MRI Sludge Collectors

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2 MRI Sludge Collectors S Th e El So b r a n t e w a t e r treatment p l a n t in Oakland, CA installed 22 MRI Hoseless Cable-Vac systems. ludge collection products built on ex Meurer Research, Inc. began developing high-quality equipment in 1978 to provide water and wastewater treatment facilities with effective, reliable and economical methods of removing sludge from sedimentation basins. Over the years, MRI has built upon these standards by incorporating new ideas and technology into the design and manufacture of its products. The result is three fully engineered devices: one based on suction, the Hoseless Cable-Vac; one based on scraping, the U/S Ultra-Scraper; and one based on tradition, the Retro Cable-Vac. MRI Hoseless Cable-Vac eliminates the hose. Only the MRI Hoseless Cable-Vac tm sludge collector* delivers all the benefits of suction sludge removal without the need for hoses. Perfect for use in new or existing basins, the patented system has four key components: Tandem header pipes with tangential flow nozzles* optimize sludge removal Telescoping sludge conduit* eliminates the need for hoses and is self-priming Reel-to-Reel Drive* ensures reliable power without tensioning MRI s signature control system combines sophisticated operation with communications MRI U/S Ultra-Scraper doubles performance. Equipped with double-acting, reciprocating linear blades, the MRI U/S Ultra-Scraper is two times more effective than conventional scrapers. The high-capacity system has four key components: Two transport racks with scraper blades are assembled without field welding Reliable drive unit uses either hydraulic or electric power Cross collector optimizes sludge removal MRI s signature control system offers easy adaptability

3 perience. At t h e facility in Br i s b a n e, Au s t r a l i a, MRI U/S Ultra-Scrapers and Plate Settlers optimize tertiary wastewater treatment. MRI Retro Cable-Vac available as new system or retrofit. In addition to the Hoseless Cable-Vac and U/S Ultra-Scraper, MRI offers the Retro Cable-Vac with flexible hoses and guide rails. The Retro Cable-Vac is based on the original Trac-Vac system created by MRI in With well over 2,000 Trac-Vac systems sold, many have been refurbished to become like-new Cable-Vac sludge collectors. The Retro Cable-Vac is also available as a new system and consists of five main components: A single header pipe mounted on a traveling carriage A guide rail which extends the full tank length A sludge hose to transport the sludge from the header pipe out of the basin A Reel-to-Reel cable drive Control system The water treatment plant in Piedmont, AL was completely refurbished with the MRI Retro Cable-Vac. (Top) Th e To b a c c o Ro a d Wa t e r Tr e a t m e n t Pl a n t in Au g u s t a, GA utilizes t h e MRI Hoseless Ca b l e-va c u n d e r MRI stainless steel plate settlers. (Bottom) *Patented

4 MRI Sludge Collectors REa s y t o o p e r a t e, MRI s m e n u-d r i v e n, t o u c h screen c o n t r o l s y s t e m is designed t o m a n a g e multiple Hoseless Ca b l e-va c u n i t s. Co n t r o l s c a n be p r o g r a m m e d t o fully meet a treatment plant s specific needs. eel-to-reel Drive ensures reliable pow Built for simplicity, MRI s Reel-to-Reel Drive* makes the Hoseless Cable-Vac the ultimate in dependability. The above-water drive combines take-up and pay-out cables on one shared reel saving space and allowing a compact drum with the cable wrapped in a single layer without tensioning. Designed for continuous operation, the robust and energy efficient AC drive with variable frequency control can withstand a stall without sustaining damage. Adaptable control system enables sophisticated operation. The operator friendly control system automatically displays and manages all functions of the sludge collector. Through a programmable, menu-driven LCD touch screen, MRI control systems offer sophisticated SCADA and communications options and are powered by Rockwell International/Allen-Bradley. Variables include duration, speed, and frequency of operation which can be triggered by sludge depth, time, or signals from SCADA.

