Success Story | Water Management
Adaptable aeration in the birthplace of American independence
The Town of Ipswich in Massachusetts, USA has reduced the energy consumption in its wastewater treatment plant’s blower room by 47%. This has been achieved by upgrading its blower station with four KAESER rotary screw blowers, controlled by a SIGMA AIR MANAGER 4.0.
Project snapshot
| Company Name: | Town of Ipswich | Industry Sector: | Water Management |
| Location: | USA | Application(s): | Aeration systems for biological treatment | Biological aeration systems | Biological treatment |
| KAESER Subsidiary or Partner: | KAESER USA | ||
| Project Scope: | Reliably and efficiently meet the low-pressure air requirements of the activated sludge process at the wastewater treatment plant. Provide a solution that accommodates fluctuating oxygen demands, provides better aeration controls, and reduces energy consumption. | ||
| KAESER Solution: |
4 x KAESER EBS 410 CL SFC rotary screw blowers with variable speed control 1x SIGMA AIR MANAGER 4.0 compressed air management system |
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| Project Outcomes: | The energy consumption in the blower room was reduced by 47%, improving efficiency and lowering operation costs. The new system is providing better aeration control, ensuring stable dissolved oxygen levels, and enhanced wastewater treatment performance. KAESER’s advanced controls and SIGMA FREQUENCY CONTROL (SFC) technology is additionally allowing for a rapid adaptation to fluctuating demand, making the plant’s aeration system more reliable and cost-effective. | ||
The Town of Ipswich has a history of advocating for the responsible use of rate payer funds dating back to 1687, and a tradition that continues today. When their wastewater treatment plant (WWTP) required a new aeration system, they sought a solution that provided long-term value. Working with consulting firm Tighe & Bond, they leveraged Massachusetts Chapter 30B’s pre-selection process to assess lifecycle costs, efficiency, and supplier qualifications. This approach ensured they could select the best system based on overall value rather than just upfront cost.
Project Scope
Upgrading aeration efficiency for sustainable wastewater treatment
The Ipswich WWTP’s existing turbo blowers were ageing, oversized, and unable to adjust to the plant’s variable oxygen demands efficiently. The plant needed a system that could provide better turn-down control, adapt to fluctuating loads caused by diurnal swings and daytime septage loadings, and improve total nitrogen removal. The project scope included the replacement of two ageing 55 kW (75 HP) geared turbo blowers.
KAESER Solution
The midas touch
After careful evaluation, KAESER Compressors was chosen for its ability to meet the plant’s strict aeration and energy efficiency requirements. KAESER and Tech Sales NE collaborated with the engineering team and contractor throughout the design, installation, and testing phases. The chosen solution included four KAESER EBS 410 CL SFC rotary screw blowers with variable speed control and 37 kW (50 HP) motors, a SIGMA AIR MANAGER 4.0 (SAM 4.0) master blower station controller, along with new aeration control PLCs, updated valves, reconfigured piping, and new flow meters.
This configuration expanded the plant’s station flow range from 510 to 9,516 Nm³/h (300 to 5,600 SCFM), compared to the previous system’s 1,869 to 7,816 Nm³/h (1,100 to 4,600 SCFM). The SAM 4.0 controller dynamically adjusts pressure setpoints, ensuring optimal efficiency by automatically balancing blower loads and providing redundancy. With pandemic-related supply chain delays affecting project timelines, KAESER provided a complimentary rental blower, while Tech Sales NE supplied a generator and necessary piping to keep the project on schedule. This temporary setup allowed the plant to continue operations without disruption while awaiting permanent equipment installation.
Project Outcomes
The gold standard in performance
