DISTAR – MANUFACTURER OF PROFESSIONAL TOOLS

Wastewater treatment for the production of diamond tools at DiStar

DiStar is a manufacturer of professional diamond tools for construction, stone, and concrete processing. Operating in the Ukrainian market since 1994, with its headquarters located in the city of Poltava, the company is focused on the implementation of a long-term strategy for technical and social development. Its objective was to secure a leading position in the high-quality diamond tool market both in Ukraine and internationally. Today, the company is the largest manufacturer of diamond tools for construction and stone processing in Eastern Europe and a leader in the production of innovative professional diamond tools in partnership with leading global companies. All products are manufactured at the company’s own facilities using state-of-the-art automated production lines. Brand recognition and growing demand for DiStar products are driven by high quality, optimal technical characteristics, and a wide range of tools.

Drawing on extensive European experience, as well as using high-quality raw materials and modern production equipment, DiStar has obtained relevant quality certifications in accordance with international standards, including ISO 9001:2015, ISO 14001:2015, and others. The company’s production capacities allow for the manufacture of up to 200,000 diamond segments and 50,000 diamond cutting discs per month.

In order to ensure proper certification for export, demonstrate a high level of corporate social responsibility, and minimize the environmental impact of production, DiStar management approached the company ZIKO with the objective of treating industrial wastewater.

ZIKO specialists visited the production facility, conducted wastewater analysis, performed tests to select effective chemical reagents, and developed an engineering solution using industrial wastewater treatment systems. As a result of the wastewater study, it was identified that the effluent contained high concentrations of nitrogen-group organic contaminants and heavy metals, while no exceedances of hexavalent chromium (Cr⁶⁺) were detected. Laboratory studies showed that a high content of organic substances in wastewater has a negative impact on the efficiency of electrocoagulation.

The developed engineering solution for wastewater treatment operates as follows:

1. Wastewater is directed to existing equalization tanks, where flow rate and contaminant concentrations are equalized. The equalization tanks are designed for maximum daily capacity.
2. The equalized wastewater is evenly pumped, using a pump installed in the last existing tank, into a settling tank. After the settler, the water flows through a mixing channel into a reactor–clarifier with a suspended sludge layer.
3. Additionally, an alkaline reagent solution is dosed into the mixing channel using a dosing pump from the reagent unit, and, if necessary, a flocculant solution is also dosed via a dosing pump. The pH level is continuously monitored using a pH sensor.
4. After clarification in the suspended-sludge clarifier, the treated water is supplied to a polishing filter. To achieve maximum treatment efficiency, the filter is equipped with a water recirculation system through the filter media. The treated water is then discharged into the sewer network.
5. Sludge from the clarifier is transferred via an airlift to a sludge accumulation tank. Filter backwash water is also directed to this tank, from where it is pumped to a filter press for dewatering. The dewatered sludge has a moisture content of 75%, is stored in a dedicated container, and is subject to disposal.

As a result of the successfully implemented solution, DiStar is able to manufacture high-quality diamond products for construction and stone processing without causing negative environmental impact. ZIKO engineers periodically visit the facility to inspect and monitor the operation of the installed equipment.

A video demonstrating the achieved level of wastewater treatment is available via the provided link.

If you are interested in implementing a similar project or have any questions, please contact us using the provided contact details. Our managers will assist in selecting equipment tailored to the specific needs of your enterprise.