Aeration101 R2

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Aeration101 R2

  1. 1. AERATION 101 Presented by : Tom Frankel Director 08/31/09
  2. 2. 08/31/09 I. HISTORY
  3. 3. 08/31/09 British Patent No. 22952, Filed 11 October 1913 Subject: Wastewater aeration based on a porous diffuser. 1916 - San Marcos, Texas - l20,000 gpd (approx.) at continuous-flow operation - diffused aeration
  4. 4. 08/31/09 II. DESIGN & PROCESS OVERVIEW
  5. 5. 08/31/09 PROCESSES: BNR SBR MBR UASB CONVENTIONAL EXTENDED AERATION FIXED FILM DESIGN TOOLS: PROCESS SIMULATION (i.e. Biowin) 3d MODELING MANUFACTURER WEB SITES
  6. 6. PROCESS SIMULATION 08/31/09 Model your plant to determine how changes in SRT and Anoxic/aerobic volumes affect your effluent before you make those changes.
  7. 7. 08/31/09 BLOWER TYPES: MULTISTAGE CENTRIF. SINGLE STAGE CENTR. ROOTS TYPE BLOWERS CONTROL SYSTEMS: MANUAL D.O. CONTROL FEED FORWARD
  8. 8. 08/31/09 BLOWER CONTROL SYSTEMS Conventional D.O. control Feed Forward Off-Gas control
  9. 9. 08/31/09 INPUT DATA Aeration system design requires consideration of many factors. BOD, COD, NH3-N, Process Type, Wastewater temperature, Air temperature from blowers and distance from blower room, Altitude at site, Treatment goals, Average to Peak ratios, Industrial influent, target MLSS, Chlorides in the wastewater, Scaling potential of wastewater, Future growth plans for plant and/or growing community, Previous experience with diffusers, elastomers and metals at the plant, Priority for capital cost of energy efficiency (cost of power$$) To do a proper job of aeration system design, your supplier will need a lot of information from you!
  10. 10. 08/31/09 III. IN – SITU MONITORING SYSTEMS
  11. 11. 08/31/09 PRESSURE MONITORING SYSTEM DIFFUSER BACK PRESSURE
  12. 12. 08/31/09 PILOT GRID INSTALLATION – PERMITS RETRIEVAL AT ANY TIME TO MONITOR DIFFUSER FOULING, SOTE AND BACK PRESSURE WITHOUT DRAINING TANKS
  13. 13. 08/31/09 IV. OXYGEN TRANSFER TESTING
  14. 14. INDEPENDENT NON-STEADY STATE TESTING SOTE TEST per ASCE STANDARDS IN CLEAN WATER 08/31/09
  15. 15. 08/31/09 INDEPENDENT STEADY STATE TESTING IN PROCESS WATER FOR ALPHA DETERMINATION
  16. 16. 08/31/09 INDEPENDENT NON-STEADY STATE TESTING
  17. 17. 08/31/09 COMPETITIVE RESULTS
  18. 18. 08/31/09 NEW VS. OLD MEMBRANE PERFORMANCE
  19. 19. 08/31/09 V. TYPES OF AERATION SYSTEMS AND THEIR RELATIVE EFFICIENCIES
  20. 20. BUBBLE PATTERNS 08/31/09 Fine Bubble Diffuser Coarse Bubble Diffuser 2% SOTE/FT 1% SOTE/FT
  21. 21. 08/31/09 TUBE DIFFUSERS <ul><li>Consider quantity and location of orifice and seal </li></ul><ul><li>Consider method of rubber molding and materials of construction </li></ul>                                                                            
  22. 22. 08/31/09 FINE BUBBLE DISC DIFFUSERS – CONNECT TO PIPE WITH SADDLES, GROMMETS OR GLUE-ON BASES
  23. 23. COARSE BUBBLE DIFFUSERS <ul><li>These are often used in digesters, sludge holding tanks, and equalization basins. </li></ul>08/31/09
  24. 24. JET AERATORS <ul><li>Used only in the smallest SBR’s, due to their high energy consumption. Jets require a pump + a blower, whereas diffusers need only a blower. Useful in Digesters with highly thickened solids. </li></ul>08/31/09
  25. 25. SURFACE AERATORS <ul><li>Pictured are low and high speed surface aerators </li></ul><ul><li>Maintenance and freezing are concerns </li></ul><ul><li>“ dead zones” may appear at corners </li></ul><ul><li>Useful in Anoxic/Anaerobic zones </li></ul>08/31/09
  26. 26. STATIC AERATORS <ul><li>Used only in lagoons. Efficiency is similar to coarse bubble diffusers . </li></ul>08/31/09
  27. 27. FLOATING LATERAL SYSTEMS 08/31/09 Used in earthen lagoons with membrane liners where decanting is not possible, and floor prohibits installation of a fixed grid.
