Tailored solutions with unmatched expertise. FRC Systems is your trusted wastewater solutions provider. Contact Us See Us In Action The FRC Difference With nearly 50 years of industry experience and thousands of Dissolved Air Flotation (DAF) installations across the globe, FRC Systems is dedicated to leveraging our extensive application expertise in wastewater treatment solutions to benefit you. We’re committed to offering ongoing support and innovative solutions for the future. About FRC Systems Meet Our Team Almost 50 Years of Industry Leadership Thousands of Worldwide Installations Application Experience and Endless Knowledge Client Focused. Solutions Based. Results Guaranteed. Why Choose FRC Systems? Application Experience & Know-How Our design and engineering teams are led by highly regarded specialists in the wastewater treatment field with an average of 25+ years of experience in the industry. Client Focused All of our systems are engineered for the specific challenge at hand. We focus on client objectives from the beginning of the design process through installation and start-up. Our goal is not just to make a system that works, but one that works for you. Personal Attention Each project receives one-on-one attention throughout the entire process from a dedicated project manager and a team of our experienced engineers. Quality You Can Trust The FRC design process includes professional submittals with detailed 3D drawings for approval before manufacturing. Our products are constructed using laser-cut, stainless-steel manufacturing and assembly to ensure quality control. FRC Systems transformed our wastewater treatment process. Their expertise and innovative solutions have significantly improved our plant’s efficiency. We’re grateful for their ongoing support and highly recommend their services. Chief Product Officer Food & Beverage Company The installation of FRC Systems’ wastewater treatment solution was seamless and professional. Their team’s knowledge and dedication have made a noticeable difference in our operations. We couldn’t be happier with the results. Facilities Design Manager Health & Beauty Company Choosing FRC Systems for our wastewater treatment needs was a game-changer. Their system is reliable, and their customer service is exceptional. We’ve seen a marked improvement in our environmental compliance and operational costs. Plant Operations Director Oil & Gas Company FAQ What is Dissolved Air Flotation (DAF)? Dissolved Air Flotation (DAF) is a water treatment process that is highly effective in the removal of suspended solids (TSS), fats/oils & grease (FOG), biological oxygen demand (BOD) and other contaminants from water. It is particularly effective in situations where conventional sedimentation methods are less efficient. Here’s a breakdown of what DAF is and its primary uses: Air Dissolution: In DAF, air is dissolved into water under pressure in a specialized tank, saturation tube or pump. Pressure Release: When this pressurized water is injected into the flotation vessel, the pressure drops which releases the dissolved air as tiny microbubbles. Flotation Mechanism: These microbubbles attach to suspended particles and contaminants, causing them to rise to the surface. Skimming: The accumulated material (sludge or float) at the surface is skimmed off, while the clarified water is collected from below. What Are Some Uses of DAF? DAF is used in a variety of applications, including: Industrial Water Treatment: In industries such as food and beverage, oil and gas, and pulp and paper, to treat process water and wastewater. Municipal Wastewater Treatment: To remove solids, algae, phosphorus and other contaminants before further treatment or discharge. Sludge Thickening: DAF is used thicken biological sludge, reducing the overall sludge volume reducing transportation, handling and disposal costs. Drinking Water Purification: To remove algae, particulates, and other contaminants from source water. Pre-treatment: As a pre-treatment step for more advanced treatment processes, enhancing overall efficiency. Stormwater Management: To treat runoff and reduce pollutants before discharge. Does FRC Provide Rentals or Pilots? With the largest Dissolved Air Flotation (DAF) rental fleet in the US and equipment ranging from 10–3,000 gpm, we can tailor a solution to your needs. All FRC rental equipment is available for short-term and long-term rental agreements as well as pilot testing and long-term lease agreements. FRC rental systems and stand-alone equipment are installed in a “plug-and-play” configuration for ease of installation and start-up. Once in place on-site, the unit can be operational within a matter of hours. What is a Flocculator? A Flocculator from FRC Systems is designed to provide the necessary mixing action and retention time to chemically treat wastewater. Here’s how it works: Coagulation: Coagulants are added to the wastewater to break emulsions and form micro-flocs. Flocculation: Flocculants are then added to agglomerate these micro-flocs into larger, more robust macro-flocs. Mixing: Mixing: The flocculator ensures proper mixing energy required by the chemicals and maintains the integrity of the flocs, which is crucial for effective separation in the subsequent Dissolved Air Flotation (DAF) process. FRC Systems offers both Plug-Flow Reactors (PFR) and Continuous-Stirred Tank Reactors (CSTR) as flocculators, each designed to optimize the chemical treatment process. What is the difference between the PCL, PCCS and PWL? The main differences between PWL, PCL, and PCCS Dissolved Air Flotation (DAF) systems from FRC Systems lie in their design and application: PWL (Open-Tank DAF System): Design: Open tank, low-built separators with side walls typically 8 to 10.5 feet tall. Application: Better suited for