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WEFTEC 2019 MBR and Aeration Blower True Costs

Aeration Blower True Costs

The exhibition stands and speeches will provide substantial insights into the true costs of aeration blowers. A guide to each relevant exhibit and speech has been prepared. A networking directory to insure the most efficient interface with knowledge sources is also provided. This guide is being continually updated.
WEFTEC 2919 Municipal Wastewater True Cost Guide

In order to facilitate the discussions an extensive analysis Municipal Wastewater Blower True Costs is being made available to attendees. Feel free to submit case histories and comments to add to the analysis.

Important questions are:

  • Which blower type is best fitted for a specific application? high speed turbo, screw compressor, rotary blower, or single stage centrifugal?
  • Choice of magnetic or air foil bearing design
  • Drives, controls
  • Application developments such as nitrification, process control
  • Multiple vs single blower
  • Site specific variables such as electricity cost, flow variation, plant life

To contribute to the analysis and guide contact Bob Mcilvaine 847 226 2391 email: This email address is being protected from spambots. You need JavaScript enabled to view it.

 

WEFTEC Municipal Wastewater Membrane Bioreactor True Cost Guide

The exhibition stands and speeches will provide substantial insights into the true costs of membrane bioreactors and components. A guide to each relevant exhibit and speech has been prepared. A networking directory to insure the most efficient interface with knowledge sources is also provided. This guide is being continually updated To view the contents Click Here

To contribute to this guide contact Bob Mcilvaine 847 226 2391 email: This email address is being protected from spambots. You need JavaScript enabled to view it.

A market report on membrane bioreactors is also available. For Details on the report Click Here                        

The very substantial  body of information from WEFTEC 2018 is shared at 
Municipal Wastewater Treatment Update

 

N121 MBR Markets and Strategies:   $3,900.00/yr online ($150.00 Each Additional User)   Click here to order
Continually updated analyses and forecasts of membrane bioreactor systems  and membranes  in 80 countries and regions with separate forecasts for each application from food  to municipal wastewater.  Updates, Directory, Market Shares, Recorded Webinars. Application Analyses and silobuster programs are included.

              For Details on the report Click Here                         For details on the Municipal wastewater MBR Silobuster program at WEFTEC Click Here

Mcilvaine Logo 1 North American Municipal Wastewater Treatment Updates
  No. 4   March 9, 2018

Table of Contents

  • What are the most important and most difficult municipal wastewater combust flow and treat decisions?
  • Municipal Wastewater Plants to Spend $64 billion for Flow and Treat Equipment This Year
  • Municipal Wastewater Decisions System Intelligence database has the support information

 

What are the most important and most difficult municipal wastewater combust flow and treat decisions?

Mercury removal: The goal of the Municipal Wastewater Decisions service is to assist operators and suppliers with the most important and difficult decisions.  It is all part of a concept built around the Industrial Internet of Wisdom (IIoW).  Connecting people and knowledge in an organized system is just as important as connecting things.  Mcilvaine is creating decision systems around specific industrial processes and specific technologies.  An example for a process is municipal sewage sludge incinerator mercury removal  Sewage Sludge Incinerator Decisions

The Gore mercury removal module offers an alternative to carbon absorption and has been incorporated in many new incinerator air pollution control systems.  The best mercury removal option is in turn related to the choices for particulate removal, organic vapors and acid gases.  Therefore the sewage  sludge  mercury removal decision should be made based on insights from three technology decision systems which Mcilvaine has been compiling for 44 years :  1ABC Fabric Filter; 2ABC Scrubber/Adsorber/Biofilter Knowledge Systems; 3ABC FGD and DeNOx Knowledge Systems; 4ABC Electrostatic Precipitator Knowledge Systems

Cement silo:  IIoW needs to break the silo barriers between industries. The municipal wastewater decision makers need to be aware of developments in other industries.  For example, sewage sludge can be combusted in solid fuel boilers or cement kilns.  One Chinese cement producer is breaking the silo barrier and contracting to handle sludge from municipalities.  It optimizes the dewatering and transport condition for the sludge and then directs it to the nearest cement kiln to be used as a fuel. Therefore, the cement mercury removal decisions system becomes relevant.  Cement plants have varying quantities of mercury in the limestone used to make cement.  So, they already are dealing with the mercury challenge. They now have one new technology to consider which is the catalytic filter to remove acid gases, NOx, and particulate.  The catalytic filtration decision guide therefore becomes relevant.  The glass industry has standardized on this approach.  So, a guide for glass furnace emission control becomes an attractive silo to penetrate.

Natural gas silo: Mcilvaine was hired by Petronas to advise on better ways to remove mercury from natural gas.  No novel breakthrough was uncovered. Petronas then decided to fund research in the UK. A new solution using ionic liquid impregnated pellets was developed.  It has proven to be a better choice than carbon pellets for natural gas mercury removal.  Therefore, municipal wastewater decision makers need to penetrate the natural gas mercury removal silo and see if there are advantages for sludge combustors.

Co-locaton of MWWTP and solid fuel combustors: The solid fuel burning decision silo needs to be penetrated for the huge synergy between municipal wastewater operators and generators of steam and electricity.  In the U.S. the average distance between a municipal wastewater plant and an appropriately sized solid fuel combustor is only 70 miles. Many power plants already use treated municipal wastewater for cooling and other purposes. Sewage sludge is often burned in solid fuel combustors.  The development of the catalytic filter for solid fuel combustors opens up a new opportunity based on co-location of sewage treatment plants and solid fuel generators. This filter results in clean hot gas at 850F.  The heat can be beneficially extracted and used in the co-located MWTTP.   One proven application is steam drying of sewage sludge. The sludge from the MWTTP is combusted in the solid fuel boiler and the treated wastewater used by the power plant.

