Use of Biowin for Process Troubleshooting / Design for a Unique Wastewater

Transcription

1 Use of Biowin for Process Troubleshooting / Design for a Unique Wastewater OWEA Plant Operations and Lab Analysis Workshop W. James Gellner

2 Outline Introduction / Problem Overview Plant Issues Biowin Overview Special Sampling Simulations for Plant Troubleshooting Simulations for Upgrade Design Summary / Conclusions

3 Plant Overview Turkey processing plant 37,000 turkeys per day Direct discharge permit Repeated ammonia and solids violations led to IDEM Agreed Order ATS hired to perform CPE

4 Plant Schematic CHEMICAL ADDITION (ph & Alkalinity Control, Hydrated Lime) PROCESSING PLANT (Kill Through Deboning Including All Screening) ANAEROBIC LAGOONS / FLOW EQUILIZATION (2.24 MG, 8.52 MG) ACTIVATED SLUDGE TANK (0.83 MG) CLARIFICATION TANK (0.22 MG) TERTIARY FILTRATION (Schrelber Fuzzy Filter, 0.4 microns) DISINFECTION (UV) CASCADE AERATION RAS EMERGANCY BYPASS EFFLUENT WAS AEROBIC LAGOONS / BACKUP FLOW EQUILIZATION (9.07 MG)

5 Effluent Requirements Parameter 30 Day Concentration (mg/l) Daily Concentration (mg/l) BOD Total Suspended Solids Ammonia (summer) Ammonia (winter) Oil and Grease E coli 125/100 mls 235/100 mls ph > 6.0 S.U. and < 9.0 S.U. Dissolved Oxygen > 6 mg/l winter > 5 mg/l summer

6 Influent Loadings Parameter Average Daily Maximum Flow 0.61 MGD 1.20 MGD BOD lb/day (760 mg/l) 8060 lb/day COD 8190 lb/day (1610 mg/l) lb/day TSS 1120 lb/day (220 mg/l) 2070lb/day NH3 790 lb/day (155 mg/l) 1620 lb/day Alkalinity 3120 lb/day (610 mg/l) 5280 lb/day

7 ATS / Hazen and Sawyer 11/2008 CPE / Process Evaluation Detailed sampling & analysis DAF implementation Design of improvements

8 Ammonia / Solids Violations Repeated (inconsistent operations) Overwasting of biological solids Lagoon solids slugs Overfeed of lime to biological system Poor settling filaments FLIP!

9 BioWin Overview Influent (Eff ANA#2) Influent Mixer RAS Mixer Schreiber MLSS Tank Final Clarifier FC Effluent Lime RAS/WAS Splitter WAS Full plant simulation software ASDM Activated Sludge/Anaerobic Digestion (IWA) Graphical user interface User friendly, Windows style Requires detailed characterization

10 BioWin Overview (cont) Steady state / dynamic simulations Tailored to domestic waste Ability to import/export data Allows multiple simulations for what-if and process sizing analysis

11 Why Use Biowin? Process troubleshooting tool Evaluate effect of solids on system performance Operations staff education Simulations provide good examples for operations staff Design tool Size / optimize new processes for improvements

12 Special Sampling Characterize influent Capture process conditions Allow for accurate representation of process performance

13 COD Components Total COD Biodegradable Unbiodegradable Soluble Particulate Soluble Particulate

14 TKN Components Total TKN Free Ammonia Organic Nitrogen Biodegradable Unbiodegradable Soluble Particulate Soluble Particulate

15 The Filtration Tree Symbol Filter Representation XX Not filtered Represents total sample (with particulate and soluble) XG Glass fiber 1.5 micron XM Membrane filter 0.45 micron XF Flocculated / filtered with 0.45 micron Traditional breakpoint between particulate and soluble Difference between XM and XG represents colloidal Used to estimate readily biodegradable material (COD)

16 Special Sampling Overview 3 days for each event Composite sampling Process grabs at 9am and 9pm Total of ~ 400 samples and analysis Special sampling performed in June (prior to DAF) and in September 2009 (after temp DAF installation)

17 Sampling Schematic CHEMICAL ADDITION (ph & Alkalinity Control, Hydrated Lime) PROCESSING PLANT (Kill Through Deboning Including All Screening) ANAEROBIC LAGOONS / FLOW EQUILIZATION (2.24 MG, 8.52 MG) INSTALLED DAF ACTIVATED SLUDGE TANK (0.83 MG) CLARIFICATION TANK (0.22 MG) TERTIARY FILTRATION (Schrelber Fuzzy Filter, 0.4 microns) DISINFECTION (UV) CASCADE AERATION RAS EMERGANCY BYPASS EFFLUENT DAF SLUDGE SAMPLE LEGEND WAS GRAB COMPOSITE AEROBIC LAGOONS / BACKUP FLOW EQUILIZATION (9.07 MG)

18 Special Sampling Results Constituent 1 st Sampling Event Unfiltered (mg/l) 2 nd Sampling Event Unfiltered (mg/l) TSS COD BOD CBOD TKN NH NOxN NO 2 N TP PO 4 P Ca Mg

