Hydro DynaSand(R) Filters Help Keep Tyre Production Rolling

Flexsys Rubber Chemicals Ltd is a multi-national chemical manufacturer producing rubber chemicals, predominantly for use in tyre manufacture. Flexsys' Ruabon site, near Wrexham, uses water extracted from the River Dee in the manufacturing processes. To ensure the water is of the right purity, it is passed through a Hydro International treatment plant, comprising 2 Lamella separators units and 3 DynaSand® DS 5000 filters to remove all sediment and other matter.

"Water is essential to our production processes," comments Senior Mechanical Engineer John Ferrari, "so having the Hydro treatment systems that are low-maintenance, high quality and trouble-free is critical.

"An average of 3,600 cubic metres per day of incoming water is treated. It is initially dosed with a poly aluminium chloride flocculant before passing through the Lamella separators to remove the bulk of the sediment. The water then flows through the DynaSand(R) filter units in parallel, before being treated with a biocide and stored in the 300 cu.m. buffer tanks. Backwash from the Lamella separators and the DynaSand(R) filters is treated in our existing site wastewater biological treatment plant before discharge to the river.

"The treated water is not only used directly in chemical manufacture but also for a variety of other uses such as for making up cooling water circuits, supplying vacuum pumps, ejectors and scrubbers and for steam generation. It is also needed to maintain a reservoir of fire fighting water."

As well as the Lamella separators and DynaSand(R) filters, the water treatment plant consists of pumps, storage tanks, dosing equipment and instrumentation.

The DynaSand(R) units comprise a sand filter bed held within a hopper into which the water, pre-dosed with coagulant, is pumped via a manifold to deep within the sand. The water flows up through the sand bed, where solids are trapped on the grains of sand, into the open space above the sand, and the cleansed water exits via a weir at the top to the buffer tank.

The sand containing the entrapped solids is continuously air lifted from the bottom of the hopper, washed by a turbulent mixing action, and the clean sand allowed to return to the sand bed at the top to ensure a circular cleansing cycle. The wash water with separated solids is discharged separately for treatment.

The Johnson Lamella separator provides initial clarification of sediment carrying water with a footprint which can be as little as 10% that of an equivalent settling pond. The patented flow control system passes the incoming water evenly up over a number of lamella plates held in parallel, allowing settled out solids to trickle to the bottom discharge hopper, whilst the clarified water exits at the top of the unit.

For further information please email Hydro International

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