Sludge dewatering conditioning
Preparation of polymer solution upstream of screw presses or other selected sludge-dewatering equipment.
Confirm sludge characteristics, polymer response, required solution concentration and dosing range.
Chemical preparation and dosing
Automatic Polymer Preparation Unit
An automatic dry-polymer make-down system that meters powder and water, mixes the solution through staged tanks and supplies prepared polymer for wastewater or sludge conditioning.
- 9 KSPYJ standard model sizes
- 500-6,000 L/h preparation capacity
- PLC-controlled automatic operation
- SS304 and PP tank configurations
Product overview
Controlled Dry-Polymer Make-Down for Conditioning Duties
A product-level view of the preparation duty, automatic sequence, model range and configuration boundaries.
The KSPYJ automatic polymer preparation unit combines dry-powder storage and feeding, water regulation, staged mixing, level sensing and PLC control in one equipment arrangement. The range includes nine preparation capacities from 500 to 6,000 L/h.
In automatic operation, tank level signals initiate water admission and powder feeding. Three agitators start and stop in sequence according to configured delays, allowing the solution to progress through the preparation tanks before it is withdrawn for the selected dosing duty.
PAM is a typical dry-polymer application. Final concentration, powder-feed calibration, tank material, dosing-pump scope and control interfaces must be confirmed from the actual polymer, required solution output and downstream process.
The U.S. EPA sludge-dewatering design manual provides independent context on polymer conditioning, dry-polymer preparation, mixing and representative testing; it does not establish a universal polymer product or dose.
Functional mapEquipment-level view
- 01
Powder storage and feeding
A covered hopper and screw feeder hold and meter dry polymer into the preparation stage.
- 02
Water regulation
The inlet valve, flowmeter and connected instruments regulate and indicate make-up water flow.
- 03
Staged mixing
Three agitators disperse and mix the polymer solution through the tank compartments.
- 04
Level monitoring and control
Level signals coordinate automatic refill, mixing and low-level alarm functions through the PLC and HMI.
- 05
Prepared-solution outlet
Prepared solution leaves through the selected outlet or project dosing-pump arrangement.
Engineering advantages
Why Use a Polymer Preparation Unit?
Evaluate the equipment through operating implications, not decorative feature claims.
- 01
Automatic preparation cycle
PLC and level control coordinate water inlet, powder feeding and staged agitation for the configured operating sequence.
- 02
Adjustable powder feed
The screw feeder uses frequency adjustment and can be checked by a timed weighing test for the selected polymer and concentration.
- 03
Visible water-flow setting
A float flowmeter and inlet valve provide a direct reference for make-up water adjustment during setup.
- 04
Staged solution mixing
Three mixers support sequential preparation rather than relying on a single mixed tank.
- 05
Material configuration options
SS304 and PP tank configurations are available across the KSPYJ model range.
- 06
Project dosing integration
Dosing pumps, VFDs, remote start-stop signals and other interfaces can be defined in the agreed project scope.
Applications
Typical Polymer Preparation Applications
The unit prepares polymer solution for selected wastewater and sludge-conditioning duties. Polymer selection and dose require representative testing.
Dissolved air flotation
Flocculant preparation for wastewater conditioning before dissolved air flotation.
Use representative wastewater testing to establish polymer type, dose and mixing conditions.
Industrial wastewater clarification
Polymer make-down for processes that require controlled flocculant preparation and dosing.
Provide design flow, wastewater variability, chemical data and downstream clarification duty.
Municipal wastewater and sludge
Preparation of polymer solution for selected liquid or solids treatment stages.
Confirm operating schedule, polymer storage, make-down demand and dosing redundancy.
Process-water solids separation
Polymer preparation where suspended solids are conditioned before an approved separation process.
Verify water chemistry, process compatibility and the required prepared-solution output.
Performance
Key Operating Parameters
The values below are standard references. They are not guaranteed process results or a substitute for project-specific selection.
| Parameter | Value / range | Engineering note |
|---|---|---|
| Standard model range | KSPYJ-500 to KSPYJ-6000 | Nine standard capacities are available across the model range. |
| Preparation capacity | 500-6,000 L/h | Confirm continuous, peak and batch solution demand for selection within the standard range. |
| Operating mode | PLC control, fully automatic operation | Final automatic sequence, alarms and remote interfaces are project-specific. |
| Power supply | 380 V / 50 Hz / 3 phase | Confirm the site supply before manufacturing release. |
| Total installed power | 2.5-5.4 kW | Range across the nine standard models, excluding project-specific optional equipment. |
| Powder feeder | 0.37 kW; reduction ratio 1:100 to 1:10 | Reduction ratio changes by model. Calibrate actual feed by timed weighing with the selected polymer. |
| Agitators | Three units; 0.55-1.5 kW each | The motor power and 25-130 or 65-130 r/min range depend on the selected model. |
| Effective tank capacity | 0.5-6.0 m³ | Effective tank capacity depends on the selected KSPYJ model. |
| Tank configurations | SS304 or PP | Confirm wetted-material compatibility, plate thickness, reinforcement and final dimensions for the project. |
| Solution concentration | Project-specific | Use 0.15% only as a setup reference and do not exceed 0.2% in the first tank without verifying the limits for the actual polymer. |
Working principle
How the Polymer Preparation Unit Works
The sequence meters water and powder, disperses the polymer, mixes it through staged tanks and supplies prepared solution under level control.
