January 13, 2026
Reduce Energy Consumption with Advanced Grit Management®
Energy efficiency is one of the most pressing challenges for wastewater treatment plants today.
Rising energy costs, aging infrastructure, and increasing regulatory requirements make it essential for municipalities to find ways to optimize operations without compromising performance.
One of the most overlooked contributors to excessive energy use is grit: tiny particles of sand, silt, and other inorganic material that enter the treatment plant and reduce treatment process efficiency. Oldcastle Infrastructure’s Advanced Grit Management® solutions are designed to tackle this problem head-on, helping plants reduce energy consumption, protect equipment, and improve overall performance.
The Hidden Energy Cost of Grit
Fine Bubble Aeration is one of, if not, the largest consumers of energy in a wastewater treatment plant. When grit enters aeration basins, and digesters as well as other downstream processes, it accumulates and reduces effective capacity. Grit buries aeration diffusers, forcing blowers, mixers, and pumps to work much harder to maintain treatment performance, driving up energy consumption. Grit also causes wear and tear on mechanical equipment over time, shortening its lifespan and increasing maintenance costs.
For many plants, the energy penalty caused by grit is quite substantial. Eliminating grit in the headworks is one of the most effective ways to reduce energy demand and improve operational efficiency throughout the plant.
How does Advanced Grit Management® Work?
Oldcastle Infrastructure offers a suite of grit removal technologies engineered to deliver high performance with minimal maintenance. These systems capture fine grit particles down to 75 microns before they enter energy-intensive processes, preventing accumulation and reducing the load on downstream equipment.
HeadCell®
The HeadCell® stacked tray separator uses advanced hydrodynamics to remove fine grit in a compact footprint. Its no-moving-parts design ensures low maintenance while achieving 95% removal of grit 106 microns and larger at peak flows. By preventing grit from entering aeration basins, HeadCell keeps the diffusers clean and at maximum process efficiency.
OpTeaCup® Grit Washing and Grit Snail® Dewatering
For grit washing and dewatering, our OpTeaCup® and Grit Snail® systems provide clean, dry grit ready for disposal. These systems minimize organic content and reduce hauling costs, further contributing to operational savings.
Grit King®
The Grit King® is an advanced hydrodynamic separator that uses structured flows to augment gravitational forces to separate grit from water. The Grit King offers phenomenal grit separation performance with no electrical needs and typically less than 6” of required headloss. The Grit King® is an economical choice for new or existing municipal or industrial wastewater applications looking to reduce their energy consumption.
Energy Savings in Action
Treatment plants that have implemented advanced grit management systems report on measurable reductions in energy use. By removing grit before it reaches aeration basins, facilities can maintain optimal oxygen transfer efficiency, reduce blower run times, and lower overall power consumption. In addition, preventing grit accumulation in digesters improves mixing efficiency and reduces the energy required for sludge processing.
Beyond Energy: Total Plant Protection
While energy savings are a major benefit, advanced grit management systems also deliver long-term value by reducing maintenance costs, extending equipment life, and improving process reliability.
With Oldcastle Infrastructure’s advanced grit management solutions, plants can achieve:
- Lower energy consumption in aeration and sludge treatment
- Reduced wear on pumps, blowers, and mixers
- Fewer unplanned shutdowns and costly cleanouts
- Compliance with stringent performance standards
Ready to Improve Your Efficiency?
Reducing energy consumption starts with eliminating grit. Oldcastle Infrastructure’s Advanced Grit Management® systems provide proven solutions for plants of all sizes, from large municipal facilities to small community treatment systems.
Learn more
- Discover our Advanced Grit Management® solutions
- Learn more about our HeadCell® solution
- Read our HeadCell® product brochure
- See the benefits of our TeaCup® and Grit Snail® systems
- View the Grit Snail® product brochure
- Learn more about the Grit King®
- Read our Grit King® product brochure
- Contact us today to learn how our grit removal technologies can help you cut energy costs, protect your equipment, and optimize your operations
