Polymer consumption can rise because of changes in sludge, solution, dosing, mixing, injection point, pumps, or machine parameters.
Confirm the calculation basis
Compare consumption as active mass against dry solids rather than only solution volume or pump setting. Changing solution concentration can make volume figures misleading.
Check solution preparation
Powder feeding, wetting, mixing, maturation, water quality, and storage affect polymer availability. Inconsistent solution often leads operators to increase dosing.
Check dosing point and mixing
Polymer needs adequate distribution and contact time. Insufficient mixing causes poor distribution while excessive shear can damage flocs.
Relate usage to sludge changes
Changes in production, pH, solids, oil, temperature, or upstream chemicals can alter demand. Take a new sample and repeat screening before continuing to raise dosage.
