Articles & Case Studies

Pontsticill Sludge

Posted: Monday 7th November 2011

Euroby has recently completed the commissioning of two Flottweg C5E decanter centrifuges at Dwr Cymru’s Ponsticill Water Treatment Plant.

Flottweg AG’s superb “C” range of decanter centrifuges are tasked with dewatering sludge from an upland reservoir water treatment plant. They were installed to replace two existing centrifuges which were underperforming and to accommodate an increase in sludge production.

Capable of throughputs between 10 and 90m3 of sludge per hour, shortly to increase further, the C range is specifically designed for municipal and potable sludges.

A complete design rethink has resulted in a machine boasting the highest performance, coupled with the lowest capital and running costs

The improved machine geometry of the new C-Series dramatically reduces electrical energy consumption. Efficient acceleration of the product in the feed zone combined with improved internal scroll designs result in smaller installed horsepower requirements and lower overall energy consumption ( 20-30% reduction), EFF 1 motors are fitted as standard.

Due to a higher internal sedimentation volume, the capacity is increased by 10-20% above a similar-sized machine, which ultimately results in lower investment costs. It is now possible to use a smaller machine for the required feed rate without reducing processing performance.

These technological advances were key to Euroby winning the project - the Flottweg C series machines accommodated the increase in throughput without the need for significant additional space and provided a net reduction in overall energy requirements together with an increase in cake dry solids content. Operations staff have also noted a significant decrease in noise levels.

Capital costs have been reduced without compromising material choice. The “C” range uses centrifugally cast duplex stainless steel bowls, and scrolls, featuring flame sprayed tungsten carbide leading edge coatings which easily withstand all but the most abrasive sludge, and hard metal wear bushings which can be easily replaced on site.

Scroll bearings are sealed for life - other lubrication is taken care of by a manual or automated centralised greasing system.

Power transmission is provided via Flottweg’s superb SimpDriveTM which facilitates speed differential control based on torque loading.

The C type Centrifuges and associated MCC’s and support steelwork were supplied and installed at the Ponsticill site by Euroby’s engineers who were also contracted to remove the redundant equipment.

All work was carried out without disruption to the normal operation of the WTP, within budget and the required timescale.

Work on each dewatering stream was completed in turn, with operational dewatering capacity maintained using one of Euroby’s fleet of mobile dewatering centrifuges.

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