Process water recycling systems

Chemical waste water

treatment systems

www.rosler.com 1
 Process water recycling systems I Chemical waste water treatment systems

Mass Finishing Shot Blasting AM Solutions

High-performance equipment Customer-oriented equipment Comprehensive solutions for

and innovative technologies – technology and intelligent additive manufacturing,
productive and cost-effective process solutions – long-lasting especially 3D post processing
and energy-efficient equipment

80 More than 80 years of experience

15 locations –
over 150 distributors –
over 1,500 employees across the globe

Worldwide Customer Experience Center

More than 15,000

different types of media and compounds

Our technical service –

round-the-clock support
24 h

Transfer of professional knowledge

by certified trainers

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Contents

Process water recycling 4

Environmentally friendly consumables, Rösler Turbo-Floc® system 5

Process water recycling systems 6-9

Accessories for recycling systems 10 -11

Wastewater cleaning systems 12 -13

Media and Compounds 14

Customer Experience Center 15

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 Process water recycling systems I Chemical waste water treatment systems

PROCESS WATER RECYCLING

For ecological and economic reasons recycling of the process for modern process water cleaning systems, which ensures pro-
water in connection with industrial manufacturing operations cess stability. Powerful systems, combined with sophisticated
is highly desirable. The principle of the 2-phase separation of process technology, allow for a wide range of applications, re-
solids/liquids with centrifugal force has become the standard aching well beyond just mass finishing processes.

How it works
The dirty water, contaminated with solid particles, is
transferred directly from the mass finishing machine to
the centrifuge or through a pump station (lifting station).
A pre-screen collects larger contaminants at the inlet of
the collecting tank. The premature settlement of the so-
lid particles to the bottom of the collecting tank is pre-
vented with a built-in electric stirrer. The dirty water is
continuously supplied to the rotating aluminum drum of
the centrifuge with a compressed air diaphragm pump.
The high centrifugal force created by a rotational drum
speed of up to 3,000 RPM ensures that even very small
and lightweight solid particles are deposited as solid
sludge on the drum wall.

The cleaned liquid is picked up by a collecting tube and

returned to the mass finishing machine (or other users).
After a preset time the sludge can be removed from the
drum by simply lifting the specially designed polyuretha-
ne sludge basked out of the drum. In automatic centri-
fuges the sludge is mechanically removed with a peeling
knife scraping it from the drum wall. Depending on the
required water volume multiple mass finishing machines
can be connected to one process water recycling system.
Fully automatic system Z 1000 ASS II-Turbo

Applications
Mass finishing – Rösler centrifuges are the standard for the successful separation of solids from industrial liquids.

Other applications
 Machining/grinding centers: Maintenance of coolants/lubricants and grinding oil
 Technical ceramics: Maintenance of the process water for saw cutting, grinding and polishing
 Glass industry: Technical applications, optical glass, etc.
 Solar/wafer production: Saw cutting, grinding
 Paint booths: Maintenance of the overspray collecting water curtain
 ECM processes: Maintenance of the electrolytes
 High pressure water jet blasting: Cleaning and removal of coatings in the aerospace industry
 Reclamation: of gold, silver, copper, etc. from process liquids
 General sludge dewatering: Reduction of the residual water content prior to sanitary landfill disposal

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Environmentally friendly consumables are
the best path to optimum process water
treatment

Rösler is the only supplier who offers a comprehensive

equipment range but also produces ceramic and plastic media,
mass finishing compounds, waste water and process water
cleaners. Thousands of recycling and wastewater cleaning
systems are successfully running at our customers all over the
world. Why don’t you take advantage of our know how?

Rösler Turbo-Floc® system

The proprietary Turbo-Floc® system from Rösler augments the

mechanical cleaning performance of centrifuges with special
process water cleaners, thus producing process water qualities
that meet the most stringent requirements. The process water
cleaners combine tiny solid particles into larger flocs, which
can then be removed from the process water very effectively.
The compounds required for the actual mass finishing process
are not touched and are returned to the processing machine.
Special cleaning agents even remove oil and emulsified
substances from the process water.
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Depending on the required water volume and the specific 2
3
application we can offer automatic peeling centrifuges, type Z
1000 ASS II-Turbo, and semi-automatic basket centrifuges, type
Z 800 HA Turbo-Floc® or Z 800 K HA Turbo-Floc®.
1 Process water prior to treatment

The result 2 Process water after addition of process water cleaner -

(The solid particles now combined into larger “flocs” are easier
to separate and precipitate.)
4 Very clean work pieces
4 High process stability 3 Process water after passing through a centrifuge
(The solid particles were deposited as sludge on the wall of
4 Long uptimes of the process water the rotating drum.)

