Energy efficiency in wastewater treatment

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Domenic Chase
6 years ago
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1 Energy efficiency in wastewater treatment Armin Müller Industry Segment Management Water/ Wastewater Festo AG & Co KG Esslingen, Germany

Festo an independent family-owned company Some Facts & Figures Pneumatic & Electric

Systems, Training & Consulting Founded in 1925 Turnover 2,4 billion (2014) R&D

000 Customers worldwide Festo Technology Centre and Headquarters, Esslingen Festo

2 Festo an independent family-owned company Some Facts & Figures Pneumatic & Electric Automation Technology offering solutions for Factory & Process Automation Learning Systems, Training & Consulting Founded in 1925 Turnover 2,4 billion (2014) R&D Investments: 9 % of turnover 61 international Festo companies Customers worldwide Festo Technology Centre and Headquarters, Esslingen Festo Customer Service Centre and production plant, St. Ingbert Components in countless variants Employees worldwide

Supporting our customer s advanced automation as no one

Global Production Center 4 Regional Service Center 26

31 in Europe 10 in America, 3 in Africa With more than

3 Supporting our customer s advanced automation as no one else can Network Danube Region Worldwide presence: 11 Global Production Center 4 Regional Service Center 26 National Service Center 61 Festo Companies: 18 in Asia, 31 in Europe 10 in America, 3 in Africa With more than 250 subsidiaries Authorised dealers in further 39 countries 3

Reasons, why energy efficiency investigations have to be accelerated In the overall generation, transmission and utilization of electrical energy The highest saving potential is in production plants

4 Reasons, why energy efficiency investigations have to be accelerated In the overall generation, transmission and utilization of electrical energy The highest saving potential is in production plants This potential can be exploited by various means like Energy efficient components Smart automation solutions (e.g. online control of oxygene injection in wastewater treatment plants) Changes in process design Tremendous potential for Energy savings, e.g. 20% of the electrical energy of municipalities in Germany is consumed by WWTP / 4

pumped to trickling filter 6 pumps in basement 3-5 pumps always in operation, 1 redundant

5 Pumping station: Energy savings Waste water Pre-clarification Trickling filter Final clarification Sludge to digestion Pump Sewage from pre-clarification and return water is pumped to trickling filter 6 pumps in basement 3-5 pumps always in operation, 1 redundant Specification pump: power consumption 90 kw, flow rate 500 l/s Delivery head 8-9 m Pipe diameter DN 350

Situation before retrofit From Pre - clarification knife pump check knife gate valve gate To Trickling filter Arrangement is standard solution for pump

using check valves - Pipe system starts to vibrate due to pressure oscillation (water hammer) - Check valves are partially worn out and leacking after 12

6 Situation before retrofit From Pre - clarification knife pump check knife gate valve gate To Trickling filter Arrangement is standard solution for pump stations Pump Problems - Energy needed in steady state operation to open the valve - Disk reduces in general pipe diameter - Water hammer during shut down using check valves - Pipe system starts to vibrate due to pressure oscillation (water hammer) - Check valves are partially worn out and leacking after 12 years of operation - During pump downtimes microorganisms producing gas, a bubble is generated below the check valve. Result : the pump does not start by itself 6

Situation after retrofit From Pre-clarification To Trickling filter knife pump spacer knife Advantages gate gate automated - Less power consumption at same flow rate -

cylinder is thight - During opening of knife gate gas bubble escapes, pump starts automatically Energy savings - 89469 kwh / year -5 pumps in operation, results in sum 11.

7 Situation after retrofit From Pre-clarification To Trickling filter knife pump spacer knife Advantages gate gate automated - Less power consumption at same flow rate - Higher flow rates can be reached, because disk reduced active valve/pipe diameter within the former solution - Lower noise level - No leackage - knife gate with DLP cylinder is thight - During opening of knife gate gas bubble escapes, pump starts automatically Energy savings kwh / year -5 pumps in operation, results in sum EUR -2% percentage energy savings on total demand for electrical energy of WWTP - -Invest for retrofit: EUR in total - Invest for retrofit only check valves: EUR in total

8 Energy saving German Wastewater Treatment Plant Situation after retrofitting Pump Pumps with knife gate and DLP actuator Air reservoir with refigeration dryer and distributor 8

9 Energy-autonomous fficient control of a stormwater overflow basin Reason and Tasks of SWOB Intake SWOB Overflow Relief structure for combined water system (rainwater and sewage) in function as a buffer to relief the canalization in case of a heavy rain event Direct connection to the wastewater treatment plant would require a large scaling of the pipes RWOB at the right places in the canalization lead to an economic pipe scaling SWOB consists of FIC Emergency valve WWTP A manhole chamber with mechanical grill for withdrawal mineralized coarse matter A RetentionTank body with overflow on inlet and a throttle valve on outlet side. This regulates the waterflow accordance the available capacities in the sewage plant Sensory feedback such as flow rate and water level influence the control process in an automated system Outlet throttle valve Application flow control manhole Regulates the outflow to the sewage plant with a throttle valve Emergency valve in pre-set position ensures function if gate valve fails There is often an additional flushing valve in case of clogging 9

10 Implementation Concept Of The Energy-Self-Sufficient-System 10

11 Implementation Concept Of The Energy-Self-Sufficient-System The advantages of the energy-autonomous automation of these decentralised devices are: - Saving of the investment costs of connecting to the public power supply grid - Central operation and monitoring, i.e. saving of costs of manual operation and monitoring, - Continuous monitoring of the plant and the automation system 11

Pilot plant RÜB-Anger in Neulingen-Bauschlott Example RWOB in Neulingen- Bauschlott, DE In

installed 22 urban districts and quarters are connected to the Abwasserverband 39 stormwater

overload A gate valve releases the retained water slowly in the canalization The process data are

12 Pilot plant RÜB-Anger in Neulingen-Bauschlott Example RWOB in Neulingen- Bauschlott, DE In cooperation with Abwasserverband Weißach und Oberes Saalbachtal a selfsustaining system has been installed 22 urban districts and quarters are connected to the Abwasserverband 39 stormwater overflow basins/ retention tanks withhold precipitation amount to pretend the sewer network form overload A gate valve releases the retained water slowly in the canalization The process data are daily recorded The pilot plant is an individually designed system solution which is adapted to the particular requirements 12

13 Thank you for your attention! /

Automation in one of the most modern water treatment plants in Europe. Water s long journey

Automation in one of the most modern water treatment plants in Europe Water s long journey Fresh, clean drinking water straight from the tap is something that many people in industrial nations take for