Diffuser Comparisons
Comparison to Other Coarse Bubble Diffusers
Air Release Holes. Most coarse bubble diffusers have up to 10 or 12 air release holes. The Flexcap Diffuser has 16 Air Release Openings, which provide superior aeration and diffusion performance. |
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The efficiency of oxygen transfer depends on many factors, including the type, size and shape of diffusers and the tank geometry. Since the introduction of the activated sludge process in the early 1900s, many different types of subsurface or diffused aeration devices have been designed and developed that will dissolve oxygen into wastewater. Diffusion devices have ranged from simple individual holes or slots drilled into a section of pipe to more elaborate devices with small diameter particles fused together.
Diffuser Cap Design – AS SHOWN BELOW From a side view, compare the distinctions of Flexcap’s more advanced design (on left) to a competitors’ flexible diffuser (on right). |
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| COARSE BUBBLE VS. FINE BUBBLE AERATION
Although their size, shape and material of construction may vary considerably, diffused aeration devices are usually classified by the relative diameter of the bubbles they produce:
Oddly enough, there is no precise delineation between the diameters of fine and coarse bubble diffusers. For decades, coarse bubble diffusers were used throughout the entire wastewater and water treatment systems. When the cost of energy climbed in the mid-1980s, fine bubble diffusers replaced the coarse bubble diffusers for primary treatment processing. Primary treatments typically require 20-23% oxygen transfer rate. Using the same energy consumption, coarse bubble diffusers would only supply 10% and would require almost 2-3 times more energy to produce the same results as the fine bubble diffusers. HOWEVER, in the secondary treatment (or side processing) phases, the small air openings in fine bubble diffusers are not an advantage. In these processing tanks, floc (particles), sediment and carbonate buildup tend to plug or clog the fine or small air release openings. Coarse bubble diffusers are the mainstay solution. |
AERATION REQUIREMENTS
Aeration systems for conventional wastewater activated sludge plants typically account for 45-60% of a treatment facility’s total energy consumption. To define what improvements would be most cost-effective requires an understanding of how to create a simplified model of the system. WastewaterAeration requires equipment for the biological process and for mixing that keeps the solids suspended for a more effective treatment. Although there are many types of aeration systems, there are two basic methods of aerating wastewater:
DIFFUSER COMPARISON GUIDE (coming in late 2011) |
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Customer Reviews and Testimonials
FIRST FLEXCAP DIFFUSER INSTALLATION
The initial Flexcap diffusers were installed in 1985 for a treatment plant in Michigan. According to their facility operations manager, their Flexcap coarse bubble aeration diffusers are STILL performing as required.
HOW MUCH WILL YOU SAVE?
- Annual Cost of Diffuser Replacements
- Annual Cost of Maintenance
to test and/or replace diffusers - Downtime
of wastewater treatment processing during diffuser servicing or replacement
COST-SAVINGS: TIME AND BUDGETS
As cost considerations always play a factor in operating budgets, we can help you with recommendations for efficient, quality alternatives next diffuser replacements or aeration systems provider.
As a long-standing aeration diffusion and systems provider, we offer our Flexcap diffuser replacement guarantee that you will not have to clean or replace your Flexcap Coarse Bubble Diffusers for at least the next 20 years!
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