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.

If you haven’t already, be sure to check out Part 1 & 2 before continuing here. 5. Dissolved Air Distribution: Why Methodology Matters The way whitewater is generated and distributed into the incoming wastewater stream has an impact on floc formation and flotation within the DAF vessel. Let’s compare two common approaches. Vertical Saturation Tank Configuration Some DAF manufacturers utilize a vertical saturation tank paired with a specialty whitewater pump and a diaphragm valve assembly to generate and inject whitewater. While this method can be effective, it has notable drawbacks: Excess Air Issues : The vertical saturation tank is designed to vent undissolved air from the top. However, some undissolved air escapes through the side-mounted discharge line, entering the flotation cell. This can cause large bubbles to enter the flotation cell, disrupting the sludge and immersing solids back into the water. Limited Coverage : Often these systems rely on a single dissolved air injection port into the wastewater stream immediately before it enters the DAF.  This single injection point can distribute whitewater unevenly, resulting in inconsistent bubble coverage.  Additionally, the large stream of white water injected at one single location can cause shear forces on the newly formed floc, breaking them apart typically requiring additional polymer. Slow Saturation : Start-up procedures often require time for whitewater to disperse across the DAF Cell. Manuals often recommend waiting 5-10 minutes before initiating treatment, delaying operational workflows. Angled Saturation Tube and Whitewater Manifold Configuration In contrast, systems using an angled air saturation tube and a whitewater distribution manifold offer several advantages: Complete Air Removal : Excess air escapes from the elevated end of the angled tube, ensuring only dissolved air enters the flotation cell. This eliminates large bubbles, maintaining stable sludge flotation. Even Distribution : Whitewater manifolds feature multiple injection ports strategically placed across the width and height of the DAF tank.  Additionally, some white water can be injected at the time of floc formation when the DAF is paired with a Pipe Flocculator Reactor. This design ensures uniform microbubble distribution throughout the wastewater, enhancing separation efficiency and preventing overloading in specific areas. Rapid Saturation : With multiple injection points, these systems saturate the tank in under 60 seconds, significantly reducing start-up times and improving overall productivity. Reduced Footprint and Complexity :  When properly configured the Angled Saturation Tube has an incredibly high air to water contact area relative to the size of the Saturation Tube.  This results in extremely high saturation efficiency in a small footprint.  Additionally, with no need for level sensors, automatic relief valves, proprietary aeration valves or other moving parts, complexity is kept to a minimum. Key Takeaway: Design Details Matter When evaluating DAF systems, take a close look at the dissolved air distribution design. Ask the manufacturer: How does the system manage excess air? What measures ensure even whitewater distribution? How long does it take to saturate the tank and begin treatment? Does the system rely on complex components? These details can make the difference between a smooth operation and one plagued by inefficiencies. 6. Application-Specific Design: A Tailored Approach Materials Selection Consider the example of a cattle processing plant, where wastewater is laden with abrasive, gritty solids. A typical DAF system with a cast iron recycle pump might initially seem cost-effective but would fail prematurely due to abrasive wear. A better choice would be a pump with a CD4MCu casing, offering higher hardness and resistance to abrasion. Thoughtful materials selection prevents costly downtime and replacement expenses.  Understanding the application and tailoring the equipment to that application leads to a reliable, trouble free system. Process Engineering The application also dictates critical engineering parameters, such as: Hydraulic Surface Loading Rate : The rate at which wastewater flows through the DAF system’s effective separation area. Solids Loading Rate : The rate at which the DAFs free separation area is loaded with solids. Air-to-Solids Ratio : The ratio of dissolved air relative the solids being removed by mass. For instance, primary poultry solids separate more easily than biomass solids from an activated sludge system. Using the same design parameters for both would result in an oversized poultry DAF and an undersized biomass separator—wasting resources in one case and failing to meet performance requirements in the other. Questions to Ask When selecting a DAF system, don’t hesitate to ask: Why was this configuration chosen for my application? What material upgrades are available to address specific challenges? Explain the calculations behind system sizing and performance metrics? A manufacturer’s ability to provide clear, application-specific justifications reflects their expertise and ensures you receive a system optimized for your needs. 5. Dissolved Air Distribution Methodology The method used to distribute whitewater into the incoming wastewater stream makes all the difference in the way sludge forms and floats inside the DAF vessel. Let’s examine two different approaches. Some DAF manufacturers employ a specialty whitewater pump, vertical saturation pipe and diaphragm valve assembly to generate and inject whitewater into the incoming wastewater. Others use ANSI recycle pumps, an angled air saturation tube, and a whitewater distribution manifold with multiple ball valve and tubing assemblies. A comparison of these two configurations might sound like splitting hairs, but it’s definitely worth some consideration.  The vertical saturation pipe configuration is designed to bleed off air that doesn’t dissolve into solution. While most excess air will escape from the top of the tube, the side-mounted whitewater discharge line will draw some portion of it into the tank. As excess air enters the flotation cell, large bubbles form and burp at the water’s surface. These bubbles disturb already floating sludge and immerse solids back into the water.With an angled configuration, excess air escapes out the elevated portion of the tube as whitewater flows out from the lowest point. No undissolved air can enter the flotation tank because the water flows from top to bottom, not the other way around. DAF systems that use vertical tubes typically only have one dissolved air injection port. When flowing 100 gpm (1.67 gallons per second) of wastewater into the flotation cell, a single dissolved air injection point is unable to effectively and evenly spread whitewater over the entire incoming solution. Some portion of the flow gets a huge shot of whitewater, while other parts go entirely without. It’s up to the hydraulic patterns inside the flotation cell to distribute the bubbles. Often times this works, but it’s unpredictable and uncontrollable. A habitual problem with this design is that solids cannot float to the water’s surface quickly enough to keep up with the incoming flow. By all calculations, a system designed to process 100 gpm of wastewater is unable to achieve that flow rate because solids are not separating quickly enough. DAF systems with whitewater distribution manifolds do not have this issue. Numerous whitewater injection ports are placed across the width of the flotation cell at different heights to evenly distribute micro-bubbles all throughout the DAF tank in a controllable manner. The start-up routines for these two configurations also varies by nature of the whitewater injection system. A single air injection port saturates the tank with whitewater from one origin. As tanks are sized longer and wider, it takes more and more time for the bubbles to disperse throughout the whole tank. Some manufacturers’s DAF operation manuals suggest allowing 5-10 minutes for tank saturation before opening the wastewater influent valve and proceeding with treatment. DAF systems with an air distribution manifold are fully saturated within 60 seconds or less. Shorter start-up time means less waiting around and more getting work done. The lesson is to get in closer and examine the design differences. The details matter. Ask the manufacturer about their design justifications. 6. Application Specific Design Think of a hammer, a tool meant to deliver impact to an object. Now, picture one in your mind. What do you see? If you’ve ever worked in carpentry maybe you visualized a claw hammer.  Metalworking? A ball-peen hammer with a hemispherical head. Maybe you’re a stonemason and thought of a brick hammer with its long chisel-shaped blade. Everyone thinks of the hammer they use in their trade. But no one should know better than the hammer-maker which one is the most appropriate for a specific task. A DAF system manufacturer should have that same level of expertise and knowledge about which DAF system design is most suited to a specific application. If a designer is using the same DAF system for a dairy acidulation process as they use in a cattle abattoir plant, that’s like a rail worker using a judge’s gavel to pound in a railroad spike – similar tool, wrong application. The application specific design largely comes down to materials selection and process engineering. Take for example a DAF system used in a cattle kill plant. Without understanding that these types of facilities generate wastewater laden with sandy, gritty materials, a manufacturer may opt to use their design standard, say a cast iron pump. Unfortunately for the person who buys this DAF system, their gritty wastewater will wear pin holes in the pump casing and eventually cause a pump failure. This results in down-time and replacement of the most expensive component on the system. When something like this happens, not only does it reflect poorly on the manufacturer, but also on the engineer/consultant that presented it to the end client as the right solution. The master craftsman would understand the gritty nature of cattle wastewater and select a pump casing with high Brinell Hardness, like CD4MCu. On the process side, the DAF designer should understand how to properly calculate and interpret hydraulic surface loading rate, solids loading rate, and air-to-solids ratio based on the application at hand. Solids in poultry kill plant wastewater separate infinitely easier than those from the effluent of an activated sludge system. Using the same values for each of these processes would likely result in an oversized poultry DAF and an undersized bio-mass separator. You’re the one buying the system, don’t be afraid to question why a specific configuration was selected over another and be sure to ask for an explanation of the calculations behind your system sizing.