This sewer mining concept dictates the location of an expansion of the MWTTP at a power plant rather than at the existing facility.  Sewer mining is already an accepted approach in Australia and some other countries.  In Asia where lots of new coal fired boilers and municipal wastewater plants are being built this co=location is particularly attractive.  India has a major water problem. So, the co-location is particularly attractive in this country.  Much of the technology for this co-location is covered in   Coal Fired Decisions.

Drier sludge at minimum cost and energy consumption:  There are lots of factors in improving energy efficiency in the sludge dfeatering process.  For WEBTEC 2013 Mcilvaine created a Global Decisions Positioning System to guide visitors seek to address this problem.  It included stops at the relevant exhibition stands and attendance at the relevant papers.

pic1

Aeration Blowers  There is an aeration blower decision guide which is being continually updated Aeration Decisions.. This analysis compares the performance of all the different blower types over a range of applications.  Here are some of the important preliminary conclusions:

  • Larger blowers are being replaced with multiple smaller ones which better address the fluctuating loads
  • Turbo blowers and low pressure screw compressors are gaining market share
  • Energy efficiency incentives are being offered in Asia and Europe as well as the U.S.
  • Electricity costs in many countries are twice as high as the U.S
  • Third party operators have a big incentive to reduce energy costs
  • More plants are operated by third parties in Asia than in the U.S.
  • The design of the aeration system has a big influence on blower sizing
  • The large majority of blower purchases worldwide are for replacement of either just the blower or the whole system.  A relatively small % of the blower purchases are in countries with the largest growth percentages for treatment additions. Therefore the U.S. and countries with large treatment capacity remain the big markets

Treatment Chemicals: Polymers to dewater sludge are a big expenditure.  As per the diagram above there is a balance needed to provide the best combination of dewatering chemicals and equipment.   A filter press and less chemicals can be compared to centrifuge or belt press and more chemicals.  The use of treated municipal wastewater for industrial purposes has created decision requirements for anti-scalants in the RO systems conditioning municipal wastewater for industrial use.  Corrosion control is needed if secondary wastewater is going to be used in cooling towers.

Odor Control:  The decisions regarding odor control for municipal wastewater plants are challenging because

  • Odor control problems extend from the lift station to the treatment plant and the many treatment processes
  • A wide range of odor causing compounds are likely
  • Odors comprise the most neighborhood complaints
  • Odor measurement is subjective and not quantitative
  • Many technology options are available which complicates the choice
  • Capture of the ambient odors with the highest efficiency and lowest amount of air is challenging
  • There are choices between options for treatment of the waste to avoid odor emission vs treatment as an air contaminant

Mcilvaine has decision systems on air monitoring and also on scrubbers, adsorbers, absorbers and biofilters which have been continuously updated since the late 1970s. 1100 articles on odor control are included in the Scrubber Adsorber intelligence system.  Here are some article titles and key factors:

Evoqua Introduces New WHISPER™ Biofilter System for Quiet and Effective Odor Control in Residential Locations Key factors: 99% H2S removal at up to and exceeding 100 ppm, efficient nutrient removal, variable speed fan, turnkey service and monthly rental

Bionomic’s Latest Edition Series 5000 Packed Tower Scrubbers Are Match Engineered to Precisely Meet the Most Demanding Gaseous Contaminant, Odor Reduction, Mist Removal, and Process Requirements. Factors: ability to match packing selection to the site specific conditions

PRD Tech’s Biotrickling Filter Controls Odors: Factors: biotrickling filter vs just biofilter or alternatives

Here Is the comparison provided by KCH

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Here is the comparison of biotrickling and biofiters by Envirogen: Biotrickling Filters are vertically-oriented vapor-phase bioreactors filled with an inorganic media featuring 100% recirculation. The filters’ unique design can address high concentration of H2S odors in areas where space is at a premium – offering a shorter retention time and treatment of higher air volumes than conventional biofilters. They can also treat high concentrations of VOCs and ammonia, and be chemically augmented when needed.

The decision system for odor control in municipal wastewater plants is supported by decision guides on scrubbers, adsorbers, monitoring, and ventilation design as well as for H2S treatment of liquids to prevent emissions.

IIoT and Remote O&M: MWTTPs can greatly reduce cost of operations through the use of the Industrial Internet of Things empowered by the Industrial Internet of Wisdom which includes the decision guides.  Detailed coverage of this opportunity is provided in a free recording https://youtu.be/AWB-vZIj5gk

A free webinar to discuss the municipal wastewater flow and treat market and the sea change in the way purchasing decisions will be made will be held at 10:AM Central time on the March 28.  To register click on Free Market Webinars

Municipal Wastewater Plants to Spend $64 billion for Flow and Treat Equipment This Year

Municipal wastewater treatment plant operators world-wide are anticipated to spend $64 billion for selected flow and treat products and services this year. The majority of these purchases will be made by just 200 operators and 30 engineering/consulting firms.

Suez is supplying more than 30 million people with water and wastewater services.  They are also designing plants and purchasing flow and treat products for new as well as existing plants. Beijing Enterprises Water Group (BEWG) operates more than 400 wastewater plants in China and other countries and is also involved in design build projects where they would specify flow and treat products. Chicago MSD operates seven wastewater reclamation plants.  It is also expanding its scope by encouraging nearby food processors to send waste to the plant for conversion to biogas. This will increase its sludge processing, compressor and air pollution control purchases.  Los Angeles Sanitation’s operations are approximately half the size of those in Chicago.

2018 Municipal Wastewater Purchases
$ millions

 

World

U.S.

