When United Utilities faced a critical failure at one of their wastewater treatment plants, they needed a fast, effective solution - and they needed it urgently. Two of their existing blowers had already failed, and within weeks, the third followed suit. With aeration at risk and consent compliance hanging in the balance, they turned to Corgin for emergency support.

The challenge? Deliver reliable aeration in an Activated Sludge Process (ASP) lane - without the conventional blower and diffuser setup.

A Different Approach to Aeration

Traditionally, ASP lanes rely on fixed blower systems and fine bubble diffuser air (FBDA) to provide aeration. While effective, these systems are often clunky, high-maintenance, and slow to deploy in emergencies.

Corgin’s Spiral Aerators offered a radically different approach: portable, surface-mounted aerators that combine mixing and aeration in one compact unit.

Despite initial doubts about their effectiveness compared to FBDA systems, United Utilities agreed to trial the Spirals. Over two rapid installations, a total of 17 Spiral Aerators were deployed across the aeration lanes.

Proven Performance Under Pressure

The results were clear.

The Spiral Aerators delivered strong mixing and sufficient aeration to maintain biological treatment and prevent consent failure. Drone footage captured after the install shows the Spirals performing seamlessly - visibly agitating the water surface and ensuring oxygen transfer throughout the lanes.

What surprised UU was not just the speed of deployment, but the Spirals’ ability to match the performance expectations of traditional systems. While FBDA systems focus solely on aeration, Spiral Aerators offer the added benefit of mixing, helping to keep solids in suspension and improving overall treatment efficiency.

Why Spiral Aerators Work

The Spiral Aerator’s design allows it to:

• Deliver oxygen efficiently through surface agitation
• Provide robust mixing, reducing dead zones
• Operate with minimal maintenance
• Be deployed quickly, ideal for emergency or temporary setups

As outlined on the Spiral Aerator product page, these units are not only effective but also versatile—suitable for lagoons, tanks, and now, as proven, ASP lanes.

Changing Perceptions in Wastewater Treatment

This installation is a clear example of how innovation can challenge long-held assumptions in the industry.

While blowers and diffusers have long been the default, the success of Spiral Aerators in this emergency scenario shows that alternative solutions can be just as effective - if not more so.

United Utilities’ experience highlights the importance of flexibility and responsiveness in wastewater management. And for Corgin, it’s another demonstration of how our solutions can rise to the occasion, even under the most demanding circumstances.