During the project development process, you will eventually narrow down a list of potential dissolved air flotation (DAF) system manufacturers. At this stage, the critical task is to determine which manufacturer and system best meet your specific needs. How Should You Choose? Whether you are an engineer specifying equipment for a client, a plant owner addressing wastewater treatment challenges, or someone seeking a deeper understanding of wastewater process equipment, this guide aims to provide a comprehensive understanding of key DAF system design considerations. By exploring mechanical and process design elements in this series, you will gain valuable insights to evaluate DAF systems effectively. This knowledge will enable you to identify superior designs and, most importantly, make an informed purchasing decision. Given the significant investment, selecting the right DAF system is essential. 1. Aeration System: The heart of the DAF unit. The aeration systems is the central component of a DAF, representing one of the largest capital and maintenance expenses. Therefore, understanding its design and functionality is crucial. Below is a breakdown of common pump types used in DAF aeration systems and their respective advantages and limitations. Multistage Impeller Pumps These pumps are often referred to as "whitewater pumps".  They draw atmospheric air (or compressed air) into the pump, where impellers mix/shear the air with water to create micron-sized bubbles that dissolve into the solution. While effective in generating whitewater, multistage impeller pumps pose several challenges in wastewater environments: Low Solids Tolerance : These pumps are prone to failures when handling oily, stringy, or gritty materials, which are common in wastewater applications. Cavitation/Airlock : In general, these pumps are not designed to handle entrained air.  Air can collect at the eye of the impellers which can cause loss of flow (airlock) and binding.  Air being introduced to the pump for “white water” generation can cause cavitation leading to increased energy usage, increased noise/vibration, and in more extreme instances cause damage to seals, bearings and impellers. Dependency on Manufacturer-Specific Components : These pumps tend to be “special order” or made in low quantities. Typically, these pumps must be sourced directly from the manufacturer which can lead to high replacement cost and extended downtime due to limited availability or long lead times. Multistage impeller pumps can generate quality “white water”; however, they lack the robustness in a wastewater environment where solids, grit and oily materials are prevalent.  With the high associated maintenance costs and lower reliability, most DAF manufacturers have moved away from the Multistage Impeller Pump.   Regenerative Turbine Pumps Regenerative turbine pumps are another type of pump often marketed as "whitewater pumps". These pumps are often characterized as providing high discharge pressures associated with positive displacement pumps with the versatility of a centrifugal pump.  They utilize a turbine-like impeller with radially oriented blades/vanes to draw in atmospheric or compressed air and mix with water to create microbubbles.  When choosing a Regenerative Turbine pump for a DAF application it is important to consider: High Pressure Capability : These pumps can generate high pressures and low flows in a compact design.  They can operate at discharge pressures of 90-120 psi in DAF applications while being resistant to cavitation and other ill effects of air entrained fluids. Clean Liquid Requirement : Due to tight internal clearances, these pumps typically require liquids with minimal abrasives or solid content, limiting their suitability for wastewater treatment. Limited Parts Availability : Popular models, such as those manufactured by Nikuni, often have very small supplier networks, leading to limited options in accessing quick replacement parts. Several manufactures utilize regenerative turbine pumps for “whitewater generation” on their DAF units, and their compact footprint make them a popular choice for upgrades of older Multistage technology.   Tight tolerances and poor solids handling make them less suitable for certain wastewater environments and care should be taken to ensure proper application. End-Suction Centrifugal Pumps End-Suction Centrifugal pump are produced by many pump manufacturers and are available in a variety of materials and configurations that can be adapted to a wide variety of applications.  Due to the large variety in available pumps, there is a high degree of versatility across various industries, including food processing, oil refining, and chemical manufacturing.  As with any pump selection, application is important.  Here are some important considerations when evaluating a system using an end suction centrifugal pump. Simplified Whitewater Generation : In most DAFs that use an end-suction centrifugal pump for “whitewater” generation, the pump is utilized only for the pressurization of the recycle stream.  The air and water are mixed in a separate vessel or saturation tube, meaning the pump is only doing what it was design for (pumping).  This ensures that the pump can be selected for high efficiency and reliability.  In some designs, manufacturers will use the pump in a similar manner to the Multistage pump where atmospheric air (or compressed air) is injected at the pump suction and the pump is used to dissolve the air.  When the pump is utilized in this manner, it is prone to the same Cavitation/Airlock issues as the Multistage Pump. Adaptability : These pumps can be selected based on the application to handle a wide variety of liquids (with or without solids) and can be fitted with various materials and alloys for corrosive environments. Manufacturer Choice : Unlike specialized whitewater pumps, the end-suction centrifugal pump is typically not mixing the air in water.  This allows more choice in manufacture and style of pump.  Some DAF providers can work with the end user to select a pump that aligns with their preferred manufacturer/plant standard providing improved access to parts and service.    By assigning the task of whitewater generation to a static tube or vessel, end-suction centrifugal pumps focus solely on pressurization, enhancing reliability and efficiency. When evaluating DAF systems, the aeration system reflects the manufacturer's design philosophy. Prospective buyers should inquire about the reasoning behind the selected pump type and its suitability for their specific wastewater treatment needs. 2. Controls and Automation: Enhancing Operational Simplicity The operational efficiency of a DAF system often hinges on its control and automation features. A well-designed system should be intuitive and user-friendly, akin to the seamless functionality of modern smartphones. Unfortunately, some DAF systems rely on overly complex operational procedures and have limited automation to reduce costs.  This typically leads to increased labor, frustration, and hidden expenses. Often these systems require frequent operator intervention and manual procedures which take more time and require more knowledge from the operator: Start/Stopping the system based on incoming flow. Make regular adjustments to the DAF aeration system to achieve “whitewater” generation. Manually adjust chemical dosing rates based on changing flows and/or pH. Check the system for faults and evaluate performance based on visual inspection. In contrast, a well-automated system streamlines operations significantly by: Automatically starting and stopping the treatment system as determined by incoming flow and tank levels. Automating the aeration features such as low-pressure detection, system warm-up and off-cycle air purging. Automatically adjust chemical dosing rates based on flow rate to the system and pH. Report and alarm system faults and provide warnings for reduced system performance. Trend and store data for system flows, tank levels, pH turbidity, chemical consumption, and alarms. When considering a DAF system, request details its operating procedure and automation. This will provide insights into its usability and the time/labor necessary to operate it.  A system with intuitive controls not only saves time but also reduces operational errors and long-term costs.

