Wastewater operators can employ efficient components to drive down system energy costs. Here are some of the latest asset management products, drives, heat exchangers and recovery systems, efficiently-designed motors, pumps, blowers and mixers, and renewable energy systems that plants are utilizing to help manage energy consumption.
Liquid membrane sealing system
ENESEAL HR single-component, water-based, ceramic-filled liquid membrane from ENECON Corporation cures to a durable, seamless, flexible skin that refracts and reflects heat to save energy while resisting moisture. It is suitable for insulation including plastics, concrete, brick, block, slate, tiles, wood, metal, bitumen, glass and tar/asphalts. It is applied by brush, roller or spray. Clean up requires only soap and water. 888/436-3266; www.enecon.com.
Lab and robotics enclosures from HEMCO Corporation isolate liquid-handling workstations, HPLC equipment, sample weighing, high-throughput screening, powders handling and other lab processes by providing exhaust air systems or HEPA-filtered clean workstations. They are built to protect personnel from hazardous fumes and processes from contamination. 800/779-4362; www.hemcocorp.com.
The Sigma Air Manager (SAM) 3D blower controller from Kaeser Compressors combines industrial computer and Internet technology to improve operations with stable pressure and low energy costs. It adjusts airflow to maintain desired dissolved oxygen levels and minimize energy consumption. Alternating base- and peak-load blowers balance service hours and improve reliability. It includes an integral Web server for remote viewing of system activity. An optional Sigma Air ControlPlus stores system data for reporting, system audits, control optimization and long-term trend analysis. 877/586-2691; www.kaeser.com.
KEPServerEX from Kepware Technologies manages communication through a platform that supports an array of proprietary communication protocols, APIs, automation system interfaces and open standards such as OPC and SNMP. The single-server platform supports more than 150 drivers, providing more than 250 unique protocols, allowing consolidation of data from various sources to ensure data consistency and reliability, reduce network traffic and provide an efficient platform for automation communications. 207/775-1660; www.kepware.com.
Automotive-grade paint system
The 10-step automotive-grade POWER ARMOR paint system from KOHLER Power Systems improves finish durability of generator tanks and enclosures. It combines a cleaning and conversion process to prepare metal parts for adhesion, along with an epoxy electrocoat and powder topcoat for advanced corrosion resistance, abrasion protection and color retention. Excess powder is recycled for waste reduction. The system is free of heavy metals and leaves a textured industrial finish that surpasses 3,000-hour salt spray corrosion tests. 800/544-2444; www.kohlerpower.com.
Pump life cycle cost calculator
The Met-Pro Global Pump Solutions online calculator lets operators quickly estimate total life cycle cost for one or more pumps. Users input data including initial pump costs, installation costs and annual recurring costs. The calculator accounts for energy costs in the state and generates an analysis. 215/723-8155; www.mp-gps.com.
Energy management software
StruxureWare for Water software from Schneider Electric includes an easily configurable dashboard that allows ad hoc reporting and analysis. Operators use several tools that aggregate energy and related data into a single platform for analysis of energy savings. The power monitoring functions deliver data as actionable information through a customizable, user-friendly interface accessible from computers and hand-held devices on the network. The functionality can be scaled from small to large systems. 770/329-3878; www.schneider-electric-water.com.
Power factor correction bank
The kVAR StacoVAR Mini wall-mountable automatic power factor correction bank from Staco Energy Products maintains the desired power factor through a microprocessor-based controller that adjusts to system load conditions. Models are available from 11.5 to 28 kvar at 208 volts, 15 to 37.5 kvar at 240 volts, and 28 to 75 kvar at 480 volts. The compact design includes capacitors, reactors, contactors and fuses. It includes environmentally friendly, self-healing metalized polypropylene film dry-type capacitors, each in an aluminum cylindrical housing and with an overpressure device and discharge-resistor safety system. 866/261-1191; www.stacoenergy.com.
