How Inline Dynamic Mixing Can Reduce Your Polymer Consumption by Over 20%

As you may know, effective sludge treatment relies on proper polymer use. Excessive polymer consumption not only indicates inefficient treatment but also increases operating costs. On top of that, polymer itself is not that cheap.

In most dewatering operations, a significant amount of polymer is simply wasted due to inefficient mixing. Conventionally, polymer is added directly into the flocculation tank of the dewatering machine and mixed with the sludge by an agitator. However, this simple mixing method may not work well when sludge conditions are difficult or unstable. As a result, the polymer and sludge may not mix evenly.

When sludge conditions change, operators often need to manually adjust the polymer dosage to maintain stable dewatering performance. This requires additional time and operator attention.

But what if you could optimise the contact between the polymer and the sludge before it even reaches the tank?

Here is how integrating an Inline Dynamic Mixer into your sludge architecture stops chemical waste, builds stronger flocs, and drastically improves your dewatering efficiency.

Developed in cooperation with the Czech Technical University in Prague, the AMCON DM Series (Dynamic Mixer) is engineered to solve the exact problem of insufficient flocculation.

Instead of relying solely on slow mixing in the flocculation tank, the Dynamic Mixer provides active inline mixing directly in the pipeline. A motor-driven mixing shaft operates at 300 to 1,700 rpm, with the speed adjusted by a Variable Frequency Drive (VFD).

The Dynamic Mixer thoroughly blends the sludge and polymer before they enter the dewatering machine, providing several key operational advantages:

• Lower Dilution Ratios: Because the mechanical mixing is highly efficient, the polymer does not need to be heavily diluted to disperse properly. This significantly reduces your preparation water consumption.
• Stronger Flocs: Instant, high energy mixing creates highly resilient flocs that do not easily break apart during the dewatering phase.

Visual comparison: Flocculation quality without (left) and with (right) the AMCON Inline Dynamic Mixer.

• Blockage Prevention: Unlike traditional pipe restrictors, the active mixing chamber is designed to minimise the risk of blockages, even when processing thicker sludges.
• Integrated Protection: The unit is industrial grade. It features a check valve on the chemical inlet to prevent sludge backflow, alongside optional dry run sensors and thermistors to protect the mechanical seal and motor.

In wastewater treatment, performance needs to be proven by real-world data. After extensive laboratory and on-site testing to optimise chemical dosing, the AMCON Inline Dynamic Mixer has demonstrated clear improvements in performance.

On average, upgrading a standard dewatering line with a Dynamic Mixer delivers:

• A 22% reduction in polymer consumption: Contributes to lower OPEX and helps improve the Return on Investment (ROI) of the equipment.
• Cake dryness improves for approximately 1.2%: Improvement of cake dryness helps reducing disposing cost.
• A 3% improvement in capture rate: Cleaner filtrate water returned to the upstream treatment process helps reduce the biological load on the aeration tanks.
• A 5% increase in throughput: The dewatering machine can process more and stable sludge due to superior floc stability.

You do not need a complete facility overhaul to achieve these savings.

While the Dynamic Mixer operates in perfect synergy with the VOLUTE DUO™ RVP Series, its standard flange and union connections make it incredibly easy to integrate into any existing process. Whether you are using a belt press, a centrifuge, or a Dissolved Air Flotation (DAF) unit, the mixer can be installed inline to improve flocculation.