Basic Design Concepts of MBR
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- James Stevens
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1 Basic Design Concepts of MBR Class III & Class IV OTCO Workshop Wednesday August 15, 2007 Terry M. Gellner, P.E CT Consultants, Inc
2 Outline Types of Membranes MBR WWTP and General Sizing Criteria Common Terms and Definitions Review of Hollow Fiber and Flat Plate Components What s s on the Horizon
3 Referenced Text Membrane Systems For Wastewater Treatment by Water Environment Federation
4 Referenced WWTP Cauley Creek WWTP Georgia Forsyth WWTP Georgia Savannah WWTP - Georgia Hyrum WWTP Utah Hampton WWTP Georgia Delphos WWTP Ohio Mt Sterling WWTP Kentucky Green Castle WWTP - Indiana
5 Membrane Bioreactor Systems Types of Membranes MBR WWTP and General Sizing Criteria Common Terms and Definitions Review of Hollow Fiber and Flat Plate Components What s s on the Horizon
6 Membrane Classifications Microfiltration (MF) Ultrafiltration (UF) Nonofiltration (NF) Reverse Osmosis (RO)
7 Comparison of Membrane Filtration Processes Comparison of Membrane Filtration Processes Contaminants Rejected MBR Performance
8 General Process Characteristics MF and UF Low Pressure Size Exclusion Pathogenic bacteria and some viruses MBR Systems, polishing and post treatment NF and RO Higher Pressure Size Exclusion plus diffusion charge Pathogenic bacteria, viruses, dissolved solids and ions Secondary polishing and post treatment
9 Typical Types of Membranes Nozzle Membrane Panel Spacer Membrane Sheet Reinforced Structure Biomass Effluent Hollow Fiber Microstructure
10 Membrane Bioreactor Systems Types of Membranes MBR WWTP and General Sizing Criteria Common Terms and Definitions Review of Hollow Fiber and Flat Plate Components What s s on the Horizon
11 MBR? A membrane bioreactor (MBR) is a combination of suspended growth activated sludge biological treatment and membrane filtration equipment performing the critical solids/liquid separation function that is traditionally accomplished using secondary clarifiers and filters.
12 Conventional Activated Sludge
13 MBR Activated Sludge
14 Process Overview Schematic
15 Process Units and Sizing Criteria Preliminary Treatment Screening Grit/Grease Removal Activated Sludge Process Aeration Tank Membrane Bioreactor Biological Nutrient Removal Post Treatment Disinfection Post Aeration
16 Preliminary Treatment Screening Type One Dimensional Bar type (Slotted) Two Dimensional Perforated hole Capture Mode Size 1, 2 or 3 mm Operation
17 Grit and Grease Types observed Vortex Aerated Grit Headcell Partical Size Grease/Scum
18 Activated Sludge Process Permitted Design Criteria Flow Rates Pollutant Loadings CBOD, TSS, TKN, NH3, TP, TN Biological Nutrient Removal Basin Types and Volumes
19 Membrane Bioreactor Sizing Membranes are Hydraulically Restricted Low Flow Average Daily Flow Maximum Daily Sustained Flow Peak Instantaneous Flow Membrane design flow Operating MLSS Concentration Temperature Equalization
20 Post Treatment Disinfection Chemical Ultraviolet Disinfection Open Channel Ultraviolet Disinfection Close Conduit Is disinfection needed? Post Aeration
21 Hyrum WWTP UV Disinfection
22 Savannah WWTP Disinfection
23 Typical Permeate Sample
24 Permeate Quality Water reuse is popular
25 Membrane Bioreactor Systems Types of Membranes MBR WWTP and General Sizing Criteria Common Terms and Definitions Review of Hollow Fiber and Flat Plate Components What s s on the Horizon
26 Gross Flux The volume of water that passes through a membrane per unit time and per unit surface area of the membrane. Flux is often normalized based on temperature. Instantaneous Permeate Flow /Surface Area
27 Net Flux The total Permeated Flow over 24 hours divided by the total surface area expressed in gallons per minute per square foot. Total Permeate Flow/ Surface Area
28 Total Surface Area The total surface area represents the total membrane surface area available for treatment in a membrane system.
29 Transmembrane Pressure The difference between average/concentrate pressure and the permeate pressure is the driving force. The TMP is a means to assess fouling. TMP = feed pressure permeate pressure
30 Fouling The build up of impurities on the membranes such as colloidal materials. Fouling reduces flux through the membrane and increase the TMP. Micro fouling is the build up of impurities in the membrane pores.
31 BioFilm A thin layer of sludge on the membrane. Biofilm occurs on all membranes. Some manufacturers rely on biofilm. Other choose to ignore it.
32 Biohydraulics Term developed by Enviroquip. Bio hydraulics is the interrelationship between the BIO-logical process and the HYDRAULIC characteristics of the membranes.
33 Permeability The permeability of a membrane is the flux rate divided by the transmembrane pressure. P = Flux / TMP
34 Recovery Recovery is the concept of restoring the hydraulic characteristics of the membrane. Recovery is achieve by membrane cleaning.