Inverter drive bearing Protection rings
Maintenance-free AEGIS bearing protection rings from Electro Static Technology make energy savings and bearings sustainable by diverting damaging currents safely to ground. Vertical hollow-shaft pump motors can be protected by installing a ring next to the motor’s guide (lower) bearing and carefully applying ceramic insulation to the carrier that holds the thrust (upper) bearing in place at the motor’s drive end. 866/738-1857; www.est-aegis.com.
Variable-frequency drive control panel
The OLS Series control panel from Orenco Controls contains integrated variable-frequency drives (VFDs) that can optimize system operation and reduce energy usage up to 40 to 50 percent. The VFDs also prolong pump and system life by reducing hard starts and water hammer. Multiple drives can be configured through one simple human-machine interface. Each panel and its enclosure can be designed and built specifically for application and set-up needs. The outdoor-rated panel, housed in a weatherproof enclosure, also offers circuit protection, heat dissipation systems (fan or A/C), phase and voltage protection and level controls. 877/257-8712; www.orencocontrols.com.
Integrated vector drive
The integrated vector drive from seepex, Inc. has a digital display for metering and general transfer progressive cavity pumps. It integrates the pumps with a single reduction gearbox, a four-pole TEFC inverter-rated electric induction motor and a vector-type variable-frequency drive in a NEMA 4 enclosure. The vector capability has an internal sensorless feedback system for accurate speed control and stability. The pump and drive combination can cover a performance band of 0.08 to 60 gph and pressures up to 260 psi. 937/864-7150; www.seepex.com.
Medium-voltage AC drive
The MV1000 medium-voltage AC drive from Yaskawa America combines compact modular design, high efficiency and low harmonics. Its Smart Harmonics technology reduces input total harmonic distortion to less than 2.5 percent without filters, exceeding the requirements of IEEE519-1992 by almost 50 percent. It also provides galvanic isolation between power input and output. It uses two 5-volt step bridges per phase to generate 17-level line-to-line voltage output delivered to the motor. Several motor control modes are available to fit a wide range of applications. It also features a compact modular design that facilitates transportation, installation, and maintenance. It is available in 2.4- and 4.16-kV models in four different frame sizes. 800/927-5292; www.yaskawa.com.
Heat Exchangers/Recovery Systems
Sludge spiral heat exchanger
Sludge Spiral Heat Exchangers from Alfa Laval cost-effectively keep digesters warm, preheat sludge before dewatering and pasteurize sludge. They are compact and self-cleaning and have high heat transfer efficiency and low pumping power consumption. 866/253-2528; www.alfalaval.us/wastewater.
Heat exchange system
The HX heat exchanger system from DDI Heat Exchangers can connect to sewage lines and integrate into a building’s heating and ventilation system to recover heat and cooling energy from sewage. It is easy to access, low in maintenance and reliable. It can be easily integrated with existing wastewater infrastructures. 514/696-7961; www.ddi-heatexchangers.com.
Biosolids thermal hydrolysis system
The EXELYS-DLD biosolids thermal hydrolysis system from Kruger USA, used in the company’s DLD (Digestion-Lysis-Digestion) configuration, optimizes energy production and solids reduction. The DLD configuration combines double digestion separated by the system. Sludge is fed to the first digester, which can operate in a mesophilic or thermophilic state. The easily degradable solids are converted to biogas. The material is then dewatered and fed to the continuous thermal hydrolysis system. The heat is recovered for steam generation and heating of the first digester. The hydrolysed material is then digested in the second (mesophilic) digester, where all solubilized solids are converted to biogas. 919/677-8310; www.krugerusa.com.
Combination boiler/heat exchanger
The combination boiler/heat exchanger from Walker Process Equipment is a tube-in-tube heat exchanger on a base with a hot-water boiler. It integrates with water piping, fuel lines, instruments and a complete electrical control system. The dry-back, double-pass boiler is heated with a forced-draft burner. The exchanger has a sludge/water counter-flow arrangement that maximizes heat transfer. The boiler maintains 180 degrees F water temperature, assuring optimal boiler exhaust temperature as heat is transferred from the burner flame to the boiler water. 630/892-7921; www.walker-process.com.
