Efficient and reliable technology for waste water purification

Reduce costs for your sewage treatment plant and sewage system using the right technology

Safe and reliable disposal of waste water i.e. the detection, treatment and purification of municipal and industrial waste water is becoming more and more important for the protection of waters, the environment but also for sustaining quality of life. Municipalities, waste water associations and private operators of sewage treatment plants and sewage networks are being confronted with a wide range of requirements and specifications designed by the legislator to ensure the (drinking) water of tomorrow stays clean. Last but not least, to avoid the entry of noxious substances, heavy rain events need to be safely handled and the reliable drainage of waste water ensured at all times. At the same time, heavy rain incidents need to have as few effects as possible on the quality of waste water purification and the Waste water Ordinance needs to be observed at all times to prevent contamination of waters and the environment. In addition surface water and waste water need to be detected and sewered separately where possible. Waste water should be discharged via the sewage system and waste water treatment in the sewage treatment plant also needs to be as energy-efficient as possible while conserving resources. Organic loads need to be decomposed, nitrogen and phosphate safely eliminated. As the same time the focus is on heavy metals and trace elements, as well as chemical and pharmaceutical residue in the waste water. The requirement to separate microplastics in future and recover valuable phosphates is presenting yet more, new requirements for sewage technology.

At the same time demographical changes and changes in living habits are influencing waste water collection and purification. Above all there is the wish to keep the costs for waste water removal and waste water purification as low as possible and ideally even to reduce them. Consequently waste water technology needs to be developed and adapted on a continuous basis, incorporating the latest knowledge into building new systems for waste water treatment and waste water purification or expanding and upgrading existing systems so that water is purified as best as possible, ensuring the ground is stressed as little as possible.

Vogelsang has been a reliable and innovative partner for waste water technology for decades now. We offer our customers efficient components for the economically efficient operation of sewage networks or sewage treatment plants such as waste water pumps and slurry pumps, macerators and disintegration systems. Every single one of our products is designed for economical, reliable operation. Coupling together several machines and optimal coordination of individual components using intelligent control technology enables us to provide efficient system solutions for individual problems.

Safe and reliable disposal of waste water i.e. the detection, treatment and purification of municipal and industrial waste water is becoming more and more important for the protection of waters, the environment but also for sustaining quality of life. Municipalities, waste water associations and private operators of sewage treatment plants and sewage networks are being confronted with a wide range of requirements and specifications designed by the legislator to ensure the (drinking) water of tomorrow stays clean. Last but not least, to avoid the entry of noxious substances, heavy rain events need to be safely handled and the reliable drainage of waste water ensured at all times.

At the same time, heavy rain incidents need to have as few effects as possible on the quality of waste water purification and the Waste water Ordinance needs to be observed at all times to prevent contamination of waters and the environment. In addition surface water and waste water need to be detected and sewered separately where possible. Waste water should be discharged via the sewage system and waste water treatment in the sewage treatment plant also needs to be as energy-efficient as possible while conserving resources. Organic loads need to be decomposed, nitrogen and phosphate safely eliminated. As the same time the focus is on heavy metals and trace elements, as well as chemical and pharmaceutical residue in the waste water. The requirement to separate microplastics in future and recover valuable phosphates is presenting yet more, new requirements for sewage technology.

At the same time demographical changes and changes in living habits are influencing waste water collection and purification. Above all there is the wish to keep the costs for waste water removal and waste water purification as low as possible and ideally even to reduce them. Consequently waste water technology needs to be developed and adapted on a continuous basis, incorporating the latest knowledge into building new systems for waste water treatment and waste water purification or expanding and upgrading existing systems so that water is purified as best as possible, ensuring the ground is stressed as little as possible.

Vogelsang has been a reliable and innovative partner for waste water technology for decades now. We offer our customers efficient components for the economically efficient operation of sewage networks or sewage treatment plants such as waste water pumps and slurry pumps, macerators and disintegration systems. Every single one of our products is designed for economical, reliable operation. Coupling together several machines and optimal coordination of individual components using intelligent control technology enables us to provide efficient system solutions for individual problems.