19 Influent Fractions Fbs - Readily biodegradable (including Acetate) [gcod/g of total ] Default 1 st event 2 nd event Fac - Acetate [gcod/g of readily biodegradable ] Fxsp - Non-colloidal slowly biodegradable [gcod/g of slowly degradable ] Fus - Unbiodegradable soluble [gcod/g of total ] Fup - Unbiodegradable particulate [gcod/g of total ] Fna - Ammonia [gnh3-n/gtkn] Fnox - Particulate organic nitrogen [gn/g Organic N] Fnus - Soluble unbiodegradable TKN [gn/gtkn] FupN - N: ratio for unbiodegradable part. [gn/gcod] Fpo4 - Phosphate [gpo4-p/gtp] FupP - P: ratio for influent unbiodegradable part. [gp/gcod]

20 Biowin Setup DAF - Future Influent (Eff ANA#2) Influent Mixer RAS Mixer Schreiber MLSS Tank Final Clarifier FC Effluent Lime RAS/WAS Splitter WAS June 2009 data used for troubleshooting September 2009 data used for process sizing

21 Lime Solids Scenarios Influent (Eff ANA#2) Influent Mixer RAS Mixer Schreiber MLSS Tank Final Clarifier FC Effluen Lime RAS/WAS Splitter WAS Lime feed varied to increase CaCO 3 solids in reactor CaCO 3 model ph modeling turned off to accommodate precipitate model

22 Lime Solids Results CaCO 3 Solids = 3500 mg/l 16 Clarifier Effluent NH3N (mg/l) MLSS = 4500 mg/l Temperature = 10.2 deg C CaCO 3 Solids = 2500 mg/l VSS SRT (Days) Effluent NH3 20 VSS SRT (days) , , , , MLVSS (mg/l)

23 Lagoon Solids Scenarios Influent solids of 100, 160, 300, 600, 1000 Ratio d solids in influent fractions & COD MLSS of 2000 & 3500 mg/l Three different temperatures No change in soluble constituents

24 Lagoon Solids Results - Winter 160 Steady State Simulations with Influent Q (0.6 MGD) and T=9.74oC 140 Schrieber Tank Effluent NH3N (mg/l) Schreiber Tank Influent TSS (mg/l) 3,500 mg/l MLSS 2,000 mg/l MLSS

25 Lagoon Solids Results - Average 80 Steady State Simulations with Influent Q (0.6 MGD) and T=17.73oC 70 Schrieber Tank Effluent NH3N (mg/l) Schreiber Tank Influent TSS (mg/l) 3,500 mg/l MLSS 2,000 mg/l MLSS

26 Lagoon Solids Results - Summer 1.40 Steady State Simulations with Influent Q (0.6 MGD) and T=26.07oC 1.20 Schrieber Tank Effluent NH3N (mg/l) Schreiber Tank Influent TSS (mg/l) 3,500 mg/l MLSS 2,000 mg/l MLSS

27 Process Recommendations Permanent DAF effluent 100 mg/l TSS LSI control strategy Denitrification tank / WAS Storage Increase / recover alkalinity Prevent float Chemical feed / flocculation / splitter New settling tank NRCY / RAS Pump Station

28 Reactor Sizing Simulations Inf (Eff ANA#2) DAF Carbon Bypass Splitter Inf & NRCY Mixer RAS Mixer Anoxic_1 Carbon Bypass Mixer Schreiber Tank NRCY Splitter FC FC Eff Lime RAS/WAS Splitter DAF Solids (back to lagoon) WAS Added denitrification reactor to Biowin Evaluated COD removal and NO 3 reduction

29 Reactor Sizing - Effluent Nitrate Anoxic Reactor Hydraulic Retention Time (based on Q = 0.61) Simulated Effluent Nitrate Concentration (mg/l) 0 hrs (no anoxic zone) hrs hrs 93 8 hrs hrs 59 NOTES: MLSS = 3000 mg/l Temp = 9.74 deg C Internal recyle rate of 300 % of influent flow rate

30 Reactor Sizing COD Consumption 4,500 Filtered COD Consumed in Anoxic Reactor, (ppd, COD-XG) 4,000 3,500 3,000 2,500 2,000 1,500 1, COD Removed = 700 mg/l COD Removed = 550 mg/l 3,000 mg/l MLSS - T=9.74oC 3,000 mg/l MLSS - T=17.73oC Anoxic HRT (hours, Inf Q)

31 Reactor Sizing Effluent Ammonia Simulated Clarifier Effluent NH3N, (mg/l) Efflent NH3N- w/o AX Efflent NH3N - AX HRT = 6hrs Simulated Clarifier Effluent NO3, (mg/l Efflent NO3N - w/o AX Efflent NO3N - AX HRT = 6hrs Q = 0.61 MGD Anoxic HRT = 6 hours Temperature = 9.74 deg C 3,000 2,750 2,500 2,250 2, MLSS (mg/l)

32 Reactor Sizing Internal Recycle FC Effluent NO3N, (mg/l) % 50% 100% 200% 300% NRCY (%, Inf Q) Q = 0.61 MGD Anoxic HRT = 6 hours Temperature = 9.74 deg C

33 Reactor Design

34 Current Status Under construction Complete by 3/31/2011

35 Summary / Conclusions Biowin useful as a tool in both troubleshooting and design Illustrative tool Multiple simulations allows for process optimization Effectiveness of model dependent on characterization Tailored to domestic, but can be flexed for industrial wastes and unique sidestreams

36 Questions?