MCC Huatian's Independently Researched & Developed 'Aeration Water Treatment Equipment' Solves Worldwide Technical Problem

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Recently, the 'Centrifugal Self-suction Mixing Inverted Umbrella-type Aerator' environmental protection water treatment equipment, independently researched and developed by the MCC Huatian Research Institute of Water Technology, smoothly attained United States patent licensing. This makes it the only type of aeration equipment independently researched and developed by Chinese enterprises in our country to attain an international patent. This patented technology has successfully solved the worldwide technical problem of how to aerate or oxygenate deep sewage, and provides the newest evidence that China's water treatment equipment leads the world.

　　Guided by demonstration effect

At the end of June 2015, three technological products successfully developed by MCC Huatian passed the national-level appraisal presided over by the CMIF: 'Centrifugal Self-suction Mixing Inverted Umbrella-type Aerator', 'Connected Balanced Rotating-Disc High-efficiency Aerator', and 'Small-tooth-difference Decelerating Submersible Water Impeller'. Specialists in the industry agree that the first two technological products reach the international leading level, and the third reaches the international advanced level.

In December 2015, the group of patents with 'Centrifugal Self-suction Mixing Inverted Umbrella-type Aerator' at its core was awarded the Gold Medal for patents in Anhui Province.

As original China Association of the Environmental Protection Machinery Industry Vice Chairman and Secretary-General Guo Baolin commented, 'This is praiseworthy. In its water treatment equipment, MCC Huatian has relied on its own technical force, complete patented technology inventions, product design and manufacture, and engineering application, as well as chiefly editing the industrial and national standards of such products.' As a central enterprise with the nature of a design and research institute, MCC Huatian has always insisted on technological innovation and business promotion through science and technology, followed a constant cycle of scientific research, design, construction, debugging and operation, established projects with scientific research tasks completely sourced from engineering practices, rapidly transformed scientific and technological achievements into productivity to serve production and marketing, and combined excellent water treatment equipment technology with advanced technologies, thereby opening channels for sustainable development.

MCC Huatian already has nearly 20 sewage treatment plants with BOT construction which can serve as the bases for equipment application, comparison and verification, and has accumulated experience through a large quantity of technological achievements transferred into actual productivity, proving to be advantageous for making its projects into demonstration projects and rapidly promoting its achievements.

As MCC Water Treatment Engineering Technology Center Director, MCC Huatian Chief Expert and Research Institute of Water Technology Dean Cheng Hanfei pointed out, 'MCC Huatian is a leading applied-technology engineering company. Its research and development tasks are sourced from actual engineering demands and its achievements are ultimately applied in practical engineering.' With private enterprises as the main body, technical support is mostly brought in for the manufacturing of wastewater treatment process equipment in our country. We lack independently original technologies and our product quality has no high technical content. In order to facilitate the survival of these enterprises, product standards and requirements are enacted at a low level; as a result, key wastewater treatment equipment made in China has no speaking right internationally. To this end, we will select breaches, start from the core equipment and set up our own brands. Besides strengthening the influence of the enterprise, it is necessary to step towards production service-oriented business, carry out such specialized services as craft and equipment diagnosis and maintenance in industries at home and abroad, and comprehensively promote our own core competitiveness.

　　Led by competitive products

The aerator is a core part of any sewage treatment plant and one of the most primary energy consumption devices. The electric energy consumption of a sewage treatment plant's oxygen supply and aeration unit is generally more than half the energy consumption of the whole plant, and this is why the oxygen delivery capacity and energy efficiency of the aerator equipment are always key indicators for judging excellent performance.

The 'Centrifugal Self-suction Mixing Inverted Umbrella-type Aerator' that has attained the US patent this time is a fourth generation product researched and developed by MCC Huatian. It has already been successfully applied in sewage treatment plants in Shouguang and Pingyin of Shandong Province, Xuancheng, Laian and Tianchang of Anhui Province, and Changle of Fujian Province.

Chief Designer Wang Yueping explained that the fourth generation product has an innovation point based around the design of the waterpower components. This design revolutionizes the operating nature conditions of the aerator in the oxidation ditch, completely changing the fluid, flow field and flow state in the oxidation ditch and improving the wastewater on the surface, in the middle and at the bottom of the oxidation ditch. Dissolved oxygen can be made uniform, so there is no longer a 'dead zone' in the oxidation ditch. In this way, the anaerobic organic matter in the sewage can be sufficiently and efficiently oxygenized, and a life source is provided for oxygen-consuming cultures.

MCC Huatian's second, third and fourth generation of Inverted Umbrella-type Aeration Technology are all national invention patents with successful applications. For instance, the second-generation products have been used for 11 years in Pingyin, Shandong, and no machinery malfunction has occurred up to now; the third-generation products have been applied in Shouguang Shandong and have operated steadily for 8 years, with 9 4m aerators saving electricity expenses of more than RMB 2.3 million per year.

