1. Case Basic Information
1.1 Project Subject
- Provider: HELLA WATER, a professional supplier of high-performance water treatment product, specializes in customized organic wastewater treatment solutions for the food and dairy industry.
- Core Product: 300m³/day Integrated Milk Factory Wastewater Treatment System (combines air flotation, anaerobic, A2O biochemical, sedimentation, and disinfection processes)
- Project Objective: Treat high-concentration organic wastewater from milk production to meet discharge standards, achieving efficient removal of COD, BOD, SS, and grease.
1.2 Treatment Scale & Water Quality Parameters
Treatment Scale
- Daily Treatment Capacity: 300 m³
- Hourly Treatment Capacity: 40 m³/h (peak flow)
Inlet & Outlet Water Quality
| Parameter | Inlet Concentration | Outlet Concentration |
|---|---|---|
| COD (Chemical Oxygen Demand) | ≤6000 mg/L | ≤125 mg/L |
| BOD₅ (Biochemical Oxygen Demand) | ≤3000 mg/L | ≤25 mg/L |
| pH | 6.0~9.0 | 6.0~9.0 |
| SS (Suspended Solids) | ≤600 mg/L | ≤50 mg/L |
| Grease | ≤500 mg/L (estimated, milk factory typical value) | ≤10 mg/L (estimated) |
1.3 Core Equipment Specifications
| Equipment Module | Specifications | Quantity |
|---|---|---|
| Dissolved Air Flotation Machine | 40 m³/h; Size: 6.0×2.8×3.2m; Carbon steel anti-corrosion; Includes PAC/PAM dosing devices | 1 set |
| Anaerobic Tower | 300 m³/day; Size: φ3.5×10.0m; Internal/external anti-rust paint; Three-phase separator | 2 units |
| Integrated A2O Equipment | 300 m³/day; Size: 15.0×3.0×3.0m; Includes anaerobic/anoxic/aerobic/sedimentation/disinfection tanks | 6 sets |
| Stacked Screw Filter Press | Sludge dewatering; Moisture content: 75-85% | 1 set |
| Aeration Fan | Model SR100-5.5; Air volume: 6 m³/min; Power: 5.5kW; 2 for use, 1 for backup | 3 units |
| Dosing Equipment | PAC/PAM disinfection dosing devices; PE barrels + metering pumps | 4 sets |
| Control System | PLC touch screen control cabinet; Manual/automatic integration | 1 set |
1.4 Design Standards & Compliance
The system adheres to core national and industrial standards, including:
- GB 8978-1996: Integrated Wastewater Discharge Standard
- GB 50014-2006: Code for Design of Outdoor Drainage
- JB2932-1999: Technical Specifications for Water Treatment Equipment
- Food Industry Wastewater Treatment Technical Specifications
- ISO 9001: Quality Management System Certification
1.5 Application Scenarios
- Medium-sized milk processing factories (raw milk cleaning, product processing wastewater)
- Dairy product manufacturing wastewater treatment (yogurt, cheese production)
- High-concentration organic wastewater treatment in the food processing industry
- Regions with strict environmental discharge requirements for organic pollutants
2. Project Core Pain Points & Requirements
2.1 Industry Common Pain Points
- High Organic Load: Milk factory wastewater has extremely high COD (≤6000 mg/L) and BOD (≤3000 mg/L), posing a heavy burden on biological treatment.
- Grease Contamination: Contains a large amount of milk fat and proteins, which easily cause equipment clogging and sludge floating.
- Fluctuating Water Quality: Batch production leads to significant fluctuations in wastewater flow and pollutant concentration, affecting treatment stability.
- Sludge Production: High organic content results in large sludge yields, requiring proper disposal to avoid secondary pollution.
- Strict Discharge Standards: Environmental regulations impose strict limits on organic pollutants, demanding efficient and stable treatment effects.
2.2 Customer Core Requirements
- Efficient Purification: Achieve COD removal rate ≥98%, BOD removal rate ≥99%, and SS removal rate ≥92% to meet discharge standards.
- Grease Removal: Effectively remove milk fat (removal rate ≥98%) to prevent equipment clogging and sludge deterioration.
- Stable Operation: Adapt to water quality/quantity fluctuations and maintain consistent effluent quality.
- Sludge Minimization: Reduce sludge production and simplify disposal (e.g., reuse as agricultural fertilizer).
- Easy Operation: Realize semi-automatic/fully automatic control to reduce manual intervention.
3. Hella Water Customized Solutions
3.1 Process Design: Multi-Stage Organic Wastewater Treatment
The solution adopts a “Grille Regulation → Dissolved Air Flotation → Anaerobic Tower → A2O Biochemical → Sedimentation → Disinfection” integrated process, tailored for milk factory wastewater:
- Pretreatment Stage:
- Grille Regulation Tank (civil engineering): Adjusts water quantity and quality; perforated aeration prevents SS sedimentation.
- Dissolved Air Flotation Machine: Cooperates with chemical dosing system (PAC/PAM) to remove 98% of grease and 90% of SS. Micro-bubbles adsorb suspended solids and grease, forming scum scraped by the chain scraper, reducing subsequent biochemical load.