Investing in wastewater treatment equipment, especially a Dissolved Air Flotation (DAF) system, requires careful consideration. While manufacturers may promote a wide range of options, the responsibility ultimately lies with the engineer and/or end user to ensure the system aligns with their specific needs. A well-informed decision will ensure a DAF system integrates seamlessly into the treatment process and provides long-term value. To make the right choice, it’s important to explore the design and operational differences between manufacturers. These factors can significantly influence system performance, maintenance requirements, and overall efficiency. Here are seven essential topics to discuss with potential suppliers before making your decision: 1. What Type of Recycle Pump Is Used? The recycle pump is the core component of any DAF system. Its design, efficiency, and maintenance requirements play a pivotal role in system performance. Ask the supplier: Why was this specific pump chosen? How does it compare to other options in terms of reliability and efficiency? What are the expected maintenance intervals and costs? A robust and well-maintained pump can minimize downtime and operational disruptions. 2. What Materials Are Used in DAF Construction? The longevity and resilience of a DAF system depend heavily on the materials used in its construction. Discuss: Whether the materials can withstand harsh environmental and chemical conditions. The expected lifespan of the system under regular operation. Maintenance requirements to ensure durability. Investing in high-quality materials can significantly reduce long-term costs associated with repairs and replacements. 3. How Does the DAF Thicken Sludge? Efficient sludge thickening is critical for reducing waste disposal costs and optimizing system performance. Inquire whether the system: Offers mechanical features to improve sludge dryness. Relies primarily on chemical additives for thickening. A well-designed system should strike a balance between mechanical and chemical solutions to enhance efficiency without excessive chemical dependence. 4. How Is Whitewater Distributed in the DAF Tank? Uniform whitewater distribution ensures consistent treatment performance across the entire tank. Ask the supplier: Whether the system uses a single distribution port or a more uniform approach. How this design affects overall treatment effectiveness. Consistent whitewater distribution improves the system’s ability to remove contaminants and handle variable wastewater loads. 5. Why Does or Doesn’t the DAF Have Plate Packs? Plate packs can enhance the system’s treatment efficiency by increasing effective surface area for separation and allow for higher hydraulic capacity. Discuss with the supplier: Whether plate packs are installed, and the reasoning behind this choice. The hydraulic and solids loading rates of the system to understand its capacity and performance. Plate packs may not be the right choice for all applications, but they can significantly improve efficiency for wastewaters with lower solids concentrations. 6. What Is It Like to Operate the DAF? Operational ease is a key factor in the success of any treatment system. Evaluate: The level of automation provided by the system. User-friendliness of startup, shutdown, and day-to-day operations. A well-designed DAF system should streamline operations and minimize manual intervention, even when faced with fluctuating wastewater conditions. 7. What Project-Specific Factors Influence the DAF Design? Tailoring the DAF system to your facility’s unique requirements ensures optimal performance. Discuss: How the system handles grit and other challenging components of your wastewater. Whether corrosion-resistant materials are used for critical components. Whether the system design can accommodate your facility’s space constraints. A customized approach to system design demonstrates the supplier’s commitment to meeting your operational needs.   Making an Informed Decision By addressing these seven key topics with potential suppliers, you can gain a comprehensive understanding of the DAF system’s capabilities and limitations. Taking the time to evaluate your options thoroughly will help you select a system that meets your facility’s requirements while minimizing operational challenges and costs. Remember, the right DAF system is not just an investment in equipment but also in the long-term efficiency and sustainability of your wastewater treatment process.

