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1. © ESR Technology Ltd.
Optimising RAM Pump
Operation to Reduce the
Cost of Sludge Processing
Paul Hawthorne
Technical Director
EMS Industries Ltd

2. EMS Industries Ltd
Manufacturing Engineering Solutions
presented by
PAUL HAWTHORNE
Technical Director

3. INTRODUCTION
THE EFFECTIVE USE OF RAM PUMPS
Capability to pump thick sludges often under-utilised
Perceived problems with pumping thick sludges
Operational issues need to be understood
OPTIMISATION BY ADAPTIVE CONTROL
Matching the pump capability to prevailing conditions
Process and energy saving benefits

4. RAM PUMP PERFORMANCE
THE NATURE OF SLUDGE
The effect of viscosity
Suction losses
Static resistance
PERFORMANCE CONSTRAINTS
Resistance to Movement
Limiting Speed of Operation
SLUDGE THICKNESS VARIATIONS
Pump size stroke rate
Adaptive control

5. RAM PUMP PERFORMANCE

6. PREVIOUS DEVELOPMENTS
SUCTION LINE PULSATION
Controlled beneficial use of pulsations
Assists in overcoming static resistance
Combats “rat-hole” problems as suction inlet
Invigorates the sludge to reduce settlement
SUCTION MONITOR
Suction line vacuum measured on upstroke
Pump upstroke speed controlled to suit conditions

7. PREVIOUS DEVELOPMENTS

8. NEW DEVELOPMENTS
PUMP OPTIMISATION BY ADAPTIVE CONTROL
Refinement of previous developments
Fully adaptive control to suit sludge conditions
Pump speed optimised based on several parameters
Optimum throughput maintained
Energy minimised
Provides flexibility to cope with changing conditions

9. PUMP OPTIMISATION

10. OBJECTIVES
ADAPTIVE PUMPING TRIAL
Investigate feasibility of reliably pumping thick sludges
Explore the economic benefits of pumping thick sludge
Demonstrate the reliable operation of adaptive control

11. ADAPTIVE PUMPING TRIAL
THE INSTALLATION

12. ADAPTIVE PUMPING TRIAL
THE ADAPTIVE PUMP SYSTEM
An EMS hydraulic ram pump
An EMS adaptive control system
Sludge blanket measurement instrument
Sludge density measurement instrument
Sludge flow rate measurement instrument
Data-logging system

13. ADAPTIVE PUMPING TRIAL
OPERATION OF THE ADAPTIVE SYSTEM
Start of pump on blanket level and/or settlement time
Stop pumping as sludge density lowers
Minimise power required at given output

14. TRIAL RESULTS
SLUDGE DENSITY
FLOWRATE
BLANKET LEVEL
POWER

15. TRIAL RESULTS
THE RESULTS DEMONSTRATED
Sludge in excess of 5.5% regularly pumped
Pumping time 30mins in 4 hours
Sludge blanket level stability maintained
BOD removal improved
THESE RESULTS HAVE BEEN RELIABLY
REPEATED FOR OVER A YEAR

16. ANALYSIS OF RESULTS
EXISTING PUMP SYSTEM
Volume pumped in 4 hr period = 18 m3
Pumping regime – 10 min pumping, 10 min stopped
Solids % pumped = 2 - 2.5%
Average Power/hr required = 3.75 kWhr
Amount of solid pumped in 4 hr period = 450 kg
ADAPTIVE PUMP SYSTEM
Volume pumped in 4 hr period = 9 m3
Pumping regime – 30 mins pumping in 4 hours
Solids % pumped = 5.5%
Average power/hr required = 0.94 kWhr
Amount of solids pumped in 4 hr period = 495 kg

17. ADAPTIVE PUMPING BENEFITS
PROCESS BENEFITS
Pump more solids less water
Optimise the use of existing PST’s
PLANT RESILIENCE
Ability to cope with variable sludge conditions
Reliable operation
ENERGY SAVINGS
Consume only the power required to suit the duty

18. THE NEXT STAGE
USING THE BENEFITS OF THICKER SLUDGE
Revaluate the process stream
Reduce or eliminate secondary thickening
Achieve significant energy savings
LIFECYCLE COST EVALUATION
Evaluate all relevant factors
Energy saving
Capital cost savings
Plant resilience

19. CONCLUSION
Adaptive control facilitates pump optimisation
Efficiency maintained with varying sludge thickness
Potential to reduce or eliminate secondary thickening
Potential significant energy savings
Choices options for plant design offered

20. ANY QUESTIONS?