- Anaerobic Treatment Stage:
- Anaerobic Tower: Filled with high-efficiency anaerobic fillers; under anaerobic conditions, anaerobic microorganisms decompose 60-70% of COD into biogas (methane) and water. Three-phase separators ensure gas-liquid-solid separation, improving treatment efficiency.
- Biochemical Treatment Stage (A2O Process):
- Anoxic Tank: Facultative microorganisms convert organic nitrogen to ammonia nitrogen; use organic carbon sources to reduce NO₂⁻-N/NO₃⁻-N to N₂, achieving denitrification. DO ≤0.5 mg/L.
- Aerobic Tank: Autotrophic nitrifying bacteria convert ammonia nitrogen to nitrate; combined fillers provide attachment sites for microorganisms. DO ≥3 mg/L, gas-water ratio 15:1. Nitrate reflux pump realizes internal circulation for denitrification.
- Deep Treatment & Disinfection Stage:
- Sedimentation Tank: Cone-bottom design facilitates sludge precipitation; sludge return pump sends part of the sludge back to the anoxic tank to maintain microbial concentration.
- Disinfection Tank: Chlorine-based disinfection equipment inactivates pathogenic microorganisms, ensuring effluent compliance.
- Sludge Treatment Stage:
- Sludge from sedimentation tanks is concentrated in the sludge tank; stacked screw filter press dewaters sludge to 75-85% moisture content. The sludge, rich in organic matter, is reused as agricultural fertilizer.
3.2 Core Technical Advantages
| Technical Highlight | Description |
|---|---|
| Targeted Grease Removal | Dissolved air flotation machine efficiently removes milk fat, preventing clogging of subsequent anaerobic and aerobic systems. |
| High-Efficiency Anaerobic-Aerobic Synergy | Anaerobic tower reduces high COD load; A2O process realizes simultaneous nitrogen and phosphorus removal, ensuring effluent compliance. |
| Robust Equipment Design | Carbon steel double-sided full welding (kerosene leak detection); galvanized steel filler brackets (diameter 10mm) for durability; reinforcement ribs enhance equipment strength. |
| Intelligent Control | PLC touch screen control cabinet supports manual/automatic switching; remote monitoring of key parameters (flow, DO, liquid level) reduces labor. |
| Sludge Resource Utilization | Sludge is reused as organic fertilizer, reducing disposal costs and environmental impact. |
3.3 Key Supporting Systems
- Pre treatment filtration system: Grille + air flotation ensures inlet water quality for subsequent biochemical treatment.
- Aeration System: Three Roots blowers (2 for use, 1 for backup) guarantee stable oxygen supply for aerobic reactions.
- Dosing System: Automatic PAC/PAM/disinfectant dosing adjusts dosage based on water quality, optimizing treatment effect.
4. Project Effectiveness Verification
4.1 Pollutant Removal Efficiency
| Pollutant | Inlet Concentration | Outlet Concentration | Removal Rate |
|---|---|---|---|
| COD | ≤6000 mg/L | ≤125 mg/L | ≥98.1% |
| BOD₅ | ≤3000 mg/L | ≤25 mg/L | ≥99.2% |
| SS | ≤600 mg/L | ≤50 mg/L | ≥91.7% |
| Grease | ≤500 mg/L | ≤10 mg/L | ≥98.0% |
| Ammonia Nitrogen | ≤300 mg/L (estimated) | ≤15 mg/L (estimated) | ≥95.0% |
4.2 Operational Performance
- Stability: Continuous operation for 8000 hours with stable effluent quality; adapts to ±25% flow fluctuations and ±30% COD concentration changes.
- Energy Efficiency: Total power consumption ≤1.2 kW·h/m³, lower than similar wastewater treatment systems (1.5-2.0 kW·h/m³).
- Sludge Reduction: Annual sludge production ≤15 tons (dewatered), 40% less than traditional processes; reused as agricultural fertilizer.
- Maintenance Cycle: Routine maintenance once a month (clean air flotation scum, check aeration equipment); anaerobic tower inspection every 6 months.
4.3 Economic & Environmental Benefits
- Economic Benefits: Annual sewage discharge fee savings ≈USD 18,000; sludge disposal cost reduction ≈USD 5,000; equipment service life ≥10 years.
- Environmental Benefits: Annual reduction of COD emission by ≈2,117 tons; BOD emission by ≈1,071 tons; reduces water pollution and protects local water ecosystems.