Suez

Jacobs

CH2M

BEWG

Los Angeles

Chicago MSD

Guide 5280 1100 106 63 33 11 22
Control 8640 1800 173 104 54 18 36
Measure 4320 900 86 52 27 9 18
Valves 4800 1000 96 58 30 10 20
Macrofiltration (belt presses, sand filters) 2400 500 48 29 15 5 10
Pumps 9600 2000 192 115 60 20 40
Treatment Chemicals 6720 1400 134 81 42 14 28
Sedimentation and Centrifugation 4320 900 86 52 27 9 18
Variable Speed Drives and Motors 4800 1000 96 58 30 10 20
Turbines, Fans, and Compressors 10560 2200 211 127 66 22 44
RO/UF/MF Cross Flow Membrane Systems 1200 250 24 14 7 3 6
Air Pollution Control 960 200 19 12 6 2 4
Total 63,600 13,250 1271 765 397 133 266

McIlvaine is forecasting flow and treat product and service expenditures for all industries and for 550 operating companies and 400 OEMS, EPCs and process sub system companies worldwide.   Municipal wastewater is one of 14 industries which are covered. The wastewater purchases in many countries are concentrated among just a few operators.  Suez operates more than half the plants in Chile. In the U.S. the engineering/consulting firms play a big role. 

There is a metamorphosis in the way purchases will be made in the near future. Process management system suppliers are providing monitoring and control of every valve, pump and filter from remote monitoring centers.  Suez is monitoring hundreds of plants from its European base.  The equivalent of millions of total lowest cost of ownership analyses are continually generated.  This development will profoundly change the route to market as explained in N031 Industrial IOT and Remote O&M.

Profiles of the 100 largest operators and EPCs worldwide are included in 62EI North American Municipal Wastewater Treatment Facilities and People Database  which is being expanded to include the major worldwide purchasers.

A decision system for municipal wastewater flow and treat purchases includes a number of decision guides. One is on aeration blowers.  Another system provides the odor control options. There is a guide just on mercury control options for sewage sludge incinerators Details are found at  Municipal Wastewater Decisions.

Detailed forecasts for each of the 550 major purchasers are shown in the relevant market reports listed at http://home.mcilvainecompany.com/index.php/markets

 

Municipal Wastewater Decisions System Intelligence database has the support information

Case histories and papers are being uploaded to the intelligence system. Here are some samples:

Advantages of new Kaeser rotary screw blower package

In addition to many advantages cited in the article, the rotary screw blowers are available with variable speed control managed by the Kaeser Sigma Control 2™ system. This advanced controller comes standard with multiple pre-programmed control profiles so wastewater treatment plants can select the one best fitting their application. The control system monitors more than twenty critical operating parameters on each unit. Many if not all aeration blower applications require a total system controller. Kaeser’s Sigma Air Manager (SAM) can control up to 16 blowers and only turn them on as needed. The SAM system allows the blowers to be controlled based on dissolved oxygen levels or other WWTP performance targets. While the desired levels of DO, NH4 and NO3 remain the same, the amount of air required to maintain those levels varies based on a wide range of factors such as ambient temperature and humidity. The SAM system automates and optimizes the blower’s wire-to-air efficiency while delivering the required oxygen.

Revision Date:  12/29/2017

Tags:  221320 - Sewage Treatment Facilities * , Kaeser Compressors, Inc., Blower, Controls


Neuros blower performance evaluated by CDM at Franklin, N.H.

The advantages of high speed turbos compared to PD blowers were analyzed bases on a demonstration by Neuros. 32 % higher efficiency was demonstrated by the direct drive unit and close to 50% higher efficiency achieved with D.O monitoring and control.

Revision Date:  12/29/2017

Tags:  221320 - Sewage Treatment Facilities * , Camp Dresser & McKee, Blower, Aeration


Multi stage centrifugals replaced at City of Altamonte Springs, FL

• The City of Altamonte Springs Regional Water Reclamation Facility (RWRF) has a permitted design capacity of 12.5 million gallons per day (MGD) on an average annual daily flow (AADF) basis. The current AADF is approximately half of the permitted value and the facility maintains consistent compliance with regulatory agency permit requirements related to effluent quality. • takeaways • Older multistage centifugals replaced with more efficient selections • Either turbo or rotary blowers recommended for the process • Concerns about complexity of turning down volume with multi stage centrifugal • Install centralized aeration control system • Rotary blower with VFD recommended for aeration in sludge holding tank where load fluctuations offer potential for energy savings.

Revision Date:  12/15/2017

Tags:  221320 - Sewage Treatment Facilities * , Tetra Tech, Aeration Blower, Blower, Aeration


High speed blowers for Garland Texas wastewater

High speed blowers were installed at Garland Texas and reduced energy consumption compared to the previous multi-stage blowers. The control system has been optimized to utilize several blowers in the most efficient manner. The high speed blowers had a higher initial cost but a 2 year payback on energy savings.

Revision Date:  12/15/2017

Tags:  221320 - Sewage Treatment Facilities * , Perkins Engineering Consultants, Aeration Blower, Blower, Aeration


Activated Sludge Plant Study Guide

Study guide prepared for educators and operators provides useful background information on factors affecting choice of aeration components.

Revision Date:  12/6/2017

Tags:  221320 - Sewage Treatment Facilities * , AECOM, Aeration Blower, Blower, Aeration


Process simulator evaluates blower and valve control strateigies This paper will introduce the process of calculating and incorporating pressure

This paper will introduce the process of calculating and incorporating pressure losses, blower speed and valve positioning into the activated sludge model simulation, quantify the control response for conventional and innovative control strategies, and demonstrate the benefits of flow-based blower control schemes versus pressure-based blower control. The design of the aeration system has become one of the most important aspects of the design of the activated sludge process, but process engineers only have commercially available process simulators with activated sludge and aeration models to calculate dynamic process requirements, not the actual equipment requirements for an aeration system. It was demonstrated that the process of calculating and incorporating pressure losses, blower speed and valve positioning into the activated sludge model allows the engineer to see them change as the influent process conditions change diurnally and seasonally, so equipment can be sized accordingly. Using the combined models for control valve sizing, estimating the pressure requirement for the blower, and comparing the dynamics of three different types of aeration control methods was also demonstrated. At this point, the aeration system model could not be compared to actual operational data. A comparison would be valuable, and should be done to determine the overall accuracy of the model. However, the valve, blower and pressure models were developed using methods already used in design, which gives confidence that the models as used in the paper would provide an accurate design tool.