high solids loading rates. The skimmer assembly rotates against the hydraulic flow, shortening sludge skimming distance and eliminating solids carry-over. PCL (High-Rate DAF System): Design: Features corrugated plate packs that increase the effective separation area, allowing for a smaller footprint. Application: Ideal for high hydraulic loads with lower solids loading rates. The plate packs help maintain laminar flow and increase effective separation area which increases overall system performance. PCCS (High-Rate DAF System): Design: Similar to PCL, the PCCS features a high-rate design and corrugated plate packs. However, the PCCS is specifically designed to fit within a shipping container, making it easily transportable. Ideal for temporary or mobile wastewater treatment needs, such as remote locations or construction sites. Application: Efficient for removing Total Suspended Solids (TSS), Fats, Oils, and Grease (FOG), and other pollutants from wastewater. Each system is tailored to specific wastewater treatment needs, with PWL being more suitable for higher solids content and PCL/PCCS for higher hydraulic loads. If you have a specific application in mind, I can help you determine which system might be the best fit! Is FRC a part of Sulzer? In 2018, FRC Systems joined the Chemtech division of Sulzer, where our clients receive our expert team’s dedicated attention backed by Sulzer’s global resources. Contact

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If you’re relying on coagulants to adjust pH, it’s time to rethink your approach. Coagulants are specifically designed to aid in solids coagulation, not to serve as pH adjusters. The distinction is critical, yet many wastewater treatment facilities inadvertently misuse coagulants in this way. The question is simple: why use iron or aluminum salts for pH adjustment when acids (like sulfuric acid) or bases (such as sodium hydroxide) are specifically designed for this purpose? By understanding the role of coagulants and their proper application, facilities can avoid unnecessary costs, inefficiencies, and complications. The True Purpose of Coagulants The primary function of coagulants is to coagulate solids in wastewater, not to adjust pH levels. This fundamental concept is sometimes overlooked by wastewater operators and environmental engineers. Coagulants, such as aluminum- and ferric-based compounds, generally work by neutralizing the electrical charges to destabilize emulsions enabling them to form together into a floc. These flocs can then be separated from the water more easily. While many coagulants do have an acidic nature and can reduce pH as a secondary effect, relying on them for pH adjustment is inefficient and problematic. Misuse of Coagulants This issue arises when facilities attempt to lower pH levels using coagulants instead of acids. For example: pH Neutralization Before Treatment : Aluminum- and ferric-based coagulants operate most effectively within a specific pH range (alum: 5.5–7.5; ferric: 5.0–8.5). When wastewater has a higher pH, the correct approach is to use acids like sulfuric or hydrochloric acid to bring the pH into the optimal range. However, some operators incorrectly add coagulants in large quantities to achieve this adjustment, which leads to several unintended consequences. Negative Impacts of Misusing Coagulants Under/Overdosing When pH is used to determine the amount of coagulant being dosed rather than rates that have been determined through jar testing there is the obvious potential to underdose or overdose.  The effects of underdosing are self-evident in that adding too little may not achieve destabilization of the emulsion and result in poor performance.   Overdosing, however, can also be a problem as it can cause a reversal in charge (overcharge) which can return the colloidal particles back to an emulsified state. High Costs Coagulants are significantly more expensive than acids or bases. Using coagulants for pH adjustment results in unnecessary chemical expenses, as large volumes are required to achieve the same effect that a smaller quantity of sulfuric acid could accomplish. Increased Sludge Volume Coagulants are metal-based, which means they contribute to the volume of sludge generated during wastewater treatment. Excessive use of coagulants leads to higher sludge production, increasing the costs and labor associated with its storage, dewatering, and disposal. Elevated COD Levels When coagulants are added in excess and there are insufficient solids for them to bind with, the unreacted metals dissolve into the water. This can increase chemical oxygen demand (COD), potentially disrupting downstream biological treatment processes. Best Practices for pH Adjustment The proper way to adjust pH in wastewater is to use the appropriate chemical reagent: Use acid (such as sulfuric acid) to lower pH. Use base (such as sodium hydroxide) to raise pH. Once pH is within the desired range, apply coagulants to achieve the necessary water clarity. Coagulant dosing should always be determined based on the clarity of the treated water, not to manipulate pH. Pro Tip: Perform a jar test  to determine the optimal coagulant dosage. When the treated water appears clear and solids are clumped into stable flocs, the coagulant dosage is correctly calibrated. A Smarter Approach By minimizing coagulant usage and applying it solely for its intended purpose, facilities can significantly reduce costs, lower sludge production, and maintain a more stable wastewater treatment process. If your facility struggles with pH adjustment and coagulant misuse, FRC offers systems that automate pH balancing with the correct chemicals, ensuring an efficient and cost-effective treatment process. Contact us to learn more about designing a solution tailored to your needs.