Process water cleaner (recycling systems)

Liquid cleaners for recycling
Type AR 8401 AR 8403 AR 8404 AR 8405 AR 8407
Function Cationic polymers for effective process water recycling
Usage either as delivered or after dilution with water at the ratio 1:1 up to 1:10 about 0.1 – 1.0 kg/m3

Pulverprodukte für die Kreislaufpflege

Type AR 7120 AR 7134
Function Process water cleaners in powder shape allow the effective removal of oil and grease from recycling systems; minimal salt buildup in
the process water
Usage Depending on the contamination 0.1 kg/m3 -1.0 kg/m3

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 Process water recycling systems I Chemical waste water treatment systems

PROCESS WATER RECYCLING SYSTEMS

Centrifuges Z 800 HA Turbo-Floc® + Z 800 K HA Turbo-Floc®

Manual sludge removal
The semi-automatic basket centrifuges stand out with their clean water tanks are all integrated into one unit. Of course,
excellent separation performance and their compact design the heart of the system is the centrifuge designed and built by
allowing them to be placed in direct vicinity of the mass finish- Rösler.
ing equipment. The centrifuge itself, controls, dirty water and

Impressive engineering
4 Precision balanced drum made from aluminum;
alternatively made from stainless steel for corrosive liquids

4 Easy to maintain design of the filling system and the

collecting tube

4 Special guiding cone for optimum separation results

4 Automatic discharge of residual liquid from the drum

Z 800 K HA Turbo-Floc® with dirty Z 800 HA Turbo-Floc® with dirty water
4 Special sludge basket for simple removal of the sludge tank
water and clean water tank

4 Controls with modern PLC controller, fully installed and

ready to run

4 Feeding of the dirty process water by adjustable

compressed air diaphragm pump (pulse controlled)

4 Sturdy, reinforced plastic tanks made from high quality

polyethylene

4 Easily changeable pre-screen at the dirty water tank inlet

4 Level indicator by float switch with “full” alarm

4 Angled tank bottom for easy emptying out of the tank

4 Stirrer built into the dirty water tank

4 Separate clean water tank; optional

4 Sturdy, wear resistant diaphragm pump technology

4 Locking of the centrifuge lid electrically controlled

4 Automatic water and compound replenishment dosing

system; optional

4 Turbo-Floc® package for the addition of process water

cleaner; optional

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 Type Z 800 HA Z 800 K HA
Turbo-Floc® Turbo-Floc®

Max. rotational speed (RPM) 2,930 2,930

Max. “g” value 1,750 1,750

Max. sludge volume (l) 11 11

basket capacity (kg) ² 28 28

Max. capacity1 (l/h) 1,200 1,200

Installed power (kW) 5.0 5.0

Average power draw (kW) 2,2 2,2

Dirty water tank (l) 250 340

Clean water tank (l) - 400

Cooling of the process water - optional

Automatic water and compound replenishment dosing

optional optional
system
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With mass finishing process water: Depending on the load with solids and the desired cleaning effect

² Density 2,5 g/cm³

Compact centrifuge RZ 60 M-V-KB

Manual sludge removal
The semi-automatic 2-phase centrifuge is ideal for applications finishing as well as for all kinds of other industrial liquids.
with low solid particle loads. They can be employed for mass

 Compact, movable unit

 Coated steel tank
 Easy to maintain design of the filling system and the
collecting tube
 Special sludge basket for simple removal of the sludge
 Drum made from aluminum
 Combined dirty and clean water tank with feeding pumps
 PLC controls
 Locking of the centrifuge lid electrically controlled
 Plug & Play system

Type RZ 60 M-V-KB

Max. rotational speed (RPM) 4,100

Max. “g” value 1,800

Max. sludge volume (l) 1.8

basket capacity (kg) ² 4.5

Max. capacity 1 (l/h) 400

Installed power (kW) 1.5

Dirty water/clean water tank (l) 25/35

1 With mass finishing process water: Depending on the load with solids and the desired cleaning effect

² Density 2.5 g/cm³

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 Process water recycling systems I Chemical waste water treatment systems

CENTRIFUGE Z 1000 ASS-II-Turbo

Automatic sludge removal
The special feature of the fully automatic recycling centri- wall after the centrifugal cleaning cycle. The sludge simply
fuges is the automatic peeling of the sludge from the drum drops into a sludge wagon below the centrifuge.

