CONSIDERATIONS IN SELECTION AND OPERATION OF A WASH WATER RECYCLE SYSTEM. THE NEXT GENERATION THINKING OUTSIDE THE BOX.
The design phase represents the first and most crucial portion of selecting a recycle system. Many vendors carry "off-the-shelf" recycle systems, The Next Generation is semi-custom built in that we have a basic system that is custom designed for each location. We have employed a BUILDING BLOCK design allowing additions and modifications to be made in the field as needed. From adding automatic pH control to automatic water make-up control.
Large in ground separators required by some recycle systems hold up to 1,000 gals. of waste water and could be mixed with rain water in violation of storm water permit. High water table could prevent using this type of separator.
The Next Generation uses a simple wash pad design with single sump box and screen trap connected to pump tank located next to recycle system this prevents wash water from mixing with rain water. Sump pump, pumps the wash water from the pump tank to the top of the above ground separator leaving the sump box empty of any wastewater.
ABOVE GROUND SEPARATOR THE NEXT GENERATION The wastewater flows downward in the center inlet pipe and is discharged into the bottom of ABOVE GROUND SEPARATOR tank. A truncated conical baffle ensures proper distribution of the incoming flow. The conical configuration of the baffle forces the flow downward, accelerating separation of the solid particles by gravity. These particles continue down to the bottom as the direction of the liquid flow is turned upward. The upward gradient accelerates the flotation process, forcing any lighter floating material to the top of the tank. Where it is skimmed off either continuously or intermittently. The clarified liquid exits the ABOVE GROUND SEPARATOR through a screen diffuser then over another conical baffle and through the annular space between the outlet pipe which surrounds the inlet pipe. The actual discharge point is several feel below the surface of the liquid level in the separator vessel. This ensures that the clarified liquid will be free from floating and settling contaminants. The external outlet port is gravity flow through a 2 inch pipe connected to the treatment/storage tank.
SINGLE PASS TECHNOLOGY.
Other recycle system use single pass technology, this means that untreated water enters the recycle system through some type of mechanical separator. This separator will only allow a small flow of wastewater normally 5 to 10 G.P.M. to pass through a coalescing area one time.
CLOSED LOOP CONTINUOUS RECYCLE SYSTEM DESIGNED AND BUILD BY THE NEXT GENERATION IN WASTE WATER TREATMENT TECHNOLOGY USES ONE TANK FOR TREATMENT AND STORAGE.
Only one tank is used to store and treat waste water from pressure washing, water is picked up from the bottom of the treatment/recycle tank by the filter pump then pumped through the large proprietary media filter continuously, removing solids to 20 microns (this proprietary media never needs changing) returning to the treatment/recycle tank through an air injector to aerate the water controlling bad odor. The vast amount of air injected into the water called DAF (Dissolved Air Flotation) removes any VOC's such as Gasoline, solvents and Diesel, no other recycle system has this capability. The large amount of air injected into the treatment/recycle tank also evaporates large amounts of water in some cases 150 to 200 gals. per day. The air injector is fixed by design and will never change and requires no service.
AquaClean recycle system and others us FIBER WOUND CARTRIDGE FILTER which are unable to collect the volume of particals as a MEDIA FILTER USING THE NEXT GENERATION PREPARATORY MEDIA. The media filter is backwashed as need and never needs changing unlike fiber wound filter that must be replaced often at a cost of $30.00 to $40.00 each Aqua Clean could have a operating cost over $4,000.00 a year while The Next Generation operation cost is less than $200.00 a year.
This treatment method is complex using Programmable Logic Controller. Do you have the technical ability to trouble shoot this type of system?
PROVEN METHOD TO REMOVE HEAVY METALS.