FRC’s flocculators disperse chemicals in mixing zones that increase flow-through velocity Chemical costs are often the most significant operating expense for industrial wastewater treatment systems, far surpassing energy costs. For example, running a PCL-60 DAF system at full capacity (660 gallons per minute) for 24 hours costs roughly $30 in electricity. However, chemical costs, determined by flow rate and wastewater composition, can amount to five or six times that figure annually. Reducing chemical usage is not just a cost-saving opportunity but also a step toward more efficient and sustainable operations. Here are seven actionable strategies to optimize chemical consumption in your DAF system: 1. Equalize and Mix Flow Achieve consistent wastewater quality by collecting and homogenizing all plant wastewater, including rainwater and yard runoff. Mixing high-solids streams with lighter loads dilutes the solids concentration, allowing for flow-paced chemical dosing rather than reacting to peaks and valleys. This proactive approach minimizes the need for additional chemicals to handle variations in loading. 2. Use Pre-Screening Equipment Reducing the volume of solids entering the DAF system is crucial. Simple mechanical screens, such as rotary drum screens or tight floor drain screens, can significantly lower total suspended solids (TSS). By removing easily separable solids mechanically, chemical dosing can focus on harder-to-separate contaminants, improving efficiency and reducing costs. 3. Calibrate Dosing Pumps Accurate dosing is essential to avoid waste. Calibrate your liquid chemical feed pumps regularly using a graduated cylinder to measure output at various settings (e.g., 10% to 90% capacity). For example, if your pump delivers 35 ml/min instead of the intended 30 ml/min, you’re overdosing by 15%. Proper calibration can save thousands of dollars in unnecessary chemical expenses. 4. Use the Right Chemicals for pH Adjustment Using coagulants to adjust pH is inefficient and costly. Instead, rely on dedicated pH reagents, such as sulfuric or hydrochloric acid, to bring wastewater to a neutral range. Metal-based coagulants like aluminum or iron should only be used for their intended purpose—coagulation within the appropriate pH range—not for pH adjustment. This approach improves both cost efficiency and overall treatment performance. 5. Optimize Chemical Dispersion Proper chemical dispersion ensures maximum effectiveness. In DAF systems, chemicals are introduced via mixing tanks or pipe flocculators. Mixing tanks use mechanical agitators, while pipe flocculators rely on flow velocity and shear forces. Both methods can work effectively, but adherence to operational guidelines is critical. Regularly evaluate your dispersion method to ensure chemicals are being used efficiently. 6. Treat to Permit Requirements Over-treating wastewater can be unnecessarily expensive. If your permit requires TSS levels below 250 mg/L, aim to meet but not significantly exceed that limit. While clear water with <10 mg/L TSS might look impressive, it’s not always necessary. Use only the minimum amount of chemicals required to remain compliant with regulatory limits, balancing cost and performance. 7. Conduct Regular Jar Tests Jar testing is one of the simplest ways to optimize chemical dosing. Collect a wastewater sample, add incremental doses of coagulant using a pipette, and observe coagulation. This quick test allows for real-time adjustments to dosing rates, ensuring you use only what’s needed. Regular jar tests can prevent chemical overuse and maintain effluent quality within compliance limits.   A Word of Caution While reducing chemical usage is a worthy goal, eliminating chemicals entirely can lead to inefficiencies and higher costs elsewhere. For example: Poor Sludge Quality:  Without coagulants or flocculants, many suspended solids remain in the water, leading to watery sludge and suboptimal effluent quality. This shifts costs from chemical treatment to sludge management and biological processes. Lost Value in Recovered Solids:  In some industries, such as rendering, adding chemicals enhances solids recovery. The additional recovered product often offsets the cost of the chemicals, improving profitability. Each situation requires careful evaluation to balance cost savings with operational effectiveness.   Conclusion Optimizing chemical use in your DAF system can lead to significant cost savings without compromising performance. By implementing strategies like equalizing flow, pre-screening, calibrating dosing pumps, and regularly testing dosing rates, you can ensure efficient operation while maintaining compliance with regulatory requirements. For more guidance on improving your DAF system’s performance, reach out to our experts at FRCInfo@sulzer.com .

The pump is the heart of any Dissolved Air Flotation (DAF) system, influencing capital costs, operational efficiency, and maintenance expenses. FRC Systems deliberately chooses standard “off the shelf” end-suction centrifugal pumps over specialty DAF pumps for these compelling reasons: 1. No Air in the Pump Chamber Specialty DAF pumps, such as regenerative turbine or multi-stage impeller configurations, rely on drawing air into the pump chamber. This air is mixed and sheared with water to produce micro-sized bubbles to generate whitewater. While effective for whitewater generation, introducing air into a pump often leads to cavitation and airlock — a phenomenon that can damage internal components and increase the frequency of costly repairs. In contrast, FRC uses end suction centrifugal pumps that are designed to move water exclusively, without incorporating air into the chamber. By avoiding air-induced cavitation risks, these pumps ensure greater reliability and durability over time. 2. Lower Operating Pressure FRC end-suction centrifugal pumps operate at a lower pressure range of 70–90 psi, compared to the 90–110 psi typical of specialty DAF pumps. This reduction in operating pressure not only decreases the risk of wear and tear but also translates to significant savings in electrical consumption, reducing long-term operational costs. 3. High Solids Tolerance Specialty DAF pumps are less tolerant of solids due to their design. When restarting a DAF system after downtime, residual solids entering the pump can cause damage and reduce its lifespan. FRC standard centrifugal pumps, on the other hand, are selected and constructed with a higher tolerance for solids, making them more robust and capable of handling unexpected debris during startup or operation. 4. Standardized Components End-Suction Centrifugal pump are produced by many pump manufacturers and are available in a variety of materials and configurations that can be adapted to almost any application.  Due to this large number of standard pump configurations, there is a high degree of versatility across various industries, including food processing, oil refining, and chemical manufacturing.          Specialty DAF pumps, however, often require proprietary parts available only from the pump manufacturer—frequently sourced internationally, leading to long delivery times and higher costs. 5. Lower Acquisition Cost The standardized nature of end-suction centrifugal pumps fosters competition among manufacturers, driving down acquisition costs. These pumps can be less than 1/3rd the purchase price when compared to the high price tag of specialty DAF pumps. This cost advantage makes them a more economical choice both initially and in the event of replacement. Feature Specialty End Suction Centrifugal Risk of Cavitation Med - High Low Operating Pressure Medium to High (90–110 psi) Medium (70–90 psi) Solids Tolerance Low High Parts Availability Low – Typically from a single source High – Widely available from multiple vendors Acquisition Cost Medium - High Low - Medium Ability to select Pump based on Application Low - Medium High When weighing the options for a DAF system, centrifugal pumps offer a clear advantage in terms of reliability, efficiency, and cost. Their robust design, industry standardization, and lower operating pressures make them an ideal choice for wastewater pretreatment systems. At FRC Systems, we’re committed to delivering solutions that prioritize performance and value.  Our recycle pump design exemplifies that commitment, ensuring your DAF system operates efficiently while keeping costs manageable. Ready to learn more? Contact us today for expert advice tailored to your wastewater treatment needs.