The approved component image identifies the main equipment arrangement. Final pipework, pumps and controls depend on the agreed scope.
- 01
Load dry polymer
Fill the hopper with the approved dry polymer and confirm that the feeder is clear of lumps or residue.
- 02
Set make-up water
Open and adjust the water supply using the inlet valve and flowmeter for the required preparation duty.
- 03
Calibrate powder feed
Set the screw-feeder frequency and verify actual delivery through a timed weighing test.
- 04
Wet and disperse
Powder enters the make-up water and the first mixer begins dispersing the polymer.
- 05
Stage mixing
The following mixers start after configured delays as solution moves through the preparation tanks.
- 06
Supply prepared solution
The prepared solution is withdrawn for the selected dosing duty while level control coordinates the next cycle.
Equipment video
See the Polymer Preparation Unit in Operation
Follow an automatic powder dosing system through an operational test covering dry-polymer feeding, initial wetting, staged dissolving and continuous solution preparation. The footage helps connect the component diagram and working sequence on this page with a complete assembled unit. It should be used to understand process order and equipment integration; preparation concentration, maturation time, output and control settings remain project-specific and must be confirmed for the selected polymer and treatment duty.
What to look for
- Controlled transfer of dry polymer from the storage and feeding section.
- The wetting, mixing and staged preparation sequence within the unit.
- How the assembled equipment supports continuous prepared-solution delivery.
System configuration
Typical Polymer Preparation System Configuration
A complete duty combines dry-polymer storage, screw feeding, make-up water control, staged mixing, level control and prepared-solution dosing interfaces.
Final interfaces and included equipment are defined by the agreed project scope.
Before releaseConfiguration decisions to confirm
- 01
Polymer type and form
Confirm the dry polymer, supplier data, bulk density, storage requirements and compatibility with wetted materials.
- 02
Preparation capacity
Size the unit from required solution flow, concentration, operating hours and peak demand.
- 03
Tank material
Select SS304, PP or an approved custom material from chemical compatibility and site conditions.
- 04
Feed calibration
Define the screw-feeder frequency range and commissioning weighing procedure for the selected powder.
- 05
Dosing scope
Confirm whether dosing pumps, duty-standby arrangement, VFDs and discharge pipework are included.
- 06
Control interfaces
Confirm HMI functions, alarms, remote start-stop, permissives and plant-control integration.
- M1
Dry polymer hopper
Stores the selected powder and supports controlled delivery to the feeder.
- M2
Screw feeder
Meters dry polymer at the calibrated frequency setting.
- W1
Make-up water
Valve and flowmeter regulate the water supplied to the preparation unit.
- P1
Initial wetting and mixing
Polymer is dispersed in the first preparation stage.
- P2
Staged mixing
Subsequent mixers operate according to the configured delay sequence.
- R1
Prepared solution
Solution is routed to the selected dosing pumps and conditioning point.
Main equipment
- KSPYJ Automatic Polymer Preparation Unit
Supporting / optional equipment
- Dry-Polymer Hopper
- Screw Feeder
- Three Agitators
- Water Inlet Valve and Flowmeter
- Level Sensors
- PLC and HMI Control Cabinet
- Optional Dosing Pumps and VFDs
Technical data
KSPYJ Models & Standard Dimensions
The table presents the standard model range. Confirm the final model, tank material, dimensions, ports, electrical supply, control components and optional dosing scope in the approved project specification.
Scroll horizontally to review all technical fields on smaller screens.
