Jiangsu Hengfeng Fine Chemical Co., Ltd.

A large textile dyeing factory recently upgraded its Dissolved Air Flotation (DAF) system to improve wastewater clarification performance. However, shortly after commissioning, the flotation system experienced unstable sludge separation, high effluent turbidity, and frequent scraper blockage.   By introducing Hengfeng Flocculant C9202 and implementing on-site process optimization, the plant successfully restored stable operation and achieved continuous, compliant discharge.   Site Overview   Industry: Textile dyeing & finishing Wastewater capacity: 2,500–3,000 m³/day   Wastewater characteristics: High COD (3,500–4,200 mg/L), suspended solids 1,200–1,800 mg/L, strong color, high surfactant content, and fine colloidal particles typical of dyeing processes.   Flotation system configuration: Two 150 m³/h Dissolved Air Flotation (DAF) units PAC prepared at 5% concentration Polymer manually prepared at 0.1% concentration Designed hydraulic retention time: 25–30 minutes   Initial Issues: Flotation retention time exceeded 40 minutes. Sludge layer was thin and unstable. Effluent SS fluctuated between 250–400 mg/L. Sludge moisture remained above 82%. Sludge accumulation frequently caused scraper blockage, leading to intermittent production interruptions.   Problem Analysis   After on-site inspection and process monitoring, our technical team identified several key causes:   1. Insufficient Floc Strength The previously used polymer had relatively low molecular weight and charge density. The formed flocs were small and fragile, easily breaking under hydraulic shear and reducing bubble attachment efficiency.   2. Improper Coagulation–Flocculation Coordination PAC dosage fluctuated between 40–50 kg/h due to manual adjustment, resulting in incomplete charge neutralization. Meanwhile, operators reduced polymer dosage out of concern for overdosing, leading to insufficient bridging.   3. High Surfactant Interference Textile wastewater contains dispersants and surfactants that weaken bubble–floc adhesion, requiring stronger and denser floc formation to ensure stable flotation.   4. Operator Misinterpretation Previous surface foaming was incorrectly attributed to polymer overdosing, when in fact it was caused by residual surfactants. This misunderstanding led to chronic under-dosing and unstable clarification performance.   Technical Solution   Optimized Chemical Strategy   Hengfeng introduced a coordinated PAC + C9202 dosing program.   PAC was maintained at 5% concentration with a stabilized dosage of 65–75 kg/h to ensure sufficient destabilization of colloids.   Hengfeng Flocculant C9202 was prepared at 0.15% concentration with proper aging time of at least 60 minutes. The polymer dosage was dynamically adjusted between 3.5–4.5 kg/h (dry basis equivalent), based on floc formation and effluent clarity.   C9202, with optimized cationic charge density and higher molecular weight, significantly enhanced bridging capacity and produced larger, more compact flocs suitable for flotation systems.   Dosing Point Optimization   PAC was injected at the rapid mixing tank inlet to ensure full charge neutralization.   C9202 was added in the slow mixing zone before DAF entry, reducing shear intensity and preserving floc integrity before contact with dissolved air bubbles.   Operator Training & Standardization   Our team conducted on-site training to:   Standardize solution preparation procedures   Clarify correct interpretation of foam phenomena   Establish visual floc assessment guidelines   Implement routine dosing records and adjustment protocols   This eliminated inconsistent manual operations and ensured stable chemical control.   Performance Results   After three days of process optimization and continuous monitoring:   Flotation retention time returned to the designed 25–28 minutes. Effluent suspended solids decreased steadily to below 80 mg/L. COD removal efficiency improved to approximately 70–75%. Sludge moisture content decreased to 75–78%, improving downstream dewatering performance. The sludge layer became thick, uniform, and stable, without collapse or “floating patch” defects. Scraper blockage was eliminated, and uninterrupted production was achieved.   The DAF system resumed stable operation, meeting discharge standards while reducing operational risk.   Project Outcome   Through formulation optimization, dosing control, and operator training, Hengfeng successfully transformed an unstable flotation system into a reliable, continuous wastewater treatment process.   This project demonstrated that flotation efficiency depends not only on equipment design, but also on proper chemical synergy, correct dosing strategy, and field-level technical expertise.   Hengfeng Commitment   At Hengfeng, we provide more than flocculants —   We deliver complete process solutions supported by:   • Advanced polymer technology • Site-specific dosage optimization • On-site technical guidance • Long-term operational support   With Hengfeng Flocculant C9202, textile wastewater flotation systems can achieve higher efficiency, improved sludge performance, and sustainable, stable operation.

