OBG PRESENTS: Alphabet Soup: MBBR Ain'tExactly ENR or IFAS!€¦ · Trickling filters...

OBGPRESENTS:

AlphabetSoup:MBBRAin't ExactlyENRorIFAS!LessonsAlongtheWaytoOptimizationTri-AssociationConference2017 8/30/17 2:30PM-3:00PMBillMeinert&NedTalbot,OBG

ProjectOverview

Overview

MMoving

BBed

BBiofilm

RReactor

FixedBiofilm/IR/TN(&someTP)Removal FixedBiofilm+SS/IR+RAS/TN+EBio-P

IIntegrated

FFixed-Film

AActivated

SSludge

Protectedbiomassonplasticmediaexpandscapacityandeffluentquality

Nutrients,peakflows,coldtemps

3

MBBRforMartinsburg

Benefits Obstacles

4

MBBRPiloting

PilotedSeptember2011– March2012

WarmandCold,DryandWet,IRAdjustments

AirdistributionandDOcontrol(+/-),Noclarification

Initial– Nitrification,startup,warm&cold(vs.Tower)

5

Comparison– DN,TowerEffluentDO&temp,Carbon

Pre- &Post-AnoxicMBBRSizing

BOD-limitedNutrientRemoval(addCarbon)

WRRFProject:MARTINSBURG,WV

3MGD(12MGDinfluent,10MGDpeaktobio)

5mg/LTNeffluentlimit

0.5mg/LTPeffluentlimit

ProjectSummary

Demo:

Tricklingfilters

Nitrificationtower

Modifications:

NewHeadworks,Biological,BallastedPolishing

ImproveClarification,Disinfection,AnaerobicDigestion

NewSolidsHandling,OperationsBuilding

Tankconfiguration

Minimizeapproachvelocity(~30-35m/hr max)

Failsafestocontainmedia

Physicalandoperational

ImportantDesignDetails

Variationbetweenvendors

Pre-purchase/selection

7

Pre-PurchaseSelection

Suez(IDI) Kruger Biowater Technology Headworks

Operationaldeadline– June2016

Pre-purchasedMBBR

Lowestlife-cycle,capitalcosts

PotentialchangetoIFASinfuture

8

MartinsburgWWTPUpgrade

SimplifiedProcessFlowDiagram

9

1.Headworks

2.MBBR

4.Co-Mag

3.Disinfection

5.SolidsHandling

6.O&M,Lab

10

New5mmscreensandgritPHASE1(INTERIM)HeadworksTrickingFilterNit.TowerTank2

Pre-Anoxic

EffluentChannel

Swing

InternalRecycle

Re-Aeration

Nitrification

Post-Anoxic

Tank 1

IR

Tank 2

INTERIMWASTEWATERTREATMENT

Keep1tricklingfilteronline

Site/sizerestrictions

BuildMBBRin2stages

CanalsobypassTank1

Maintenance

Or,ifmediablockage

11

NEWTANKS

Allowedfor“ideal”reactors

SquareZones

3-4ft freeboard

Overflowsbetweenreactors

12

MartinsburgWWTPUpgrade

InterimWastewaterTreatment

13

Changefrom8hrto24hrcompositeSampling

8-hrovernightcomposite

24-hrovernightComposite

(a30%jump)

Headworks

Status:Constructed,Optimized

PHASE2(FINAL)HeadworksTank1+2

SolidsHandlingOperations

15

ConstructionStaging,Startup,Optimization(LessonsLearned)

MBBREquipmentPre-PurchaseChallenges

TimingofEquipmentDelivery

StorageDuringPhasing

VendorControlsEngineerTurnover

LackofVendorStartupSupport

ContractCoordination

Phase1StartupJune2015

InitialStartup

• PESplitbetweenTFandMBBR• AllflowtoNitrificationTower• CoagulanttoPC– removeBOD

After2weeksofoperation

• AllPEtoMBBR• Toweroffline• CoagulantContinued

MinimumflowrequiredforfilterarmsSlowbiologicalgrowthonmediaConstruction6monthsbehind

LESSONSFROMCONSTRUCTION

IRzoneflapgates

Highmixingvelocity

MinimizeDOentrainment,MediabackintoIRzone

Flatscreenaddition

Still- mixingisgood!

Keepsmediafromblocking

Squaretanks,airscourfacilitateroll

Warrantylengths

Tank2endnearperformancetest

19

Phase2StartupMarch2016

VariableMBBRInfluentLoading

ConstructionImpacts- AnaerobicConditionsinPrimaryClarifiers

ConstructionSequencing,DiurnalVariations- HighAmmoniainDewateringFiltrate

Interim,PartialProcessPerformance

Limiteddatatodrivedecisions

SCADATrendingnotonline

NutrientProbesnotinstalled

Onlygrabandcompositesamples

Toomuchconstructionworkwaspushedtotheend!

LESSONSFROMCONSTRUCTION

AerationSystemSafetyFactorisKey

Adequateblowerpressure/tempcapacity

AutoDOcontrolofeachzoneaddspressuretosystem

Monitortemp/pressurealarmsseparatelyfortroubleshooting

ManualBlowerControlistricky

CheckDOatseveraltimesduringtheday

Underaerationduringdayworsethanoveraerationatnight

MotorizedValveSetupCritical

Integratewithprocesscontrolperformancetesting

NitrificationProcessPerformance8/2016-8/2017

Nitrificationestablished,ButLostdueextendedaerationsystemissues Nitrificationre-established,

UsingSwingZone,CorrectingMBBRbiofilmmigration

Nitrifier &Denitrifier PopulationsandSwingbySeason

Pre-Ax Nit-1 Nit-2 Post-AxSwing

DenitrificationProcessPerformance8/2016-8/2017

NitrificationestablishedinPhase1,DenitrificationinPhase2

Denitrificationestablished,butnotoptimizeduntilSCADA,Auto,andCarbonfeedandAerationSystemfixed

CoagulantfeedandCoMag ballastedflocusedtopolisheffluentTSSandTP.

Conclusions&PlanGoingForward(Post-Construction)

ProcessDifferencesReinforcedduringConstruction&Operation

SuspendedGrowthProcess• Biologycanmovethroughoutprocesstrain• 2mg/LorlessDOinliquidphaseforaerobicprocesses• Suspendedbiologyactsasabuffer• DOcarryovercontrolledbytaperedaerationtomatchload

FixedFilmProcess• Biologyfixedinzones.Adjustmentstaketime.• 3-4mg/LDOliquidphasetodriveoxygenintofilm• QuickerDOchanges.DOcontrolmorechallenging.• HigherpotentialforDOcarryovertopost-anoxic.Additionalcarbonneededfordenitrification.

…anddifferentmixing(RAS,IR)andsludgewastingabilities.

Optimization&PathForward

AutoDOandcarboncontrolrequiredforoptimization.

Blowersbeingmodifiedtoprovidebetterpressure/temperaturecapability

Swingzoneuseandnumberoftrainsrequiredinwintertobeoptimizedduringnextcouplemonths.Transitiontostartearly.

Solidsrecycleswillbeanalyzedtodeterminewaystospreadoutammoniaload– Equalization?

OBG|THERE’SAWAY

Questions?Bill.Meinert@obg.com,443-474-7332;Ned.Talbot@obg.com,301-731-1150