5 er. Conventional Sludge Collector Innovative tandem collectors maximize efficiency. In c o n v e n t i o n a l s l u d g e c o l l e c t o r s (Fi g u r e A), t h e i n c o m i n g f l o w e n t e r s a t t h e b o t t o m a n d c o n t i n u e s u p w a r d, p e r p e n d i c u l a r t o t h e i n t e r n a l f l o w, w h i c h is m o v i n g laterally t o w a r d t h e center o u t l e t. Th i s c a u s e s t h e t w o f l o w s t o collide a t the orifices, disrupting the flow pattern and decreasing sludge removal. Figure A The key to the Hoseless Cable-Vac s ability to deliver increased solids removal is the innovative design of its tandem collectors.* Unlike conventional equipment, MRI s system has two collectors instead of one, with sludge collection orifices located on the side and facing forward, rather than pointing downward. This allows for enhanced, one-way directional sludge extraction as the assembly moves forward. On the reverse stroke, suction ceases. The orifices direct the sludge into the collection pipe tangentially (see illustration above), organizing the flow to remove more solids with less water and prevent clogging. MRI s Ex c l u s i v e Ta n d e m Co l l e c t o r s Wi t h MRI s t a n d e m c o l l e c t i o n d e s i g n* (Fi g u r e B), t h e i n c o m i n g f l o w e n t e r s t a n g e n t i a l l y t o t h e b o t t o m o f e a c h c o l l e c t o r, c a u s i n g t h e i n t e r n a l f l o w t o t r a v e l in a s p i r a l t o w a r d t h e center o u t l e t. As t h e spiraling f l o w passes e a c h orifice it is r e-energized by t h e i n c o m i n g f l o w. Th i s c r e a t e s a u n i f o r m, o r g a n i z e d flow pattern that increases sludge removal and prevents clogging. Reel-to-Reel Drive High Water Level Figure B Unlike other systems, MRI s Hoseless Cable-Vac operates without guide rails on the basin floor enabling quick, simple installation. It can be used in new or existing basins with flat, sloping or slanted floors. Even in continuous operation, the collector is virtually maintenance free due to all stainless steel construction, long-life wheels and bearings, and a simple cable-winch drive. Si d e view o f MRI Hoseless Cable-Vac s h o w s t h e simplicity o f t h e s i n g l e reel drive system. Th e l o w-p r o f i l e d e s i g n enables use u n d e r plate settlers, tube settlers or in open basins. Ba c k w a r d Fo r w a r d Double Cable Pulleys Urethane Castors Single End Cable Pulley *Patented

6 MRI Sludge Collectors N ow Co m p u t e r Fl u i d Dynamic (CFD) Design Th e h y d r a u l i c s a r e c a r e f u l l y designed u s i n g CFD analysis to distribute flows both frontto-back and side-to-side. there is a an efficient choice MRI Hoseless Cable-Vac: low profile, floor-hugging and powerful. MRI s Hoseless Cable-Vac features a floor-hugging, telescoping sludge removal pipe and a simple, powerful cable-winch movement. Durable enough for continuous operation, treatment plants generally run the Hoseless Cable-Vac from one to several times a day. Offering a highly scaleable design, the MRI Hoseless Cable-Vac is available in flow rates from 25 gpm to 2,000 gpm. MRI U/S Ultra-Scraper: double-acting blades increase effectiveness. MRI s U/S Ultra-Scraper s unique design houses a series of scraper blades mounted on two racks. Each rack moves in opposition to the other creating a backward and forward action of approximately 2. The reciprocating design greatly increases solids removal, delivering unsurpassed effectiveness. MRI U/S Ultra-Scraper Double -Acting Blades Th e b a c k w a r d s t r o k e o f t h e s c r a p e r b l a d e s s l i d e s u n d e r t h e s e t t l e d s o l i d s. (To p) Th e f o r w a r d s t r o k e p u s h e s t h e s e t t l e d s o l i d s t o w a r d s t h e e n d o f t h e b a s i n. (Bo t t o m)

