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Referenz

Punktlandung im Belebungsbecken

H2Ortner aus Passau hat mit WAGO-Technik ein Reglermodul entwickelt, das es Betreibern von Kläranlagen ermöglicht, die Gebläse ihrer Belebungsbecken je nach Belastung des Abwassers bedarfsgerecht zu steuern. Das spart Strom, verringert die Stickstoffkonzentration im Ablauf und erhöht die Betriebssicherheit. Die Praxis zeigt: In vielen Fällen können Anlagenbetreiber die Investition allein durch den Erlass der Abwasserabgabe refinanzieren.
In jeder modernen Kläranlage gibt es Mitarbeiter, die rund um die Uhr im Einsatz sind, ohne Urlaubsanspruch und sogar ohne Bezahlung: Bakterien, die im Belebungsbecken Schadstoffe im Abwasser abbauen. Die für die sogenannte Nitrifikation – die Umwandlung von stickstoffhaltigem Ammonium in Nitrat – zuständigen Mikroorganismen verlangen lediglich Sauerstoff für ihr Werk.

Vorteile des WAGO-Controllers PFC200:

  • Der Controller ermöglicht eine webbasierte Kontrolle und Parametrierung der Prozesse.
  • Über die übersichtliche Oberfläche lassen sich alle Daten schnell erfassen.
  • Die umfangreichen Schnittstellen ermöglichen optimale Bedingungen zur Kommunikation mit verschiedenen Steuerungen.

Unnötig hohe Abgaben

Der Sauerstoff wird über Gebläse in die Belebungsbecken eingetragen. Gerade in kleinen und mittelgroßen Kläranlagen erfolgt deren Steuerung meist über eine Zeitschaltung – unabhängig davon, wie groß die Abwasserbelastung im Zulauf tatsächlich ist. Auch die Dynamik der biologischen Prozesse im Belebungsbecken bleibt dabei unberücksichtigt. In der Regel wird hier nach dem Motto „Viel hilft viel“ verfahren: Lieber etwas länger belüften, um sicher zu gehen, dass die geforderten Grenzwerte auch tatsächlich eingehalten werden. Da die Gebläse jedoch sehr viel Strom benötigen, treibt diese Fahrweise die Energiekosten in die Höhe. Zudem beeinträchtigt ein Übermaß an Sauerstoff den der Nitrifikation folgenden Prozess der Denitrifikation, bei der das gebildete Nitrat zu molekularem Stickstoff abgebaut wird. Die Ablaufwerte sind daher meist nicht so niedrig, wie sie sein könnten. Das hat zur Folge, dass Anlagenbetreiber häufig eine unnötig hohe Abwasserabgabe bezahlen müssen.

Bedarfsgerechte Gebläsesteuerung

Gute Gründe für den Abwasserreinigungs-Spezialisten H2Ortner aus Passau, eine Lösung für die bedarfsgerechte Gebläsesteuerung zu entwickeln! Das mit Automatisierungstechnik von WAGO ausgerüstete System namens „NiDeEco“ stellt sicher, dass die aeroben Bakterien im Belebungsbecken jederzeit optimal mit Sauerstoff versorgt werden. „Mit unserem Reglermodul senken die Betreiber von Kläranlagen die Stickstoffkonzentration im Ablauf und reduzieren zugleich ihre Energiekosten“, erklärt Geschäftsführer Josef Ortner. Darüber hinaus macht es das System möglich, die Elimination von Phosphor zu optimieren.

Dynamik der Prozesse im Bild

NiDeEco steuert die Gebläse und damit die Nitri- und Denitrifikation abhängig von der Belastung des Abwassers. Als Ausgangspunkt dienen die aktuellen Sauerstoff-, Ammonium- und Nitratwerte, die von vorhandenen oder neu zu installierenden Sensoren erfasst werden. Die Daten werden per Funk an das Reglermodul übertragen. Dort ist eine Software hinterlegt, die anhand der Sensordaten die Abbauleistung ermittelt und auf dieser Basis den optimalen Sauerstoffeintrag berechnet. Dabei arbeitet das System nicht mit Einzelwerten, sondern mit Kurvenverläufen. „So können wir die Dynamik der Prozesse berücksichtigen – ein großer Vorteil bei der punktgenauen Steuerung der Gebläse“, erläutert Ortner. NiDeEco ist dabei nicht nur in der Lage, Gebläse direkt anzusteuern, sondern auch übergeordnete Steuerungen zu adressieren.

process_referenz_ortner_land_klaeranlage_becken_wasser_2000x1125.jpg

Das Reglermodul von H2Ortner ermöglicht Klärwerkbetreibern, eine unnötig hohe Stickstoffkonzentration im Ablauf zu vermeiden.

