Welcome to Qingdao Qingtian Environmental Engineering Co., Ltd. QTDL stacked screw sludge dehydrator. This sludge dewatering machine is widely used in municipal sewage, food brewing, slaughtering and breeding, pharmaceutical, paper, leather, textile printing and dyeing, machinery processing and other industries sludge dewatering. Please read this manual carefully before use, familiar with the dehydration principle of this sludge dehydrator, various performance and installation operation requirements, so as to be able to skillfully operate this equipment.
Description:
1. This manual is specially prepared for the personnel responsible for operation and management of the user. Please be sure to submit this manual to these personnel.
2. After receiving the equipment, the user should immediately conduct an appearance inspection. If there is any injury such as bump, feedback to our company for verification immediately, so that our company can judge whether the equipment can work normally according to the damage situation of the equipment, and repair and remedy it in time to ensure that the equipment works normally.
3, equipment startup, debugging, operation and maintenance work can only be carried out by trained professionals. Before the first operation, the operator must be familiar with the operating procedures in this manual. These regulations help to maintain efficient operation of equipment, reduce wear and tear, and extend service life.
4. The equipment shall be guaranteed according to the contents specified in the contract, but the spare parts of authentic Qingtian Environment Company must be used. If spare parts of other manufacturers are used, the company will not bear the losses caused thereby. Secondly, our company will not be responsible for losses caused by improper operation or non-compliance with our operating procedures, or by wrong operation by non-specialized operators.
 
First, the basic principle of stacked screw sludge dehydrator
QTDL series stacked screw sludge dehydrator is one of our main products. In recent years, it has been widely used in sludge dewatering and other industrial process dewatering fields, and has achieved good results.
Stacked screw sludge dehydrator is a new type of solid-liquid separation equipment, which uses the screw extrusion principle, through the strong extrusion force generated by the change of screw diameter and pitch, and the tiny gap between the floating ring and the fixed ring to realize the extrusion dehydration of sludge.
* Construction principle:
 The main body of the stacked screw sludge dehydrator is composed of multiple fixed rings and floating rings, and the screw shaft penetrates through the filter device. The former section is a concentrating section, and the latter section is a dewatering section. The concentrating and squeezing dewatering of sludge are completed in one cylinder, replacing the traditional filter cloth and centrifugal filtration mode with a unique subtle filter mode.

* Dehydration principle:
After gravity concentration in the concentration part, sludge is transported to the dehydration part. In the process of advancement, with the gradual reduction of filter slits and pitch, and the blocking effect of the back plate, a large internal pressure is generated, and the volume is continuously reduced to achieve the purpose of full dehydration.


* Dehydrator workflow
1. Concentration: When the screw pushes the shaft to rotate, the multiple solid active laminations located on the periphery of the push shaft move relatively, and under the action of gravity, water is filtered out from the relatively moving laminations to achieve rapid concentration.
2. Dehydration: the concentrated sludge moves forward continuously with the rotation of the screw shaft; along the direction of the sludge cake outlet, the pitch of the screw shaft gradually decreases, the gap between the rings gradually decreases, and the volume of the spiral cavity shrinks continuously; under the action of the back plate at the outlet, the internal pressure gradually increases, and under the continuous operation of the screw shaft in turn, the moisture in the sludge is squeezed out, and the solid content of the filter cake is continuously increased.
3, self-cleaning: the rotation of the screw shaft, to promote the continuous rotation of the floating ring, the equipment relies on the fixed ring and the movement between the floating ring to achieve a continuous self-cleaning process, thus skillfully avoiding the traditional dehydrator widespread blockage problem.

 
 
 
 

* advantages of stacked screw sludge dehydrator
wide application
1. Apply to municipal sewage, food, beverages, chemicals, leather, welding materials, paper, printing and dyeing, pharmaceutical and other industries sludge.
2. Suitable for dehydration of high and low concentration sludge. When dewatering low-concentration sludge, it is unnecessary to construct a concentration tank and a storage tank, thereby reducing construction cost, phosphorus release and anaerobic odor generation.
small design
1. Compact design, dehydrator contains electric control cabinet, metering tank, flocculation mixing tank and dehydrator body.
2. Small footprint, easy maintenance and replacement; light weight, easy to carry.
Not suitable for blocking
1. It has self-cleaning function. It is not necessary to clean to prevent clogging of filter slits, so as to reduce the amount of flushing water and reduce the burden of internal circulation.
2. Good at dewatering oily sludge.
low speed operation
1. The rotation speed of the screw shaft is about 2~3 rpm, and the power consumption is extremely low.
2. Less trouble, less noise and vibration, safe operation.
simplicity of operator
1. Through the electric control cabinet, it is linked with the dissolving machine, sludge pump, dosing pump, etc. to realize 24-hour continuous operation.
2. Daily maintenance time is short and maintenance operations are simple.
durable
1. The body is all made of stainless steel, which can maximize the service life.
2. The replacement parts are only the screw shaft and the loose ring, and the service cycle is long.
 
