Use of Biowin for Process Troubleshooting / Design for a Unique Wastewater OWEA Plant Operations and Lab Analysis Workshop W. James Gellner
Outline Introduction / Problem Overview Plant Issues Biowin Overview Special Sampling Simulations for Plant Troubleshooting Simulations for Upgrade Design Summary / Conclusions
Plant Overview Turkey processing plant 37,000 turkeys per day Direct discharge permit Repeated ammonia and solids violations led to IDEM Agreed Order ATS hired to perform CPE
Plant Schematic CHEMICAL ADDITION (ph & Alkalinity Control, Hydrated Lime) PROCESSING PLANT (Kill Through Deboning Including All Screening) ANAEROBIC LAGOONS / FLOW EQUILIZATION (2.24 MG, 8.52 MG) ACTIVATED SLUDGE TANK (0.83 MG) CLARIFICATION TANK (0.22 MG) TERTIARY FILTRATION (Schrelber Fuzzy Filter, 0.4 microns) DISINFECTION (UV) CASCADE AERATION RAS EMERGANCY BYPASS EFFLUENT WAS AEROBIC LAGOONS / BACKUP FLOW EQUILIZATION (9.07 MG)
Effluent Requirements Parameter 30 Day Concentration (mg/l) Daily Concentration (mg/l) BOD 5 20 30 Total Suspended Solids 20 30 Ammonia (summer) 0.93 1.85 Ammonia (winter) 1.77 3.54 Oil and Grease 10 15 E coli 125/100 mls 235/100 mls ph > 6.0 S.U. and < 9.0 S.U. Dissolved Oxygen > 6 mg/l winter > 5 mg/l summer
Influent Loadings Parameter Average Daily Maximum Flow 0.61 MGD 1.20 MGD BOD5 3860 lb/day (760 mg/l) 8060 lb/day COD 8190 lb/day (1610 mg/l) 13300 lb/day TSS 1120 lb/day (220 mg/l) 2070lb/day NH3 790 lb/day (155 mg/l) 1620 lb/day Alkalinity 3120 lb/day (610 mg/l) 5280 lb/day
ATS / Hazen and Sawyer 11/2008 CPE / Process Evaluation Detailed sampling & analysis DAF implementation Design of improvements
Ammonia / Solids Violations Repeated (inconsistent operations) Overwasting of biological solids Lagoon solids slugs Overfeed of lime to biological system Poor settling filaments FLIP!
BioWin Overview Influent (Eff ANA#2) Influent Mixer RAS Mixer Schreiber MLSS Tank Final Clarifier FC Effluent Lime RAS/WAS Splitter WAS Full plant simulation software ASDM Activated Sludge/Anaerobic Digestion (IWA) Graphical user interface User friendly, Windows style Requires detailed characterization
BioWin Overview (cont) Steady state / dynamic simulations Tailored to domestic waste Ability to import/export data Allows multiple simulations for what-if and process sizing analysis
Why Use Biowin? Process troubleshooting tool Evaluate effect of solids on system performance Operations staff education Simulations provide good examples for operations staff Design tool Size / optimize new processes for improvements
Special Sampling Characterize influent Capture process conditions Allow for accurate representation of process performance
COD Components Total COD Biodegradable Unbiodegradable Soluble Particulate Soluble Particulate
TKN Components Total TKN Free Ammonia Organic Nitrogen Biodegradable Unbiodegradable Soluble Particulate Soluble Particulate
