03 En Actiflo Softening


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03 En Actiflo Softening

  1. 1. Actiflo™ Softening for industrial water & drinking water applications Isabelle Lemaître - Philippe Sauvignet Technical Department
  2. 2. Actiflo ® Softening - Agenda <ul><li>Principles </li></ul><ul><li>Technology description </li></ul><ul><li>Actiflo® Softening Strengths </li></ul><ul><li>Industrial and Municipal potential applications </li></ul><ul><li>History of development program </li></ul><ul><li>Design Tools </li></ul><ul><li>On going and further development program </li></ul><ul><li>Results of Actiflo® Softening EdF Cattenom Nuclear Power plant </li></ul>
  3. 3. Actiflo® Softening : Process Principle <ul><li>Chemical precipitation of : </li></ul><ul><ul><li>hardness, </li></ul></ul><ul><ul><li>alkalinity, </li></ul></ul><ul><ul><li>silica </li></ul></ul><ul><ul><li>and other constituents (e.g., heavy metals) </li></ul></ul><ul><li>from water and wastewater by the addition of : </li></ul><ul><ul><li>lime / soda, </li></ul></ul><ul><ul><li>carbonate ion, </li></ul></ul><ul><ul><li>metallic salts </li></ul></ul><ul><ul><li>and polymer, </li></ul></ul><ul><li>in an Actiflo® including a reaction tank. </li></ul>
  4. 4. Actiflo® Softening : Process Principle Main chemical reactions involved <ul><li>Lime (& soda ash) softening </li></ul><ul><ul><li>CO 2 neutralisation and precipitation </li></ul></ul><ul><ul><li>Precipitation of temporary and permanent Ca Hardness </li></ul></ul><ul><ul><li>Precipitation of temporary and permanent Mg Hardness </li></ul></ul><ul><li>Coagulation with FeCl3 </li></ul>
  5. 5. Actiflo® Softening – Technology combines within a single treatment line <ul><li>a Dynamic Mixing stage for chemicals injection </li></ul><ul><li>an Enhanced Precipitation reactor with TURBOMIX™ </li></ul><ul><li>an Accelerated Flocculation stage with TURBOMIX ™ </li></ul><ul><li>a Lamella settling unit </li></ul><ul><li>a Sludge recirculation system that allows the re-injection of sludge </li></ul>Coagulation Maturation Contact CAP Filtration Raw water Coagulation Maturation (Floculation) Clarification 60 m/h Softening reactor Carbonates & Sand recirculation Hydrocyclone Scraper Carbonates return Towards sludge treatment FeCl3 Lime Microsand
  6. 6. <ul><li>Main advantage: Compactness </li></ul><ul><li>Actiflo ® Softening challenges competitors: Densadeg softener 20 – 30 m/h </li></ul>Actiflo ® Softening - Strengths Conventional precipitation softening : 2-6m/h Multiflo™ Softener: 20-30m/h Actiflo ® Softener : 60-80m/h
  7. 7. Actiflo® Softening Industrial and municipal potential applications <ul><li>Membrane pretreatment for reduction of potential scaling </li></ul><ul><li>Plant Water and Cooling Tower Make-up Water Production </li></ul><ul><li>Cooling Tower Sidestream recycling and blow-down reuse </li></ul><ul><li>Oil & Gas Produced Water Recycling </li></ul><ul><li>SAGD water treatment for reuse </li></ul><ul><li>Phosphorus removal </li></ul><ul><li>Flue Gas Desulfurization Wastewater Treatment </li></ul><ul><li>Acid Mine Drainage Treatment </li></ul><ul><li>Wastewater Reuse ( Steel & metals industry, secondary WW…) </li></ul><ul><li>Drinking water production </li></ul>
  8. 8. <ul><li>Dec. 2004 : Patent about TURBOMIX reactor </li></ul><ul><li>July 2005 : Patent about ACTIFLO Softening </li></ul><ul><li>2005-2006 : VWS first references with MultifloTM softening </li></ul><ul><ul><li>Iscor Newcastle (river water) and Sasol Landlord (cooling water reuse) </li></ul></ul><ul><ul><li>Clarification velocity < 10 m/h, conventional reaction tank (no TURBOMIX) </li></ul></ul><ul><li>2006 : Request from VWS Bus’ to Tech. Dept. of an industrial development program </li></ul>Actiflo ® Softening History of d evelopment program
