Flotation systems are essential in industrial wastewater treatment, removing suspended solids, oils, and contaminants. This guide addresses common problems—such as clogging, chemical imbalances, equipment faults, and poor floc formation—and provides practical troubleshooting tips to maintain optimal performance.

Flotation units play a critical role in treating industrial wastewater by separating contaminants from water via buoyant air bubbles. However, operators sometimes face issues that compromise performance and efficiency. This guide provides practical solutions for troubleshooting common problems in these systems, ensuring that your treatment process remains robust and cost-effective.

How a Flotation Unit Works

In a typical flotation system, a pressurised stream of recycled treated wastewater is mixed with air, forming minute bubbles. These bubbles attach to suspended solids and oils, making them buoyant so they rise to the surface for removal. The clarified water then exits the unit for further treatment or reuse.

A dissolved air flotation (DAF) unit combines a pressurised stream of recycled treated wastewater with a solution containing minute air bubbles. These bubbles attach to the solids in the water, making them buoyant and causing them to rise to the surface for removal. The clarified effluent then exits the DAF unit for further treatment or reuse.

Common Issues and Troubleshooting Tips

Clogging

Issue:

Blockages may occur in the inlet or within the tank due to accumulated particles, algae, or debris. This hinders water flow and reduces separation efficiency.

Troubleshooting Tips:

  • Regularly inspect and clean the inlet and tank.
  • Adjust flow rates to minimise turbulence and encourage settling.

For more detailed guidelines on managing clogging in wastewater systems, refer to the Water Corporation guide on trade waste permits.

Chemical Imbalance

Issue:

Improper dosing of coagulants and flocculants can lead to suboptimal floc formation, reducing the unit’s effectiveness.

Troubleshooting Tips:

  • Verify dosing rates and adjust based on water quality.
  • Conduct jar tests to determine optimal chemical levels.
  • Monitor pH levels and ensure even mixing of chemicals.

Air-Solids Interface

Issue:

Ineffective air mixing can result in inadequate bubble formation or poor attachment to solids, diminishing separation efficiency.

Troubleshooting Tips:

  • Inspect air delivery components such as compressors and blowers.
  • Fine-tune air flow rates to ensure proper bubble dispersion.
  • Check for leaks in the system that might affect performance.

Equipment Malfunction

Issue:

Mechanical failures—such as pump or compressor issues—can disrupt the flotation process.

Troubleshooting Tips:

  • Implement regular maintenance schedules for all components.
  • Monitor equipment for unusual noises or vibrations.
  • Replace worn parts promptly and ensure all connections are secure.

Sludge Handling

Issue:

Inefficient removal of accumulated sludge can lead to system build-up and decreased performance over time.

Troubleshooting Tips:

  • Adjust skimming or scraping mechanisms to optimise sludge removal.
  • Monitor sludge levels and ensure effective dewatering and disposal processes are in place.

Floc Formation

Issue:

Suboptimal floc formation may result from incorrect chemical dosages or inadequate mixing, reducing overall separation efficiency.

Troubleshooting Tips:

  • Review and optimise the types and dosages of coagulants and flocculants.
  • Adjust mixing intensity and duration to promote effective floc growth.
  • Monitor operational conditions such as pH and temperature.

Conclusion

Troubleshooting and optimising your flotation system is key to ensuring efficient wastewater treatment. Addressing issues like clogging, chemical imbalances, and equipment malfunctions will help maintain system performance and extend the unit’s lifespan. By following these practical steps, you can achieve reliable operation, reduce maintenance costs, and ensure that your facility meets environmental standards.

For further assistance or to discuss tailored solutions, please contact Baldwin Industrial Systems. You can also explore our Wastewater Treatment Services for additional insights.