Koch Membrane Systems, Inc. Matias Amor Regional Sales Manager. WEX Casablanca Nov 2014

Transcription

1 Koch Membrane Systems, Inc. Matias Amor Regional Sales Manager WEX Casablanca Nov 2014

2 Koch Industries Transforming Daily Life TM Roots in refining industry Global presence in nearly 60 countries About 140,000 employees 140 Bi dollars company Not publicly traded One of the largest privately held companies in the world Unique philosophy: Market Based Management (MBM ) p 2

3 Introduction to Koch Membrane Systems KMS is a global leader in membrane filtration technology and engineering support KMS has been in business for almost half a century and has close to 20,000 installations worldwide KMS is a comprehensive solutions provider and offers system design, process engineering, piloting and field service expertise The markets for KMS products are split into two key segments: Water & Wastewater, and Industrial & Life Sciences 3

4 KMS Organization Headquarters Wilmington, USA Manufacturing Wilmington, USA Spiral Pressurized Hollow Fiber Tubular Aachen, Germany Submerged Hollow Fiber Sales and Engineering Offices Bahrain Brazil France China Germany India Italy Australia Spain Singapore UK USA Wilmington, Massachusetts Corporate Headquarters Aachen, Aachen, Germany Germany 4

5 KMS Timeline 1963 ABCOR Founded Tubular Technology 1991 KMS Acquires ROMICON Hollow Fiber Technology 2004 KMS Acquires PURON MBR Technology 1985 ABCOR Renamed Koch Membrane Systems, Inc. (KMS) 1998 KMS Acquires FLUID SYSTEMS Spiral RO/NF Technology 5

6 Water and Wastewater Solutions Municipal Water and Wastewater Industrial Water and Wastewater Drinking Water Seawater Desalination Surface Water Ground Water Brackish Water Wastewater Water Reuse Tertiary Treatment Process Water Wastewater Reuse Boiler Feedwater Produced Water High-Purity Water Desalination 6

7 Industrial & Life Sciences Solutions Food Industrial Biotechnology Beverage Pharmaceutical Intermediates Dairy Automotive & Appliance General Industrial 7

8 KMS Product Offering 8

9 Cost KMS Product Positioning Tubular FEG TM PURON MBR PURON HF MegaPure TM TARGA TM II ,000 Solid Tolerance (mg/l) 100,000

10 TARGA TM II

11 TARGA TM II Product Features 4-Log Virus Removal Tight pore size of membranes and narrow distribution Fiber Ideally suited to meet stringent regulations Competitive Replacement Costs Robust Fiber Improved pore size distribution and membrane morphology Wide range of cleaning ph (1.5 to 13) Small footprint Large diameter: 10 one of the largest modules in the industry Intelligent Control Intelligent process controls integrated with system design Handles variations in water quality with minimal operator intervention Optimized, cost effective rack design, considered one of the most efficient rack designs in industry Requires small space and footprint 11

12 Membrane Regulatory Status Cartridges and pass kits certified to NSF 61 Cartridges passed testing for California Department of Health (CDPH) and US EPA Long Term 2 Enhanced Surface Water Treatment Rule (LT2) 12

13 Membrane Challenge Testing Results Testing Results confirmed the following: Consistent Log Removal Values (LRV) greater than 4 (>99.99% removal) for virus, cryptosporidium, and Guardia Intentionally compromised membrane can also achieve greater than 4 LRV for virus, cryptosporidium, and Guardia LRV calculations can be calculated with Hagen-Poiseuille method 13

14 TARGA TM II 10 Diameter Cartridge Approximate Length of Element inches Active Membrane Area per Element ft Inside Diameter of Fiber inches Approximate Length of Fiber feet 6 4 Nominal Molecular Weight Cutoff Daltons 100,000 Membrane Material/Construction Membrane Surface Characteristics Membrane Charge Polyethersulfone Hydrophilic Neutral Acceptable Range of Operating Pressures psi 1-30 (TMP) Acceptable Range of Operating ph Values 5-9 Acceptable Range of CIP ph Values Oxidant Tolerance Total Chlorine ppm 500 at ph > 9.5 Lifetime Total Chlorine Exposure ppm-hrs 500,000 Hydrogen peroxide % 10% Potassium permanganate ppm 5.5