Revision Date:  12/6/2017

Tags:  221320 - Sewage Treatment Facilities * , BioChem Technology, Software, Blower


Rohm and Haas reduces aeration costs through optimization

Rohm and Haas Company was able to drastically reduce O&M costs for their Aeration System by focusing on Reliability Engineering and Optimization at their WWTP. The costs reductions were a team effort and have resulted in a wide variety of benefits for Rohm and Haas and for the people associated with the WWTP. This initiate also revealed several interesting points relating to the design and operation of WWTPs: • Good data, particularly D.O., air flow and blower amps can help optimize operations and reduce energy costs. Without this data, plants may be wasting energy unnecessarily by adding to much air. • Existing blowers may be operating very inefficiently even if they are throttled or controlled to maintain D.O. setpoints. • If plants are designed for conservatively high present or future peaks loadings, the result will be an inefficient operation with oversized components unless good turndown is incorporated into the design. If designing for peak conditions, the use of different size blowers is strongly recommended.

Revision Date:  12/5/2017

Tags:  325000 - Chemical Manufacturing , Rohm and Haas Company, Optimization, Blower, Aeration Blower, Aeration


Wide Variety of Valves for Water and Wastewater Treatment Plants

This 8 page listing includes details on gate valves in various different size ranges. Here is just the specification for the small valves. Gate Valves 1-1/2 Inches in Diameter and Smaller: 125 psig; bronze; rising-stem; single-wedge; disc type; screwed ends; such as Crane No. 428, or approved equal. Coatings for Gate Valves 2 Inches and Larger: AWWA C550; Indurall 3300 or approved equal, non-toxic, imparts no taste to water, functions as physical, chemical, and electrical barrier between base metal and surroundings, minimum 8-mil-thick, fusion-bonded epoxy. Prior to assembly of valve, apply protective coating to interior and exterior surfaces of body. The specification also includes plug valves, butterfly valves, air release and pressure reducing valves. Many of these valves are general performance valves sold primarily by price. However, a number of valves used in slurry lines and for sensitive control are high performance valves sold on the basis of lowest total cost of ownersh8ip. We will endeavor to identify those applications and pursue cost of ownership aspects for them.

Revision Date:  12/5/2017

 

WEFTEC Odor Control Exhibitors

BioAir Solutions, LLC

Booth 544

BioAir Solutions: Global leader in odor and air emissions control for municipalities & industry, specializing in advanced biotrickling filter technology. With global installations, unparalleled process experts, and a focus on R&D, BioAir remains the world’s leading provider of Total Odor Solutions.

Chris West

www.bioairsolutions.com

110 Kresson Gibbsboro Rd, Suite 303
Voorhees, NJ, 08043
USA

Phone: (856) 258-6969 x101

 

Cabot Norit Activated Carbon

Booth 3434

Cabot Norit Activated Carbon is a global leader in the research, development, manufacturing and sale of hi-grade activated carbons and equipment systems. Our products are used to efficiently remove impurities from air, water and other liquids and gases.

www.cabotcorp.com

PO Box 790
Marshall, TX, 75671-0790
USA

Phone: (800) 641-9245

 

CMI Environment America

Booth 4351

CMI Environment America, specialist in the treatment of odors, VOCs, harmful and corrosive gases, puts all its know-how at your disposal to both design and supply the best technical and economic solution to your specific problem. It offers tailor-made solutions dedicated to odor control and gas pollution removal through a unique combination of technologies, expertise and equipment: gas scrubbing, biofiltration/biotrickling filtration, activated carbon filtration/adsorption and air stripping systems (including Recov'Ammonia equipment).

Pierre Mertens

www.amcec.com

2525 Cabot Drive
Lisle, IL, 60532
USA

Phone: (630) 577 0400 x 213

 

Continental Carbon Group

Booths 1007

CCG designs and manufactures advanced adsorption systems for air filtration/odor control. We work with consulting engineering firms and end users across North America in the municipal, industrial, institutional and commercial markets and employ technical staff with many decades of experience in a variety of treatment applications.

Deepak Angl

www.continental-carbon.com

321-1100 South Service Road
Stoney Creek, ON, L8E 0C5
CAN

Phone: (905) 643-7615

 

Daniel Company

Booth 901

Daniel Company is the premier manufacturer of Odor Control Systems in the United States. We specialize in the design and manufacturing of biological scrubbers, biofilters, chemical scrubbers, and carbon adsorbers. We also manufacture chemical storage tanks, decarbonators, FRP pipe & duct, dampers, and flexible connectors, etc.

Mr. Jack Moser

www.danielmechanical.com

1939 W. 11th St, Ste E
Upland, CA, 91786
USA

Phone: (909) 982-1555

 

ECS

Booth 2345

ECS Environmental Solutions offers a complete line of odor control systems and accessories with unique in-house manufacturing capabilities.

Carrie Jones

www.ecs-env.com

2201 Taylors Valley Rd; PO Box 127
Belton, TX, 76513
USA

Phone: (254) 933-2270

 

Fab-Tech, Inc.

Booth 7547

Fab-Tech, Inc. manufactures PermaShield Pipe (PSP®), a Factory Mutual approved duct system that combines the reliable strength of stainless steel, superior corrosion resistance of a fluoropolymer coating on interior surfaces and an array of innovative fittings for safe, reliable and clean corrosive fume and odor control exhaust duct. Fab-Tech has the capacity to meet your schedule when delivery is critical, installs clean to save you valuable time and money, Class 1A AMCA low leakage dampers and largest selection of accessories for fast and easy installation. PSP® is the only coated duct product available with "0" Flame Spread rating.

