{"id":2872,"date":"2026-10-14T10:18:40","date_gmt":"2026-10-14T10:18:40","guid":{"rendered":"https:\/\/sensaratech.com\/industrial-sbr-double-capacity-respirometry\/"},"modified":"2026-10-14T10:18:40","modified_gmt":"2026-10-14T10:18:40","slug":"industrial-sbr-double-capacity-respirometry","status":"publish","type":"post","link":"https:\/\/sensaratech.com\/en\/industrial-sbr-double-capacity-respirometry\/","title":{"rendered":"From 1 to 2 cycles a day: double the capacity of an industrial SBR, without construction work"},"content":{"rendered":"<style> .snr{--g:#7cb955;--gd:#4e8f2a;--ink:#1d2a14;--tx:#3f444b;--soft:#f2f8ee;--line:#e2ead9;font-family:Sora,Arial,sans-serif;color:var(--tx);line-height:1.6;font-size:16px;max-width:1140px;margin:0 auto;padding:0 16px} .snr *{box-sizing:border-box} .snr h1,.snr h2,.snr h3{font-family:Sora,Arial,sans-serif;color:var(--ink);line-height:1.2;margin:0} .snr 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.limit{position:absolute;left:0;right:0;border-top:2px dashed #c0392b;z-index:2} .snr .limit span{position:absolute;right:0;top:-24px;font-size:12px;color:#c0392b;font-weight:600;background:#fff;padding:0 4px} .snr .legend{display:flex;gap:18px;font-size:13px;margin-top:12px;flex-wrap:wrap} .snr .legend i{display:inline-block;width:12px;height:12px;border-radius:3px;margin-right:6px;vertical-align:-1px} .snr .compare{display:grid;grid-template-columns:1fr 1fr;gap:0;border-radius:18px;overflow:hidden;border:1px solid var(--line)} .snr .compare>div{padding:24px} .snr .compare .before{background:#f6f6f4} .snr .compare .after{background:var(--soft)} .snr .compare h3{font-size:14px;letter-spacing:.1em;text-transform:uppercase;margin-bottom:10px} .snr .quote{background:var(--ink);color:#fff;border-radius:18px;padding:32px 36px;font-size:clamp(18px,2.2vw,24px);line-height:1.45} .snr .quote b{color:#a6dd7c;font-weight:600} .snr .cta{background:var(--g);border-radius:24px;padding:36px 40px;display:flex;justify-content:space-between;align-items:center;gap:24px;margin:40px 0 56px;color:var(--ink)} .snr .cta h2{margin:0 0 6px} .snr .cta p{margin:0;max-width:640px} .snr .btn{display:inline-block;background:var(--ink);color:#fff!important;text-decoration:none!important;border-radius:30px;padding:14px 28px;font-weight:600;white-space:nowrap} .snr .note{font-size:12px;color:#7a7f86;margin-top:10px} @media(max-width:860px){.snr .kpis{grid-template-columns:1fr 1fr}.snr .grid2,.snr .compare{grid-template-columns:1fr}.snr .steps{grid-template-columns:1fr}.snr .cta{flex-direction:column;align-items:flex-start;padding:28px}.snr .bars{gap:8px}} <\/style> <div class=\"snr\"> <div class=\"hero\" style=\"padding-top:8px\"> <p class=\"lead\">An industrial waste management company doubled the throughput of its reactor by measuring sludge activity in every cycle. It also found out where it was over-aerating.<\/p> <div class=\"chips\"><span class=\"chip\">Industrial waste management<\/span><span class=\"chip\">SBR reactor<\/span><span class=\"chip\">SN8 + AI cycle analysis<\/span><\/div> <\/div> <div class=\"kpis\"> <div class=\"kpi\"><b>\u00d72<\/b><span>treatment capacity: from 1 to 2 SBR cycles per day<\/span><\/div> <div class=\"kpi\"><b>1,431&nbsp;h<\/b><span>of excess aeration detected<\/span><\/div> <div class=\"kpi\"><b>45&nbsp;%<\/b><span>of cycles ended with organic matter still undegraded<\/span><\/div> <div class=\"kpi\"><b>42,941&nbsp;kWh<\/b><span>of avoidable aeration energy<\/span><\/div> <\/div> <section class=\"grid2\"> <div><div class=\"eyebrow\">The challenge<\/div><h2>A fixed cycle for a load that changes every day<\/h2> <p>The plant treats highly variable industrial effluents in an SBR reactor aerated by blowers. The cycle always had the same length, whatever the load.