Optimizing Wastewater Treatment Processes: BINDER Group’s Intelligent Aeration Control Systems
BINDER Group develops technologies for modern wastewater treatment plants with a focus on process optimization and energy saving. The company provides systems and equipment designed to improve aeration control, increase process reliability, and reduce energy consumption in wastewater treatment processes.
The Aeration System: Components and Equipment
The aeration system in biological wastewater treatment consists of several components working together in one integrated system. These components include blowers, air flow meters, control valves, sensors, process control systems, diffusers, pumps, and mixers. All components influence each other within the system, and some of them change their properties over the years.
VACOMASS®: Aeration Control System
One of the main technologies developed by BINDER Group is the VACOMASS® aeration control system. VACOMASS® measures, controls, and distributes air to the aeration tanks in a precise and load-dependent way. This allows the system to provide high cleaning performance and process safety while reducing energy consumption. The system combines innovative technologies and high product quality in order to achieve sustainable investment and the lowest possible life cycle costs.
Precise Air Flow Meter
A key component of the VACOMASS® system is the precise air flow meter. Airflow meters are typically installed in the main header pipe, subheaders, and dropper pipes for each control zone. These devices use thermal dispersion technology, which is not affected by pressure or temperature changes.
They provide very precise measurements due to customized calibration and have very low pressure drop. A reference sensor measures air temperature, and the signal remains stable over a long period of time with almost no maintenance required.
VACOMASS® Jet Control Valve
BINDER developed the VACOMASS® jet control valve, which is an aerodynamically optimized control valve with a linear operational characteristic across a wide operating range.
The valve has a very low-pressure loss in the control mode of 2–5 mbar only. Conventional control valves often operate with a 40–70 mbar pressure drop, which increases energy consumption.
Due to this low pressure drop, the VACOMASS® jet control valve can achieve direct energy savings of up to 15%. The valve also features robust construction, an integrated flow conditioner, a short installation length, and gas-tight shut-off.
VACOMASS® Elliptic Diaphragm Control Valve
This aerodynamically optimized diaphragm control valve provides an exceptionally high air flow capacity. The typical pressure drop in control mode is 10–15 mbar, and the valve closes gas-tight. When the valve opening increases from 70% to 100%, the air flow rate can triple at the same pressure drop, which is ideal for diffuser maintenance and flexible operation.
VACOMASS® Flexcontrol: Real-Time Control with AI
This modular PLC-based system works with the plant SCADA system and can be used for new installations as well as renovation or expansion projects. Flexcontrol performs dynamic aeration control in real time with artificial intelligence. The goal is precise and flexible aeration control for demand-driven air supply while controlling blowers, pumps, and other equipment in the aeration system. The system uses actual process information and checks the quality of sensor signals. If a signal fails a plausibility check, the system informs the operator and automatically uses substitute values until the sensor signal becomes valid again.
Energy Savings Achieved by the VACOMASS® System
Reduction of total nitrogen in the effluent can be achieved through precise aeration control, ammonia-based DO control, and improved denitrification. Energy savings can also be achieved through several factors:
- Pressure drop of the valve: 5–15% energy savings
- Dynamic header pressure: 8–10% energy savings
- Precise aeration control: 10–20% energy savings
- Ammonia-based DO control: 8–15% energy savings
- Diffuser maintenance: 5–15% energy savings
Conclusion
BINDER Group offers advanced control systems for wastewater treatment, focusing on process optimization and energy savings. The VACOMASS® control system includes components like precise air flow meters and control valves that enhance aeration control. This system achieves high performance efficiency while reducing energy consumption by up to 50%. Additionally, the Flexcontrol smart system utilizes artificial intelligence for dynamic aeration control, improving nitrogen removal and enhancing the quality of treated water.