35 Membrane Bioreactor Systems Types of Membranes MBR WWTP and General Sizing Criteria Common Terms and Definitions Review of Hollow Fiber and Flat Plate Components What s s on the Horizon
36 Membrane System Components Feed Stream, RAS and WAS Air Systems Membranes and Hardware Permeate System Flux Maintenance Systems Integrity Monitoring System Programmable Logic Controller
37 Comparison of Leading Manufacturers Hollow Fiber - Zenon - General Electric Flat Plate - Kubota Enviroquip a subsidiary of Eimco
38 Cauley Creek WWTP - Zenon
39 Cauley Creek WWTP Aeration Tanks
40 Forsyth WWTP - Zenon
41 Forsyth WWTP Fine Screening of RAS
42 Savannah WWTP Aeration Tanks
43 Hollow Fiber Flow Scheme
44 Zenon Membrane Rack
45 Immersed Membrane Train Air Separator Permeate Pump Air Manifold Permeate Manifold Cassette Permeate Header
46 Process Air System
47 Forsyth WWTP Aeration and MBR Blowers
48 Hollow Fiber Membrane Air System
49 Forsyth WWTP Air and Permeate Piping
50 Forsyth WWTP Pneumatic System Compressors
51 Hollow Fiber Permeate System
52 Hollow Fiber Flux Maintenance System Relax Air System with Air Pulsing Backpulse System Chemical Cleaning Backpulsing Maintenance Cleaning Recovery Cleaning
53 Forsyth WWTP Permeate system
54 Cauley Creek WWTP RAS and Backpulse Tank
55 Savannah WWTP Permeate System
56 Savannah WWTP Chemical Feed System
57 Forsyth WWTP Scum Removal System
58 Hollow Fiber Integrity Monitoring System Anoxic and Aeration Dissolve Oxygen Process Air System Flow and Pressure MBR Air System Flow MBR Tank - Level Turbidity Permeate
59 Hyrum WWTP - Kubota
60 Hyrum WWTP
61 Hyrum WWTP MBR Tank
62 Hampton WWTP - Kubota
63 Hampton WWTP
64 Delphos WWTP Membrane Deck
65 Flat Plate Feed Forward Flow Scheme 1
66 Flat Plate Membrane Flow Scheme 2
67 Kubota Flat Plate Membrane
68 The Kubota panel type MBR
69 Process Air System
70 Delphos WWTP Process Aeration
71 Flat Plate Membrane Air System
72 Hyrum WWTP Membrane Air Piping
73 Delphos WWTP Process and MBR Blowers
74 Delphos WWTP Air System and Hardware
75 Flat Plate Permeate System
76 Hyrum WWTP Permeate Piping
77 Hyrum WWTP Anoxic Tanks
78 Delphos WWTP Pipe Gallery
79 Delphos WWTP Permeate Pumps
80 Hampton WWTP Permeate System
81 Flat Plate Flux Maintenance System Relax Air Scour Clean In Place Chemical Cleaning
82 Flat Plate Air Scour Blow Off
83 Hampton WWTP Chemical System
84 Delphos WWTP Chemical System
85 Delphos WWTP Chemical Feed Connections
86 Flat Plate Integrity Monitoring System Anoxic Level and Meter Flow Process Air System Flow and Pressure Air System to MBR - Flow Aeration Dissolve Oxygen and NaDH MBR Tank Level Permeate - Turbidity
87 Turbidity Meters
88 MBR Flow Meter and Valves
89 Programical Logic Controller
90 System Comparisons Hollow Fiber Process Air System MBR Air System Pneumatic System Permeate System Backpulse System Chemical System Tank Drain System Integrity System PLC System Flat Plate System Process Air System MBR Air System Permeate System CIP Chemical System Integrity System PLC Controller
91 Hollow Fiber Summary Relies on pore size of membrane Promotes frequent flux maintenance Uses regular membrane cleaning Promotes support facilities for primary equipment Promotes multitasking of equipment Appears more focused on filtering through membrane
92 Flat Plate Summary Relies on biofilm to aid in filtering Promotes regular flux maintenance Uses less frequent membrane cleaning Minimizes on site equipment Separates equipment uses Focus is on biohydraulics
93 Membrane Design Approach There are more differences than similarities Learn the difference in the technology Visit existing plants with design team Question the membrane suppliers The design is site specific The biology is important Compare equal systems Select the system that suits you
94 Membrane Bioreactor Systems Types of Membranes MBR WWTP and General Sizing Criteria Common Terms and Definitions Review of Hollow Fiber and Flat Plate Components What s s on the Horizon
95 What s s on the Horizon Application of MBRs is expanding Size of plant continues to increase More focus on Headworks Optimizing operations is a point of focus Hollow Fiber is beginning to look more at Biology (TTF & ctoc) WEF has established a COP
96 Questions Terry M. Gellner, P.E. CT Consultants, Inc