  9. 9. Actiflo ® Softening History of d evelopment program <ul><li>2007 – 2009 : Development Program: </li></ul><ul><ul><li>Lab Tests about Actiflo and Multiflo softening </li></ul></ul><ul><ul><li>D&B of 2 mobile Multiflo/Actiflo Softening pilot plants </li></ul></ul><ul><ul><li>Pilot Studies: </li></ul></ul><ul><ul><li>Coca Cola, Acapulco  1st Actiflo® Softening industrial scale reference in May 09 </li></ul></ul><ul><ul><ul><li>Well water </li></ul></ul></ul><ul><ul><ul><li>Flow-rate: 110 m3/h – Reaction tank RT: 30 min. – upflow velocity: 37 m/h </li></ul></ul></ul><ul><ul><ul><li>Solids recycle ratio 10-20:1 </li></ul></ul></ul><ul><ul><ul><li>Alkalinity: 190  54 ppm as CaCO3 – Turbidity 2 NTU </li></ul></ul></ul><ul><ul><li>Coffeyville, Ks – CVR Energy refinery – February 2009 </li></ul></ul><ul><ul><li>EDF Cattenom Nuclear Power Plant </li></ul></ul>
  10. 10. Actiflo ® Softening – Design Tools <ul><li>Actiflo ® Softening mass balance calculation </li></ul><ul><li>Optimised performances with : </li></ul><ul><li>Continuous recirculation Carbonates </li></ul><ul><li>Ajustable return/extraction rate </li></ul>
  11. 11. Actiflo ® Softening – Design Tools <ul><li>PEARL process design Actiflo® Softening module – Under development </li></ul><ul><ul><li>Precipitation calculations: </li></ul></ul><ul><ul><ul><li>Based on thermodynamic equilibrium (solubility) with stoechiometric dosages </li></ul></ul></ul><ul><ul><ul><li>Take Activity coefficients into account to correct the solubility constants </li></ul></ul></ul><ul><ul><ul><li>Simultaneously solve the different precipitation reactions </li></ul></ul></ul><ul><ul><ul><li>Alkalinity include OH- + HCO3- + CO32- + NH3 + HPO42- + PO43- + B(OH)4- + S2- + HS- + SO32- (+ theoretically SiO(OH)3-) </li></ul></ul></ul><ul><ul><ul><li>Partially implement “Ion pairing effect”: ions not 100% dissolved as free ions – tied up as soluble aqueous species </li></ul></ul></ul>
  12. 12. Actiflo ® Softening – Design Tools Current limits of PEARL Actiflo® Softening module <ul><li>Softening / precipitation calculations: </li></ul><ul><ul><li>Assessing the potential for precipitation just on solubility curve is too optimistic, </li></ul></ul><ul><ul><li>Oversaturation required </li></ul></ul><ul><ul><li>Kinetics not taken into account </li></ul></ul><ul><ul><li>Process is never 100% efficient </li></ul></ul><ul><ul><li> Enter a “ process efficiency ” according to experience (from pilot trials) </li></ul></ul><ul><ul><li> Dosage used for precipitation = total dosage x process efficiency </li></ul></ul><ul><ul><li> Remaining dosage used to raise pH </li></ul></ul>
  13. 13. Actiflo ® Softening – Design Tools Current limits of PEARL Actiflo® Softening module <ul><li>No relationship between upflow velocity and outlet TSS </li></ul><ul><li> pilot trials, operation feedback </li></ul><ul><li>Makes not prediction of metal hydroxide precipitation </li></ul><ul><li>High rate softening Process Note , including Actiflo® Softening and Multiflo ® softening - Under development </li></ul><ul><ul><li>First revision to be issued end of 2009 </li></ul></ul>
  14. 14. Actiflo® Softening On going and further development program <ul><li>EDF pilot trials on Moselle river water and on cooling water </li></ul><ul><li>Multiflo® Softening and Actiflo® Softening in parallel on the same river water quality, in cold temperature conditions </li></ul><ul><li>Complementary laboratory tests </li></ul><ul><li>Ultimate target : Modeling chemical softening processes in order to be able to preliminary design Actiflo® Softening (and Multiflo® Softening) units without prior Jar-Tests or pilot trials, for all kind of water. </li></ul>
  15. 15. Actiflo ® Softening pilot Trials EdF Cattenom Nuclear Power plant
