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Intelligent dense-phase sludge conveying over long distances

Hydro Prokav’s  intelle Sludge Transfer (i ST) System offers a smart, automated solution for transferring dewatered sludge with solid content ranging from 20% to 40%—efficiently covering distances up to 1000 meters. The IST system ensures lower energy consumption, minimal maintenance requirements, and reduced environmental footprint. Engineered for precision and reliability, it’s a future-ready solution for industries seeking cleaner, safer, and more cost-effective sludge handling.

Units & Systems Used:

Progressive cavity pump with hopper feed: Handles challenging sludge feed efficiently, forming a dense sludge plug suitable for onward pneumatic conveying

Lubricant dosing for friction reduction: A polymer-based wall lubricant is injected to create a boundary layer, enabling smooth sludge flow through pipelines and boosting energy efficiency

Air compressor unit: A compact sludge plug is gently propelled using pulsating compressed air, reducing pump discharge pressure and overall power consumption

Automated intelligent control: Integrated control unit manages pump, air injection, dosing, and safety—complete with remote parametrization, real-time monitoring, and safety interlocks

Benefits

Low maintenance, compact design: With lubrication and air injection units in place, mechanical stress on the pump discharge is significantly reduced—resulting in a longer service life and a more compact footprint.

User and Environment-Friendly Design: An enclosed system designed to protect users and the environment by minimizing contact, contamination, odor, and manual handling.

Better Savings: Save valuable man-hours, reduce transportation costs and associated maintenance cost for improved operational efficiency and a stronger return on investment (ROI)

Efficient Conveying System: This efficient, tailor-made conveying system is engineered with advanced techniques to outperform traditional methods such as belt and conveyor systems.

Technical Specifications

Conveying Capacity: 0.5–15 m³/h

Discharge Pressure: Up to 4 bar

Pipe Length: Up to 1,000 m

Viscosity: 5,00,000 cP

Dry Solids Content: 20–40%

Temperature: 46°C

Applications

  • Environmental & Wastewater Treatment: Efficient long-distance sludge transfer in Effluent Treatment Plants (ETPs) and Sewage Treatment Plants (STPs).
  • Thermal Processing & Recycling: Seamless conveyance of sludge into thermal units or disposal systems for energy recovery and waste reduction.
  • Agricultural Spreading: Reliable sludge transport for land application and fertilization, supporting sustainable farming practices.
  • Industrial Waste Handling: Versatile performance across industries such as food processing, manufacturing, pharmaceuticals, chemicals, and paper—handling sludges with solid content with ease.