KENNETH E. NEU, M.S. ENVIRONMENTAL / HEALTH ...

ENVIRONMENTAL / HEALTH PRODUCTS & SERVICE

Central States-Water Environment Association May 14-16. 2012 St. Charles, IL

KENNETH E. NEU, M.S.ENVIRONMENTAL / HEALTH

PRODUCTS & SERVICEP. O. BOX 101

PHILLIPS, WISCONSIN 54555Business Cell: 262-628-1300

E-MAIL: [email protected]


Complete Mix Moving Media Fixed Film: Industrial Pretreatment When There is

Trouble DownstreamKen Neu, MS

Environmental / Health Products & Service

Industrial Pretreatment Case Study


Contents of Presentation

Fixed Film Moving MediaØMBBR: Complete Mix Fixed Film (CMFF) &

Combined Fixed Activated Sludge (CFAS)ØAdvantages & ExamplesØCase Study-High Strength Waste-- Industrial Pretreatment Retrofit Upgrade


Moving Media Aerobic Reactor Treatment

q Referred to as Moving Bed BioReactor (MBBR)q Developed in the 1990’s by several entitiesq Specifically shaped carrier elements mfg. from

extruded polyethylene tube, cut to short pieces, with internal & external additions for added surface area and structural integrity

q 0.91 to 0.96 Specific Gravity, carriers become neutrally buoyant with biological accumulation



q Various shapes, sizes of Biofilm Carrier Elements (media), manufactured in various countries

q Used in many applications globally for municipal and high-strength industrial applications for BOD removal &Nitrification / Denitrification


Moving Media Aerobic Reactor Treatment Small Biofilm Carrier Elements

Samples of Various Style Carriers


Fixed Film Moving Media Reactor Treatment

Moving Media system, Aerobic and Anoxic modes, typical Biofilm Carrier Elements.



Full-scale Moving Media WWTP-Municipal or Industrial


Hybrid System

Definition: A wastewater treatment system that incorporates some form of additional technology into the reactor to enhance the level of treatment. In this case, Combined Fixed Activated Sludge (CFAS) using Biowater Technology BioMedia. Goal/Advantage: Offers the potential to increase the plant capacity or the level of treatment without expanding the number of structures.


Combined or Integrated Fixed Film Activated Sludge Aerobic Reactor



Media Designation : BWT-X This media has 9 cells, is used in domestic & industrial (high strength) wastewater treat-

ment applications.

Width/height : 15mm

Length : 8.5mm (tol.±0,5mm)

Perimeter outside : 56 mm

Perimeter inside : 197 mm

Tolerances according to : DIN 16941/3

Wall thicknesses : 0,3 (Tol.±0,1mm)



Media Designation : BWT-15 This media has 25 cells ,substantially more surface area, and is used in nitrification & denitrification applications in water and

wastewater biological treatment.

Width/height : 15mm

Length : 5 mm (tol.±0,5mm)

Perimeter outside : 56 mm

Perimeter inside : 258.6 mm

Tolerances according to : DIN 16941/3

Wall thicknesses : 0,3 (Tol.±0,1mm)



➤ Material: Polyethylene, high density (HDPE).➤ Colour & Sp. Wt: Natural. Raw = 0.96 (± 0.02)

kg/l, Finished =0.95 (± 0.02) kg/l.➤ Add-Max® 104 is added to the material to

improve stabilization for the extruding process.➤ The biofilm carrier elements are produced from

a material and with a procedure that ensures proper operation for its service life.



Main Data BWT-X BWT-15

Weight 125 kg/m³ (in bulk) 166 kg/m³ (in bulk) Surface Area by Weight

5.0m2/kg 4.97m2/kg

Protected surface area per M3

6 22m2 or 190 sq ft/ cu ft. 828m2 or 253 sq ft/ cu ft.

