Aerobic Digestion With Membrane Thickening Is SOS

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Aerobic Digestion Processes with Membrane Thickening is SOSBryen Woo, PEOWEA Conference 201012/13/2010

SOS Sustainable Operating SolutionAn aerobic digestionprocess with membranethickening is SOS,Sustainable OperatingSolution. This SOS makespeople stress free andhappy!Without membrane thickeningan aerobic digestion processcan be this SOS!2

Digestion ExpertiseWEFTEC 1997 - 2001AEROBICDIGESTIONWORKSHOPVOL III 1999AEROBICDIGESTIONWORKSHOPCD-ROMFine Tuningthe ControlledAerobic DigestionProcessVOL I 1997The ChallengeOf MeetingClass BWhile DigestingThicker Sludges recognized as the industry leader in aerobicdigestion and thickening at high solids concentrations3

Digestion ExpertiseManual of Practice No. 11 Operation of Municipal WWTPVolume III:Solids ProcessesChapter 31:Aerobic DigestionAuthor:Elena Bailey4

Digestion ExpertiseMOP No. 8 5th Ed., 2009 Design of Municipal WWTPsVolume III:Solids Processing and ManagementChapter 25: StabilizationSection 3 : Aerobic DigestionAuthor:Miguel Vera5

Membrane Thickening InstallationsDatePlantCityStateLiquid ProcessMBT/ PAD-KPAD-KJun-04Dundee WWTPDundeeMIMBRJun-04Arlington WWTPArlingtonWASBRMBTJul-04Troy WWTPTroyMOMBRPAD-KAug-04McFarland Creek WWTPChagrin FallsOHMBRPAD-KNov-04Gnadenhutten WWTPGnadenhuttenOHMBRPAD-KApr-05Delphos WWTPDelphosOHMBRStormmasterPAD-KApr-05Cottonwood WWTPManorTXMBRAug-05Lewes WWTPLewesDEMBRMBTNov-05East Dundee WWTPEast DundeeILCASPAD-KApr-06Yakama IN CasinoToppenishWAMBRPAD-KMay-06Woodside STPYaphankNYCASPAD-KMay-06Stoutsville WWTPStoutsvilleOHMBRMBTJun-06North Lewisberg WWTPNorth LewisbergOHMBRMBTJul-06Harvest MonroviaHunstvilleALMBRMBTJul-06Bob's Creek WWTPLincoln CountyMOMBRPAD-KAug-06Hamden WWTPHamdenOHMBRMBTAug-06Shelton WWTPSheltonWAMBRMBTSep-06Lake of the Pines WWTPAuburnCAMBRPAD-KNov-06Concrete WWTPConcreteWAMBRPAD-KDec-06Providence EstatesO'FallonMOMBRPAD-KFeb-07Westford-Acton WWTPActonMAMBRMBTApr-07Winlock WWTPWinlockWAMBRPAD-KJun-07Burwell Road WWTPHunstvilleALMBRMBTJun-07Highland Lake Estates WWTPMonroeNYMBRMBTApr-08Alpine WWTPAlpineWYMBRPAD-KJul-08Union Rome WWTPUnion RomeOHMBRPAD-KOct-09C'oeur d'Alene CasinoC'oeur d'AleneIDMBRPAD-KDec-09Cayce WWTPCayceSCOXPAD-KNov-10Davie WWTPDavieFLMBRPAD-K6

Installations Near Ohio (Northeast US)7

Why Use Aerobic Digestion with MembraneThickening?Benefits of Membrane Thickening1.Improved thickening Thickening of WAS without using polymer.- Reduced chemicals and disposal cost. 2.Thickening of WAS to 3% solids (5% with a dual step) independentof settling characteristics in a single step.Less sludge volume to handle or dispose.Reduced operator attendance. No Set-up or clean up time No constant attendance while thickening8

