Siltbuster Process Solutions (SPS) has designed, manufactured and installed a DAF unit for Dynatec Systems, for use at a UK automotive factory


he SPS DAF unit was introduced to treat the suspended solids in the

wastewater, ensuring that the site improved its resilience and overall plant performance, and to help meet tighter consent compliance. The car plant produces wastewater at rate

of up to 50m³/hr. This contains free floating oil and suspended solids, that need to be treated before the water can be discharged to sewer. In order to remain compliant and to future proof the operation, the existing treatment plant needed a revamp. This meant refurbishing an old DAF unit and introducing a Siltbuster D50 DAF into the treatment process. The renovated unit removes the ‘coarse’ free floating oil and some of the suspended solids. The wastewater is then chemically conditioned with flocculant, before being put through the D50 to further reduce the suspended solids. In order to install the D50 DAF, it had to be craned over a warehouse. Thanks to Siltbuster manufacturing all its equipment offsite, the crane movements could be kept to a minimum, and the

unit could be tested prior to dispatch. In addition, the new DAF was fabricated

in such a way that all the steelwork could easily link to the existing walkway at the plant, providing safe and easy access for the operator. The DAF houses a new whitewater system – here atmospheric air is dissolved under pressure and then released, creating micro-fine air bubbles which attach themselves to the solids, and rise to the surface, enabling the solids to be easily separated from the water. Both the new and existing DAF units

have automated settled sludge valves on individual timers. The standard D50 control panel was modified so that the pump for the existing DAF as well as the two valves are operated from the new DAF panel, making access and control on site more efficient. Rich Matthews, general manager at

Siltbuster Process Solutions, said: “By fabricating and testing the new DAF at our Monmouth facility, it saved precious time and space on site, and it meant that our unit was working effectively as soon as it was connected.”


A leading independent school has improved its water quality and reduced its costs by introducing two new products from Next Filtration. Set in 200 acres of Suffolk countryside, the Royal Hospital School’s Reverse Osmosis (RO) system was proving insufficient and expensive to operate. Facilities manager, Nigel Griffiths, said: “With 11 boarding houses and 57 residential houses, plus visitors and staff, we can have around 1,000 people on site. This gives our team a huge responsibility to ensure that the supply from our borehole to our water tower is of the highest quality - constant and consistent. “The borehole water is naturally hard and high in iron, so needs treatment, but the existing reverse osmosis

plant was not only inadequate for the task, but its energy and maintenance costs were unacceptable.” Griffiths said that despite ongoing maintenance, the site’s filters eventually had to be replaced (at a cost of

£6,000). The RO plant was also only just achieving a flow rate sufficient to sustain the water tower, reaching 8m3

for the RO plant was £2,000, so the search for a better system began. After taking samples and reviewing installation and running costs, Geyser Thermal Energy, working in

conjunction with Next Filtration, were given a 6-month trial to show what they could do to improve the school’s water system. Next Filtration introduced its Sand mono-bed media to remove the iron (and also ammonia) from the borehole supply, replacing the existing filters that required regular maintenance. A high- purity Clinoptilolite, Next Sand benefits from a high surface area and micro-porous character that provide a filtration performance of <5 micron, compared to 12 to 15 microns for multimedia. For the Royal Hospital School, the lighter weight and lower volume would mean lower capital costs and a

longer-lasting product. And because the media is not consumed in the filtration process, a simple periodic backwash keeps the media clean and operating efficiently for five years or more. Then, to reduce scale, Next Scale Stop was introduced. This product costs nothing to run, and has a bead-

media life of three years. It doesn’t actually release anything into the water, it simply starts a catalytic process of creating micro crystals of scale, which then continue to attract calcium and magnesium ions, preventing them attaching to pipework and metals as they travel through the water system. Griffiths said: “Overall, the new system from Next Filtration and Geyser Thermal Energy is proving an

excellent buy with a 10-month return on investment. Firstly, we no longer have an inflated electricity bill – and with the addition of a new pump, we are comfortably achieving a flow rate to our water tower of 16- 17m3

/hour – about double what we previously had, enabling off-peak electricity use.”  /hour at best – with a borehole pump running 24/7 at an annual cost of £2500. The annual electricity bill

The SPS DAF unit was working effectively as soon as it was connected on site

Tom Doherty, CEO at Dynatec Systems,

agreed: “We chose SPS for their unique project-based approach. Their experts worked closely with us to understand the specific requirements we needed in order to help us refurbish our plant and they did everything we wanted and more, with minimal disruption. Siltbuster also provide us with continued support and service through their team of engineers.”

Siltbuster Process Solutions


DMN UK has just released its first Magnetic Separator demonstration unit. The range is designed to remove sub- micron metal contamination (including particles of 304 and 316 stainless steel) from dry, free flowing products such as sugar, grain, flour and other granulates and powders during processing. Removing metallic contamination is vital to avoid batches of expensive ingredients having to be destroyed. But, in addition to this, is the effect that metallic contamination can have on rotary valves and other processing machinery. The separators will help increase the life of rotary valve vanes and blades by preventing metal contamination from entering the unit in the first place and causing damage. The ideal location for a separator is as close to the rotary valve as is practical. The easy-clean design allows DMN

Magnetic Separators to be safely and quickly cleaned down by removing the magnetic cores from their fully welded 316 stainless steel tube housings. Their reliability means they offer minimal loss of performance over a long period. The DMN specification comes with

interlock switches as standard to prevent any possibility of operative injury being caused by opening the magnet. All units can be ATEX certified for use in Zones 20, 21 and 22 or in gas Zones 0, 1 and 2. DMN Westinghouse


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