Pilot Testing a High-Speed Turbo Blower at the City of Plano, Illinois Water Reclamation Facility" Presented by: Mark J. Halm, P.E. - Yokhana Alkass, LEED AP EEC, PC Darrin B. Boyer - City of Plano- Illinois
Presentation Outline Today s presentation will focus on: Plant Background Liquid Train Design Elements Solids Train Design Elements Existing Blowers Technology Results
Background The $13.6 million Improvements Project was completed in November 2006. Designed for Biological Nutrient Removal The design average flow capacity of the plant was increased from 0.95 MGD to 2.44 MGD.
Liquid Train Design Elements Preliminary Treatment Building houses: Raw sewage enters the building via gravity Two 6 mm bar screens, washers and compactors Two aerated grit tanks Three recessed impeller grit pumps Two grit classifiers Conveyor for compacted/washed screening and classified grit
Liquid Train Design Elements Secondary Treatment Control Building houses: The mixed liquor flow distribution valves to the final clarifiers, The non-potable water reuse pumps, The plant drainage/scum pumps, and The internal return pumps which pump mixed liquor at a rate up to 300% of the influent flow to the anoxic selectors for denitrification Series Selector Tanks for Biological Nutrient Removal
Liquid Train Design Elements Secondary Treatment, continued: Series Aeration Tanks Two 75 foot diameter Final Clarifiers New Blower Building and 1.2 MW Generator
Liquid Train Design Elements UV Disinfection Discharge to Cedar Dell Golf Course Irrigation Pond and Finally to Big Rock Creek and the Fox River SCADA Control System
Design Elements
Solids Train Design Elements WAS Holding Rotary Drum Thickening Aerobic Digestion Centrifuge Dewatering Sludge Storage and Land Application
Focus on Blowers Sizing of the Centrifugal Blowers (AOR): Average Month BOD5 Load of 3,750 lbs/d Average Month TKN Load of 562 lbs/d Max Month approximately 20% greater than average day Average Month AOR 7,354 lbs/d Oxygen Maximum Month AOR 8,825 lbs/d Oxygen
Focus on Blowers Sizing of the Centrifugal Blowers (SOR): Alpha 0.6 Beta 0.98 SOTE 30% Max Month SOR of 18,950 lbs/d at 20 degrees C Airflow Requirement of 2,527 scfm
1-Jan-11 1-Feb-11 1-Mar-11 1-Apr-11 1-May-11 1-Jun-11 1-Jul-11 1-Aug-11 1-Sep-11 1-Oct-11 1-Nov-11 1-Dec-11 FLOW, MGD Focus on Blowers 3.500 3.000 2.500 2.000 1.500 1.000 0.500 0.000
1-Jan-11 1-Feb-11 1-Mar-11 1-Apr-11 1-May-11 1-Jun-11 1-Jul-11 1-Aug-11 1-Sep-11 1-Oct-11 1-Nov-11 1-Dec-11 AOR, LBS/D Focus on Blowers 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1,000 500 -
Total Load on Blower Focus on Blowers Aerobic Zones of BNR Process: Aerated Channels: Anoxic/Anaerobic Selectors: WAS Holding: TOTAL AIR LOAD: 2,527 scfm 900 scfm 866 scfm 1,250 scfm 5,543 scfm
Focus on Blower Spec 2004 SCFM is determined at 68 degrees F and 38% RH To Correctly Specify the Blower Need to Calculate ACFM SCFM to ACFM (adjust for temp., altitude, relative humidity) Three Blowers at 2,490 ACFM Capacity
1-Jan-11 1-Feb-11 1-Mar-11 1-Apr-11 1-May-11 1-Jun-11 1-Jul-11 1-Aug-11 1-Sep-11 1-Oct-11 1-Nov-11 1-Dec-11 SCFM REQ'D Focus on Blowers 1,400 1,200 1,000 800 600 400 200 -
Focus on Energy With the Rising Cost of Energy and the Environmental Impacts of Producing Power, Energy Conservation is Again in the Forefront EPA has Published a Compendium of Energy Saving Concepts for Wastewater Treatment Facilities in September of 2010 EPA 832-R-10-005 In WWTP s the largest demands for power are typically the blowers and raw sewage pumps
Focus on Energy The City s Water Reclamation Facility is Gravity Fed. The City elected to pilot test a turbo blower unit with the goal of evaluating the operational capabilities and potential energy savings APG-Neuros had a unit available of approximately the size required and was willing to pilot test
Focus on Turbo Blower Technology Turbo blowers operates at speeds of 20,000 rpm to more than 40,000 rpm Initial Pilot of a NX-100 Neuros Blower
Focus on Turbo Blower Technology Initial Pilot of a NX100 Revised Pilot with a NX75
Focus on Turbo Blower Technology
Focus on Turbo Blower Technology Differences in Technologies Bearing- Magnetic or Air Foil Impeller- Cast or Forged One Core-Dual Core There are a Number of Manufacturer s of Turbo Blowers: Neuros APG HIS ABS K-Turbo Atlas-Copco
Focus on Installation Blower building was designed for 4 centrifugal multistage blowers 3 are in service Therefore, there was a space for the pilot Normally only one blower required for process Therefore, plant staff was able to cannabalize piping and valves and make electrical connections using parts from one of the spare centrifugal blowers.
Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 kw-hr/d Focus on Results Monthly Average Power Demand 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 -
Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 kw-hr/d Focus on Results Blower Power / Total Power 45% 40% 35% 30% 25% 20% 15% 10% 5% 0%
Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Focus on Results Monthly Power Cost for Activated Sludge Blowers $8,000 $7,000 $6,000 $5,000 $4,000 $3,000 $2,000 $1,000 $0
Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Dollars Focus on Results $120 Cost/ Day per 1,000 Pounds of AOR/Day $100 $80 $60 $40 $20 $-
Focus on Results Total Costs for Installation Approximately $185,000 Projected Annual Savings - $45,000 Simple Payback- Approximately 4 years NPV of Savings over 20 years - $675,000
Thank You to the City of Plano For Their Assistance in Preparing This Presentation