CeraMac -19 Demonstration plant Ceramic Microfiltration at Choa Chu Kang Waterworks G.Galjaard, J.Clement, W.S. Ang, M.H. Lim

Transcription

1 CeraMac -19 Demonstration plant Ceramic Microfiltration at Choa Chu Kang Waterworks G.Galjaard, J.Clement, W.S. Ang, M.H. Lim WS106 Development of sustainable water supply in Singapore KIVI Conference Delta Cities November 12, 2014

2 acknowledgement PUB Singapore s national water agency Environment Water Institute (EWI) Singapore Black&Veatch United Engineering Singapore (UES) Metawater RWB water services University of Arizona (Snyder Group) Xylem, WEDECO, ITT 2

3 3 background

4 introduction PWN Technologies founded in 2010, spin off of R&D department of PWN PWN is the Water Supply Company of North-Holland (1920) source is mainly (very challenging ) surface water connections 1.7 million customers 105 million m 3 per year 500 employees PWN Technologies (PWNT) carries out applied water treatment research technology provider SIX and Ceramac offices in Singapore, the Netherlands, the UK 35 million Euro turnover in

5 micro/ultrafiltration (MF/UF) low pressure membrane filtration process small pores 10nm 0,1 µm removal of all colloidal and suspended matter removal of bacteria and viruses absolute filtration water quality effluent independent of quality influent water quality effluent independent of capacity easy to automate relatively small footprint and modular 5

6 micro/ultrafiltration (MF/UF) alternative for conventional pretreatment (CSF) disinfection barrier pretreatment for reverse osmosis installed capacity worldwide 3500 MGD all polymeric membranes operational problems polymeric membranes membrane fouling short membrane lifetime membrane integrity 6

7 courtesy of Pentair X-flow 7

8 8

9 courtesy of Zenon GE 9

10 ceramic membrane advantages long life expectancy > 15 years? capability to use strong cleaning chemicals and oxidants no risk of fiber breakage very narrow pore size distribution can be operated with very high backwash rates and BW pressure 10

11 Metawater ceramic MF membrane D = 0.18 m L = 1.5 m 11

12 courtesy of Metawater 12

13 courtesy of Metawater 13

14 ceramic membrane disadvantages economical feasibility low productivity at high backwash intervals 14

15 100 productivity as function of backwash interval productivity [%] existing ceramic block design P.C. Kamp, G.Galjaard (2009), Brisbane backwash interval [min]] 15

16 PWN Technologies CeraMac on the market since elements in 1 pressure vessel improved economical feasibility higher productivity very compact, low footprint less stainless steel lower energy consumption alternative for polymeric membrane processes 16

17 100 productivity as function of backwash interval productivity [%] 80 Ceramac design 60 existing ceramic block design P.C. Kamp, G.Galjaard (2009), Brisbane backwash interval [min]] 17

18 reatment Plant Andijk PWN 5500m 3 /h: CeraMac building 18

19 19 May 2012 Brussels Winner IWA Europe & West Asia Applied Research

20 interest PUB in CeraMac PUB in near future relies on desalination, water re-use and surface water treatment In all these treatment process low pressure membrane filtration plays an important part PUB operate at the moment the world s biggest polymeric ultrafiltration plants operational challenges/difficulties at all of them 20

21 interest PUB in CeraMac prove of technology advantages ceramic membranes CeraMac process determine realistic capital and operational costs determine and optimise pre-treatment conditions determine water recovery experience in operation develop important data and knowledge for a full-scale design 21

22 demonstration testing program design and construction of 3 MLD CeraMac demonstration plant site location Choa Chu Kang Water Works very challenging water side by side comparison can be made with existing failing polymeric system of GE Zenon 18 months of operation funding of Environment Water Institute (EWI), PUB, and PWNT 22

23 23

24 Choa Chu Kang Waterworks phase 1 commissioned in 1975 ( m 3 /d) source is blended surface water from 3 reservoirs Tengeh Kranji Pandan phase 2 commissioned in 1981 (also m 3 /d) phase 1 upgraded in 2008 sand filters replaced by polymeric UF to control suspended (biological) matter 24

