Headworks

ProTechtor® Multi-Rake Bar Screens

The Kusters Water Multi-Rake Bar Screen was developed to solve the most demanding problems associated with wastewater pre-treatment. Kusters Water improved the basic design of conventional bar screens to offer a unique product to meet the ever increasing process needs of end users. The Kusters Water Multi-Rake Bar Screen combines fine or coarse screening with high solids capture rates, robust construction, long life, and low O&M costs all in one screen. This combination ensures operation when you need it most.

Functional Principle
Wastewater flows through the tapered stainless steel bars while the non-biological solids, such as paper and plastics, are trapped on the screen face. The screenings are removed from the tapered bars by rake arms fixed between two heavy duty roller chains. These rake arms utilize laser cut teeth that precisely engage and clean the tapered bars to a depth of 10 mm. The screenings are conveyed from the bars over a dead plate, where they have sufficient time to drain, and are discharged at the top of the screen into a dumpster, conveyor or compactor. The Multi-Rake Bar Screen is designed to tightly seal to the walls of the channel to prevent any bypass from occurring and, due to the design of the lower frame, a recess in the floor of the channel is not required.

Case Study
Product Brochure

  • Rugged stainless steel construction
  • Automatic “jam” reversing
  • High hydraulic capacity, low headloss
  • Insensitive to grit and stones
  • “Maintenance free” bottom bearing, or fixed guide
  • Dual speed operation
  • Trapezoidal Bar Design
  • Replaceable bolt-in bars
  • US Manufactured (ISO 9001:2008)
  • 3-Year Factory Warranty
  • Bar spacing as small as 4 mm
  • Channel widths from 1 to 15 feet
  • Standard channel depths to 40 feet
  • Custom channel depths available greater than 40 feet
  • Bar spacing from 4 to 100 mm (1/8” to 4”)
  • Standard angles of inclination: 50°, 75°, 80°, 85°, 90° from horizontal
  • Frame: 304 or 316 stainless steel
  • Tapered Bars: 304 or 316 stainless steel
  • Roller Chain: 304 or 316 stainless steel
  • Sprockets and Shafts: 304 or 316 stainless steel
  • Lower Bearings: Long life ceramic
  • Drive: Shaft mounted gearbox
  • Materials for special applications available on request
  • Municipal sewage treatment plants
  • Industrial wastewater treatment
  • CSO screening applications
  • Wastewater pump stations
  • Sludge Screening

Protechtor® Perforated Plate Filter Screens

The Kusters Water Perforated Plate Filter Screen was developed to solve modern day screening problems which occur in wastewater pretreatment. The Kusters Water Perforated Plate Filter Screen eliminates operational disruptions caused by fibrous and other inorganic material. Depending on the perforated panel, the screened material is greater compared to a bar screen. The quality of the screened effluent is noticeably improved, which in turn improves performance and protects downstream equipment.

Product Brochure

  • Rugged stainless steel construction
  • Completely enclosed
  • Screenings positively conveyed to discharge point
  • Filter elements optimally cleaned due to patented panel shape
  • Allows passage of grit without malfunction
  • Ability to handle high grease discharges without clogging
  • Perforated panels resist stapling effect of fibrous material
  • Ease of maintenance
  • Indoor or outdoor installation
  • Channel widths from 1 to 10 feet
  • Standard channel depths to 36 feet
  • Filter element perforations of 3, 6, and 10 mm are standard
  • Angles of inclination: 50°, 60°, and 75°
  • Frame: 304 or 316 stainless steel
  • Filter Element: 304 or 316 stainless steel
  • Chain: Wear resistant 304 or 316 stainless steel
  • Sprockets: Wear resistant 304 or 316 stainless steel
  • Side Seals: Delrin® plastic
  • Drives: Shaft mounted helical gear

ProTechtor® Centerflow Band Screen

The Kusters Water ProTechtor® Centerflow Band Screen, with its vertical orientation, is an excellent alternative to applications with limited footprint and headspace. Influent flow enters the screen in the middle of the screen frame, and is positively screened as the flow transitions from the inside and passes through the traveling perforated filter belt through the sides and bottom. Optimally spaced lifting tines are attached to filter panels to capture and elevate larger items to the internal discharge point. Screenings are washed off via spray headers and/or a combined motorized brush assembly, and are discharged to an internal flume or screenings washer compactor, which transports the screenings outside of the screen frame. The quality of the screened effluent is drastically improved which in turn improves performance and better protects downstream equipment.

