MBRs The Future of Wastewater Treatment PURON MBR. Tim Jordan KMS Midwest RSM

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1 MBRs The Future of Wastewater Treatment PURON MBR Tim Jordan KMS Midwest RSM

2 Koch Membrane Systems We are a global leader in membrane filtration technology We have been in business for half a century, with approximately 20,000 installations worldwide We are a comprehensive solutions provider. We offer system design, process engineering, piloting and field service expertise Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

3 Timeline of Innovation ABCOR Founded. Introduced Tubular and Spiral Technology Introduced ROMICON Inside-out Hollow Fiber (HF) Cartridges Introduced PURON Submerged membrane Technology Introduced Dairy-Pro Spiral Product Line 1985 ABCOR Renamed Koch Membrane Systems, Inc. (KMS) 1998 Introduced FLUID SYSTEMS RO/NF Technology 2013 Introduced PURON MP outside-in HF Cartridges Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

4 Water and Wastewater 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 Wastewater Reuse Boiler Feedwater Produced Water High-Purity Water Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

5 Industrial and Life Sciences Food Industrial Biotechnology Beverage Pharmaceutical Intermediates Dairy Automotive & Appliance General Industrial Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

6 Membrane Products Submerged Hollow Fiber Supported membrane for difficult wastewater applications (MBR) Supported membrane for high solids filtration Pressurized Hollow Fiber Membranes Inside-out and Outside-in membranes Products tailored to various market needs Spiral Wound Elements Industry pioneers in spiral membrane technology Range of MF, UF, NF and RO products Tubular Membranes Market leader in tubular products Product designed for high solids and other tough applications Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

7 Standard Systems Packaged Systems Modular Systems UF System Reverse Osmosis System KONSOLIDATOR System Juice System WINEFILTER System KPAK E-Coat System Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

8 KMS Product Positioning Wide range of products to handle different applications TARGA II MEGAPURE PURON HF PURON MBR TUBULAR 50 mg/l 250 mg/l 2000 mg/l 15,000 mg/l Solids Tolerance Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 9

9 Submerged MBR Modules MBR modules Municipal Wastewater Industrial Wastewater Treatment & Reuse Food & beverage Oil & gas Pulp & paper Semiconductor Chemical processing Braided fibers for longer life Central aeration and single header design for better solids management Optimized air scouring Energy efficient Easily retrofittable Reduced system footprint Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

10 Submerged Hollow Fiber Modules HF modules Municipal Wastewater Secondary effluents Tertiary effluents Industrial Wastewater Secondary effluents Tertiary effluents High Solids Surface water Braided fibers for longer life Central aeration and single header design for excellent solids management Optimized air scouring for energy efficient operation Energy efficient Easily retrofittable Reduced system footprint Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

11 Membrane Bioreactors (MBR) vs. Conventional Activated Sludge Conventional Activated Sludge System Incoming Wastewater Pre- Treatment Anoxic Zone Aerobic Zone Settling Tank Sand Filter/Clarifier Effluent RAS Membrane Bioreactor (MBR) Incoming Wastewater Pre- Treatment Anoxic Zone Aerobic Zone UF Effluent RAS Takeaway: Membrane Bioreactors offer better effluent quality and smaller footprint compared to conventional activated sludge process Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 12

12 MBR RAS Pumping 2 mm PT DN N RAS pumping in MBR typically 4x influent flow rate. MBR RAS important to balance MLSS between membrane tank and bioreactor. Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 13

13 Pressure difference [bar] Membrane Spectrum Saline solutions Viruses Bacteria 100 RO 10 NF UF MF Sand filtration Particle size [µm] Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 14

14 Pretreatment Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 16

15 Pretreatment Requirements for MBR Gap Meshed Perforated vertical horizontal <1 mm <2 mm <2 mm Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 17

16 Comparison Microorganisms: Membrane Pore Size E. Coli ~ µm Hepatitis, Coliphages, Polio ~ µm B. Subtilis ~ 0,3 µm poresize ~ 0.01 µm poresize ~ 0.2 µm Ultrafiltration Microfiltration Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 19

17 MBR Module air air permeate Fiber support Membrane bundle Module row Module Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 20

18 Potential Problems clogging sludging reduction of permeate flux danger of biological growth through the membranes extensive pretreatment (fine screen with 0,5 0,75 mm) Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

