25% Biogas Boost in Sparta, WI
Aging infrastructure and inefficient mixing were holding back the wastewater resource recovery facility in Sparta, Wisconsin, from maximizing its biogas potential. However, a cutting-edge digester mixing system has transformed operations, significantly improving performance and efficiency.
The Challenge: Limited Mixing, High Maintenance
Built in 1950, the WRRF serves 10,000 residents and processes effluent from food processing, dairy industries, landfill leachate, and septage brought in, struggled with underperforming digesters.
The facility’s two 50,000-gallon digesters suffered from poor mixing, leading to reduced anaerobic digestion efficiency and frequent maintenance challenges. “Our old, basic mixing system just blew air upwards in the digesters, which wasn’t very efficient,” said Ed Hanson, Wastewater Treatment Plant Manager at Sparta WRRF. Additionally, debris accumulation in the digesters further reduced capacity, making maintenance a complex and time-consuming task.
The Solution: Landia GasMix System
To address these issues, Sparta WRRF installed the Landia GasMix system, a modern external mixing solution that optimizes tank conditions without the need for frequent tank draining. The system features venturi nozzles for enhanced circulation and a chopper pump to minimize debris buildup. Unlike the previous setup, all mechanical components are located outside the digesters, simplifying maintenance and minimizing operational disruptions.
The Results: Increased Biogas Production and Cost Savings
The impact of the new system was immediate. “At startup, we saw excellent turbulence and improved gas capture from the digesters,” Hanson said. Encouraged by the initial success, the facility installed a second GasMix unit six months later.
Since implementing the new mixing system, the WRRF has achieved a 25% increase in biogas yield, allowing it to use the captured methane to efficiently heat the digesters. Additionally, better sludge breakdown has led to improved volatile solids destruction and higher-quality biogas production.
“Maintenance is easy now,” Hanson noted. “We can check and adjust the pumps externally, eliminating downtime and improving safety.”
A Model for Efficiency and Sustainability
The Sparta WRRF’s investment in the Landia GasMix system showcases how innovative technology can transform wastewater treatment facilities. By enhancing biogas production, simplifying maintenance, and reducing operational costs, the facility is now positioned for long-term efficiency and sustainability.
For WRRFs facing similar challenges, this case study highlights the value of upgrading to an advanced digester mixing system. With Landia GasMix, facilities can boost performance, improve safety, and unlock the full potential of their biogas production capabilities. Landia GasMix can be used with most tank types and at tank volumes up to approx. 350,000 ft³ and for sludge with DM up to 14%.
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