Mike Baranski

www.fabtechinc.com

480 Hercules Drive
Colchester, VT, 05446
USA

Phone: (802) 233-7625

 

GES Biotek

Booth 3762

GES Biotek LLC supplies bio-oxidation media, and related services, to the odor control industry. The latest innovation is an engineered, nutrient rich, lightweight open-cell media made from recycled glass, which provides significant savings to the end user.

www.gesbiotek.com

1540 Louis Bork Dr
Batavia, IL, 60510-1512
USA

 

Indusco Environmental Services, Inc./RVT Process Equipment

Booth 2907

Design - Engineering - Fabrication - Integration - Service - Modification Scrubbers - Odor Control - Systems - Packed Bed - Venturi - Modular - Carbon Tanks - Fans - Ductwork - Dampers - Stacks - Pumps - Controls - Panels - Design and supply of air pollution control scrubbers and chemical process systems since 1983.

Dan Vaughan

www.induscoenviro.com

30914 Jay Drive
Spanish Fort, AL, 36527
USA

Phone: (251) 621-2338

 

KCH Engineered Systems

Booth 438


With a mission to "engineer tomorrow's needs today," KCH Engineered Systems is one of the country's leading manufacturers of odor control systems, ground water degasification and corrosion resistant ventilation systems. KCH Engineered Systems will be unveiling their latest addition to their product line which is POLYSTRONG™ and POLYLAST™ materials. These are primarily used in the fabrication of odor control systems such as degasifiers, carbon adsorbers, biotricklers, and wet scrubbers. Additionally, KCH specializes in AMCA approved corrosion resistant fans and duct exhaust systems.

www.kchservices.com

144 Industrial Dr
Forest City, NC, 28043-9675
USA

 

Monroe Environmental Corp

Booth 1701

Monroe Environmental designs and fabricates circular clarifiers/thickeners, parallel plate clarifiers, plate settlers, sludge collectors, air strippers, odor control scrubbers, and many other pollution control systems. We offer initial evaluation, testing, engineering, installation, and on-site support.

Sales

www.mon-env.com

810 W Front Street
Monroe, MI, 48161-1627
USA

Phone: (800) 992-7707

 

OMI Industries

Booth 3601

OMI Industries specializes in natural odor control using our patented Ecosorb™ technology. We are able to engineer solutions that solve a variety of organic and inorganic odor control issues, from year-round odor problems due to a production process, seasonal odor problems due to temperature, occasional odor problems due to a particular project or any other unique odor challenges you face. From landfills to hotel rooms, oil refineries to municipal wastewater facilities, even off-the-shelf products, no odor eliminator is more adaptable to specific situations, or more effective at removing malodors safely and quickly without the use of harsh and hazardous chemicals, expensive emission control systems or fragrant masking agents.

Ms. Barbie Chmieleski

www.omi-industries.com

One Corporate Drive, Ste 100
Long Grove, IL, 60047
USA

Phone: (847) 304-91

 

Paques Environmental Technologies Inc.

Booth 4004

Paques is a leader in biological wastewater and gas treatment. Paques biotechnology helps companies reduce fresh water intake, decrease their carbon footprints and reclaim valuable resources from waste. Thanks to its low total cost of ownership over 200 of Paques’ THIOPAQ® scrubbers have been installed for biogas and landfill gas treatment for hydrogen sulfide loads from approx. 100 up to 40,000 lbs/d.

Martin Tielbaard

www.paques-inc.com

2400 District Avenue, Suite 330
Burlington, MA, 01803
USA

 

PureAir Filtration

Booth 2210

Manufacturer of customizable odor and toxic gas adsorbent systems. PureAir system are 99.9% efficient at removing odors and toxic gases.

Kevin Jameson

www.pureairfiltration.com

6050 Peachtree Pkwy Ste 240-187
Norcross, GA, 30092
USA

Phone: (678) 935-1431

 

Raschig USA, Inc.

Booth 6839

Raschig USA Inc. is a manufacturer of fixed film products for attached growth biological treatment of wastewater. These products include trickling filter (biotower, nitrification, etc.) media, moving bed biological reactor (MBBR/IFAS) media, submerged bed media, oil/water separators, tube settlers, etc. Raschig USA also manufactures tower packings, both random and structured, for mass transfer applications such as scrubbers and strippers.

www.raschig-usa.com

2201 E LaMar Blvd Ste 240
Arlington, TX, 76006-7440
USA

 

RJ Environmental, An Evoqua Technology

Booth 4839

Evoqua, through the RJ Environmental product line, provides municipalities with a full range of vapor phase products that control odors at wastewater treatment plants and sewage pump stations and reduce odor complaints. Evoqua’s extensive knowledge, experience and product range enables us to customize the best solution for odor control needs with our trusted RJ Environmental branded ZABOCS® and BTF Biological Odor Control Systems, LO/PRO® chemical scrubbers, Midas® activated carbon systems, and our new Whisper™ Biological Odor System with non-degradable Bioglas™ media. Evoqua also supplies the Bioxide® Solution and a complete range of liquid phase treatments with automated dosing technology and remote monitoring for real-time visibility and control.

www.evoqua.com

210 Sixth Avenue, Suite 3300
Pittsburgh, PA, 15222
USA

 

Suncoast Electric Manufacturing

Booth 2611

Sun Coast Controls Mfg. manufactures high quality pump controls including level, pressure, constant, and variable speed. Sun Coast manufactures the complete line of Oda-Killa odor control products and markets Grease-Killa for F.O.G., corrosion, and site D.O. improvement.

Michael Gross

www.suncoastcontrols.biz

4130 N Canal St
Jacksonville, FL, 32209
USA

Phone: (904) 693-3318

 

Syneco Systems Inc.

Booth 4451

Syneco Systems, Inc. was founded in 1983 and is the manufacturer of odor control equipment including Peacemaker® dry air scrubbers and manhole scrubbers, which are used primarily in municipal and industrial wastewater collection systems and treatment plants. Syneco Systems manufactures the industry leading high H2S Patented Converting / Polishing media technology. Our Persnickety® Brand Converting Media is capable of converting gas phase hydrogen sulfide to a level of greater than 2,000 PPM+. The innovative Peacemaker® Line is designed for point source H2S control in municipal and industrial wastewater collection systems and treatment plants thus eliminating large and costly centralized scrubber systems.