15 Common Applications Ground Water Iron and Manganese Removal Ground water under the influence for drinking water Surface Water for Potable Use Clarified water Direct coagulation Seawater (pretreatment to RO) Wastewater Secondary treated water Tertiary treated water Pretreatment to RO

16 Submerged Reinforced PURON Membranes a.- Modules for Membrane Bioreactors (MBR) b.- PURON HF submerged membranes c.- PURON MP Pressurized membranes

17 Cost KMS Current and Future Water Product Positioning Tubular FEG TM PURON MBR PURON HF MegaPure TM TARGA TM II ,000 Solid Tolerance (mg/l) 100,000

18 Control Membrane Fouling Keep the membranes clean: Air scour Backflush Maintenance cleaning Recovery cleaning 2012, Koch Membrane Systems, Inc. All rights reserved. p 18

19 PURON Membrane and Support PURON membrane fiber Other membrane fibers braid braid membrane polymer Polymer is penetrating the braid Polymer is not penetrating the braid 2012, Koch Membrane Systems, Inc. All rights reserved. p 19

20 PVDF Pore Size Distribution Pore Diameter Distribution Pore Size (nm) Narrow pore size distribution and smaller pores keep foulants away resulting in stable long-term permeability

21 Example: PURON MBR Technology Air Permeate Air Fiber support Membrane bundle Module row Module 2012, Koch Membrane Systems, Inc. All rights reserved. p 21

22 PURON MBR Module design Single Header + Central Aeration Reduced clogging & sludging Reduced energy consumption for air scour Membrane bundle 2012, Koch Membrane Systems, Inc. All rights reserved. p 22

23 Baffle Plates Air lift recirculation Improved mixing Proper sludge management Increased aeration effectiveness 2012, Koch Membrane Systems, Inc. All rights reserved. p 23

24 Product features for high solids tolerance.03 um Pore Size PVDF High Rejection with Chemical stability Single Header Better Solids Management Central Aeration More Effective Cleaning Braided Fiber Great Fiber Strength Operating Modes Custom fit for application p 24

25 PURON MBR Membrane Modules 37/41 m and 300 m and 600 m and 1800 m 2 L91 x B89 x H239 cm L166 x B89 x H236 cm L224 x B176 x H253 cm Piloting Small Industrial Small Municipal Medium/large Industrial Medium Municipal Large Industrial + Municipal (> app m 2 ) 2012, Koch Membrane Systems, Inc. All rights reserved. p 25

26 MBR vs. Conventional Activated Sludge Conventional Activated Sludge System Incoming Wastewater Pre- Treatment Anoxic Zone Aerobic Zone Settling Tank Effluent RAS Membrane Bioreactor (MBR) Incoming Wastewater Pre- Treatment Anoxic Zone Aerobic Zone UF Effluent RAS 2012, Koch Membrane Systems, Inc. All rights reserved. p 26

27 PURON MBR A Decade of Growth PURON Founded 2,000 m 3 /d Belgium 50 th Reference 12,000 m 3 /d China 43,500 m 3 /d France st Pilot Installation 340 m 3 /d Germany KMS Integration 2 nd Generation launched 100 th Reference 56,200 m 3 /d Brazil 2012, Koch Membrane Systems, Inc. All rights reserved.

28 PURON References Longest Running Sobelgra, Belgium 8 years of operation (2004) Largest Aquapolo, Brazil 56,200 m3/day Municipal Plants 53 in operation Industrial Plants 63 in operation 2012, Koch Membrane Systems, Inc. All rights reserved. p 28

29 Pre-Engineered PURON Systems Solutions Pilot Systems Modular Systems Packaged Systems 2012, Koch Membrane Systems, Inc. All rights reserved.

