Industry: Energy / Pump-as-Turbine.
Location: Westerwald, Germany.
Client: Dillkreis Süd waterworks.
Turning pressure into power.
Nestled in the picturesque Westerwald region of Germany, the Dillkreis Süd waterworks faced a growing challenge: how to harness untapped energy potential from their existing infrastructure while maintaining operational efficiency.
Historically, pressure-reducing valves (PRVs) were used in the supply line between two storage basins to regulate water flow. However, this system not only wasted energy but also missed an opportunity to generate power sustainably.
With a drop height of 100 meters and a flow rate of 145 cubic meters per hour, the energy potential was significant. However, implementing a solution without disrupting ongoing operations required precision, innovation, and expertise.
PLEUGER’s innovative vision.
Recognizing the unique opportunity at Dillkreis Süd, PLEUGER proposed an ingenious solution: repurposing their high-efficiency submersible motor pumps as turbines for energy recovery. This approach, known as Pump-as-Turbine (PaT) technology, offered a cost-effective way to generate power while aligning with the client’s sustainability goals.
PLEUGER’s team, led by project manager Erik Schäfer, collaborated closely with the Dillkreis Süd waterworks team to design, customize, and install the optimal solution.
The key innovation lay in the precise adaptation of the PLEUGER 8” pump unit, reengineered for reverse operation as a turbine.
Every detail was considered – from adapting the impeller to match the water volume and head, to adapting the pump hydraulics and integrating a pressure jacket made of durable chrome steel. Combining PLEUGER hydraulics with the water-filled PLEUGER Asynchron M8 motor as a two-pole generator was the optimal technical solution with its high efficiency and durability.
The result? A highly efficient, horizontally installed unit with a pressure jacket made of chrome steel and impellers crafted from durable Noryl. The system was designed for seamless integration into the existing infrastructure, with activation and deactivation completed in just 150 seconds, without disruption.
Powering Sustainability.
When the system went live, the transformation was immediate. Energy that was once wasted was now creating power. Each year, the turbine generates 90,000 kWh – enough to significantly offset operational costs while reducing CO2 emissions by 60 tons annually. For Dillkreis Süd, this meant saving €24,000 every year and taking a decisive step towards sustainability.
The success didn’t stop there. Inspired by the results, the waterworks installed a second PLEUGER turbine in 2013, doubling their capacity for energy recovery.
“The precise design of the PLEUGER hydraulics makes it possible to use it as a turbine in our plant. Due to the good experience, we expanded our sustainability strategy with another PLEUGER turbine.”
Environmental and societal benefits.
Beyond the immediate operational benefits, the project underscored the potential for water utilities to contribute to global sustainability goals. By replacing traditional PRVs with PLEUGER’s innovative solution, Dillkreis Süd demonstrated how existing infrastructure could be optimized for energy recovery and environmental stewardship.
Ongoing benefits.
90,000
kWh/year
60
tons of CO2
reduced annually
€24,000
saved every year
By turning pressure into power, Dillkreis Süd set a new standard for energy efficiency.
The project proved that innovation doesn’t have to be disruptive. With precise engineering and thoughtful design, existing infrastructure can evolve into something extraordinary.
A Partnership for the future.
The Dillkreis Süd project is proof that small changes can create massive impact.
This is what drives us: innovation for a sustainable future.
Today, we’re building on this success, bringing Pump-as-Turbine technology to facilities around the world, and empowering industries to embrace sustainability. All possible through vision, collaboration, and innovation.
Transform your operations.
Contact PLEUGER today.
Made for water. Engineered for life.
Made for water. Engineered for life.
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