Green Technology

Maximising thermal hydrolysis manufacturing with the right pump

Maximising thermal hydrolysis manufacturing with the right pump
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Zero-downtime-and-no-drop-off-in-performance-with-SEEPEX-PC-pumps-and-Digital-Solutions
SEEPEX cites zero downtime and no drop off in efficiency with its PC pumps and digital options.

Pumps producer SEEPEX provides a number of ideas on a recent problem

In accordance with authorities sources, there are 7,078 sewage remedy works (STW) in England and Wales, and 10,814 STW in Scotland and Northern Eire. Pumping and storing sludge cake through the wastewater remedy course of may be expensive, driving water corporations to applied sciences that cut back their quantity to minimise such prices.

This may be achieved by means of standard Anaerobic Digestion (AD) or by means of Superior Anaerobic Digestion (ADD) processes, corresponding to Thermal Hydrolysis Course of (THP). ADD can cut back the quantity of solids and enhance the yield of biogas used to energy engines. This could make vegetation vitality self-sufficient or generate revenue by exporting energy to the Nationwide Grid.

Anglian Water’s Cotton Valley
At Cotton Valley Sludge Therapy Centre (STC), one among Anglian Water’s ten major STCs, competitor’s progressive cavity pumps have been put in to again combine the dewatered sludge and pump it into the THP. The 2 pumps have been costing general circa £100K every year resulting from rotor and stator adjustments each 3-6 months.

Their lack of ability to switch not more than 3.5m3/h (bottleneck and limiting biogas manufacturing) meant the location was not capable of meet the design standards limiting the quantity of imported uncooked cake being dealt with to solely 120 tonnes per day. Moreover, earlier than pump upkeep might be carried out, the silo needed to be emptied. This additionally meant cake imports from satellite tv for pc websites needed to be diverted, which resulted in substantial logistical prices.

SEEPEX equipped and put in two custom-made open hopper pumps with a dimensionally an identical hopper to suit inside the similar footprint of the unique pumps while delivering over 55% elevated throughput capability from 3.5m3/hr to five.5m3/hr.

Previous to the set up of the brand new pumps, Anglian Water was processing approx. 120 tonnes per day of imported sludge cake with each pumps working. With the brand new pumps put in, the shopper is now capable of exceed this by 50% (from 120 tonnes as much as 180 tonnes) while sustaining the identical footprint and motor dimension.

“As a result of reliability and efficiency of the brand new SEEPEX pumps there is a rise in uptime of the cake import facility at Cotton Valley,” stated Luke Fish, Manufacturing Supervisor at Anglian Water. “This has not solely allowed us to extend the sludge throughput on web site and subsequently generate extra biogas however has additionally given us vital financial savings in logistics and uncooked cake storage prices.”

At a significant superior digestion plant within the UK…
Current competitor’s progressive cavity (PC) pumps at a big AD plant have been unreliable, inflicting downtime to the thermal hydrolysis streams. When the THP feed pumps have been offline, this affected manufacturing and biogas era. To handle this, SEEPEX delivered a custom-made open hopper PC pump fitted with Preserve-In-Place know-how to interchange the unique pump, incorporating situation monitoring and digital options.

SEEPEX Preserve-In-Place know-how consists of Rotor Joint Entry (RJA) and Drive Joint Entry (DJA) which simplifies upkeep and improves availability of kit. To enrich these options, the pump’s baseplate is manufactured in three items (on wheels) which permits particular person sections of the pump to be eliminated for upkeep or main overhaul.

SEEPEX Digital Options facilitate preventative upkeep, tools availability and course of optimisation, which has a direct affect on reactive prices and biogas manufacturing – contributing to web zero targets and elevated sustainability.

Since set up, there was zero downtime and no drop off in efficiency, and the sludge dealing with course of has gained resilience.

SEEPEX-9-m-open-hopper-pumps-fitted-at-cake-belt-reception-facility
SEEPEX 9m open hopper pumps fitted at a cake belt reception facility.

At one other main UK thermal hydrolysis plant…
SEEPEX open hopper pumps have been used to interchange unreliable chain conveyor programs. These pumps are utilized in two functions. Firstly, to move the imported dewatered sludge from the imported belt services at a capability of as much as 75 m3/h with dry solids as much as 32% to both of the 2 pre-THP silos, enabling a 20-minute turnaround time for the vehicles to unload and forestall backlog of automobiles. Secondly, to move the indigenous dewatered sludge from the 4 decanting centrifuges to a 3rd pre-THP silo.

Pump upkeep is carried out at floor degree, bettering well being and questions of safety related to working at peak with the earlier conveyor set up. As well as, with the brand new SEEPEX pumps, the location now advantages from elevated availability of their THP streams with subsequent enhancements in gasoline yield.

The important thing: Reliability and proper feedstock
To realize the total advantages of superior digestion by thermal hydrolysis requires dependable and environment friendly supply of feedstock to the method. SEEPEX options mix again mixing experience with open hopper PC pump know-how to each switch and mix imported and indigenous dewatered sludges to the exact DS % content material. This ensures optimum digestion and maximises biogas manufacturing, decreasing carbon footprint.



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