Alle Werte jederzeit im Blick

Herzstück des Reglermoduls ist der WAGO-Controller PFC200. Die Parametrierung und Kontrolle der Prozesse erfolgt webbasiert. Die Mitarbeiter können mithilfe eines handelsüblichen PCs, eines Tablets oder eines Smartphones über eine geschützte IP-Adresse auf den Controller zugreifen. Das verschafft ihnen Flexibilität, da sie auch aus der Ferne, etwa von zuhause aus, alle Werte im Blick behalten. Dank einer übersichtlichen Oberfläche sind alle relevanten Daten schnell erfassbar. Zudem können die Mitarbeiter sämtliche Parameter auf diesem Wege ohne jeden Aufwand selbst einstellen. „Uns war wichtig, statt einer Black Box eine Lösung zu schaffen, die unsere Kunden unabhängig von einzelnen Herstellern macht“, sagt Ortner. Der WAGO-Controller bietet weitere wichtige Vorteile. „Dazu zählt zum Beispiel die Möglichkeit, die Parametrierung und Visualisierung über die IP-Adresse direkt im Reglermodul vorzunehmen. Zudem bietet das Produkt mit seinen Schnittstellen optimale Möglichkeiten zur Kommunikation mit verschiedenen Steuerungen. Und nicht zu vergessen: WAGO zeichnet sich durch ein sehr gutes Preis-Leistungs-Verhältnis aus“, erklärt Ortner.

Refinanzierung über den Erlass der Abwasserabgabe

In bundesweit zwanzig Klärwerken – meist kleinen und mittelgroßen Anlagen – ist NiDeEco bereits im Einsatz. In allen Fällen ist es gelungen, den Stromverbrauch der Gebläse um mindestens zwanzig Prozent zu reduzieren. Das entlastet die Betreiber erheblich, was sich etwa am sogenannten Einwohnerwert zeigt, der die Kapazität eines Klärwerks beschreibt: Bei einer auf 10.000 Einwohnerwerte ausgelegten Anlage zum Beispiel bedeuten zwanzig Prozent Reduktion rechnerisch eine Ersparnis von jährlich mindestens 17.000 Euro. Dazu kommt: Die Anlagenbetreiber sind drei Jahre lang von der Abwasserabgabe befreit, wenn es ihnen gelingt, einen der drei relevanten Ablaufwerte – die Stickstoff- und Phosphorkonzentration oder den Bedarf an chemischem Sauerstoff – um zwanzig Prozent zu senken. Mit dem System von H2Ortner ist es in der Regel kein Problem, den Stickstoffgehalt in dieser Größenordnung zu reduzieren. Da das Reglermodul keine hohe Investition erfordert, lässt es sich in vielen Fällen schon allein durch den Erlass der Abwasserabgabe refinanzieren. „Das gilt sogar für Anlagen, deren Einwohnerwert unter 7.000 liegt, so dass die Abwasserabgabe niedrig ist“, betont Ortner. „NiDeEco hat sich damit also schon vom ersten Tag an amortisiert.“

WAGO-Kläranlage-Bürosituation.jpg

Herzstück der neuen Technik von H2Ortner ist der WAGO-Controller PFC200. Mithilfe der bedarfsgerechten Gebläsesteuerung werden Kosten gesenkt und die Umwelt geschont.

Weniger Umweltbelastung und geringere Kosten

Zum finanziellen Vorteil kommt ein Gewinn an Sicherheit. Denn wenn die Gebläse allein nach vorab festgelegten Zeiten gesteuert werden, kann es passieren, dass bei einer sehr hohen Schadstoffkonzentration im Zulauf zu wenig Sauerstoff für die Nitrifikation zur Verfügung steht. Das belastet die Umwelt – und kostet die Anlagenbetreiber in der Folge viel Geld, da sich die Höhe der Abwasserabgabe nach den Schadstoffen im Ablauf bemisst.