Why Use Aerobic Digestion with MembraneThickening?Benefits of Membrane Thickening3.Reduced Footprint Smaller tanks No chemical storage Less concrete and less airrequirements resulting in less energy/electrical usage- Ideal for rehabs and small plants.-Could use existing overloaded aerobic digesters - SHT4.Produces a High Quality Permeate when used with anAerated Digester(s) or SHT Reduces Total N (NH3/NO3) and P in the permeate. Substantialrelease of these nutrients in liquid stream going back to the headof the plant compromises the performance of the BNR activatedsludge process. Permeate can be combined with effluent without reducing quality. Sludge for disposal has reduced Total N as well.9

Why Use Aerobic Digestion with MembraneThickening?Benefits of Membrane ThickeningMembrane Thickening Processes reduces capital costsassociated with the construction of additional tanksDesign%SolidsRequiredDesign SRT(Days)RequiredVolume(gallons)ConcreteRequired toBuild Tanks(cubic yd)ConcreteCosts( 600/yd3)Design Air(scfm)Decant1.75602,055,4801,333 800,0008,240P.A.D-K3.042699,440638 385,0002,800P.A.D-K Process will reduces energy costsDesignTotal Brake HPDemand for BlowersConvert EnergyUsage in KilowattsAnnual Energy Costs( 0.06/KWH)DecantP.A.D-K333 hp113 hp249 kW85 kW 131,000 45,000Based on 3.0 MGD Class B Aerobic Digestion Facility Design10

The P.A.D -K ProcessP.A.D -K stands for Pre-Thickened Aerobic Digester using a Kubota Flat PlateMembraneIdeal for:MBR WWTPsDecentralized facilities orReduced operations staffClass B Applications11

How Does Membrane Thickening Work?How Does Sludge Get Thickened With a Membrane? An MBT submerged membrane unit is used to create a physical barrieracross which to extract clear water from sludgeAir diffuser incorporated in lower part of cassette12

Membrane Thickener FactsMembrane ThickenerKubota Membrane Thickener Facts: PE membrane ultrasonically welded to ABS plate Air diffuserincorporated in lower part of cassette Nominal pore size 0.4 micron, effective pore size 0.1 micron Effective filtration area 8.6 ft2 per cartridge MBT Design flux 5 gfd @ 20 C MBT Cross flow velocity is 2.25 ft / sec13

The P.A.D -K ProcessDigester 2Digester 1Anox.BasinMBT14

Minimum Maintenance Of MembraneThickener RequirementsMaintenance Automated Diffuser Cleaning, approx. 30 min/dayMembrane Relax, approx. 1min/10minChemical Cleaning, in-situ clean every 6 months,approx 2 hour durationNO NEED TO DRAIN TANKS OR TAKE OUT OF SERVICE FOR CHEMICAL CLEANING!15

Aerobic Digestion ChemistryAerobic Digestion is a biological processsimilar to Activated Sludge.Activated Sludge GrowthAerobic Digestion DecayProcess control is required to maintainhealthy biomass16

Aerobic Digestion Chemistry1. Digestion:C5H7NO2 5O2 4CO2 H2O (NH4HCO3)BiomassAmmonium Carbonate2. Nitrification:NH4 2O2 H2O 2H NO3AmmoniaAcid Nitrate3. Digestion with Nitrification:C5H7NO2 7O2 5CO2 3H2O HNO3BiomassNitric Acid17

Aerobic Digestion Chemistry4. Digestion with Nitrification:C5H7NO2 7O2 5CO2 3H2O HNO3BiomassNitric Acid5. Denitrification:C5H7NO2 4NO3- H2O NH4 5HCO3- 2N2Biomass NitrateAmmoniaN GasAlkalinity6. Complete Nitrification / Denitrification:C5H7NO2 5.75O2 5CO2 3.5H2O 0.5N2BiomassN Gas18

Aerobic Digestion Chemistry18% Oxygen Savings:3. Digestion with Nitrification:C5H7NO2 7O2 5CO2 3H2O HNO3Versus6. Complete Nitrification / Denitrification:C5H7NO2 5.75O2 5CO2 3.5H2O 0.5N219

