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DESCALING PROJECTS 

Here are just a few of the diverse projects that FlowScience has entirely replaced Chemical, Acid and Jetting Treatment for scaling control

Greentree Landfill: Waste-Water Treatment Plant Case Study Q&A
THE PROBLEM

“Keeping the water moving”; The biggest challenge was treating the daily leachate from the landfill plus outside liquids in a costly and efficient manner.  The treatment plant is a “complex critter” that renders itself by nature due to pH needed levels in the matrix to scaling.  To maintain consistent operating flow, chemicals and or manual removal of scaling was continually necessary.

A renewal NPDES permit contained new parameters which are regulated by the TMDL of the receiving discharge stream.   It was immediately recognized that meeting the new limit would require significant changes to the existing chemical treatment processes and these changes would also trigger a change in the existing O&M practices.

HOW WAS SCALING AFFECTING THE OPERATIONS?

 

There were two types of scaling which need to be delt with. The first is in the landfill leachate collection/conveyance system. The other is scaling due to the treatment of the leachate.

HOW WERE YOU MANAGING IT?

 

Collection pumps were replaced, when necessary, lines were jetted as necessary in the collection system.  At the treatment plant ports are installed for acid cleaning, and processes are taken offline for cleaning. Excessive down time, equipment repair, and labor was the “norm”. Descaling chemicals were added to extend operation life between down times.

HOW HAS FLOWSCIENCE CHANGED YOUR OPERATIONS?

Since the installation of the FlowScience LSC equipment, we have stopped using chemical descaling additives entirely and reduced downtime for cleaning dramatically (it was a miserable job and laborers were difficult to retain). On the high pH end of treatment cost for descaling chemical ranged from $300 to $1,300 per day depending on the volume and quality of the water treated

Scale Forms on Pipes, Tanks, Mixers, Pumps and Transducers
scaled ultrasonic
leachate scale waste water treatment system
leachate scale from biological reactor
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Cement Industry - Methane Stripping Waste Water Plant
THE PROBLEM

A hard deposit build up was observed after the plant had been running for some weeks which eventually resulted in restricting the discharge pipeline, coating the discharge pumps and reactor walls. After removal a sample was sent to ALS Laboratories for analyses and stated to be largely Calcium Carbonate. Sequence of events On plants with light scaling a chemical additive is often used to remove or reduce the scaling. Phoenix conducted trials on dissolving the Longford scale with chemical additives in their laboratory but concluded that the scaling at Longford was so severe as to render scale reduction by chemicals impractical and very costly.

THE SOLUTION

Scale control by using ionising of particles in the liquid is offered by many companies. After discussions and investigating the options, it was agreed to install the Vulcan system on the pipeline at Longford. The MSP was drained and cleaned before the trial started. The system is a control panel with electronics attached to pads wrapped around the pipeline. The system remains on 24/7, Scale continued to build up after the system was set to work and after the trial period there was no reduction in the scale build-up, and it remained hard and difficult to remove. Further searching found FlowScience had a similar system but with documented successful results when used on Leachate plants. It was agreed between Cemex, Phoenix and FlowScience to install their system at Longford on a trial basis to see if scale buildup could be reduced with their system. Phoenix removed the system and installed the FlowScience system when it arrived from Canada. The FlowScience system includes pads on pipelines (inflow and outflow), pads around discharge pumps and a free-standing pipe suspended in one reactor with pads..

THE RESULTS

Shortly after start-up a very slight deposit can be seen on the pumps -21-06-2023. Two days later showed little change on the pumps. 2nd visit - no change 3rd visit - no change 4th visit - slightly more scale but reported as soft. 5th visit – no change 6th visit – no change 7th visit – no change 8th visit – no change on pumps. Discharge tank shows slight soft scale buildup and no restrictions to the discharge pipe. 9th visit – no change 10th visit – During this visit the reactor chamber level was lowered to observe the tank wall scale. A video was taken to show the deposit was thin and soft. Prior to the 10th visit one discharge pump had failed. Our engineer removed the volute, and it clearly shows there is no scale build-up. The likely cause is a capacitor failure not related to the trials. 3.2. Conclusion The plant is running as per design with no signs of scale inhibiting performance. Some scale has appeared during the trial but is slight and soft and therefore not inhibiting the plant operation. Ongoing it is recommended that checks are undertaken, as in the trial, during the maintenance visits. Note ; Whilst the control panels are rated at 10amps each the running current is under 1 amp. Running costs are therefore minimal