  16. 16. Pilot Plant location & purpose <ul><li>EdF (Cattenom Site) : Nuclear Power plant (4 x 1300 MW) </li></ul><ul><li>Purpose : Feedwater to cooling tower treatment </li></ul><ul><li>Source : River Moselle </li></ul><ul><ul><li>Turbidity : 5 to 100 Ntu (typically 15 Ntu) </li></ul></ul><ul><ul><li>Organic Matter : 3.5 to 5 mg/l DOC (SUVA < 3) </li></ul></ul><ul><ul><li>Alkalinity / TAC :15 to 17°F (150 – 170 mg/l as CaCO 3 ) </li></ul></ul>
  17. 17. Power Plant General Process flow diagram Cooling tower Nuclear Reactor Industrial water production Boiler feed water production Condensate polishing To WWTP To WWTP To WWTP Actiflo® Softening on : Surface water = River Moselle Actiflo® Softening on : Cooling water circuit = 1.6 x river Moselle Purge return to river
  18. 18. Actiflo ® Softening operational setting <ul><li>Lime softening (Solution @ 100g/l); Dose : 120 – 130 ppm </li></ul><ul><ul><li>Calculation based on 8 x Δ Alk = 8 x 15°F = 120 ppm </li></ul></ul><ul><ul><li>Target Alkalinity < 30 mg/l as CaCO 3 </li></ul></ul><ul><li>Coagulation (FeCl3 41%) : 20 – 30 ppm </li></ul><ul><li>Polymer A-PAM (AN934 SNF) : 0.4 ppm </li></ul><ul><li>µsand (drinking water – GA39) Effective size : 80 µm UC = 1.4 </li></ul><ul><li>µsand concentration = 5 kg/m 3 </li></ul><ul><li>Feedflow : 65 m 3 /h (60 m/h rise rate) </li></ul><ul><li>Recirculation rate (cyclone overflow) : 8.5 m 3 /h </li></ul><ul><li>Contact time softening : 10 mn (flow 65 + 8.5 = 73.5 m 3 /h) </li></ul><ul><li>Sludge discharge flow : 0.3 – 0.5 m3/h ( < 0.8% water loss) </li></ul>
  19. 19. <ul><li>Softening Turbomix reactor </li></ul><ul><ul><li>Contact time : 10 min @ 60 m/h </li></ul></ul><ul><ul><li>TSS concentration : 3.5 to 4.5 g/l </li></ul></ul><ul><ul><li>Solids ratio recirculated / formed : 20/1 </li></ul></ul><ul><li>Lime addition into a specific tank (mixed with sludge) </li></ul><ul><li>Sludge extraction by overflow discharge </li></ul>Actiflo ® Softening operational setting
  20. 20. Initial results (Clarified water & sludge) <ul><li>Clarified water quality at 60 m/h:- </li></ul><ul><ul><li>TSS < 5 mg/l (Turbidity < 1 Ntu) </li></ul></ul><ul><ul><li>Alkalinity (CAE) < 30 ppm pH 8.5 </li></ul></ul><ul><ul><li>Δ THT : 100 - 120 mg/l as CaCO3 </li></ul></ul><ul><ul><li>40% DOC removal! </li></ul></ul>MA cyclone underflow MA cyclone overflow <ul><li>Carbonate sludge: </li></ul><ul><ul><li>Concentration : 30 to 60 g/l </li></ul></ul><ul><ul><li>No build-up of carbonate around µsand </li></ul></ul><ul><ul><li>Good separation sand/sludge </li></ul></ul>
  21. 21. Current and future test work <ul><li>On river Moselle </li></ul><ul><ul><li>Run without coagulant (only with a small acid dose) </li></ul></ul><ul><ul><li>Compare coagulant dosing point upstream & downstream softening tank </li></ul></ul><ul><ul><li>Reduce solids ratio (purge more = lower sludge concentration ) </li></ul></ul><ul><li>On cooling tower water (1.6 x river Moselle) </li></ul><ul><ul><li>Run at 80 m/h </li></ul></ul><ul><ul><li>Reduce contact time (softening down to 8 mn) </li></ul></ul><ul><ul><li>Experience higher solids (Turbidity load) up to 30 – 40 Ntu </li></ul></ul><ul><ul><li>Experience higher Alkalinity </li></ul></ul><ul><ul><li>Experience higher DOC (Organic Matter) </li></ul></ul><ul><ul><li>Study legionnella removal </li></ul></ul>
  22. 22. Conclusions <ul><li>Very promissing early results </li></ul><ul><ul><li>More pilot trials needed to validate design enveloppe </li></ul></ul><ul><li>Excellent rise rate capability (60 m/h may be more) </li></ul><ul><li>Interesting organic removal capabilities (to be studied more) </li></ul><ul><li>High sludge concentration (30 – 60 g/l) extremely good thickening capability </li></ul><ul><li>Wide range of application both industrial and Municipal </li></ul><ul><li>Should sell like hot cakes… </li></ul>
  23. 23. <ul><li>Thank You! </li></ul>