Aerobic Digestion ChemistrypH Cycle:1. Digestion: (pH UP)C5H7NO2 5O2 4CO2 H2O NH4 HCO32. Nitrification: (pH DOWN)NH4 2O2 H2O 2H NO34. Denitrification: (pH UP)C5H7NO2 4NO3- H2O NH4 5HCO3- 2N220

SHOW ME THE BENEFITSCase Studies of AerobicDigestion Processes withMembrane Thickening21

Miyazaki WWTP, JapanMiyazaki WWTP, JapanOldest Installation using Membrane Thickener in the World(Since 1999)22

Miyazaki WWTP, JapanCommissioned:Waste Type:Liquid Process:MBT Size:MBT Flux:Air Scour:Solids Conc.:Chemical Cleaning:Diffuser Cleaning:1999 (11 years)MunicipalSBR300 plates5.3 gfd0.35 scfm/plate3.1%4 / year30 min /day23

Minch Malt WWTP, Athy, IrelandOldest Ovivo InstallationHigh Solids Concentration: 45,000 mg/LUsing Membrane Thickener (Since 2001)24

Mitch Malt WWTP, Athy, IrelandCommissioned:Waste Type:Liquid Process:MBT Size:MBT Flux:Air Scour:Solids Conc.:Chemical Cleaning:Diffuser Cleaning:2001 (9 years)IndustrialMBR150 plates3.9-9.6 gfd0.49 scfm/plate4%-5.5%2 / year30 min / day25

Minch Malt WWTP, Athy, Ireland6.0Total Solids (%) TS (%)Influent TS (%)0.00246Trial No.810Influent Flow – 11,900 gpd26

Dundee WWTP, MichiganMBR and PAD -K27

Dundee WWTP, MichiganCommissioned:Liquid Process:MBT Size:MBT Flux:Air Scour:Solid Conc.:Chemical Cleaning:Diffuser Cleaning:2005MBR (1.2 MGD)800 plates4.5 gfd Designat 4.5 degrees C0.35 scfm/plate3%-5.25%2-3 / year (scheduled)30-45 min / day28

Dundee WWTP, MichiganDigester #2Digester #1MBTEngineer: ArcadisHistory: Objective was to reduce the haulingto 2 times per year. Tanks aredesigned to store 180 days at 3%solids. Operator friendly when comparedto other systems. Enviroquip’s Aerobic Digestionexperience rated higher whenevaluated against othervendors/technologies.29

Dundee WWTP, MichiganThickening PerformanceSep & Oct 2005 Operation654WASMBT ThickenerDigester #1Digester #2% solids 3210Date30

Dundee WWTP, MichiganMBT Permeate Results4BODTSSNH332109/59/159/2510/510/1531

Dundee WWTP, MichiganJanuary 2007 to June 2008 DataSustainable Permeate Qualitybefore it’s blended with MBR effluentBOD:1.12 mg/lTSS:2.00 mg/l0.22 mg/lNH3-N:0.03 mg/lNO3-N:TP:1.09 mg/l **BioP MBR upstream32

Dundee WWTP, Michigan Sludge Hauling CostSummaryYearsGallons HauledDry TonsYearly Cost2004 (0.6 MGD SBR)248,885 – Belt943,200 – Truck1,192,100 - Total22.67 – Belt99.39 – Truck122.06 - Total 16,850 – Belt 30,088 – Truck 46,938 - Total2005 (1.2 MGD MBR)MBT operational for2nd half of year only572,400 – Belt432,000 – MBT1,004,400 - Total55.62 – Belt47.55 – MBT103.17 - Total 39,135 – Belt 14,623 – MBT 53,758 – Total2006887,400 - MBT130.48 – MBT* 32,739 - MBTBelt press was needed for years 2003 -05 due to lack of storage space.Sludge Hauling costs for first full year of operation of MBT in 2006was 32,739 which is cheaper than the last 5 years* Sludge Production minimized due to N/DN33

