1 Full-Scale Testing of Innovative High Rate Filter Media for Plant Expansion Bob Raczko, P.E....

1

Full-Scale Testing of Innovative High Rate Filter Media for Plant Expansion

Bob Raczko, P.E.United Water

2

UWMX WTP

Location: Manalapan, NJ Size: 5 mgd (790 m3/hr), but needs to be expanded to 8 mgd

(1,260 m3/hr) to meet increasing water demands within next several years

Plant Processes: - Coagulation/flocculation/two-stage

sedimentation/filtration/disinfection/finished storage/finished water pumping- Powdered Activated Carbon (PAC) added to second stage sedimentation for

seasonal taste and odor (T&O) control Filters currently are major limiting step in process:

- 6 filters (5 with 1 out of service for backwashing) operate at a nominal rate of 3 gpm/sf (7.3 m/hr)

- Based on previous Filtralite testing at Haworth, NJDEP will allow testing up to 7 gpm/sf (17 m/hr)

- Also evaluating larger anthracite/sand media, NJDEP will allow testing up to 5 gpm/sf (12 m/hr)

If successful, new media will allow filtration capacity to be expanded without increasing the number of filters, which will significantly reduce capital expenditures

3

HAWORTH WTP – PREVIOUS PILOT TESTING

Compared: Conventional anthracite/sand Filtralite – expanded clay media:

– Larger size media– Larger macropore size for solids capture

Findings: Filtralite achieved comparable performance at 7.5 gpm/sf

compared to anthracite/sand at 5 gpm/sf Filtralite achieved longer filter runs, less headloss

development

4

UWMX WTP DEMONSTRATION TESTING

Received approval from NJDEP to modify two filters for demonstration test: New underdrains Provide additional depth for both anthracite/sand and

Filtralite medias

Received approval from NJDEP to conduct demonstration test: Anthracite/sand – test up to 5 gpm/sf Filtralite – test up to 7 gpm/sf Evaluating:

– Turbidity– Particle count– Headloss development – Volume Treated, Run Time

5

ParameterFilter 4 Existing

Filter 5Filtralite

Filter 6Anthracite/

SandTop Layer 12” No. 1

anthracite21” 2.0 mm

Filtralite21” 0.95-1.05 mm anthracite

Bottom Layer

12” 0.45-0.55 mm sand

10” 1.0 mm Filtralite

10” 0.50-0.60 mm sand

Support Gravel

17” (graded) 10” pea gravel 10” pea gravel

FILTER MEDIA SPECIFICATIONS

6

EXISTING MEDIA AND UNDERDRAINS

7

NEW ANTHRACITE/SAND MEDIA AND UNDERDRAIN

8

FILTRALITE MEDIA AND UNDERDRAIN

9

NEW UNDERDRAIN - NOZZLES

10

TESTING TO DATE

Initial Testing (11/10/12 – 1/12/13):– Target flow ~ 1 mgd– Filter 5 (Filtralite) and Filter 6 (new A/S) – premature turbidity/particle

breakthrough, believed to be caused by PAC addition in second clarifier; Filter 4 (existing filter) is fine

– Added PACl as filter aid– Improved turbidity/particle performance– Initially plant operated 16 hr/day (low demands); switched to 24/7 operation

on 1/6 (shut down on weekends); turbidity/particle performance more stable; Filter 6 more stable than Filter 5

1/13/13 – 1/24/13:– Increased Filter 5, Filter 6 in steps: 1.2 mgd, 1.4 mgd, 1.5 mgd, 1.6 mgd– PACl filter aid continued– Maintained turbidity/particle performance; shorter filter runs (as expected);

Filter 6 more stable than Filter 5

Testing stopped on 1/25/13:– High TDS in raw water (road salting)– Plant switched to Aquifer Storage and Recovery (ASR) wells

11

11/1

3/12

11/1

6/12

11/1

9/12

11/2

2/12

11/2

5/12

11/2

8/12

12/1

/12

12/4

/12

12/7

/12

12/1

0/12

12/1

3/12

12/1

6/12

12/1

9/12

12/2

2/12

12/2

5/12

12/2

8/12

12/3

1/12

1/3/

13

1/6/

13

1/9/

13

1/12

/13

1/15

/13

1/18

/13

1/21

/13

1/24

/13

0

500

1000

1500

2000

2500

3000

3500

Volume Treated (minimum flow 1 mgd, max turbidity 0.05 ntu)

Filter 4 Filter 5 Filter 6

Volu

me T

reate

d (

MG

)