5. Case Corresponding Product Quotation Description
5.1 Total Quotation Overview
| Item | Description | Total Amount (USD) |
|---|---|---|
| Core Equipment | 40m³/h Dissolved Air Flotation Machine | 12,370 |
| 300m³/day Anaerobic Tower (2 units) | 58,800 | |
| 300m³/day Integrated A2O Equipment | 125,000 | |
| Stacked Screw Filter Press | 4,000 | |
| External Mounting Materials | Pipes, flanges, valves, etc. | 25,000 |
| Total Project Quotation | – | 225,170 |
5.2 Key Equipment Quotation Details
Dissolved Air Flotation Machine (40m³/h)
| NO | Name | Specification | Quantity | Remark |
|---|---|---|---|---|
| 1 | Main Body | 6.0×2.8×3.2m, carbon steel anti-corrosion | 1 set | Double-sided full welding, kerosene leak detection |
| 2 | Dissolved Air Tank | ZTRQ-40 | 1 set | Carbon steel |
| 3 | Reflux Pump | ZTQS-40, 7.5kW | 1 unit | HELLA WATER |
| 4 | Air Compressor | ZTKY-40, 2.2kW | 1 unit | HELLA WATER |
| 5 | PAC/PAM Dosing Devices | 2000L PE barrel + 1.1kW stirrer + 120L/h metering pump | 1 set each | HELLA WATER |
| 6 | Control Cabinet | Manual/automatic integration | 1 unit | Carbon steel spray |
Anaerobic Tower (300m³/day)
| NO | Name | Specification | Quantity | Remark |
|---|---|---|---|---|
| 1 | Equipment Body | φ3.5×10.0m, internal/external anti-rust paint | 2 units | Double-sided full welding |
| 2 | Three-phase Separator | Multilayer gas-liquid-solid separation | 2 sets | HELLA WATER |
| 3 | Inlet Lift Pump | WQ43-13-3, 3kW | 2 units | HELLA WATER pump |
| 4 | Control System | Manual/automatic integration | 1 unit | Carbon steel spray |
5.3 Quotation Terms
| Term Type | Details |
|---|---|
| Validity Period | 20 working days from the date of quotation |
| Payment Terms | T/T: 30% prepayment for production, 70% payment before shipping |
| Production Cycle | 30-40 days |
| Warranty Period | 2 years from the date of delivery (free repair/replacement for non-human damage) |
| Installation & Maintenance | Free online guidance (manual, video); on-site installation available at extra cost |
6. Frequently Asked Questions (FAQ)
6.1 Installation & Commissioning
Q: What are the on-site installation requirements for the system?
A: The system requires an indoor/outdoor installation area of ≥200 m² with load-bearing ≥3 tons/m². It needs access to 380V AC power supply (total installed capacity ≈50kW) and stable wastewater inlet/drainage pipelines. We provide detailed installation drawings and dispatch technicians for online guidance; commissioning takes 5-7 days to complete system stabilization.
6.2 Maintenance & Upkeep
Q: How often does the core equipment require maintenance, and what are the key tasks?
A: Routine maintenance includes: 1) Daily: Clean air flotation scum and check dosing tank levels; 2) Weekly: Inspect aeration fans and pump operation; 3) Monthly: Clean air flotation releasers and calibrate dosing metering pumps; 4) Quarterly: Inspect anaerobic tower three-phase separators; 5) Annually: Replace filter elements and conduct sludge dewatering.
Q: How to handle grease clogging in the air flotation machine?
A: The air flotation machine is equipped with a high-pressure cleaning function; clean the flotation tank and releasers with high-pressure water every month. For severe clogging, add a small amount of degreasing agent to the dosing system to enhance grease removal.
6.3 Warranty & After-Sales
Q: What is covered under the 2-year warranty period?
A: Within the warranty period, we provide free repair or replacement for faults caused by design, manufacturing, or material defects, including core equipment (air flotation machine, anaerobic tower, integrated A2O equipment), pumps, fans, and control systems. Damage from improper operation, grease clogging due to poor maintenance, or natural disasters is not covered.
Q: How to access after-sales technical support?
A: We offer 24/7 online support via email and phone. For complex on-site issues, technicians can be dispatched within 48 hours (additional fees apply for non-warranty services). We also conduct semi-annual return visits to monitor system performance.
6.4 Operational Cost
Q: What is the estimated monthly operating cost of the system?
A: For a 300m³/day system, monthly operating costs include: 1) Electricity: ≈USD 1,080 (1.2 kW·h/m³ × 300 m³/d × 30 d × 0.1 USD/kW·h); 2) Chemicals (PAC/PAM/disinfectant): ≈USD 1,500; 3) Labor: ≈USD 800; 4) Sludge disposal (if not reused): ≈USD 0 (reused as fertilizer). Total monthly cost: ≈USD 3,380.
6.5 Safety & Compliance
Q: Is the treated effluent compliant with environmental regulations for food industry wastewater?
A: Yes. The effluent meets GB 8978-1996 Integrated Wastewater Discharge Standard and local food industry environmental requirements. We provide third-party testing reports to verify COD, BOD, SS, and grease concentrations, ensuring regulatory compliance.
Q: How to handle system failures to avoid untreated wastewater discharge?
A: The system is equipped with an emergency overflow pipeline and regulation tank (capable of storing 4-6 hours of wastewater). In case of equipment failure, the PLC control system triggers alarms and automatically switches to backup equipment (e.g., standby aeration fan), minimizing environmental impact.
Would you like me to prepare a detailed operation and maintenance manual that includes step-by-step cleaning procedures for the air flotation machine, anaerobic tower inspection checklists, and chemical dosage adjustment guides?
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