  28. 28. RELATIVE EFFICIENCY 08/31/09 AERATOR SAE #O2/HR-HP wire Membrane 5-9 Ceramic 5-9 Jet 2-3 Static tube 2-3 Coarse bubble 2-3 Low Speed 2.5-3.5 High speed 1.5-2.25 Submerged turbine 2.5-3.5
  29. 29. 08/31/09 VI. MEMBRANE FOULING
  30. 30. DID YOU KNOW….? 08/31/09 90% of failures of a membrane diffused aeration system are caused by failed membranes ?
  31. 31. 08/31/09 DID YOU KNOW….? In most cases, the cost of replacing membranes in a tank is higher than the cost of those membranes , when you consider hidden costs? LABOR & CLEANING OUT OF SERVICE = NO INCOME!! STEADILY DECLINING PERFORMANCE = ENERGY $$
  32. 32. 08/31/09 DID YOU KNOW….? EPDM is a very durable material, but it is susceptible to fouling, which may include permanent swelling, shrinking, or crust? Calcium Carbonate (lime) Calcium Sulfate (gypsum) Petroleum Dairy Products Animal Fat Vegetable Oils Alcohol
  33. 33. 08/31/09 DID YOU KNOW….? Plastic gas cans are made of polyethylene, which is not recommended for gasoline or diesel service. Lab bottles that store aggressive solvents are also made of polyethylene, which is not recommended for those solvents.
  34. 34. 08/31/09 DID YOU KNOW….? The first PTFE coated frying pan was developed in France by TEFAL in 1954?
  35. 35. 08/31/09 DID YOU KNOW….? Re: PTFE coated EPDM membranes Those diffusers have a track record in service since late 2004, and have outlasted plain EPDM membranes in aggressive applications by a 10:1 margin.
  36. 36. 08/31/09 PTFE MEMBRANES – Failure Mode? Not Yet We observe that a biofilm layer does form on PTFE Membranes, though it takes a long time to form, and when it Does, even in aggressive environments, it can be removed With a fingertip. The scale does not affect performance and Does not enter the slits. See below…
  37. 37. 08/31/09 Why PTFE??? – Don’t let this happen to you!
  38. 38. 08/31/09 DID YOU KNOW….? Test report #84395 dated April 30, 2009 proves that SSI’s patent-pending surface fluorination reduces plasticizer loss in an aggressive hot acetone solution compared to standard EPDM membranes by 25%. Phoenix 91 st Ave is retrofitting 2 basins in 2009 with fEPDM from SSI. Not with fEPDM!!! New Old Older Fossil
  39. 39. 08/31/09 DID YOU KNOW….? Not all EPDM is created equal. One manufacturer uses Compression Molding and 700% elongation material. Most others are using injection molding and 500% elongation material, to save cost.
