Krofta Sludge Blanket Controller
Real-Time monitoring and adjusting of sludge blanket thickness
Optimal sludge thickness for best performance
Efficient sludge management is critical for optimal performance of a Krofta DAF. The Krofta Sludge Blanket Controller (SBC) automates this process, continuously monitoring sludge blanket thickness to ensure consistent removal.
By eliminating manual adjustments, the Krofta Sludge Blanket Controller improves performance and reduces operational costs.
Key Features and Advantages
- Real-Time Monitoring: Advanced LED+ Photocell sensors detect sludge blanket levels with precision.
- Automatic Adjustments: The SBC controls scoop speed to maintain ideal sludge thickness.
- Improved Efficiency: Optimized sludge consistency reduces de-watering costs and enhances clarified water quality. Its easy integration with Krofta DAF systems ensures seamless operation.
- Reduced chemical consumption: With the SBC, operators can achieve precise, consistent results while reducing chemical usage and improving overall plant efficiency.
How does the Sludge Blanket Controller works?
A Krofta Sludge Blanket Controller is an optical sensor system that continuously measures the thickness or position of the sludge layer (the floating solids blanket) inside the DAF tank.
It monitors in real time:
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The height of the sludge blanket from the water surface.
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The density or solids concentration of the blanket.
This data is sent to the DAF control panel or SCADA system for automatic adjustment of:
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Skimmer speed or frequency
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Sludge discharge timing
Chemical dosing rate (in advanced setups)
Why does a Sludge Blanket Controller matters?
In a DAF, optimal performance depends on maintaining a stable sludge layer:
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Too thin → poor solids capture (solids escape with clarified water).
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Too thick → risk of sludge carryover, clogging, or air distribution problems.
Manual control (operator observation) is subjective and delayed.
The SBC provides continuous, objective measurement, ensuring the DAF always runs in its optimal operating window.
How does the Sludge Blanket Controller improves DAF performance?
1.Optimized skimming and sludge removal
- The SBC automatically starts or stops the surface skimmer based on actual sludge thickness.
- Prevents over-skimming (wasting water and energy) or under-skimming (carryover and reduced clarity).
Result:
- Constant sludge removal rate.
- Improved clarified water quality.
- Reduced operator intervention.
2. Enhanced chemical dosing control
- When the sludge blanket rises too fast, it can indicate:
- Insufficient flocculation or air-bubble attachment.
- Higher TSS load or changes in feed composition.
- The SBC data can feed a closed-loop control system that automatically adjusts coagulant/flocculant dosing.
Result:
- Consistent TSS removal despite fluctuating loads.
- Reduced chemical consumption (only dose what’s needed).
3. Increased hydraulic stability and throughput
- Stable sludge blanket = stable hydraulic conditions.
- Prevents short-circuiting, channeling, or sludge rollover.
Result:
- Better flow distribution and contact time.
- Higher hydraulic loading possible without compromising effluent quality.
d. Predictive maintenance and alarm functions
- Detects abnormal blanket buildup (air loss, clogging, feed surges).
- Sends early alarms for operator intervention before performance drops.
Result:
- Avoids unexpected downtime.
- Protects pumps, skimmer motors, and instrumentation.
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