SludgeVision is a technology designed to optimize the sludge dewatering process in wastewater treatment plants, specifically for use with gravity belt press equipment. It combines hardware and software to assist plant operators in controlling the polymer dose required for optimal sludge dewatering. The result? Unprecedented savings, improved performance, and a more sustainable process.
SludgeVision uses a strategically mounted camera and a Base Station to continuously monitor your gravity belt press. The system’s computer vision algorithms analyze the visible fractions of sludge and belt in real-time, providing immediate insights into dewatering efficiency. This feedback enables operators to make on-the-fly adjustments or integrate SludgeVision into existing PLC/SCADA systems for automated polymer dosage control.
SludgeVision transforms sludge dewatering from a heuristic, labor-intensive practice into a data-driven, automated process control application.
The SludgeVision PCS combines a non-invasive, real-time HD camera, a computer-vision engine, and a control system designed for sludge dewatering using belt presses. It continuously monitors sludge dewatering, delivering immediate insights into belt-press performance.
Time Savings: Operators can step away from constant monitoring and focus on other tasks.
Polymer Savings: Maintain optimal dosage and reduce chemical usage, lowering operational costs.
Consistent Performance: Real-time control ensures reliable sludge separation quality, even as sludge composition and belt-press conditions fluctuate.
SludgeVISION is an advanced computer-vision–based system that optimizes sludge dewatering and thickening in belt filter presses and thickeners. It replaces subjective, manual observation with real-time, data-driven control to improve performance, reduce polymer consumption, and save operator time.
SludgeVISION uses a non-invasive, industrial-grade HD camera to continuously monitor the gravity section of your belt press or thickener. Proprietary computer vision software analyzes the video stream in real time, calculating the visible fraction of belt versus sludge. This data is used to provide actionable feedback or automatically adjust polymer dosage through your existing control systems.
SludgeVISION consists of:
All components are designed for industrial wastewater environments.
The Base Station is the central hub of the system. It hosts the SludgeVISION software, processes camera data, and manages communication with your polymer system, PLC, or SCADA for real-time monitoring and control.
Key benefits include:
By continuously monitoring sludge behavior and belt exposure, SludgeVISION delivers precise feedback on dewatering efficiency. This allows polymer dosage to be optimized in real time—eliminating overfeeding while maintaining or improving performance.
Yes. When integrated with the Polymer Control System (PCS), SludgeVISION can run in Auto Mode, automatically adjusting polymer pump speed based on real-time process conditions. This creates a true closed-loop control system.
SludgeVISION includes a built-in Safe Mode fail-safe. If communication is interrupted or the camera feed is lost, the system automatically reverts to a predefined, safe polymer pump speed to prevent over- or under-dosing.
Yes. SludgeVISION’s algorithms are trained to differentiate between sludge and belt material, even when the belt is dirty, stained, or uneven in color. This ensures reliable analysis under real-world operating conditions.
Absolutely. SludgeVISION is designed for seamless integration with:
No major process changes are required.
Yes. While polymer dosage optimization is the primary application, SludgeVISION’s analytics can also support optimization of other process variables, such as:
Overall dewatering process stability
No. The camera system is non-invasive and does not interfere with normal operation. Installation is straightforward and can be supported by CleanWater1’s service team.
SludgeVISION is available through both:
Your CleanWater1 sales representative can help determine the best option for your facility.
CleanWater1 offers:
These services ensure your system runs optimally from day one and over the long term.
Yes. CleanWater1 offers a SludgeVISION Try & Buy program, allowing you to trial the system at your plant and evaluate performance before making a final decision.
Yes. While its primary function is polymer dosage control, the system’s analytical capabilities can be expanded to provide insights for optimizing other parameters, such as belt press speed.
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