| Model | Capacity (L/h) | Powder feeder | Agitator power | Installed power | SS304 overall dimensions (mm) | PP overall dimensions (mm) |
|---|---|---|---|---|---|---|
| KSPYJ-500 | 500 | 0.37 kW / 1:100 | 0.55 kW × 3 | 2.5 kW | 1550 × 1210 × 1600 | 1560 × 1250 × 1550 |
| KSPYJ-1000 | 1,000 | 0.37 kW / 1:100 | 0.75 kW × 3 | 3.0 kW | 1550 × 1320 × 1870 | 1660 × 1250 × 1750 |
| KSPYJ-1500 | 1,500 | 0.37 kW / 1:60 | 0.75 kW × 3 | 3.0 kW | 2050 × 1350 × 1880 | 1780 × 1350 × 1850 |
| KSPYJ-2000 | 2,000 | 0.37 kW / 1:40 | 0.75 kW × 3 | 3.0 kW | 2050 × 1350 × 2100 | 2000 × 1500 × 1950 |
| KSPYJ-2500 | 2,500 | 0.37 kW / 1:40 | 1.1 kW × 3 | 4.2 kW | 2450 × 1500 × 2100 | 2500 × 1500 × 1950 |
| KSPYJ-3000 | 3,000 | 0.37 kW / 1:20 | 1.1 kW × 3 | 4.2 kW | 2450 × 1550 × 2200 | 2700 × 1600 × 1960 |
| KSPYJ-4000 | 4,000 | 0.37 kW / 1:20 | 1.1 kW × 3 | 4.2 kW | 3100 × 1650 × 2250 | 3000 × 1800 × 2000 |
| KSPYJ-5000 | 5,000 | 0.37 kW / 1:10 | 1.5 kW × 3 | 5.4 kW | 3100 × 1950 × 2100 | 3300 × 1900 × 2150 |
| KSPYJ-6000 | 6,000 | 0.37 kW / 1:10 | 1.5 kW × 3 | 5.4 kW | 3100 × 2100 × 2400 | 3500 × 1900 × 2250 |
Equipment selection
How to Select the Right Polymer Preparation Unit
Selection begins with the actual polymer, required solution output and concentration, then confirms materials, dosing scope, utilities and controls.
- 01
Polymer type
Provide the polymer form, product data, bulk density, storage conditions and supplier preparation guidance.
- 02
Required solution output
Define continuous, peak and batch prepared-solution flow together with operating hours.
- 03
Preparation concentration
Confirm the working concentration and downstream dilution or dosing requirement from process testing.
- 04
Mixing and aging duty
Define the required wetting, mixing and maturation sequence for the selected polymer.
- 05
Construction material
Select the tank and wetted materials from polymer chemistry, water quality and the installation environment.
- 06
Dosing arrangement
Confirm pump quantity, flow range, pressure, duty-standby philosophy and VFD requirement.
- 07
Utilities and controls
Provide water pressure and quality, power supply, remote signals, alarm requirements, footprint and access constraints.
Engineering support
From Equipment Selection to System Integration
Support is presented as a practical engineering workflow, without unverified company statistics or outcome claims.
- 01
Polymer-duty review
Review polymer form, preparation guidance, concentration and downstream conditioning duty.
- 02
Model selection
Evaluate required solution output, operating schedule and tank material against the standard KSPYJ range.
- 03
Feed calibration planning
Define the timed weighing and water-flow checks needed for commissioning with the selected powder.
- 04
Dosing integration
Define dosing pumps, pipework, VFDs, duty-standby arrangement and downstream interfaces.
- 05
Control coordination
Confirm level logic, mixer delays, alarms, remote signals and plant-control requirements.
Technical FAQ
Polymer Preparation Unit Frequently Asked Questions
The answers separate general selection logic from the values that require a project-specific technical review.
01What is an automatic polymer preparation unit?+
It is a make-down system that meters dry polymer and water, mixes the solution through staged tanks and supplies prepared polymer to a selected dosing or conditioning process.
02What capacities are available in the standard KSPYJ range?+
Nine models from KSPYJ-500 to KSPYJ-6000 cover 500 to 6,000 L/h of preparation capacity. Final selection requires the actual concentration and operating schedule.
03How does the automatic preparation sequence work?+
Level signals call for water and powder feed, the first mixer starts, and the following mixers operate according to configured delay settings. Prepared solution is withdrawn while the control system coordinates the next refill cycle.
04Which polymers can the unit prepare?+
PAM dry polymer is a typical application. Suitability for a specific polymer must be confirmed from its product data, bulk density, preparation guidance and material compatibility.
05How is the powder-feed rate set?+
The screw feeder uses frequency adjustment. Run a timed manual test, collect and weigh the powder, repeat the test and use the measured delivery to set the required concentration.
06Are SS304 and PP versions available?+
SS304 and PP tank configurations are available across the model range. Final construction, thickness and reinforcement must be confirmed for the selected chemical and site.
07Can dosing pumps be included?+
Dosing integration is a configurable project item. Pump quantity, flow, pressure, control and duty-standby requirements must be defined before release.
08What information is needed for selection?+
Provide polymer data, required prepared-solution flow and concentration, operating schedule, downstream duty, dosing-pump requirements, preferred material, make-up water, power supply, control signals and site constraints.
Engineering inquiry
Need Help Selecting the Right Polymer Preparation Unit?
Share your polymer data, required solution flow and concentration, operating schedule, downstream dosing duty and site conditions. KUOSI can use the confirmed inputs to evaluate the appropriate KSPYJ model and configuration.