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Enviromental Preservation
Air diffuser - SEIKA ecorator

Key features

No clogging

Larger section area of the air-discharge component helps prevent clogging. Intermittently operable.

 

No sediment on the tank bottom

The ejector mechanism employed in the body assures a vast fluid passage area in the cylinder. The ecorator sucks up a large amount of sludge/ carrier and can fully agitate heavy sludge in the tank.

 

High oxygen absorption rate

The ejector and venturi cutter generate fine air bubbles .In addition, the powerful airlift effect repeatedly and finely breaks down the sucked air-bubble water.

 

Energy saving effect

The lower pressure loss combined with the high oxygen absorption rate at the air discharge point reduces the burden on the blower, enabling stable operation with reduced power consumption.

 

100% maintenance-free

Because it does not clog, the ecorator does not require regular cleaning or parts replacement. In addition, because it does not decline in performance, it is suitable for long-term use.

 

The sucking power of the SEIKA ecorator (compared with the old model)
ECO1000 Existing model

 

Principle

Interior structure and the principle of fine air bubble creation

Newly developed 3-D venturi polytope model

The 3-D polytope model based on the venturi principle creates a pressure difference between the passing water and the air bubbles, and breaks down large bubbles into fine ones in order to increase the oxygen absorption rate. The use of polypropylene (PP) also helps improve the chemical and high-temperature resistance.

 

Ejector-style air discharge part

The ejector-style air discharge part sucks up sludge, carrier, and water from the tank bottom and achieves powerful agitation of the contents. In addition, the enough clearance and suface polish with the PP resin/SUS helps prevent clogging.

 

Interior structure and the principle of fine air bubble creatio

 

Point1

Water that reaches the surface is sucked to the tank bottom by the down flow, which increases the DO value of the oxygen-rich part.

 

Point2

The fluid generates a stripping phenomenon and creates fine bubbles approx. 300 μm in diameter.

 

Point3

The flow along the venturi bumps and the direct flow together generate a stripping phenomenon (vortex) that creates fine air bubbles.

 

Comparison

SEIKA ecorator Other manufacturers' products
Lifetime 10 years or longer (based on past records) Simple interior structure with no consumable parts. 2 to 5 years. The rubber is easily broken.
Clogging 99% clogging-free (based on past records) Clogging is unavoidable
Small rubber outler holes always get clogged because of the large resistance force.
Accumulated sludge No sludge at the tank bottom
Vacuum-cleaner level of sucking power.
Accumulated sludge at the tank bottom. Sludge accumulation is inevitable due to the small airlift effect and the absence of a suction port.
Electricity costs Low electricity costs
The SEIKA ecorator enables high oxygen absorption rate, minimal pressure loss, and intermittent operation, and consumes less power with a reduced burden on the blower.
High electricity costs
Installation and piping Simpler and less expensive installation. Because the agitation area per pipe is wider, the total required length of pipe is significantly shorter.In addition, the installation is simpler and less expensive. More pipes and cost are required for installation, because the agitation area per pipe is small.

Specifications

Model Material Air blow amount per pipe (m3/min) Agitation area per pipe Water depth con-
formed
Body Air piping Connector Weight Lower limit Stan-
dard
Upper limit
ECO-1000 PP SUS304 (JIS10K40A flange) Integrated (PP/SUS) 3.7 0.7 1 1.4 6~7㎡ 2m or more

Delivery reference

120 disc diffusers were replaced with 60 ECO-1000 systems

 

Problems with current diffusers/Request from a client (food factory) for improvements

  • Because the inflow load varies depending on the season, it is necessary to carry out intermittent aeration for effluent disposal. However, disc diffusers tend to clog and do not allow aeration to be conducted.
  • There is a pile of festering sludge in the brown section of the image on the right, which is essentially a “dead space”.
  • After 3 years of using the disc diffusers, the DO rate ceased to increase.
  • Maintenance-free air diffusers are preferred.
  • The enegy costs for aeration-blower-based diffusers are a factor.
  • Because both the ventilation volume and the operational area per unit are small for the diffusers, the piping costs has been reduced.

 

Conditions for effluent discharge

 

The number of disc air diffusers: 120 The number of ecorator diffusers after replacement: 60
Water depth: 4.5 /hour oxygen absorption rate 7% 11.5%
Pressure loss 210mAq (300l/min) 30mAq (1000l/min)
Agitation area 1㎡/unit 8.5m2/unit
Blower 11kW x 3, 22kW x 1 11kW x 2, 22kW x 1

 

Results after the installation of the ecorators


Agitation by the ecorator
Aeration with a ventilation volume of 0.56 m3/min.
The accumulated sludge at the tank bottom was removed by the powerful airlift effect of the ecorator.

  • Solution to sludge accumulation
  • The ecorator allows intermittent operation, even when the inflow load is small. In addition, uniform aeration can now be conducted with a small ventilation volume at 0.56m3/min which is out-of specification.
  • Because there is no clogging, the oxygen absorption rate has become stable, which has also made the DO rate stable.
  • Electricity consumption is reduced by 11 kW for the aeration blowers.
  • Maintenance-free.
  • Because both the ventilation volume and operational area per unit are small for the diffusers, the piping cost has been reduced.

 

Ecorator Jr.

Launched in July 2012! High-performance cylindrical air diffuser, the Ecorator Jr.

Downsized version of the ECO-1000
Because the Ecorator Jr. has the same air-flow volume and uses the same connector diameter as those of existing air diffusers (membrane diffusers), replacement is easy.

         NEW !!
         Go to delivery reference
         (Japanese only)

Key features

  • Clogging-resistant
    With the same structure as the ECO-1000, the Ecorator Jr. is clogging-resistant and enables intermittent operation.
  • Easy to switch from current air diffusers.
    With a connector diameter of Union 20A, the Ecorator Jr. can be connected to existing header tubes.
  • Can suck up sludge.
    With its ejector-structure, it can suck up sludge-water from the bottom and mix it uniformly inside the tank entirely.

 

Enviromental Preservation