<\/p> <p>Nobody was measuring what happened inside the reactor, so there was no way to know whether the cycle was too long, too short or just right.<\/p><\/div> <div class=\"compare\"> <div class=\"before\"><h3>Before<\/h3><ul class=\"check\" style=\"filter:grayscale(1)\"><li>1 fixed-length cycle per day<\/li><li>No measurement of the biology<\/li><li>&#8220;Just in case&#8221; aeration<\/li><\/ul><\/div> <div class=\"after\"><h3>With SN8<\/h3><ul class=\"check\"><li>2 cycles per day<\/li><li>Activity measured in every cycle<\/li><li>Clear view of where air is missing or wasted<\/li><\/ul><\/div> <\/div> <\/section> <section> <div class=\"eyebrow\">The solution<\/div><h2>The respirometer as the &#8220;eyes&#8221; of the SBR<\/h2> <div class=\"steps\"> <div class=\"step\"><h3>Measure<\/h3><p>The <b>SN8<\/b> online respirometer, with 2 sampling points, automatically measures sludge activity (OUR\/SOUR) and biodegradable COD in every cycle.<\/p><\/div> <div class=\"step\"><h3>Analyse<\/h3><p>An <b>AI cycle analysis<\/b> compares each cycle with its real biological activity and detects when the sludge has finished its job and when it has not.<\/p><\/div> <div class=\"step\"><h3>Optimise<\/h3><p>With that information the plant shortened its cycles and <b>doubled its capacity<\/b>, without construction work or a new reactor.<\/p><\/div> <\/div> <\/section> <section class=\"grid2\"> <div><div class=\"eyebrow\">Results<\/div><h2>The same energy, badly distributed<\/h2> <p>Across 559 analysed cycles, the diagnosis found two problems at once:<\/p> <ul class=\"check\"><li>In many cycles the sludge reaches endogenous respiration long before aeration ends: <b>1,431 h of blowers running for nothing<\/b>.<\/li><li>In <b>45&nbsp;%<\/b> of cycles, on the other hand, aeration stops before degradation is complete.<\/li><li>Measured avoidable energy cost: <b>\u20ac5,153<\/b> over the period analysed, around <b>\u20ac8,200\/year<\/b> with full data coverage.<\/li><\/ul><\/div> <div class=\"card\"><div class=\"eyebrow\">Next step<\/div><h3>Tailor-made cycles<\/h3><p>Automatically adjust the aeration time of each cycle to the activity measured by the SN8: more air where it is needed, less where it is not.<\/p><\/div> <\/section> <section> <div class=\"quote\">Measuring the biology in every cycle made it possible to <b>double the SBR&#8217;s capacity<\/b> and to find where aeration was being wasted.<\/div> <\/section> <div class=\"cta\"><div><h2>What is happening in your reactor?<\/h2><p>We install the SN8 respirometer at your plant as a <b>trial with purchase option<\/b>: if you are convinced, it stays; if not, we remove it.<\/p><\/div><a class=\"btn\" href=\"https:\/\/sensaratech.com\/en\/contact\/\">Request a trial<\/a><\/div> <p class=\"note\">Cycles per day from plant data. Other figures measured by the SN8 between July 2025 and September 2026, with 290 valid days out of 434. Energy calculated with a 30 kW blower and \u20ac0.12\/kWh. Client anonymised.<\/p> <\/div>","protected":false},"excerpt":{"rendered":"<p>An industrial waste management company doubled its SBR capacity and detected 1,431 h of excess aeration by measuring sludge activity in every cycle with the SN8 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