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Thames Water
Expel filtration system is estimated to save Thames Water Utilities site tens of thousands of pounds.
Ready to Stop Equipment Failure and Save Thousands?
Project Background:
Thames Water Utilities Limited, a leading facility in wastewater management, has long relied on advanced Thermal Hydrolysis Processing (THP) to treat sludge before anaerobic digestion. This stage is critical for reducing sludge volume and enhancing biogas production. Compressed air is vital for operating THP equipment. However, the plant faced recurrent compressed air contamination issues. Contaminants such as moisture, oil emulsion fluids and solid particulates caused the pneumatically actuated valves to fail. Failing valves on THP equipment can lead to the following:
System Integrity Issues: Contaminants can cause blockages or weak points in the system, leading to potential safety hazards such as unexpected pressure releases or bursts.
Biological Process Impact: If compressed air contaminants compromise the thermal hydrolysis process, the downstream anaerobic digestion process can also be affected—incomplete hydrolysis results in less efficient digestion, lower biogas production, and higher residual sludge volumes.
Compromised Process Efficiency: Contaminants can cause corrosion of metal components in THP systems, leading to further equipment failures, leaks and increased maintenance costs.
The plant incurred substantial costs due to compressed air contamination, which caused part replacement and downtime. The site’s operations manager reported that equipment failures necessitated over £10,000 in annual part replacement costs, and the downtime this generated translated to a loss of £17,000 per day. The company wanted urgent action to mitigate these disruptions and maintain operational efficiency. Naturally, they turned to ERIKS, a universally recognised industry leader in offering their customers the best product selection.
Summary:
Application
Thermal Hydrolysis Processing (THP).
Cost Saving
£10,000 per year in replacement valve costs.
£17,000 per day of downtime.
Payback Period
One month.
Why Did Thames Water Choose Expel?
Expel achieved a return on investment within one month!
ERIKS knew that the Expel filtration system would solve the issues Thames Water Utilities were experiencing. Unlike any other potential solution, Expel promised to provide a permanent and fail-safe solution to stop problems associated with the three primary sources of compressed air contamination. Its advanced filtration technology uses physics to continually remove 99.999% of liquid water, oil emulsion fluids and solid particulates to 1 micron. In contrast, conventional filters use disposable internal elements made from disposable materials like mesh or sponge to trap contaminants. Such products can never guarantee that pneumatic equipment is protected, even if they are brand new. Furthermore, they require continual maintenance and part replacement costs.
By installing Expel, the facility stopped premature valve replacement and downtime costs. Expel achieved ROI within one month, and the company saved money and ran the THP system without any issues from compressed air contaminants.
The Results:
Drastically Reduced Costs: After installing Expel, the facility observed a drastic reduction in the need for part replacements. By protecting the THP equipment from contaminants, Expel saved Thames Water approximately £10,000 annually in replacement valves that would otherwise get damaged by compressed air contaminants.
Minimised Downtime: Expel’s reliability led to a substantial decrease in unplanned downtime. The filtration system’s unmatched equipment protection ensures that the THP system operates smoothly without interruptions.
Improved Operational Efficiency: By providing consistently clean compressed air, Expel improved the overall efficiency of the THP process. This enhancement reduced operational costs and contributed to higher biogas production and better sludge management, further optimising the plant’s performance.
Enhanced Safety and Compliance: Eliminating contaminants minimised the safety risks associated with equipment failure and potential pressure bursts. Additionally, maintaining clean air ensures compliance with environmental and safety regulations.
Our team is ready to answer your questions.
David specialises in improving business efficiency. By building strong industry relationships, David ensures Expel’s revolutionary technology delivers real value to businesses.
With vast pneumatics knowledge, Johan specialises in on-site assessments to identify strategic installation points to maximise performance and eradicate contamination.
Lauren is a key point of contact for customers. She handles general inquiries and provides exceptional after-sales support, ensuring a smooth customer experience.