Filter Aid Started 12/4

24/7 Opera-tion Started 1/6

1.2

1.4

1.2

1.41

1.4

1.41

1.5

1.5

1.5

1.6

1.6

Note: 1. Filters 5,6 flows were 1 mgd on 1/19

12

11/1

3/12

11/1

6/12

11/1

9/12

11/2

2/12

11/2

5/12

11/2

8/12

12/1

/12

12/4

/12

12/7

/12

12/1

0/12

12/1

3/12

12/1

6/12

12/1

9/12

12/2

2/12

12/2

5/12

12/2

8/12

12/3

1/12

1/3/

13

1/6/

13

1/9/

13

1/12

/13

1/15

/13

1/18

/13

1/21

/13

1/24

/13

0

1

2

3

4

5

6

7

8

Headloss(to end of run)


Headlo

ss (

ft)

Filter Aid Started 12/4

24/7 Opera-tion Started 1/6

13

0.9 1 1.1 1.2 1.3 1.4 1.50

10

20

30

40

50

60

70

Run Time vs Flow


Flow (MGD)

Run T

ime (

Hours

)

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INITIAL TESTING OBSERVATIONS

Filter 5 (Filtralite): Lowest Headloss Development Can operate at higher flowrates Concern with stability of turbidity/particle performance

Filter 6 (new anthracite/sand): Lower headloss development than Filter 4 (existing media) Can operate at higher flowrates More stable turbidity/particle performance than Filter 5

(Filtralite)

15

TESTING 4/22/13 – 9/14/13

Longer term (two - three week) operation at each flowrate

Goal is to establish acceptable performance at flowrate of 1.5 - 1.6 mgd in order to be able to high rate filters and avoid need to provide additional filters

Eliminating need for additional filters would save approx. $3 million in capital costs

Also evaluate performance w/o filter aid (is media seasoned?)

16

4/26

/201

3

4/30

/201

3

5/4/

2013

5/8/

2013

5/12

/201

3

5/16

/201

3

5/20

/201

3

5/24

/201

3

5/28

/201

3

6/1/

2013

6/5/

2013

6/9/

2013

6/13

/201

3

6/17

/201

3

6/21

/201

3

6/25

/201

3

6/29

/201

3

7/3/

2013

7/7/

2013

7/11

/201

3

7/15

/201

3

7/19

/201

3

7/23

/201

3

7/27

/201

3

7/31

/201

3

8/4/

2013

8/8/

2013

8/12

/201

3

8/16

/201

3

8/20

/201

3

8/24

/201

3

8/28

/201

3

9/1/

2013

9/5/

2013

9/9/

2013

9/13

/201

30

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

Average Flowrate (while target flow maintained)


Flo

w (

mgd)

ASR Blending started 8/22

17

4/26

/201

3

4/30

/201

3

5/4/

2013

5/8/

2013

5/12

/201

3

5/16

/201

3

5/20

/201

3

5/24

/201

3

5/28

/201

3

6/1/

2013

6/5/

2013

6/9/

2013

6/13

/201

3

6/17

/201

3

6/21

/201

3

6/25

/201

3

6/29

/201

3

7/3/

2013

7/7/

2013

7/11

/201

3

7/15

/201

3

7/19

/201

3

7/23

/201

3

7/27

/201

3

7/31

/201

3

8/4/

2013

8/8/

2013

8/12

/201

3

8/16

/201

3

8/20

/201

3

8/24

/201

3

8/28

/201

3

9/1/

2013

9/5/

2013

9/9/

2013

9/13

/201

30

1000

2000

3000

4000

5000

6000

Volume Treated(while target flow maintained)


Volu

me T

reate

d (

Thous G

al)


18

4/26

/201

3

4/30

/201

3

5/4/

2013

5/8/

2013

5/12

/201

3

5/16

/201

3

5/20

/201

3

5/24

/201

3

5/28

/201

3

6/1/

2013

6/5/

2013

6/9/

2013

6/13

/201

3

6/17

/201

3

6/21

/201

3

6/25

/201

3

6/29

/201

3

7/3/

2013

7/7/

2013

7/11

/201

3

7/15

/201

3

7/19

/201

3

7/23

/201

3

7/27

/201

3

7/31

/201

3

8/4/

2013

8/8/

2013

8/12

/201

3

8/16

/201

3

8/20

/201

3

8/24

/201

3

8/28

/201

3

9/1/

2013

9/5/

2013

9/9/

2013

9/13

/201

30.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

Headloss (while target flow maintained)


Headlo

ss (

ft)


