ZeeWeed MBR Technology Update - SAWEA MBR Tech (Chris... · ZeeWeed MBR Technology Update ... •...
Transcript of ZeeWeed MBR Technology Update - SAWEA MBR Tech (Chris... · ZeeWeed MBR Technology Update ... •...
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ZeeWeedZeeWeed MBR MBR Technology Update Technology Update Chris JefferyZENON Environmental Inc
SAWEA Workshop, 2005
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Presentation Outline
ZeeWeed® MBR Technology
ZENON MBR Technology Update
New ZENON Projects
Q & A
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ZeeWeed® MBR Technology
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ZeeWeedZeeWeed®® 500 Flow Diagram500 Flow Diagram
Principles of ZeeWeedPrinciples of ZeeWeed®®
Immersed MembranesImmersed Membranes
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Membrane Filtration
0.0001 0.001 0.01 0.1 1 10 100µm
hairCrypto-sporidium
smallest micro-
organism
polio virus
Suspended solidsSuspended solids
ParasitesParasites
BacteriaBacteria
Org. macro. moleculesOrg. macro. molecules
VirusesViruses
ColloidsColloidsDissolved saltsDissolved salts
Sand filtrationSand filtration
MicrofiltrationMicrofiltration
UltrafiltrationUltrafiltration
NanofiltrationNanofiltration
Reverse OsmosisReverse Osmosis
ZENON membrane range
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• Reinforced for maximum strength and maximum life
• Failure proof / double barrier
• High solids tolerance
ZeeWeedZeeWeed®® 500 500 –– Robust MembraneRobust Membrane
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ZeeWeed® Cassette Scale-UpLarger Plants = Larger Cassettes
ZW-500a (1997)
4,000 ft2
80,000 gpd
ZW-500c (2000)
5,500 ft2
110,000 gpd
ZW-500d (2002)
16,300 ft2
326,000 gpd
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ZeeWeedZeeWeed®® 500d500d –– CassetteCassetteOptimized Building BlockOptimized Building Block
• Compact– High packing density = small
footprint– Low energy costs
• Accessible– Easy to remove modules and
cassettes
• Simple– Fewer connections, valves =
higher reliability– Lower capital costs
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ZeeWeedZeeWeed®® 500d500d –– TrainTrain
ZeeWeed® Membrane Cassettes
Permeate Header
Air Header
Air SeparatorMain Permeate
Header
Permeate Pump
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Overall ZeeWeed® MBR Design
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Simple, Modular ZeeWeed® Design
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ZW MBR Technical Update
1.1. Drivers for Change Drivers for Change -- EfficiencyEfficiency
2.2. Effective PreEffective Pre--TreatmentTreatment
3.3. Simplified System Design Simplified System Design
4.4. Comprehensive Cleaning ToolboxComprehensive Cleaning Toolbox
5.5. Optimized Life Cycle Costs Optimized Life Cycle Costs -- EnergyEnergy
6.6. Membrane Life and WarrantyMembrane Life and Warranty
7.7. Chemical ConditioningChemical Conditioning
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Total Capital CostsTotal Capital Costs
0
500
1,000
1,500
2,000
2,500
0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000
Flow rate, m3/d
Tot
al c
apita
l cos
ts ($
/m3 /d
)
CASMBRCAS-TF
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Total O&M CostsTotal O&M Costs
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000
Flow rate, m3/d
Tot
al O
&M
cos
ts ($
/m3 )
CASMBRCAS-TF
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Total LifeTotal Life--Cycle CostsCycle Costs
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000
Flow rate, m3/d
Tot
al li
fe c
ycle
cos
ts ($
/m3 )
CASMBRCAS-TF
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Pre Screening Experience & Recommendation
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Hollow Fibre Flat Sheet
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Acceptable Screen Types
• Internally-fed rotary drum screen
• In-channel rotary drum screen
• Rotating brush screen
• Travelling band screen
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Screening Requirement
• ≤2 mm mesh or punched hole, with no possibility of screenings carry-over or bypass
• Preferred: ≤1 mm mesh or punched hole screening
• European market is well on the way to acceptance of ≤1 mm screens
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Brescia, Italy
2.5 years of operation
2-mm Huber in-channel rotary drum
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Schilde, Belgium
2 years of operation
1-mm Huber in-channel rotary drum
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Varsseveld, Netherlands
5 months of operation
0.8-mm rotating brush
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Benefits of Fine ScreeningBenefits of Fine Screening
Higher sustainable flux
Longer membrane life
Longer cleaning intervals
Less equipment maintenance
Insurance: protection of most valuable asset!