A technology that sets new standards

 Fully automatic operation, controlled by PLC pressed air diaphragm pump (pulse controlled)
 Turbo-Floc® package for the addition of process water  Easy to maintain design of the filling system and the
cleaner collecting tube
 Vibration control of the centrifuge motor with automatic  Electronically controlled linear movement of the peeling
stop function knife, made from wear resistant stainless steel
 Powerful main drive with speed control  Residual sludge pan with self-cleaning function,
 Precision balanced drum made from aluminum; alterna- pneumatically actuated movement
tively made from stainless steel for corrosive liquids  Movable sludge wagon, can be tilted for easy unload
 Feeding of the clean water to the mass finishing (optional with frame for big bag)
machine(s) by compressed air diaphragm pump  Automatic water and compound replenishment dosing
 Feeding of the dirty process water by adjustable com- system / optional

Dirty water

Clean water

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Z 1000 ASS-II-Turbo Z 1000 ASS-II-Turbo Tandem

Type Z 1000 ASS-II-Turbo

Max. rotational speed (RPM) 2,650

Max. “g” value 1,716

Drum capacity (kg) ² 55

Max. capacity 1 (l/h) 2,500

Installed power (kW) 11

Average power draw (kW) 2.2

Dirty water tank (l) optional 3 700/1,000/2,000

Clean water tank (l) optional 3 700/1,000/2,000

Cooling of the process water optional

Automatic water and compound replenishment dosing

optional
system

1 With mass finishing process water: Depending on the load with solids and the desired cleaning effect

2 Density 2.5 g/cm³

3 Higher volumes of liquids upon request

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 Process water recycling systems I Chemical waste water treatment systems

ACCESSORIES FOR RECYCLING SYSTEMS

1. Constant temperature of the process water

A constant process water temperature is desirable for equip-
ment and process reasons. With some mass finishing machines,
especially with centrifugal disk finishing machines, the friction
energy in the work bowl is transformed into heat, which has to
be dissipated by the process water. High process water tempe-
ratures can cause deteriorating finishing results and can even
cause damage to the processing equipment. Cooling systems,
precisely calibrated to the equipment performance, prevent a
dangerous temperature rise in the process water, ensuring a
stable process.

2. Recycling tanks
The capacity of the recycling tanks is individually adapted to the
required process water volume.

 Combination tanks:
A single tank assembly with two chambers for dirty water
and clean water with a volume of 2 x 700 liters

 Individual tanks:
Combination tank
Separate dirty water and clean water tanks with volumes
of either 2 x 1,000 liters or 2 x 2,000.

 Technical details, combination and individual tanks:

- Sturdy, reinforced plastic tanks made from high quality
polyethylene
- Easily changeable pre-screen at the dirty water tank
inlet
- Level indicator by float switch with “full” alarm
- Angled tank bottom for easy emptying of the tank
- Stirrer built into the dirty water tank; also available for
the clean water tank (optional)
Individual tank
- Sturdy, wear resistant diaphragm pump technology
- Wide overflow channel for the internal cleaning loop

 Pump (lifting) station:

- For supply of the dirty water from the mass finishing
machine to the centrifuge
- Sturdy tank with angled bottom (3 sides)
- Compressed air diaphragm pump controlled by the
water level
- Screen for catching coarse solid particles
- Level indicator by float switch with “full” alarm
Pump (lifting) station

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3. Rösler recirculation tank, type R... AB
For many mass finishing applications with low process water vo- Filling of the recirculation tank with water takes place with the
lumes a Rösler high performance centrifuge might not be the simultaneous injection of the required compound.
most economical choice. In these cases a recirculation tank can
be a cost efficient alternative.

The dirty process water from the mass finishing machine is fed Technical details:
into the recirculation tank equipped with multiple cascades re-  Sturdy, re-enforced plastic tanks made from high quality
sulting in the precipitation/separation of metal and media fines. polyethylene
The clean water passing through the last cascade is returned to  Removable partitions facilitate the cleaning of the tank
the mass finishing machine with a pulse controlled compressed  Adjustable compressed air diaphragm pump
air diaphragm pump. (pulse controlled)

Recirculation tank, model R 350 AB

Type R 150 AB R 350 AB R 750 AB R 1100 AB

Tank volume (l) 150 350 750 1,100

Suitable for waste water volumes (l/h) ca. 30 ca. 70 ca. 150 ca. 220

Tank dimensions lxbxh (mm) 700 x 400 x 580 1,150 x 760 x 520 1,990 x 970 x 520 1,990 x 1,310 x 520

Inlet height dirty water (mm) 450 440 440 440

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 Process water recycling systems I Chemical waste water treatment systems

WASTEWATER CLEANING SYSTEM AWA...