II. Preparations before formal operation of equipment
Please confirm the installation position of the machine and electrical box before the spiral sludge dehydrator is put into formal operation. It is recommended to install in a well-ventilated indoor environment. Shelters must be built to protect against rain and heat preservation when installed outdoors.
① Check whether there is polymer flocculant in the liquid medicine device, whether the liquid medicine device can operate normally, and whether it can form linkage with the machine.
② Turn off all operation selection switches on the electric control cabinet.
③ Please adjust the liquid level adjusting pipe (or mud inlet pump) to set the mud inlet amount.
4. The proportion of chemicals, and adjust the dosing pump, set the dosage of polymer flocculant. According to the sludge content in sewage, the concentration of the medicine is matched, and the sludge content is more, and more medicine is added. Less mud, less medicine. Under normal circumstances, the equipment uses polyacrylamide (PAM) coagulant (sludge of different properties plus different varieties of about agent, the drug variety is generally determined by the sample experiment), cationic agent for acidic water, anionic agent for alkaline water, the larger the molecular weight, the better, but the corresponding cost will increase, the molecular weight of the usual drug can meet the requirements of 8 - 10 million units. Add 0.62 parts per thousand PAM coagulant into the medicine bucket filled with tap water and stir evenly to make PAM coagulant fully dissolved in water. The stirring time can be about 60 minutes.
5 When the polymer flocculant and sludge react in the flocculation mixing tank, check whether ideal alum flowers are formed. The ideal diameter of alum flower is about 5~10 mm. If the ideal alum flower cannot be formed, the type of medicine and the amount of dosage are one of the reasons.

(6) alum flowers flow into the main body of the stack snail, and are processed to form mud cakes and discharged from the mud cake discharge port. The pressure in the main body of the stacked snail gradually increases as the sludge flows in, and it takes a certain amount of time (approximately 60 minutes) to form a formed mud cake.
III. Start-up and use of equipment
 1. Connect the spiral sludge dehydrator with the flocculation reactor, connect the flocculation reactor with the sludge pump and the dosing machine, and connect the drainage pipeline and flushing pipeline of the spiral sludge dehydrator. First check the tightness of each valve and pipeline, whether each electrical appliance is open normally, turn on the power supply, check whether the rotation of each motor is correct, if it is reversed, adjust the control line to the correct rotation.
3. Start the sludge pump to feed sludge, and at the same time start the dosing pump to feed medicine. Observe the flocculation effect of sludge. The sludge must be fully flocculated to separate the muddy water in the sludge. The floc is better above 8 mm. Must control the sludge into the amount of mud and medicine into the amount of adjustment at any time, so that the flocculation effect to achieve the best, the treatment capacity to achieve the best.
4, open the stack screw host, adjust the speed of the host, start the frequency conversion reading can be set at about 40, first reduce the baffle gap, so that there is a certain amount of sludge in the screw cavity. Dilute sludge is discharged at the sludge outlet first, and dry sludge is slowly discharged. At this time, stop and adjust the baffle gap (usually about 3-15 mm). However, it is necessary to adjust the baffle gap according to the actual situation, enlarge the gap for more mud, and reduce the gap for less mud. Never seal the baffle, so that mud can not be discharged to increase the load of the reducer, resulting in equipment damage and motor burn. Observe the water content in sludge. If the water content in sludge is high, slow down the rotation speed of main engine and narrow the baffle gap. If the water content is low, speed up the rotation speed of main engine and enlarge the baffle gap. Thereby achieving the maximum effect of water content requirement and sludge output in sludge.
5, in the stack screw host work for about 20 to 60 minutes to open the washing device to wash the host surface sludge, each time about 5 minutes. Rinse surface sludge off duty.
6. The sludge entering the sludge dehydrator must be uniform, and there must be no mud sometimes in the sewage, which directly affects the sludge output of the equipment. When there is mud, the mud is discharged normally. When there is no mud, the mud discharged is very thin and even water is discharged directly. The moisture content of sludge cake is different with different sludge properties.
IV. Commissioning and operation of equipment
Adjusting moisture content of dehydrated cake
The adjustment of moisture content and treatment capacity of dehydrated mud cake is realized by back pressure plate and screw shaft frequency converter.

