Full Circle - All in One Slurry Plants

The All In One is the ultimate Stone Fabricators wastewater equipment solution. It combines the clarifier, water tank, and pump skid into a single monolithic unit for easier, more compact installations. The core of the clarifier (the plate pack) and the control systems have undergone a major generational upgrade. The plate pack has been completely redesigned based on computational fluid dynamics and new plate materials, including an exclusive flow regulation technology developed by Full Circle Water. They were built to perform at full flow; they do not rely on throttling valves on the slurry inlet line. The system removes well over 95% of the solids in the slurry water with virtually no maintenance or babysitting required. For CNC spindle feed a simple large filter on the CNC spindle ensures that the water quality needed is met.

The touchscreens are big and bright with an easy-to-use interface and diagnostic capabilities. Almost any operation on the variable frequency drive (VFD), such as changing water pressure settings, can be easily completed from the touchscreen. If something goes wrong (like a purge valve not opening) the system knows and alerts the operator. If a purge valve sticks open, the system knows and shuts down. The system automatically adjusts to work load, purging more when the system is used more heavily (and not at all when the system is idle). Going to a second shift or working a Saturday won’t throw the system into chaos. Chemical dosing can be adjusted from the touchscreen without guesswork. Flow sensors can tell you how much water your shop is using (current and daily average). There is even a sensor to alert the operator if the system is low on polymer. And everything is tied into a multi-color status light and alarm that can be freely magnetically mounted on the system, so you know at a glance (or siren) if something has gone wrong.

Articulate error messages make it easier for the customer to self-diagnose and correct problems, making them more confident in the system and reducing the load on tech support. Solid state sensors have replaced all float switches on the advanced models, removing the risk of the float getting tangled or the contacts in it failing. A new generation of mechanically simplified, robust chemical pumps should reduce failures. Larger feed tanks make refilling easier, allowing a full gallon at a time of flocculant to be added. Other features, like a screen between the clarifier and water tank, reduce the potential for problems and downtime.

There are two control packages. The basic control package offers a similar functionality to our current design (a simple purge timer and a manual on/off switch for the repress pump). Basic systems include a stainless-steel pit stir wand for stirring up the pit as needed; the basic controller does not support an automatic pit stir system.

The advanced controller system uses a new 7″ touchscreen controller networked to a new suite of sensors and new VFDs to control the repress pumps. The advanced system comes standard with an automatic pit stir system. Advanced controller configurations include purge valve position sensors, a light stack/alarm, and low chemical sensors. A solid-state flow sensor—which tracks the amount of water being used by the shop—is available as an option.