High Efficiency Motors/Pumps/Blowers/Mixers
Aerator and mixer motor
Endura Series high- and premium-efficiency motors from Aqua-Aerobic Systems suit Aqua-Jet surface aerators and AquaDDM direct-drive mixers. They are available in a variety of power ratings and operate under severe conditions. They require no greasing and limited maintenance. 800/940-5008; www.aqua-aerobic.com.
ZS Blowers from Atlas Copco use energy efficient screw technology. They offer oil-free air TÜV-certified according to ISO 8573-1 CLASS 0 (2010). 866/546-3588; www.efficiencyblowers.com.
Magnetic drive pump
DB Series sealless magnetic drive pumps from Finish Thompson use neodymium magnetic technology for corrosive-duty applications. The plastic mag-drive pump is up to 70 percent efficient. 814/455-4478; www.finishthompson.com.
High-speed centrifugal blower
The Hoffman Revolution from Hoffman & Lamson, Gardner Denver Products, delivers up to 45 percent energy savings, provides high reliability with little maintenance, and is factory prewired and tested in an ergonomic sound enclosure for plug-and-play operation. A small footprint reduces installation costs. It has a 1-meter certified sound rating below 80 dBa, a self-contained cooling system, air-filtration elements, high-efficiency impeller, magnetic smart bearings and blow-off valve assembly. 866/238-6393; www.hoffmanandlamson.com.
Energy-efficient submersible mixer
Submersible mixers from KSB offer robust design and power savings. They have a tandem mechanical sealing arrangement and a lip seal that seals the shaft. A leak-proof cable entry keeps water from wicking inside the motor. 804/222-1818; www.ksbusa.com.
Thrust pump motor
Vertical normal thrust (HP shaft) enclosed fan-cooled (TEFC) catalog motors from Nidec Motor Corporation have NEMA premium-efficiency levels, 50 Hz/60 Hz capability, cast-iron bearing caps and shaft slingers on both ends for IP54 protection. Designed for pump OEMs and aftermarket replacement, they are designed for centrifugal, turbine, sump and process pumps. P-Base and C-Face catalog motors are available from 1 through 200 hp at 3,600 and 1,800 rpm speeds. Modifications include models for hostile duty, inverter duty, D-flange, special shafts (JM/JP), special voltages and high altitude or ambient. 888/637-7333; www.usmotors.com.
The Hydromatic HPE Series premium-efficient solids-handling pump from Pentair / Myers is available up to 200 hp and is engineered for low life cycle costs and long life. It uses a premium-efficient, oil-filled motor that saves energy and has low operating temperatures and permanently lubricated bearings for long life. Features include a switchable seal for easy change, optional quick-disconnect cord, optional shaft-grounding ring for use with VFDs, a bronze sleeve bearing that eliminates the labyrinth ring and a seal-leak detector. 888/416-9513; www.hydromatichpe.com.
The RB 4000 centrifugal blower from Republic Blower Systems combines powerful air movement, robust control and easy maintenance. It reaches high pressure using low horsepower, saving energy. It can be used for concrete slurry containment and grinding systems, in landfill gas recovery and in aeration systems. It generates a high-velocity stream of air that can be easily controlled by adjusting the aluminum or stainless steel air knife attachment, depending on the application. The permanently grease-packed ceramic-hybrid ball bearings require no maintenance, while the bearing assembly is easy to access. 800/847-0380; www.republicsales.com.
Disc aerators from Siemens Water Technologies provide high mechanical efficiency, simple operation and lower energy and maintenance costs. The durable plastic design is lightweight and compatible with existing structures and needs no baffles or mixing equipment for oxygen transfer. They suit single- and multichannel ditches. Upgrades to disc aeration can support simultaneous nitrification/denitrification. 866/926-8420; www.water.siemens.com.