•  Back pressure plate clearance setting

Reduce moisture content: By reducing the gap between the back plates, the pressure in the body of the stack is increased, thereby reducing the moisture content.
Increase moisture content: By increasing the gap of the back plate, the pressure in the body of the stack is reduced, thereby increasing the moisture content.
　　※ Note: Please do not adjust the gap of the back plate to less than 4 mm.
The smaller the clearance of the back plate, the greater the pressure inside the equipment, the lower the moisture content of the mud cake, but it will also cause a great burden on the machine, resulting in accelerated wear of the vulnerable items (loose ring, screw shaft).

•  Set screw shaft inverter

Reduce the moisture content: the frequency of the inverter is lowered, the rotation speed of the screw shaft is reduced, and the processing capacity is correspondingly reduced. The sludge concentration and dehydration time in the main body of the snail become longer, so that the moisture content decreases.
Increase the moisture content: the frequency of the frequency converter is raised, the rotation speed of the screw shaft is increased, and the processing capacity is correspondingly increased. The concentration and dehydration time of sludge in the main body of the snail becomes shorter, so that the moisture content increases.
※ Note, screw shaft inverter * can be adjusted to 50r/m, water content in 99% of the sludge in the case of normal work can be adjusted to 40r/m. Specific debugging experiments can be conducted according to the field conditions.
The greater the rotation speed of the screw shaft, the greater the sludge treatment capacity, the higher the moisture content of the sludge cake, but it will also cause a great burden on the machine, resulting in accelerated wear of the vulnerable products (floating ring, screw shaft).
V. Matters needing attention in operation adjustment
1. After the initial commissioning of the machine, there is no need for other adjustments except for liquid supplement.
2. Please check the residual amount of liquid medicine regularly.
3. When the sludge concentration changes greatly (more than 10%), the shape of the sludge will change greatly. Please adjust the amount of sludge, the moisture content of the dehydrated sludge cake and the treatment amount.
Adjustment of sludge concentration under fluctuating conditions
The sludge concentration may affect the treatment capacity when it changes. Please adjust it by the following methods.
・To increase the throughput, increase the rotation speed of the screw shaft drive motor and increase the sludge intake by sludge pump or screw pump.
・To reduce the throughput, slow down the rotation speed of the screw shaft drive motor and reduce the sludge intake by sludge pumps or screw pumps.
※ If the clearance of the back plate is not adjusted, it is possible to cause excessive sludge accumulation in the main body of the stack. In this case, it will not only lead to electrode overload, but also accelerate the wear of wearing parts such as loose rings and screw shafts.
Adjustment in case of high water content
※ A decrease in sludge concentration will lead to a decrease in solids dosage, resulting in a high moisture content. The pressure in the main body decreases due to the decrease of solid dosage, which reduces the dehydration performance. In this case, increase the amount of mud to achieve the effect of increasing the solids dosage.
※ In case of increasing sludge intake, if the liquid level is higher than the high liquid level (H position) in the flocculant mixing tank, the excessive sludge will be discharged through the overflow pipe. * It is good to ensure the continuity of dehydration by appropriately adjusting the flow rate of the sludge pump.
※ In the case of increased sludge intake, if the sludge concentration becomes high, it will exceed the normal treatment capacity of the stack screw body, and the sludge level will often be higher than the * high level (H position) on the flocculation mixing tank, so that the return system will operate, and the returned sludge will return to the sludge well, increasing the workload of the sludge pump.
VI. Maintenance and inspection
1, special attention; before work, turn off the sludge pump and dosing pump, the host continues to work for about 20 minutes, observe whether the sludge inside the host is discharged. Avoid sludge squeezing the main screw, especially when it is not used for a long time (more than five days), all the sludge in the screw machine must be discharged, and the surface and inner cavity must be cleaned to avoid blocking the screw machine, burning the motor, frequency conversion and damaging the screw machine body, etc., causing unnecessary losses. Empty the sludge in the flocculation reactor and rinse the tank with tap water. At the same time, the drainage tank will be washed clean to prevent sludge hardening mud. The specific methods are as follows:
◆ Precautions for long-term downtime
In case of shutdown for more than one week (2-3 days for easily dried sludge)
In case of shutdown for more than one week, in order to protect the machine, the following operations must be carried out:
① In order to prevent the sludge in the tank from rotting and drying, the sludge in the flocculation mixing tank should be emptied from the cleaning outlet and washed with water.
※ To drain the sludge from the mixing tank, keep the mixer stirring and open the gate valve below the mixing tank. This will allow the sludge in the tank to be emptied smoothly.
② Let the back pressure plate open to the maximum and let the screw shaft in the main body run for 1 hour. Wait until all the sludge in the main body is discharged, and then wash it properly with water.
③ Turn off the main power supply in the electric control cabinet.
<Three months or more downtime>
If the shutdown is more than 3 months, the following work must be carried out in addition to the above work "in the case of shutdown for more than 1 week (easy drying sludge for 2-3 days)."
① In order to prevent the port of the electric control cabinet from rusting, the door of the electric control cabinet must be closed, and the indoor air must be kept unobstructed.
② In order to prevent the electromagnetic relay in the electric control cabinet from rusting, the machine should be manually operated once every 3 months.
2, pay attention to the temperature below 0 degrees when freezing absolutely can not use this equipment. After the body freezes, use warm water to melt all the ice before starting.
3, screw main engine reducer factory has been filled with oil (when using, please check the reducer oil standard, confirm the fuel consumption), in the first work of about 2000 hours to change the oil, after the oil change in the work of about 3000 hours.
4. Inspection and abnormal response
Please make proper use of the forms attached to the manual for routine and periodic inspection.
In addition, please refer to the operating instructions of each machine when checking or abnormal conditions occur in motors, pumps, inverters, etc.
◆ Daily inspection items