Content of a big bag :

Dependent on the preferred bag size (typically 1-2 M3)


Water Environment Federation’s (1998) MOP 8, “Design of Municipal Wastewater Treatment Plants” Surface Area of Stationary Media Bundles

Typical Wastewater Strength Categories

Surface Area , Sq Ft /Cu Ft of Media Volume

High Strength Waste: 30.5 sq ft/cu ftDomestic, BOD removal: 36 sq ft/ cu ftNitrification applications: 42- 48 sq ft/ cu ft

RBC: – std den / high den 34 sq ft & 56 sq ft / cu ftBWT-X @ 65% fill fraction 124 sq ft / cu ftBWT-15 @ 65% fill fraction 165 sq ft / cu ft



Advantages: HIGH SURFACE AREA q About 190 –250 FT2 / FT3 Specific bulk

surface area

q About 130-175 square feet per cubic foot within the reactor at 70 % volumetric filling



Advantages:

q Process is continuous and requires no backwashing--operates as once-through or recirculation

q Cost-effective, compact design

q Stable & robust process: handles hydraulic and organic load variations



Advantages:EASY UPGRADING OF ACTIVATED SLUDGE PLANTS TO HIGHER CAPACITIESq addition within the Activated Sludge unit

process to achieve IFAS/CFAS status, andq added as a separate unit process- within

Flow Path, upstream or downstream of existing Fixed Film or Activated Sludge



q Carriers move throughout tank with aeration or by movement of water by mixers in an anoxic tank, no “dead” / unused space in tank

q Intimate contact of biomass w/ substrate & air

q Near 70 % fill level of media in the reactor q Strainer retains carrier elements within the tank


Small Media Aerobic Reactor Treatment(SMART process for wastewater treatment)


Small Media Aerobic Reactor Treatment(SMART process for wastewater treatment)

q EHS has DOWN-SIZED this technology to Very Economical SMALL FLOW and ON-SITE wastewater treatment applications, using Pre-Cast Concrete tanks up to 40,000 gallons.

q Wisconsin approval (Dept. of Safety & Professional Services) attained for the Small Flow (<1000 P.E.) ON-SITE AEROBIC TREATMENT SYSTEM, with several EHS-SMART-Treat™ systems installed since 2001


Small Media Aerobic Reactor Treatment(SMART-Treat™ for wastewater treatment)

EHS SMART System Small Flow Sizing, BOD + Nitrogen RemPop Equiv

WW Qgpd STE

Inf BOD Lbs / day

Reactorgallons

HRT-av Q, hrs

Media, % fill

Tank Depth

6 450 0.92 320 31 16 3.5

50 4,000 7.7 5300 5 64 4

500 40,000 77 8350 5 64 6

1000 80,000 154 16,500 5 64 10


Small Media Aerobic Reactor TreatmentThe EHS SMART-Treat™ process


Small Media Aerobic Reactor TreatmentSMART-Treat™ at a convenience store, Oconto Cty


EHS-SMART-Treat™ process at an Eight-unit Apartment building, Grafton, WI


EHS SMART-Treat™ treatment process at an 8-unit apartment building, Grafton, WI (8/03)

Design Flow: 1,600 gallons per dayInstallation & Start-Up: June 27, 2003Date: August 17,2003 BOD, mg/l TSS, mg/l NH3-N, mg/lGrab CompositeSettled. Effluent

4 7 < 2.0


EHS SMART-Treat™ treatment process at a single family residence, Sheboygan, WI (7/03)


EHS SMART-Treat™ process at single family residence, Sheboygan, WI (July, 2003)


Small Media Aerobic Reactor Treatment SMART-Treat™ process on-site high strength waste

Westwood Golf & Supper Club, Phillips, WIHigh-Strength Waste EHS-SMART System (4500gpd)

GTST

MBBR

MBBR

Clarifier

Claifierr

*

Raw WW Sample Point

& Surface Cleanout

Proposed test reactorPump for proposed test& clarifier

*Enclosure to hold all e le ctricalpane ls , blowe r, & sample rs .