Individuelle Auslegung des Systems

Ausgehend von einer sorgfältigen Analyse der technischen und wirtschaftlichen Gegebenheiten passen die Experten von H2Ortner das System stets individuell an die jeweilige Anlage an. So ist es zum Beispiel nicht in jedem Fall notwendig, Sensoren für sämtliche Werte (Sauerstoff, Ammonium, Nitrat) zu installieren. „Unsere Kunden bekommen für eine geringe Investition ein Regelsystem, das exakt auf ihre Bedürfnisse zugeschnitten ist“, sagt Ortner. Damit stellen die Anlagenbetreiber sicher, dass sich ihre aeroben Bakterien im Belebungsbecken jederzeit pudelwohl fühlen – und sparen so Energiekosten, erhöhen die Betriebssicherheit und verbessern die Wasserqualität im Ablauf.

Ihre Vorteile mit dem Controller PFC200:

  • Programmierung gemäß IEC 61131-3

  • Kombinierbar mit Hochsprachen

  • SPS- und IT-Funktionen in einem Gerät

  • Vielfältige Schnittstellen, Funktionen und Einsatzbereiche

Text: Kay Miller | WAGO

Foto: Ralph Diermann

Produktübersicht

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WAGO in der Praxis

Referenzen aus dem Bereich Verfahrenstechnik

WAGO setzt als Partner und Innovationsführer viele interessante Projekte um. Erfahren Sie, was wir für kreative und effiziente Lösungen im Bereich Verfahrenstechnik ermöglichen.

Automatisierung für Pipelines

Begleitheizanlagen verhindern das Vereisen der Pipelines bei sibirischen Temperaturen. Zum Einsatz kommen dabei explosionsgeschützte

process_landschaft_brunnen_schnee_2000x1500.jpg

Geregelte Kläranlagen

Die bedarfsgerechte Steuerung spart Strom, verringert die Stickstoffkonzentration und erhöht die Betriebssicherheit. Möglich gemacht mit WAGO-Technik.

process_referenz_ortner_explosionsschutz_klaeranlage_becken_filter_2000x1500.jpg

Automatisierte Überwachungspegel

Für den Betrieb der Förmitztalsperre misst das Wasserwirtschaftsamt Hof viele Pegelstände. Für die Sicherheit der Sperre kommt WAGO-Technik zum Einsatz.

process_landschaft_windkraftanlagen_see_felder_2000x1500.jpg
Ihr Ansprechpartner bei WAGO

Weitere Serviceangebote:

Das könnte Sie auch interessieren

Mehr aus dem Bereich Prozesstechnik

Ganz gleich, ob modulare Prozessautomation, Explosionsschutz, Cyber-Security oder Prozess 4.0 – WAGO bietet Lösungen für jede Herausforderung der Branche.

Modulare Prozessautomation

Wandlungsfähige Produktionsprozesse sind der Schlüssel zu Flexibilität, Effizienz und Losgröße 1. Mit WAGO lassen sich Produktionsmodule individuell und herstellerunabhängig kombinieren.

process_modulare-prozessautomation_gettyimages-457978501_2000x1500.jpg

Energiemanagement

Energiesparen ist gut für die Umwelt und das Geschäft. Wer dabei gut analysiert und agiert, kann nachhaltig profitieren. WAGO ist Ihr Partner für effektives Energiemanagement.

process_referenz_prozessindustrie-4-0_visualisierung_software_energiemanagement_tablet_produktion_halle_2000x1500.jpg

Smart Data

Die Digitalisierung von Bestell- und Produktionsprozessen ist für alle Unternehmen eine große Chance. WAGO unterstützt Sie dabei, alle Potentiale zum Vorteil zu nutzen.

digitalisierung_smart-data_zwei_personen_rechner_fabrikanlage_arbeitssituation_GettyImages-482172147_2000x1500.jpg

Empfehlungen zum Weiterlesen

WAGO in anderen Branchen

Automatisierungs- und Kontakttechnik von WAGO ist nicht nur im Bereich Prozess- und Verfahrenstechnik vertreten. Erfahren Sie, welche Lösungen WAGO in anderen Branchen bietet.

Marine & Offshore

Moderne Antriebstechnik, die Vernetzung von Teilsystemen – Automatisierung und Digitalisierung sind auf dem Schiff Standard.

Marine_FINAL_V4_2000x1500.jpg

Energietechnik

Mithilfe moderner Automatisierungs- und Digitalisierungstechnologien entstehen kommunikative Smart Grids.

Energy_FINAL_V6_2000x1500.jpg