Managing Editor Elaine Coles gets a first hand view of HUBER Technology UK’s innovative DFMA containerised solution for sludge treatment from Paul Blackoe. The newly-appointed Engineering & Operations Director at the wastewater technology specialists explains the myriad benefits which are seeing water companies beating a path to HUBER’s door.

Elaine Coles: As an editor, I regularly receive a lot of information and press briefings about a wide range of equipment and services, including video walkthroughs.

However, there’s nothing like seeing technology at first hand in the water sector to really appreciate the benefits it can bring to water companies’ operational processes – and HUBER’s containerised S-DISC solution for small scale sludge thickening undoubtedly ticks all the boxes.

With a solid background in both mechanical and electrical engineering working across utilities in both the UK and overseas, Blackoe brings a wealth of expertise and experience to his new role.

An informative hour looking at HUBER’s onsite containerised S-DISC, followed by an interesting discussion, clearly demonstrated why a number of the UK water companies are opting for this innovative solution as part of their AMP8 toolkit.

Paul Blackoe explained:

“Ahead of the start of AMP8 we’ve seen a real uptick in interest in and uptake of our containerised Dfma S-Disc solution – we’ve already sold a number of these units into the Uk water companies and more are currently in the process of being assembled. They are all being built in the UK at our Chippenham HQ and we have optimised our in-house production process for a fast turnaround.”

HUBER’s S-DISC thickener lies at the heart of the containerised S-DISC – the well-proven sludge thickening technology is already in place at more than 1070 reference sites worldwide and over 90 here in the UK.

According to Blackoe, the COVID epidemic afforded the HUBER team the rare luxury of time to step back and really think about the water companies’ pain and pinch points in their operational processes and where the regulatory landscape is becoming increasinlgy rigorous.

“We started out originally with the idea of creating something in a containerized unit to be used primarily for trial purposes, beginning with listing out all the criteria we thought it was important to meet.

“We were all generally in agreement that the new wastewater treatment processes needed to comply with the stringent requirements of the AMP8 Water Industry National Environment Programme would inevitably result in the generation of increasing amounts of sludge”, he says. "Something which would only add to the existing logistical and transportation challenges the water companies face at small rural treatment works."

However, as the project progressed, Blackoe explains their initial thinking extended beyond a trial concept:

“So with these sites in mind, we came up with the idea of a packaged, cost-effective solution for small scale sludge thickening to help them tackle their biosolids challenges.”

DfMA approach includes standardisation, reduced costs and project lead time

During the development process, HUBER took a Design for Manufacture and Assembly (DfMA) approach which focussed on:

• reduced project lead time
• reduced production costs
• reduced site assembly time
• standardisation around a plant layout optimised for operation and performance
• full compliance with Water Industry M & E Specifications (WIMES)

Containerised solution has de-risked and removed many potential health and safety risks

Photo: Simulating service and overhaul activities with a mini electric pick & carry crane

Blackoe is particularly keen to bring out one aspect of the containerised solution where the water companies are seeing major benefits - a significant reduction in health and safety risks.

“We're de-risking everything for the customer,” he says.

According to Blackoe, who has worked across a number of industries, safety on site is a major issue within the water sector:

“In my experience, the greatest risk generally always primarily lies with construction. In the water sector environment, this not infrequently includes working at height, building large structures which may need to be located underground and involves major ground excavation works.

“With the S-Disc unit they can see that to be able to just literally crane the S-DISC container into position - it doesn't even need to be bolted down – is a huge plus.”

The mindset HUBER has applied means it has considered all of the operational requirements and taken all of those issues into account – so the S-DISC containerised solution has de-risked and removed many of those potential dangers.

Blackoe’s own practical experience both working in the UK and overseas means he’s also very aware of the fundamental importance of meeting exacting safety requirements and standards – be they electrical, machinery directives, ATEX regulations etc .

In his view, while there is a lot of commonality in terms of health and safety law, regulations and standards, the Health and Safety Executive regime in the UK is by far and away the most stringent and rigorous.

He continues:

“Obviously as a company we are aware the need to be compliant with all of these – which is front and centre of all our products and solutions.

“We’ve also taken great care to ensure that the design meets all the requirements of the water industry, including all electrical and mechanical specifications.

“So, massive health and safety benefits – everything is specifically designed for ease of access, meaning the S-DISC itself and every single piece of ancillary equipment can be easily accessed, operated, maintained and replaced whenever it’s necessary.

“The mindset we have applied means we have considered all of the operational requirements and taken all of those issues into account – and our DfMA containerised solution has de-risked and removed many of those potential dangers.”

Growing customer uptake means hire assets are “pretty much permanently out”

Photo: containerised S-DISC size 1 at St. Davids Sewage Treatment Works

Blackoe says the growing demand for the solution is reflected in the use now being made of its hire assets and equipment which are “pretty much permanently out” – HUBER is currently building more to meet the level of demand the company is now seeing.

