BNR to R1 Will it Fit and Can I Afford It

BNR to R1 Will it Fit and Can I Afford It

BNR to R1
Will it Fit and Can I
Afford It
2010 HWEA Conference
Honolulu, HI
Brandy Nussbaum
Jim Georger
I. Kruger, Inc
BNR to R1-How it’s done
BNR
Clarification
Reuse Water
Tertiary
Filtration
MBBR + ACTIFLO + Discfilter Example
MBBR
Full System Responsibility
Process Guarantee
Small Footprint
Ease of Operation
Process Stability
Proven Processes
Cost Effective
Economically Efficient
ACTIFLO
Hydrotech
Discfilter
Reuse Water
MBBRTM – What is it?
BOD Reduction
Nitrification
Moving BedTM: Biology grows
on virgin polyethylene media
that is kinetically active in a
reactor.
Denitrification
Lagoon
Treatment
System
MBBR™ – When & Where?

Industrial application with no solids issues

Site restrictions / small footprint required

Post Nitrification after existing lagoons

Pre Denitrification prior to recirculation sand filters

Upgrades to existing fixed film facilities

Post-Denitrification of clarified effluent

Remote location facility for minimal operation attention

High infiltration (resistant to wash out)
AnoxKaldnes MBBR™ Advantages
Space Reductions - Trickling Filter vs. MBBR™
EXISTING TRICKLING FILTERS
KALDNES
MBBR
30 ft2/ft3
76 ft2/ft3
VOL = 140,750 ft3
VOL = 39,960 ft3
AT EQUAL LEVELS OF BOD REMOVAL:
MBBR Provides Twice the Biofilm Surface Area in ¼ Reactor
Volume as Trickling Filter
Kinetics = MBBR is More Active & Efficient than Trickling Filter
MBBR™ Application Nitrification
• (NH3-N >>> NO3-N & NO2-N)
•Greenfield or cold temperature applications where nitrification is
needed and space is a factor.
•After a lagoon which performs BOD removal and limits upgrade.
Lagoon
Treatment
System
AnoxKaldnes MBBRTM Advantages
Flexibility in Design – Add Future Capacity without Adding New Tankage &
Postpone Investment until later
Current
Load
40%
Increase Filling degree by adding more biomedia
Future
Load
65%
Maximum Fill of
K1 Biomedia
Fairplay WWTP
Volume Comparison
Existing Lagoon System
7,400,000 Gallons
Conventional Waste
Activated Sludge
Process Volume
420,000 Gallons
Kruger/AnoxKaldnes
Process Volume
125,000 Gallons
*Diagram courtesy of Burns & MacDonnell Engineering
AnoxKaldnes Advantages










Ability to retro-fit existing tankage
Nitrification at extreme temps (<45 F; 6 C)
Stable under large load variations, toxic shocks, pH
Ability to handle high organic & TSS concentrations
Flexible reactor design - future capacity, just add media
Small footprint
Media, sieves & aeration system are designed not to clog
Minimal maintenance
No return activated sludge required (in Pure MBBR Configuration)
Guaranteed process
Components to the AnoxKaldnes
Treatment System
MAJOR COMPONENTS
Media
Stainless Steel Aeration System
Stainless Steel
Sieve Assemblies
Components to the Anoxic MBBRTM
Treatment System
MAJOR COMPONENTS
Media
Stainless Steel
Flat Sieve Assemblies
Tank
Mixers
Biofilm Carrier Elements
K3TM
500 m²/m³ in bulk
(152.4 ft2/ft3)
25 mm (~1”) diam
9 mm (>0.33”) length
Biofilm Carrier Elements
BIOFILM CHIPTM - M
1,200 m²/m³ in bulk
(365 ft2/ft3)
48 mm diameter x 2.2 mm
thick
BIOFILM CHIPTM - P
900 m²/m³ in bulk
(274 ft2/ft3)
45 mm diameter x 3 mm thick
Aeration Grid Layout
Fixed-in place stainless steel
aeration system. In-field oxygen
transfer efficiency comparable to
fine bubble aeration – due to
media interaction with bubbles
K1 Sieve Assembly - Aeration Reactor
Fixed-in place stainless steel
sieve assemblies. Designed for
2 inch’s head loss per reactor at
peak hydraulic flows.
POIPU WWTP
MBBR CASE STUDY
Poipu WWTP Design Criteria
Initial
Future
0.5 MGD
1.0 MGD