Small Media Aerobic Reactor TreatmentSMART-Treat™ process on-site high strength waste

Example: EHS-SMART Treat System, Westwood Data, up to 30 samples, 12/01-4/02, analyzed at certified labs.

BOD5 mg/l

TSS, mg/l

TKN, mg/l

NH3-N, mg/l

NO3-N, mg/l

Temp-C

pH DO,mg/l

GT Eff

1619 530 80.3 44.5 -- 14.6 5.3 0.5

ST Eff

164 125 -- -- -- 9.8 6.9 0.4

Final 16.2 14.5 2.6 0.5 8.3-10.5

7.0 7.1 5.4

% Rem

99.0 97.3 96.8 98.9 -- -- -- --

Note: Complete Nitrification & 83-86% Total Nitrogen Reduction via recirculation to Septic Tank


EHS SMART-Treat™ System-Stonecroft Condominium, Grafton, WI

SurgeVolume

OUT

EHS Small Wastewater Flow MOVING BEDBIOFILM REACTOR (MBBR)

BioSolids toClarifier

Biosolids to Lift station

OUTtoPump-Tank/Septic Tanks

Environmental / HealthProducts & ServicePO Box 21Richfield, WI 53076

Small Flow MBBR Wastewater TreatmentStonecroft Condominiums Grafton, Wisconsin

Raw SewageLift Station

High Water LevelAlarm Float

Air BlowerElec Control

Central Electrical Control Panel

Existing Lift stationElec. Control Panel


Small Media Aerobic Reactor Treatment(SMART-Treat™ for wastewater treatment)

Stonecroft Condominium EHS-Smart System Startup 11/02

Sample Date Ammonia field test, mg/lDec 6, 2002 35 mg/l, cloudy-startup phaseDec 20, 2002 25 mg/l, Clear, Est. BOD&TSS <30mg/lFeb 3, 2003 7.5 mg/l, Sparkling, Est. BOD <20mg/lApril5, 2003 1.5 mg/l Same-Excellent Treatment


Industrial Pretreatment – EHS/BWT Case StudyUpgrade of a Sanitaire Package Plant treating a Food Waste


Industrial Pretreatment—EHS/BWT Case StudyDesign Data for Pkg Plant Upgrade to MBBR

Parameter Flow, Concentration or Load

Flow 25,000 gal per day

BOD5 7,200 mg/L 1,500 lb/d (682 kg/d)

TSS 960 mg/L 200 lb/d (91 kg/d)

TP 30 mg/L 6.26 lb/d (2.85 kg/d)NH3-N 50 mg/L 10.43 lb/d (4.74 kg/d)

Temperature 50-80oF 50-80oF (10 – 27 oC)


Effluent Pre-Treatment Permit Target Effluent Values for Sanitaire Pretreatment Plant (Values were exceeded periodically-BEFORE Retrofit)


Flow 25,000 gal per day

BOD5 240 mg/L 50 lb/d (22.75 kg/d)

TSS 240 mg/L 50 lb/d (22.75 kg/d)

TP 7 mg/L 1.5 lb/d (0.66 kg/d)


Industrial Pretreatment—EHS/BWT Case StudyNew 40,000 gal Flow Equalization tank added


Industrial Pretreatment – EHS/BWT Case Study Planned Retrofit-add surface area to former EQ tank section


Industrial Pretreatment—EHS/BWT Case Studyw/ Rivers Bend Engineering & Biowater Technology

v Roughing Tank (RT) Eff. Goal: = / > 30% BOD Reductionv HRT @ design flow = 13 hr. (in a 14,000 + gallon volume)v Carrier Elements Added:17. 6 Cu M BWT-X (33 % fill fraction)v Design for 12.74 # BOD/d/KSF @ Design Organic Loadv Air Added to Roughing Tank: 450 CFM—but do not need .v At present, use existing AS aeration in retrofitted moving media

roughing tank section. Turned OFF supplemental AS aeration.


