Project Name: Retrofit of Non-Metallic Chain & Flight Sludge Collectors at a Municipal WWTP

Year: 2025

Capacity: 30,000 m³/d; 8 sedimentation tanks

Product Type: Non-Metallic Chain & Flight Sludge Collectors (Tank width: 7.4m, Length: 35m; high-strength fiberglass structure)

 

Client Pain Points:

As the first underground WWTP in the area, the plant faced frequent chain breakages and partial system collapses, causing sludge removal failures and operation interruptions. 

 

Key issues included:

• Poor component compatibility and weak chain performance

• Frequent scraper dislodgement and inadequate safety protection

• Lack of overload and anti-derailment monitoring systems

 

Solution:

K.G.MATZEN provided a professional retrofit service with the following highlights:

Scope: Phased replacement of all 8 sludge collectors; reuse of existing scum pipes and effluent launders

 

Upgrades:

• Fully new Non-Metallic Chain & Flight Sludge Collectors with lightweight, corrosion-resistant design and low resistance

• High-strength three-section fiberglass shaft for torsion and bending resistance

• Enhanced NMC-152 fiberglass-reinforced PBT chains, tensile strength up to 3.4 tons

• Overload protection with mechanical shear pins and limit alarm mechanism

• Anti-disengagement end shoes and >60mm wall clearance at scraper ends

• Wall-mounted supports extending >200mm to prevent scraper drop

• Real-time scraper operation monitoring system for tilt/sync issues

• ≥12mm dual-sided wear shoes, ≥5year design life

• Self-lubricating underwater components for easy maintenance

• Low energy use with 0.55kW SEW gear motors

• Integrated remote alert system for smart operation

 

Services Provided:

• On-site investigation and system diagnostics

• Custom design and manufacturing

• Installation and commissioning

• Configuration of drive and safety systems

• O&M training and full lifecycle support

• Expansion planning and spare parts provision

 

Project Outcomes:

• Eliminated risks of chain breakage and system collapse

• High operational stability and suitability for underground applications

• Reduced failure rate and maintenance frequency

• Lower energy use and simplified upkeep

• Enhanced integration between underground treatment structure and landscape