Sewage Sludge Pumps: Time and Cost Savings Through Maintenance-Friendly Design
NEMO® progressing cavity pump reduces maintenance time up to 66 percent
Sewage treatment plants worldwide are faced with the challenge of dewatering the sewage sludge to reduce the volume or mass and thus make the product reusable. As a global specialist in the field of environment and energy, NETZSCH offers you pumps and systems optimised to your requirements for conveying sewage sludge.
We will show you how to pump sewage sludge without interruption and, at the same time, achieve savings by using the particularly maintenance-friendly NEMO® progressing cavity pump in FSIP® design.
Sewage sludge pumps: How to save an additional pump
Sewage sludge is a waste product of wastewater treatment in sewage treatment plants and consists of water, organic, and mineral substances. The composition of the medium and the high solids content poses significant challenges for pumps and systems. The high proportion of organic and mineral substances makes uninterrupted pumping very difficult. A regional water supplier in northern Italy used two conventional progressing cavity pumps for this purpose. One of the two pumps was used to convey sewage sludge into the centrifuge, while the second was permanently in standby mode to stand in for breakdowns or maintenance work. This resulted in high costs for the operator.
Preventing long downtimes when pumping sewage sludge
Due to the use of conventional progressing cavity pumps to convey the sewage sludge, maintaining the conveying elements was associated with a high effort. It was necessary to remove the entire pump from the pipeline to remove the rotor and stator. To change the conveying elements, the end connection had to be removed, the stator had to be pulled forward from the rotor, and the drive train had to be dismantled. Furthermore, when positioning the sewage sludge pump, it was necessary to consider an additional dismantling length and to keep enough space free to the front. Due to this effort, significant interventions in the pump were associated with a more prolonged standstill of the sewage treatment plant, loss of production and personnel costs.
Up to 25 percent energy savings when pumping sewage sludge
To save the stand-by unit for the cost efficiency of the plant and at the same time ensure an almost uninterrupted loading of the centrifuge with sewage sludge, NETZSCH recommended the replacement of the conventional pumps with an innovative NEMO® progressive cavity pump in FSIP® design (Full Service in Place). This means that the pump must not be removed from the sewage treatment plant to replace the rotor and stator. This reduces your maintenance times by up to 66 percent and thus saves resources and costs. To open the inspection cover of the sewage sludge pump, only five screws are required, which can be loosened in no time without special tools. After removing the cover, loosening one screw to separate the rotor-stator element from the coupling rod is sufficient. The rotating unit can be lifted out, and the pump interior is freely accessible. The additional replacement length is a thing of the past. This makes the pump particularly suitable for confined spaces in sewage treatment plants.
All in all, replacing all wearing parts can be completed in less than half the time previously required. The progressing cavity pump functions in a straightforward and resource-saving way in combination with the iFD-Stator® 2.0. Here, the elastomer is not vulcanised into the housing as is usually the case but is fixed by axial compression. By separating the steel casing and the elastomer stator, the latter can be easily removed together with the rotor. This makes maintenance even more accessible. Especially in maintenance-intensive applications such as pumping sewage sludge, this increases the economic efficiency of your system. Around 25 percent less energy is consumed during the pumping process, and the pump drives can be dimensioned accordingly smaller. In addition, the stators last about twice as long thanks to the lower load - in conjunction with the easy maintenance provided by the FSIP® concept, you thus reduce your downtimes to a minimum.
Thanks to the innovative and robust construction of the NEMO® progressing cavity pump in FSIP® design, nothing stands in the way of uninterrupted and cost-effective pumping of sewage sludge.