Flotation systems such as Dissolved Air Flotation (DAF) units, are key in industrial wastewater treatment. They remove suspended solids, oils, fats and grease to make wastewater compliant and safe for reuse or discharge. But when things go wrong, whether it’s poor floc formation or faulty pumps, it can slow down your operations, increase costs and even risk non-compliance.
In this guide, we break down common flotation system issues and how to fix them quickly and easily on-site.
How Do Flotation Systems Work?
In most industrial applications, DAF systems are used. These units inject air-saturated water into a treatment tank under pressure. As the pressure drops, microscopic air bubbles form and attach to suspended particles, lifting them to the surface. Skimmers then remove the sludge, while the clarified water flows on for further treatment or discharge.
For DAF units to work efficiently, everything from bubble size to chemical balance and mechanical parts needs to be in sync.
If your system isn’t performing as it should, call our team on (02) 4954 0440 for fast support and expert advice. We can help troubleshoot the issue and get your wastewater system working once again.
Common Flotation System Issues and Practical Solutions
Pipes or Tanks Clogged
Issue:
Solids, algae or debris can block inlets, pumps or pipework, which reduces flow rates and treatment efficiency.
Solutions:
- Clean inlets, pipes and tanks regularly
- Add upstream screening or sediment traps
- Adjust flow rates to reduce turbulence
For more detailed guidelines on managing clogging in wastewater systems, refer to the Water Corporation guide on trade waste permits.
Chemical Imbalance
Issue:
Poor dosing or incorrect chemical selection (coagulants/flocculants) causes weak or unstable flocs.
Solutions:
- Conduct jar testing to determine ideal chemical dosages
- Monitor and adjust pH as needed
- Ensure even distribution of chemicals with proper mixing”
Poor Air to Solids Attachment
Issue:
Bubbles don’t attach to solids due to poor saturation or pressure faults.
Solutions:
- Inspect compressors, air saturators and pumps
- Optimise pressure settings and check for leaks
- Ensure consistent flow for bubble-particle contact”
Equipment Malfunctions
Issue:
Wear and tear on pumps, skimmers, or air injection systems causes performance drops.
Solutions:
- Follow a proactive maintenance schedule
- Replace worn parts and inspect seals, bearings, and drive components
- Monitor for unusual vibrations or noise during operation”
Sludge Build-Up
Issue:
Skimmers or scrapers are not removing sludge effectively, reducing capacity.
Solutions:
- Adjust scraper or skimmer speed and contact angle
- Monitor sludge layer thickness
- Increase frequency of sludge removal”
Poor Floc Formation
Issue:
Low mixing energy or incompatible chemicals result in light, ineffective flocs.
Solutions:
- Review chemical selection and dosage rates
- Adjust mixing speed, time and shear force
- Monitor water temperature and pH for ideal reaction conditions”
Keep Your System Running at Peak Performance
Poor flotation performance doesn’t just affect one part of your wastewater treatment system; it’s a bottleneck for your whole process. By addressing issues early, you improve system reliability, reduce chemical and maintenance costs and maintain compliance.
Need help diagnosing performance issues? Contact Baldwin for expert advice and service across Sydney and regional NSW.
Troubleshooting DAF Systems FAQs
How Often Should DAF Systems Be Cleaned?
Weekly or fortnightly, depending on load and site conditions. Regular cleaning prevents blockages and keeps the system efficient.
Can Changing The Coagulant Improve Flotation Performance?
Yes. Different wastes respond better to specific chemicals. Jar testing helps find the right mix.
How Do I Monitor Air Saturation In A Flotation System?
Use pressure gauges and flow meters. Regularly inspect saturator tanks and air lines for leaks.
How Often Should Flotation System Components Be Maintained?
Perform weekly checks and monthly servicing on pumps, compressors, and skimmers to avoid downtime.
What Are The Warning Signs That My Flotation System Needs Attention?
Look for poor sludge removal, cloudy effluent, unusual noises, or inconsistent bubbles.
Does Wastewater Temperature Affect Flotation System Efficiency?
Yes. Higher temperatures reduce air solubility, which can lower flotation effectiveness.