Preparation is key to minimizing downtime and maintaining the efficiency of your Dissolved Air Flotation (DAF) system. At FRC, we’ve conducted rigorous testing on every component used in our DAF systems to ensure they meet the highest standards of quality and reliability. However, even the most durable systems are not immune to wear and tear over time. While a failure may not occur this month, this year, or even next year, it’s inevitable that components will eventually require replacement. When that time comes, having the right spare parts on hand can make all the difference. To help you stay prepared, we’ve compiled a core list of essential spare parts for your DAF system. All FRC DAF systems use standardized components, with variations only in size. If you don’t already have these parts in your inventory, reach out to us . With your system details on file, we can quickly provide you with an accurate quote for the components you need. Essential DAF Spare Parts Aeration Assembly Poly Flow Tubing 90° Elbow FNPT x FNPT Fittings NPT Straight Fittings Close Nipple Fittings Skimmer Assembly Sprockets Pillowblock Bore Bearings Drive Motor Conveyor Chain (assembled) Conveyor Chain (links) Hinge Pins Auger Assembly Drive Motor Gland Packing Pneumatic Panel Solenoid Valves Pressure Switch Air Flow Meter Filter Regulator Poly Flow Tubing Miscellaneous Fittings (Straight, 90° Elbow, Tee NPT x P/L) Take Action Today If your spare parts inventory is running low, don’t wait until a critical failure occurs. Use our DAF spare parts request form, and we’ll ensure you receive the components you need to keep your system operating smoothly. By maintaining a well-stocked inventory of these essential parts, you’ll be ready to address any challenges that arise, keeping your operations running efficiently and minimizing costly downtime.

At FRC, we offer two primary Dissolved Air Flotation (DAF) system designs: the Plate Pack or High Rate DAF System  and the Open Style DAF System . Deciding which system to use for a specific wastewater application depends on several factors, including solids loading rate, hydraulic loading rate, and available floor space. Understanding these considerations is key to selecting the most efficient and cost-effective solution for your wastewater treatment needs. Key Design Factors DAF systems are designed based on two fundamental parameters: Solids Loading Rate : Determines the free surface area required to separate solids effectively.  On both a Plate Pack DAF and Open Style DAF the free area is typically considered to be the sludge skimming surface area. Hydraulic Loading Rate : Determines the effective separation area needed to maintain laminar flow and prevent turbulence or re-entrainment of solids.  On a Plate Pack DAF, the effective area is the projection of the total plate pack area on the horizontal plane (typically ½ of the total installed plate area for plates installed at 60 degrees), while on an Open Style DAF the effective area is the same as the free area (sludge skimming surface area). In general, Plate Pack DAF systems  are ideal for applications with high hydraulic loading and low solids loading , while Open Style DAF systems  are better suited for applications with high solids loading .  Plate Pack DAF systems have a large effective area relative to their free area offering both cost saving and space-saving benefits.  This makes them advantageous in facilities with limited floor space when the application allows for their use. 1. Solids Loading Rate The solids loading rate measures the mass of dry solids that can be separated per unit of free surface area per hour (typically lbs/sqft/hr or kgs/m2/hr). This rate varies by application and is influenced by the characteristics of the solids being treated.  The application may dictate a solids loading rate as low as 2 lbs/sqft/hr or allow for as high as 15 lbs/sqft/hr. Applications with fast-separable solids, such as primary poultry wastewater, allow for higher solids loading rates. Conversely, slower-separating solids, like biomass, require lower loading rates for effective separation. For example, if a wastewater stream contains 1,000 pounds of solids per hour , a DAF system designed for: 2 lbs/sqft/hr  would require 500 sqft  of free surface area. 10 lbs/sqft/hr  would require 100 sqft  of free surface area. This is a large difference in the size of the DAF.  Not understanding how the application affects the Solids Loading Rate could lead to major error in DAF sizing. 2. Hydraulic Loading Rate The hydraulic loading rate evaluates the volume of wastewater flow over a unit of effective separation area per unit time (typically gpm/sqft or m3 per hr/m2), ensuring the flow remains laminar and prevents turbulence.  Typically, this falls in the range of 1 to 3 gpm/sqft for most industrial applications but can go as high as 10 gpm/sqft in some applications.  The DAF’s internal recycle rate should always be included in this calculation. Example :An open style DAF with 48 sqft of free area, processing 65 gpm of low solids loaded wastewater with a 22 gpm recycle flow: (65gpm+22gpm)/48sqft=1.81gpm/sqft The same flow through a plate pack DAF with 7 sqft of free area and 65 sqft of effective separation area: (65gpm+22gpm)/65sqft=1.34gpm/sqft Although the hydraulic loading rates are similar, the size difference between the two systems becomes apparent: Open tank DAF: 13' L x 8' W x 8' H Plate pack DAF: 7' L x 4' W x 8' H The plate pack system occupies roughly one-quarter the footprint  of the open tank design, making it an attractive option when space is limited and the solids loading allows for it. 3. Other Considerations The available building size and floor space is often a critical factor in DAF system design. While an open style DAF can handle a wider range of applications, its larger footprint and higher cost may be impractical in facilities with space constraints, and a plate pack DAF may be more suitable. Example Application : A pork processing facility generates 450 gallons per min (gpm)  of wastewater containing 570 lbs/hr of dry solids . Using a solids loading rate of 7.5 lbs/hr/sqft , the required free separation area is: Free Area Requirement – (570 lbs/hr) / (7.5 lbs/sqft/hr) = 76 sqft Using a hydraulic loading rate of 2 gpm/sqft and 100 gpm recycle flow, the required effective separation area is:   Effective Area Requirement – (410 gpm + 100 gpm) / (2 gpm/sqft) = 255 sqft In this application the Plate Pack DAF system provides the same treatment capability while occupying significantly less space and at a lower cost. DAF Size : Open Style DAF : ~31' L x 10' W x 8' H Plate Pack DAF : ~16' L x 8' W x 10' H   Selecting the Right DAF System Ultimately, the choice between a Plate Pack and Open Tank DAF systems depends on the application’s specific requirements: solids and hydraulic loading rates, space constraints, and budget considerations. Plate pack systems can offer a smaller and more cost-effective footprint in situations with lower solids loading and high hydraulic loading, while open style systems are effective at handling high solids loading. At FRC, we tailor DAF system design to balance performance, capital investment, and operational costs. Whether the application allows for a compact, high-rate solution or dictates a larger open style design, we can help identify the ideal system for your wastewater treatment process. Contact us  today to explore your options and design the most effective DAF solution for your needs.

