PC Pasteurisation Pump Upgrade Proves Its Worth
Project Overview
With concerns over the reliability and maintenance costs of the sludge pasturisation pump, this STW trialled 3 progressive cavity pumps from different brands. The Toro-Kronoa PC proved itself to be the best solution.
Challenge
The site’s pasteurisation system is critical to ensure compliance with ABPR and PAS110 standards. It processes approximately 45 m³/hr of digestate (6% DS), primarily municipal sludge co-digested with food waste, at 70 °C for one hour.
Frequent failures of the existing WIMES-compliant progressive cavity (PC) pump caused repeated downtime. Wear-rate required rotor replacements every 4-5 months, leading to extended maintenance interventions and process instability.
The existing pump was unable to withstand continuous duty at 8 bar system pressure. Failures resulted in significant operational disruption and increased OPEX due to frequent wet-end part replacements.
Solution
Atlantic Pumps, in partnership with Toro-Kronoa, supplied a Toro S65 225-12 Progressive Cavity Pump designed for high-solids, high-temperature municipal sludge applications.
Key technical features:
- Two-stage PC pump rated to 12 bar for system headroom.
- Stator: NBR-based elastomer suitable for 70 °C continuous and 90 °C peak operation.
- Rotor: Hardened tool steel for superior wear resistance and compressive strength.
- Bearing Assembly: Bearing and Mechanical Seal Assembly added to bear the pressure and increase the life of the motor and gearbox.
- Short-pitch (S-type) geometry providing improved solids handling, reduced shear, lower internal velocities, and extended service life.
The Toro S65 PC pump was installed as a direct replacement, fitting within the same space and no significant pipework modifications were required. Commissioning was completed with support from Atlantic Pumps and site maintenance teams.
Results
Within a few months, it was clear the project had improved reliability, vastly reduced maintenance frequency, and enhanced the pasteurisation process stability while maintaining compliance and throughput volumes.
Pressure testing of the pump shows little wear, indicating it will be some time yet before the first wear part needs replacing.
- Unplanned downtime: Non-to-date; only condition monitoring checks performed.
- Component longevity: Wear parts still performing; lifespan increased from 3 months to 6 + months.
- Maintenance interventions: Reduced frequency; fewer confined-space entries and risk associated with major part replacements.
- Process performance: Improved stability and control across the pasteurisation system.
- Financial outcome: Higher initial CAPEX offset by OPEX savings and reduced operational risk.
To discuss how your pasturisation or other process pumps might be improved, reach out to our water lead, Martin Gillman via email: [email protected] or phone: 07984 246 552.
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