Focus Box

No more clogging of pumps

Ensuring wet wipes do not lead to excessive waste water charges

To keep waste water charges as low as possible, trouble-free operation of sewers is a basic prerequisite. Operators therefore expect a high level of reliability from pumps used there - even during heavy rain incidents. This is an important aspect in these times of increasingly marked climate fluctuations. High degrees of efficiency are also expected from pumps so that waste water can be pumped through the waste water pipes and sewers energy efficiently while conserving resources.

On to wet wipes article

Waste water applications at sewage plants and channels

Pumps and macerators suitable for sewage treatment plants are the basis for economical waste water treatment and waste water purification. This means long-lasting technology with low operating costs and energy requirements that can be serviced and repaired quickly if required. All important parts can thus be replaced by your own personnel – on site without removing the pump or macerator from the pipes. As an alternative to this, a reliable and economical range of services is becoming increasingly important for many sewage works operators. Depending on individual requirements, this may range from simple shipment of spare parts to a full-service contract. It is precisely this diversity that we are able to offer for our Vogelsang rotary lobe pumps and macerators. From consultation and concept planning to after-sales service, we can accompany you at all times as a competent partner.

Reliable pump technology for treatment and pumping of waste water and slurry

The various media are pumped in sewage treatment plants, including

  • waste water
  • abrasive primary sludge/raw sludge
  • secondary sludge/surplus sludge
  • mixed sludge
  • organic slime
  • sewage sludge including with a high level of dry matter content.

It is important here to use pump technology that is designed for this wide range of media that pump this reliably and trouble-free.

Universal waste water pump for diverse tasks

In particular on small sewage treatment plants, a universal pump which can be deployed in several procedures and process steps is often required. The benefit here with the Vogelsang rotary lobe pump is the simple changeover of direction of flow while the pump capacity remains the same. In this way, using a single pump, waste water and sludge can be simply recirculated between tanks and sump or fecal matter removed from disposal vehicles or tankers filled with sewage sludge. Since delivery rate is proportional to speed, the pump capacity can simply be variably adjusted via the variable frequency drive while the delivery rate remains the same. By taking into account dry matter content and the viscosity of a medium, pipe diameter and pipe length, the delivery rate of waste water pumps and slurry pumps can therefore be adapted individually. In practice this means, for example, feeding of digestion towers, thickening and drainage is regulated and efficient, yet at the same time delivery with high pressure or over large distances is also possible. In particular when it comes to circulation in digesters, a high pump capacity makes a positive difference where space requirements are at a premium since little room is often available here for installation of a pump.

Cutters, regardless of whether they are dual-shaft shredders or macerators, are the efficient solution for reducing the size of foreign matter in sewage treatment plants and separating heavy materials. Unlike integrated cutting units, with separate dual-shaft shredders or macerators, the design can be optimally adjusted to the application avoiding a compromise having to be made for speed between pump operation and the shredder function. In this way foreign matter in waste water or sludge is shredded economically and pumps and other units are reliably protected from foreign matter.

Reliable static thickening and digester circulation

Entangled materials from digesters clog up slurry pumps and block mixers unless these are protected by a cutter. The XRipper waste water grinder shreds and reduces entanglements and foreign matter like wood or plastic parts to an easy-to-handle size. This protects pumps from damage and clogging and ensures pipelines remain free. At the same time dual-shaft macerators based on the contactless principle of operation are low-wearing and will win over customers due to their long service lives.

No chance for entangled materials and floating layers

Hairs and fibers from textiles or cotton buds cause the formation of entangled materials and floating layers in digesters. Even small amounts of entangled material will render sludge inhomogeneous, increase the required drive power and have a negative effect on drainage and mechanical thickening. Contact-based macerators like the RotaCut are self-sharpening shredders, which cut even fibers and hairs, thereby macerating them. This prevents the formation of entangled materials and prepares sludge homogeneously. It also leads to more uniform operation of decanters and centrifuges and improved draining or thickening.