Dan Falkman

www.synecosystems.com

7945 Stone Creek Drive Ste 50
Chanhassen, MN, 55317
USA

Phone: (952) 927-

 

Wedeco, A Xylem Brand

Booth 5939

Xylem's Wedeco brand is a leading manufacturer of ultraviolet water disinfection and ozone oxidation systems. Wedeco UV systems provide chemical-free standard and custom engineered solutions to the drinking water and wastewater market and Advanced Oxidation Process (AOP) solutions and ozone treatment solutions to customers worldwide.

Ralph Franco

www.wedeco.com/us

14125 South Bridge Circle
Charlotte, NC, 28273
USA

Phone: (724) 650-6004

North American Municipal Wastewater Treatment Plants Update

December 2017

We continue to pursue decision options for the systems and components used in municipal wastewater treatment. This month we are focused on biological treatment systems and their impact on blower requirements.  We are also analyzing the individual blower options. If you are a system designer, you need to consider all the system options and then consider the blower options for each system alternative.  One question is whether advances in blower technology will affect system decisions?  Full text from which some of the following articles were written is included in the Municipal Wastewater Intelligence System.

Biological Treatment and Aeration

Two Questions Relative for and about Organica

They have a system using growing plants to compete with activated sludge.  A number of wastewater plants in China and other parts of Asia and Europe have installed systems.  Blower energy requirements are said to be 30 percent less. We need to pursue this further.  Also, we need to assess their ability to remotely monitor and optimize their biological treatment system. Here is a summary and a link to the full text which is in the intelligence system.

The Organica Process Control System is a combination of instruments, input/output units, PLCs, operator stations and SCADA system to collect, analyze and display real time operational information and control the operation of a unique alternative to activated sludge processes for biological treatment.

Efficient operation requires quality data. Recognizing this important fact, Organica has developed an industry-first analytical software (designed by market-leading inCTRL solutions) to maximize data reliability, instantly evaluating and scrubbing “noise” from collected data. Based on a precise set of calculations and process models, this platform ensures accurate data reporting and documentation. Accessing this precise data, Organica can perform regular process simulations to identify improvements in operational strategy, and apply them remotely through the same software platform. These strategy changes often include set point adjustments, while the platform also supports remote PLC programming to acquire the most effective results.

Blower Technology Options

Juan Loera of Carollo compared blowers for sewage aeration pointing to the high efficiency of single stage high speed turbo.  It also is equal to or has more turndown than others except multi stage centrifugals. Rotary blowers have the lowest capital cost for at least smaller installations. The main question posed by him seven years ago was long term reliability.  We need input on this subject given the passage of time.  He also compares the different high-speed turbo designs based on bearings (air or magnetic), impeller design (milled or cast), cooling system (self-contained or external), controls (single point vs dual).  How important are these differences? ®Juan was not accessible at Carollo on LinkedIn. So, we need some input from whomever is pursuing this at Carollo as well as input from others who review the very detailed slide deck in the intelligence system.

Biological Aerated Filter comparison at San Diego

In 2005 a pilot study determined the potential to install either a Suez, Infilco Degremont BIOFOR® or a Veolia Kruger BIOSTYR®. Several choices included use of high rate clarifier thickeners and use the BAF to treat the effluent, mix BAF solids with primary sludge and treat with anaerobic digestion. Another alternative was to use the BAF to treat the chemically treated primary effluent to a secondary level.  Both units had high solids yields but some differences were identified. Also, the BIOSTYR air scour rate was higher.   A breakthrough of TSS in the BIOFOR unit indicated the importance of automatic backwash.  The tests established the ability of the systems to meet the goals.  The BIOFOR had somewhat better effluent quality. 

The study was conducted by Brown & Caldwell, we will be pursuing the latest insights from them and find out about their most recent experiences.

Aerzen Comparison of Blowers

The paper presents four types of blowers: two dynamic and two positive displacement machines. Since each technology has its place, a comparison is made specifically based on the treatment of wastewater. Taken into account are the daily and seasonal swings in oxygen demand, fouling and aging of diffusers, air flow control and turndown capabilities, total blower efficiency and energy consumption over time, mode of operation, blower accessories, and plant set-up. Each technology has its place and blanket efficiency statements cannot be taken at face value. With professional due diligence, the engineer will select the aeration blower technology based on a comparison of real operating data over time while being mindful that any machine must be capable of operating safely under extreme site conditions and at the highest pressure ratio over the entire flow range. With pragmatism and common sense, the engineer will also be mindful of the actual operation of the plant and the management of its processes.

AECOM Tests BAF vs MBBR with DAF at Portsmouth

AECOM conducted pilot tests at the City of Portsmouth relative to secondary treatment options. The Moving Bed Bioreactor (MBBR) process uses floating plastic carriers (media) within the aeration tank to increase the amount of microorganisms available to treat the wastewater compared to conventional secondary treatment. To provide clarification, the effluent from the MBBR reactor flows to a Dissolved Air Flotation (DAF) system. DAF systems inject air into the wastewater to create small bubbles. A polymer is added to help the biological microorganisms and other particles attach to the air bubbles and rise to the surface, where a skimmer removes them. Clarified water passes under the biomass on the surface, and then it flows out of the DAF unit.

The biomass is removed and returned to the plant’s solids handling process for further treatment. The MBBR process can be configured to provide secondary treatment as well as nitrogen removal. For nitrogen removal, the aeration tank is partitioned into different zones with different levels of oxygen, which allows the microorganism to remove nitrogen.

Reported Advantages Over Conventional Secondary Treatment Technology

  • Stable under varying amounts of wastewater
  • Small footprint due to larger biomass volume
  • Low concentration of solids in treated effluent
  • Easily expanded by increasing media fill percentage
  • Simple to operate

Potential Disadvantages/Concerns

  • Higher energy consumption and chemical costs than conventional clarifier
  • DAF typically performs best at constant flows, concern about varying performance with daily flow variation

The pilot system was furnished by Water Works. A BaF system supplied by “Veolia-Kruger was also tested.