Influent Flow

Influent BOD (250 mg/L) 1,043 lb/day
2,085 lb/day

Influent TSS (250 mg/L)
1,043 lb/day
2,085 lb/day

pH
6.5 – 7.5

Temperature Range
68-77°F

MBBR Reactor Volume
98,800 gallons

Percent Fill of Media
34%
65%

Air Flow Required
1,065 SCFM
2,130 SCFM

Effluent BOD
<10 mg/L
<10 mg/L
Poipu WWTP
WAIKOLOA WWTP
CASE STUDY
Waikoloa WWTP
Phase I-Start-up 2008
Phase II-Start-up October 2009
Phase III-TBD
Retrofit existing basins, 3 trains of 3 reactors in series
Waikoloa WWTP Design Criteria
1 x 3 Trains

Influent Flow
0.267 MGD

Influent BOD
668 lb/day

Influent TSS
501 lb/day

Influent TKN
67 lb/day

Temperature Range
22-30oC

MBBR Reactor Volume
gallons

Total Media Surface Area
3,708 ft3

Max Air Flow Required
2,970 SCFM

Effluent BOD Guarantee
≤10 mg/l

Effluent NH3-H Guarantee
≤1 mg/l
Waikoloa Layout
MBBR + ACTIFLO + DiscFilter Example
MBBR
Full System Responsibility
Process Guarantee
Small Footprint
Ease of Operation
Process Stability
Proven Processes
Cost Effective
Economically Efficient
ACTIFLO
Hydrotech
Discfilter
Reuse Water
High Rate Clarification
ACTIFLO
ACTIFLO® Process Schematic
SLUDGE
HYDROCYCLONE
BALLASTED FLOCS
TO HYDROCYCLONE
POLYMER
MICRO-SAND
CLARIFIED
WATER
COAGULANT
RAW
WATER
INJECTION
COAGULATION
MATURATION
TUBE SETTLER
WITH SCRAPER
ACTIFLO Historical Development
1991
1st Actiflo® installation:
Neuilly Sur Marne, France
(Drinking Water, 57 MGD)
1960s
2006
Fourth Generation Actiflo®
Turbo, 32 gpm/sf
1993
1st Actiflo® in Canada,
Kahnawake, QC
(Drinking Water 2 MGD)
First Generation:
Cyclofloc, 6 gpm/sf
Dec 2008
1958
Microsand use in
flocculation & settling
first patented in
Hungary
1988
Third Generation:
Actiflo®, 16 gpm/sf
1970s
Second Generation:
Fluorapid, 8 gpm/sf
1997
510 Actiflo® plants
in 41 countries
1st Actiflo® for wastewater treatment
(Herford, Germany, 15 MGD)
1st Industrial Actiflo® at Scott Paper, QC,
Canada (1 MGD)
ACTIFLO: A Worldwide Success Story
510
500
441
400
378
323
300
273
235
200
198
143
100
0
80
2
5
6
8
12
17
22
37
96
48
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
&
beyond
Current Technologies
Actiflo DW
Classic - cost competitive, small foot print
Turbo – better mixing and smaller foot print than Classic
ActiFloc – package Actiflo with Filters
With PAC – feed ahead Actiflo for TOC reduction (40 – 70%)
Carb – feed with sand for enhanced TOC reduction
MEM – Actilfo Norit membranes
HCS – high concentration sludge (1%)
Actiflo WW
Tertiary – cost effective, Phosphorous Removal – 95+ % reduction
High Rate Secondary
Duo (primary, wet weather)
MBBR – Actiflo
Actiflo Disc Filter- reuse
Actiflo Wet Weather, CSO SSO – intermittent use
BioActiflo – soluble BOD reduction (90%)
Total Number of ACTIFLO Plants Worldwide = 500
# of Plants
Capacity in m3/s
250
206
200
150
140
150
98
100
80
50
29
0
Drinking Water
Mun. Wastewater
Industrial
Distribution of Worldwide ACTIFLO Installations
Total Installations as of 2006 = 384
Drinking Water
100
Mun. Wastewater
Industrial
86
80
65
60
40
23 25
25
33
30
22
17
20
4
18
15
8 8
5
0
USA
Canada
France
ROE
ROW
Worldwide Distribution of 114 ACTIFLO Wastewater Installations
(December 2008)
Number of Installations
Worldwide Distribution of 114 ACTIFLO Wastewater
Installations
55
50
45
40
35
30
25
20
15
10
5
0
Tertiary
48
Stormwater
32
Multi-Purpose
Biofilter Backwash
Primary
14
11
Treatment Application
9
ACTIFLO® Process
Technique:
Attaching flocs to MICROSAND particles
(Ballasting) with the help of a floc aid
POLYMER.
Result:
Ballasted floc particles with enhanced settling
characteristics and high rate flow.
ACTIFLO® Process
Ballasted Floc Diagram
Microsand
Particle
Floc
Microsand
Particle
Microsand
Particle
Particles acquire 2.65 S.G.
For Enhanced Settling
ACTIFLO® Photomicrograph of ballasted floc
particle
~ 150 µm
ACTIFLO® Process Schematic
SLUDGE
HYDROCYCLONE
BALLASTED FLOCS
TO HYDROCYCLONE
POLYMER
MICRO-SAND
CLARIFIED
WATER
COAGULANT
RAW
WATER
INJECTION
COAGULATION
MATURATION
TUBE SETTLER
WITH SCRAPER
ACTIFLO® Process
GENERAL PROCESS STEPS
Process Step
Process Result
Coagulation Tank
Rapid Mix, Coag Addition
Injection Tank
Rapid Mix, Polymer and Sand
Addition
Maturation Tank
Slow Mix for MICROSAND Floc
Formation
Clarification Tank
MICROSAND/Floc Settling
Sand Pump
Recirculation of
MICROSAND/Floc
Hydrocyclone
Floc Separation and
MICROSAND Injection
ACTIFLO® Process -- Mixing
•
Injection, Coagulation,
Maturation Mixing
•
•
•
•
•
•
•
Hydrofoil Blades
Coagulation Rapid
Mix
Coagulant Dispersion
Injection Rapid Mix
Sand and Polymer
Contact
Maturation, Slow Mix
Floc Growth
ACTIFLO® Process – Microsand
Recirculation Pumps