Disintegration procedures lead to a higher gas yield and reduced sewage sludge incidence

Two essential and increasingly more important cost factors can be positively influenced using appropriate technology: (External) energy requirements and disposal costs for the incident sewage sludge. Since the requirements of the Sewage Sludge Ordinance often no longer permit recycling in agriculture, the only option is cost-intensive sewage sludge incineration or time-consuming, area-intensive humification of sewage sludge. Countless attempts have therefore been made at reducing the quantity of sewage sludge incurred from the outset.

Modern disintegration procedures are a good option here. The electrokinetic disintegration procedure BioCrack by Vogelsang dissipates aggregates and colloids in the sludge, reduces EPS and ensures simpler access of bacteria to the nutrients, which significantly increases decomposition. This also manifests itself as a second, positive effect since the gas and electric yield of digesters is increased. Due to heightened own-energy production, the sewage treatment plant saves energy, which would otherwise have to be procured. In addition sewage sludge can be drained better on many plants. This is accompanied by reduced costs since less coagulation agents are required and less sewage sludge need to be disposed of.

Reliable, trouble-free pumping of sewage and waste water in the sewage system is essential. For this the sewers and pipes need to be sufficiently sized for heavy rain events and minimal water quantities should not lead to deposits in dry periods. At the same time, installation space is often at a premium. For this reason users will often ask themselves the question as to which lifting stations have low space requirements. Do waste water pumps need have a dry setup or is this recommended - for instance to prevent an ATEX design in wet applications? If so, this usually means that the waste water pump can prime and needs to be resistant to dry running. Vogelsang rotary lobe pumps from the VX series and IQ series are outstanding as waste water pumps. They are compact, can be installed in the smallest of spaces and require extremely little room due to what is known as their hitched design. At the same time they can be serviced or repaired quickly and simply on site. And they also cater to the growing requirement for higher delivery heights or pressures, enabling increasingly longer distances from large central sewage works to be handled. Furthermore, they can prime wastewater from deep sumps as they are highly resistant to dry running.

Grinding of foreign matter in wastewater

Time and time again, municipal sewage or commercial and industrial sewage contains foreign matter that has no business being there. This enters the sewage system in various ways, where it causes considerable problems. Sewage network operators are therefore on the lookout for technical solutions that can handle foreign matter. Waste water grinders like the XRipper twin-shaft grinder or the RotaCut macerators with integrated heavy material separators win over customers due to their many different qualities and features.

The XRipper waste water grinders reduce the foreign matter contained in waste water like wet wipes, textiles and waste to unproblematic sizes. These solids are then so small they no longer cause clogging or blockages in downstream waste water pumps and fittings but are large enough for them to be filtered reliably from the waste water by the screen. The contactless principle of operation is important for low-wearing operation here while the range of installation options also plays an important role. Waste water grinders can be installed in three different ways:

  • in the classic, highly easy to maintain design with geared motor for installation in pipeline networks
  • in a vertical arrangement with the motor arranged above the XRipper where space is at a premium.
  • with an open housing for use in sewers or assembly directly in front of inlets, outlets of central shafts and pump sumps

At the same time, with all three designs, operating companies profit from our unique QuickService concept where all wastewater grinders are low maintenance and can be repaired or serviced on site quickly and simply.

Highly compact heavy material separation and maceration

Another essential function that is found time and time again in sewage systems is separation of heavy material like stones and metal parts and also the macerating of foreign matter like waste and wood. In older open sluices for instance, an adequate screen and/or foreign matter separator is often lacking in front of the waste water pump. Due to upgrades, partial upgrades and the considerable variations in regional developments, each application is often very different to the other so that individual solutions are required that do justice to the relevant volume flow, available space or the maximum electrical power available. The RotaCut macerator by Vogelsang comes in an extensive range of models with numerous features and options, reliably separates heavy material, macerates floatable disruptive matter and even shreds stubborn foreign matter like coarse pieces of wood using the AutoReverse function. Thanks to the sophisticated control technology, the waste water macerator can be connected to remote maintenance and operating parameters are displayed online.

