DIGESTER FOAMING. Maintenance for Biosolids Systems. Steve Walker Senior Operations Specialist. September 13, sw510s1.pptx/1
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1 DIGESTER FOAMING CAUSES AND SOLUTIONS CWEA Math, Operations, and Maintenance for Biosolids Systems Seminar September 13, 2011 Steve Walker Senior Operations Specialist sw510s1.pptx/1
2 LEARNING OBJECTIVES Causes Process control Operational Process digester internal Control methods Process control Operational awareness Process monitoring Physical improvements Installed improvements sw510s1.pptx/2
3 PERSONAL EXPERIENCE $3M catastrophic failure of digester roof $1M repair of fixed holding tank roof Saved two other digesters from roof failures Ruined one pair of beige Dockers sw510s1.pptx/3 3
4 WHAT CAUSED FAILURE Over-wasted secondary Filaments Much more volume compared to primary Gas mixing system piping approach Plugged flame arrestors from foam Level indicator wrong From foam entrained in contents Didn t shut off mixer soon enough sw510s1.pptx/4 After first failure, reduced active volume created organic overload of other units in service (i/s)
5 CAUSES sw510s1.pptx/5
6 PROCESS CONTROL CAUSES The blend of primary sludge to secondary sludge The more primary sludge, the better Measured as pound to pound, not gallon to gallon Excessive filaments in the secondary sludge Nocardia and microthrix parvicella add bulk and structure to foam Feed fluctuations Both solids loading and volume sw510s1.pptx/6
7 OPERATIONAL CAUSES Inadequate or inconsistent mixing Rapid changes create unpredictable results Gas binding of pump used to mixing Excessive and/or fine bubble mixing Can change the specific gravity and fluff the contents Rapid change in internal pressure Cogeneration e o demands ds Moisture in gas handling system sw510s1.pptx/7
8 OPERATIONAL CAUSES Insufficient volume Liquid level too low Processing volume taken up by grit or scum raft Units out of service for maintenance or construction ti Results in solids loading rates greater than design Temperature fluctuations Created by heating or feed disruptions Rapid change in liquid level sw510s1.pptx/8
9 INTERNAL CAUSES Microorganisms competing for food Acid formers vs. methane (alkalinity) formers Surfactants Oil and grease Overdosed polymer in thickening or dewatering processes There are usually multiple contributors sw510s1.pptx/9
10 POTENTIAL CONTROL METHODS sw510s1.pptx/10
11 PROCESS CONTROL Primary sludge and secondary sludge ratio Maximize primary solids removal efficiency Maximize primary BOD removal efficiency Filaments in the wasted secondary sludge Review operating conditions and take corrective action Feed fluctuations Ideal is constant feed of comparable volume to all digesters in service sw510s1.pptx/11
12 OPERATIONAL CAUSES Insufficient volume Confirm liquid level Confirm active volume Understand seasonal trends of sludge production Rapid change in liquid level Strive for consistent dewatering feed rates Check valving, especially after maintenance work Be suspicious of the level indicators sw510s1.pptx/12
13 OPERATIONAL CAUSES Inadequate or inconsistent mixing Avoid on/off control If problem is recirculation pump gas binding, change type Review directional mixing approach Excessive or fine bubble mixing Adjust equipment Rapid change in internal pressure Strive for consistent feed Drain moisture traps sw510s1.pptx/13
14 INTERNAL CAUSES Temperature fluctuations No more than 1 degree F per 24 hour change up or down Avoid septic sludge More acidic than fresh sludge so greater reaction with alkalinity Surfactants Review e scum and FOG feed rates Avoid polymer overdose sw510s1.pptx/14 O OBSERVE SYMPTOMS; FIND CAUSES
15 OPERATIONAL AWARENESS Placing a digester in service Ramp the feed up slowly Avoid seeding with poor quality sludge Ramp up mixing system slowly Maintain heat throughout sw510s1.pptx/15
16 OPERATIONAL AWARENESS Taking a digester out of service Ramp down the mixing system slowly Lower liquid level slowly as this sludge is usually transferred to other units in service sw510s1.pptx/16
17 OPERATIONAL AWARENESS Feed strategies Ideal is constant loading to each unit in service Minimize downtime between feeding Withdrawal strategies Consistent rate from all units in service Feed disruptions Plan maintenance and construction activities sw510s1.pptx/17
18 PROCESS MEASUREMENT Criteria Measurement Comment Feed volume gallons per feed cycle Equal to all units i/s Feed volume gallons per day Equal to all units i/s Feed solids pounds per feed cycle Equal to all units i/s Feed solids pounds per day Equal to all units i/s Primary solids to pounds / pounds 50% primary sludge or secondary solids greater ratio Volatile solids pounds/cubic foot/day Overload = loading rate 10% greater Gas pressure inches W. C. 16 +/- 2 sw510s1.pptx/18 Confirm, sample, analyze, record, track/trend and publish
19 PROCESS MEASUREMENT Criteria Measurement Comment Liquid level feet Determines active volume Freeboard feet 6 ft or greater from top Foam depth feet Minimal Volatile acids mg/l Alkalinity mg/l VA/Alk ratio mg/l / mg/l Temperature degrees F (mesophilic) Grit accumulation feet (quarterly) Lost active volume sw510s1.pptx/19 Confirm, sample, analyze, record, track/trend and publish
20 HIGH-TECH MEASURING DEVICE Works with grit, scum and foam sw510s1.pptx/20
21 MAINTENANCE sw510s1.pptx/21 Cover will not float if it weighs more than the gas can lift
22 MAINTENANCE FLOATING COVERS Wash off overflow Do not store anything on the roof such as the fan used for venting during cleaning work Confirm the pressure relief pallet weights Grease the corbels Inspect the ballast troughs make sure the drain ports are open sw510s1.pptx/22
23 PHYSICAL IMPROVEMENTS sw510s1.pptx/23
24 VIEWING PORTS sw510s1.pptx/24 Use to determine the foam depth and how much freeboard is available
25 FOAM DEPTH GUIDE Stainless steel; extends 9 inches away from sidewall; 8 feet long; Z-shaped jog at every foot sw510s1.pptx/25
26 MULTIPLE LEVEL INDICATORS Compare the bubbler level to the radar level. The difference is foam. sw510s1.pptx/26 Bubbler works off of pressure. The specific gravity of the digester contents becomes less with more entrained gas.
27 MOISTURE SEPARATION Trapped water or foam can stop gas flow. sw510s1.pptx/27
28 PRESSURE RELIEF HATCHES Containment area for small spills Weighted to open at 2 to 3 inches WC greater than typical gas pressure sw510s1.pptx/28
29 FOAM TROUGH WITH SPRAY BAR Allows the foam to drain out of the digester, but creates other problems where it discharges. sw510s1.pptx/29
30 WHAT WAS DISCUSSED Causes Process control Operational Process - internal Control methods Process control Operational awareness Process monitoring Physical improvements Installed improvements sw510s1.pptx/30
31 DIGESTER FOAMING CAUSES AND SOLUTIONS Thank you for being a wastewater treatment professional. Be proud of your contributions. sw510s1.pptx/31
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