Aerofloat designed and built a Dissolved Air Flotation (AeroDAF) system for Macadamias Australia inside a 20 foot HQ shipping container, minimising costs and installation time.
Aerofloat was engaged by a macadamia farm to create a wastewater treatment plant that would meet the company’s increased production. Watch the video to see how Aerofloat’s team designed and built a Dissolved Air Flotation (AeroDAF) system for the macadamia processing facility. The system was custom built inside a 20 foot HQ shipping container, which minimised site installation time and costs, and provided a neat solution for the client.
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Background
Located in Queensland, Australia, Macadamias Australia needed to improve production growth and manage the increased wastewater flows by updating its existing wastewater treatment system.
The existing system managed wastewater flows from the cleaning of vegetables and nuts at the plant but was insufficient to meet the production growth changes. Diversification in the food types being produced at the site also meant an enhanced system was required.
The existing wastewater treatment plant pumped effluent into a lagoon where bacteria completed the treatment process. The increased flows due to production growth at the site meant that the lagoon was not sufficient to meet the increased wastewater; Aerofloat was engaged on to upgrade the site to ensure it met council standards.
The Aerofloat Solution
Aerofloat installed its Dissolved Air Flotation (AeroDAF 100) unit at the site, constructing the system inside a 20 foot HQ shipping container at its Sydney warehouse. This ensured the system was easily shipped to the macadamia farm once the client was ready for installation.
In addition to the AeroDAF 100, Aerofloat installed a 25,000 litre balance tank complete with pH correction and air mixing, a rotary drum screen (to remove any solids such as macadamia nut husks from the effluent), a sludge tank with air mixing and an automated poly skid. A chemical dosing board, effluent pH testing and correction unit was also included, helping to ensure compliancy with the local council’s regulations.
The shipping container was carefully adapted to meet the harsh Queensland climate. The screen was added on a mezzanine on the roof of the container, and air conditioning installed to ensure all system components were kept at the recommended temperature for operations. The container was also insulated using BONDOR and the floor rendered chemical-resistant using Phenoline (often used to line the inside of large tanks).
Results
Clever pre-planning and the innovative use of a shipping container to house the main Dissolved Air Flotation system allowed Aerofloat to install the solution at the Queensland site.
The wastewater treatment system will remove suspended solids, reduce the BOD and correct the wastewater pH to ensure the outgoing effluent will reach the evaporation lagoon standards set by the local council.
Aerofloat also installed remote monitoring on the system to enable data flow between the operators and Aerofloat’s engineers. This also allowed Aerofloat’s engineering team to initially commission the system remotely. The system is due to be fully commissioned in October 2020.
Watch the video to see how Aerofloat was able to re-purpose the shipping container to provide a Dissolved Air Flotation solution for Macadamias Australia.