What makes FRC Systems’ Dissolved Air Flotation (DAF) design a top choice for wastewater operators? These five key advantages keep operations running efficiently and consistently. 1. Simple and Intuitive Operation Operational simplicity is a cornerstone of FRC’s DAF systems. By automating processes where possible and incorporating redundant components to prevent failures, FRC minimizes operator intervention. Starting the system is as straightforward as pressing a button, and routine maintenance involves quick, simple checks. FRC understands that a reliable and easy-to-use system is essential for smooth operations, which is why every aspect of the design focuses on usability and dependability. 2. Resilience to Process Variability Wastewater treatment is inherently unpredictable, often requiring systems to adapt to sudden flow spikes or unusual influent characteristics. FRC’s DAF systems are engineered with the flexibility to handle these challenges without compromising performance. By leveraging extensive applications experience, FRC designs systems that remain stable and efficient even under fluctuating conditions, ensuring reliable compliance across a range of scenarios. 3. Efficient Sludge Management Dryer sludge means less mess, reduced equipment demands, and fewer disruptions. FRC DAF systems employ advanced techniques to produce exceptionally dry sludge, which simplifies downstream dewatering and reduces the risk of bottlenecks during maintenance or unexpected downtime. By reducing wet-sludge volume, FRC ensures operators spend less time managing sludge and more time focusing on critical tasks. 4. Accessible Standard Components FRC takes the guesswork out of maintenance with detailed documentation for every component used in their systems. Operators can easily identify parts, locate replacements, and keep spare inventory on hand using a comprehensive parts list with pricing. Additionally, thoughtful design places critical components like valves and gauges at accessible heights, reducing strain and improving efficiency during routine maintenance. These small yet significant details demonstrate FRC’s commitment to operator-friendly design. 5. Comprehensive Troubleshooting Support Effective troubleshooting is critical for maintaining uninterrupted operations. FRC equips operators with a detailed troubleshooting guide that addresses potential mechanical and process issues, providing clear steps to diagnose and resolve problems. Whether it’s adjusting chemical dosing rates, fine-tuning water levels, or calibrating skimmer settings, FRC’s guide empowers operators to act decisively and confidently, turning challenges into manageable solutions. The Bottom Line FRC Systems’ DAF design earns high praise from operators for its reliability, ease of use, and adaptability. By addressing the real-world challenges of wastewater treatment with practical and innovative solutions, FRC ensures operators can rely on their systems day in and day out. If a dependable, operator-friendly DAF system is what you need, FRC is ready to deliver. Contact us today to learn more about how we can support your wastewater treatment needs.

Each year across North America, warmer summer weather triggers the growth of algae in surface water bodies. In some cases, algae blooms are also caused by inadequate management of wastewater discharges. A striking example of this issue can be seen in Lake Erie, where recurring HABS (Harmful Algae Blooms) have become a significant concern. Understanding Algae Growth Algae thrive under specific conditions, including sufficient nutrients (such as nitrogen and phosphorus), optimal light levels, favorable pH, and warm temperatures. When phosphorus levels in a water body rise, algae growth tends to increase proportionally. This excess algae contributes to the production of dead organic matter, which can lead to anoxic (oxygen-deprived) conditions. Anoxic water environments can cause significant ecological harm. Deprived of oxygen, aquatic ecosystems deteriorate as fish and plant life die and decay, resulting in septic conditions and unpleasant odors. Tackling Algae Outbreaks Addressing algae blooms requires a two-pronged approach: Prevent Nutrient Overload The most effective long-term solution is to reduce phosphorus levels in agricultural runoff, which is the primary source of nutrient pollution. Preventing excessive nutrient input is essential to stopping algae growth at its source. Remove Existing Algae Blooms While chemical additives can suppress algae growth, they do not physically eliminate the dense mats of algae from the water. For effective treatment, the algae must be removed along with the excess phosphorus that supports its growth. Dissolved Air Flotation (DAF): A Targeted Solution One of the most efficient methods for algae removal is Dissolved Air Flotation (DAF), combined with phosphorus precipitation. The DAF process physically separates algae and suspended solids from the water, clarifying it and reducing phosphorus concentrations simultaneously. How DAF Works: Clarification: The DAF system introduces microbubbles into the water, which attach to algae and other suspended particles. This causes the solids to float to the surface, where they are skimmed off. Phosphorus Precipitation: Adding a coagulant or precipitant binds soluble phosphorus into a solid form, which can then be removed during the flotation process. This dual-action approach effectively halts algae blooms and restores water quality. Proven Success DAF systems have been successfully deployed to manage algae outbreaks in various surface water bodies. This reliable and efficient technology not only removes visible algae mats but also addresses the underlying cause—phosphorus pollution. Conclusion Managing algae blooms requires both proactive nutrient management and effective removal strategies. Dissolved Air Flotation offers a proven, practical solution for tackling algae outbreaks while improving water quality and reducing ecological harm. By combining DAF technology with phosphorus reduction efforts, we can restore balance to aquatic ecosystems and prevent future outbreaks. For more information on algae removal and DAF systems, contact our team to learn how we can support your water treatment needs.

