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Advantage of Brightway Slurry Separation Plant

To meet the growing requirements of micro-tunneling projects worldwide, Brighway developed the slurry separation system, so called BWSP or Brightway slurry separation plant system, are specially designed for micro-tunneling separation with slurry mud conveyance in various ground condition, which is an important factor of every successful micro-tunneling operation.

BWSP slurry separation plant

BWSP slurry separation plant

Depending on the tunneling diameter, the excavation rate, the viscosity slurry rate, and geological conditions, Brightway offers efficient separation solutions.

In below introduction, we illustrate the operation of Brightway BWSP system, suitable for the wide range of geological conditions from very coarse to ultra fine.

The basic BWSP250 system is consisted of primary screen separation and secondary vacuum assisted cyclones for fine solids removal down to 60 microns/ 20 microns. The equipment are mounted on the 20′ standard container that operates as the storage tank. The tank is divided into  2 compartments. The slurry is pumped from the TBM / PIPE JACKING MACHINE to BWSP primary linear shaker, utilizing the High G force to allow the efficient conveyance of solids in the minimal foot print.

The high-G shaker is addressed with 3 wire woven stainless steel panels given the total screen area of 2.5 m². The screen separate the coarse material from the fluids and convey to the disposal. The screened slurry flow into the 1st compartment of the storage tank.

From here, the slurry fluids is pumped to the secondary vacuum assisted hydra-cyclones for secondary separation down to 60 microns. The fluids inside the body of the cyclones creates the centrifugal force.

The conical section increase the force and causes the large particles to settle. Solids accumulates at the bottom,when the weight of he solids exceeds the elastic force of the cyclone underflow, the solids dumps. Clean fluids and smaller particles are caught as the spiral and exit the vortex finder into the overflow pipe. Rather than small diameter, high pressure cyclones, the BWSP system utilizes the large diameter low pressure hydra-cyclones, the vacuum assisted cyclones separate the solids at low pressure, minimizing the share of effect that creates finer solids in the slurry which is more difficult to remove. The cyclone operates continuously without plug in.

The solids underflow exits to the high G force linear motion shaker screen for dewatering.

This dewatering  screen deck utilizes the ultra fine wire woven stainless steel screen technology, dewaters and removes he ultra fine solids. The lighter material that smaller than 60 micro exits through the fluids overflow and discharged to the 2nd compartment of the storage tank.

Now BWSP system removes the most of solids bigger than 60 microns.

For geography conditions mainly with coarse and sandy materials, the above solution is capable to keep the slurry for operation. As the geography charges for finer silts and clays, further separation is required.

With the additional BWLW365G decanter centrifuge and BWVC vertical clarifier, it is possible to clean the slurry to 2 microns and maintain a close slurry circuit. In this case, the slurry containing the particles smaller than 60 microns is pumped from the 2nd compartment of the storage tank to the BWVC clarifier.

decanter centrifuge

decanter centrifuge

Prior to the slurry entering into the clarifier, the polymer flocculant is introduced by the means of BWFU flocculant unit. The treated slurry enters the charmber of the clarifier and flocked solids sinks to the conical bottom, and the clearer water rises up to overflow to return to the clean water storage tank. The flocked ultra fine solids accumulated and is pumped to the decanter centrifuge for dewatering.

The sludge enters the centrifuge though the feed tube. The BWLW365G decanter centrifuge is specially designed for the BWSP system. The centrifuge creates the high G force to increase the speed of the solids settling. and separate the sludge into the liquid and the solids phase.

The solids  phase is mechanically extracted with the internal scroll and disposed. The liquid phase is discharged to the clean water storage tank from where it is finally transfered to the return tank.

The use of BWSP separation system ensures the operation of the TBM/ Micro-tunneling or pipe jacking  and reduces both the environment impact and the disposal cost. The modular design provides flexibility in the limited work space for the large range of geography conditions and performance rate.