30 PURON PLUS Packaged Systems Blowers Aeration Tank Description: Filtration Pkg. Scope: Filtration + Bio Pkg. Scope: Package Systems Standard complete pre-engineered MBR system solutions Membranes, Membrane tank, Membrane blowers, Permeate extraction system, Filtration system valves/instrumentation, CIP system, PLC Fine screening, Bioreactor tanks, Bioreactor equipment/valves/instrumentation, Drain pump Feed equipment, Air compressor, Effluent turbidity, Chemical Optional Scope: dosing/disinfections, UV system, Shelf spares AADF Capacity (MGD) Flux (lmh) Product Model Industrial Municipal Industrial Municipal Area Type P to to to to m2 PSH300 P to to to to m2 PSH600 Anoxic Tank P-100 Ancillary Skid Membrane Tank P , Koch Membrane Systems, Inc. All rights reserved. p 30

31 PURON PLUS Modular Systems Description: Included Scope: Modular Systems Custom configurable MBR system solutions (pre-engineered components) Membranes, Membrane tank, Membrane blowers, Permeate extraction system, Filtration system valves/instrumentation, CIP system, PLC Feed equipment, Fine screening, Drain pump, Air compressor, Bioreactor equipment/valves/instrumentation, Effluent turbidity, Chemical dosing/disinfection, UV system, Optional Scope: Shelf spares AADF Capacity (MGD) Flux (lmh) Product Model Industrial Municipal Industrial Municipal Area Type M-4S.15 to to to to m2 PSH600 M-2L.23 to to to to m2 PSH1800 M-3L.34 to to to to m2 PSH1800 M-4L.46 to to to to m2 PSH1800 M-5L.57 to to to to m2 PSH1800 M-6L.68 to to to to m2 PSH1800 Membrane Tank M-6L M-3L Ancillary Skid Blowers 2012, Koch Membrane Systems, Inc. All rights reserved. p 31

32 Pretreatment Requirements Fine Screening <2.0 mm punched plate No bypass permitted Grease removal to limit FOG in the feed to the membrane to 10 mg/l or less Grit removal where grit is expected (coastal plants) 2012, Koch Membrane Systems, Inc. All rights reserved.

33 Bioreactor Design Considerations Many different considerations: Mixed Liquor Suspended Solids (MLSS) Concentration: 3-12 g/l Solids Retention Time (SRT): days Hydraulic Retention Time (HRT): 4-12 hours Influent flows Influent water quality Effluent requirements All affect membrane system operation 2012, Koch Membrane Systems, Inc. All rights reserved. p 33

34 Membrane Tank Considerations Separate membrane tank Better MLSS concentration control Better DO control Simplify recovery cleaning Membrane tank sizing Optimized for proper sludge management Tank feed configuration Gravity vs. Pump Sludge momentum effects Overflow and foam control 2012, Koch Membrane Systems, Inc. All rights reserved. p 34

35 Reversible Pump Permeation Configuration PIT Discharge FIT CIP Membrane tank Reversible pump 2012, Koch Membrane Systems, Inc. All rights reserved. p 35

36 Permeate System: Reversible Pump Realized CIP Inlet Aeration Header Permeate Flow Meter 4x PSH1500 per train Permeate Pump 2012, Koch Membrane Systems, Inc. All rights reserved.

37 Air Scour Aeration Strategy System Influent Condition Aeration Mode Description No Flow Stand-By Aeration is used only to periodically mix the membrane tanks to ensure that no settling occurs. Moderate Flows Intermittent Aeration is applied to one train at a time. The full design air flow for one train is directed to each train sequentially to a maximum of four trains. This is both the most energy efficient and most used aeration mode. Peak Flows Continuous Aeration is directed to all trains simultaneously. A portion (typically half) of the full design air flow is applied to each train. Aeration is interrupted to each train periodically to clean the aeration nozzles. Note: The combined total air cycle time per train (on and off) must be greater than 120 seconds to avoid patent infringement. 2012, Koch Membrane Systems, Inc. All rights reserved. p 37

38 Permeability Filtration Intervals in Submerged Mode Operation with constant permeate flux Backflushing Filtration interval Flushing time Intermittent aeration Time 2012, Koch Membrane Systems, Inc. All rights reserved. p 38

39 Chemical Cleaning As membranes produce water, a fouling layer forms on the membrane surface and the required filtration pressure (transmembrane) rises. Over time, this fouling layer will not be effectively removed by normal air scouring and backflush. Chemical cleaning of the module becomes necessary Two basic procedures are used: Maintenance Cleaning (MC) used to maintain the permeability Recovery Cleaning (RC) used to restore the permeability to original parameters 2012, Koch Membrane Systems, Inc. All rights reserved. p 39

40 Chemical Cleaning Concentration Time cleaning efficiency cleaning chemicals Temperature 2012, Koch Membrane Systems, Inc. All rights reserved. p 40

41 Maintenance Cleaning Protocol 4-6 l/m2h PIT FIRC CIP discharge Membrane tank Reversible pump FIRC Chemicals 2012, Koch Membrane Systems, Inc. All rights reserved.