Atlanta, GA – December 11, 2024 – FRC Systems, a leading provider of innovative wastewater treatment solutions, is proud to announce its participation in the 2025 International Production & Processing Expo (IPPE). The event will take place January 28–30, 2025, at the Georgia World Congress Center in Atlanta. Visitors are invited to stop by the FRC Systems booth (C19167) to meet with the knowledgeable FRC Team to discuss their treatment needs. FRC Systems Booth at IPPE 2024. As the largest annual event for the poultry, meat, and feed industries, IPPE provides an unparalleled opportunity for professionals to explore the latest advancements in production, sustainability, and compliance. FRC Systems will bring its expertise to the forefront, showcasing solutions designed to meet the evolving needs of wastewater management. The booth will feature FRC Systems’ high-performance DAF unit, renowned for its ability to effectively remove suspended solids, fats, oils, and grease from industrial wastewater streams. This reliable and efficient solution has become a cornerstone for industries such as food processing and manufacturing, where maintaining clean effluent and meeting environmental regulations are top priorities. In addition to the DAF unit, FRC Systems will showcase the Multi-Disk Volute Press, a revolutionary sludge dewatering system designed for compactness, energy efficiency, and exceptional performance. By reducing sludge volumes and lowering disposal costs, the Multi-Disk Volute Press provides a practical and cost-effective solution for businesses seeking to optimize their operations. “Our team is excited to return to IPPE in 2025 to showcase how FRC Systems can help businesses address their wastewater challenges with confidence,” said Greg Walsh of FRC Systems. “From the DAF unit to the Multi-Disk Volute Press, we’re presenting technologies that deliver real-world results while supporting sustainability and compliance goals.” FRC Systems’ booth will be staffed by a team of experienced sales and technical support professionals, ready to engage with attendees and discuss their unique wastewater management needs. Whether visitors are seeking to upgrade existing systems, ensure regulatory compliance, or explore new technologies, FRC Systems’ team will provide tailored guidance and support. “We’re committed to being a trusted partner for our clients, offering not just products, but also the expertise to implement effective wastewater solutions,” said Adriaan van der Beek of FRC Systems. Attendees are encouraged to stop by the FRC Systems booth (C19167) to learn how the company’s advanced solutions can help them achieve their wastewater management goals while improving operational efficiency and reducing costs. Please visit www.frcsystems.com for more information about FRC Systems and its suite of wastewater treatment technologies. About FRC Systems FRC Systems is a global leader in wastewater treatment solutions, delivering innovative and efficient solutions and technologies for a wide range of industries. With a focus on improving performance, reducing environmental impact, and enhance compliance, FRC Systems provides tailored solutions to meet the specific needs of its clients.

FRC Headquarters July 10, 2014 FRC Systems International, an industry leader in wastewater treatment system design and manufacturing, has opened its new corporate headquarters in Cumming, Georgia. The new facility will allow FRC to expand its staff and better serve its partners in more than 20 countries around the world. “Our existing facility was bursting at the seams,” said Adriaan van der Beek, President of FRC Systems. “With increased office space and warehousing capacity, we are poised to continue a record of positive growth while maintaining our unyielding commitment to deliver trusted wastewater solutions.” “This new office is just the beginning,” Adriaan further explained. “Our fabrication and testing facilities are also expanding to accommodate increased throughput.” FRC designs and builds wastewater treatment systems based on dissolved air flotation (DAF) technology, which uses micro-bubbles to float oily and solid contaminants to the water’s surface for skimming and removal. These solutions help protect the environment by keeping pollutants out of local waterways.

December 12, 2012 FRC is proud to announce the opening of a new office in Whitby, Ontario Canada. FRC Systems Canada will now provide services and support to Canadian markets through a local office. As a world leader in industrial wastewater treatment solutions, FRC designs systems for industries such as Food Processing Plants, Oil and Gas Facilities, Cosmetic Production Plants, Metal Processing, as well as General Manufacturing and Municipalities. Our combination of reliable technology and tailor-made solutions for each application creates an outstanding value for our customers. Services offered by FRC’s team of engineers includes process design, electrical control design, detailed engineering and DAF (Dissolved Air Flotation) production, layout of the DAF system and recommended chemical DAF concepts. Our high-tech design and manufacturing capabilities ensure the client’s environmental needs are addressed in the most efficient and economical manner possible.

September 22, 2014 Central America’s largest poultry producer, DIP-CMI, re-vamped its existing wastewater treatment infrastructure with modern, space-saving technologies to meet strict water quality regulations for discharging effluent into the local waterway. The upgraded facility, located in San Jose, Costa Rica, processes more than 100,000 birds per day, preparing them for distribution to local markets. As part of their continuous improvement process, DIP-CMI hired FRC Systems International to design and construct a 1.9-million-liters-per-day wastewater treatment facility, which includes a new dissolved air flotation system and sludge dewatering belt press. Common among poultry processing plants, the facility’s wastewater is heavily laden with organic contaminants which contribute to elevated levels of total suspended solids (TSS); fat, oil and grease (FOG); and chemical oxygen demand (COD) — all of which are regulated water quality parameters. To comply with their direct discharge permit, the facility was required to meet the following concentrations: <30 mg/L of TSS <10 mg/L of FOG <100 mg/L of COD FRC designed a process that included preliminary screens, chemical and physical separation equipment, aeration lagoons, and sludge management systems to effectively meet these requirements. The allotted space for the new wastewater treatment infrastructure was unusually small for the volume of wastewater to be processed. As such, the design of the equipment, as well as the layout of all the components in the building, needed to be pieced together in as tight a configuration as possible. FRC opted for a plate-pack design to accommodate higher flow rates by building taller tanks, rather than longer and wider ones. Floor space is limited, so the design took advantage of available vertical space. FRC’s belt press also employs this design characteristic — stacking each of the dewatering and pressing zones on top of one another — as opposed to arranging them in a lateral configuration like other comparable systems. With these technologies and the help of three-dimensional modeling, FRC designed a two-story system that fits the allotted space and contains the process equipment necessary to meet the facility’s water quality requirements. Sampling data from the first six months of operation show sufficient reduction in TSS, FOG, and COD concentrations to safely comply with discharge requirements. Going forward Dissolved air flotation is often the most economical and efficient technology to treat wastewater with elevated levels of solids or oils. Beyond poultry processing, the technology can be used in any animal rendering application, as well as in the general manufacturing and oil and gas industries. DIP-CMI continues to grow in Central America, so the wastewater treatment technologies employed at the San Jose facility will be used elsewhere — helping maintain the company’s environmental-sustainability goals. The outlook of the food production market in Central and South America is bright, and as other companies continue to expand throughout the region, water quality regulations will require them to make the same efforts in environmental stewardship. This article originally appeared in the July/August 2014 issue of World Water magazine, a WEF publication.

