DAGYEE Skid-Mounted Polymer Activation Unit – Efficient Flocculant Dissolution for Sludge Dewatering and Thickening

Description

Automatic polymer preparation unit – Dry & Liquid Polymer Dosing System for Water Treatment

This is a dedicated polymer activation unit built specifically for sludge dewatering and thickening applications. It takes dry powder or liquid polymer, dissolves it properly, activates it fully, and delivers a consistent solution to your dewatering equipment—centrifuges, belt presses, screw presses, or thickeners.

The unit uses a three-chamber design. The first chamber mixes the polymer with water. The second chamber gives it time to activate. The third chamber stores the ready-to-use solution. The whole process is automated, so your operators don't have to stand over it adjusting feed rates or checking solution quality.

Sludge dewatering is one of the most demanding polymer applications. The polymer needs to be fully activated to work effectively. Under-matured polymer means wetter cake, higher disposal costs, and more polymer consumption. Over-sheared polymer means poor flocculation and dirty centrate or filtrate. This unit is designed to avoid both problems.

Product Overview

The DAGYEE Polymer Preparation Unit is a fully automated system for continuous preparation of polymer solutions from dry powder or liquid polymers. The unit combines precise polymer metering, controlled wetting, gentle mixing, and age-dependent discharge to produce fully activated polymer solutions with consistent concentration and quality.

Key Components:

• Polymer powder hopper with level sensor

• Precision dosing screw feeder driven by VFD motor

• Pre-wetting system to prevent agglomeration

• Three-chamber tank (mixing + maturation + storage)

• High-speed mixer in mixing chamber

• Low-speed mixer in maturation chamber

• Automatic water control with flow meter

• PLC control panel with HMI touch screen

• Complete piping and skid mounting

Core Function:
The system takes raw polymer powder or liquid, meters it accurately, mixes it with water, matures it to full activation, and stores the ready-to-use solution for dosing to the application point—all automatically and continuously. The PLC controls the entire sequence, from water filling to polymer feeding to solution transfer between chambers.

How the Activation Process Works

Step 1: Polymer Feeding
Dry powder is stored in a hopper with a tapered bottom. The taper stops the powder from bridging—a common problem that causes inconsistent feed rates. A variable speed screw feeder pulls powder from the hopper and delivers it to the wetting zone. The screw speed is controlled by a VFD, so you can adjust the feed rate precisely for different polymers and concentrations.

The feeder outlet has a heating element. This is important for PAM powders, which absorb moisture from the air and can clog the screw. The heater keeps the powder dry and flowing consistently.

For liquid polymers, a metering pump replaces the screw feeder. The pump draws emulsion or solution polymer from a drum or bulk tank and delivers it to the mixing zone.

Step 2: Pre-Wetting
As the powder leaves the feeder, it hits a water spray that wets every particle. This step is critical. If dry powder hits water without being pre-wetted, it forms lumps—"fish eyes"—that never dissolve. Those lumps waste polymer and can block screens and nozzles in your dewatering equipment.

The pre-wetting device uses a spray pattern designed to separate the particles so they dissolve completely. No lumps, no waste.

Step 3: Dissolution
The wetted polymer enters the first chamber with additional water. A high-speed mixer breaks up any remaining agglomerates and starts the dissolution process. The polymer begins to hydrate and uncoil. This chamber operates at high speed to ensure rapid and complete dissolution.

Step 4: Maturation
The partially dissolved solution overflows into the second chamber. Here, a low-speed mixer keeps the solution moving gently—just enough to maintain uniformity without tearing the polymer chains apart.

This is where the polymer actually activates. The chains uncoil and become effective flocculants. The solution stays in this chamber for a programmed time, typically 30 to 60 minutes, depending on the polymer type and concentration.

Step 5: Age-Dependent Transfer
The system does not transfer solution to the storage chamber based only on level. It waits until the solution has been in the maturation chamber for the full programmed time. This ensures that only fully activated polymer reaches the storage chamber and, eventually, your dewatering equipment.

Step 6: Storage and Dosing
The matured solution moves to the storage chamber. A gentle agitator keeps it uniform without damaging the polymer. When your dewatering equipment calls for polymer, the solution is ready to go. Level sensors in the storage chamber control the preparation cycle automatically.