42 Cost KMS Current and Future Water Product Positioning Tubular FEG TM PURON MBR PURON HF MegaPure TM TARGA TM II ,000 Solid Tolerance (mg/l) 100,000

43 Introducing MegaPure Hollow Fiber Ultrafiltration Free fibers release dirt better. 2013, Koch Membrane Systems, Inc. All rights reserved.

44 The MegaPure System Design Virtually unbreakable PVDF membranes Compact high-flux cartridge design Complete MegaPure System Compact 6 Pack Skid Design Shown Proprietary Fiber Tip Seal p 44

45 Advanced Cartridge Design Traditional Designs Potting at Both Ends MegaPure Design Single Potting Dead zones Dual Aeration promote potting unable restricts to fiber penetrate sludging, fiber movement fiber reducing bundle surface effectively area, output and energy efficiency VS Free fiber construction Solids Unique fall to the allows bottom single-potting more where complete they construction are easily air scouring drained away p 45

46 MegaPure Primary Applications Industrial Process Tertiary Wastewater Desalination Pre-treatment Potable Water Advantages: Advantages: Advantages: Advantages: Excellent water quality with UF Membrane Removes suspended & colloidal solids Low energy & chemical costs Higher Recoveries Handles clarifier upsets Able to tolerate high coagulant doses for Phosphorus removal Low energy cost Excellent water quality prolongs RO life Coagulants can help manage Red Tide events Low Maintenance 4-log rejection of Crypto and Guardia Suited for turbid surface waters Handles high coagulant doses for TOC/color removal p 46

47 The MegaPure Advantage Avoid Pretreatment The MegaPure system s high flux and solids tolerance capabilities can eliminate the need for costly clarifiers and chemical pretreatments. Less Downtime Polyester reinforced membranes and a unique single-potting design help to avoid downtime associated with cleaning cycles, sludging and fiber repair. Less Chemicals Superior chemistry and a tight pore structure deliver more stable membrane performance without the need for extensive chemical cleans. easy $ Simple Operation Minimal connections, an intelligent user-interface and outstanding membrane reliability create one of the easiest-running filtration systems available. Save Money Superior output, simplified operation, reduced maintenance & pretreatment costs and compact footprint all add up to cost savings for you! p 47

48 System Scalability 6-Pack Design Up to 0.2 MGD Each system has fresh and sea water equipment lists Pre-Engineered System Options: MP-6 (Package Plant) MP-10 (Package Plant) MP-24 MP-40 MP Cartridge Design Up to 2.0 MGD Costing Complete for all sizes in both sea and fresh water construction p 48

49 PURON (High Flow) HF Product Overview

50 Cost KMS Current and Future Water Product Positioning Tubular FEG TM PURON MBR PURON HF MegaPure TM TARGA TM II ,000 Solid Tolerance (mg/l) 100,000

51 PURON High Flow (HF): What is it? New product introduced for high solids water and tertiary applications PURON HF uses PVDF membrane supported on braid Single header design with central aeration At least 44% more area compared to the improved 1800 m2 PURON MBR module. Solids tolerance of over 1000 mg/l PURON HF p 51

52 PURON HF Markets Tertiary Treatment Surface Water RO Pretreatment Position for tough to treat waters where secondary clarifier is not working effectively Surface Water treatment with high TOC loading or turbidity spikes Can be used for SW desalination; additional cost for frames High coagulant dosages for stringent P removal (either in bioreactor or upstream of membrane) High coagulant dosages for TOC/Color removal High oxidant dose for Fe or Mn removal Will guarantee SDI less than 3; For more stringent guarantees please contact process group p 52

53 PURON HF Membrane Modules 53 m m m m 2 Dimensions Dimensions Dimensions Dimensions L: 92mm W: 828mm H: 2319mm L: 906mm W: 893mm H: 2490mm L: 1662mm W: 893mm H: 2525mm L: 2244mm W: 1755mm H: 2530mm Surface areas are all nominal p 53