McFarland Creek WWTP, OhioEngineer: CT ConsultantsMBR and Two Stage PAD -K34

SMUs Installed Directly inDigesters3535

McFarland Creek WWTP, OhioCommissioned:Waste Type:Liquid Process:MBT Size:Air Scour:Solids Conc.:Diffuser Cleaning:2005 (5 years)MunicipalMBR (1.8 MGD)400 plates0.53 scfm/plate3.5%-5.5%30 min / day36

McFarland Creek WWTP, Ohio60,00050,000TSS (mg/L)Thickening tank /2511/141/32/22DateThickening tank 2Membrane thickening at McFarland Creek WWTP was able to thicken up to 5% solids.37

McFarland Creek WWTP, OhioMcFarland Creek WWTP BFP ResultsAnnual BFP run time w/o PAD -K8,736 hoursAnnual BFP run time with PAD -K3,744 hoursReduction BFP run time57.14%

Union Rome WWTP, OhioEngineer: CT ConsultantsMBR and PAD -K39

Union Rome WWTP, OhioCommissioned:Waste Type:Liquid Process:MBT Size:Air Scour:Solids Conc.:Diffuser Cleaning:2010MunicipalMBR1,000 plates0.53 scfm/plate3.5%-4.5%30 min / day40

Union Rome WWTP, OhioUnion Rome WWTP Membrane Thickening TS Results5.04.5Effluent TSConcentration (%)4.0Influent Jun-10Aug-10Sep-10DateThe TS concentration was MORE THAN TRIPLED by thickening withmembranes at Union Rome WWTP.41

Union Rome WWTP, OhioJanuary 2010 to October 2010 DataSustainable Permeate Qualityafter it’s blended with MBR effluentBOD: 1.0 mg/lTSS: 1.0 mg/l 0.1 mg/lNH3-N:TP: 5.0 mg/l **No BioP in the Liquid Process Upstream42

Stoutsville WWTP, OhioEngineer: R.D. ZandeCommissioned:Plant Size:Liquid Process:MBT Size:Air Scour:Solids Conc.:Chemical Cleaning:Goal:2006 (4 years)50,000 GPDMBR50 plates0.53 scfm/plate2.5%-4.0%4 / yearReduce SludgeHauling Trips43

Stoutsville WWTP, OhioStoutsville WWTP Membrane Thickening TS Results3.5Concentration (%) TS1.5Influent TS1.00.50.0May-10 Jun-10 Jul-10Jul-10 Aug-10 Aug-10 Sep-10 Oct-10 Oct-10 Nov-10Date44

Stoutsville WWTP, OhioStoutsville WWTP ResultsAvg. Annual Hauling Volume w/o MBT208,000 gal.Avg. Annual Hauling Trips w/o MBT26Avg. Annual Hauling Volume with MBT136,000 gal.Avg. Annual Hauling Trips w/o MBT17Reduction of sludge being hauled34.61%Reduction of hauling trips34.61%45

SHOW ME THE BENEFITSCase Studies of MembraneThickening followingConventional Activated SludgeProcessesFirst Installation in 200546

East Dundee, IL Project BackgroundEngineer: Trotter and Associates 1.15 MGD Oxidation Ditch Extended Aeration Facility - 1998 2.30 MGD expansion to include Membrane Thickening- 20034747

East Dundee, IL Sludge HandlingRAS/WAS P.S.Final ClarifierFinal ClarifierSludge StorageRASSludge dewateringWAS HoldingThickened SludgeCentrateCentrateDigester #1Digester #2Digester #3Digester #4 Two (2) WAS Holding TanksCentrifuge ThickeningFour (4) STD Aerobic DigestersSludge Holding TankCentrifuge Dewatering4848

