WISA conference - 4th Annual Forum of the EU Strategy for the

Energy efficiency in wastewater treatment
Armin Müller
Industry Segment Management
Water/ Wastewater
Festo AG & Co KG
Esslingen, Germany
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Festo – an independent family-owned company
Some Facts & Figures
• Pneumatic & Electric Automation
Technology offering solutions for
Factory & Process Automation
• Learning Systems,
Training & Consulting
• Founded in 1925
• Turnover 2,4 billion € (2014)
• R&D Investments: 9 % of turnover
• 61 international Festo companies
• 300.000 Customers worldwide
• 30.000 Components
in countless variants
Festo Technology Centre and
Headquarters , Esslingen
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Festo Customer Service Centre
and production plant, St. Ingbert
• 17.800 Employees worldwide
Supporting our customer‘s advanced automation as no one else
can
Network Danube
Region
Worldwide presence:
61 Festo Companies: With more than 250
11 Global Production Center 18 in Asia, 31 in Europe subsidiaries
4 Regional Service Center 10 in America, 3 in Africa Authorised dealers in further
26 National Service Center
39
countries
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Reasons, why energy efficiency investigations have to be
accelerated
• In the overall generation, transmission
and utilization of electrical energy
The highest saving potential is in
production plants
• This potential can be exploited by
various means like
/
•
Energy efficient components
•
Smart automation solutions (e.g.
online control of oxygene
injection in wastewater
treatment plants)
•
Changes in process design
 Tremendous potential for Energy
savings, e.g. 20% of the electrical
energy of municipalities in Germany is
consumed by WWTP
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Pumping station: Energy savings
Pre-clarification
Trickling
filter
Final clarification
Waste
water
Sludge to digestion
Sewage from pre-clarification and return water is pumped to trickling filter
 6 pumps in basement
 3-5 pumps always in operation, 1 redundant
 Specification pump: power consumption 90 kW, flow rate 500 l/s
 Delivery head 8-9 m
 Pipe diameter DN 350
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Pump
Situation before retrofit
From Pre - clarification
To Trickling filter
knife
gate
pump
check
valve
Arrangement is standard solution for pump stations
knife
gate
Pump
Problems
- Energy needed in steady state operation to open the valve
- Disk reduces in general pipe diameter
- Water hammer during shut down using check valves
- Pipe system starts to vibrate due to pressure oscillation (water hammer)
- Check valves are partially worn out and leacking after 12 years of operation
- During pump downtimes microorganisms producing gas , a bubble is generated below the
check valve.
Result : the pump does not start by itself
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Situation after retrofit
From Pre-clarification
To Trickling filter
knife
gate
pump
spacer knife
gate automated
Advantages
- Less power consumption at same flow rate
- Higher flow rates can be reached, because disk reduced active valve/pipe diameter
within the former solution
- Lower noise level
- No leackage - knife gate with DLP cylinder is thight
- During opening of knife gate gas bubble escapes, pump starts automatically
Energy savings
- 89469 kWh / year
-5 pumps in operation, results in sum 11.276 EUR
-2% percentage energy savings on total demand for electrical energy of WWTP
-Invest for retrofit:
25.000 EUR in total
- Invest for retrofit only check valves: 18.000 EUR in total
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Energy saving German Wastewater Treatment Plant
Situation after retrofitting
Pump
Pumps with knife gate and DLP actuator
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Air reservoir with refigeration dryer and distributor
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Energy-autonomous fficient control of a stormwater overflow basin
Reason and Tasks of SWOB
Intake
Overflow
SWOB
•Relief structure for combined water system (rainwater and
sewage) in function as a buffer
•to relief the canalization in case of a heavy rain event
•Direct connection to the wastewater treatment plant would
require a large scaling of the pipes
•RWOB at the right places in the canalization lead to an
economic pipe scaling
SWOB consists of
Emergency valve
FIC
WWTP
Outlet throttle valve
•A manhole chamber with mechanical grill for withdrawal
mineralized coarse matter
•A RetentionTank body with overflow on inlet and a throttle
valve on outlet side. This regulates the waterflow accordance
the available capacities in the sewage plant
•Sensory feedback such as flow rate and water level
influence the control process in an automated system
Application flow control manhole
•Regulates the outflow to the sewage plant with a throttle
valve
•Emergency valve in pre-set position ensures function if gate
valve fails
•There is often an additional flushing valve in case of clogging
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Implementation Concept Of The Energy-Self-Sufficient-System
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Implementation Concept Of The Energy-Self-Sufficient-System
The advantages of the energy-autonomous automation of these decentralised devices
are:
-
Saving of the investment costs of connecting to the public power supply grid
-
Central operation and monitoring, i.e. saving of costs of manual operation and
monitoring,
-
Continuous monitoring of the plant and the automation system
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Pilot plant RÜB-Anger in Neulingen-Bauschlott
Example RWOB in NeulingenBauschlott, DE
• In cooperation with “Abwasserverband
Weißach und Oberes Saalbachtal” a selfsustaining system has been installed
• 22 urban districts and quarters are
connected to the “Abwasserverband”
• 39 stormwater overflow basins/ retention
tanks withhold precipitation amount to
pretend the sewer network form overload
• A gate valve releases the retained water
slowly in the canalization
• The process data are daily recorded
The pilot plant is an individually designed system
solution which is adapted to the particular
requirements
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Thank you for your attention!
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