He explains that generally, water companies are making use of the S-DISC container to use in one of two situations:

“Firstly, when a client has a sudden emergency or have suddenly understood they have a need. In that situation they might come to us to ask us to install the kit on long term hire, ahead of making a future purchase.

“Secondly, they want to trial before they purchase – for example, where they might want to prove process to deal with problematic sludges to ensure that they can achieve effective thickening of the product.

“We have a trial unit approved process which offers the customer a combined hire/trial option. In the meantime, while that’s in position we will build a unit for them which meets the same specifications. Once complete, we can ship it out for delivery and installation and swap it with the hire unit which we take away – a process which wouldwe would anticipate takinga couple of days.”

Water company customers can also see the advantages of using the S-DISC in a pre-existing building in which case HUBER can deliver it on a skid simply without the container.

Blackoe continues:

“The beauty of the containerised S-DISC is that it’s been fully tested and commissioned before being trailered out to the customer – and once it arrives it can be rapidly deployed with minimum on-site construction time. Something that our customers can quickly grasp.

“We’re also seeing increasing interest from customers with smaller sites, more rural treatment works where meeting the requirements of the WINEP are pushing up demand – something we think/ are confident will continue in AMP8.

Removing risk for the client and keeping costs down

Image: operating principle of the HUBER S-DISC

At the end of the day, in Blackoe’s view in addition to removing risk for the client, the S-DISC package also provides them with a highly cost-effective solution.

“When you add in the fact that it’s ready made and the customer doesn’t have the added on-cost of getting planning permission to erect a new building to house it,” he explains, “it completely removes the costs of construction right from the beginning – the initial design work needed prior to planning, relocating or installing equipment into other buildings. Particularly important at smaller, more isolated sites where no buildings or other suitable structures exist.

“We do a full day's worth of commissioning and a week’s worth of testing and iron out any teething problems.

“We do testing, programming and dry commissioning in our workshop ahead of shipping to site. We check all of the sensor inputs so we can pick up and resolve any potential issues and fine tune the assembly and operation of complex equipment - which are all caught here.”

“Whenever they see the S-DISC solution in action, they’re sold”

Blackoe’s enthusiasm is catching – and seeing the S-DISC container at first hand you can immediately see how easily it can go on to a site and the considerable advantages it offers to customers.

The S-DISC and all ancillary equipment are first positioned in place on a galvanised steel skid which is then incorporated into a purpose-built shipping container which has been designed with bi-fold doors on both sides and double doors at each end.

Opening up the container, Blackoe talked me through the decision making process. As someone who usually only gets a helicopter view of water industry operational processes, even I can see the benefits of being able to get to every piece of kit which is intentionally located along the periphery on all four sides.

“What’s not to like?” Blackoe says, “ whenever they see it in action, they’re sold.”

All of the equipment is mounted at working height level – so no-one needs to stand on anything else in order to be able to reach and access things they need to work on.

Image: optimised plant layout 

The main control panel can be accessed from inside via the personnel door, this is where the operator will control the plant. There is the potential to offer a process bypass option (feed pump kept in operation) via a secondary control panel located off the back the main panel, for maintenance operations should it be required. The customer can access the panel from that side if they need to power down to isolate all of the other equipment internally. In the event that any of the equipment inside the container fails, any components can be safely and independently isolated for maintenance and taken out if necessary.

“Stripping down the pump for example, which is part of the solution, is a very straightforward process”, Blackoe says, “they can quickly isolate it to work on in situ or take it out if necessary.”

“In the unlikely event that you need to remove the whole skid, the assembly can simply be decoupled then lifted out quickly and easily, without having to disassemble a building in the process.”

Blackoe is rightly proud of the attention given to every last detail of the S-DISC container design - each part has been designed to be completely interchangeable, right down to couplings, flanges, bolts etc which can all simply be swopped out and replacements swapped in.

“Standardization enables us to remove huge costs for clients”

He explains:

“We’ve optimized everything, removed a lot of the constraints that normally accompany bespoke design – the resulting standardization enables us to remove huge costs for clients.”

In his view, it’s vitally important to fully understand what it is the customer needs and where the pain and pinch points lie.

“Our approach to clients is - this is a large part of your risk and your pain as a business. Our technical solution has not only done what you've needed in terms of thickening sludge and reducing your tankering costs - in the process we've also removed a potential headache in terms of safety-critical issues.

“Our focus has always been about smart design to make sure that nobody is put at risk – both during installation and operation.”

Blackoe concludes:

“We get a lot of visitors who want to learn about the containerised solution. And we’re always happy to receive more – because everyone who sees the solution first-hand can immediately grasp the value and potential advantages they offer in terms of their own sites.”

For more information:

Visit HUBER Disc Thickener S-DISC | HUBER Technology 

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