Enhancing efficiency of wastewater applications

There are many challenges facing wastewater plants and industrial wastewater managers. How can the operators of these facilities increase operational efficiency as part of their wastewater applications?

Wastewater plants, mines, and manufacturing industries face complex challenges. Older plants need to be upgraded to achieve efficiency targets. At the same time, plants are looking for ways to lower operating costs. Operators are also looking to improve the plant’s productivity, including enhancing energy efficiency, operational efficiency, and resource utilisation.

There is also an increased focus on reusing wastewater wherever possible. This is particularly the case when looking at water scarcity. More countries are facing the same challenge when it comes to the availability of water for both potable and non-potable purposes.

This is where Bonfiglioli steps in to support the water and wastewater industries. It is a family-run Italian company with a global presence. Bonfiglioli’s three business units, Discrete Manufacturing & Process Industries, Motion & Robotics, and Mobility & Wind Industries, embody all the expertise and experience needed to support its customers’ growth.

Understanding the wastewater industry

Harry Singh is the National Sector Manager for Bonfiglioli Australia. He’s been working for Bonfiglioli for more than 13 years and has an insight into how the company can help wastewater plants become more productive. The wastewater treatment sector in Australia faces many challenges.

“The cost of living is one of the big issues,” Singh said. “The increase in energy prices is hurting many wastewater plants. It’s also critical that these facilities reduce the impact of maintenance and downtime on their facilities, as that is a period where they are not working on waste, which costs them money. Finally, they have to work tirelessly to ensure there are no accidents and as little contamination of waste streams as possible.”

Gear motors and gearboxes are crucial in improving wastewater treatment plants’ overall efficiency and performance. They work constantly to ensure that materials are moved where needed.

“It is essential that the gear motor selection is accurate,” he said. “The right gear motor is based on the operational needs and size of the plant. Plant managers want gear motors with the highest possible efficiency, as it reduces running costs through using less energy.”

The gear motors should also have the correct bearings and gear life. The goal is to have the longest possible life for the gear motor system, which reduces its long-term replacement cost. That’s why several factors need to be considered when selecting a gearbox and gear motor solution.

What is important?

“Understanding the power demands and output torque is critical,” Singh said. “Getting that relationship right is key to increasing the facility’s efficiency. Wastewater plant managers also need to consider the gear motor system’s service factor and the bearings’ life.”

Another aspect is having the proper oil viscosity. That is because it can minimise friction and mitigate wear and tear on the system. This is why the oil level indicator is needed, as it can prevent damage to the drive through a lack of lubrication.

“The dry well system is mandatory on all our devices,” he said. “That’s to avoid contamination from oil leakage. We also include desiccant or pressure filter breathers to prevent moisture from entering the drive.”

Singh pointed out that maintenance is essential for any wastewater management facility. It needs to be done in a timely manner as per the manufacturer’s recommendations.

“Taking an oil sample during maintenance and getting it checked can also determine if there are any abnormalities within the lubrication system,” said Singh. “If detected earlier, this can save downtime and money. We have found that some customers can be too busy to properly maintain their machines, but it winds up costing them more later.”

Keeping up to date with the latest technology can improve the efficiency of wastewater treatment facilities. Bonfiglioli offers a range of accessories that can help operators understand the internal operations of the drive system.

“We had a situation with one of our council customers,” Singh said. “They wanted a drive with an auto-shutdown system. Bonfiglioli provided the right instrumentation to achieve this goal while adding vibration analysis. This has become the standard package for this client, who has now saved a lot of labour and money.”

Working together

Collaboration is vital when gearmotor specialists talk with wastewater treatment plant operators. Gearmotor specialists need to understand the plant’s operations, and the operators must appreciate that getting the right gearmotor is fundamental to improving the plant’s efficiency and productivity.

“Bonfiglioli has a range of equipment and accessories that can be added to our drive systems,” Singh said. “They can be used remotely or from a control room, which means operators do not need to get close to the equipment.”

These features provide protection and vital readings. These readings can include load, vibration, temperature, and oil levels, among many other essential readings.

“The more the protective features are used, the better the outcomes for the wastewater treatment plant. That’s particularly the case when it comes to efficiencies and cost savings.”

For more information, visit https://www.bonfiglioli.com/australia/en