Chemical wastewater treatment systems based on the principle not be utilized: Processing of multiple metals in a mass finishing
“precipitation/flocculation” are rounding off our product portfo- system, particularly high quality requirements for the surface
lio. They are employed whenever process water recycling can- finish or mass finishing processes with acidic compounds.

How it works
The dirty water is cleaned in batches by precipitation and

flocculation:

Stage A: Collection of a batch of dirty water

Stage B: Treatment by precipitation and flocculation

Stage C: Sedimentation of the flocs

Stage D: Filtration/sludge dewatering, possibly recycling A B C D

Treatment process
For the removal of the contaminations from the dirty requirements of our customers: Flocculants, Flocculation
water to below the legally permissible limits we offer support compounds, Neutralizing agents, Combination
cleaning agents that are individually adapted to the products. These products come in liquid or powder form.

Semi-automatic systems AWA...C-SF and AWA...C-FP

The product type C-SF und C-FP is ideal for effective precipitation/ Buffering and treatment takes place in a single, low profile tank
flocculation of small dirty water volumes, which do not have to be that allows the direct gravity feeding of the liquid from the mass
automated but require a high degree of process safety. finishing machine into the tank. Dewatering of the sludge can be
done with filter bag or filter press.

AWA 500 C-SF

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Automatic systems AWA...K-FP and AWA...K
For continuous dirty water volumes over 500 liters/h we recom- tralization, the dosing of the flocculant, the sludge dewatering and
mend the utilization of automatic treatment systems. The PLC the final control filtration of the clean water. Dewatering of the
controller monitors and controls the supply of dirty water, its neu- sludge can take place with chamber filter press or centrifuge.

1. Collection 3. Sludge separation

or

2. Treatment /Sludge buffer 4. Post filtration

Dirty water Clean water

Type Performance Thin sludge Filter size/ Quantity of filter plates

AWA 500 C-SF 500 l/batch Dual bag filter 2 x 120 l

Semi-automatic

AWA 1000 C-SF 1,000 l/batch Dual bag filter 2 x 120 l

AWA 1000 C-FP 1,000 l/batch Filter press 4/15/30 St. 1

AWA 2000 C-FP 2,000 l/batch Filter press 4/15/30 St. 1

AWA 1000 K-FP 1,000 l/h Filter press 4/15/30 St. 1

AWA 2000 K-FP 2,000 l/h Filter press 4/15/30 St. 1

AWA 4000 K-FP 4,000 l/h Filter press 6/15/25 St. 1

Fully automatic

AWA 1000 K-RZ 1,000 l/h Centrifuge RZ 150 A –

AWA 2000 K-RZ 2,000 l/h Centrifuge RZ 150 A –

AWA 4000 K-RZ 4,000 l/h Centrifuge RZ 150 A –

1 Volume of filter plates 3.2 l or 10 l

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 Media and Compounds

MEDIA AND COMPOUNDS

In addition to our machine program, we also offer the most experience in the field of surface finishing we can provide our
comprehensive range of media and compounds in the world. All customers with tailormade processes for new applications and
our consumable products have been developed and produced solutions for product improvement and cost reductions.
in-house with „Made in Germany“ quality. With over 80 years of

Stable and repeatable finishing processes are our specialty.

The world’s largest range of media and compounds

With around 15,000 products our portfolio of consumables
is the largest in the world. It includes ceramic and plastic
grinding and polishing media, compounds and process
water cleaners. All our consumables can be individually
adapted to the needs and requests of our customers.

Our ceramic media production

Quality Excellent product availability

Our production complies with the most stringent Our central warehouse in Germany stocks more than
environmental standards and is subject to strict quality 8,000 tons of media and compounds. In addition, our
controls per DIN EN ISO 9001 and 50001. global network of branches and many of our channel
partners maintain warehouses with consumables close
to our customers.

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Customer Experience Center

CUSTOMER EXPERIENCE CENTER

MASS FINISHING

A major strength of the Rösler business approach is that we branches have their own Customer Experience Centers (CEC),
look at all aspects of a finishing task. The equipment and the equipped with the latest finishing equipment.
processes are individually tailored to the respective finishing To investigate the various finishing possibilities, in our CEC we
requirements, but also to their optimal integration into the are conducting processing trials with the work pieces of our
customer’s manufacturing operation. Most of the Rösler sales respective customers.

