Some images are technical illustrations. Real installation photographs where marked.
Overview
The CG SAF™ (Shallow Air Flotation) System is a high-efficiency primary treatment unit designed for the rapid removal of suspended solids (SS), fats, oils, and greases (FOG) from industrial wastewater. Compared to conventional Dissolved Air Flotation (DAF) systems, the SAF achieves significantly higher hydraulic loading rates in a dramatically shallower tank — making it more compact, faster to install, and less expensive to construct. The system uses micro-bubble technology combined with optimised flocculation to achieve FOG removal efficiencies exceeding 95%, making it the preferred pre-treatment choice before biological systems such as MBR, SBR, or UASB.
How It Works — Working Principle
Incoming wastewater enters a flash-mix chamber where coagulant and flocculant are dosed under rapid mixing conditions, causing suspended particles and FOG droplets to agglomerate into larger floc. The conditioned wastewater then enters the shallow flotation chamber where pressurised recycle water — saturated with dissolved air at 4–6 bar — is released through micro-pore nozzles to generate a dense cloud of micro-bubbles (10–100 μm). These micro-bubbles attach to the floc particles, reducing their effective density below that of water. The buoyant floc-bubble complexes rise rapidly to the surface, forming a concentrated sludge layer that is continuously removed by an automated skimmer. Clarified effluent exits from the lower zone of the tank and proceeds to downstream biological treatment.
Key Technical Features
- Hydraulic loading rate: 5–15 m³/m²/hr (2–3× conventional DAF)
- FOG removal efficiency: 92–99%
- TSS removal efficiency: 85–95%
- Micro-bubble generation via pressure dissolution and micro-pore nozzles
- Automated surface skimmer — adjustable speed and depth
- Integrated flash-mix and flocculation chamber
- Stainless steel SS304 or SS316 construction (food-grade available)
- PLC-controlled operation with dosing pump integration
- Compact modular design — fast installation, minimal civil works
- Low retention time: 5–20 minutes
- Operates 24/7 continuously without operator attendance
- Chemical dosing compatible: coagulant, flocculant, pH adjustment
Typical Design Parameters
| Parameter | Range / Value |
|---|---|
| Hydraulic Loading Rate | 5–15 m³/m²/hr |
| Retention Time | 5–20 min |
| FOG Inlet | Up to 2,000 mg/L |
| FOG Outlet | < 30 mg/L |
| TSS Removal | > 90% |
| Recycle Ratio | 15–30% |
| Air Pressure | 4–6 bar |
| Bubble Size | 10–100 μm |
| Construction | SS304 / SS316 |
| Flow Range | 50–2,000 m³/day |
Applications
- Pre-treatment before MBR, SBR, or UASB biological systems
- Edible oil refinery and hydrogenation plant effluent
- Dairy processing: milk, cheese, yoghurt, butter production wastewater
- Meat and poultry slaughterhouse effluent
- Fish and seafood processing plant wastewater
- Food and beverage manufacturing — pre-treatment
- Rendering and animal by-products processing
- Palm oil mill effluent (POME) pre-treatment
- Car wash and vehicle service station wastewater
- Grease trap management for commercial kitchens
Advantages
- 2–3× higher hydraulic loading than conventional DAF — smaller tank required
- Shorter retention time means faster response to load changes
- Modular construction — easily expanded or relocated
- Lower civil construction cost vs conventional DAF tanks
- Lower energy consumption per m³ treated
- Integrated coagulation/flocculation — single compact unit
- Suitable for retrofit into existing ETP as primary stage upgrade
- Produces concentrated float sludge — easier dewatering
- NSF/food-grade construction available for food industry applications
- Automated operation reduces operator workload
Frequently Asked Questions
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