The Filtration Tree Symbol Filter Representation XX Not filtered Represents total sample (with particulate and soluble) XG Glass fiber 1.5 micron XM Membrane filter 0.45 micron XF Flocculated / filtered with 0.45 micron Traditional breakpoint between particulate and soluble Difference between XM and XG represents colloidal Used to estimate readily biodegradable material (COD)
Special Sampling Overview 3 days for each event Composite sampling Process grabs at 9am and 9pm Total of ~ 400 samples and analysis Special sampling performed in June (prior to DAF) and in September 2009 (after temp DAF installation)
Sampling Schematic CHEMICAL ADDITION (ph & Alkalinity Control, Hydrated Lime) PROCESSING PLANT (Kill Through Deboning Including All Screening) ANAEROBIC LAGOONS / FLOW EQUILIZATION (2.24 MG, 8.52 MG) INSTALLED DAF ACTIVATED SLUDGE TANK (0.83 MG) CLARIFICATION TANK (0.22 MG) TERTIARY FILTRATION (Schrelber Fuzzy Filter, 0.4 microns) DISINFECTION (UV) CASCADE AERATION RAS EMERGANCY BYPASS EFFLUENT DAF SLUDGE SAMPLE LEGEND WAS GRAB COMPOSITE AEROBIC LAGOONS / BACKUP FLOW EQUILIZATION (9.07 MG)
Special Sampling Results Constituent 1 st Sampling Event Unfiltered (mg/l) 2 nd Sampling Event Unfiltered (mg/l) TSS 165 154 COD 1513 1294 BOD 5 623 520 CBOD 5 529 421 TKN 221 234 NH 3 129 183 NOxN 0.5 0.43 NO 2 N 0 0.05 TP 34.8 36.6 PO 4 P 10.4 11.7 Ca +2 28.4 91.1 Mg +2 10.3 13.8
Influent Fractions Fbs - Readily biodegradable (including Acetate) [gcod/g of total ] Default 1 st event 2 nd event 0.27 0.560 0.515 Fac - Acetate [gcod/g of readily biodegradable ] 0.15 0.000 0 Fxsp - Non-colloidal slowly biodegradable [gcod/g of slowly degradable ] 0.5 0.150 0.27 Fus - Unbiodegradable soluble [gcod/g of total ] 0.08 0.083 0.058 Fup - Unbiodegradable particulate [gcod/g of total ] 0.13 0.283 0.29 Fna - Ammonia [gnh3-n/gtkn] 0.75 0.582 0.606 Fnox - Particulate organic nitrogen [gn/g Organic N] 0.5 0.250 0.25 Fnus - Soluble unbiodegradable TKN [gn/gtkn] 0.02 0.020 0.02 FupN - N: ratio for unbiodegradable part. [gn/gcod] 0.035 0.035 0.035 Fpo4 - Phosphate [gpo4-p/gtp] 0.75 0.297 0.32 FupP - P: ratio for influent unbiodegradable part. [gp/gcod] 0.011 0.560 0.515
Biowin Setup DAF - Future Influent (Eff ANA#2) Influent Mixer RAS Mixer Schreiber MLSS Tank Final Clarifier FC Effluent Lime RAS/WAS Splitter WAS June 2009 data used for troubleshooting September 2009 data used for process sizing
Lime Solids Scenarios Influent (Eff ANA#2) Influent Mixer RAS Mixer Schreiber MLSS Tank Final Clarifier FC Effluen Lime RAS/WAS Splitter WAS Lime feed varied to increase CaCO 3 solids in reactor CaCO 3 model ph modeling turned off to accommodate precipitate model
Lime Solids Results 180 18 160 CaCO 3 Solids = 3500 mg/l 16 Clarifier Effluent NH3N (mg/l) 140 120 100 80 60 40 MLSS = 4500 mg/l Temperature = 10.2 deg C CaCO 3 Solids = 2500 mg/l 14 12 10 8 6 4 VSS SRT (Days) Effluent NH3 20 VSS SRT (days) 2 0 0 0.00 500.00 1,000.00 1,500.00 2,000.00 2,500.00 MLVSS (mg/l)