Directional floating mixer
The 9000 Series MAXFLO directional floating mixer from S&N Airoflo saves energy by operating at low speeds and low horsepower, while providing high pumping rates and directional flow. It offers direct pumping rates of 10,000 to 20,000 gpm with 5 or 10 hp units and can add anoxic mixing for denitrification in oxidation ditches and other activated-sludge processes. It enhances the performance of floating aerators and lagoons by reducing algae growth, odor, short-circuiting, and sludge and debris buildup. The low-speed impeller works well with rags and debris. Maintenance points are above the water line. 877/247-6356; www.airoflo.com.
The Enviroprime System pump series from Thompson Pump provides automatic priming with no spilling of pump fluids during initial priming and continued priming throughout operation. They are suited sewer bypasses and wastewater and are available in sizes from 2 to 18 inches with capacities up to 11,000 gpm and heads to 430 feet. The handle solids up to 4 inches. 800/767-7310; www.thompsonpump.com.
Multistage centrifugal blower system
Multistage centrifugal blower systems from Universal Blower Pac are optimized for energy efficiency. They use DC motors with variable-speed controllers and Hibon-Ingersoll Rand Performer/High Performance Series multistage centrifugal blowers. They include total process control and acoustical enclosures. The optimized systems can be combined with EE-PAC high-efficiency screw blower systems for widely fluctuating process demands. Models deliver airflows to 34,000 cfm and a pressure rise of 16 psig. 317/773-7256; www.universalblowerpac.com.
Chemical metering pump
The Qdos 30 chemical metering pump from Watson-Marlow Pumps Group delivers 5,000 to 1 flow from 0.002 to 8.0 gph at 100 psi, while integrating through IP66 manual, analog and PROFIBUS control options. With ReNu pumphead technology, it is fully sealed to safely handle caustic, abrasive, viscous, shear-sensitive and gaseous fluids and slurries. Control features include fluid level monitoring, fluid recovery, line priming and intuitive flow calibration. A sealed design and fluid recovery eliminate waste and protect operators. A menu-driven interface with a 3.5-inch TFT color display provides high-visibility status indication. 800/282-8823; www.wmpg.com.
Severe-duty electric motor
The W22 electric motor from WEG Electric Corp. is designed for performance and energy savings. It has an optimized cooling system, large and accessible terminal box, a bearing seal system and low vibration. 800/275-4934; www.weg.net/us.
Inline centrifugal pump
The Stratos GIGA from WILO USA is a high-efficiency, single-stage inline centrifugal pump that features an inline circulator, allowing it to fit in tight spaces. It has an efficient EC motor that is designed for use in hot-water heating systems, air conditioning, closed cooling circuits and industrial circulation systems. Features include heads to 167 inches and flows to 275 gpm, integrated electronic power adjustment, red button technology and display, and availability in glanded construction, mechanical shaft seal and flanged connections. It received an honorable mention in the 2013 AHR Expo Innovation Awards. 866/945-6872; www.wilo-usa.com.
Renewable Energy Systems
Sludge and waste digestion system
The Aecomix system from Nijhuis Water Technology digests organic wastes into biogas and digestate, producing carbon-neutral energy. The system can include raw material storage and preparation, such as sterilization, pasteurization and maceration; balancing and mixing of the raw materials; biogas conditioning; digested solids separation and processing; and digestate treatment. 312/300-4101; www.nijhuis-water.com.
Biogas conditioning system
The BioCNG conditioning system from Unison Solutions converts biogas to fuel for compressed natural gas (CNG) vehicles. Biogas is piped to the gas-conditioning system from an anaerobic digester. Hydrogen sulfide, moisture, siloxanes, volatile organic compounds and carbon dioxide are removed. The fuel is then routed to a CNG fueling station and compressed for use in vehicles. Systems can produce up to 1,100 gallons of gasoline equivalent (GGE) per day at a production cost of 65 cents to $1.15 per GGE with potential for renewable fuel credits. 563/585-0967; www.unisonsolutions.com.