Product Brochure

  • Rugged stainless steel construction
  • Completely enclosed
  • Optional dual speed drive
  • Screenings positively conveyed to an internal discharge point
  • Screenings removed from the screen by an integral flume or optional integral compactor
  • Filter panels optimally cleaned by either a brush/single spray bar arrangement or by a dual spray bar arrangement
  • Allows passage of grit without malfunction
  • Perforated panels resist stapling effect of fibrous material
  • Optional positive sealing between filter panels (3mm and less)
  • Ease of maintenance
  • Indoor or outdoor installation
  • Optional integral bypass door built into the screen
  • Channel widths starting at 2.5 feet
  • Panel widths from 2 – 10 feet
  • Panels: 3 mm stainless steel or 10 mm non-metallic
  • Standard channel depths to 40 feet (other depths on request)
  • Filter element perforations of 2 mm – 10 mm are standard (other sizes on request)
  • Angle of inclination: 90°
  • Frame: 304 or 316 stainless steel
  • Filter Element: 304, 316 stainless steel or non-metallic
  • Chain: Roller chain 304 or 316 stainless steel
  • Head shaft sprockets: Wear resistant 304 or 316 stainless steel
  • Side Seals: UHWMPE
  • Lower turnaround: Stainless Steel (304 or 316)
  • Drive(s): Shaft mounted helical gear

ProTechtor® Screenings Washer Compactors

The Kusters Water wash compactor is synonymous with hygienic and efficient handling of screenings. Screening disposal is a cost factor for every installation; wet screenings are heavy and increase disposal costs. The fecal matter in the water must also be delivered to the subsequent sewage purification process. The Kusters Water wash compactor reduces the weight and volume of the screenings while washing out more than 95% of fecal matter. Kusters Water wash compactors provide high performance combined with low operating costs to provide an excellent cost/performance ratio.

Operation
The screenings are discharged directly from a screening unit, conveyor, or flume to the press feed hopper. The screw then transports the screenings to the washing zone were service water is added and the organic matter is washed out. Fecal matter is loosened and washed off the screenings in the wash zone by a washboard/friction process. Hairs, fibers, etc. which could cause mechanical breakdowns and blockages in the downstream process are retained in the screenings. The water and solubilized organics which are removed by this process are then returned to the wastewater channel via a collection pan. The screw then delivers the washed screenings to the press zone where they are dewatered, with the water also being delivered back to channel via the collection pan. The dewatered screenings are then discharged via a discharge pipe to a container, or conveyor. A shredding device or optional bagging unit are also available for installation on the end of the discharge pipe if desired.

Product Brochure

  • Rugged stainless steel construction
  • Indoor or outdoor installation
  • Ease of maintenance
  • Durable Hardox 400 screw for long life
  • Shafted screw design for greater compaction strength
  • Heavy duty spherical shaft bearing
  • Integral washing system
  • High reliability
  • Reduction of waste disposal costs by minimizing volume and weight of screenings
  • Low maintenance costs
  • Easily adapted to suit existing installations
  • Screw diameter: 200 mm, 300 mm, 350 mm (8”, 12”, 14”)
  • Throughput: Up to 450 ft³/hr
  • Fecal matter reduction: Greater than 95%
  • Volume reduction: 60-70%
  • Weight reduction: 60-70%
  • Housing: 304 or 316 stainless steel
  • Discharge pipe: 304 or 316 stainless steel
  • Conveyor screw: Wear resistant Hardox 400 steel
  • Wear strips: 340 BHN steel

