How can we improve our sludge transport efficiency? One new tool is air powered and sustainable.
The Australian wastewater industry has long relied on traditional mechanical conveyors and belt systems to transport dewatered sludge. However, SEEPEX’s Smart Air Injection (SAI) is changing the game. Offering significant cost savings over conventional systems, SAI provides an innovative, energy-efficient solution for transporting thick, dewatered sludge and biosolids.
What is unique about SAI?
The SAI system is a precisely engineered sludge handling solution developed by SEEPEX, a global leader in progressive cavity pump technology. SAI combines progressive cavity pumping with dense-phase pneumatic conveying to transport highly dewatered sludge exceptionally efficiently.
Unlike traditional methods that use belt or screw conveyors, SAI moves dewatered sludge in short, dense plugs through a pipeline using compressed air pulses. This process minimises friction and energy losses, as the air interacts only with these dense plugs rather than the entire pipeline. Enhancing efficiency further, SAI injects a minimal yet effective amount of polymer, keeping usage low while ensuring efficient sludge transport. This cost-effective approach quickly pays for itself.
With a low-pressure pump, accessible maintenance features and PN10 piping, the system is energy-efficient but also maintenance-friendly and gentle on its components. SAI can transport sludge up to 1,000 metres, making it versatile and suitable for a variety of installations, including wastewater treatment plants and industrial facilities.
Advantages over conventional conveyors
SAI stands out for its energy efficiency, offering significant savings over traditional conveyor systems. Belt and screw conveyors often require multiple mechanical components and motors due to continuous resistance along the entire length of the conveyor, resulting in higher energy requirements. In contrast, the SAI system minimises friction losses within the pipeline, further reducing energy consumption.
In addition to energy savings, SAI reduces both operational and maintenance costs. The low pressure minimises wear and tear on the entire system, extending the lifespan of components like pumps, pipelines, and valves. This is in stark contrast to conveyor systems, which incur higher maintenance costs due to the constant mechanical movement and friction they endure.
SAI offers maintain in place features with smart conveying technology, which allows rotor and stator replacements in less than an hour with minimal space requirements. In contrast, conventional conveyor systems, with their numerous moving parts, such as belts, pulleys, and bearings, demand regular maintenance and frequent replacements. This complexity leads to more downtime during servicing and makes traditional systems less reliable over time.
SAI provides operational flexibility, especially in constrained environments or brownfield sites where space is limited. The system can be retrofitted into existing infrastructure without significant modifications. Traditional conveyor systems, on the other hand, often require substantial structural support and space, making them less suitable for retrofitting into tight or vertically constrained spaces. The compact, mobile nature of the SAI system allows it to fit seamlessly into existing layouts with little to no disruption to operations. This flexibility is particularly valuable in the wastewater and by-product management sectors, where continuous operation is critical.
The SAI system operates in a sealed pipeline, reducing the risk of odour release or emissions, which are common issues with traditional belt conveyors. This enclosed system improves safety and working conditions and improves environmental compliance. This is particularly true in urban or residential areas where odour control is crucial. Additionally, SAI eliminates the risk of material spillage or leakage, further enhancing its environmental credentials. In contrast, with their open design, traditional conveyors often require extra odour extraction systems and are prone to biosolids falling off the belt during transport.
SAI’s streamlined design significantly reduces the physical footprint required for sludge conveyance. Traditional belt conveyor systems are bulky, requiring multiple stages of mechanical transportation, including vertical lifts and additional supporting structures. This complexity can lead to higher construction and operational costs, particularly in retrofitting scenarios. SAI, on the other hand, uses a single pipeline to transport dewatered sludge directly to the destination, whether it is a silo, truck, or incinerator. This complexity reduction saves space, shortens construction time, and lowers associated costs.
Proven global success
SEEPEX’s SAI system has been successfully deployed in over eighty facilities worldwide, proving its effectiveness in municipal and industrial contexts. At the Hetlingen wastewater treatment plant in Germany, the installation of SAI resulted in energy savings of 20-25 per cent and a significant reduction in maintenance costs. The plant handles approximately 46,000 tonnes of sludge annually, and the switch to SAI has proven to be a cost-effective, low-maintenance solution.
SEEPEX’s Smart Air Injection is a transformative innovation in dewatered sludge transport. With advantages such as energy efficiency, cost savings and environmental and operational improvements, it is a compelling choice for wastewater resource recovery facilities in Australia. As more installations showcase its benefits, SAI aims to become an industry standard, providing a sustainable, efficient, and cost-effective solution for sludge conveyance.
For more information, visit seepex.com