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

Polymer Preparation unit Model

Polymer preparation Unit Advantage

Reduced Chemical Consumption
Proper polymer activation significantly reduces chemical usage. Automated systems typically reduce polymer consumption by a substantial margin compared to manual batching, delivering significant cost savings over time.

Precision Preparation and Dosing
The use of variable frequency drive screw feeders and accurate water metering ensures consistent solution concentration. The ratio of water flow to powder feed rate determines concentration, and the automated system maintains this ratio precisely.

Considerable Savings in Running Costs
Precise polymer preparation reduces waste and optimises performance. Well-controlled hydraulic retention and contact times ensure the polymer reaches full activation before dosing, maximising its effectiveness.

Labour Saving and Easy Operation
The system is fully automated. Operators only need to spend a short time per day on refilling the hopper and visual inspection. No dedicated operator is required for continuous operation.

Space Saving and System Centralisation
The compact skid-mounted design integrates mixing, maturation, and storage in one unit. This saves valuable plant space and simplifies installation.

Optimised Mixing Properties
Separate high-speed and low-speed mixers in different chambers ensure proper dissolution without damaging polymer chains. This preserves flocculation performance and ensures complete polymer activation.

Zero Powder Loss
Enclosed systems eliminate dust exposure and ensure full utilisation of polymer without waste. This improves operator safety and reduces chemical costs.

Material: Stainless Steel, PP, or FRP

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 the heart of the dry polymer preparation system. Its design and operation directly impact solution quality and chemical consumption.

Precision Auger and VFD Control
The powder feeder uses a precision-machined screw auger driven by a variable frequency drive motor. The VFD allows the operator to control the exact RPM of the screw, ensuring accurate polymer feed regardless of powder characteristics or hopper level.

Heated Discharge Pipe
Polymer powders, especially polyacrylamide, are hygroscopic and can absorb moisture from the air, causing clogs at the feeder outlet. DAGYEE installs a heating element around the feeder discharge pipe to prevent this common issue, ensuring consistent powder flow and reducing maintenance.

Pre-Wetting System
To prevent agglomeration and ensure complete dissolution, dry polymer is wetted immediately after metering. The pre-wetting device uses a carefully designed water spray pattern to separate individual polymer particles before they enter the mixing chamber. This prevents the formation of undissolved lumps that waste chemical and can cause blockages downstream.

Tapered Hopper Design
The polymer hopper is designed with tapered geometry to promote consistent powder flow. A level sensor alerts operators when refilling is needed, ensuring uninterrupted operation. This design eliminates bridging and ensures the screw feeder receives a consistent supply of powder.

Anti-Caking Heater
Polymer powders can absorb moisture from the air and form lumps that prevent flow. DAGYEE units include a gentle heating element at the feeder discharge to prevent moisture from accumulating on the screw. This is essential for powder flow consistency, particularly with polyacrylamide powders that are prone to caking.

Direct Coupling
The screw feeder motor is directly coupled to the auger for precise speed control and reliable operation, eliminating belt slippage and ensuring consistent feed accuracy.

Polymer preparation Unit Feature

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

Summary

The DAGYEE Skid-Mounted Polymer Activation Unit is a dedicated system for sludge dewatering and thickening applications. It uses a three-chamber design to dissolve, mature, and store polymer solution. The age-dependent discharge ensures polymer is fully activated before it reaches your dewatering equipment. The heated feeder outlet prevents powder caking. The low-shear maturation preserves polymer chain integrity.

The result is consistent polymer solution quality, lower chemical consumption, drier cake, and cleaner filtrate. Your centrifuges and belt presses work better because they're getting the polymer quality they were designed for.

Contact Us

The DAGYEE Polymer Activation Unit is designed specifically for sludge dewatering applications. It delivers fully activated polymer solution to centrifuges, belt presses, and thickeners, producing drier cake and lower polymer consumption.

Contact our team for a free consultation and system sizing for your dewatering application.

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.

Inquiry Us

Quantity：

Company Name：

Add：

Tel：

Fax：

Your Name *

Your Email *

Product Name

Your Message *