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Membrane Filtration System Design
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Filtration Package Plants
• Standard MWW units• ZENON Standard
components• Cost savings due to
pre-engineering
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Full Scope Package Plants
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Custom Membrane System Design
• Reversible pumps
• Removal of air separator
• Siphon designs
• Redundancy
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Not So Simple Design
Creemore Cauley Creek
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Simple Design – Reversible Pump
Bioreactor Membrane
Mixed Liquor Recycle
Permeate
Membrane Aeration
Cleaning Chemical
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Simple Design using Reversible PumpsWoodstock NordKanal
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Permeate by Gravity / Siphon
• ZENON uses a Controlled Siphon – control valve
• 25 ft minimum head
• ZeeWeed® MBR plants– Lowestof, UK
– Buxton, UK - 4.4 mgd– Linwood, GA – 7 mgd under
design
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Membrane Cleaning
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ZENON Cleaning Toolbox
• In-situ membrane cleaning• Reduce handling of membranes
• Fully automated cleaning procedure• Reduce operator requirements
• Regular, less intense cleaning• Maintain a higher membrane permeability
• Backpulse cleaning chemicals• Improved cleaning effectiveness
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MBR Operation Philosophies
Long run time with recovery cleaning:- ability to peak with fouled membrane?- ability to recover permeability?
Perm
eabi
lity
Frequent maintenance cleaning:- always ready to peak- cleaning off “fresh” deposits
Time
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Automated Membrane Cleaning
Bioreactor Membrane
Mixed Liquor Recycle
Permeate
Membrane Aeration
Cleaning Chemical
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Energy Optimization
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MBR Energy Users
Biological Process Aeration
Membrane Aeration
Anoxic Mixers
RAS Flow Permeate Flow
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MBR Energy Users
Bio Process Aeration42%
Membrane Aeration34%
RAS Pumping10%
Permeate Pumping4%
Misc1%
Anoxic Mixing9%
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Optimizing Energy Efficiency• Biological process aeration
– Select MLSS to optimize OTE• Alpha factor decreases at higher MLSS• Limitation on OUR at higher MLSS
– Nit/DeNit recovers energy and alkalinity
– Fine bubble aeration in bioreactor
• Membrane aeration– Optimize membrane depth– Cyclic aeration
Membrane unit #1
Membrane unit #2
Blower
Blower running continuously Fast action
butterfly valves
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Bio-Process NPV vs. MLSS Concentration
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MLSS Distribution MLSSmembrane tank = (R+1) x MLSSbioreactor
R
0
2
4
6
8
10
12
14
16
1 2 3 4 5 6 7 8 9 10
Recycle Rate (RQ)
Mem
bran
e Ta
nk M
LSS
(g/L
)
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MLSS Distribution MLSSmembrane tank = (R+1) x MLSSbioreactor
R
0
2
4
6
8
10
12
14
16
1 2 3 4 5 6 7 8 9 10
Recycle Rate (RQ)
Mem
bran
e Ta
nk M
LSS
(g/L
)
Design
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Membrane Aeration
• Optimize membrane submergence to reduce blower discharge pressure
• Effective scouring with course bubble aeration
• Optimized cyclic aeration based on flow
Membrane unit #1
Membrane unit #2
Blower
Blower running continuously Fast action
butterfly valves
US Patent 6,245,239
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10/30 Aeration at ADF
• Optimized cyclic aeration based on flow
• Maintain 10/10 Aeration at or above ADF
• Run at 10/30 Aeration below ADF
• 50% Savings compared to 10/10 = 7-10% LCC
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10/10 Sequential Aeration
• 4 blowers on
• each blower sized to aerate ½ of one train
Note – Airflow is blue
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10/30 Sequential Aeration
• 2 blowers on
• each blower sized to aerate ½ of one train
• same instantaneous air flow rate as 10/10 BUT ½the average
Note – Airflow is blue
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Evolution of ZeeWeed Membrane Aeration
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
ZW150(1994)
ZW500a(1997)
ZW500a(1999)
ZW500c(2000)
ZW500d(2003)
ZW500d(2005)
Cyclic Aeration
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ZeeWeed® Cassette Scale-UpLarger Cassettes = Lower Capital + O&M Costs
Increasing Size Decreasing $ / gal
ZW-500c (2000)
5,500 ft2
110,000 gpd
ZW-500d (2002)
16,300 ft2
326,000 gpd
ZW-500d (2005)
21,800 ft2
436,000 gpdZW-500a (1997)
4,000 ft2
80,000 gpd
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Membrane Life and Warranty
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Key Factors for Key Factors for Extended Membrane LifeExtended Membrane Life
Select a robust membrane
Protect the membrane
Keep the membrane clean
Design with a conservative flux
Finite life time capacity
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Design Flux Selection• Based on long-term, full-scale experience,
rather than short-term data or pilot studies
• Design based on limiting hydraulic conditions– Maximum Flow– Minimum Temperature– Performance Beyond 5 Years– Minimum Safety Factor
Recommend Specifying Minimum Membrane Area or Maximum Peak Flux
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Life Time Membrane Capacity
Operating Flux[gfd]
5 yrs[gal/ft2]
8 yrs[gal/ft2]
10 yrs[gal/ft2]
15 yrs[gal/ft2]
5 9,125 14,600 18,250
36,500
54,750
27,375
10 18,250 29,200 54,750
15 27,375 43,800 82,125
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Chemical Conditioning
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Sludge Quality?• Settleability not
important• Sludge Quality is a
factor• How do we measure?
