Compact Leachate Treatment System for Small-Scale Waste Incineration Plants
Project Background
Small-scale waste incineration plants (processing 50–200 tons/day of solid waste) are increasingly common in county-level cities and rural areas. These facilities generate 10–50 ton/day of leachate that must be treated to meet discharge standards before release.
Unlike large incineration plants that can justify dedicated leachate treatment buildings and complex multi-stage systems, small facilities face unique constraints: limited space, limited budget, limited on-site technical staff, and the need for a simple, reliable system that runs with minimal intervention.
Torvexus developed a compact, integrated leachate treatment system specifically for this market — delivering full treatment capability in a minimal footprint with plug-and-play simplicity.
Challenges for Small Incineration Plants
- Limited space: Treatment equipment must fit within a small equipment room, often less than 50 m²
- Limited budget: Capital and operating costs must be proportional to the small leachate volume
- Limited staff: No dedicated water treatment operator — system must be highly automated with remote monitoring capability
- Variable feed quality: Leachate composition fluctuates significantly with waste composition and seasonal changes
- Strict discharge standards: Same regulatory requirements as large plants — no relaxation for small scale
System Design
Torvexus designed a two-stage membrane system with all components integrated into a compact indoor layout:
Stage 1: Ultrafiltration (UF) Pre-treatment
- Tubular or hollow fiber UF for solids removal and RO protection
- Automated backwash and chemical-enhanced backwash (CEB)
- UF permeate: SS < 2 mg/L, turbidity < 1 NTU
Stage 2: Reverse Osmosis (RO) Desalination
- Single or two-stage RO depending on feed TDS
- Integrated antiscalant and acid dosing system
- Permeate meets discharge standards without additional polishing
Key Specifications
| Parameter | Value |
|---|---|
| Design capacity | 10–50 ton/day (customizable) |
| Pre-treatment | UF (tubular or hollow fiber) |
| Main treatment | Single/two-stage RO |
| Feed water COD | 2,000–8,000 mg/L (after biochemical) |
| Permeate COD | < 100 mg/L |
| Overall recovery | 70–80% |
| Footprint | < 40 m² (for 30 ton/day system) |
| Control system | PLC + HMI with 4G remote monitoring |
| Chemical dosing | Integrated antiscalant + acid + NaOH dosing |
| Power supply | 380V / 50Hz, three-phase |
Design Highlights
- All-in-one layout: UF, RO, chemical dosing, cartridge filters, and control panel arranged in a single equipment room — no separate chemical storage building needed
- Plug-and-play delivery: All piping, wiring, and instrumentation pre-installed at factory — on-site commissioning within 3–5 days
- Unattended operation: Fully automated PLC control with auto-start, auto-flush, auto-CEB, and fault alarm — designed for sites without dedicated operators
- 4G remote monitoring: Real-time system status, alarm notification, and parameter adjustment via mobile app or web portal
- Low chemical consumption: Optimized dosing control reduces chemical costs to minimum levels
- Easy maintenance: All components accessible from front — no need to disassemble adjacent equipment for membrane replacement or pump service
Performance Results
- Permeate quality: COD < 100 mg/L, ammonia < 15 mg/L, TDS < 500 mg/L — meeting Class A discharge standards
- System availability: > 95% with automated fault recovery
- CIP interval: 25–35 days under normal operating conditions
- Operating cost: < ¥15/ton permeate (including chemicals, power, and membrane replacement)
- Membrane life: UF > 3 years, RO > 3 years with proper maintenance
Why Choose Torvexus for Small Incineration Plants?
- Right-sized solutions: Systems designed from the ground up for small volumes — not oversized large-plant equipment scaled down
- Proven track record: Multiple installations at county-level incineration plants across China
- Complete service: From system design and manufacturing to installation, commissioning, and long-term membrane supply
- Fast delivery: Standard configurations available with 4–6 week lead time
- Remote support: 24/7 remote monitoring and troubleshooting via 4G connection
Conclusion
Small incineration plants deserve purpose-built leachate treatment systems — not compromised versions of large-plant equipment. Torvexus compact membrane systems deliver full treatment performance in a fraction of the space and cost, with the automation and remote monitoring that small facilities need for reliable, unattended operation.
