Sludge treatment

Efficient solutions for wastewater treatment plants

Choose a reliable sludge treatment solution

Handling large amounts of sludge is an expensive and complex operation. As treatment plants become larger and more sophisticated, problems become even more complex and costly. That is why it is important to make the right configuration and equipment choices during the initial planning stages. Flygt has the proven experience and equipment that can provide reliable, efficient solutions for handling sludge in the treatment process. Efficient pumping Depending on varying sludge characteristics, the correct duty point can be a difficult challange to meet. For environmental reasons, there is at the same time a need to reduce the volume of sludge by thickening it. This too puts high demands on pumping ability. The unique design of the N pump has proved very effective in general sludge treatment applications. Clogging-related downtime and subsequent maintenance costs are being dramatically reduced and efficiency is being secured, thanks to Flygts solutions. With the addition of a large range of Progressive Cavity (PC) pumps we can offer a self-priming rotary displacement pump for challenging sludge situations. The design is very resistant to clogging and produces a consistent, accurate flow. Dependable mixing solutions Submersible mixers are indispensable in the modern treatment plant because they can be easily positioned and oriented to maximize efficient mixing in any size tank. In thick sludge, good mixing results can be obtained by using the Flygt hydro ejector. Most customers dealing with sludge treatment want a pump/mixer solution or configuration rather than a specific unit. Flygt's know-how in applications and fluid dynamics is the defining factor here.

A system tailored to your needs

Cost-saving aeration systems Aeration systems are in general very energy consuming. Therefore fine tuning of the system is essential. For instance, the best choice can be the Flygt coarse bubble ejector, Flo-Get, because of its simplicity, efficient mixing and good oxygen transfer in the aerobic sludge stabilisation processes. On the other hand, the Sanitaire range of fine bubble systems with membrane and ceramic discs offers an efficient and complete floor covered aeration system. Systems engineering for optimal solutions Flygt engineers can recommend and design the most efficient system on the basis of data provided by the customer. We are able to predict accurate outcomes for both pumping and mixing applications based on years of research to define the behavior of sludge in all aspects of treatment. This efficiency translate into lower operational costs in the long run. With Flygt's global network of facilities, we are nearby to assist in providing accurate and efficient solutions for any pumping, mixing or aeration problem. Preventive medicine is the best cure The consequences of systems failure are often drastic. If equipment in a biological treatment process breaks down the restart can take weeks, involving potentially enormous costs. The same occurs when treatment becomes non-functional due to equipment failure. This is why professionals turn to Flygt as the inventor and market leader of reliable system solutions.

Should problems arise, you can count on the Flygt service network which reaches into more than 130 countries around the world. And you never have to worry about spare parts availability. We provide spares for a minimum of 15 years after manufacturing is stopped on a particular unit. The level of maintenance and support required from us is always tailored to your needs, on your terms.

Sludge treatment
As wastewater plants become larger and more sophisticated, the demands for cost-effectiveness and reliability grow too. In order to apply the correct solution, it is essential to understand the requirements of each individual plant. This is why we do not sell one standard solution, but offer a wide range of customised applications, to ensure optimisation. The plant shown here is a composite illustration of sludge treatment with anaerobic digestion as stablilisation. It explains how our products can be used in numerous applications.

1. Removal of primary sludge

Settable solids are pumped to the sludge treatment.

2. Removal of secondary sludge (RAS & WAS)

Return activated sludge (RAS) is continuously pumped back to the reactor. An excess part of the settled sludge, waste activated sludge (WAS), is pumped away for further treatment.

3. Pumping of imported sludge

Sludge from septic tanks, industries and other wastewater treatmant plants is brought to a storage tank. Then it is pumped to the sludge treatment or to the plant inlet.

6. Pumping of mechanically thickened sludge

The dry solids content and the viscosity of the further thickened sludge can become very high and may hardly be poured out of a bucket. This puts high demands on the pump.

7. Mixing in the anaerobic digester

To achieve a large active reactor volume in the stabilisation process, efficient mixing is required.

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4. Withdrawal of gravity thickened sludge

Primary, secondary and imported sludge is thickened separately or mixed. The character of the thickened sludge differs widely and pumps have to be choosen depending on origin and possible addition of polymers.

5. Crushing of solids in sludge

To avoid clogging and wear of mechanical units the macerator takes care of rags and fibers that have managed to pass through the screens.

8. Recirculation of sludge in the anaerobic digester

To keep the biological process alive in the digester, the temperature has to be kept elevated by recirculating the sludge through a heat exchanger by pumps.

9. Mixing of stored sludge

To avoid settling in the storage tanks, mixers are required.