End Suction, Split Case
Rubber Lined for Slurry
application
 Constant Speed
 Monitoring:
• Pump Status
• Pressure Switch to
shutdown pump in event
of high or low head
condition and activate
alarm via PLC
• Seal Water flow
 2-duty and 1-stand-by pump
ACTIFLO® Process – Hydrocyclone Sludge
Separation
OVERFLOW
(SLUDGE)
SLURRY
FEED
AIR CORE
INNER
VORTEX
OUTER
VORTEX
APEX
APEX
APEX
UNDERFLOW
(SAND)
Actiflo® Process – Lamella
Clarification
 Increased loading
rates
 50% Turndown
 150% Design
 Reduced Retention
Time
 Chemical
Optimization
ACTIFLO® Settling Test
Demonstration:
3 Seconds Elapsed Time
ACTIFLO® Settling Test Demonstration:
2 Minutes Elapsed Time
600
120%
500
100%
400
80%
300
60%
200
40%
100
20%
0
0%
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Sample Events
TSS in
TSS out
Removal Eff.
18
19
20
Removal Eff.
Concentration (mg/l)
City of Greenfield, IN.
ACTIFLO TSS Performance
2005 - 2006
Murfreesboro, TN – Treatment Summary
Coag.
Type
Dose
mg/L
Poly
Dose
Fe2SO4
13
ACH
NTU
TSS
Phosphorous
BOD
Raw
Efflue
nt
Raw
Effluent
Ra
w
Effluent
Raw
Effluent
14
1,615
1.4
2,731
8.8
55.4
0.83
154
1.1
5
14
1,784
1.2
2,840
5.8
65.0
2.33
154
4.3
No
Coag.
--
14
1,714
1.4
2,883
9.0
53.3
2.49
150
1.6
Plant*
--
--
1,442
1.4
2,619
7.4
60.3
2.57
154
2.0
* Averaged data collected from the plant’s secondary clarifier reflecting a rise rate of 1 gpm/ft2
ACTIFLO® TURBIDITY SPIKE TEST,
Salisbury, NC
Raw Water Turbidity (NTU)
5.0
19
24
25
28
400
4.0
INFLUENT
300
3.0
200
EFFLUENT
100
2.0
1.0
0
12:00
14:00
16:00
18:00
20:00
0.0
Settled Water Turbidity (NTU)
500 Alum (mg/l) =
14
16
ACTIFLO® TURBIDITY SPIKE TEST,
Talapoosa, AL
10.0
750
8.0
600
6.0
450
4.0
300
Raw Wate r
2.0
150
Se ttle d Wate r
0.0
13:40
13:55
14:09
14:24
14:38
Time
14:52
15:07
15:21
0
15:36
Raw Water Turbidity (NTU)
Settled Water Turbidity (NTU)
Turbidity Spike Vs. Filter Run Time
Raw Water Turbidity = 84.0 - 697.0 NTU
ACTIFLO® Chandler, AZ, December, 2003
ACTIFLO® Relative Installed Footprint
Comparison
1.0 MGD Actiflo Package Plants
1.0 MGD Actiflo Package Plant
Actiflo Package Plant
ACTIFLO®
WHY CHOOSE ACTIFLO?
1. Performance, Excellent Settled Water Quality
2. Rapid Response
3. Process Stability
4. Process Flexibility
5. Small Footprint (Compact Treatment)
6. Experience
HYDROTECH Discfilter
MBBR + ACTIFLO + Discfilter Example
MBBR
Full System Responsibility
Process Guarantee
Small Footprint
Ease of Operation
Process Stability
Proven Processes
Cost Effective
Economically Efficient
ACTIFLO
Hydrotech
Discfilter
Reuse Water
Hydrotech Filtration

