crushing/aggregate plant always need to treat process wastewater to meet the government discharge requirement for environmental protection.
Wastewater from crushing plant dewatering unit and wheel washer for sand.
Solutions:
1, Recommended proven treatment process (industry-standard thickener + flocculation + advanced filtration process)
Complete process flow
Wastewater inlet channel → bar screen debris removal → pre-grit settling hopper (recovering coarse sand) → center-drive thickener (NXZ type) main thickening → fully automatic PAM/PAC dosing system flocculation and sedimentation → thickener overflow clean water → precision sand filter (retains particles above 60 μm) → treated water discharged to river up to standard
High-concentration underflow sludge at thickener bottom → slurry pump transfer → sludge buffer mixing tank → high-pressure chamber plate-and-frame filter press for dewatering → mud cake transported off-site (can be used as backfill or aggregate for brick making); filtrate returned to the front regulating tank for reuse.
2, Total capital expenditure (CAPEX) budget (equipment + steel structure + piping + electrical control + installation and commissioning)
2.1, Pretreatment unit: inletbar screen, regulating buffer tank, coarse sand recovery hopper, wear-resistant lifting slurry pumps (2 duty + 1 standby) Total approx. 39,000 USD
2.2, Core thickening system: NXZ-9m center-drive thickener, steel structure tank with anticorrosion Total approx. 78,000 USD
2.3, Flocculation dosing system: twin-tank PAM maturation mixingtank, manual feeding,metering dosing pumps 6,000 USD
2.4, Sludge dewatering system: 2 sets of fully automatic 600 m² plate-and-frame filter presses 137,800 USD (foundation + installation approx. 30,000 USD)
2.5 Installation, steel structure support, anticorrosion, piping laying, equipment positioning and commissioning: on-site hoisting, welding, anticorrosion, water-flow linkage commissioning approx. 78,000 USD
Total investment —— —— 340,000 USD
3, Operating cost (OPEX) estimate (based on 200 m³/h full load, 300 operating days/year, 24-hour working system)
Basic pricing basis
Industrial electricity price: 0.158 USD/kWh; cationic PAM flocculant: 4,333 USD/ton;operator monthly salary: 887 USD/person
Itemized unit cost (per ton of wastewater)
3.1, Electricity cost: 0.082 USD/m³
The total installed power of the entire system is about 105 kW, with a power consumption of 0.52 kWh per ton of water. The main power consumers are the thickener drive, filter press, feed pump, and filter backwash pump.
3.2, Chemical cost: 0.039 USD/m³
3.3, Labor cost: 0.032 USD/m³
One operator is assigned, with an annual labor cost of 39,394 USD, allocated to the per-ton water cost.
3.4, Wear parts maintenance cost: 0.028USD/m³
Annual amortization of filter press filter cloth, slurry pump impellers, valve seals, and filter media replacement.
Comprehensive total operating cost perton of water treatment: 0.181 USD/m³
Total daily operating cost (4,800 m³): 870 USD
Total annual operating cost (300 days): 260,800 USD
Supplementary revenue: recovery of coarse sand and off-site backfill of dewatered sludge cake can offset about 25% of operating costs.
4, Site Area Estimation
4.1, Main equipment area (thickener + filter press workshop + chemical dosing room +filtration room):30 m ×24 m = 720 m²
4,2, Clean water tank + sludge cake yard + maintenance passage: 40 m × 22 m = 880 m²
4.3, Total land requirement: approximately 1,600 m² in total
The site only needs a hardened floor; the thickener area shall undergo anti-seepage and anti-corrosion treatment.
5, Overall Delivery Cycle for Supply, Installation, and Commissioning
5.1, Equipment production cycle: all equipment factory fabrication completed within 30 calendar days after the contract prepayment is received;
5.2, Equipment transport to site: 20 calendar days (subject to variation based on the aggregate plant’s geographic location);
5.3, On-site installation, piping connection, and steel structure positioning: 20 calendar days;
5.4, Water flow commissioning, chemical dosing ratio commissioning, and discharge compliance acceptance: 7 calendar days
Overall cycle from signing contract to compliant water flow: approximately 70 calendar days
It can meet the urgent production start-up needs for environmental protection rectification.
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