Problem: A mining company was washing and de-icing their large mining equipment with a 150-200 gpm water cannon monitor system. In the summer, washes typically averaged 1-2 hours, using 9,000 to 24,000 gallons per vehicle.
In the winter months, however, the company used the same water cannon monitor system to defrost the equipment and then wash it. Defrosting in the depths of winter could often take up to 10 hours which added an additional 90,000 to 120,000 gallons per vehicle!
The company called Wash Bay Solutions and asked us to develop a heavy-duty washing solution that would greatly reduce their water usage.
Solution: With input from the client, our engineers enhanced our existing demucking system with a new nozzle design to produce our 60 GPM @ 1000 PSI Mighty Monitor system.
The key to this system is our specially designed, multi-directional, 60 gpm @ 1000 psi nozzle. These nozzles are trolley-mounted so they can ride along I-beam systems, immediately adjacent to the vehicle. Specialized hose trolley systems attached to the nozzles allow the operator to wash the 60-ton mining vehicles almost single-handedly!
These nozzles are trolley-mounted so they can ride along I-beam systems, immediately adjacent to the vehicle. Results: The client is very happy the ease-of-handling, range of movement, and washing power of the new design. They are able to wash their large trucks quickly and effectively, using less time and about 1/10 of the amount of water than they did with the water cannons.
Using only 60 gpm of reclaimed water, our Mighty Monitors will effectively remove heavy accumulations of dirt and mud – saving thousands of gallons of water per cleaning.
Get the power of a fire hose with a fraction of the water usage!
Robustly designed for heavy industrial applications such as mining and oilfield services, our MM Series Mighty Monitors are great for cleaning large haul trucks, steel tracked vehicles or any heavy equipment caked with mud, clay, ice, grass or muck.
For drilling and construction equipment applications, our 20 gpm Mighty Monitor system cleans quickly and effectively, in half the time of a typical pressure washer.
Our new 60 gpm nozzle and trolley assembly
For mining applications, we have developed a revolutionary heavy-duty Mighty Monitor system to replace the standard high volume water cannons that have been used for decades. Our systems combine increased pressure and specialized nozzles to ensure a quality wash. Using only 60 gpm of reclaimed water, our Mighty Monitors will effectively remove heavy accumulations of dirt and mud – saving thousands of gallons of water per cleaning.
Fast and effective cleaning while saving time, water and water treatment costs – a win-win-win situation!
Mighty Monitor System Features:
20-60 GPM Capacities
Uses only a fraction of water used in traditional water monitors or water cannons
Water Treatment Solutions for Trains and Locomotives
Rail is by far one of the most efficient means of transportation. It is estimated that one train can move a ton of freight almost 500 miles on a single gallon of fuel. Today, Rail Companies are aggressively embracing environmental initiatives by investing in new technologies that further reduce their carbon footprint, energy use, and water consumption.
We can help rail companies keep the trains clean and in good working order AND help them reach their environmental goals. Engineered and manufactured for the locomotive industry, our Rail & Locomotive (RL Series) Systems are heavy-duty, multi-stage wash water reclaim systems which can be combined with our single or multi-stage wash and rinse arches for a complete wash system that uses a fraction of the water of other wash systems on the market.
In the first stage our RL Systems, the water is processed through a stainless steel clarifier oil water separator which removes most suspended solids (TSS), essentially all settleable solids and all free and dispersed non-emulsified oils from the waste stream.
After the clarifier separator, the water is further processed for re-use by going through an extremely efficient filtration process utilizing fully automated solids filtration and a proprietary blended activated carbon (GAC) polishing filtration. Processed water passing through the system will be free of particles greater than 10 microns in size, substantially all emulsified oils, waxes and other volatile organic compounds.
RL Series Multi-Stage/Multi-Pass Filtration
RL SERIES STANDARD FEATURES:
High-Efficiency Pumps
Corona Discharge Ozonation System
Solids Handling & Separation
TSS & FOG Reduction
Multi-Stage / Multi-Pass Filtration
Pressurized Blended Carbon Polishing Filter
Auto-Backwashing Filters
Stainless Steel Construction
NEMA 4X Control Panel with PLC controller
Depending on the location, many options are available to maximize the efficiency of the wastewater treatment system including:
To reduce both hauling costs and water usage, many oil field services companies have installed our Drilling Equipment (DE Series) Systems to treat and recycle their wastewater.
Oil and gas drilling, including hydraulic fracking, is a complicated endeavor. The nature of the work ensures that dirt, downhole acids, crude residues, waxes, and grease coat down-hole motors, pumps, subs, drill pipe, tanks, and vehicles. Constant washing and NDT testing is essential to maintaining the equipment in good working order. These processes, however, produce an enormous amount of water. Often, the wastewater is stored onsite and disposed of every few weeks – which can get very expensive.
