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客戶應用 2023年11月20日

高精度的曝氣池

利用 WAGO 技術，來自 Passau 的 H2Ortner 開發了一個控制器模組，使廢水處理工廠的操作員能夠基於需求對他們的曝氣池中的鼓風機進行由廢水汙染程度取決的控制。這種類型的控制可以節省電力、降低排放物中的氮氣濃度並提高運作可靠性。實務經驗表明，在許多情況下，工廠經營者僅透過免除廢水處理費就可以收回投資。

在任何現代化的污水處理廠中，都有團隊成員晝夜不停地工作，沒有假期，甚至沒有工資：在曝氣池中分解廢水中有害物質的細菌。所有負責硝化作用（將含氮氨轉化為硝酸鹽）的微生物都需要氧氣。

WAGO PFC200 控制器優勢：

此控制器允許架構於網路的過程控制和參數化。
架構清晰的介面使所有數據都能快速掌握。
綜合的介面為與各種控制器的通訊提供了最佳條件。

不必要的高額收費

氧氣經由鼓風機注入曝氣池。在中小型廢水處理廠中，這些工廠通常由計時器控制 – 無論廢水進水的實際污染程度如何。這種方法也繞開了曝氣池中生物過程的動力學。這個過程通常假設「多即是好」：最好再曝氣一段時間，以確保實際達到所需的極限值。然而，由於鼓風機需要大量電力，這種方法會增加能源成本。此外，過量的氧氣阻礙了硝化反應後的階段 — 反硝化 — 其中產生的硝酸鹽隨後被還原為分子氮。因此，排放值並沒有想像的那麼低。結果是工廠經營者常常必須支付不必要的高額廢水處理費。

基於需求的鼓風機控制

這些就是為什麼 H2Ortner，一家來自 Passau 的廢水淨化專業公司，為基於需求的風機控制開發解決方案的一些原因。該系統名為「NiDeEco」，配備 WAGO 自動化技術，確保曝氣池內的好氧細菌始終擁有最佳的氧氣供應。CEO Josef Ortner 解釋道：「我們的控制器模組使廢水處理工廠的操作員可以減少排放中的氮濃度，同時降低能源成本。」此外，該系統還使最佳化除磷成為可能。

過程動態概覽

NiDeEco 根據廢水污染程度控制鼓風機，進而控制硝化和反硝化。由現有或新安裝的感測器記錄的當前氧氣、氨和硝酸鹽值是起點。數據無線傳輸到控制器模組，其中軟體應用根據感測器數據確定治療性能，然後在此基礎上計算最佳氧合水平。系統不使用單獨的值，而是使用曲線級數。Ortner 解釋道：「這使我們能夠考慮過程的動態 – 這對於精確控制鼓風機來說是一個巨大的優勢。」在此過程中，NiDeEco不僅可以直接控制鼓風機，還可以處理更高級別的控制器。

時刻關注所有數值

控制器模組的核心是 WAGO PFC200 控制器。過程的參數化和監控是架構於網路的。員工可以使用標準 PC、平板電腦或智慧型手機透過安全的 IP 位址存取控制器。這給了他們靈活性，因為他們可以從遠處（例如在家中）關注所有數值。架構清晰的介面可以快速掌握所有相關數據。此外，這使得員工可以輕鬆地自行設定所有參數。Ortner 說：「對我們來說，重要的是建立一個解決方案，使我們的客戶獨立於各個製造商，而不是一個黑盒子。」 WAGO控制器還具有更多重要優勢。「例如，其中包括透過 IP 位址直接在控制器模組中執行參數化和視覺化的選項。此外，憑藉其多種介面，該產品提供了與不同控制器進行通訊的理想選擇。也不要忘記 WAGO 出色的性價比，這真的很突出，」Ortner 解釋道。

透過免除廢水處理費收回投資

NiDeEco 已在德國各地的 20 個廢水處理廠中使用，大部分是中小型工廠。在每種情況下，功耗都已成功降低了至少 20%。這顯著減少了操作員的負擔，這可以使用描述廢水處理廠能力的群體當量來說明。例如，對於為 10,000 人設計的工廠，減少 20% 意味著每年節省至少 17,000 歐元。此外，如果工廠經營者成功將三個相關排放值之一 — 氮或磷濃度或化學需氧量 — 降低 20%，則可免收廢水排放費三年。利用這種由 H2Ortner 組成的系統、通常很容易達到如此程度的氮濃度降低。由於控制器模組的投資成本相對較低，因此在許多情況下，僅透過免除廢水處理費即可收回成本。Ortner強調：「這甚至適用於為人數不到 7,000 人提供服務的工廠，這些工廠的廢水排放量較低，」「因此，NiDeEco 從第一天起就收回了成本。」

減少環境影響和降低成本

這些優勢包括財務安全性的提升。如果只能以預設的時間間隔控制鼓風機，則當進水污染物濃度非常高時，可用於硝化作用的氧氣可能會太少。這對環境造成了負擔，因此工廠營運商花費了大量資金，因為廢水費用是根據排放物中的污染物水平確定的。

客製化系統設計

在仔細分析技術和經濟狀況的基礎上，H2Ortner 的專家總是針對特定工廠客製化系統。例如，沒有必要在所有情況下安裝所有值的感測器（氧氣、氨和硝酸鹽）。Ortner說：「只需少量投資，我們的客戶就可以獲得完全根據他們的要求量身定制的控制器系統。」這使得工廠操作員能夠始終保持曝氣池中的好氧細菌處於良好狀態，進而降低能源成本，同時提高運作可靠性並改善排放水質。

文字：Kay Miller | WAGO

照片：Ralph Diermann

產品概覽

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