check point	inspection item	examine
electrical machinery	for proper functioning	□
	Any unusual noises?	□
	Vibrating or not	□
counter pressure plate	Is the gap set properly	□
	Is the variation range of moisture content of dehydrated cake too large?	□
main body	Is the solid content of filtrate abnormal?	□
gauge tank	Is there sludge accumulation around the return pipe and weir?	□
flocculation mixing tank	Whether there is sludge accumulation around the motor and reducer	□
	Whether the right alum is formed	□

◆ Regular inspection items

check point	inspection item	examine
electric control cabinet	Are all kinds of indicators lit normally?	□
electrical machinery	Abnormal fever	□
	Is there an oil leak?	□
	Is the current similar to normal?	□
transducer	Does it operate according to set point	□
	Do you have abnormal fever?	□
	Is the display and LED illuminated properly?	□
main body	Is the floating ring moving?	□
	Is there a significant amount of filtrate leaking out of the gaps between the rings	□
gauge tank	Is there a change in mud intake?	□
automotive fasteners nuts	for loose	□
piping valve	for loose	□
	Is it cracked or damaged?	□

◆ Handling of abnormal situations

abnormal portion	abnormal contents	possible reasons	countermeasure
electric control cabinet	LED is off	Indicator light exceeds service life	change
electrical machinery	immobility	overload	Contact our company or agency
		The motor itself fails.	replace the motor
		bad contact	check the line
	abnormal heating	overload	reduce the load
		motor fault	replace the motor
		Voltage too high (low)	check voltage
	abnormal murmur	motor fault	replace the motor
		Foreign matter mixed in impeller	Remove foreign matter or replace motor
	vibration	screw loosening	tighten the screws
		motor fault	replace the motor
	oil leak	motor fault	replace the motor
transducer	Does not operate according to set point	Wrong setting method	Please refer to the inverter manual
	abnormal heating	Start, stop too often	Please refer to the inverter manual
		Voltage too high (low)	Please refer to the inverter manual
	vibration	Set screw loose	screw down
		inverter fault	Replace the frequency converter
	Display and LED lights do not light up	bad contact	check the line
		inverter fault	Replace the frequency converter
counter pressure plate	Not adjusted to a proper clearance	Back pressure plate fixing screws loose	Tighten the screws after adjusting to a suitable clearance
	The variation range of water content in mud cake is too large	sludge character change	Please refer to the manual
main body	The floating ring does not move	Floating ring wear	Contact our company or agency
	Too much mud leakage from filter cracks	Not forming proper alum flowers	Please refer to the manual
		Too much mud.	Reduce sludge intake through sludge pumps, etc.
		The screw shaft rotates too slowly	Speed up the screw shaft rotation
	Filtrate solids too high	Not forming proper alum flowers	Please refer to the manual
		Too much mud.	Reduce sludge intake by regulating sludge pumps, etc.
		The screw shaft rotates too slowly	Speed up the screw shaft rotation
gauge tank	Sludge accumulation around return pipes and weirs	-	Remove accumulated sludge
flocculation mixing tank	Sludge accumulation on horizontal tubes or motors	-	Remove accumulated sludge
automotive fasteners nuts	start	-	screw down
piping valve	start	-	screw down
	rupture	-	Replace the damage