19 Potential Problems Edge clogging Gap clogging low flow rate on the edges leads to clogging uneven plate gaps are susceptible to clogging resulting in: high aeration rates Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

20 MBR Module air air permeate Fiber support Membrane bundle Module row Module Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 23

21 MBR Operating Concept Single Header + Central Aeration Reduced clogging & sludging Reduced energy consumption for air scour Membrane bundle Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 24

22 Mechanical Strength of MBR Membrane PURON hollow fiber membrane No fiber breakage during operation Long membrane lifetime Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 25

23 Baffle Plates Air lift recirculation Improved mixing Proper sludge management Increased aeration effectiveness Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 26

24 Sludge Management in Fiber Bundle Aeration creates horizontal sludge flow inside the bundle Filtration leads to sludge dewatering and concentration Gaps in fiber bundle bundle sludging during higher fluxes reduce sludging Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 28

25 Header Element Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

26 MBR Membrane Modules 37/41 m m m m 2 Row Small Industrial Medium/large Industrial Large Industrial + Municipal Small Municipal Medium Municipal Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 30

27 MBR General Automation Filtration (Cyclic Aeration) Ventilation (Cyclic Aeration) Backflush (Cyclic Aeration) Filtration (Cyclic Aeration) Maintenance Clean Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 31

28 General Operation Modes PIT FIRC Filtration Mode Filtrate cleaning chemicals PIT Backflush Mode FIRC 2015 Koch Membrane Systems, Inc. All rights reserved worldwide. For related cleaning trademark chemicals information, visit Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 32

29 Air Cycling CLOSED OPEN CLOSED CLOSED FIT VFD Blower TRAIN 1 TRAIN 2 TRAIN 3 TRAIN 4 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 33

30 Treatment Plant top view Biological process tank RO elements Submerged modules Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

31 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 35

32 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 36

33 California MBR Facility Application: Municipal Wastewater Capacity: 3.4 MGD average day flow; 7.2 MGD peak day flow; 10.4 MGD peak hour flow Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 37

34 Reuse Projects Aquapolo, São Paulo, Brazil Largest MBR system in Latin America Converts wastewater to high quality water for industrial uses Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

35 Anaerobic or Aerobic Figure 2: Samples from a Landfill Leachate MBR utilizing tubular membranes (left to right): UF Feed UF concentrate (~20g/L TS) UF Effluent Carbon Polished UF Effluent Sludge from MBR (~5% TS) Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 40

36 External Cross Flow Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 41

37 Pre-Engineered System Solutions -Packaged -Modular Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

38 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-200 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 43

39 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, Optional Scope: Chemical dosing/disinfection, UV system, Shelf spares AADF Capacity (MGD) Product Model Industrial Municipal Area Type M-4S.15 to to m2 PSH600 M-2L.23 to to m2 PSH1800 M-3L.34 to to m2 PSH1800 M-4L.46 to to m2 PSH1800 M-5L.57 to to m2 PSH1800 M-6L.68 to to m2 PSH1800 Membrane Tank M-6L M-3L Ancillary Skid Blowers Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 44

40 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 45

41 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 46

42 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 47

43 KMS Product Positioning Wide range of products to handle different applications TARGA II MEGAPURE PURON HF PURON MBR TUBULAR 50 mg/l 250 mg/l 2000 mg/l 15,000 mg/l Solids Tolerance Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 48

44 System Design Single-header PURON MP membrane Bundle Enclosed PURON MP Cartridge PURON MP Skid Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 49

45 Cartridge Features Free floating membranes allow more complete air scouring Sediment is easily removed during backwash Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 50

46 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 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

47 8 Diameter Cartridge Product datasheet completed. Overview: Membrane Area: 546 ft 2 (51 m 2 ) Pore Size: 0.03 µm Membrane Chemistry: PVDF Filtration Class: Hollow Fiber UF Feed Flow Path: Outside-In Wet New Cartridge Weight: 100 lbs (46 Kg) Height: 81 inch (2 m) Max Chlorine Cleaning Conc.: 1000 ppm Free Cl Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 53

48 Membrane Regulatory Status Certification primarily required for Drinking Water: NSF 61 CERTIFICATION Received Q1, 2014 EPA Long Term Surface Water (LT2) and California Department of Public Health Accreditation - Estimate approval Q3, 2015 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. 54

