Role of regression analysis and variation of rheological data in calculation of pressure drop for sludge pipelines

Sludge pumps in wastewater treatment plants are often oversized due to uncertainty in calculation of pressure drop. This issue costs millions of dollars for industry to purchase and operate the oversized pumps. Besides costs, higher electricity consumption is associated with extra CO2 emission which creates huge environmental impacts. Calculation of pressure drop via current pipe flow theory requires model estimation of flow curve data which depends on regression analysis and also varies with natural variation of rheological data. This study investigates impact of variation of rheological data and regression analysis on variation of pressure drop calculated via current pipe flow theories. Results compare the variation of calculated pressure drop between different models and regression methods and suggest on the suitability of each method. [Display omitted] •The suitable regression analysis to model sludge flow behaviour.•Impact of regression method on pressure drop calculation.•Pressure drop calculation using modified Herschel–Bulkley model.•Impact of variation of rheological data on pressure drop calculation.•Suitable rheological models at different shear rate range.