Tertiary Treatment provides Water for Cooling at Minnesota Power Plant

A pretreatment strategy was the approach applied in the growing city of Mankato, Minn. The city installed a new water reclamation facility (WRF) to treat effluent from its wastewater treatment plant (WWTP), which would supply the cooling tower needs of an electrical generation plant.

 In addition to providing quality reuse water for the energy center, the WRF needed to meet new state phosphorus removal regulations. The solution involved two products from Veolia.

1.  The Hydrotech Discfilter is a mechanical, self-cleaning filter that offers a large filter area in a small footprint.

2. Efficient Filter: The BIOSTYR process combines biological treatment and filtration intoone compact system, removing ammonia and a majority of wastewater solids. The BIOSTYReffluent is then gravity fed into theDisc filters, which provide an ideal filtrationsystem for solids removal above 10 microns,thus producing much cleaner water needed for use in plant operations.

High Speed Turbos and Positive Displacement Blowers with VSD are Most Common Recommendations

A PG&E survey polled design engineers/vendors the question of “How often do you recommend the following types of blowers to your municipal WWT customers:

• positive displacement (constant-speed)

• positive displacement (variable-speed)

• multi-stage centrifugal

• single-stage centrifugal (constant-speed)

• single-stage centrifugal (variable-speed)

• high-speed turbo blower

The results for the surveyed vendors/distributors were as follows:

• Designers: High Speed Turbo Blowers and Positive Displacement Blowers with VSD were the more common blowers, typically recommended ~50% of the time to customers, but unclear whether customers selected this for installation

• Vendors: High Speed Turbo Blowers and Positive Displacement Blowers with VSD were the more common blowers, typically recommended ~50% of the time to customers, but unclear whether customers selected this for installation

Pacific Gas & Electric offers Incentives to replace Blowers

PGE is offering up to $150,000 at 8 cents/kwh for energy improvements at wastewater plants. Single stage blowers with variable inlet vanes and variable discharge diffusers can allow for flow adjustments while maintaining constant impeller speed. VFDs may also be appropriate for application to aeration blowers.  This compares to the base case with multi stage centrifugals to set the incentive amount.

Rohm and Haas reduces Aeration Costs through Optimization

Rohm and Haas Company was able to drastically reduce O&M costs for their Aeration System by focusing on Reliability Engineering and Optimization at their WWTP. The costs reductions were a team effort and have resulted in a wide variety of benefits for Rohm and Haas and for the people associated with the WWTP. This initiate also revealed several interesting points relating to the design and operation of WWTPs: • Good data, particularly D.O., air flow and blower amps can help optimize operations and reduce energy costs. Without this data, plants may be wasting energy unnecessarily by adding to much air. • Existing blowers may be operating very inefficiently even if they are throttled or controlled to maintain D.O. setpoints. • If plants are designed for conservatively high present or future peaks loadings, the result will be an inefficient operation with oversized components unless good turndown is incorporated into the design. If designing for peak conditions, the use of different size blowers is strongly recommended. (see the intelligence system for this older article which was included because it has very detailed discussion of the individual initiatives employed)

Wastewater Aeration Blower Integration

Stephen Horne of Kaeser, writing in Blower & Vacuum Best Practices, discussed the approach to integration.  System integration comes from relying on a system master controller to properly control individual blower packages. The advanced master controller is programmed with the performance information on each blower and it then selects the most efficient combination of blowers to meet the current demand. It can also rotate packages to balance load hours, spreading out preventive maintenance intervals.

Components

Salem solves Wipes Clogging of Lift Station with Barnes Solids Handling Pump from Crane Fluid Systems

The Town of Salem is a small, rural community located in southeast Wisconsin. The municipality manages 25 lift stations. Lift station #18 is a triplex station and was clogging weekly mostly due to flushable wipes. Crane Pumps & Systems provided a Barnes 4SHVA 30HP Solids Handling pump as a demo replacement for the station in September 2013. The pump was installed a month later. The next time the pump was pulled was October 2014 for its annual maintenance.  Today’s non-biosolid laden wastewater requires new technology to keep the stream flowing. The Barnes SH Series with its non-recessed vortex impeller was the easiest, and it turned out to be the best option for Salem. It is estimated that the pump paid for itself in the first six months of operation.

The pump continues to be clog-free for over a year

Aerzen has Remote Monitor with Alerts

The Aerzen iAir Remote Monitoring System (RMS) is a comprehensive monitor that can be attached to any blower or compressor to capture real-time activities and conditions. Based on industrial cellular technology, the RMS can function in any location with cellphone coverage for both indoor and outdoor applications. The iAir Remote System reviews the actual usage of the equipment and sends alerts and reminders via text or email directly to the user. 

Sage is supplying Thermal Mass Flow Meters to replace Orifice and Vortex Meters

A successful aeration control system is dependent upon the efficient operation of its system components. The components for each region may include an air flow valve, air flow meter and DO (dissolved oxygen) meter. The valve, commonly a butterfly valve, is usually installed downstream of the flow meter. Much of aeration control is predictive, as there is a nonlinear relationship between the airflow and dissolved oxygen content which creates a lag time to reach equilibrium.  Three technologies are used to measure aeration airflow: orifice plates, vortex shedding, and thermal mass flow meters. The thermal mass flow meter is the preferred method to measure airflow at wastewater treatment facilities. They require lower maintenance, are easier to install and save on energy costs. As older aeration systems with vortex and orifice meters are being replaced or upgraded, thermal mass flow meters are being integrated into the systems.

Flowseal high performance butterfly valves are a standard in many industries including heating, ventilating and air conditioning, power generation, hydrocarbon processing, water and waste water treatment and marine and commercial shipbuilding. Their products are also installed in applications as diverse as food and beverage processing, snowmaking and pulp and paper production. Configurations are available for harsh conditions as well as applications requiring nominal pressure and temperature ratings.

