High-Viscosity Polymer Preparation Unit – Heavy-Duty System for Thick Polymer Solutions

Description

DAGYEE Polymer Unit

Certain industrial applications require high-viscosity polymer solutions with concentrations significantly higher than standard water treatment applications. Oilfield enhanced oil recovery (EOR), paper coating, textile printing, and specialty chemical manufacturing demand polymer solutions with concentrations of 3-5% or higher, using high-molecular-weight polymers such as polyacrylamide (PAM), carboxymethyl cellulose (CMC), xanthan gum, and guar gum.

Conventional polymer preparation units are not designed for these demanding conditions. High-viscosity solutions create increased torque loads, require longer mixing times, and demand specialized feeding and pumping systems.

The DAGYEE High-Viscosity Polymer Preparation Unit is specifically engineered for these challenging applications. Featuring heavy-duty construction, oversized motors, high-torque mixers, and specialized feed systems, this unit delivers consistent, lump-free high-viscosity polymer solutions for the most demanding industrial processes.

Product Overview

The High-Viscosity Polymer Preparation Unit (Model PPU-HV-3000) is a specialized system designed for preparing concentrated polymer solutions with viscosities up to 50,000 cP. The unit operates on a three-chamber system (dissolution + maturation + storage) with oversized components to handle the increased loads of high-viscosity operation.

The system features heavy-duty mixers with high-torque motors, specially designed impellers for viscous fluids, and oversized screw feeders capable of handling high-density powders. All wetted parts are constructed from SS316L or abrasion-resistant materials to ensure long service life in demanding environments.

Key Features:

• Capacity: 500 ~ 5,000 L/h (concentrated solution)

• Viscosity Range: Up to 50,000 cP

• Concentration Range: Up to 3-5% (depending on polymer type)

• High-molecular-weight polymers: PAM, CMC, Xanthan Gum, Guar Gum

• Three-chamber system with heavy-duty mixers

• High-torque variable frequency drive motors

• SS316L construction with abrasion-resistant components

• Specialized feeding system for high-density powders

• Siemens PLC + HMI with torque monitoring

The system operates in two main modes: solution preparation and dosing.

1. Solution Preparation

• For dry reagents (lime, powdered carbon, dry coagulants): reagent is fed from hopper via feeder into mixing device, mixed with water to specified concentration. Finished solution is stored in tank.

• For liquid reagents (chlorine, hypochlorite, liquid coagulants): reagent is delivered from storage tank via dosing pump to dissolution tank (if dilution needed) or directly to dosing pump.

2. Dosing
Finished solution is delivered to the process via dosing pumps with adjustable capacity. Dosing is controlled by signals from process controllers (flow, pH, turbidity, ORP) or according to process specification.

Control Modes:

• Automatic — from process controllers

• Semi-automatic — from control panel

• Manual — local pump and valve control

Key features

• Efficient batch preparation: Designed for maximum efficiency with a batch preparation philosophy, ensuring smooth operations.
• Premium stainless steel construction: High-quality stainless steel materials and components guarantee product excellence and long-term reliability.
• User-friendly PLC Panel: Adjust dry polymer feed rate and dilution water flow rate easily through the user-friendly PLC panel.
• Fully automatic operation: DAGYEE Polymer Prep Units are fully automatic, streamlining operations and reducing maintenance costs.
• Optimized polymer consumption: Units optimize polymer consumption, minimizing waste and maximizing performance.

Polymer Preparation unit Model

Polymer preparation Unit Advantage

• Avoid the need for manual operations – Prevent dosing errors, operation stops.
• Standardization of the obtained polymer – Concentration, maturation time, homogeneity.
• High efficiency mixers – Provide a low flow mixing for a homogeneous flocculant polymerisation without mechanical deterioration.
• Optimised process – Visual access to the process and alarms, fieldbus distributed control (optional) provides informative and easy to access equipment and status application updates, controlled costs. Intelligent system that feeds the process when needed, regulated by an ultrasonic level switch.
• Reliability and Robustness in Any Environment.

Material: Stainless Steel, PP, or FRP

Material	Pros	Cons	Best For
SS304	Stands up to corrosion, strong, lasts a long time	Higher cost	Most projects
SS316	Even better corrosion resistance	Costs more than 304	High salt, very corrosive conditions
PP (Polypropylene)	Cheap, handles chemicals well	Low strength, ages faster	Small, low requirement projects
FRP (Fiberglass)	Handles chemicals, lightweight	Expensive, hard to fix	Chemical plants, special conditions

Bottom line: If your budget allows, pick stainless steel. Pay once and use it for 15 years. You will not have to think about it again.

