The operator of the wastewater treatment plant had been struggling with oxygen deficiency in the biological tanks due to inefficient aeration, as the existing membrane elements (ABS/Nopon PIK300 diffusers) were over 20 years old and completely worn out. We presented the operator with 4 possible solutions from three different manufacturers, outlining the advantages and disadvantages of each. The operator decided on an equivalent replacement of the existing diffusers with new ones from the German manufacturer Supratec, which did not require any modifications to the existing manifold network and were 40% cheaper than the existing ABS PIK300 diffusers from Sulzer. The replacement process was carefully planned. Firstly, one of the 4 pools was emptied in January to inspect the condition of the manifold network and the compatibility of the new diffusers before they were ordered. The replacement of diffusers in the first line (2 pools) followed in March, where the operator emptied and cleaned the pools, and our expert team removed the old diffusers and installed the new ones in just 7 hours, under very challenging weather conditions. The line was started up, waited for a month for the biological processes to fully establish, and then in April, the diffusers in the second line were also replaced, which was completed in a single day. 

With this project, we have demonstrated that it is possible to find completely equivalent replacements for existing membrane elements by having a good understanding of the market. This approach allows for significant cost savings without compromising the quality of the diffusers or the execution of the replacement process (modifications to the existing manifold network). Therefore, we invite users of Sulzer ABS PIK300 membrane diffusers, in particular, to contact us so that we can find a very cost-effective solution for their replacement needs.