East Dundee, IL ExpansionRAS/WAS P.S.Final ClarifierFinal ClarifierSludge StorageRASSludge dewateringWAS HoldingCentrateCentrateThickened SludgeAnoxicDigester #1MembraneMixingBasinFiltrateDigester #2Digester #3Digester #42.3 MGDSludge Handling Facilitywith Membrane ThickeningAlso added Fine Screen on top of Anoxic Tank4949

East Dundee WWTP, Illinois ExpansionIssues and Solutions after Carrousel MD Installation1.2.3.4.Centrifuges Relied on for Double Duty Install Dedicated Membrane Thickening SystemFine Bubble Diffuser System could not handle 4% solids Replace Fine Bubble Membranes w/ Medium BubbleIncreased Solids Loading Due the Expansion & BNR Operate at Higher TemperatureDigestion Facility Being Operated in Batch Mode Reconfigure for Continuous Process50

Case StudyArlington, WA1.68 MGD SBR Facility (2004)(4000 to 6000 mg/l feed)Evaluation of Short-Term Methodsfor Handling SolidsBy Kennedy/Jenks Consultants51

Arlington WWTP, WashingtonMBT 1MBT 2ExistingSludgeStorageTank 1ExistingSludgeStorageTank 252

Arlington WWTP, WashingtonSource: Report by Kennedy-Jenks Consultants53

Arlington WWTP, Washingtonvs. actual 14 lbs/ DT or 13,500 more per yearor 270,000 more @ 20 Yr life cycle costSource: Report by Kennedy-Jenks Consultants54

Woodside WWTP, New YorkBiological Process: Concentric Circular PlantGOAL: Reduce number of sludge hauling tripsLess gallons to haul per year:Sludge hauling reduction 625,783 gal.Savings per year 59,449ROI of 2.57 years based solely on hauling55

Carrousel MD :Carrousel Biological Process Followed byMembrane Thickening DigestionCarrousel Membrane Digestion56

Carrousel MD :Carrousel Biological Process Followed byMembrane Thickening DigestionConversion of Existing Carrousel with 2 DitchesMembrane Thickener57

Cayce WWTP, South CarolinaEngineer: American Engineering ConsultantsCarrousel MD: Coming To A Theatre Near YouCurrent Site8 MGD Cap.To be expanded to25 MGDCarrousel MDselected to protectBioP Carrousel Ditch58

Cayce WWTP, South Carolina Layout at 25 MGDBioP CarrouselSolids Handling59

Cayce WWTP, South Carolina Carrousel MDStart-up Plant Flow Intermediate Plant Flow Design Influent Plant Flow WAS concentration Design digestion SRT 8 MGD12 MGD25 MGD 10,000 mg/l20 daysMembranemodules inSeries60

Cayce WWTP, South Carolina Carrousel MDBenefits:Eliminated Construction of a thickener building Reduced number and size of digesters by operating at 4% TS Provided flexibility for a gradual flow increase. Reduced O&M costs by eliminating use of polymer for thickening Reduced O&M costs due to lesser aeration / energy needs. Reduced O&M costs due to lesser supervision needs. Safeguard high quality BioP Carrousel effluent 61

ConclusionsAerobic digestion processes using membrane thickening offer superior thickeningperformance without the use of polymer compared to other technologies Membrane thickening processes require very minimal operator attentionPermeate produced from membrane thickening processes contain very low nutrientlevels and can be sent to disinfection or to the head of the plant withoutcompromising the performance of upstream BNR activated sludge processes. Membrane thickening processes feature many financial benefits such as savings onhauling cost, operating cost, energy costs, and ideal for retrofits eliminating cost ofbuilding new tanks. Aerobic Digestion using Membrane Thickening is SOS,Sustainable Operating Solution62



Aerobic Digestion Process. Class B Of Meeting While Digesting Thicker Sludges The Challenge. VOL I 1997. WORKSHOP DIGESTION AEROBIC. CD-ROM recognized as the industry leader in aerobic digestion and thickening at high solids concentrations. Digestion Expertise. 4.

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