Customer: Aquaplasma Technologies Group Pty Ltd, Adelaide, Australia
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Requirement
Aquaplasma Technologies Group, based in Adelaide, South Australia, has spent several years developing a proprietary water treatment process capable of treating seawater, wastewater,
greywater, blackwater and other contaminated water sources.
The technology operates as a zero liquid discharge system, converting dissolved minerals,
contaminants and impurities into a recoverable dry particulate stream while producing purified water. By generating dry solids that can be safely collected and managed, the process offers a sustainable approach to water treatment and resource recovery.
A critical requirement was the efficient separation and collection of the dry particulate stream generated during treatment.
The requirements of the separation process were:
- Clean collection of particulate product without a membrane or filter.
- High efficiency retention, ideally close to 100% for particulates greater than 50 microns in size.
- Suitable for a dry steam flow rate of 150 m³/hr (88 CFM) and operation with hot dry steam (circa 80°C).
- Internal surface finishes to cGMP standards.
- No power or services required.
- Easy to clean and empty, with potential future adaptation for a safe-change collection pot for hazardous products.
- Suitable for possible future scale-up.
Solution
Traditional zero liquid discharge systems can be costly, generate waste streams, require membrane replacement, and are difficult to maintain. Aquaplasma therefore sought a simple method to separate dry particulates from a dry steam stream and approached Hanningfield regarding the Uni-Dust range of high-efficiency cyclone separators. The Uni-Dust cyclones are sized according to gas flow rate, require no power, and contain no filter media, eliminating ongoing replacement and maintenance costs.
Although the application was novel and previously untested with this type of dry steam stream, modelling indicated a flow rate of approximately 100–150 m³/hr, making the Uni-Dust Type 5 suitable for pilot-scale evaluation. A demonstration unit was supplied, installed downstream of the treatment stage, and insulated to retain heat, with a sight glass and collection vessel added.
The cyclone now serves as the final solids recovery stage, separating particulates from the steam before downstream condensation into purified water, with recovered mineral powders and other by-products collected for removal, reclamation or further analysis.
Results
Following installation of the Uni-Dust cyclone, the Aquaplasma pilot plant was tested using seawater and hyper-salinated desalination effluent. Collection rates ranged from approximately 35 g to 200 g of powdered solids per litre of water processed, depending on feed composition. Particulate retention was estimated to be close to 100% for the 50–150 micron size range generated by the process.
The results validated reliable operation with hot dry steam streams, achieving efficient solids recovery without filters, membranes, or external power. Following the successful trials, Aquaplasma purchased the demonstration Type 5 cyclone, which now forms an integral part of its pilot plant and validation platform. The Uni-Dust range also provides a clear pathway for future scale-up into larger commercial systems.
Conclusion
The successful implementation of the Hanningfield Uni-Dust Type 5 cyclone demonstrates the flexibility and effectiveness of cyclone separation technology in novel process applications.
By providing efficient particulate recovery without filters, membranes, moving parts or external power requirements, the Uni-Dust system enabled Aquaplasma to achieve reliable solids separation within its pilot-scale water treatment process.
The project highlights how established powder handling technologies can successfully support emerging environmental and resource recovery applications while providing a clear pathway for future commercial scale-up.