InteSys Scaled Process Systems

Integrting Zeroday’s wide range of allied and complementary product lines provides economic, effective and highly scalable process solutions. Putting the puzzle together innovatively and creating new opportunities to save money.

These Integrated Systems (InteSys™ processes) are an ideal fit in the following situations:

  • For very small to medium sized operations; InteSys processes are particularly scalable to specific application size.
  • Quick to set up and put into operation; typically does not require concrete and construction, making installation easy.
  • Lower cost versus alternative process systems that might be considered.
  • For short duration projects, such as pond emptying and dewatering.

Based on project requirements and process data developed by testwork, Zeroday develops a process design, initial installation costs and projected operating costs for an effective system suited to your application.

Systems Zeroday has installed using  our product lines have included:

Mineral process reagent system:

Zeroday was contracted and installed a 24 LMI pump reagent system entailing the construction of three (3) pump stations, installation of 860 feet of ½” stainless steel reagent distribution tubing and 1300 feet Tygon feed lines throughout a mill. Included were automatic mixing systems for two of the reagents (each consumption level of 1-2 drums a month), installation of two (2) additional reagent head tanks with continuous recycle, in line reagent filtering to prevent precipitated chemicals from plugging the system and 4 chemical remote controllers to allow reagent addition changes away from the actual pump location.

Municipal digested sludge dewatering system:

Small municipalities (particularly those with 750 and fewer connections) who digest their sludges and seasonally liquid apply their sludges find that using a InteSys process incorporating polymer, polymer mix-feed equipment and Sludge/Dump Sacks is a particularly cost effective and easy to setup and use. These systems are typically operated only 2-6 times a year to empty their digesters using a single Sack until filled when a new Sack is placed. Annual operating costs excluding dewatered solids haulage are below $10,000 for dewatering 30-70 dry tons sludge per year.

Winery pH adjust and dewatering system:

In winery situations involving very low volumes wastewater that have high starches, sugar and alcohol loadings, before discharge to a municipal sewer system the discharge pH and BOD/COD levels must be controlled. In these circumstances, Zeroday will install an auto pH control loop with caustic/base for pH adjustment, coagulant and polymer mix-feed systems and a Dump Sack for removal of waste stream solids which can be easily taken to a dump for disposal. Utilizing this system has provided target discharge pH levels and a dramatic COD level reduction from as high as 13,000 ppm down to 1,000 ppm or less due to the solids removal.

Pond dewatering projects:

When a pond (mineral, digested organic sludge, alum sludges) require clean out, the typical approach is to contract a dredger to pump out the slurry/sludge which is fed to a belt press or centrifuge for dewatering and haulage to disposal …a very expensive proposition. A highly cost effective alternative is installation of an InteSys process incorporating polymer product, polymer mix-feed system and Sludge Sacks. The sludge is flocculated while being pumped to the Sludge Sack.  In situations such as this application, Zeroday can supply in line flocculation performance monitoring devices that control the polymer feed pump to ensure optimum flocculation and optimum Sack drainage and dewatering performance. While dependent on the project size, even incorporating dredging, the dredge and dewatering costs are typically 33-50% of a dredge-belt press/centrifuge operation.

Zeroday continually develops and adds product lines that complement existing offerings. Our goal is to creatively and innovatively enhance our treatment packages to offer greater value to our customers.

To assess whether an InteSys process will provide you large benefits, contact Zeroday (email: Support@ZerodayLLC.com or phone: +1 (503) 582-9067 or (877) 582-9067 for a project review and system design, including a cost analysis for your consideration.