ProTechtor® Internally Fed Drum Screens

Principle of Operation
Influent to the drum is controlled by means of various inlet pipe designs, based on the type of material processed and flow rate required, which distribute the infl uent over a large area of the drum to ensure efficient use of the drum open area. As the drum rotates, screened fluids pass through the perforations in the drum and fall into the water collection trough underneath the drum and are then discharged. Solids are retained within the drum and are dewatered as they are moved to the elevated end of the drum by the internal screw auger. The screenings are then discharged into a dumpster, conveyor, or compactor. The perforated drum is continuously cleaned by means of a friction drive brush. An internal spray bar is also supplied to allow intermittent spray cleaning if required.

Product Brochure

  • Rugged stainless steel construction
  • Completely enclosed
  • Screenings positively conveyed to discharge point
  • Ease of maintenance
  • Indoor or outdoor installation
  • Automatic Integral overflow with alarm and separate outlet prevents contamination of filtered effluent
  • Multiple influent pipe designs for various applications
  • Perforations from 0.6 to 3 mm
  • Drum: 304 or 316 stainless steel
  • Housing: 304 or 316 stainless steel
  • Inlet pipe: 304 or 316 stainless steel
  • Access covers: Molded ABS thermoplastic
  • Brush: Polyethylene
  • Spray Bar: 304 or 316 stainless steel
  • Raw sewage screening
  • Sludge dewatering
  • Pulp and Paper mills
  • MBR protection
  • Food processing

ProTechtor® Headworks Complete Plants

The Kusters Water HCP unit provides a total headworks solution for small and large facilities. The raw influent flow undergoes a series of pre-treatment processes including: Fine Screening, grit collection, grease collection and conveying.

HOW IT WORKS
Raw flow is introduced through a flanged inlet located on the HCP, then passes through a mechanical fine screen, the screenings are captured, washed, conveyed and compacted prior to discharge. The flow passes through an aerated grit chamber where grit settles while organic material is kept in suspension. Grease is collected in an adjacent grease compartment and skimmed off with a scraper, then pumped out of the unit. The settled grit is removed, classified and dewatered with horizontal and inclined grit screws.

Product Brochure

  • Multi-Rake Bar Screens
  • Grease Removal
  • Vortex Grit Removal
  • Drum Screens

Spiral Screw Screens

Kusters Water offers a complete line of in channel or in-tank screening systems. Each unit utilizes a perforated plate or v-wire screen section to effectively remove unwanted solids and debris from the influent. The screenings are transported via a shaftless conveyor to the compactor and washing zone, where they are cleaned, dewatered, then finally discarded into a receptacle or optional bagging system. Screens can be installed in-channel or in a self-contained stainless steel tank.

Product Brochure

  • Perforated drum perforations from 1.0 to 10 mm
  • Wedge wire mesh drum openings from 0.5 to 10 mm
  • Channel or tank mounting
  • Integrated screenings wash system
  • All stainless steel construction 304 or 316
  • Integral compaction and dewatering
  • Duplex spray wash system
  • Bolt On-Off Replaceable Brushes
  • Municipal sewage treatment plants
  • Industrial wastewater treatment
  • MBR pre-screening

ProTechtor® In Channel Perforated Drum Screens

The In Channel Drum Screen is suitable for treating flow rates up to 50 mgd per screen.

Principle of Operation
In channel perforated rotary drum screens are used to improve the suspended solids capture rate in wastewater treatment plants from the typical 10-20% range of course bar screens to the 60-80% range. Taking more of the inert solids out of the flow greatly improves the treatment process and reduces operation and maintenance costs. Today’s modern in channel rotary drum screens are inclined 30-35 degrees. As the inflow enters the rotary drum, the flow level rises to a pre-set level causing the drum drive to turn on. As the drum turns, the combined duplex spray and brush cleaning system cleans the inside of the drum. The screenings (captured solids) fall by gravity into an inclined conveyor screw. The screw then transports the screenings to the compaction zone for dewatering and compaction.