 

 
VII. Preparation and debugging method of liquid medicine of stacked screw sludge dehydrator
A. Drugs:
Polyacrylamide (PAM), sludge dewatering machine multi-use cationic type, molecular weight in 1000- 12 million units can be. The higher the molecular weight, the better the effect, but the cost will increase.
B. Proportion:
1. Polyacrylamide 1‰ - 2‰, 1000 kg water plus 1-2 kg dry powder, molecular weight of 8 - 1 - 2 million units
2. In practical application, PAM (anion 10 million units) can be matched by 1 first. Add or subtract according to flocculation conditions (see commissioning method below for details).
For example, the diameter of your mixing tank is 700mm and the height is 700 mm. The effective volume of the stirring tank is 0.15 square meters, and the stirring tank can add about 150kg of water. When the PAM is mixed, 0.15 kg of PAM dry powder can be added.
C. Stirring method and time:
1. The stirring time of PAM solution can be controlled at more than 60 minutes, so that it can be used after aging. After stirring, open the valve and put it in the prescription box for later use. In winter, due to the low temperature, the stirring time can be more than 90 minutes.
2. When preparing the solution, add water in the stirring tank first, then turn on the mixer, and then slowly add PAM along the vortex. Note that PAM cannot be put into it quickly at one time, otherwise PAM will agglomerate to form fish eyes and cannot be dissolved.
After adding dry powder, it should generally continue to stir to ensure that it is fully dissolved, and the specific stirring time can refer to the time mentioned above. PAM dissolved should be used as soon as possible, anionic type generally do not exceed 36h, cationic type dissolved easily hydrolyzed, should be used within 24h.
D. Dosage addition:
Dosage to adjust according to the actual situation, different properties of sludge used by the dosage is different, even if the same nature of sludge, but also according to the desired effect, the use of different dosage to adjust, in general, within a certain limit and solubility, the greater the dosage, the better the effect, but the higher the cost, but sometimes too much dosage, will also play the opposite role, taking into account cost-effectiveness and effect, the pursuit of a reasonable and economical dosage is the key to sewage treatment. Dosage size to flow meter or metering pump scale shall prevail. When debugging equipment, the flow rate of flowmeter can be preset according to the usual dosage. For example, for a spiral stacker that processes 3T of water-containing sludge (referring to the amount of sludge) per hour, the liquid medicine can be controlled to the scale of rotor flowmeter at about 40L/H, and then debugged according to the following methods.
E. Commissioning method:
1) Prepare PAM solution according to the above method.
2) After about 1-2 minutes, take a beaker of water from the flocculant box to see the size of the suspended floc. If there is a large floc and it rises quickly, and the water is clear. If the floating is very slow and the floc is very small, it is necessary to increase the PAM dosage until satisfaction.
That is, the flow rate or dosage of dosing system should be adjusted according to the size of suspended floc and the quality of effluent. If the floc is small and does not float completely, it is necessary to increase the flow rate or increase the dosage.
F. Precautions for dosing system:
1, mixing tank water should not be too much, should add water to the top of the tank below 250-300mm is appropriate, add water is too full, after the mixer will be stirred and overflow.
2, PAM solution and sewage reaction time is very short, PAM in the flocculation box reaction time of about 2-4 minutes. Therefore, the closer the flocculation reaction box is to the host, the better. For equipment layout, please refer to the operating instructions.
3. If magnetic pump is used for dosing, water must be added when dosing, and it is forbidden to empty when there is no liquid medicine, so as not to damage the pump.