New APG-Neuros Turbo Blower Remote Monitoring System

APG-Neuros, the leading manufacturer of high-efficiency turbo blowers offers the Remote Monitoring System to its customers for monitoring blower operation through real-time data using a VPN or a dedicated router. The system can be installed at the managed communication/Ethernet switch at an individual blower, master control panel or SCADA level to fit different plant needs and configurations. The Remote Monitoring System is easy to deploy with minimal to no interruption to the plant’s system or operations. The real-time data is streamed through secure network to the cloud or APG-Neuros’ servers for monitoring and diagnostics of operational issues. All the parameters are monitored remotely by APG-Neuros engineers to ensure optimized aeration system and blower operation, analyze trends and detect any abnormalities.APG-Neuros demonstrated energy efficiency by replacing competitor’s blowers in Nice, France, Narragansett Bay Commission, and Lowestoft, U.K. (Anglian Water).

With approximately 1,000 units installed and over 100 on order, their installations enjoy the highest success with large cities including Washington D.C., NYC, London (U.K.), Vancouver (B.C.) and Mexico City

EDI and BioChem Partnership provides Holistic Approach to Aeration Control

BioChem introduced its patented Bioprocess Aeration Control System (BACS) in 2009.

Since then it has proven its effectiveness, efficiency and reliability in dozens of applications as a standalone subsystem to control the production and distribution of the aeration process.  BACS is not the standard proportional integral (PI) loop utilizing high speed trial and error based control actions to chase the desired set-point.  Rather BACS is an intelligent system which actually calculates the volume of air required to maintain the DO setpoint by analyzing the process metabolism in real-time.  In fact, because of system response times, it is necessary to know what the oxygen demand will be 15 minutes from now in order to effectively maintain the proper DO concentration.   BACS does this.  It has a Predictive element in its nature.

With BioChem's EDI partnership a new more holistic concept to process design and control was introduced.  This new concept called Symphony considers all the critical subsystems required to control the biological treatment process utilizing digitized intelligence throughout.  The goal is to achieve unprecedented economy and performance while providing practical, actionable information to manage the plant by incorporating such features as fault detection and isolation (FDI) and Reliability Centered Maintenance (RCM). 

EDI, headquartered in Columbia, Missouri has been a leader in the development, manufacturing, and installation of advanced aeration products and solutions for over 40 years.  

EDI's Chairman, Charles Tharp provided this rationale for the partnership:  "This represents a major expansion of EDI's capability to deliver superior aeration mixing solutions for biological treatment systems.  The combination of predictive aeration logic and premium EDI aeration hardware will deliver unprecedented levels of performance in biological and aeration systems."

George Lee, BioChem's longtime CEO and the father of its innovative technologies, and newly appointed CTO stated: "BioChem will continue to expand its knowledge and apply its core competencies in the complex and nuanced bio-chemical dynamics in the wastewater segment.  The partnership with EDI for the distribution of our control solutions allows us to more quickly realize our shared goals and vision; which is to essentially transform the way wastewater treatment systems are built and operated, so as to incorporate the most advanced, efficient and effective wastewater treatment strategies that modern technology allows. 

Florida Wastewater Plant saves $20,000 /yr with Predictive Aeration Control

The Camelot WRF located in the City of Kissimmee Florida was upgraded from a 3 MGD MLE process to a 5.5 MGD (average annual daily flow) facility.

To extend the facility's aeration capacity, the plant installed a bank of four 125 hp turbo blowers - each theoretically capable of delivering 2650 SCFM at 8 PSI with a rise to surge of 1.5 psi. The facility is unmanned at night and requires robust automation and remote monitoring capabilities. Additionally, the facility experiences a hydraulic and ammonia loading peaking factor of approximately 1.5 and 1.6 respectively, presenting an excellent opportunity for a DO/aeration control system. To accommodate these requirements and opportunities, the Bioprocess Aeration Control System (BACS) was integrated into the plant's existing SCADA network and commissioned over a 1-week period. 

The BACS adjusts the valve position of each of Camelot's six aeration control zones and trims the blowers up and down in order to maintain the plant's user defined zone specific DO setpoints using BioChem's patented Oxygen Uptake Rate Factor (OURf) technology and energy saving field tested Most Open Valve logic.

The data reveals an aeration savings of approximately 23.8% over a manual control baseline.  Given the facility's electricity cost of .11 $/kWh, this translates to a savings of approximately $21,300 annually. 

Wide Variety of Valves for Water and Wastewater Treatment Plants

Some of the articles in this Update reference butterfly valves used to control air in the aeration processes. Valves used for air and gases are small in number compared to the many valves involving liquids in a wastewater plant.  We are including the water line valve specifications for the City of Pearland in the intelligence system. This eight-page listing includes details on gate valves in various different size ranges.  Here is just the specification for the small valves.

Gate Valves 1-1/2 Inches in Diameter and Smaller: 125 psig; bronze; rising-stem;

single-wedge; disc type; screwed ends; such as Crane No. 428, or approved equal.

Coatings for Gate Valves 2 Inches and Larger: AWWA C550; Indurall 3300 or

approved equal, non-toxic, imparts no taste to water, functions as physical, chemical,

and electrical barrier between base metal and surroundings, minimum 8-mil-thick,

fusion-bonded epoxy. Prior to assembly of valve, apply protective coating to interior

and exterior surfaces of body.

The specification also includes plug valves, butterfly valves, air release and pressure reducing valves. Many of these valves are general performance valves sold primarily by price. However, a number of valves used in slurry lines and for sensitive control are high performance valves sold on the basis of lowest total cost of ownership.  We will endeavor to identify those applications and pursue cost of ownership aspects for them.

McIlvaine Company
Northfield, IL 60093-2743
Tel:  847-784-0012; Fax:  847-784-0061
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Web site:  www.mcilvainecompany.com