  40. 40. 08/31/09 VII. QUALITY
  41. 41. 08/31/09 THE DEVIL IS IN THE DETAILS <ul><li>EPDM compounds are specially formulated for wastewater </li></ul><ul><li>applications providing: </li></ul><ul><li>Even specific gravity, thickness, and tear resistance </li></ul><ul><li>Greater resistance to elongation and tearing </li></ul><ul><li>(multidirectional tear resistance) </li></ul><ul><li>Resistant to material property changes. </li></ul><ul><li>High modulus for elasticity. </li></ul><ul><li>Proper taper to reduce unit stress. </li></ul><ul><li>High oxygen transfer efficiency. </li></ul><ul><li>Extended service life </li></ul>
  42. 42. BURST TEST 08/31/09
  43. 43. 08/31/09 PLASTIC PARTS SUPPLIER QC MONITORING & PROTOCOL
  44. 44. 08/31/09 MEMBRANE SUPPLIER QC MONITORING & PROTOCOL
  45. 45. 08/31/09 LARGE PROJECT – MIL 105E TEST PROTOCOL
  46. 46. 08/31/09 IN-HOUSE TESTING & REPORTS
  47. 47. 08/31/09 IN-HOUSE TESTING & REPORTS
  48. 48. 08/31/09 IN-HOUSE TESTING & REPORTS
  49. 49. 08/31/09 VIII. PIPING SYSTEM FABRICATION & MATERIALS
  50. 50. 08/31/09 PLASTIC PIPE FABRICATION
  51. 51. 08/31/09 SS PIPE FABRICATION
  52. 52. 08/31/09 IX. DESIGN TOOLS & CALCULATORS
  53. 53. 08/31/09 WEB (.NET)+ LOCAL CALCULATION SOFTWARE
  54. 54. 08/31/09 WEB (.NET) BASED DRAFTING SOFTWARE
  55. 55. 08/31/09 WEB (.NET) BASED DRAFTING SOFTWARE Typical Results
  56. 56. 08/31/09 X. COMPONENTS & THEIR IMPORTANCE
  57. 57. SUPPORTS 08/31/09
  58. 58. EXPANSION JOINTS 08/31/09
  59. 59. 08/31/09
  60. 60. REPLACEMENT MEMBRANES 08/31/09
  61. 61. 08/31/09 XII. TYPICAL SYSTEMS
  62. 62. 08/31/09 SYSTEMS
  63. 63. 08/31/09 SYSTEMS
  64. 64. 08/31/09 SYSTEMS
  65. 65. Replacement Diffusers 08/31/09
  66. 66. 08/31/09
  67. 67. 08/31/09 The following graph depicts the performance of two tanks in Denmark. Tank 1 has Nopon TM 300 size diffusers. In Tank 2, SSI replaced the Nopon TM membranes with SSI 12” retrofit membranes. The two tanks ran side by side. Notice how the valve to the air supply in the SSI tank is mostly closed, and the valve to the air supply in the Nopon TM tank is mostly open, yet the DO is higher in the SSI tank, in spite of receiving much less air.
  68. 68. 08/31/09 Hi Tom. Here the first result of changing from Nopon TM 215 to AFD 350/PTFE. Saving ca 16%. But we have to adjust the plant concerning the pressure, so I ’ ll be back. I would like to end about 25%. Med venlig hilsen/With best regards   Pumpteknik ApS/SSI North Europe Dan Christensen   www.pumpteknik.dk Tlf.: ++45 49161676, Fax.: ++45 49161696 Mobil: ++45   31655158 - e-mail mobil: [email_address] Skype member: Pumpteknik Ad1) Totalt elforbrug Elforbrug til beluftning Procent beluft ud af total Indløbsflow Elforbrug total pr. m3 vand Elforbrug beluftning pr. m3 vand kwh kWh % m3 kWh(total)/m3 kWh(beluftning)/m3 maj-07 49958,00 12238,00 24% 201744,00 0,25 0,060661036 jan-08 66713,00 12719,00 19% 232016,00 0,29 0,054819495 feb-08 58877,00 11429,00 19% 224598,00 0,26 0,050886473 Besparelse 16%
  69. 69. 08/31/09 XII. OPERATION, MAINTENANCE, AND TROUBLESHOOTING MANUALS
  70. 70. 08/31/09 XII. DEMONSTRATION/ Q & A SESSION
  71. 71. 08/31/09 THANK YOU!

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