November 20, 2014 FRC has been awarded perfect marks in contractor safety ratings on the ISN network – a resource that helps establish partnerships between hiring clients and contractors by promoting corporate transparency across management, training, and safety infrastructure. “We always place concerted effort on procedure, safety, and documentation” emphasizes FRC Systems President, Adriaan van der Beek, “these reviews validate that we are doing things the way they ought to be done.” From the beginning phase of project feasibility studies through final installation and operation, FRC keeps one goal at the top of mind – building trust. “The industrial wastewater industry is rife with new organizations that depart as quickly as they come,” explains van der Beek, “it’s risky for hiring companies to do projects with contractors that don’t have a track record and may not be around a few years down the line. Who do they turn to when there’s a problem?” For this reason, numerous food, manufacturing, and oil & gas market leaders have relied on FRC Systems to deliver wastewater solutions that help them reach their environmental sustainability goals. Interested readers can learn more about FRC on ISN by visiting  https://www.isnetworld.com/ .

If you haven't already, read Part 1: The Ultimate DAF System Buyer's Guide 3. Materials of Construction When selecting a DAF system, durability is paramount. The harsh environments that DAF systems are exposed to demand robust materials to ensure long-term performance and minimize replacement costs. Let’s explore the most common options for tank construction, along with their advantages and limitations: Concrete Steel-reinforced concrete basins are commonly used in large municipal wastewater treatment plants. These basins are robust and leak-resistant but come with high costs due to the extensive civil work required, including excavation, steel reinforcement, concrete forming, and coating. Additionally, because they must be built on-site, concrete DAF basins are not typically practical for industrial facilities. Polypropylene Polypropylene is favored by some manufacturers for its lower material cost, decent strength, and broad chemical resistance; however, it has drawbacks. Exposure to extreme temperatures or UV radiation can degrade the material, causing discoloration and cracks. At temperatures below 32°F, it becomes brittle and prone to cracking. Furthermore, polypropylene’s degradation over time makes refurbishment rarely viable. Most manufacturers offer a limited warranty of around 10 years for polypropylene tank structures. Epoxy-Coated Carbon Steel Epoxy-coated carbon steel combines the strength of steel with the corrosion resistance of an epoxy coating, making it suitable for applications with high Total Dissolved Solids (TDS). However, in industries like food processing, this material is less reliable. Free fatty acids present in floating sludge can erode epoxy coatings, exposing the steel to rust and compromising structural integrity. While initially perceived as a cost-effective alternative to stainless steel, achieving comparable strength and corrosion resistance often makes epoxy-coated carbon steel similarly expensive. Stainless Steel Stainless steel is widely used in DAF tank construction due to its durability and versatility. Its natural chromium oxide layer prevents rust, allowing it to withstand temperatures from -320°F to 1500°F. Stainless steel is well-suited for both indoor and outdoor applications, and modifications can be easily made without the need for recoating. Tanks made from stainless steel can remain structurally sound for decades, retaining a high resale value and often being refurbished for continued use. However, stainless steel does come at a higher initial cost and may not perform well in environments with high chloride concentrations, which can cause pitting or corrosion.   4. Sludge Thickening Mechanisms The core function of a DAF system is to remove solids and oil contaminants from wastewater.  Sludge disposal is one of the largest costs of operating a DAF system. Achieving dryer sludge reduces the sludge volume which increases efficiency and reduces disposal costs. Sludge consistency depends on several factors, with the largest being the chemical processes used to treat the wastewater.  That said, a carefully engineered design will include features that can increase sludge dry solids performance.  Sludge Dewatering Grid A dewatering grid is a stationary framework of angled steel plates installed at the water’s surface. This grid locks sludge in place as it rises, allowing it to dewater before skimmer blades push it toward the sludge ramp. Retention in the grid ensures higher dry solids content, resulting in less watery sludge. Without a dewatering grid, sludge may accumulate near the ramp and get forced back into the water, undoing any prior dewatering. Speed Adjustable and Time Adjustable Skimmer System Varying the speed of the skimmer system on a DAF unit can influence the dry solids content of the sludge.  If the skimmer runs too quickly it can create turbulence which can resuspend solids causing carry over in the effluent.  A skimmer system that runs too slowly allows the sludge blanket to overthicken which can cause the same issue.  An optimal speed should remove the last 10-15% of sludge from the surface of the DAF. In applications where the sludge volume produced is low, it may not be necessary to run the skimmer continuously.  Turning the skimmer off intermittently will allow the sludge blanket to thicken and dewater producing a dryer sludge.  A system with the ability to run the skimmer at operator adjustable intervals can improve the dryness of the sludge without requiring operator intervention.  Easily Adjustable Effluent Weir The water content of the DAF sludge is directly influenced by the level of the water inside the DAF vessel.  In most DAFs this level is set with adjustable weirs.  If the weir is too high, the skimmer system removes more water with the sludge.  If the weir is too low the sludge can overthicken causing resuspension of solids and carryover in the effluent.  A weir system that is quick and easy allows for optimization of the water level in the DAF which improves sludge dryness. By incorporating these features, DAF systems produce thicker sludge, leading to significant cost savings. Thicker sludge requires less storage, smaller dewatering equipment, and reduced chemical usage for filtrate reprocessing. When evaluating DAF systems, ask manufacturers how their designs optimize sludge consistency. Key questions include: What mechanisms ensure drier, thicker sludge? How can operators adjust sludge thickness to meet process requirements? By prioritizing these features, you can select a DAF system that balances performance, reliability, and cost-efficiency.