Flotation Plants for Industrial Wastewater
Our Products and Solutions
WAWACS FLOT - Flotation Plants
Industrial wastewater is as individual as the operation it comes from. That is why every WAWACS project begins with a thorough analysis of your specific situation: What contaminants are present? What volumes need to be treated? What legal discharge limits must be met?
Based on this analysis, we work with you to determine the most suitable treatment process – whether flotation, sedimentation, neutralization or a combination of several stages. The result is a system precisely tailored to your requirements, designed for long-term reliable operation.
Solutions for Wastewater Treatment
Emulsion Splitting and Flotation Plants
Advantages
High treatment performance
removal of suspended solids, grease and oils
Small footprint
space-saving, modular design
Low maintenance
automated control and easy cleaning
Sustainability
reuse of process water possible
Low consumption
low consumption of chemicals, electricity and compressed air
Functional Description
During the entire process, the pH value of the wastewater is continuously monitored and, if necessary, adjusted.
In the plant, special cracking and flocculating agents are added and mixed evenly. This step leads to the splitting of the emulsions and the binding of the pollutants in so-called flocs. The flocs are then distributed in the water using a mixing process and attached to microscopic little air bubbles.
In the flotation chamber, larger macro-flocs are formed, which are transported to the water surface by fine air bubbles, where they are removed either by raising the water level or with a scraper.
The cleaned water from the flotation plant can either be reused in a recycling module or discharged into the sewer. The resulting sludge is dewatered using a belt filter, a chamber filter press or a decanter and then disposed of.
Use of Flotation Plants
Sample Flow Scheme Wastewater Treatment
Function and Application
Microbubbles remove contaminants
Removal of the flotation sludge in the first flotation stage using a surface scraper.
Technical Data
Type | Capacity |
WAWACS FLOT ECO 3.500 | up to approx. 3,5m³/h |
WAWACS FLOT ECO 5.000 | up to approx. 5m³/h |
WAWACS FLOT ECO 7.500 | up to approx. 7,5m³/h |
WAWACS FLOT ECO 10.000 | up to approx. 10m³/h |
WAWACS FLOT ECO 15.000 | up to approx. 15m³/h |
Larger plants | Larger systems also available on request |
Typical Applications for Flotation Plants
- Washing water with cooling lubricant emulsions from the metal-cutting industry
- Washing water from pipe production
- Waste water from degreasing and cleaning processes in sheet steel processing
- Waste water from car dealerships with parts cleaning systems
- Waste water from floor cleaning machines
- Production wastewater from bakeries and confectioneries
- Paint wastewater from paint production or scenery painting
- Waste water from the production of creams and skin care products in the cosmetics industry
- Kitchen wastewater with lipophilic (fat-soluble)
Scope Flotation Plants
We offer our standard systems in the ECO configuration in the following sizes.
Depending on the application, flotation systems generally consist of the following system components:
- Feed pump
- Flotation tank 1 with scraper
- Flotation tank 2 for post-flotation and integrated buffer tank
- Dosing pumps with pH monitoring (cracking, neutralization, flocculants)
- Polymer mixing station (tank, agitator, concentrate pump, fresh water valve)
- Control cabinet with PLC control and display
- Flotation equipment (flotation pump, valves, pressure gauge, pressure switch)
- Filter tank for sludge dewatering
Accessories and Extensions
Depending on the application and customer requirements, we offer the following extensions:
- Flow measurement (system throughput and chemical consumption) with visualization on the display and monitoring
- Remote module for online monitoring
- Discharge pump to increase system throughput
- Second flotation stage as buffer tank for washing systems
- Control (PLC and display) according to customer requirements
- Optimized sludge discharge for high sludge load
Need help with wastewater treatment? We are the experts!
FAQ Flotation Plants
What is a dissolved air flotation (DAF) system and how does it work?
A dissolved air flotation (DAF) system is a wastewater treatment unit that removes suspended solids, oils, and fats using microbubbles. Water is pressurised with dissolved air, then released. The resulting microbubbles attach to contaminant particles and float them to the surface as a skimmable sludge layer. WAWACS builds DAF systems for typical flow rates of 1-20 m³/h.
Which industries benefit most from DAF systems?
DAF systems are ideal wherever wastewater contains oils, fats, suspended solids, or paint particles: Food & beverage (fats, proteins, starch), metal finishing (coolant emulsions, cutting oils), automotive (paints, oils, wash water), chemical/pharmaceutical, and textile processing.
What is the difference between flotation and sedimentation?
Sedimentation relies on gravity to settle heavy particles as bottom sludge. Flotation actively lifts light particles (oils, fats) to the surface using microbubbles.
What is the typical size of a WAWACS DAF system?
WAWACS engineers each system to the client’s specific requirements. Typical flow rates are 1-20 m³/h. For higher throughputs or complex multi-contaminant streams, we design integrated custom systems.
What discharge limits apply to industrial wastewater in Germany and the EU?
In Germany, discharge limits are regulated by the Abwasserverordnung (AbwV) and vary by industry. Key parameters include COD, TSS, hydrocarbons, heavy metals, and pH. EU-wide, the Industrial Emissions Directive (IED) applies. WAWACS designs every system to meet the client’s applicable limits – with operational safety margins.
Can WAWACS service or upgrade existing DAF systems from other manufacturers?
Yes. WAWACS offers maintenance, inspection, and modernisation of DAF systems from many manufacturers. Services include system audits, spare parts supply, PLC updates, and process optimisation – available worldwide.