1984 Hydrotech Founded
• “Triangle Filter” Aquaculture 2500+ units
 1989 Drumfilter Introduced
• Municipal/Industrial/Aquaculture 3500+ Units
worldwide (25% Municipal)
 1995 Discfilter Introduced
• Municipal/Industrial 700+ units worldwide
• Polyester Cloth Used Today
 1997 First Municipal Filter in US
• 125+ installations
Discfilter Applications
 Primary, Secondary &
Tertiary Filtration
 Water Reuse – Title 22
 Process Water Filtration
 Process Water Recovery
With Tank – Type 1F
Models:
 HSF1700
 HSF2200
7.5 MGD West Brunswick, NC
(HSF2212/11-1F)
Without Tank – Types 2F
Models:
 HSF1700
 HSF2200
16.8 MGD Palm Coast, FL
(HSF2218-2F)
Oconomowoc WI – TBF Retrofit
Hydrotech – Reduced Sectional Footprint
Ease of Installation
Discfilter Parts
•
BW Pump
•
Cover
•
Influent Box
•
BW Discharge
•
Filter Media
Discfilter Operation





Gravity Flow
Stationary Filter Discs
Partially Submerged
Automatic Operation
Continuous Operation
Discfilter Operation

Level sensor activated

Counter-current spray backwash

All discs cleaned with each
rotation during backwash

Basin not drained during
backwash

Filter not off line for backwash

No separate clean water tank
required for backwash supply

Uses filtered water

1-3% Required for Backwash
Discfilter Operation
8”-10”
Moving Spray Bar



Prevents streaking of media
More efficient than stationary nozzles
Spray header retracts from basin
• Nozzles replaceable from
walkway
• Nozzles not submerged
• Not susceptible to fouling
Backwash Cleaning System
Moving
Spray Bar
With Nozzles
Backwash
Collection
Backwash Cleaning System
Collection Trough
Backwash Water
Backwash Cleaning System

Scum and floatables captured
Modular Filter Panels
1700 Panel
 Woven polyester
media
 Filtration range 101000µm
 Less susceptible to
fouling
 Long Lifespan
 Simple attachment
2200 Panel
Simple Filter Maintenance




All components including filter media accessible from
walkway
Basin entry not required for routine maintenance
Basin not drained for component maintenance
High level of operator safety
Simplified Control Requirements
 Only one pump and one drive
motor
 No automatic valves
 No sludge pump
 PLC not required
 Allen Bradley or Square D
Hydrotech Controls



Easy and straight-forward controls
SCADA outputs
NEMA 4X enclosure
Automatic Cleaning System - ACS
Chemical Cleaning Skid Schematic
Discfilter 1
Control Panel
Discfilter N
Control Panel
typical
PLC
DF Chemical
Spray Header
Typical
Discfilter 1
Cleaning Skid
Control Panel
V
Back pressure Valve
Level
Alarm
PS
typical
Pulsation
Dampener
Discfilter N
Pressure
Switch
Magnetic Drive Pump
12 gpm @ 40 PSI
V
Skid Boundary
Day Tank
Coag/Floc System
Summary







Compact design
Robust construction
Economical
Low maintenance
Ease of Operation
Range of models
125+ installations in US and Canada
Why Kruger?





Inside out – easy access, clean
No Plugging
Only one backwash pump
No sludge removal required
Value added features (No blinding)
•
•
Coag/Floc tank
Automatic cleaning system
 Low energy – 1.5 Hp, 5 Hp
MBBR + ACTIFLO + Discfilter Example
MBBR
Full System Responsibility
Process Guarantee
Small Footprint
Ease of Operation
Process Stability
Proven Processes
Cost Effective
Economically Efficient
ACTIFLO
Hydrotech
Discfilter
Reuse Water
Questions