Whether used for rare pumping tasks, construction measures at sewage works or in emergencies like floods, there are lots of different applications for mobile pumps. For this reason mobile pump units in particular need to be able to handle the widest range of media such as

  • municipal sewage
  • industrial wastewater including where loaded with chemicals
  • fecal matter
  • sewage sludge
  • liquid manure
  • oil and old oil

It is important here that the unit can be transported quickly and simply and commissioning is equally simple. The basis for this is individual configuration of the overall unit, entirely according to the needs and requirements of the customer.

The individual waste water pump for individual application profiles

When it comes to mobile pumps, this is our motto. If the mobile unit is to be operated self-sufficiently and independently, we recommend a drive with combustion motors. Where the relevant vehicles are available however, a mechanical drive using a cardan shaft is a low-cost option.

Yet if the mobile pump only needs to be moved within a small area, assembly on a hand trolley or simple trailer will suffice. And for rare usage locations that are far away, assembly on a rigid frame is a good variation, as this way the mobile unit can be loaded via forklift truck or crane. Maximum mobility is offered by assembly on a vehicle trailer, which enables relatively fast and simple transport of the unit.

Vogelsang VX series and IQ series rotary lobe pumps are ideal for mobile use due to their wide range of features as, among other things, they are self-priming and resistant to dry running, have a large free passage and can also pump highly abrasive media or media with high dry matter content. If a variable delivery rate is required, the pump is operated using a variable frequency drive. Alternatively a drive using a combustion motor is also possible. The Vogelsang rotary lobe pump is also ideal where long distances need to be covered.

Case studies of waste water applications

Case Study - Lautertal - XRipper XRP136-560QD

Case study on Lautertal municipality, pumping station Hoergenau
Problem: Clogging of pumps by modern hygiene articles
Solution: Retrofitting of the XRipper XRP136-560QD

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Case Study - Freiberg sewage treatment plant – Rotary lobe pump IQ114-81

Problem: Little space for installing, servicing and maintaining an additional pump
Solution: Vogelsang rotary lobe pump IQ112-81

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Case Study - hanseWasser Bremen GmbH - RotaCut RC5000 Inline

Problem: Malfunctions of centrifuges in dewatering
Solution: Vogelsang-RotaCut® RC 5000 Inline with ACC

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Case Study - Willstaett sewage treatment plant - RotaCut Inline

Problem: High operation costs for feeding the digestion tower in the Willstaett sewage treatment plant
Solution: Vogelsang RotaCut® Inline

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Case Study - Sewage treatment plant in Krefeld - RotaCut RC5000 Inline

Problem: Blockages and damage to the displacement pumps of the sewage station
Solution: VOGELSANG RotaCut® 5000 Inline

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Case Study - Gespringwasser Schmalkalden - XRipper XRS100-90Q

Problem: High amount of maintenance required due to entangled material
Solution: XRipper XRS100-90Q

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Case Study - Environment agency in Osan - XRipper XRS186-260QG

Problem: Blockages and clogging in centrifugal pumps caused by coarse matter in the wastewater
Solution: XRipper XRS186-260QG – designed specifically for installation in shafts

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Case Study - sewage plant in south Germany - BioCrack

Problem: Excessive running costs at sewage treatment plant
Solution: VOGELSANG BioCrack electro-kinetic disintegration unit

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Case Study - dairy Zott GmbH & Co. KG - BioCrack

Problem: Strong fluctuation in utilization, low gas yield
Solution: Electrokinetic disintegration with Vogelsang BioCrack

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Case study - Wonnegau local authority association - XRipper XRP136-140Q

Problem: Pumps being clogged by wet wipes and sanitary products
Solution: Retrofitting of the XRipper XRP136-140Q

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Vogelsang products for waste water applications