Optimization of Aeration Control and
Biogas Quality Monitoring
The need to increase energy efficiency while stabilizing processes and meeting the new environmental goals of the city of Kiel required a comprehensive modernization of the existing aeration system. By implementing low-pressure-loss control valves and an intelligent process control system, significant savings were achieved, and process stability was sustainably improved.
Customer Benefits
- Annual energy savings:
approx. € 300.000 - Demand-based air distribution and regulation of air injection into long, narrow tanks
- Reduction in oxygen carryover, improving biological nitrogen removal
- Stable treatment performance even during sudden
- load fluctuations (e.g., heavy rainfall)
- Flexible, future-proof operation with expandable
- control functions due to a fully modular design
Industry
Municipal wastewater treatment
Capacity
54.000 m³/day, 364,000 PE (population equivalent)
Timeframe
2018 – 2019
Systems / Produkts
VACOMASS® jet control valves, flow meters, flexcontrol, COMBIMASS® gas analysis station
Treatment Process
Activated sludge with pre-denitrification
Technical Highlights
AI-based oxygen control, sliding pressure regulation via MOV/MIV, DO-SET NH4-N, aeration maintenance
Customer Investment
€ 450,000 (including installation and pipeline adjustments)
Annual Savings
Approx. € 300.000
Challenge
The wastewater treatment plant is the largest municipal energy consumer in the climate-conscious city of Kiel.
The existing aeration control and distribution system was inflexible, and the control valves used had high pressure losses, leading to increased electricity consumption.
During fluctuating load conditions, the treatment performance was insufficiently stable.
Only a complete modernization could unlock the full optimization potential.
Solution
BINDER supplied and implemented a measurement and control system with VACOMASS® jet control valves, air flow meters, and the flexcontrol process controller.
The rectangular tanks were divided into two zones each to dynamically calculate the constantly changing air demand along the flow path using an intelligent, AI-supported algorithm and adjust the control valves accordingly.
The system was integrated into the existing PLC infrastructure with minimal effort and in a short time.
“With flexcontrol, we were able to largely automate our biological stage
— this gives us greater process stability, less manual operation, and a noticeable efficiency boost.“Michael Wuttke, Head of Process Engineering, Bülk Treatment Plant
Typical system response to a heavy rainfall event
– automatic adjustment of oxygen setpoint, valve opening, and system pressure to stabilize treatment performance
The old compressors with manual regulation limited the required pressure increase over time. The control valves opened fully, significantly reducing the ammonium breakthrough compared to the previous situation.
Further Information
View press release … (PDF, 429 KB)