Tube Settlers in Waste Water Clarification Systems June 1, 2025 sazenviro Post in Uncategorized Clarification is a fundamental process in wastewater treatment, responsible for removing suspended solids and reducing turbidity. When space is limited or higher efficiency is needed, a tube settler system is an effective enhancement over conventional clarifiers. This article explores the technical aspects, operational benefits, and application scope of tube settlers as a wastewater clarification unit. It is designed to help engineers, plant managers, and buyers understand the design parameters and performance improvements delivered by tube settler technology. What is a Tube Settler System?Contents1 What is a Tube Settler System?2 How a Tube Settler System Works2.1 Working Principle of a Tube Settler System3 Advantages of Tube Settlers as Wastewater Clarification Units3.1 Why Use Tube Settlers in a Wastewater Clarification Unit4 Design Criteria for Tube Settler Systems4.1 Key Considerations in Tube Settler System Design5 Material of Construction for Tube Settler Modules6 Applications Across Industries6.1 Industrial Uses of a Wastewater Clarification Unit with Tube Settlers7 Comparison: Tube Settler vs. Conventional Clarifier8 Case Study: Tube Settler in Beverage Industry Effluent Plant9 Installation Guidelines9.1 Installing a Tube Settler System in Clarifiers10 Maintenance and Cleaning11 SAZ ENVIRO’s Tube Settler Systems12 Conclusion A tube settler system is a compact inclined plate or tube module installed within a clarifier to increase the settling area and enhance solids removal efficiency. The tubes are inclined at 55–60 degrees, which allows solids to settle rapidly and slide down into a sludge hopper while clarified water flows upward and out. A tube settler acts like multiple shallow sedimentation tanks stacked vertically, making clarification faster and more efficient. How a Tube Settler System Works Working Principle of a Tube Settler System Inlet ZoneWastewater enters the clarifier and flows evenly across the bottom of the tubes. Settling Zone (Tubes)The tubes, arranged at an angle (typically 60°), allow solids to settle on their surface and slide down due to gravity. Sludge CollectionThe settled solids accumulate in the bottom hopper and are removed periodically or continuously. Clarified Water OutletWater rises between the tubes to the top collection trough and exits the unit. Advantages of Tube Settlers as Wastewater Clarification Units Why Use Tube Settlers in a Wastewater Clarification Unit Advantage Description Space Saving 5–10× more surface area per footprint compared to open tanks Higher Settling Rate Up to 4× faster than conventional clarifiers Modular Design Easy retrofitting in existing clarifiers Low Maintenance No moving parts inside tubes Reduced Sludge Volume Better solid-liquid separation Uniform Flow Distribution Avoids short-circuiting and dead zones Design Criteria for Tube Settler Systems Key Considerations in Tube Settler System Design Parameter Typical Range/Guideline Tube Inclination 55–60° Tube Cross-section Hexagonal or rectangular Tube Size 50–100 mm side length (hexagonal) Tube Length 1–2 m typical Surface Overflow Rate (SOR) 1.2–2.4 m³/m²/hr Hydraulic Retention Time (HRT) 20–30 minutes Material PVC, PP, FRP, HDPE Material of Construction for Tube Settler Modules Material Characteristics Application Suitability PVC Lightweight, economical Municipal and general industrial FRP Chemical and corrosion resistant Aggressive effluents HDPE Tough and UV-resistant Outdoor tanks, long life Applications Across Industries Industrial Uses of a Wastewater Clarification Unit with Tube Settlers Industry Application Use Case Municipal STPs Secondary clarification after aeration Food Processing Clarification after DAF units or coagulation tanks Textile & Dyeing Clarification post-flocculation and pH correction Chemical & Pharma High TSS removal from batch effluents Power Plants Pretreatment in ash water recovery or raw water system Comparison: Tube Settler vs. Conventional Clarifier Feature Tube Settler System Conventional Clarifier Settling Surface Area Higher (compact design) Lower (requires more space) Footprint Requirement 30–40% of conventional size Large Sludge Removal Rate Higher efficiency Moderate Cost Moderate upfront, lower OPEX Higher civil costs Maintenance Minimal (static modules) Moderate (requires mechanical parts) Case Study: Tube Settler in Beverage Industry Effluent Plant Location: UAE Flow: 120 m³/day Influent TSS: 350 mg/L Clarifier Type: Tube settler retrofitted in concrete tank Result: TSS reduced to <30 mg/L COD decreased by 45% Plant footprint reduced by 50% compared to original plan Maintenance cost down by 40% Installation Guidelines Installing a Tube Settler System in Clarifiers Tank PreparationEnsure smooth and clean tank walls, proper inlet weirs, and sludge hoppers. Module PlacementPlace modules in rows with uniform spacing for flow distribution. Support StructuresUse corrosion-resistant SS or FRP brackets for long-term stability. Outlet LaundersMust be designed to avoid short-circuiting and ensure equal withdrawal. Maintenance and Cleaning Flush tubes periodically with air or water jets to avoid algae/scum buildup Remove modules annually for inspection if installed in aggressive effluents Replace modules every 10–15 years based on material and exposure Compact Effluent Treatment Plants SAZ ENVIRO’s Tube Settler Systems SAZ ENVIRO, a reputed manufacturer of wastewater treatment equipment, supplies tube settler systems for municipal, textile, food, and chemical plants. Key features include: Hexagonal PVC/FRP tubes Complete structural frame and SS launders Custom sizing for concrete and MS tanks Installations across India, Kenya, Qatar, Oman, and Saudi Arabia Optional aeration integration for upstream treatment stages Conclusion The tube settler system is a game-changing enhancement to traditional clarifiers. As a wastewater clarification unit, it offers higher settling rates, compact footprint, and low maintenance, making it ideal for both retrofits and new installations. Whether you’re working on a space-constrained site or looking to boost your clarifier’s efficiency, tube settlers provide a reliable and proven solution.