The use of combination of high G force shaker and conjunction of fine screen technology and consequently large open screen makes the BWSP solution as the efficient plan for the micro-tunneling industry.

Beijing No Dig Exhibitation

Beijing No Dig Exhibition on Oct 10-12,2016, another show for Brightway for trenchless industry.
I wrote the company brief for exhibition several times.
This time is different, I’d like to show more about my understanding for trenchless application as below.

Xi’an Brightway Energy Machinery Equipment Co. Ltd is a professional manufacturer which design, develop, and manufacture the solids control equipment and the mud recycling system.
Our products are environmentally friendly high-tech products which is used for the separation of the solid particles from the slurry liquid and the recycling of the clean fluids..
Brightway products are wildly used in different applications and industries such as oil and gas drilling, CBM drilling, drilling waste management, and the modern trenchless infrastructure construction.
In trenchless construction industry, the concerned applications include tunneling, micro-tunneling, pipe-jacking, bored piles construction,piling construction and diaphragm wall construction, etc
BRIGHTWAY solids control system and slurry separation plant is the necessary equipment in the above applications, which can control the slurry parameter, improve the quality and efficiency of hole forming, shorten the quality of hole cleaning time, and reduce the construction cost , the sticking accidents the pollution of the environment.

I like the X-frame design for this exhibition, and would like to share here.

NO DIG

NO DIG

TRENCHLESS CASE

TRENCHLESS CASE

BRIGHTWAY SHALE SHAKER AND ITE SHALE SHAKER

Happy to go on the interesting travel of comparison between Brightway and ITE.

We are both the solids control manufacturer, and ITE is more focused in micro-tunneling, Brightway products have been sold in oil and gas drilling , HDD, Micro-tunneling etc. I can see a lot which we need to learn from this German manufacturer. Step by step, I understand how the preciseness and practical Germany is.

Let’s go into the details. Firstly this is the detail and specification of ITE linear shale shaker with 3 screens.The ITE 3-Panel Screening Machine 3PSM is designed to dewater heterogeneous solid-liquid mixtures.

ITE shale shaker

ITE shale shaker

Transport Dimensions
Length: 2850 mm
Width: 2050 mm
Height: 1380 mm
Weight: approx. 2112 kg
Technical Specifications
Vibrator Motors
Number of motors: 2 nos.
Power: 2 x 2.2 kW = 4.4 kW
Voltage: 400 V / 50 Hz
Panel Screens
Number of screens: 3 nos.
Kind of motion: linear
Screen area: 2.4 m2
Angle adjustment: -3° to +5°
Screen Selection
Wire woven screens, stainless steel
Panel Screen 070 Mesh / 210 µm / 0.21 mm
Panel Screen 115 Mesh / 130 µm / 0.13 mm
Panel Screen 145 Mesh / 100 µm / 0.1 mm
Panel Screen 180 Mesh / 80 µm / 0.08 mm
Panel Screen 215 Mesh / 70 µm / 0.07 mm
Panel Screen 255 Mesh / 60 µm / 0.06 mm
Panel Screen 325 Mesh / 45 µm / 0.045 mm
Polyurethane
Panel Screen PU 11 x 3.5 mm
Panel Screen PU 11 x 1.5 mm