To reduce both hauling costs and water usage, many oil field services companies have installed our Drilling Equipment (DE Series) Systems to treat and recycle their wastewater. Robustly designed and manufactured for the oil and gas industry, our heavy-duty, multi-stage treatment systems clean up the water for re-use or discharge. By simplifying the water handling, many clients are able to both increase production and reduce costs, resulting in pay back periods of only months!
The important first stage is the solids handling system. Depending on the amount of solids and the wash pad design, our engineers will develop a site-specific system to remove as many solids as possible before the water goes to the filtration systems.
The next stage of the system is the stainless steel clarifier oil water separator which removes most suspended solids (TSS), essentially all settleable solids and all free and dispersed non-emulsified oils from the waste stream.
Depending on the application, the next stage could be biological treatment. Our proprietary biological filter system uses a revolutionary, patented US technology, including specifically developed microbes combined with a highly efficient aeration technology, to treat the water and remove substantially all of the COD and FOG in the water.
In the final polishing stage, the water goes through an extremely efficient filtration process utilizing fully automated solids filtration and a proprietary blended activated carbon (GAC) polishing filtration, and a corona discharge ozone generator to prevent odors. Processed water passing through the system will be free of particles greater than 10 microns in size, substantially all emulsified oils, waxes and other volatile organic compounds.
STANDARD DE Series SYSTEM FEATURES:
Stainless Steel Construction
High-Efficiency Pumps
Corona Discharge Ozonation System
Solids Handling & Separation
TSS, COD, FOG Reduction
Multi-Stage / Multi-Pass Filtration
Pressurized Blended Carbon Polishing Filters
Auto-Backwashing Filters
NEMA 4X Control Panel with PLC controller
Depending on the location, many options are available to maximize the efficiency of the wastewater treatment system including:
4-Vessel MINING & CONSTRUCTION (MC Series) TREATMENT SYSTEMS
As the demand for minerals and precious metals grows, mining companies are constantly working to keep up with demand and improve their mining methods while at the same time doing as much as they can to preserve the environment. Most mining and heavy construction work is predominantly done by heavy equipment such as LHD loaders, backhoes, excavators and dump trucks. This equipment gets coated with solids, dirt and grime on a daily basis.
Daily washing is an important part of maintaining the equipment in good working order. This washing, however, produces a lot of dirty water and solids. The most efficient way to reduce your water usage and hauling costs is to remove the solids and recycle the water.
Our Mining & Construction Equipment (MC Series) Systems are heavy-duty, multi-stage reclaim and discharge systems, engineered and manufactured for the mining and heavy construction industries.
Because of the enormous amount of solids generated by the washing process, the most critical first stage for these systems is the solids handling system. Depending on the wash pad design, our engineers will develop a site-specific system including sumps, trenches, screens and skimmers to remove as many solids as possible before the water goes to the subsequent filtration systems.
After many of the heavy solids are removed in the first stage, the water will then be processed through a stainless steel clarifier oil water separator which removes most suspended solids (TSS), essentially all settleable solids and all free and dispersed non-emulsified oils from the waste stream.
After the clarifier separator, the water can either be discharged or further processed for re-use. If the water needs to be re-used, the water then goes through an extremely efficient filtration process utilizing fully automated solids filtration and a proprietary blended activated carbon (GAC) polishing filtration, and a corona discharge ozone generator to prevent odors. Processed water passing through the system will be free of particles greater than 10 microns in size, substantially all emulsified oils, waxes and other volatile organic compounds.
MC SERIES STANDARD FEATURES:
Stainless Steel Construction
High-Efficiency Pumps
Corona Discharge Ozonation System
Solids Handling & Separation
TSS & FOG Reduction
Multi-Stage / Multi-Pass Filtration
Pressurized Blended Carbon Polishing Filter
Auto-Backwashing Filters
NEMA 4X Control Panel with PLC controller
Depending on the location, many options are available to maximize the efficiency of the wastewater treatment system including:
The Solids and Oil Water Separation Systems (SOWS) are horizontal gravity flow treatment systems designed to separate settleable solids, suspended solids, and free and dispersed oil.
New SOWS Systems Remove Both Free & Dispersed Oil AND Settable & Suspended Solids!
Introducing the new Best Available Technology (BAT) for the treatment of produced water and flow-back water. The Solids and Oil Water Separation Systems (SOWS) are horizontal gravity flow treatment systems designed to separate settleable solids, suspended solids, and free and dispersed oil.
This system is a significant improvement to the currently used CPI Separators which can only separate free oil and settleable solids – allowing a considerable amount of dispersed oil, suspended solids, and stable emulsions to pass through the system.
Applications:
Onshore and Offshore Drilling Operations
Oil Refineries
Produced Water
Waste Oil Processing Facilities
Benefits:
No moving parts
Low maintenance
Heavy duty carbon or stainless construction
The SOWS System has 5 stages of separation.
Solids Oil Water Separation
Stage 1, Inlet Area – The water mixture flows into the inlet quiescent area where the velocity of the water slows. The free oil (150 micron in size or greater) separates and rises to the surface where it is removed by a pipe skimmer.
