Nijhuis Water Technology, Inc.

588 Edward Avenue Unit 42

CASE STUDY
Application of Dissolved Air
Flotation (DAF) for Industrial
Water Conservation
Industrial consumption of water is a growing
concern as water sources around the world
are being depleted. Conservation and re-use
are the best ways for industrial users to limit
their impact on the environment. For this
application, Nijhuis Water Technology has
proven that DAF Technology can recover
over 99% of a waste water stream, improve
downstream equipment efficiency, and reduce
solids disposal and handling costs.
Richmond Hill, ON
Canada L4C 9Y6
Tel: 905-787-9292
Fax: 905-787-9595
Web: www.nijhuis-water.com
Background
A petrochemical company located in Texas requires
approximately 5 MGD of intake water for the various processes
within their plant. The source of the water is the local river. The
current system pumps the river water to the plant where it is
chemically treated in the pipeline and then to the first stage of
filtration. First stage of filtration consists of seven continuous
backwash sand filters. From the sand filters the water is further
treated to meet the various process requirements within the plant.
The continuous backwash from the sand filters (350 GPM) was
being discharged into a 12 foot deep “mud” trench for settling
before being sent to a series of lagoons and discharged. The high
concentration of sand and silt in the backwash water was filling
the trench with a thin mud requiring excavation every two
weeks. In addition to wanting to reduce their sludge handling
costs, the client was interested in recovering the waste water for
reuse.

Technology
Nijhuis Water Technology was contracted to conduct a pilot scale test using a Nijhuis counter current inclined plate separator and
dissolved air flotation. While this technology has been widely used for many years in Europe it has only recently begun to gain
acceptance as a cost effective alternative to traditional settling technologies in other parts of the world. In addition to reducing
installation space the DAF technology can provide for increased solids removal efficiencies and is not subject to upsets due to
changes in temperature of the water being treated.

Dissolved Air Flotation (DAF) uses the principles of coagulation and flocculation and the introduction of tiny micro-bubbles to
enhance the rising velocities of the treated particulate. The floated material is then skimmed off to solids disposal. Settled material
is also removed from the system.

While some applications, those requiring long retention times, require the use of Continuously Stirred Tank Reactors (CSTR) for
chemical treatment, many more can benefit by the use of Nijhuis Plug Flow Reactor (PFR) technology. Chemical addition in the
PFR based flocculator uses pipe sizes and fluid velocity to ensure complete mixing without the use of mechanical or static mixers of
any kind. In addition to the space savings, the largest advantage of the PFR technology is that there is no rotating equipment or
maintenance required.

After coagulation and flocculation, an efficient method of separation is required. The patented Nijhuis aeration system differs from
many other types of induced air or entrained air diffusion systems in that air (or nitrogen or any other gaseous media) is physically
dissolved in the recycle stream. This patented technology allows for much lower recycle flows, lower energy consumption, lower
maintenance, reduced operational costs and smaller equipment footprint. The aeration system uses Henry’s Law and controlled
pressure losses to generate very small, less than 30 micron diameter, micro-bubbles without mechanical throttling, cavitation, or any
other process that can cause premature wear on rotating equipment.

Photo on left: Sand filter

backwash to inlet of DAF.

Photo on right: DAF

Effluent and sample of
floated sludge.
Fig. 1 Nijhuis Pilot Plant Schematic Fig. 2 Nijhuis Aeration System

Testing Sample # TSS In (ppm) TSS Out (ppm) % Removal

B1 373 3 99.20
The initial objective was to reduce sludge handling B2 374 10 97.33
costs and the hazards associated with the mud trench. B3 757 5 99.34
The Nijhuis pilot system was initially installed to treat B4 1000 13 98.7
15 GPM of backwash water from the sand filters. B5 1150 54 95.3
Testing was conducted with and without the use of Table 1- Sand Filter Backwash Water Total Suspended Solids Analysis
additional chemicals. Upon witnessing the results of
the DAF system on the backwash water the client
requested testing on the treatment of the raw water Sample # NTU In NTU Out % Removal
being fed to the sand filters. This test was also
B1 240.6 2.77 98.84
conducted at a flow rate of 15 GPM. Testing was
B2 283 2.43 99.14
conducted for three days and samples taken for
B3 293.5 2.30 99.22
analysis by two independent laboratories. Testing
B4 240.3 3.25 98.64
consisted of analysis for turbidity, total suspended
B5 562.5 3.65 99.35
solids and the dry solids content of the floated sludge. Table 2 - Sand Filter Backwash Water Turbidity Analysis

Conclusions Sample # TSS In (ppm) TSS Out (ppm) % Removal

R1 55 3 94.54
Initial testing was conducted for the purpose of R2 67 3 95.55
reducing sludge handling costs. However, testing on R3 59 3 94.91
the raw river water proved that it could also provide R4 51 5 90.19
substantial benefits as pretreatment to the sand filters R5 68 4 94.11
by reducing solids loading 90% or greater. A single Table 3 - Raw Water Total Suspended Solids Analysis
Nijhuis DAF was designed to treat the 5 MGD intake
water combined with the 0.5 MGD sand filter
backwash water. Sample # NTU In NTU Out % Removal
R1 45.4 3.67 91.92
From the data gathered during the testing, Nijhuis has
R2 45.1 3.89 91.37
designed a zero discharge system that will:
R3 50.7 3.12 93.85
• Reduce Sludge Handling Costs R4 52 3.35 93.56
• Recover 0.5 MGD of Water R5 37.2 3.2 91.40
Table 4 – Raw Water Turbidity Analysis
• Improve Efficiency of Downstream
Equipment
• Provide a Concentrated Sludge Stream Sample # / Treatment Dry Solids, %
• Provide Zero Discharge B1 / None 8.8
Return on Investment based solely on reduced sludge B2 / 0.5 ppm Polymer 10.3
R1 2.29
handling costs is estimated at 19 months.
Table 5 – Dry Solids Analysis

For additional information on Nijhuis Water Technology visit our website at www.nijhuis-water.com or contact us at
info@nijhuis-water.com or by phone at (905) 787-9292.