Industrial Pretreatment—EHS/BWT Case StudyUpgrade of a Sanitaire Package Plant with Moving Media


Industrial Pretreatment—EHS/BWT Case Study Roughing Tank Stainless Steel Aeration Grid


Industrial Pretreatment—Case Study: Filling former EQ tank Retrofitted w/ Moving Media, air header, retention screen


Industrial Pretreatment—EHS/BWT Case Study Roughing Tank- SS Carrier Element Retention Screen


Industrial Pretreatment—EHS/BWT Case Study Carrier Elements –Ready to Add to Roughing Tank


Industrial Pretreatment—EHS/BWT Case StudyBiofilm Carrier Element Addition—EASY!!


EHS/BWT Case Study-Depiction of Moving Media Installed in Existing Package Plant


Industrial Pretreatment—EHS/BWT Case StudyWeir Box—to handle flow from EQ tank


Industrial Pretreatment—EHS/BWT Case StudyDigester, 2nd stage Act. Sludge, Ferric Chloride add


Industrial Pretreatment—EHS/BWT Case StudyRAS pipe installed to moving media roughing tank


Industrial Pretreatment—EHS/BWT Case StudyRAS pipe to Moving Media Roughing Tank


Industrial Pretreatment—EHS/BWT Case StudyRAS Outfall—far side of roughing tank outlet


Industrial Pretreatment—EHS/BWT Case StudyRaw WW--Sum of 7-day sampling, Nov 10-17, 2010

Flow COD fCOD TSS TP TKN Raw BOD Load (0.4 BOD:COD Ratio)gpd mg/L mg/L mg/L mg/L mg/L lb/d

10-Nov-10 2,846 2,600 420 1,300 12 89 24.6911-Nov-10 8,609 3,400 610 2,200 18 53 97.6512-Nov-10 9,637 2,300 280 1,200 13 82 73.9413-Nov-10 7,091 2,900 760 1,300 10 68.6015-Nov-10 10,987 2,700 410 1,600 16 98.9616-Nov-10 12,535 6,200 3,300 2,600 7 83 259.2617-Nov-10 21,161 5,500 2,600 12 96 388.26

Date


Industrial Pretreatment—EHS/BWT Case StudySummary-- Average & Range-- of 7-day sampling

Parameter EQ TANK Eff RT Eff ( w/ media)

Act Sludge Eff Clarifier Eff

WW Flow, gpd

Av: 10,410 gpd R= 2,846 -21,161

WW temp, F Ave = 80.5R= 73.0-84.5

73.6 68.0-76.8

68.568.2-70.1

68.266.0-69.9

Dis. Ox., mg/l Ave = 3.4R = 0.2 – 8.3

2.80.5 - 6.2

8.17.3 – 9.7

2.70.4 – 4.3

pH, Std Units 7.3R = 6.5 -8.0

7.57.3 – 7.8

7.67.5 – 7.8

7.67.5 - 7.7


Industrial Pretreatment—EHS/BWT Case Study Summary –Ave. & Range --of 7-day sampling

Parameter, mg/l except

as noted

EQ TANKEff

Roughing Tank Eff

( w/ media)

EQ to Roughing Tank

% Reduced

Act Sludge Eff

Clarifier Eff EQ Eff to Clarifier Eff, % Reduced

COD, mg/lN = 7

36572300 – 6200

190110 – 270

94.8 % Reduction

COD-filtered N = 7

1097280 -3300

336110 – 820 69.4% R

13581 - 170

15092 – 190

86.3 % Red, AS polishing =

16.7% add’ l

BOD, mg/lN = 4

1163760 – 2200

< 2618 - < 33

97.8 % Reduction

BOD (filtered)

N = 4

46762-1600

1069 -380 77.3% R

< 8.5< 3.1 - < 21

< 3.62.7 - 4.5

99.2 % Red.AS polishing = 21.9 % add’l


Industrial Pretreatment—EHS/BWT Case Study Summary –Ave. & Range --of 7-day sampling

Parameter, mg/l except

as noted

EQ TANKEff

Roughing Tank Eff

( w/ media)

