Polymer Dosing System

Purpose: The primary purpose of a Polymer Dosing System is to provide a controlled and regulated means of introducing polymer chemicals into a water treatment process. This enhances the efficiency of various processes, leading to improved water quality, reduced sludge volume, and better overall treatment performance.

Overview: A Polymer Dosing System is a specialized system designed for the controlled injection or dosing of polymer chemicals into various industrial processes, particularly in water and wastewater treatment. Polymers are large molecules composed of repeating structural units, and they are often used to enhance the performance of processes like flocculation and sedimentation.

 

Advanced FEA Analysis & Engineering Calculations for Skid-Mounted Chemical Injection Packages

At Verito Engineering Private Limited, we specialize in providing comprehensive engineering analysis and calculations for Skid-Mounted Chemical Injection Packages, ensuring superior performance, reliability, and compliance with global industry standards.

Our expertise covers Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), Structural, Mechanical, Hydraulic, and Thermal Calculations for all critical skid components, including:

Key Engineering Capabilities

Pressure Vessel Calculations API 675-Compliant Dosing Pump Selection & Sizing Agitator & Mixing Calculations (For Chemical Preparation Skids)
  • Pressure Vessel Design & Shell Thickness Calculation as per ASME Sec. VIII Div. 1 & 2.
  • Vessel Internal Component Load Analysis (Baffles, nozzles, internals, etc.).
  • Stress Analysis for Pressure Retaining Components to ensure longevity.
  • Nozzle Reinforcement & Load Analysis to prevent failures under operational loads.
  • Flow Rate & Pressure Drop Calculation for precise chemical metering.
  • Pump Stroke Length, Plunger/Diaphragm Sizing & NPSH Calculation to prevent cavitation.
  • Pulsation Dampener Sizing for flow stability & reduced pressure fluctuations.
  • CFD Analysis for Flow Optimization in complex piping networks.
  • CFD Analysis for Flow & Performance Optimization.
  • Impeller Selection & Torque Calculation for effective chemical mixing.
  • Structural & Fatigue Analysis of Agitator Shaft & Blades for extended service life.
  • Vortex Prevention & Baffle Sizing for improved mixing efficiency.
Automation & Instrumentation for Optimized Operations Piping Stress & Pressure Calculations Structural & Skid Frame Analysis
  • PLC, HMI, SCADA-Based Automation for precise control & reduced human intervention.
  • Smart Flow Meters, Pressure Transmitters & Level Sensors for real-time monitoring.
  • Automatic Dosing Adjustment & Data Logging to optimize chemical consumption & efficiency.
  • Pipe Wall Thickness Calculation as per ASME B31.3.
  • Flange Sizing/rating, Leakage & Weld Joint Strength Assessment for high-pressure applications.
  • Surge & Transient Flow Analysis to prevent pressure spikes.
  • FEA-based validation for skid stability, seismic loads, and lifting conditions.
  • Baseplate & Pump Mounting Deflection Study to prevent misalignment.
Strainer Calculations Safety & PSV Sizing Calculations Injection Quill
  • Strainer Mesh Sizing & Pressure Drop Calculations for filtration efficiency.
  • Pressure Safety Valve (PSV) Sizing per API 520/521.
  • Overpressure & Surge Analysis for emergency scenarios.
  • Injection Velocity & Jet Penetration Analysis for precise chemical dispersion.
  • Wake Frequency Calculation to prevent vibration-induced failures.
Material Selection & Corrosion Analysis Operational Efficiency & Cost Reduction
  • Material Compatibility Assessment (SS316, Duplex, Super Duplex, Alloy 20, Hastelloy).
  • NACE MR0175/ISO 15156 Compliance for sour service applications.
  • Optimized Equipment Layout for Compact Skid Design - reduces footprint & installation cost.
  • Automated Operation to Reduce Manpower Requirements.
  • Remote Monitoring & Troubleshooting for reduced downtime & maintenance costs.

 

Key components and features of a Polymer Dosing System typically include:

Polymer Storage and Mixing Unit: The system includes a storage tank where the polymer solution or powder is stored. Depending on the polymer type and application, the polymer may be in liquid or powder form. There is often a mixing unit to prepare a homogeneous polymer solution.

Dosing Pump: A dosing pump is a critical component that accurately injects or doses the required amount of polymer into the water or process stream. The dosing pump ensures precision and control in the dosage.

Control System:A control unit manages the dosing rate based on various parameters such as water quality, flow rate, or specific process conditions. This control system helps maintain the desired level of polymer in the water treatment process.

Mixing or Flocculation Unit: After the polymer is dosed, a mixing or flocculation unit is often employed to facilitate the formation of flocs. The polymers aid in creating larger and more easily settleable flocs, which improve the efficiency of processes like sedimentation.

Polymer Dosing Systems are commonly used in various water and wastewater treatment applications:

Flocculation: Polymers are often added to enhance the formation of flocs in water treatment, aiding in the removal of suspended solids.

Sludge Dewatering: In wastewater treatment plants, polymers are used to improve the dewatering characteristics of sludge, reducing the volume of sludge produced.

Paper and Pulp Industry: Polymers are employed in the paper and pulp industry to improve drainage and retention in the papermaking process.

Mining and Mineral Processing: Polymers are used for dewatering and solid-liquid separation in mining and mineral processing operations.

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