Real-Time Sensor-Controlled Coagulant Dosing and Pressure in a Novel Sludge Dewatering System

Sludge dewatering remains a resource-intensive process, often constrained by high residual moisture content and inefficient chemical conditioning. Conventional systems typically rely on fixed polymer dosages and predetermined filtration pressures, which are unable to respond to variations in sludge characteristics, resulting in inconsistent and suboptimal performance. In this study, a real-time control system for municipal wastewater sludge dewatering was developed to dynamically regulate coagulant dosing and filtration pressure based on continuous monitoring of critical sludge parameters, including total solids (TS), viscosity, sludge temperature, and pH change following coagulant addition. The control logic, derived from empirical correlations between sludge dewaterability metrics such as time-to-filter (TTF) and capillary suction time (CST) and operational variables, enables adaptive adjustment of polyoxyethylene alkyl ether (POAE) injection and pressing conditions. Implementation of this system achieved a final cake moisture content of approximately 63% after 60 min of filtration, substantially lower than the ~84% moisture observed under static conditions. Real-time flux feedback facilitated timely pressure escalation (from 15 to 20 bar to 25–30 bar), improving water removal efficiency while avoiding premature cake blinding. The pH drop (~0.7 units) post-polymer addition served as a practical indicator of adequate flocculation, supporting dose optimization and minimizing chemical waste. The proposed system demonstrated enhanced dewatering performance, reduced polymer consumption, and greater operational robustness compared to conventional approaches. These findings highlight the potential of integrated sensor-based control to advance sludge treatment technologies by promoting smarter, adaptive, and resource-efficient dewatering operations.