial emissions from paint spraying, paper coating, plastic film coating, metal foil coating, rubber coating, and printing Recovery of ketones, alcohols, esters, aromatic compounds, and halogenated solvents Oil Mist Collectors Oil mist, smoke, and vapor removal from metal cutting fluids, metal processing coolants, processing oils, and other mist applications Metal cutting, forming and machining Parts washer exhaust Steel and aluminum processing Rolling mills Synthetic fiber processing 810 West Front St. Monroe, Michigan USA Phone: or Fax: Registered ISO 9001 and ISO Monroe Environmental Corporation 08/12