Well-known equipment expert in the industry Zhang Xinheng has called the fourth-generation products a 'revolutionary technical breakthrough'. Not only have the waterpower components (aeration impeller) overthrown the traditional structure in the world, but the reduction gears have also surpassed the existing transmission mechanisms in the world.

It is reported that this technology has attained 8 national patents including 4 domestic patents for invention and 1 US patent, and has been included in the 2014 Catalogue of Significant Environmental Protection Technology Equipment with Nationally-Encouraged Development.

　　Globally led by energy efficiency

Zhang Xinheng said that all similar surface aerators in the world have a certain fatal flaw: they can only aerate sewage 2-3m below the water surface and are unable to promote deep sewage and conduct aeration oxygenation in ponds with a depth of 4~6m, resulting in unevenly dissolved oxygen on the surface, in the middle and at the bottom of the oxidation ditch, and resulting in greater operating energy consumption and higher costs.

The new-type aerator researched and developed by MCC Huatian has impellers equipped with broaching blades, a self-suction port, dipping pipe and water-gas-solid mixing area, integrating multiple functions including rectification, improvement, suction, mixture, spraying and secondary gas-holding mixture, thereby greatly enhancing its aeration oxygenation capacity.

The reduction gear is also designed with the small-tooth-difference planetary gear transmission rather than the parallel axis bevel wheel transmission used by traditional aerators, and the reduction gear and aerator impeller combine the transit connection by means of the transmission shaft, involutory limit structure, self-locking nuts and other technologies, providing more reasonable axial and radial forces and more convenient maintenance.

The test results of the 'Centrifugal Self-suction Mixing Inverted Umbrella-type Aerator' independently researched and developed by MCC Huatian show a theoretical dynamic efficiency of 3.83kgO2/kW·h and a total dynamic efficiency of 3.2kgO2/kW·h. Compared with other similar aeration technical products at home and abroad under the same operating conditions, this aerator can completely solve the global technical problem of how to conduct aeration in deep sewage by increasing the oxygenation capacity by over 50%, decreasing the energy consumption for sewage treatment by more than 30%, and increasing the effective depth to 6m.

'As the water absorption depth is increased, the land area of the structures should be decreased accordingly,' Cheng Hanfei said. 'From this perspective, the application of this new technical product serves multiple purposes. Environmental protection and energy consumption go hand in hand. Combining the two is an extremely environmentally-friendly practice which is able to generate direct economic benefits for society and enterprises, as well as raising core market competitiveness. For these reasons, environmental protection equipment should also be energy saving. The 'Centrifugal Self-suction Mixing Inverted Umbrella-type Aerator' has accomplished this, and that's why it leads the field.'

According to incomplete statistics, the vertical spindle rotating aerator applied in sewage plants nationwide currently accounts for about 20% of all sewage plant projects. With its low operating performance and oxygenation efficiency, the vertical spindle rotating aerator is being replaced by new aeration modes; however, due to the fatal defect that aeration efficiency decreases year by year, new aeration modes are basically being replaced every 6 years, resulting in high replacement costs and difficult yearly maintenance (in the case of maintenance, the pond is required to be emptied and stopped). According to estimations, aside from those applied in new projects, the transformation of existing vertical spindle rotating aerators nationwide will save about 3.5 billion kW·h for our country yearly, which is equivalent to about 430,000 tons of standard coal.

The MCC Group has proposed the 'Four Beams and Eight Columns' strategic adjustment, requiring science research enterprises to cease blindly pursuing the increase of scale but to return to the main business of scientific research design, create high-grade products, move forward to the leading position, practically undertake the national responsibility of leading Chinese metallurgy to a higher development level, and completely match MCC's technical engineering advantages, construction and operation management advantages and equipment manufacturing and assembly advantages in order to form the new comprehensive competitive advantages of the Group. For this reason, MCC Huatian has also made corresponding adjustments and proposed the 'Five-five' development pattern: to vigorously promote the reasonable matching and rapid development of the five sections of ferrous metallurgy, environmental energy, housing construction & municipal administration, engineering consultation and real estate development, by means of improving the five capabilities of comprehensive innovation capability, specialized design capability, engineering management capability, engineering consultation capability and operation service capability. As Cheng Hanfei said, 'MCC Huatian's decision-making team pays great attention to sewage treatment, requiring the utmost increase of scale, performing as effectively as possible in each link of the complete industrial chain of 'technical research & development - design - core equipment manufacturing - construction - professional operation' for sewage treatment, and finally emerging victorious.'

Metallurgical Corporation of China Ltd. issued this content on 07 April 2016 and is solely responsible for the information contained herein. Distributed by Public, unedited and unaltered, on 12 April 2016 07:03:10 UTC

Original Document: http://www.mccchina.com/mccen/focus/_325415/390965/index.html