19

4/26

/201

3

4/30

/201

3

5/4/

2013

5/8/

2013

5/12

/201

3

5/16

/201

3

5/20

/201

3

5/24

/201

3

5/28

/201

3

6/1/

2013

6/5/

2013

6/9/

2013

6/13

/201

3

6/17

/201

3

6/21

/201

3

6/25

/201

3

6/29

/201

3

7/3/

2013

7/7/

2013

7/11

/201

3

7/15

/201

3

7/19

/201

3

7/23

/201

3

7/27

/201

3

7/31

/201

3

8/4/

2013

8/8/

2013

8/12

/201

3

8/16

/201

3

8/20

/201

3

8/24

/201

3

8/28

/201

3

9/1/

2013

9/5/

2013

9/9/

2013

9/13

/201

30

20

40

60

80

100

120

140

Run Time (while target flow maintained)


Run T

ime (

hr)


20

0.9 0.95 1 1.05 1.1 1.15 1.2 1.25 1.3 1.35 1.40

20

40

60

80

100

120

140

Run Time vs Flow4/22/13 - 8/24/13


Flow (mgd)

Run T

ime (

hr)

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Time 16-Jul-13 05:00:00 17-Jul-13 10:00:00 18-Jul-13 15:00:00 19-Jul-13 20:00:00 21-Jul-13 01:00:000

20

40

60

80

100

120

140

160

180

0.000

0.020

0.040

0.060

0.080

0.100

0.120

0.140

Filter 4 - 7/15 - 7/22

[2-3Hµm] [>3-5µm] [>5-7µm] [>7-10µm] [>10-15µm] [>15µm] Turbidity

Part

icle

Count

(counts

/ml)

Turb

idit

y (

ntu

)

22


10

20

30

40

50

60

70

80

90

0.000

0.020

0.040

0.060

0.080

0.100

0.120

0.140

0.160

0.180

Filter 5 - 7/15 - 7/22


Part

icle

Count

(counts

/ml)

Turb

idit

y (

ntu

)

23


50

100

150

200

250

300

350

0.000

0.020

0.040

0.060

0.080

0.100

0.120

0.140

0.160

0.180

Filter 6 - 7/15 - 7/22


Part

icle

Count

(counts

/ml)

Turb

idit

y (

ntu

)

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OBSERVATIONS 4/22/13 – 9/14/13

Medias appear to be seasoned (generally operate without filter aid)

Filter 5 (Filtralite): Lowest Headloss Development Can operate at higher flowrates Concern with stability of turbidity/particle performance;

susceptible to changes (hydraulic, water quality), especially near end of run

Filter 6 (new anthracite/sand): Lower headloss development than Filter 4 (existing media) Can operate at higher flowrates More stable turbidity/particle performance than Filter 5

(Filtralite)

25

FUTURE WORK

Continue testing at higher rates (currently at 1.4 mgd)

Plant is currently on a blend of surface water and ASR water because of low streamflow and need to maintain passing flow. This results in high run times and volumes treated, which are not representative.

Will evaluate higher flowrates when plant is back on full surface water (no ASR)

Consider addition of small layer of sand (about 4 inches) to Filter 5 (Filtralite) to see if that improves stability of turbidity/particle performance

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THANK YOU!

Any Questions?

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Time 06-Jan-13 06:00:00 07-Jan-13 12:00:00 08-Jan-13 18:00:00 10-Jan-13 00:00:00 11-Jan-13 06:00:000

5

10

15

20

25

30

35

40

45

50

0.000

0.010

0.020

0.030

0.040

0.050

0.060

0.070

0.080

0.090

0.100

Filter 4 - 1/5 - 1/12


Part

icle

Count

(counts

/ml)

Turb

idit

y (

ntu

)

28


50

100

150

200

250

300

350

400

450

0.000

0.020

0.040

0.060

0.080

0.100

0.120

0.140

0.160

Filter 6 - 1/5 - 1/12


Part

icle

Count

(counts

/ml)

Turb

idit

y (

ntu

)

29


100

200

300

400

500

600

0.000

0.020

0.040

0.060

0.080

0.100

0.120

0.140

0.160

0.180

0.200

Filter 5 - 1/5 - 1/12


Part

icle

Count

(counts

/ml)

Turb

idit

y (

ntu

)

30

11/1

3/12

11/1

6/12

11/1

9/12

11/2

2/12

11/2

5/12

11/2

8/12

12/1

/12

12/4

/12

12/7

/12

12/1

0/12

12/1

3/12

12/1

6/12

12/1

9/12

12/2

2/12

12/2

5/12

12/2

8/12

12/3

1/12

1/3/

13

1/6/

13

1/9/

13

1/12

/13

1/15

/13

1/18

/13

1/21

/13

1/24

/13

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

Average Flowrate (to end of run)


Flo

wra

te (

mgd)

1 Full-Scale Testing of Innovative High Rate Filter Media for Plant Expansion Bob Raczko, P.E....

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