Enhancing Sludge Dewatering with Titan Tubes
Updated: Aug 13
Project Overview of Sludge Dewatering with Titan Tubes
The client required a reliable and efficient on-site method to reduce sludge moisture content and volume before disposal or further processing. Terravua implemented a pilot system combining:
Titan geotextile dewatering tube (pilot unit)
Tie-in to the existing sludge line
Bridging spool with valves for controlled routing and isolation
Piping across the drying bed slab to feed the tube
Polymer dosing skid for accurate polymer injection and consistent flocculation
The purpose of the pilot was to provide proof-of-performance and operational confidence before scaling.
Objectives of the Pilot
The pilot focused on several key objectives:
Demonstrating stable sludge dewatering using the Titan tube
Proving that polymer conditioning improves filtration consistency and performance
Delivering controlled flow management through valves and dedicated piping
Providing clear visual confirmation of normal filtration behaviour during filling
Capturing measurable outcomes: drain time, fill height limit, water reduction, filtrate clarity
Ensuring safe pilot operation at a maximum fill height of ~1.5 m
Training the client team to operate the system independently
Solution & Installation Process
Terravua delivered a complete installation designed for real plant operation:
1) Sludge Line Tie-In
The system was tied into the client’s sludge line to ensure a stable, continuous feed source.
2) Bridging Spool with Valves (Flow Control + Isolation)
A bridging spool and valves were installed to:
Direct sludge to the tube when required
Isolate the system for shutdown or maintenance
Maintain operational flexibility
3) Piping Across the Drying Bed Slab
Dedicated piping was routed across the slab to position the feed correctly and keep the installation clean, safe, and repeatable.
4) Polymer Dosing Skid (Critical Performance Element)
A polymer dosing skid was supplied and commissioned to inject polymer into the sludge stream. Accurate dosing is essential because it:
Drives correct floc formation
Improves solids capture in the tube
Stabilises filtration performance across changing sludge conditions
What You See in the Video
The demo video shows the system running under normal full operation:
Sludge is pumped into the Titan tube at a controlled rate.
Water separates through the porous tube fabric (filtration).
Filtrate migrates externally along the tube surface and seam line.
At the seam termination area, filtrate exits as a steady, clear discharge.
A consistent clear discharge confirms that:
Filtration is active
The tube fabric is performing correctly
The sludge mass is consolidating as intended
Results / Outcomes of the Pilot
The pilot produced strong, measurable outcomes:
Drainage Time (Cycle Readiness)
After a full pumping cycle, the tube drained down within ~4–5 hours, enabling repeated cycles within a typical operating day.
Maximum Fill Height (Pilot Operational Limit)
The final supervised cycle reached approximately ~1.5 m, confirming safe operation at the pilot tube’s maximum height.
Water Reduction (Post-Handover Confirmation)
Two days post-handover, tube height reduced to approximately 200–250 mm, indicating roughly ~70% volume reduction.
Filtrate Clarity (Quality Indicator)
Clear filtrate was observed during operation and remained clear post-handover, supporting consistent ongoing separation.
Training & Handover Process
Terravua trained the client’s operational team on:
Operating procedure (start-up, filling, shutdown)
Valve positions and routing control
Polymer dosing adjustments for variable sludge
Safety controls during filling and drain-down
Routine checks and basic troubleshooting
The system was handed over with on-site supervision and operational guidance to ensure confident independent operation.
Final Notes + Next Steps
This pilot confirms that Titan tubes, when integrated with correct line control and polymer dosing, provide a practical and repeatable sludge dewatering process on a drying bed.
Next steps typically include:
Scaling to additional tubes (parallel operation)
Optimising polymer dosing setpoints for long-term use
Aligning pumping schedules to drain-down cycles
Expanding the piping layout if required
Contact Terravua for Your Dewatering Pilot or Full Installation
If your drying beds aren’t performing or sludge volumes are increasing, Terravua can deliver a full engineered dewatering package:
Titan tubes / geobags
Polymer dosing skids
Pipework, manifolds, valves
Commissioning + operator training
Contact Terravua to request a pilot demonstration or a full site-specific installation plan.
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