Articles & Case Studies

KINGFISHER BASALT WEAR PROTECTION SYSTEM CHOSEN FOR ENERGY FROM SEWAGE SLUDGE WASTE PLANT IN QATAR

Posted: Wednesday 15th June 2011

Kingfisher’s Industrial’s experience of providing wear protection systems for energy from waste plants (EFW) used in the water industry has resulted in a major order from a leading bulk handling systems manufacturer for a sewage treatment works project in the Gulf state of Qatar.

The treatment works, situated to the North West of Al Gharrafa in Qatar, operates 24hrs/365 days a year under very demanding environmental conditions. In view of these conditions, Kingfisher has provided a 20-year design life on silo cones lined with its K-Bas material, and a warranty of 400-days.

The silo cones have to cope with environmental impacts, such as maximum wind speeds up to 42m/s, relative humidity’s up 100% and ambient building temperatures of 40 deg C; with higher temperatures still in direct sunlight. A further problem is the considerable amount of salt contained in the surrounding atmosphere. This, together with the relatively high ambient humidity, can cause serve corrosion problems for unprotected equipment.

In addition to the external environmental problems, wear protection is necessary on the silo cones due to the fact that sewage sludge is highly abrasive. On its passage through sewers, sewage becomes contaminated with debris, sand, grit, deposits from environmental structures, residue from the land mass, plus metallics, and plastics. Sand and grit, in particular, are a major problem, due to their high silica content. They are highly abrasive, causing problems of wear and erosion with the equipment used to treat and process the sludge into dried sewage pellets – the culmination of the process.

The mild steel silo cones are divided into intermediate sections 4M dia. x 3M high; and lower sections 1.2m dia x 750mm high. They are all lined with Kingfisher’s K-BAS cast basalt lining system. K-BAS is an extremely hard and smooth material that is resistant to most acids and alkalis, and can be used at elevated temperatures.

An inexpensive form of wear protection, K-BAS is characterised by its excellent resistance to sliding abrasion and corrosion. This quality is key, because once the silos are empty, they are filled from the top, so the basalt lining not only has to cope with sliding friction abrasion while the silo discharges, but also from initial direct impact for a short period of time while they are re-filled.

In addition to its wear life, K-Bas was also chosen because the Basalt lining was robust enough to cope with being multi-handled, stored and shipped - open- deck, transported via land through the desert to its final destination, and then installed and craned into position without any detrimental effects. As K-Bas is applied as tiles, these demanding conditions also dictated that Kingfisher had to get the choice of adhesive, for bonding the tiles to the cones, absolutely right first time.

“This latest order provides further evidence of the increasing use of technologies designed to help extract energy and other valuable products from wastewater sludge, said Julian Brindley Sales & Marketing Director of Kingfisher. These technologies make economic sense: as a renewable energy source, sludge by-products can be used as a valuable fossil fuel substitute. However, if these plants are to achieve their projected ROI and payback timescales, wear protection is vital. Plants that process sewage sludge into pellets or granulate are continuous 24/7 operations that cannot stop for adhoc repairs and refurbishment, so optimising their wear life saves a mountain of maintenance and refurbishment costs further down the line.”




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December 2018

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