Methane Stripping Plant
Longford discharge pipework.jpeg
Pump scaling 9 02092021.jpg
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Indiana Landfill: Force Main and Sump Scaling Increasing; Costs Mounting
Scale Forms on Sump Pumps and Within ForceMain
Sump pump scaling
leachate scale on landfill
landfill lcs pipe scaling
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THE PROBLEM

The MSW landfill had been experiencing increased precipitation of leachate scale throughout areas of the collection system and sump pumps. Formation of scaling is becoming more rapid and has reached problematic stage. Jetting is a constant battle to keep leachate flow with chemical de-scalers being a pricey option. It was a Tuesday that I saw an article on Linkedin about a “breakthrough technology for leachate scale control”. The system used a charge to treatment pads on the outside of pipes and pumps and was guaranteed to not only inhibit but also remove leachate scaling. “Highly skeptical” is a word that would best describe my thoughts on a product like this. I would have heard of it by now…

HOW WAS SCALING AFFECTING THE OPERATIONS?

 

Jetting wasn't keeping up.  Additional measures were needed to keep critical LCS and sumps flowing.  Chemical treatment was quoted several times.  $300K annual was the best quote and wouldn't guarantee that jetting wouldn't be necessary in some aspects.  This was going to hurt the operating budget

HOW HAS FLOWSCIENCE CHANGED YOUR OPERATIONS?

Attaching to 2 pumps that had to be cleaned almost weekly and 2 scaled lines that were in need of cleaning more frequently; we saw results in the first week. Wells and sumps were gathering a slurry and chunks of scale (much like after jetting) and the pumps look like new after many weeks of operation in the sumps. The LSC systems worked. My goal as an operator that knows the challenges of operating and MSW today is to let others know that FlowScience is completely legit and the overall benefits are tremendous. We’re greener and we’re saving costs. That’s not a common thing to have in a product.

California Landfill; 4” Force Main: Permanent Scaling Solution Project
THE PROBLEM

The Landfill was experiencing consistent scaling of approximately 2200 linear feet of the lower 4” Force Main whereas jetting was required at least twice per year. The pipe itself would be approximately 50% scaled every 6 months and continual hydro-jetting was necessary to keep the critical line flowing. In some instances, areas of pipe needed to be cut out in super-saturated calcification points. The leachate scaling itself was familiar to other sites see in California by Gii Group.

THE SOLUTION

SYSTEM 1: FLowScience LSC 2XL (4 treatment pads) to be attached to the 4” PVC pipeline immediately following the W119B location. Prior to beginning formation of scaling.

SYSTEM 2: FLowScience LSC 1XL (2 treatment pads) to be attached to the 4” PVC pipeline immediately following the W236 location.

THE RESULTS

Upon evaluation of the drawings and the FlowScience Landfill Design form Gii connected with the engineering and landfill OPS personnel to determine the solution to be provided to keep the Force Main scale free permanently. Taking under advisement the optional start-up solution, the line was jetted one more time prior to turning on the FlowScience Leachate Scale Control Systems. One system was added to the beginning of the line and another approximately 1200 feet downstream. Once systems were turned on, LF personnel would camera the line at regular intervals. In early February 2020 the landfill turned on two (2) FlowScience systems in hopes of keeping the line clear long term. As of mid November 2020, the 4” FM continued to flow freely with only minor surface scaling becoming apparent at each camera interval. It was determined in a Zoom meeting that this minor residual scaling build-up was 99% likely attributed to varying flow rates. Further camera inspections have shown the continued scale inhibiting results and as of February 2021 there has been no additional maintenance needed to keep the FM clear and FlowScience continues to inhibit leachate scaling along the line. Personnel will continue to monitor the line and have been advised that FlowScience LSC system lifespan is approximately 15 years. The FlowScience LSC Systems have worked and have eliminated the need to jet and cut the Force Main with return on investment of under 1-year.

Scale Formation Within ForceMain
leachate scale in pipe
leachate scale
camera of leachate collection force main
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landfill biological reactor scales

Landfill SMBR

Mounting costs and maintenance with this biological reactor.  See how FlowScience kept scale in control.

landfill

12 Feet of Head

12 feet of head on top of the landfill membrane is a big problem and nothing works until...

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leachate scale

Pulp & Paper

brewery and beverage scaling

Brewery & Beverage

cement carbonate scale solutions

Cement

mining process carbonate scaling removal

Mining

— Name, Title

FlowScience Replaces Chemicals & Jetting in These Industries Too

Additional Case Studies Available Upon Request

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