10. Pumping of stabilised sludge

The sludge is fed to the dewatering unit by pumps suitable for the installed dewatering unit.

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11. Pumping of dewatered sludge

When the sludge has been dewatered, the dry solids content is very high which requires a lot from the pump for further transportation.

12. Dosing of polymer

As polymer has been prepared, it is pumped to the thickening and dewatering units.

13. Removal of reject water

From mechanical thickeners and centrifuges, the reject water is collected and pumped away for treatment.

Alternative stabilisation processes Stabilisation is the process of converting organic matter in the sludge into stable products that are resistant to further biological activity. In the picture of the treatment plant on the previous page, anaerobic digestion is used as a stabilisation process. However, there are also other ways of stabilising sludge:

Flo-Get

Mixer

Hydro ejector

1. Aerobic stabilisation Conventional aerobic digestion is performed at the ambient temperature where both intermittent and continuous feeding is seen. Auto-thermal thermophilic aerobic digestion (ATAD) can be achieved with a properly thickened sludge, and insulated tanks, where a temperature of 60 C can be reached. For both processes an efficient aeration and mixing for a long period of time is required to achieve the desired degree of solids stabilisation and pathogen inactivation.

2. Lime stabilisation Lime is added to the untreated sludge in sufficient quantities to raise the pH to 12 or higher. The high pH creates an environment that makes it impossible for most micro-organisms to survive. Consequently, the sludge will then not have any biological activity, nor pose a hygenic risk as long as the pH is maintained at this level. This requires good mixing and proper equipment for such a tough and demanding environment.

De-sludging as an alternative treatment When using aerated, facultative or anaerobic lagoons for wastewater treatment, the lagoons will eventually have to be de-sludged. De-sludging is achieved either by pumping or excavation. When pumping the application puts high demands on pumps because of the high amount of grit and rags, as no de-gritting or screening of the water is performed. De-sludging is also considered when sludge-lagoons are full and for some reason must be emptied.

Meeting your specific needs when building or upgrading an installation

Our wide range of solutions and equipment for sludge treatment ensures that you will get the best results whether upgrading and refitting an older installation or designing and constructing a new one. The equipment will perform efficiently, require minimum maintenance and offer the lowest possible cost over the life of the application. N-pumps This range of units can be used practically everywhere in sludge treatment for transporting water as well as sludge of all types (before dewatering). This type of pump can be operated either submerged on a discharge connection with guide bars or non-submerged on a stand in a dry pit. N-pumps can handle dry solids contents up to at least 6%. Progressive cavity pumps Our range of PC pumps includes polymer dosing pumps and sludge pumps where the hopper pump can handle up to 45% dry solids content. Depending on the application, we can supply pumps with stators of different geometries, to provide low noise levels, low risk of clogging and stable flow characteristics. The PC pumps can handle viscosities up to 1,000,000 mPas (cP).

Hydro ejector The hydro ejector is a liquid jet generating ejector which creates a powerful bulk flow. The hydro ejector consists of a cast iron nozzle that can be used by itself or together with a stainless steel ejector pipe. It is available in three sizes and is designed to fit the Flygt N-pump series.

Macerator To avoid clogging problems and disturbance in the sludge-treatment processes, a macerator can be fitted upstream of a PC pump. This grinding device crushes rags and fibres into manageable sizes for pumping in liquid. Solids including wood, textiles, plastic, bone and fur are crushed by the rotating impeller against the fixed cutting ring. The crushing stages result in grain sizes down to 3.5 mm or fibre sizes of 1.5 cm2, depending on type of solids.

Compact mixers Our range of compact mixers provides cost-efficient mixing solutions for solids suspension and sludge blending. These direct drive, stainless steel mixers have motor capacities of up to 30 kW (40 hp) and deliver thrust up to 7000N. Various propeller angles are available for optimised duty. The optional jet ring can reduce power consumption still further, by up to 15%. Aeration systems We offer a wide range of efficient aeration products that fulfil a variety of oxygen requirements in wastewater applications.The Flygt Flo-Get ejector operates together with a submersible pump, and is the natural choice where flexible and reliable aeration is essential. The Flo-Get provides efficient aeration combined with good mixing. The alternative Sanitaire system has a uniform air distribution, using pressurised air through high porous discs mounted on pipes attached to the tank floor.

Everything you need for reliable process pumping solutions As the worlds leading manufacturer of submersible pumps and provider of fluid handling technology, Flygt can provide you with complete pumping solutions. From planning and delivery, through installation and after sales service, Flygts competence is at your service. Through our products and services, engineers, planners and consultants have access to more than 100 years of experience, assuring the most reliable and cost-effective operation. Flygt service and sales facilities are found in more than 130 countries worldwide.

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