Stage 2, Clarifier/Solids Intercept Section – The settleable solids flow downward and are captured in the clarifier/ solids intercept section.
Stage 3, Inclined Plate Section – The suspended solids and dispersed oil flow upward through the inclined plates section. Most of the suspended solids will slide down these plates into the hopper.
Stage 4, Separation Compartment – The remaining suspended solids and dispersed oil flow into the separation compartment where the coalescing plates remove 99% of the free oil droplets 30 micron or greater. This oil rises to the surface where an oil skimmer decants it to an oil storage tank. The coalescing plates then capture the remaining suspended solids.
Stage 5, Clean Water Compartment – The flow of water will go over the overflow weir into the clean water compartment where oil absorption polishing bags trap any trace oils before the water is discharged.
A Variable Frequency Drive (VFD) system is one of the most cost effective units to run and to maintain and they are extremely easy to use.
A Variable Frequency Drive (VFD) system is one of the most cost effective units to run and to maintain and they are extremely easy to use. The VFD display makes is simple to trouble shoot. The VFD display shows various input signals which can be used to visually display and indicate system faults. The VFD system offers substantial operational and maintenance savings. A variable frequency drive extends the life of the motor, pump, and pump components. A VFD significantly reduces maintenance or service related issues. The system will only utilize the power (speed of motor and pump) to match the output demands. For example: A 20 gpm system, set up for 4 users at 5 gpm each. If there is only one user on the system outputting 5 gpm, the motor/pump will only turn at 1/4” speed to meet that demand. The VFD system shows a savings in energy costs to run the system, it only uses what it needs. On system start-ups, a VFD controlled system slowly ramps up speed to the minimal required rpm to meet the initial demand. This eliminates the huge inductive amperage load a system with standard controls requires when starting. A VFD system does not require the use of motor contactors, overloads, and fusing.
VFD benefits
Energy savings
Smoother quieter operation, eliminate water hammer
Extend pump life
Extend system component life
Extend motor life
Reduce maintenance
Functional Design
Real-time system monitoring and control (wash station duty cycle/activity, low inlet water supply and system pressure loss shutdown, and high water temperature shutdown)
Compact and versatile design allows for installation in virtually any location/environment
Systems designed/built to application requirements – provides for increased productivity
VFD increases or decreases pump/motor speed to meet the demands of single and or multiple users
Standard Equipment
Belt-driven, industrial-duty plunger or piston pump with multi-gun pressure regulator, pilot-activated flow switch, factory-set pressure relief valve and liquid-filled pressure gauge
VFD controlled with performance display screen, Nema 4x housing, and a fused disconnect
Premium-efficiency, inverter-duty motor (IP55, Class B temp. rise, Class F insulation, 40° C ambient temp. design)
In some locations such as power plants or older factories, there may be a need to install a larger oil water separator in a constrained space. There may be room for the separator, but the entrance to the separator area may be a maze of twisted steps and narrow hallways. If this is the case, we have the ability to custom engineer an oil water separator that can be built in place, piece-by-piece.
Our Built In Place Oil Water Separators are designed for those constrained locations that seem impossible. Wash Bay Solutions provides an advanced solution for this very need.
Applications include:
Power Plants
Refineries
Factories
Industrial plants
Available in a range of dimensions and flow rates, these separators can be constructed of stainless steel or carbon steel that corrosion protection applied at the factory.
To ensure each piece will be made to accommodate the facility, we will prepare detailed sub-assembly drawings for your approval prior to starting construction. Then, detailed construction drawings and instructions will be provided for onsite installation.
Like all of our separators, these constrained space oil/water separators will remove 99.9% of free and dispersed non-emulsified oil droplets in the waste stream.
Benefits
Removes free oil droplets as small as 20 microns
Reduces effluent free oil concentration to 10 ppm or less
High flow rates in a compact design
Low maintenance costs
Solids storage capability
All of our systems are constructed of heavy-duty components for maximum life and performance. They can be customized with hoppers or oil storage compartments and a variety of skimming, monitoring, and pumping packages.
Here is one of our oil water separators specifically designed for the vehicle washing industry to help remove dirt and oil.
Our oil water separators have been specially developed for treating wash water from commercial vehicle washing operations. Used in a variety of applications, our vehicle washing oil water separator systems will remove 99.9% of free and dispersed non-emulsified oil droplets in the wash water with discharge to the sewer or a treatment plant.
Applications:
Equipment Washing
Car Washing
Truck & Bus Washing
Forklift Wash Facilities
Aircraft Washing
Locomotive Washing
Marinas
Available in a range of dimensions and flow rates, our oil water separators can be can be customized with a variety of skimming, monitoring, and pumping packages. All of our systems are constructed of stainless steel or coated carbon steel and heavy-duty components for maximum life and performance. They can also be easily adapted to handle a range of input water variations including high salt content and acids.