Product Brochure

  • Perforated drum perforations from 1.0 to 10 mm
  • Wedge wire mesh drum openings from 0.5 to 10 mm
  • Channel or tank mounting
  • Integrated screenings wash system
  • All stainless steel construction 304 or 316
  • Suitable to treat flow rates up to 50 mgd per screen
  • Integral compaction and dewatering
  • Brush cleaning system
  • Duplex spray wash system
  • Municipal sewage treatment plants
  • Industrial wastewater treatment
  • MBR pre-screening

ProTechtor® Static Screens

Kusters Water offers a complete line of factory built static screens. Every screen is designed to provide trouble free liquid separation. The open screen design accommodates peak hydraulic flows and the deep influent head box reduces influent turbulence while delivering an even flow over the weir crest. A pivoting flow control baffle plate is provided to enhance even flow distribution and promote faster fluid removal by directing the fluid into the screen.

Screen housings and components are constructed from stainless steel, the screen panel includes a multi-angle design that enhances performance and promotes better solids separation than flat panels. Screen openings are available on a variety of sizes ranging from 0.02″ – 0.10″ and offered in “V” shaped or wavy wedgewire. Screen sizing is based on each project application. Standard Screen sizes range from (18″) to (120″)

Product Brochure

  • Wedge wire mesh 0.01” to 0.100”
  • All stainless steel construction 304 or 316
  • Removeable Screen Panel
  • Very Low Maintenance
  • No Moving Parts
  • Hinged Covers
  • Spray Wash System
  • Service Platform
  • Municipal sewage treatment plants
  • Industrial wastewater treatment

ProTechtor® XGT Vortex Grit Removal Systems

Kusters Water has been directly involved in the design, manufacture, supply, start up and testing of the XGT vortex grit removal technology since 1984. Based on experience with many installations, we have introduced a number of significant improvements to the system. These include the selfpriming grit pump and vortex grit classifier. The XGT vortex grit system is designed to efficiently remove both fecal and vegetable matter (corn, rice, beans, peas etc.) from the grit in the grit chamber resulting in cleaner grit with considerably lower organic content.

Product Brochure

  • Low cost and low energy usage
  • Compact design
  • High efficiency – takes full advantage of gravitational settlement
  • Simple, slow rotating paddle mechanism
  • Submersible gearhead
  • Explosion proof design
  • 304 or 316 SS construction
  • Flooded suction pump
  • Self-priming pump
  • Flat floor design
  • Steel tank construction
  • Airlift pump
  • Grit washing

ProTechtor® Traveling Grit & Grease Bridges

The traveling bridge system utilizes a dual basin configuration consisting of an aerated grit chamber and grease collection chamber. The energy baffles contain the grit and promote settling in the grit basin floor. The grit is then collected via a submerged grit pump attached to the traveling bridge. The grit slurry is fed to a grit classifier, or grit washer, for further cleaning prior to discarding. The grease accumulates within the quiescent grease zone and is positively collected along the entire basin via a skimmer mechanism and pushed into a grease pit or removed via a screw conveyor. The system is fully automated and operates intermittently, run times can be easily adjusted by plant personnel.

Removal Efficiencies
Grit removal efficiency depends on the design dimensions and design peak flow rate. At maximum design flow, the grit removal efficiency will be:

  • 95% of grit greater than, or equal to, 50 mesh in size
  • 85% of grit greater than, or equal to, 70 mesh in size
  • 80% of grit greater than, or equal to, 100 mesh in size
  • 60% of grit greater than, or equal to, 150 mesh in size
  • 15% of grit greater than, or equal to, 200 mesh in size

Product Brochure

  • Rugged steel or stainless steel construction
  • Ease of maintenance
  • Indoor or outdoor installation
  • Fully automatic operation
  • Flexible designs to meet any plant specific needs
  • High reliability
  • Low maintenance costs
  • Low energy consumption
  • Manufactured in the USA

ProTechtor® Circular Grit Collectors

Kusters Water Circular Detritus Tank, Grit Collectors are available in sizes ranging from 8 ft to 40 ft in diameter. The grit collectors utilize scraper arms that are designed to move the settled grit to the exterior of the basin where it is then discharged to a grit classifier or grit washer. Standard flow capacity ranges from 1.0 – 64 mgd in a single basin. Grit removal of >100 mesh grit is readily achieved by gravity settling.