In the food industry, caramel is more than just a basic ingredient; it is a product that requires precise control over formulation and processing. From the high-temperature reaction of sugar or glucose to the final stabilization of color and flavor, caramel manufacturing involves complex chemical and physical changes. Alongside product quality, manufacturers are increasingly challenged by environmental management issues, particularly the treatment of high-strength wastewater generated during production. Caramel manufacturing wastewater is typically characterized by deep color, high organic content, and finely dispersed suspended solids. Unreacted sugars, caramel pigments, and colloidal substances remain highly stable in water, making natural sedimentation ineffective. Traditional physical separation methods often struggle to achieve consistent results, leading to high turbidity in treated water, excessive sludge volumes, and unstable operation of downstream treatment systems. Under these conditions, polyacrylamide (PAM) has proven to be an effective and reliable solution in caramel manufacturing wastewater treatment. As a high-molecular-weight polymer flocculant, PAM works by extending its molecular chains in water and binding dispersed particles together through adsorption and bridging mechanisms. This transforms fine, stable particles into larger and denser flocs, significantly improving solid–liquid separation efficiency.   A food manufacturer specializing in liquid caramel color once faced persistent challenges with unstable clarification performance and fluctuating effluent quality. Even with increased dosages of inorganic coagulants, the sedimentation process remained inefficient, while operating costs and sludge disposal volumes continued to rise. After introducing a properly selected polyacrylamide product into the clarification stage, floc formation became faster and more uniform. Suspended caramel particles settled more rapidly, effluent clarity improved noticeably, and the overall system became easier to control and maintain. Beyond immediate improvements in turbidity and color removal, the application of PAM delivered broader operational benefits. By stabilizing the pretreatment process, the treated wastewater entering downstream biological or advanced treatment units became more consistent in quality. This reduction in hydraulic and organic load fluctuations helped protect the entire treatment system, reduced operational risks, and improved long-term reliability. As environmental regulations continue to tighten, caramel manufacturers can no longer rely on short-term or reactive wastewater treatment strategies. Achieving stable compliance while maintaining economic efficiency has become a core operational objective. In this context, polyacrylamide is not merely an auxiliary chemical but a functional component that actively supports process optimization. With proper product selection, controlled dosing, and standardized operation, PAM can deliver sustained value in caramel manufacturing applications. Its contribution goes beyond meeting discharge standards; it enables a more stable, efficient, and manageable production environment. This is why polyacrylamide has become an increasingly important and widely adopted solution within the caramel manufacturing industry.

Indonesia is one of the important producers of alumina in Southeast Asia. With the continuous expansion of alumina refining capacity, alumina plants are facing increasing challenges in solid–liquid separation efficiency, red mud settling performance, and overall operating stability.   An alumina refinery in Indonesia was seeking a more efficient flocculant solution for its clarification and mud settling process. The existing flocculant system showed unstable performance, high dosage consumption, and insufficient settling and overflow clarity, which affected production efficiency and operating costs.   Challenges Faced   During on-site communication and technical evaluation, the customer mainly encountered the following issues:   Slow settling rate of red mud, limiting the throughput of thickeners   Poor overflow clarity, causing higher suspended solids in the clarified liquor   High flocculant consumption, resulting in increased chemical costs   Unstable floc formation, sensitive to changes in slurry concentration and operating conditions   The customer required a flocculant with strong adaptability to high-alkalinity alumina slurry and stable performance under continuous operation.   Hengfeng Solution   Based on the customer’s process conditions and slurry characteristics, Jiangsu Hengfeng Fine Chemical Co., Ltd. recommended a polyacrylamide emulsion specially designed for alumina (aluminum oxide) applications.   Key features of Hengfeng’s alumina-grade PAM emulsion include:   Optimized molecular structure for high-alkalinity alumina systems   Rapid dissolution and activation, suitable for on-site continuous dosing   Strong flocculation ability to promote fast red mud settling   Formation of large, dense, and stable flocs, improving solid–liquid separation   Our technical team provided dosage guidance, preparation instructions, and on-site optimization support during the trial phase.   Implementation Process   The product was tested in the clarification and thickening stage of the alumina production process. After adjusting the dilution ratio and dosing point, the system quickly reached stable operation.   Trial parameters were optimized step by step based on:   Settling rate observation   Overflow turbidity   Mud bed stability   Chemical consumption comparison   Results and Achievements   After using Hengfeng’s polyacrylamide emulsion, the alumina plant achieved significant improvements:   Settling rate increased noticeably, allowing higher thickener efficiency   Overflow clarity improved, with reduced suspended solids   Flocculant dosage reduced, lowering overall chemical costs   More stable operation, less sensitivity to process fluctuations   The customer reported that the product performance was consistent and reliable, meeting the requirements of long-term continuous operation.   Customer Feedback   The alumina plant expressed high satisfaction with both the product performance and Hengfeng’s technical support. Based on the successful trial results, the customer moved forward with regular use of Hengfeng’s alumina-specific polyacrylamide emulsion.