FRC Systems provides wastewater treatment solutions across multiple industries, including:

• Oil & Gas – Handling produced water, frac flowback, and oily wastewater.

• Poultry Processing – Managing high-fat and protein-laden wastewater.

• Meat & Seafood Processing – Treating organic-rich effluents with high BOD and TSS.

• Municipal Water Treatment – Supporting wastewater clarification and sludge removal.

• General Manufacturing – Custom solutions for diverse industrial wastewater challenges.

Our solutions include:

• Dissolved Air Flotation (DAF) Systems – For efficient solids and oil removal.

• Chemical Treatment Systems – Coagulation, flocculation, and pH adjustment.

• Sludge Dewatering Solutions – Reducing waste volume and disposal costs.

• Filtration & Screening – For pre-treatment and solid separation.

Dissolved Air Flotation (DAF) is a wastewater treatment process that is highly effective in the removal of suspended solids (TSS), fats/oils & grease (FOG), biological oxygen demand (BOD) and other contaminants from water. It is particularly effective in situations where conventional sedimentation methods are less efficient. Here’s a breakdown of what DAF is and its primary uses:

1. Air Dissolution: In DAF, air is dissolved into water under pressure in a specialized tank, saturation tube or pump.

2. Pressure Release: When this pressurized water is injected into the flotation vessel, the pressure drops which releases the dissolved air as tiny microbubbles.

3. Flotation Mechanism: These microbubbles attach to suspended particles and contaminants, causing them to rise to the surface.

4. Skimming: The accumulated material (sludge or float) at the surface is skimmed off, while the clarified water is collected from below.

Dissolved Air Flotation, or DAF, is used in a variety of applications, including:

1. Industrial Water Treatment: In industries such as food and beverage, oil and gas, and pulp and paper, to treat process water and wastewater.

2. Municipal Wastewater Treatment: To remove solids, algae, phosphorus and other contaminants before further treatment or discharge.

3. Sludge Thickening: DAF is used thicken biological sludge, reducing the overall sludge volume reducing transportation, handling and disposal costs.

4. Drinking Water Purification: To remove algae, particulates, and other contaminants from source water.

5. Pre-treatment: As a pre-treatment step for more advanced treatment processes, enhancing overall efficiency.

6. Stormwater Management: To treat runoff and reduce pollutants before discharge.

With the largest Dissolved Air Flotation (DAF) rental fleet in the US and equipment ranging from 10–3,000 gpm, we can tailor a solution to your needs. All FRC rental equipment is available for short-term and long-term rental agreements as well as pilot testing and long-term lease agreements.

FRC rental systems and stand-alone equipment are installed in a “plug-and-play” configuration for ease of installation and start-up. Once in place on-site, the unit can be operational within a matter of hours.

A Flocculator from FRC Systems is designed to provide the necessary mixing action and retention time to chemically treat wastewater. Here’s how it works:

1. Coagulation: Coagulants are added to the wastewater to break emulsions and form micro-flocs.

2. Flocculation: Flocculants are then added to agglomerate these micro-flocs into larger, more robust macro-flocs.

3. Mixing: Mixing: The flocculator ensures proper mixing energy required by the chemicals and maintains the integrity of the flocs, which is crucial for effective separation in the subsequent Dissolved Air Flotation (DAF) process.

FRC Systems offers both Plug-Flow Reactors (PFR) and Continuous-Stirred Tank Reactors (CSTR) as flocculators, each designed to optimize the chemical treatment process.

The main differences between PWL, PCL, and PCCS Dissolved Air Flotation (DAF) systems from FRC Systems lie in their design and application:

1. PWL (Open-Tank DAF System):

   1. Design: Open tank, low-built separators with side walls typically 8 to 10.5 feet tall.

   2. Application: Better suited for high solids loading rates. The skimmer assembly rotates against the hydraulic flow, shortening sludge skimming distance and eliminating solids carry-over.

2. PCL (High-Rate DAF System):

   1. Design: Features corrugated plate packs that increase the effective separation area, allowing for a smaller footprint.

   2. Application: Ideal for high hydraulic loads with lower solids loading rates. The plate packs help maintain laminar flow and increase effective separation area which increases overall system performance.

3. PCCS (High-Rate DAF System):

   1. Design: Similar to PCL, the PCCS features a high-rate design and corrugated plate packs. However, the PCCS is specifically designed to fit within a shipping container, making it easily transportable. Ideal for temporary or mobile wastewater treatment needs, such as remote locations or construction sites.

   2. Application: Efficient for removing Total Suspended Solids (TSS), Fats, Oils, and Grease (FOG), and other pollutants from wastewater.

Each system is tailored to specific wastewater treatment needs, with PWL being more suitable for higher solids content and PCL/PCCS for higher hydraulic loads. If you have a specific application in mind, I can help you determine which system might be the best fit!

In 2018, FRC Systems joined the Chemtech division of Sulzer, where our clients receive our expert team’s dedicated attention backed by Sulzer’s global resources.