The Next Generation has a long history in treating Heavy Metal from plating shops such as Chrome, Copper Cyanide, Zinc, and other Heavy Metals. Copper base bottom paint has caused a great deal of controversy among State DEP, EPA and marina's. There are two forms of Copper present in the wash water as it leaves the boat hull. One is DISSOLVED Copper and the other is FREE Copper. DISSOLVED Copper as with any HEAVY METAL is not soluble in water as long as the pH is at or above 7 pH (neutral pH) Testing by The Next Generation in a marina has proven this. The other form of Copper is what we call FREE Copper which is washed off the hull by the pressure washer as large chips of paint captured by the sump screen. The remaining small partials are captured in the above ground separator and filter system of the closed loop recycle unit. The conclusion is as long as the pH remains above 7pH and proper filtration process is used Copper will remain the same and the need for Carbon Filter , Electrocoagulation, or Chemical treatment is not necessary.
NOTE: Most bottom paint use CUPROUS OXIDE as a form of COPPER, CUPROUS OXIDE IS INSOLUBLE IN WATER as long as the pH remains above 7pH.
The Next Generation uses UV technology to sterilize the recycled water by destroying the targeted micro organisms.
OPERATION AND MAINTENANCE
The single most important items in operation of a closed loop recycle system is maintenance. Like any other equipment or mechanical device, periodic system checks and routine maintenance will be required to keep operation at peak performance. Recycle systems are not a "black box" where dirty water goes in and clean water comes out. The Next Generation over all has the simples and easiest system to operate and maintain compared to all other recycle system on the market today. Don't be fooled by a system mounted on a trailer consisting of a filter, pump and storage tank, there are to many problems with this design to go into.
By Service Ability we mean what service is required to maintain the recycle system and the technical level required to perform the maintenance. Operating a wash water closed loop recycle system can be an expensive, labor intensive and frustrating experience. Foul odors, poor water quality, failed mechanical equipment, complicated electronic systems, and baffled employees are frequent results of a poorly designed recycle system. Personal turnover may leave a system in the hands of an untrained employee, which will ultimately lead to costly operational problems.
The Next Generation uses one pump to recycle water through the media filter, pump water through the air mixer, and supply pressure to the final filter and pressure washer. Safety controls will shutdown the unit in the case of operational error to protect the recycle system.
Simple Start and Stop push button operation.
Simple wash pad and sump system using above ground separator.
One tank to store and treat water.
Air to control bacteria and keep the water aerobic reducing sludge and bad odor, air mixer requires no maintenance and will not change over the life of the system.
Air stripping to remove Gasoline, Solvents, and fuel without using carbon filters.
Primary Medial Filter with proprietary media that is permanent and never needs changing captures small particles to 2.0 microns then backwashed to wash pad to be recovered by above ground separator in a concentrated form.
Smaller particles are removed by a 5-micron final filter before going to the pressure washer.
Flow rate to 35 GPM.
Cascade bag filters are a separate system used to collect solids from the above separator. These cloth bags collect solids from the bottom of the separator and returns the water to the wash pad to be pumped back into the above ground separator for total closed loop.
UV system to destroy micro organisms.
OPERATION COST THE NEXT GENERATION
This system uses a 1 HP 110 volt ac motor for pumping wash water through media filter, supply pressure to air injector, final filter and pressure washer. Primary media filter uses a proprietary media and never needs changing. Final filter is a reusable polyester filter and can be cleaned and reused replacement cost $75.00 and should last several years. Bag filter are cloth and can be clean and reused, however the replacement cost is less than $20.00 each, three bag required. UV lamp has a 10,000 hour life span replacement cost is $75.00
OPERATIONAL LABOR THE NEXT GENERATION
Back wash media filter once a week 10 to 20 minutes. Remove and clean final cartridge filter (check monthly) clean as need 1 hour. Sump screen requires a forklift to remove screen and dump into proper container wash and reinstall in sump, this should be done as needed before it becomes full of solids. Check level in Treatment/storage tank daily add water as need. Bag filter from above ground separator requires opening a valve from bottom of separator and allow solids to be collected in the bags once a week, because the water is returned to the wash pad the sump pump will pump water back into the separator. Time required for this task 5 to 10 minutes. Bag replacement requires sliding bag off flange and replacing with new bag.Project ID: Powerwash Recycling & Filtering System Discharge