In the freezing climate of Siberia, an innovative industrial sewage treatment plant has successfully resolved its long-standing winter operational bottlenecks. By replacing outdated wastewater treatment equipment with a highly automated, low-temperature resistant system, the facility has managed to slash sludge transportation and disposal costs by more than 40% while lowering daily labor costs by 60%.
The massive regional upgrade, officially known as the Complete Sludge Dewatering and Chemical Dosing System Project for XX Industrial Sewage Treatment Plant in Siberia, Russia, marks a significant technical milestone for local industrial and municipal wastewater processing in extreme sub-zero climates, demonstrating Qilee’s engineering capabilities in harsh environments.
Confronting Siberia’s Brutal Winter Challenges
For years, the local enterprise generated a massive volume of industrial and municipal sewage but lacked the modern infrastructure to handle it efficiently. The plant relied on traditional plate and frame filter presses, legacy machinery that occupied an immense footprint and required complicated manual intervention. More critically, the old equipment performed poorly under the region’s extreme low-temperature winter conditions, leading to low dewatering efficiency, excessive chemical consumption, and frequent winter freeze-ups. The facility was caught in a constant battle to meet local environmental protection standards and sludge reduction requirements.
Faced with an acute local shortage of on-site operators and limited technical maintenance capabilities, the client desperately needed a space-saving, low-maintenance solution. The engineering mandate was clear: deliver stable sludge treatment capacity for mixed chemical and municipal sludge despite fluctuating solid levels, and guarantee continuous, 24/7 stable operation without freezing or shutdown failures.
The Engineered Breakthrough: Screw Shafts & Heat Tracing
To stabilize operations in the harsh Russian cold, Qilee’s engineers deployed a customized, integrated wastewater solution combining a specialized screw sludge dewatering machine with a full-automatic intelligent chemical dosing machine.
Unlike traditional belt or plate-frame filters, the newly installed screw sludge dewatering machine utilizes a non-clog screw shaft structure that directly treats low-concentration sludge, completely eliminating the need for a separate sludge thickening tank. To survive the sub-zero environment, the entire machine is treated with specialized low-temperature anti-corrosion and anti-freezing technology. Water pipelines are fitted with a customized heat tracing design, and key equipment components feature dedicated thermal insulation structures to prevent ice blockages.
Complementing the dewaterer is a full-automatic dosing machine featuring a three-chamber integrated design. The unit automates the feeding, dissolving, maturing, and accurate dosing of polymer chemicals, keeping solution concentrations precisely controlled between 0.1% and 0.5%.
Crucially, the entire system is tied together via an intelligent interlocking control system. This real-time signal linkage automatically matches sludge inflow, chemical dosage, and dewatering speeds based on live data, shrinking the machinery’s physical footprint to just 1/3 of traditional equipment – a hallmark of Qilee’s compact design philosophy.
Drastic Reductions in Waste, Labor, and Costs
Data gathered since the system’s deployment shows a dramatic turnaround in both efficiency and environmental compliance:
- Sludge Reduction: The system maintains continuous, stable treatment capacity, keeping the moisture content of discharged sludge cake steadily between 75% and 80%. This massive reduction in volume has cut downstream transportation and disposal costs by over 40%.
- Chemical Savings: The automated multi-stage stirring and curing system ensures the full dissolution and activation of flocculants. By utilizing on-demand proportioning linked to incoming sludge volume, the plant has reduced flocculant consumption by 25%.
- Unattended Automation: The high automation level allows for fully automatic, unattended operation. Because the system requires only regular manual inspections, daily labor operation costs have plummeted by 60%.
- Climate Resilience & Compliance: The equipment has achieved zero freezing damage, blockages, or shutdown faults during peak winter. The discharged sludge now fully complies with local environmental protection discharge standards, entirely removing the risk of regulatory penalties.
Long-Term Cooperation Ahead
In official feedback, the client highly recognized the performance of Qilee’s complete set of sludge treatment equipment, noting that the ultra-low failure rate and simple daily maintenance have thoroughly solved their most painful operational headaches. Praising the professional overseas technical guidance, standard installation drawings, Russian-language operation manuals, and comprehensive commissioning and training services provided, the client confirmed plans for long-term in-depth cooperation and intends to purchase more water treatment supporting equipment in the near future.
The system’s main body is constructed of full 304 stainless steel, featuring built-in overload protection, frequency conversion speed regulation, and an automatic spray cleaning system to prevent sludge adhesion. Built with advanced anti-acid, anti-alkali, and low-temperature materials, the system is projected to deliver an extended operational lifespan despite the highly corrosive chemical sludge conditions.
Learn more at: https://www.qileegroup.com/
Inquires can be sent to +86 13370035529 or email qilee@qileegroup.com
Address: No. 351 Wenqu Road, Fengxian District, Shanghai, China.
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