Process development and process optimization

Our all-around approach guarantees perfect finishing State-of-the-art physical and chemical measuring equip-
solutions. This includes processing trials, process develop- ment represents a vital tool for process development and
ment, selection of the right machinery and a professional optimization.
after sales service. The entire focus of our specialists in the engineering and
In our CEC, equipped with ultra-modern equipment, we can R & D departments is on developing tailormade finishing
run practically any mass finishing process. solutions.

Product development and optimization

The enormous depth of the Rösler product range, CEC All our products, be it consumables, finishing equipment,
around the world and our well-equipped laboratory at vibratory motors, process water cleaning centrifuges, as
the Untermerzbach location in Germany are an excellent well as work piece handling systems and post processing
basis for the development of innovative and cost-efficient equipment like dryers, are developed and manufactured
products in the field of mass finishing. in-house. Such a high manufacturing depth is unparalleled
in our industry.

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 Process water recycling systems I Chemical waste water treatment systems

Mass Finishing
Shot Blasting
AM Solutions
www.rosler.com

Germany Spain Great Britain

Rösler Oberflächentechnik GmbH Rösler International GmbH & Co. KG Rösler UK Ltd.
Werk Memmelsdorf Sucursal en España Unity Grove, School Lane
Vorstadt 1 Polg. Ind. Cova Solera C/Roma, 7 Knowsley Business Park
D-96190 Untermerzbach E-08191 Rubí (Barcelona) GB-Prescot, Merseyside L34 9GT
Tel.: +49 9533 / 924-0 Tel.: +34 93 / 5885585 Tel.: +44 151 / 4820444
Fax: +49 9533 / 924-300 Fax: +34 93 / 5883209 Fax: +44 151 / 4824400
[email protected] [email protected] [email protected]
Rösler Oberflächentechnik GmbH Netherlands Brazil
Werk Hausen Rösler Benelux B.V. Rösler Otec do Brasil LTDA
Hausen 1 Reggestraat 18 Av. Antonio Angelo Amadio, 1421
D-96231 Bad Staffelstein NL-5347 JG Oss Centro Empresarial Castelo Branco
Tel.: +49 9533 / 924-0 Postbus 829 18550-000 Boituva
Fax: +49 9533 / 924-300 NL-5340 AV Oss São Paulo - Brasil
[email protected] Tel.: +31 412 / 646600 Tel.: +55 15 / 3264-1117
Fax: +31 412 / 646046 Tel.: +55 15 / 3264-1112
USA [email protected] [email protected]
Rösler Metal Finishing USA, L.L.C.
1551 Denso Road Belgium China
USA-Battle Creek Rösler Benelux B.V. Rosler SURFACE-TECH (BEIJING) CO., LTD.
MI 49037 Avenue de Ramelot 6 Beijing Office
Tel.: +1 269 / 4413000 Zoning Industriel Fu Hua Mansion, Office A-11-K
Fax: +1 269 / 4413001 B-1480 Tubize (Saintes) No. 8, Chao Yang Men North Avenue
[email protected] Tel.: +32 2 / 3610200 Beijing 100027, P.R China
Fax: +32 2 / 3612831 Tel.: +86 10 / 6554 73 86
France [email protected] Fax: +86 10 / 6554 73 87
Rösler France [email protected]
Z.I. de la Fontaine d’Azon Austria
CS 50513 – St. Clément Rösler Oberflächentechnik GmbH
F-89105 Sens Cedex and over 150 additional distributors
Hetmanekgasse 15 around the world
Tel.: +33 3 / 86647979 A-1230 Wien
Fax: +33 3 / 86655194 Tel.: +43 1 / 6985180-0
[email protected] Fax: +43 1 / 6985182
[email protected]
Italy
Rösler Italiana S.r.l. Romania
Via Elio Vittorini 10/12 Rösler Romania SRL
I-20863 Concorezzo (MB) Str. Avram Iancu 39-43
Tel.: +39 039 / 611521 RO-075100 Otopeni/ILFOV
Fax: +39 039 / 6115232 Tel.: +40 21 / 352 4416
[email protected] Fax: +40 21 / 352 4935
[email protected]
Switzerland
Rösler Schweiz AG Russia
Staffelbachstraße 189 Rösler Russland
Postfach 81 Borovaya Str. 7, bldg. 4, office 107
CH-5054 Kirchleerau 111020 Moscow
Tel.: +41 62 / 7385500 Tel. / Fax: +7 495 / 247 55 80
Fax: +41 62 / 7385580 [email protected]
[email protected] Find your contact

Pub.-Nr.: EN.154.20 – Revision: 04/2023 – We reserve the right for technical changes.

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