Case Studies

Challenge

A 200,000 m³/day municipal wastewater treatment plant was struggling with sludge dewatering. Their existing polymer achieved only 82% moisture content on belt presses, resulting in high disposal costs of $45/ton. The plant needed to reduce sludge volume by 40% to avoid building a new sludge storage facility.

Solution

We supplied our CPAM-H60 (cationic PAM, 60% charge density, 12M molecular weight). After jar testing 8 different grades, CPAM-H60 showed the best floc formation and water release. Dosage was optimized at 3.2 kg/ton dry solids — 20% less than their previous polymer.

Results

• Moisture content reduced from 82% to 74%
• Sludge volume decreased by 38%
• Polymer consumption reduced by 20%
• Annual savings: $180,000 in disposal costs
• Payback period: 2 months

Challenge

A gold CIL circuit processing 5,000 tons/day was experiencing poor thickener underflow density (35% solids). The existing flocculant degraded rapidly in the alkaline, cyanide-containing environment (pH 10.5). Water recovery was only 65%, requiring excessive fresh water makeup.

Solution

We recommended our NPAM-M12 (nonionic PAM, 12M molecular weight) which is stable in high-pH cyanide solutions. The nonionic charge avoids interference with gold-cyanide complexes. Dosage: 25 g/ton ore at 0.1% solution concentration.

Results

• Thickener underflow density increased from 35% to 52% solids
• Water recovery improved from 65% to 88%
• Fresh water consumption reduced by 60%
• Thickener overflow clarity: <50 NTU (from 200+ NTU)
• Annual water savings: 1.2 million m³

Challenge

A mature oil field with 75% water cut needed to improve sweep efficiency. Previous polymer flooding trials failed due to high salinity (TDS 85,000 mg/L) and temperature (85°C) causing rapid viscosity loss. The operator needed a polymer that maintained >10 cP viscosity at reservoir conditions.

Solution

We developed a custom PHPA grade (25M molecular weight, 28% hydrolysis) with salt-tolerant monomer modification. Lab testing confirmed 12.5 cP viscosity retention at 85°C and 85,000 mg/L TDS after 6 months aging. Injection concentration: 1,500 ppm.

Results

• Incremental oil recovery: 8.5% OOIP over 18 months
• Water cut reduced from 75% to 58%
• Viscosity retention: 12.5 cP at reservoir conditions
• Injectivity maintained at 95% of baseline
• Project NPV: $12M over 5 years

Challenge

A 500 ton/day corrugated paper mill had two problems: (1) first-pass retention was only 62%, causing excessive fiber loss and white water buildup; (2) effluent TSS exceeded discharge limits (150 mg/L vs 50 mg/L limit). They faced regulatory shutdown if not resolved within 60 days.

Solution

Dual PAM system: CPAM-M30 (30% charge density) as retention aid at the headbox (0.5 kg/ton paper), plus APAM-H15 (15M MW anionic) for effluent clarification at 2 mg/L after PAC coagulation. We provided on-site technical support for 2 weeks during commissioning.

Results

• First-pass retention improved from 62% to 89%
• Effluent TSS reduced from 150 mg/L to 28 mg/L
• Fiber loss reduced by 45% — saving $95,000/year in raw materials
• White water clarity improved, enabling 80% water reuse
• Regulatory compliance achieved in 3 weeks

Challenge

A coal preparation plant processing 800 ton/hour was losing 3% of fine coal to tailings due to poor thickener performance. The existing flocculant required high dosage (80 g/ton) and produced weak flocs that broke up in the recirculation system.

Solution

We supplied APAM-M10 (anionic, 10M molecular weight, medium charge density) optimized for coal fines. The medium MW produces strong, shear-resistant flocs. Dosage reduced to 35 g/ton with better settling rates.

Results

• Fine coal recovery improved by 2.1% (worth $1.8M/year at current prices)
• Flocculant dosage reduced from 80 to 35 g/ton (56% reduction)
• Thickener overflow clarity: <100 NTU
• Water recovery: 92% (closed loop achieved)
• Annual chemical cost savings: $120,000