Large Bubble Vertical Mixing – Energy Savings and Performance Enhancement
Transcript of Large Bubble Vertical Mixing – Energy Savings and Performance Enhancement
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LARGE BUBBLE VERTICAL MIXING
Energy Savings and Performance Enhancement
LARRY L. BELL
V.P. SALES PULSED HYDRAULICS INC.
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Aeration is 54% of the Total Power Consumed
Aeration 54%Return SludgePumping 0.46%
Gravity Thickening 0.06%
AnaerobicDigestion 14.24%
Belt Press 3.91%
ChlorinationLighting &Buildings 8.14%
WastewaterPumping 14.26%
Screens 0.02%
Grit 1.26%
Clarifiers 3.15%
Electrical Usage in WWTPs
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AERATION BASIN MIXING
• PERHAPS THE MOST OVERLOOKED ASPECT OF PROCESS TREATMENT !
• IF YOU ASK 10 PEOPLE WHAT IT IS, YOU WILL PROBABLY GET 10 DIFFERENT ANSWERS !
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HORIZONTAL MIXING
• ANY MIXING SYSTEM THAT MOVES THE LIQUID IN A HORIZONTAL PLANE IS NOT REALLY MIXING……IT IS STIRRING !
• SOLIDS TEND TO ACCUMULATE ON THE BOTTOM, IN THE CORNERS AND IN THE MIDDLE OF THE STIRRING VORTEX !
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HORIZONTAL MIXERS STIR … NOT MIX!
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VERTICAL MIXING
• MIXING SYSTEMS THAT MOVE THE LIQUID IN A VERTICAL PLANE TEND TO INVOLVE THE ENTIRE VOLUME OF THE TANK !
• LIFTING SOLIDS VERTICALLY USES THE FORCES OF BUOYANCY AND GRAVITY TO DISPERSE TANK CONTENTS MORE EVENLY WITHIN THE TANK !
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LARGE BUBBLE VERTICAL MIXERS USE BUOYANCY AND GRAVITY TO EVENLY
DISBURSE SOLIDS
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TYPES OF VERTICAL MIXERS
• 1. MECHANICAL
• 2. AIR
A. Continuous Flow
i. Fine Bubble
ii. Course Bubble
B. Pulsed
i. LARGE BUBBLE
ii. Small Bubble
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MECHANICAL VERTICAL MIXER
1. MOVING PARTS IN THE TANK NEED MAINTENANCE
2. FLUID IS PULLED DOWN THE MIDDLE OF A MIXING ZONE
AND UP THE OUTSIDE THE MIXING ZONE EDGES.
3. ALL ENERGY USED HAS TO BE SUPPLIED EXTERNALLY.
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Aeration Enhancement
Improving Nutrient Removal and Energy Efficiency
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The ultimate goal:
A. Lower Energy Costs
B. Improved Treatment Efficiencies
These can be achieved via an integrated solution:
1. Variable-speed high-efficiency blowers.
2. High efficiency diffusers.
3. Large bubble, vertical mixing system.
4. On-line instrumentation (automate the
blowers and mixing system)
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TANK VOLUME RECOVERY BY LARGE BUBBLE MIXING
SEOUL, SOUTH KOREA
• One Bubble Forming Plate per 30 foot square zone = 1-2 HP
• Achieved complete mixing in each zone (< 2% TSS variation from top to bottom)
• D.O. increased allowing blower scfm to be lowered
• BOD / NH3 removal efficiency improved allowing increased loadings
• Final pilot plant paper due out in February 2013
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AERATION ENHANCEMENT & ANOXIC MIXING
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Innovative Equalization Tank and Mixing System Eliminates SSOs, Improves Plant Performance,
and Saves Money
Project: Shelby County Lake Loramie WWTP Wet Weather Flow Equalization Improvements
Presented by: Jeremy M. Cook, PE
URS Corporation – Columbus, Ohio
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Mixing Systems Evaluated • Coarse Bubble Diffusers Submersible Propeller Mixers
Submersible Jet Pumps
Pulsed Air System
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Submersible Propellor and Jet Pumps
Simple Installation and No Blower Building
Large Horsepower Requirements (approx. 120 HP) created by large tank diameter (greater Thrust)
Capital Costs: $150,000
Electrical Cost: 120 HP @ $0.08/kwh for 90 days, 24 hr/day = $15,500
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Coarse Bubble Mixing System
2,500 scfm Centrifugal Blower (approx. 80 HP)
200 SS Wide Band Diffusers
Large tank diameter would have required a lot of SS pipe and diffusers
Need a Blower Building or Enclosure
Estimated Capital Cost: $300,000
Electrical Cost: 80 HP @ $0.08/kwh for 90 days, 24 hr/day = $10,400
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Small Precast Building to house 20 HP Compressor, 240 gal. Receiver, Solenoid Valves & PLC Controller.
1”SS Piping and 40 Bubble Forming Plates
Capital Costs: $100,000 (with building); saving $50,000
Electrical Cost: 20 HP @ $0.08/kwh for 90 days, 24 hr/day = $2,600; saving $12,900 /yr
Manufacturer: Pulsed Hydraulics, Inc. (PHI)
Lake Loramie (OH) Sanitary District
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EQ Tank
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45 FOOT DIAMETER SLUDGE
STORAGE TANK
POWER COST FORMULA
Cost = (bhp) x (0.746) x (hours) x (power
rate) / motor efficiency
Where: bhp (brake horsepower
power rate ($ per kilowatt hour)
Hours (operating hours)
motor efficiency (%)
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
EXISTING BLOWERS AND COURSE AIR
DIFFUSERS :
75 HP operating 24 hours / 7 days per
week
Power Rate is $0.07 and Motor Efficiency
is estimated at 93%
(75) x (0.746) x (24) x ($0.07) / 0.93 =
$101.07 / Day ($36,890.90 per year)
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LARGE BUBBLE VERTICAL MIXING
SYSTEM:
10 HP operating 24 hours / 7 days per
week
Power Rate is $0.07 and Motor Efficiency
System pulls 7 kw when operating on load
(not 7.46 kw if calculated 10 x 0.746 as in
above formula).
(7 kw) x (24) x ($0.07) / 0.93 = $12.65 /
Day ($4,617.25 per year)
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
ANNUAL ENERGY SAVINGS =
$32,273.65
The above calculation for the large bubble
vertical mixing system was computed on
the basis of the mixing system operating
on load 24 hours per day / 7 days per week
utilizing the full 10 HP capacity of the
compressor. Actual operating HP has
been estimated to be 4.5 to 6 HP.
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What are the mixing applications?
• Aeration / anoxic basins in WWTPs
• Sludge
• Polymer & Hypochlorite Chemical Storage Tanks
• Lift Station Wet Wells
• Flow Equalization Basins
• Elevated & Ground Level Water Storage Tanks
• Petroleum Storage Tanks (Vented)
• Foods and Beverages (Wine – Whiskey)
• Any Liquid In A Vented Vessel or Tank
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OTHER APPLICATIONS & VIDEOS
•GO TO WWW.PHIWATER.COM
•SELECT THE APPLICATION TAB
•SELECT THE APPLICATION OF INTEREST
•WATCH A VIDEO OF MIXING OCCUR OR DOWNLOAD THE APPLICATION LITERATURE
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Duration
Pulses Per
Minute
CFM
Required Input kW
CFM
Per Pulse
.3 seconds 2 times 3.4 CFM 0.97 kW 1.7 CFM
.4 seconds 2 times 4.9 CFM 1.42 kW 2.5 CFM
.5 seconds 2 times 5.5 CFM 1.57 kW 2.8 CFM
How much air is used ?