25 Tengeh CCKWW Kranji Pandan screening aeration chlorination coagulation pulsator clarification sand filtration chlorine lime alum polymer chlorine 25 lime ozonisation storage chlorine fluoride ammonia

26 CCKWW f Tengeh Kranji Pandan screening aeration chlorination coagulation chlorine lime alum polymer pulsator clarification chlorine ultrafiltration 26 lime ozonisation storage chlorine fluoride ammonia

27 specific tests and evaluation alternative for sand filters for fase2 find optimal operation flux (maximize to reduce capital costs) backwash frequency enhanced backwash frequency chemical cleaning frequency influence ozone on membrane performance long term stability operational costs sustainability 27

28 28 experimental set-up

29 possible scenario s for CCKWW Tengeh Kranji Pandan screening aeration chlorination coagulation chlorine lime alum polymer pulsator clarification chlorine CeraMac 29 lime ozonisation storage chlorine fluoride ammonia

30 possible scenario s for CCKWW Tengeh Kranji Pandan screening aeration chlorination coagulation chlorine lime alum polymer pulsator clarification ozonisation ozone 30 lime CeraMac storage chlorine carbondioxide fluoride ammoniumsulpate

31 experimental set-up phase 1: design, construction & SAT phase 2: clarified water phase 3: ozonated clarified water phase 4: longterm testing 31

32 experimental set-up phase 2 critical flux determination optimize back wash frequency optimize enhanced backwash frequency test runs are carried out at the same surface load fixed totall produced volume (m3/m2) fixed volume per filtration cycle (L/m2) fixed volume per EBW-cycle (L/m2) 32

33 operational parameters phase 2 Parameter Run 1 Run 2 Run 3 Run 4 Run 5 Run 6 Run 7 Run 8 Run 9 Flux (lmh) BW Interval (min) EBW Interval (A) 11 th BW 11 th BW 11 th BW 11 th BW 11 th BW 6 th BW 16 th BW 31 th BW 31 st BW EBW Interval (B) 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A Recovery (V%) Total Filtration runtime (h) Total Volume produced (m 3 )

34 experimental set-up phase 3 determine ozone decay with bench-scale test design ozone installation target 0,5 mg O 3 /L on membrane surface max capacity at found optimum phase 2 determine impact ozonated feed on operation at found optimum phase 2 find new optimum 34

35 35

36 36

37 summary results phase 2 37

38 250 flux [l/h.m2] TMP [kpa] 200 TMP run 1 4 (phase 2) flux actual TMP 0 3-Sep 13-Sep 23-Sep 3-Oct 13-Oct 23-Oct 2-Nov date 38

39 operational parameters phase 2 Parameter Run 1 Run 2 Run 3 Run 4 Run 5 Run 6 Run 7 Run 8 Run 9 Flux (lmh) BW Interval (min) EBW Interval (A) 11 th BW 11 th BW 11 th BW 11 th BW 11 th BW 6 th BW 16 th BW 31 th BW 31 st BW EBW Interval (B) 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A 5 th EBW-A Recovery (V%) Total Filtration runtime (h) Total Volume produced (m 3 )

40 TMP 25 C) TMP during phase /08/11 29/09/11 29/10/11 28/11/11 28/12/11 27/01/12 26/02/12 40

41 Number of particles > 1 µm particle counts feed permeate

42 3 2,5 2 1,5 1 0,5 fouling rate TMP increase rate 25 C) test run 42

43 performance evaluation TMP increase rate 25 C) 0,18 0,16 0,14 0,12 0,1 0,08 0,06 0,04 0,02 0 Average fouling rate without ozone 0,1kPa test run Calculated CIP-frequency: (220/0,1)/24 = 92 days 43

44 phase 2: clarified water start 1 st of September 2011 ended 23th of February 2012 found optimal operation flux : 200 lmh BW-frequency : 2/h EBW-frequency : 2-3/d (NaOCl 100ppm) : 0-1/d (HCl ph=2 with 100ppm H2O2) CIP frequency : >90 days water recovery : >95% 44