49 Large Skid Design PURON MP 64 Skid Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

50 System Matrix Offering Typical Capacity* per Skid, MGD (MLD) # Cartridges per skid High Fouling Medium Fouling Low Fouling / / / / / / / / / / / / / / /6.8 *For Reference Only Capacities based on : 85%System Efficiency/Uptime Skids fully populated with cartridges Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. 57

51 Applications and Pretreatment Guidelines

52 Common Applications Ground Water Iron and Manganese Removal Ground water under the influence Surface Water Seawater (pretreatment to RO) Wastewater Secondary treated water Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

53 Clarification/Sedimentation Guidelines Common coagulants: Alum, Ferric Chloride, ACH, PACl ACH and PACl are preferred Ferric Chloride for RO pretreatment Each Coagulant has an optimum ph for a particular feed water Aluminum products: ph Ferric products: ph 4-9 Post clarifier ph increase (7.5-8) can dramatically help membrane performance by causing a negative charge Polymer Flocculant Aids Cationic and neutral polymers generally are not allowed, KMs has some experience with Megnafloc LT25 Dosage rate should be as low as possible, <1 ppm Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

54 New Hampshire Site The pilot had stable winter performance with a flux of 25 gfd and stable summer performance at 40 gfd. The feed water was very fouling due to incomplete nitrification resulting in a high organics loading. PACl coagulant was added at 100 ppm resulting in approximately 20 ppm additional suspended solids feed to the pilot. A feed water quality summary is shown in Table 1. Table 1 New Hampshire Lagoon Effluent Feed Water Parameter Min Average Max Turbidity (NTU)* TSS (ppm) TOC (ppm) *Online readings, TSS was presumed higher during turbidity spikes, when sampled for this site: TSS(ppm)=0.45*Turbidity (NTU) Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 64

55 KMS Product Positioning Wide range of products to handle different applications TARGA II MEGAPURE PURON HF PURON MBR TUBULAR 50 mg/l 250 mg/l 2000 mg/l 15,000 mg/l Solids Tolerance Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 65

56 High Flow Design High solids water and tertiary applications 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-2650 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 66

57 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 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 67

58 Easy Mfg. Implementation Area Increase MBR Module HF Module Same modular design Same module frame Reduced row spacing Bundle plate slightly modified Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 68

59 High Flow Membrane Modules 53 m m m m 2 Dimensions L: 92mm W: 828mm H: 2319mm Dimensions L: 906mm W: 893mm H: 2490mm Dimensions L: 1662mm W: 893mm H: 2525mm Dimensions L: 2244mm W: 1755mm H: 2530mm Surface areas are all nominal Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 69

60 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 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 70

61 Projected Operating Costs HF Vs. MP PURON HF PURON MP Power [$/1000 gallon produced*] Surface water*** Tertiary Surface water*** Tertiary Cleaning chemicals [$/1000 gallon produced**] Membrane Replacement [$/1000 gallons produced] Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 71

62 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

63 Preliminary Design

64 WWTP Design Fluxes during Wet Weather Flows Parameter Units Without EQ With EQ Average Daily Flow MGD Maximum Monthly Flow MGD Peak Hour Flow Rate for <4 hrs MGD Average Daily Net Flux gal/ft 2 d Maximum Monthly Net Flux gal/ft 2 d Peak Hour Net Flux for < 4 hrs gal/ft 2 d Average Daily Net Flux with One Train Offline gal/ft 2 d Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 75

65 WWTP Layout Without EQ Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 76

66 WWTP Layout With EQ Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 77

67 WWTP Membrane Design Parameter Units Without EQ With EQ Membrane Module Type n.a. PSH PSH Number of Membrane Filtration Trains No. 4 4 Number of Installed Modules Per Train No. 7 4 Total Number of Installed Modules No Membrane Surface Area per Module No. 19,360 17,652 Membrane Surface Area per Train ft 2 135,624 70,611 Total Installed Membrane Surface Area ft 2 542, ,444 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 78

68 WWTP NPV Parameter Units Without EQ With EQ Annual Membrane Aeration Energy Cost $/year $35,000 $31,400 Annual Permeate Pumping Energy Cost $/year $1,600 $1,600 Annual Membrane Replacement Cost $/year $158,300 $82, Year Net Present Value $ 2015 $2,428,500 $1,437,900 Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company. p 79

69 Thank You! Koch Membrane Systems Tel: KOCH Koch Membrane Systems, Inc. is a Koch Chemical Technology Group, LLC company.

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