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Which of the following parameters are more important for MBR fouling
• TTF• DSVI• MLSS• Specific cake resistance• Silt density index (SDI)• Fouling index (FI)• Modified fouling index (MFI)• Particle size distribution
(>1.5 µm)
• Colloidal TOC• Soluble EPS• Soluble carbohydrate• Soluble protein• Soluble humic acid
• Temperature• Bound EPS• Zeta-potential
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Which of the following parameters are more important for MBR fouling
• TTF• DSVI• MLSS• Specific cake resistance• Silt density index (SDI)• Fouling index (FI)• Modified fouling index (MFI)• Particle size distribution
(>1.5 µm)
• Colloidal TOC• Soluble EPS• Soluble carbohydrate• Soluble protein• Soluble humic acid
• Temperature• Bound EPS• Zeta-potential
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Sludge Quality - TTF
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Sludge Quality?
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Chemical Conditioning• Coagulants, Polymers• Significant Improvements• Reliability• Design Implementation
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New Projects
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Traverse City, MIADF: 7.1 MGD (26,500 m3/d) Commission Date: Summer 2004
• Largest operating MBR based on peak flow
• Peak flow 17.2 mgd (65,000 m3/d)
• Primary Clarifier + Fine Screen
• 8 ZW500 trains
• Bio-P Removal
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Pooler, GeorgiaADF: 2.5 MGD (9,463 m3/d) Commission Date: November, 2004
• Located near Savanna, GA
• 4 ZW500d trains with reversible pumps
• Simple, cost effective layout & construction
• Process optimization for flows < design
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F. Wayne Hill Water Resources CenterADF: 47 MGD (177,914 m3/d) Commission Date: Summer 2005
• Largest membrane tertiary filtration plant
• 16 ZW500 Trains
• Very strict effluent limits– Turbidity < 0.1 NTU
– Particle Count < 10#/ml
• Discharges to Lake Lanier– Recreational and indirect
potable reuse
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Jackson, Ohio• Retrofit of old aeration
tanks• Will operate in parallel
with existing ox ditches• 4 trains, reversible
pumps
• Zenon evaluated against other MBRs
• Selected based on experience and costs
ADF: 2 MGD (7,571 m3/d) Commission Date: 2006/2007
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Brightwater WWTPADF: 31 MGD (117,347 m3/d) Commission Date: Expected 2009/10
• World’s Largest MBR awarded
• Phase 1 peak hour flow 44 mgd
• Phase 2 peak hour flow 57 mgd
• 10 trains at buildout• 24 mgd of Class A
Reclaimed Water• Evaluated Bid
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Marco Island, Florida• Largest skid mounted system• 5 mgd Peak Hour Flow• 3+1 train - Fully redundant
train (tank & skid)• Skid includes:
– Process pump– RAS pump– Membrane blower– PLC– MCC– All values and wiring
• Negotiated
ADF: 3 MGD (11,356 m3/d) Commission Date: June, 2006
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Peoria, ArizonaADF: 10 MGD (37,854 m3/d) Commission Date: 2007
• One of the fastest growing cities in the US
• Initial peak to 20 mgd
• Build-out to 13/26 mgd
• 10 membrane trains
• MBR evaluated against conventional
• Zenon evaluated against other MBRs
• Selected based on experience and costs
Courtesy of B&V and City of Peoria
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Henderson South Wastewater Reclamation Facility
• Fast growing community outside of Las Vegas
• Peak hour flow 13.6 mgd
• 8 membrane trains
• Evaluation based on defined lifecycle costs
• Zenon lowest LLC
ADF: 8 MGD (30,283 m3/d) Commission Date: July, 2009
Courtesy of CH2M Hill and City of Henderson
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Thank You!
Questions and Answers