45 summary results phase 3 ozone 45

46 possible scenario s for CCKWW Tengeh Kranji Pandan screening phase 3 chlorination coagulation pulsator clarification chlorine lime alum polymer ozonisation ozone 46 lime CeraMac storage chlorine carbondioxide fluoride ammoniumsulpate

47 ozone residual [mg/l] 1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0 ozone decay tests DOC = 1,8 mg/l 1,5 O3/DOC (2,7 mg/l) 0,75 O3/DOC (1,35 mg/l) 0,25 O3/DOC (0,45 mg/l) time 47

48 ozone residual [mg/l] 1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0 ozone decay tests DOC = 1,8 mg/l 1,5 O3/DOC (2,7 mg/l) 0,75 O3/DOC (1,35 mg/l) 0,25 O3/DOC (0,45 mg/l) time 48

49 TMP curve run 10 ozonated feed TMP 25 C) 200,0 150,0 Flux = 200lmh Filtr time = 30 min EBW = after 15 BW s 100,0 50,0 0,

50 TMP curve run 12 ozonated feed TMP 25 C) Flux = 240 lmh Filtr time = 30 min EBW = after 15 BW s 0,8 mg O 3 /L

51 TMP curve run 12 ozonated feed TMP 25 C) Flux = 240 lmh Filtr time = 30 min EBW = after 15 BW s 0,8 mg O 3 /L 0,5 mg O 3 /L

52 TMP curve run 12 ozonated feed TMP 25 C) Flux = 240 lmh Filtr time = 30 min EBW = after 15 BW s 0,8 mg O 3 /L 0,5 mg O 3 /L 0,8 mg O 3 /L

53 Run 14: TMP and ozone dosing Ozone concentration (mg/l) TMP 25 C) set point dose (mg/l) 80 before membrane (mg/l) after membrane (mg/l) 3, Filtration cycle 3h Flux 240 lhm 2,4 1,6 20 0,

54 TMP curve ozonated feed TMP 25 C) Filtration cycle 3h Flux 315 lhm avg kpa 54

55 TMP curve ozonated feed TMP 25 C) Filtration cycle 3h Flux 315 lhm avg kpa 55

56 TMP curve ozonated feed TMP 25 C) 61 hours filtration without BW & EBW BW EBW

57 performance evaluation Average TMP for each run 25 C) Average TMP without ozone 63 kpa Average TMP with ozone 33 kpa test run 57

58 performance evaluation TMP increase rate 25 C) 0,2 0,15 Calculated CIP-frequency: (220/0,1)/24 = 92 days 0,1 0,05 Average fouling rate without ozone 0,1kPa Calculated CIP-frequency: (220/0,01)/24 = 920 days 0-0,05 Average fouling rate with ozone 0,01kPa test run 58

59 conclusions PUB study CeraMac is technically feasible as alternative for sand filtration with and without ozone ozone dosage upfront of the membrane enhances the filtration process significantly increase of permeability lower fouling rate higher recovery found temporary optimum is unsurpassed on this water type and scale capital as well as operational costs much lower than polymeric membranes 59

60 60 Choa Chu Kang Water Works 7600m 3 /h

61 next phases for PUB June internal discussion upgrade CCKWW Dec internal plan finalized Jan start writing tender document July tender leading engineering company Sept CH2MHill leading engineering company Okt start writing separate tender documents i.e. membrane part Dec tender Process Upgrading at Choa Chu Kang Waterworks Feb Contract 1 Membrane Filtration System See more at: 61

62 epilogue PWNT s CeraMac commercial design available late 2011 first full-scale installation (5500m3/h) on-line since may 2014, WTP Andijk PWN pilots in: 62 Netherlands (PWN); United Kingdom (SWW); Switserland (EWL); Singapore (PUB, Sembcorp); Australia (Water Corp, Melbourne Water); United States (SJWC, MPU). full-scale designs made for: SJWC Montevina EWL Luzern SWW WTW Roborough

63 CeraMac -19 Demonstration plant Ceramic Microfiltration at Choa Chu Kang Waterworks G.Galjaard, J.Clement, W.S. Ang, M.H. Lim WS106 Development of sustainable water supply in Singapore KIVI Conference Delta Cities November 12, 2014