7 for maximum solids removal. Unsurpassed MRI Hoseless Cable-Vac. Flow Balancing Ring Designed f o r precision, t h e Fl o w Ba l a n c i n g Ri n g* assures even f l o w c o n t r o l f r o n t t o b a c k. Reel-to-Reel Drive Th e efficient c a b l e d r i v e d e s i g n p r o v i d e s s t r e n g t h a n d d u r a b i l i t y. By c o m b i n i n g t h e t a k e-u p a n d p a y-o u t c a b l e s o n o n e reel, t h e c a b l e is k e p t in a s i n g l e l a y e r without tensioning. Telescoping Sl u d g e Pipe Fl o o r-h u g g i n g, t h e s l u d g e pipe extends t h e f u l l l e n g t h o f t h e b a s i n, e l i m i n a t i n g t h e need f o r h o s e s. It is completely self-p r i m i n g a n d e a s y t o i n s t a l l. Tandem Header Pipes Unequalled in p e r f o r m a n c e, t h e t a n d e m header pipes h a v e t w o c o l l e c t o r s i n s t e a d o f o n e, significantly i n c r e a s i n g s o l i d s r e m o v a l. *Patented

8 High-performance MRI U/S Ultra-Scraper. Power Pivot Hydraulic Drive En s u r e s reliable p o w e r a n d h a s automated position sensing technology.* Double Thrust Linkage Pr o v i d e s f o r c e t o m o v e s c r a p e r r a c k s b a c k and forth and removes twice the sludge.* Tr a n s m i t s p o w e r f u l 20,000 lb. f o r c e f r o m Hy d r a u l i c Dr i v e t o s c r a p e r r a c k s, e n a b l i n g removal of dense sludge.* Reciprocating Flights Do u b l e-a c t i n g s c r a p e r b l a d e s m o v e s o l i d s in o n e d i r e c t i o n t o w a r d s l u d g e o u t l e t e n d a n d g r e a t l y i n c r e a s e effectiveness. Also a v a i l a b l e a s s i n g l e-a c t i n g.* *Patented

9 for ultimate performance. Engineered for integration, MRI s Plate Settlers* and Sludge Collectors* provide standard-setting performance from clarification to solids removal. MRI s Plate Settlers allow increased water flow and settling area, greatly enhancing clarifier effectiveness and productivity, while MRI s sludge collection products maximize solids removal. Reel-to-Reel Sludge Collector Drive Co m p a c t, p o w e r f u l, reliable d r i v e f o r u n d e r w a t e r s u c t i o n o r s c r a p e r sludge collector. Inclined Plates Av a i l a b l e in 5 t o 10 l e n g t h s, t h e 100% stainless steel p l a t e s a r e t h e smoothest, flattest and strongest plates in the industry. MRI Sludge Collector Lo w-p r o f i l e, f l o o r-h u g g i n g, c o m p u t e r-c o n t r o l l e d s u c t i o n o r s c r a p e r s l u d g e r e m o v a l system maximizes solids removal and enhances productivity. *Patented

10 n-site success: no field cutting or Th e MRI Po w e r Pi v o t t r a n s m i t s a 20,000 lb. f o r c e a n d enables r e m o v a l of dense sludge. Installation of the MRI U/S Ultra-Scraper is quick and simple. Substantially fabricated at the factory, the on-site contractor simply assembles the unit. No measuring, cutting, or welding is required. Efficient and fast action removes the heaviest solids. Low profile blades scrape only a thin layer of sludge with each cycle, enabling efficient removal of thick, heavy sludge and even grit and anthracite. This also allows a much higher traveling velocity than Chain & Flight and other higher profile devices. Generally, Chain & Flight moves at about 1 fpm, compared to the MRI U/S Ultra-Scraper s speedy 10 fpm or more. The MRI U/S Ultra-Scraper s speed corresponds to a sludge removal rate of 300 gpm in a 25 wide basin. Alternate blade sets hand sludge off to each other as they move back and forth. The sludge moves either to the end or center of the basin where it is extracted by a cross collector. Lo w-p r o f i l e a n d f l o o r-h u g g i n g, t h e MRI U/S Ul t r a-sc r a p e r i n t e g r a t e s w e l l w i t h MRI Pl a t e Se t t l e r s, a s s h o w n a t t h e w a t e r t r e a t m e n t p l a n t in Br i s b a n e, Au s t r a l i a. (Be l o w)

