BP Chemical – Decatur, Alabama
Custom Sludge Blanket Clarifier Improves Wastewater Treatment Efficiency
Industry: Industrial Water & Wastewater
Location: Decatur, Alabama
Client: BP Chemical
Provided by: ClearStream Engineering – www.clearstreameng.com
Challenge
BP Chemical operates multiple facilities worldwide, producing a key precursor for food-grade plastics. During the production process, fine particles enter the wastewater stream. The company needed a reliable way to remove and recover these particles—not only to meet environmental standards but also to recycle valuable materials back into production.
At the Decatur, Alabama facility, BP Chemical had been testing a competitor’s solids contact clarifier but found it was not meeting performance expectations. To explore a better solution, they reached out to ClearStream Engineering, recognized for its expertise in industrial wastewater treatment systems and custom clarifier design.
Solution
ClearStream requested a wastewater sample for detailed laboratory testing. Results revealed that the competitor’s solids contact clarifier was shearing floc particles, preventing proper settling and leading to poor effluent quality.
Based on these findings, ClearStream engineers recommended a Sludge Blanket Clarifier—a design that allows suspended solids to settle without the shearing effect of high internal sludge recycle rates. This approach trapped smaller particles effectively and produced the high-quality effluent BP required.
The process also presented unique challenges. The sludge thickened substantially at times, requiring a custom lift mechanism for the rake arms. However, the application still needed active skimming, which could not raise along with the rakes. ClearStream designed a dual-action clarifier allowing independent movement—rake arms that lift while skimmer arms remain in position.
To further enhance performance, ClearStream engineered a sludge recycle loop to prevent solids from setting up in the discharge line, maintaining smooth, continuous operation.
Results
The innovative design proved highly effective. After startup, BP Chemical achieved consistent clarification results and significant process reliability improvements. Impressed by the system’s performance, BP purchased six additional sludge blanket clarifiers for facilities around the world.
Why ClearStream Engineering
Through in-house laboratory testing, advanced design capabilities, and a deep understanding of industrial wastewater processes, ClearStream delivered a tailored solution that exceeded expectations.
Resources and Related Links
BP Chemical – Custom Sludge Blanket Clarifier Improves Wastewater Treatment Efficiency
Equipment in this Case Study
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