  • Simple Design
  • Low Operational Costs
  • Low Maintenance Costs
  • Easily Retrofit Existing Basins

ProTechtor® Grit Washers

The Kusters Water grit washer was developed with two aims in mind:

  1. To achieve a very high separation performance of the finest grit particles.
  2. To achieve grit with < 3% total volatile solids.

The Kusters Water grit washer consists of two basic items – a rotating perforated screening drum and a grit separator/washer unit, however, if the plant has fine screens (<10mm perforated screens), the screening drum can be eliminated. Special emphasis has been placed on maintaining low water consumption while achieving high grit capture rates and low volatile solids concentrations. The Kusters Water grit washer accomplishes these while providing high performance coupled with low operating costs.

Funtional Principle
The grit/water mixture is fed in via the rotating screening drum (if required). Course screenings are held back in the screening drum and discharged to a dumpster, compactor, or conveyor. The mixture of grit and water is then delivered to the grit separator unit. Organic matter is held in suspension and floated off while the grit settles in the washer tank. With the addition of water, the settled grit is separated from the remaining organic constituents using a stirring device and up-current wash water technique. The washed grit is then removed from the container, de-watered and discharged via a shafted screw.

Product Brochure

  • Rugged stainless steel construction
  • Completely enclosed
  • Ease of maintenance
  • Indoor or outdoor installation
  • Fully automatic operation
  • Optional inlet trommel screen for non-grit solids removal
  • Easily configured to suit existing installations
  • Low volatile solids
  • Low moisture content
  • Less odor

ProTechtor® Grit Classifiers

Kusters Water Grit Classifiers utilize carefully sized settling hoppers to provide accurate surface settling rates. The hopper is attached to a discharge screw assembly to remove the settled and washed grit. Classifiers are available in both single and dual designs and can be fitted with cyclone separators and designed with a retractable lower bearing assembly if desired. The grit classifiers typically have ~ 30% moisture content, with ~ 10% organics. If a cleaner, less odorous grit is required, A Kusters Water grit washer can be provided that will provide ~15% moisture, and 3-5% organics.

Product Brochure

CSO Screens

Regulations require that combined storm overflows are screened to remove floatables and sanitary solids before the excess flow is released to a water course. The Kusters Water CSO screen is designed with 4 mm mechanically cleaned bar spacings to prevent floatables bypassing the screen and retaining the solids which pass on to the wastewater treatment plant. This low cost, low maintenance CSO screen is a guaranteed solution to pollution of our waterways, rivers, canals, streams, and lakes.

Product Brochure

  • Reinforced screen bar structure
  • Duo-directional screen cleaning
  • Dual weir overflow
  • All stainless steel components
  • Extensive combined sewer experience
  • American manufactured
  • Horizontal design
  • Conservative design
  • Lower HP requirements
  • No integral overflow weir
  • Serviceability
  • Raked Bar Screen with 4 to 12 mm spacing
  • Screen frame and bars manufactured from 304 stainless steel electro-polished
  • Screen comb manufactured from polypropylene
  • Flow rate: 400 1/sec/m2 (effective screening area) (10 gallons/sec/ft2)
  • Velocity through screen: 0.9 m/sec. (3 ft/sec)
  • Screen drive is via a double acting hydraulic cylinder mounted above the screen, manufactured in 304 stainless steel and chrome plated, with self sealing end seals. Rod diameter: 25 mm (1.0 inch) Body diameter: 50 mm (2.0 inch)
  • Directional control is achieved via solenoid operated directional control valves coupled to two pressure switches.
  • Operation pressure at 735 psi
  • Pressure relief valve set at 1102 psi
  • Minimum operating pressure for hydraulic pump at 588 psi
  • Hydraulic oil is biodegradable synthetic vegetable type

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