CASE STUDY
Industrial & Municipal Water Treatment / pH Control
Burnett Lime Co. Inc., Campobello, SC
Accuracy and Reliability in High-Solids Lime Slurry Pumping
Industrial & Municipal Water Treatment • Campobello, SC • Partner: Water Treatment Supply
Project Details
- Client: Burnett Lime Co. Inc.
- Industry: Industrial & Municipal Water Treatment / pH Control
- Location: Campobello, SC 29322
- Project Type: Lime Slurry Dosing & pH Control Automation
- Equipment: Pulsafeeder HYDRAtuber Tubular Diaphragm Metering Pump
- Solution Partner: Water Treatment Supply
- Challenge: High-solids lime slurry pumping accuracy and reliability
Project Overview
Burnett Lime Co. Inc. is a recognized industry leader in pH control process technology for industrial and municipal water and wastewater treatment. Their operations rely on lime slurry — a mixture of calcium oxide and approximately 30% water — as the primary chemical for pH adjustment in aerobic digestion systems.
However, delivering lime slurry presents a significant engineering challenge. The very high solids content in the slurry creates operational problems that are common to traditional pumping technologies.
In wastewater treatment, pH accuracy is not optional. If the pH is too low (acidic) or too high (caustic), the growth of beneficial bacteria is inhibited, directly impairing the aerobic digestion and biological elimination of sewage. Burnett Lime required a pumping solution that was both highly accurate and dependable enough for continuous, uninterrupted operation.
The Challenge
Clogging at Orifices & Check Valves
High solid content caused blockages near moving parts, particularly the diaphragm, resulting in irregular flow rates and pump failures.
Diaphragm Pinch Failure
Solids buildup around the diaphragm created mechanical pinch points, leading to premature diaphragm failure, process outages, and maintenance calls.
Inaccurate Chemical Dosing
Air-operated double diaphragm (AODD) pumps could not deliver the precision required for pH-sensitive water treatment processes. Inconsistent lime delivery put the quality of aerobic digestion at risk.
Messy Hose Failures
Peristaltic hose pumps, another commonly used solution, suffered from frequent and unclean hose failures, creating operational disruption and safety concerns.
High Maintenance Burden
Both AODD and peristaltic technologies demanded constant attention, increasing operational costs and reducing plant uptime. Frequent breakdowns and messy hose replacements were an ongoing drain on resources.
Our Solution
After evaluating multiple pumping technologies, Burnett Lime Co. partnered with Water Treatment Supply to source a purpose-built solution for high-solids slurry applications. The solution selected was the Pulsafeeder HYDRAtuber — a tubular diaphragm metering pump engineered specifically for shear-sensitive, high-viscosity fluids and slurries.
Why the Pulsafeeder HYDRAtuber?
Straight-Through Flow Path
Unlike conventional diaphragm pumps, the HYDRAtuber does not allow particulate matter to settle or collect at critical surfaces. The continuous flexing action moves particles through the system without buildup.
No Clogging
Because the tube diaphragm does not create narrow orifices or restrict flow, even high-solid-content slurries pass through cleanly and consistently.
Double Diaphragm Safety
A secondary containment diaphragm provides an added layer of protection against leaks and messy ruptures — a known failure mode in both AODD and peristaltic systems.
PulsaPro Diagnostic Window
Maintenance teams can inspect diaphragm integrity visually without removing the pump from the system, reducing downtime and enabling proactive condition monitoring.
Hermetically Sealed Design
In the rare event of a diaphragm rupture, the pump remains sealed. Optional leak detection provides an immediate alert to maintenance crews, eliminating undetected failures.
Minimal Preventive Maintenance
Routine service requires only periodic oil changes and visual inspection of the wet end — no hose replacements, no complex teardowns.
Equipment Configuration
| Specification | Detail |
|---|---|
| Product | Pulsafeeder HYDRAtuber PulsaPro Tubular Diaphragm Metering Pump |
| Application | Lime slurry dosing for water and wastewater pH neutralization |
| Fluid Handled | ~30% solids calcium oxide (lime) slurry |
| Control | Precision flow-rate-based chemical feed, integrated with process pH monitoring |
| Optional Feature | Leak detection add-on for diaphragm rupture alerting |
Results & Impact
The results at Burnett Lime Co. Inc. have been definitive. The original HYDRAtuber installation has been operating in Burnett’s system continuously since 1992 — a testament to the reliability of the tubular diaphragm design under demanding, high-solids service conditions.
| Challenge | Previous Solution | Outcome with HYDRAtuber |
|---|---|---|
| High-solids slurry clogging | Air-operated double diaphragm (AODD) pump | Zero clogging. Straight-through flow path eliminates blockages |
| Inaccurate dosing & flow irregularity | Peristaltic hose pumps | Precision-controlled dosing, consistent flow rates |
| Diaphragm rupture & messy failures | Both AODD and peristaltic | Hermetically sealed; optional leak detection; no hose failures |
| High maintenance burden | Frequent breakdowns, messy hose replacements | Simple PM: oil changes + visual wet-end inspection only |
| pH control accuracy at risk | Inconsistent chemical delivery | Reliable lime slurry delivery maintains optimal pH for aerobic digestion |
Client Feedback
Before & After Comparison
| Parameter | Before Implementation | After Implementation |
|---|---|---|
| Pump Technology | AODD / Peristaltic Hose | Pulsafeeder HYDRAtuber Tubular Diaphragm |
| Dosing Accuracy | Inconsistent — flow irregularity due to solids | Precision-controlled, consistent flow rates |
| Clogging Frequency | High — solids blocked orifices & check valves | Eliminated — straight-through path prevents buildup |
| Diaphragm Integrity | Failure-prone; messy ruptures | Hermetically sealed; PulsaPro diagnostic window |
| Maintenance Effort | High — frequent pump failures & hose replacements | Minimal — oil change + visual wet-end check |
| pH Control Reliability | At risk due to inaccurate lime dosing | Consistently maintained for aerobic digestion |
| Operational Uptime | Frequent unplanned downtime | Continuous operation since installation (since 1992) |
Looking for a Proven Lime Slurry Pumping Solution?
Water Treatment Supply offers a complete range of industrial slurry metering pumps, chemical dosing equipment, and water treatment automation systems — engineered for reliable performance in demanding applications including lime slurry handling, pH control, and chemical feed for municipal and industrial water treatment.
Whether you are dealing with high-solids slurries, corrosive chemicals, or viscous fluids, our team can help you identify the right hydraulic diaphragm metering pump for your specific process requirements.