Lagoon Solids Scenarios Influent solids of 100, 160, 300, 600, 1000 Ratio d solids in influent fractions & COD MLSS of 2000 & 3500 mg/l Three different temperatures No change in soluble constituents
Lagoon Solids Results - Winter 160 Steady State Simulations with Influent Q (0.6 MGD) and T=9.74oC 140 Schrieber Tank Effluent NH3N (mg/l) 120 100 80 60 40 20 0 100 167 300 600 1000 Schreiber Tank Influent TSS (mg/l) 3,500 mg/l MLSS 2,000 mg/l MLSS
Lagoon Solids Results - Average 80 Steady State Simulations with Influent Q (0.6 MGD) and T=17.73oC 70 Schrieber Tank Effluent NH3N (mg/l) 60 50 40 30 20 10 0 100 167 300 600 1000 Schreiber Tank Influent TSS (mg/l) 3,500 mg/l MLSS 2,000 mg/l MLSS
Lagoon Solids Results - Summer 1.40 Steady State Simulations with Influent Q (0.6 MGD) and T=26.07oC 1.20 Schrieber Tank Effluent NH3N (mg/l) 1.00 0.80 0.60 0.40 0.20 0.00 100 167 300 600 1000 Schreiber Tank Influent TSS (mg/l) 3,500 mg/l MLSS 2,000 mg/l MLSS
Process Recommendations Permanent DAF effluent 100 mg/l TSS LSI control strategy Denitrification tank / WAS Storage Increase / recover alkalinity Prevent float Chemical feed / flocculation / splitter New settling tank NRCY / RAS Pump Station
Reactor Sizing Simulations Inf (Eff ANA#2) DAF Carbon Bypass Splitter Inf & NRCY Mixer RAS Mixer Anoxic_1 Carbon Bypass Mixer Schreiber Tank NRCY Splitter FC FC Eff Lime RAS/WAS Splitter DAF Solids (back to lagoon) WAS Added denitrification reactor to Biowin Evaluated COD removal and NO 3 reduction
Reactor Sizing - Effluent Nitrate Anoxic Reactor Hydraulic Retention Time (based on Q = 0.61) Simulated Effluent Nitrate Concentration (mg/l) 0 hrs (no anoxic zone) 185 4 hrs 120 6 hrs 93 8 hrs 79 16 hrs 59 NOTES: MLSS = 3000 mg/l Temp = 9.74 deg C Internal recyle rate of 300 % of influent flow rate
Reactor Sizing COD Consumption 4,500 Filtered COD Consumed in Anoxic Reactor, (ppd, COD-XG) 4,000 3,500 3,000 2,500 2,000 1,500 1,000 500 0 COD Removed = 700 mg/l COD Removed = 550 mg/l 3,000 mg/l MLSS - T=9.74oC 3,000 mg/l MLSS - T=17.73oC 4 6 8 16 Anoxic HRT (hours, Inf Q)
Reactor Sizing Effluent Ammonia 1.80 270 1.60 240 Simulated Clarifier Effluent NH3N, (mg/l) 1.40 1.20 1.00 0.80 0.60 0.40 Efflent NH3N- w/o AX Efflent NH3N - AX HRT = 6hrs 210 180 150 120 90 60 Simulated Clarifier Effluent NO3, (mg/l 0.20 0.00 Efflent NO3N - w/o AX Efflent NO3N - AX HRT = 6hrs Q = 0.61 MGD Anoxic HRT = 6 hours Temperature = 9.74 deg C 3,000 2,750 2,500 2,250 2,000 30 0 MLSS (mg/l)
Reactor Sizing Internal Recycle 140 120 FC Effluent NO3N, (mg/l) 100 80 60 40 20 0 0% 50% 100% 200% 300% NRCY (%, Inf Q) Q = 0.61 MGD Anoxic HRT = 6 hours Temperature = 9.74 deg C
Reactor Design
Current Status Under construction Complete by 3/31/2011
Summary / Conclusions Biowin useful as a tool in both troubleshooting and design Illustrative tool Multiple simulations allows for process optimization Effectiveness of model dependent on characterization Tailored to domestic, but can be flexed for industrial wastes and unique sidestreams
Questions? jgellner@hazenandsawyer.com