EQ to Roughing Tank

% Reduced

Act Sludge Eff

Clarifier Eff

EQ Eff to Clarifier Eff, % Reduced

TSSN = 7

18291200 – 2600

42292700 -5300

231% INCR w/o RAS

43713700 -5600

6030 – 110

96.7 % Reduction

Total PhosN = 7

12.67.4 -18

4.02.1 – 5.5

68 % Reduction

Tot filtered Phosphorus

2.51.7 – 3.3

2.51.1 – 3.5

2.92.0 – 5.5

TKNN = 7

80.653 - 96

8.45.1 – 12

89.6 % Reduction

TKN (filtered)

5.84.6 -6.3

5.33.1 – 6.7

6.24.0 – 12.0


Industrial Pre-Treatment Case Study Laboratory Summary –November 17, 2010

Parameter, mg/l except as noted

EQ TankEffluent

RoughingTank w/ Media

% ReductionEQ effl. to

RT effl.

AS Eff ClarEff

% ReductionEQ effl. to

Clarifier effl.

Pretreatment Effluent

Requirement

% of Design

LoadingFlow, gpd 21,161 14.7 gpm 85 % Q

WW temp, F 84.5 76.1 >8 F lower 67.2 67.1 17.4F lower

Dis. Ox, mg/l 0.5 0.5 SAME 7.8 0.4

pH, SU 6.55 7.3 .75 SU Incr. 7.7 7.6 +1 SU Incr.

COD, mg/l 5500 110 98 % Red.

COD-filtered 1900 790 59% Red. 81 92 95 % Red.

BOD, mg/l 2200 OL= 3.3#/d/ksf <33 240 mg/l 26 %

BOD - filtered 1600 380 76.3 Red. 6.2 4.5 99.7% Red.

TSS/ MLSS 2600 4400 Incr. 69 % 4800 52 98% Red. 240 mg/l 229 %30 min Vol 930ml

Phosphorus 12 2.1 82.5% Red. 7 mg/l 33.8 %

TP-- (filtered) 3.2 1.1 2.1

TKN 96 5.1 89.5% Red.

TKN--filtered 5.3 4.6 4.0


Industrial Pretreatment—EHS/BWT Case Study Ave COD, mg/l- 11/10-17/2010 Sampling Period, 91% Reduction Through Moving Media Roughing Tank


Effluent Range AFTER Package Plant Moving Media Retrofit


Pretreatment Permit

Flow 20-25,000+ gpd 25,000 gpd

BOD5 30-80 mg/L 240 mg/l

TSS 30-120 mg/L 240 mg/l

TP 0.5-2.5 mg/L 7 mg/l


Industrial Pretreatment – EHS/BWT Case StudyMoving Media Retrofitted Sanitaire Pretreatment Plant


Industrial Pre-Treatment Case Study Summary & Conclusions

Ø A More Economic Choice than Other OptionsØ Ease of Retrofit---Treatment capacity was added within

EXISTING reactor in JUST ONE (1) working dayØ Self-cleaning biological surfaces, NO clogging or cleaning Ø Provided production facility flexibility Ø The Complete Mix Fixed Film moving media reactor is

able to adapt quickly to fluctuating flows and loadsØ RAS to Roughing Tank (est. +/-75%) enhances treatment,

including potential for Biological Phosphorus Uptake.


Industrial Pre-Treatment Case Study Summary & Conclusions

v Ability to EASILY & Cost-Effectively Retrofit remainder of Sanitaire package plant as manufacturing facility expands—I.E.: Add moving media to 1st & 2nd stages of Activated Sludge tankage, to create Combined Fixed Activated Sludge (CFAS) hybrid process for the entire aeration zone.


Thank You for the Opportunity!

Ken Neu, MSEnvironmental / Health Products & Service

Phone: (262) 628-1300E-mail: [email protected]

KENNETH E. NEU, M.S. ENVIRONMENTAL / HEALTH ...

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