FRC Systems has designed skid-mounted Dissolved Air Flotation (DAF) systems  to offer a convenient, plug-and-play solution for industrial wastewater treatment. These compact units are preassembled and ready for immediate operation, providing an effective approach to removing TSS (Total Suspended Solids), FOG (Fats, Oils and Grease), BOD (Biological Oxygen Demand), COD (Chemical Oxygen Demand) and other nutrients such at TP (Total Phosphorus) from wastewater streams. A Proven Solution in Emergency and Everyday Operations Adriaan van der Beek, FRC’s Head of Sales, shared an example of the system’s effectiveness: “A small dairy in Vermont faced a crisis due to a fire at their wastewater treatment plant. We quickly mobilized a skid-mounted DAF system to address the emergency. The system demonstrated exceptional performance in removing FOG, BOD, and TP. The dairy was so impressed with its efficiency that they decided to purchase the system for permanent use.” The versatility of skid-mounted DAF systems has made them increasingly popular among industrial facilities. They can serve as: Primary solids removal systems , handling incoming wastewater streams. Secondary treatment units , performing final solids removal downstream of biological treatment processes.  Even municipal wastewater facilities  are using skid-mounted DAF units for tasks like algae removal from aeration ponds, showcasing their adaptability across various applications.   Key Features and Benefits of Skid-Mounted DAF Systems Quick Delivery Units are in stock and ready for shipment, minimizing downtime during emergencies. Low Installation Costs Preassembled and skid-mounted for straightforward setup with minimal labor or infrastructure requirements. Low Chemical Consumption Optimized treatment processes reduce reliance on chemical additives, lowering operational costs. Advanced Plug-Flow Reactor Technology Ensures even distribution of flow, enhancing system efficiency and performance. Superior FRC DAF Aeration Technology Designed for effective and reliable dissolved air flotation processes. Standard End Suction Centrifugal Pumps Durable and widely compatible components simplify maintenance and repair. DNF and DGF Capabilities Systems can accommodate Dissolved Nitrogen Flotation (DNF)  or Dissolved Gas Flotation (DGF)  for specialized applications. Flexible Rental and Lease Options Ideal for facilities requiring temporary solutions or exploring a cost-effective approach to wastewater treatment.   Discover the Right Skid-Mounted DAF System for Your Facility Whether you’re responding to an emergency or seeking a reliable, permanent wastewater treatment solution, skid-mounted DAF systems deliver efficiency, convenience, and versatility. To learn more about securing a skid-mounted DAF system for your facility, including purchase, rental, or lease options, contact us today.

Conclusion At face value, A DAF is like any another piece of industrial equipment—they’re an investment you want to make only once and have years of trouble-free operation. But the truth is, not all designs are created equal. With this guide, you now have a clearer understanding of the critical design elements that differentiate one DAF unit from another. Let’s summarize the key questions you should address with a DAF manufacturer before making a decision: What type of DAF recycle pump is used, and why? What materials are selected for tank construction? What mechanical measures are included to ensure effective sludge thickening? How is dissolved air distributed throughout the DAF tank? What are the operating procedures for the system? What specific design considerations have been made for your application? A reliable DAF manufacturer should be able to answer each of these questions thoroughly, providing clear justifications for their design choices. If a manufacturer struggles to articulate the reasoning behind their approach, it could indicate a lack of precision in their engineering process. On the other hand, a manufacturer who can confidently and thoughtfully discuss these topics is more likely to be a dependable partner in your project. Once you’re satisfied with the manufacturer’s explanations, take a closer look at their track record. A company with limited project experience may rely heavily on theoretical designs, which might not perform as well in real-world conditions. For a significant capital investment like a DAF, proven solutions are essential. Whether you’re an engineer designing a system or an end-user evaluating options, remember that choosing the right DAF is a decision you only want to make once. Take the time to ensure it’s the right one. If you’d like to discuss a specific wastewater application where a DAF system might be a fit, feel free to reach out to us—we’re here to help.