I have seen too many plants buy a PP tank to save money. Three years later, the tank is cracked and leaking. The fittings are brittle. They end up buying a stainless steel unit anyway. The cheap one ends up being the expensive one.

Feeding Screw: What Matters

The feeding screw is one of the parts that gives people the most trouble. Pay attention to three things:

• Material: Must be stainless steel. Carbon steel will rust within months. Rust gets into your polymer solution and ends up in your sludge cake.
• Anti caking: The screw end should have heating to stop powder from caking up from moisture. Without heating, the powder can harden right at the discharge point. The screw turns but nothing comes out.

• VFD control: Adjustable screw speed lets you match changing polymer demand. When your sludge flow drops, the screw slows down. When it picks up, the screw speeds up. You do not waste polymer.

3.4 Control System: The Brain of the Unit

A good unit should have PLC control with a touchscreen. Look for these features:

• Automatic water fill, powder feed, and mixing
• Concentration control (feed rate and water flow work together)
• Low level alarm (warns you before the storage tank runs dry)
• Fault alarms (feeder jam, water supply failure, and so on)

• Remote communication ready (so you can hook it up to your SCADA system)

Without good controls, you are back to babysitting the unit. An operator has to check it every hour. They have to adjust the feed rate when the sludge changes. With a good control system, the unit runs itself. The operator checks it once a shift and moves on to other work.

Polymer preparation Unit Feature

• Fully automated operation — saves labor costs and prevents dosing errors, operation stops
• Standardization of the resulting polymer — concentration, maturation time, homogeneity
• High efficiency mixer — Provides low flow mixing for homogeneous flocculant polymerization without mechanical degradation
• Optimized process — visual access to process and alarms, can feed the process when needed, regulated by ultrasonic level switches
• Compact design — easy to transport and relocate
• Safe and reliable — operation with airlift and overflow protection

Polymer preparation Unit Remark

♦ Model selection: Process capacity or flow volume is necessary
♦ Raw material: SS304 or SS316.
♦ Manufacturer: We have our own workshop so that best quality and loweat price can be provided for you.
♦ Customization: Custom-made is available.

Standard Inclusions:

• Two-chamber tank (polypropylene)

• Powder feeder with hopper and screw

• 2 mixers (dissolution + maturation)

• Water supply system with filter and valves

• Control unit (timer or PLC)

• Wheeled skid

• UPVC piping

• Operation and maintenance manual

What Makes DAGYEE Units Different

• Triple tank continuous design: Prep, aging, and storage tanks are separate. That gives you 45 to 60 minutes of aging time. No shortcuts.
• Material options: SS304, SS316, PP, or FRP depending on your conditions. We help you pick the right one for your wastewater.
• Anti caking feeding: Heated screw end, tapered hopper with smooth walls. No bridging, no caking, no surprises.
• Fully automatic PLC control: Touchscreen operation, remote communication ready. Your operator does not have to stand there and watch it.
• Precise concentration: Feed rate and water flow are tied together. Concentration stays within plus or minus 5 percent.
• Works with dry powder and emulsion: One unit handles both. Just change the settings.
• Easy maintenance: Everything you need to check or clean is right where you can reach it. No special tools required.

Summary

The DAGYEE Automatic Polymer Preparation Unit provides a cost-effective, reliable solution for your polymer mixing and dosing needs. Whether you require a compact unit for a small WWTP or a high-capacity system for large industrial applications, our team of experts can help you select the optimal solution.

Contact our team today for a detailed quotation and technical consultation tailored to your specific requirements.

Do not make the mistake of buying cheap. A low quality unit will cost you more in wasted polymer, downtime, and operator hours than you saved on the purchase price.

Still not sure what size or configuration you need?

Get in Touch:
 Free Application Assessment – We'll look at your wastewater and suggest what fits
 Customized Design – Built around your flow, space, and treatment goals
 Fast Quotation – Detailed estimate within 48 hours
 Project References – We'll share examples of similar installations
 Factory Tour – Come see our facility

DAGYEE offers free sizing help. Tell us your plant flow, sludge type, and dewatering equipment. We will tell you what fits.

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