Brightway linear shale shaker BWZS103

BRIGHTWAY SHALE SHAKER

BRIGHTWAY SHALE SHAKER

BRIGHTWAY LINEAR SHALE SHAKER

BRIGHTWAY LINEAR SHALE SHAKER

Transport Dimensions
Length: 2370 mm
Width: 1690 mm
Height: 1420 mm
Weight: approx. 1320 kg
Technical Specifications
Vibrator Motors
Number of motors: 2 nos.
Power: 2 x 1.5 kW = 3 kW
Voltage: 400 V / 50 Hz
Panel Screens
Number of screens: 3 nos.
Kind of motion: linear
Screen area: 2.1 m2
Angle adjustment: -1° to +5°
Screen Selection
Wire woven screens, stainless steel
Panel Screen 070 Mesh / 210 µm / 0.21 mm
Panel Screen 115 Mesh / 130 µm / 0.13 mm
Panel Screen 145 Mesh / 100 µm / 0.1 mm
Panel Screen 180 Mesh / 80 µm / 0.08 mm
Panel Screen 215 Mesh / 70 µm / 0.07 mm
Panel Screen 255 Mesh / 60 µm / 0.06 mm
Panel Screen 325 Mesh / 45 µm / 0.045 mm
Polyurethane
Panel Screen PU 11 x 3.5 mm
Panel Screen PU 11 x 1.5 mm
Panel Screen PU 11 x 0.7 mm
Panel Screen PU 11 x 0.3 mm

Both IDE and BRIGHTWAY  use the wedge fixed screen, the main difference is the angle adjustment structure. From manufacturing detail aspect, both ITE & BRIGHTWAY pay attention to. E.g, the plate is folded once as below picture, and not adopting the welding way as other solids control manufacturer do.

BRIGHTWAY SHAKER DETAIL

BRIGHTWAY SHAKER DETAIL

SHAKER DETAIL

SHAKER DETAIL

But BRIGHTWAY need to learn more from ITE from the professional aspect of package as below, especially it is very important to sell our products to the international market, all this can tell our culture and attitude as the international manufacturer.

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

ITE SHAKER DETAIL

To be continued.

Separation Plant Comparison between Brightway and ITE

It is chanced that one of my friend sent me the working video of the decanter centrifuge produced by one German company named ITE, and I noted that this company was in the micro-tunneling industrial and they can produce the solids control equipment and the TBM separation plant also.

I am quite interested in this company and want to study their product as my friend told me that their product were durable and he even liked their products better than Bauer and Herrenknecht,  which are the most well-known Brands for the mud separation plant.

This company was set up in 2008, and they call themselves a young and innovative company, and Brightway is even younger than ITE, but also a innovative company with a young team.

I plan to do it step by step, today’s topic is the comparison of mud separation plant ( solids control system) with treatment capacity 60-90 m3/h between Brightway and ITE.

Separation Plant HDD500 with innovative 2-Level Screening Machine and Hydrocyclone Unit for Sludge Dewatering

ITE-HDD500-1
Dimensions for transport
Length: 5500 mm
Width: 1800 mm
Height: 3200 mm
Weight (total): approx. 7300 kg
Technical specifications
Capacity : 60-90 m³/h*1
Vibrator Motors
• Quantity: 2 pcs.
• Rated power: 5 kW
• Supply voltage: 400 V / 50 Hz
Hookstrip screen (lower deck)
• Quantity: 1 pcs.
• Screen area: approx. 1,9 m²
Panel screen
• Quantity: 2 St.
• Screen area (total): approx. 2,2 m²
Angle adjustment: -3 ° to +3°
Acceleration force: 5 G
Screening machine screen area (total): 4,1 m²
*1depending on application.

TBM separation plant

TBM separation plant

Dimensions for transport
Length: 3510 mm
Width: 1800 mm
Height: 2410 mm

Technical specifications
Capacity : 60-90 m³/h*1
Vibrator Motors
• Quantity: 2 pcs.
• Rated power: 2×1 kW
• Supply voltage: 400 V / 50 Hz

Panel screen
• Quantity:2 Set.
• Screen area (total): approx. 1,2 m²
Angle adjustment: -1 ° to +5°
Acceleration force:7G
Screening machine screen area (total): 1.2 m²

Hydrocolone: 1×14″ hydrocyclone

Based on the above comparison, Brightway size is smaller but structure compact. For ITE,, they  use the motor for shale shaker with power as 5kw, which is much bigger than Brightway’s motor, but the G force Brihgtway’s is higher than ITE.