11 Advantages of the MRI U/S Ultra-Scraper : welding needed. The only double-acting, rec iproc ating linear scraper m a d e in the United States Field assembled w i t h pre-cut, pre-m a d e c omponents that bolt together for ease o f installation No field cutting and field welding required (unlike other brands) Si m p l e, quic k assembly reduces basin downtime and m i s t a k e s Th e s c r a p e r m o v e s b a c k a n d f o r t h a s t h e h y d r a u l i c d r i v e c y l i n d e r extends a n d r e t r a c t s. Th i s m i g r a t e s t h e s l u d g e t o t h e e n d o f t h e basin where it is removed by the cross-suction mechanism. Parts readily available from Colorado All drive c omponents, hydraulic parts and c ontrols from top U.S. m a k e r s such as Ro c k w e l l In ternational/allen-bradley, Baldor, Vickers, and m o r e All thrust and linkage c omponents extra heavy duty Hy d r a u l i c Dr i v e Cy l i n d e r End-o f-stroke sensors inside the c ylinder c asing permanently set to maintain a d j u s t m e n t High Water Level MRI U/S Ul t r a-sc r a p e r a l s o c a n be u s e d a s a c r o s s-c o l l e c t o r a t t h e e n d of the basin. (Above) Plate Settlers Drive Linkage Power Pivot Cr o s s Su c t i o n Me c h a n i s m Reciprocating Flights *Patented

12 MRI Sludge Colle PTrust MRI for trend-setting innovation. MRI h a s installed t h o u s a n d s o f w a t e r t r e a t m e n t p r o d u c t s w o r l d w i d e in i t s m o r e t h a n 30 y e a r s o f l e a d i n g a d v a n c e m e n t s in w a t e r a n d w a s t e w a t e r t r e a t m e n t s o l u t i o n s. Installed p r o d u c t s p i c t u r e d a r e t h e MRI Hoseless Ca b l e-vac a t Le x i n g t o n, KY, a n d MRI Pl a t e Se t t l e r s a t Gallentin, TN a n d Du r a n g o, CO. recise engineering. Proven tech Experience, reliability, creativity and know-how. These are the qualities that have enabled Meurer Research to lead advancements in water and wastewater treatment solutions since Now Meurer Research is pleased to offer a choice in superior sludge collection products continuing the innovative and efficient designs in MRI s more than 30-year history of advancements. With over 50 patents and thousands of installations, from design, engineering and production to installation, education and after-market customer service, MRI has helped utility companies, municipalities and engineers find solutions to complex issues.

13 nology. Other products available from Meurer Research are: Inclined Plate Settlers Hoseless Cable-Vac Sludge Collectors U/S Ultra-Scraper Sludge Collectors Paddle Wheel and Turbine Flocculators Membrane Pre-Treatment Package Plants Floating Plate Settlers Backwash and Residuals Reclaim Baffles Tube Settlers Pilot Plants Membrane Filters Ma n u f a c t u r e d in Go l d e n, Co l o r a d o, MRI s h i p s w a t e r treatment products worldwide.

14 Meurer Research, Inc Joyce Drive Golden, Colorado (303) FAX (303) Visit for more information Meurer Research, In c. All rights reserved. Hoseless Ca b l e-vac is a registered trademark o f Meurer Research In c. *Patented by Meurer research In c.