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Use of Biowin for Process Troubleshooting / Design for a Unique WastewaterOWEA Plant Operations and Lab Analysis Workshop
W. James Gellner
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Outline
• Introduction / Problem Overview– Plant Issues– Biowin Overview
• Special Sampling• Simulations for Plant Troubleshooting• Simulations for Upgrade Design• Summary / Conclusions
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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
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Plant Schematic
PROCESSING PLANT(Kill Through Deboning
– Including All Screening)
CLARIFICATION TANK
(0.22 MG)
DISINFECTION (UV)
RAS
WAS
EFFLUENT
ACTIVATED SLUDGE TANK
(0.83 MG)
ANAEROBIC LAGOONS / FLOW
EQUILIZATION(2.24 MG, 8.52 MG)
AEROBIC LAGOONS / BACKUP FLOW EQUILIZATION
(9.07 MG)
TERTIARY FILTRATION(Schrelber
Fuzzy Filter, 0.4 microns) CASCADE
AERATION
EMERGANCYBYPASS
CHEMICAL ADDITION (pH & Alkalinity Control,
Hydrated Lime)
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Effluent Requirements
Parameter 30 Day Concentration (mg/l)
Daily Concentration (mg/l)
BOD5 20 30Total Suspended Solids 20 30
Ammonia (summer) 0.93 1.85Ammonia (winter) 1.77 3.54
Oil and Grease 10 15E 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
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Influent Loadings
Parameter Average Daily MaximumFlow 0.61 MGD 1.20 MGD
BOD5 3860 lb/day (760 mg/l) 8060 lb/dayCOD 8190 lb/day (1610 mg/l) 13300 lb/dayTSS 1120 lb/day (220 mg/l) 2070lb/dayNH3 790 lb/day (155 mg/l) 1620 lb/day
Alkalinity 3120 lb/day (610 mg/l) 5280 lb/day
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ATS / Hazen and Sawyer
• 11/2008• CPE / Process Evaluation
– Detailed sampling & analysis
• DAF implementation• Design of improvements
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Ammonia / Solids Violations
• Repeated (inconsistent operations)• Overwasting of biological solids• Lagoon solids slugs• Overfeed of lime to biological system• Poor settling – filaments• “FLIP!”
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BioWin Overview
• Full plant simulation software• ASDM – Activated Sludge/Anaerobic
Digestion (IWA) • Graphical user interface
– User friendly, Windows style• Requires detailed characterization
Influent (Eff ANA#2) Schreiber MLSS Tank Final Clarifier
WAS
FC EffluentRAS Mixer
RAS/WAS Splitter
Influent Mixer
Lime
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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
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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
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Special Sampling
• Characterize influent• Capture process
conditions• Allow for accurate
representation of process performance
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COD Components
Total COD
Biodegradable
Soluble Particulate
Unbiodegradable
Soluble Particulate
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TKN Components
Total TKN
Free Ammonia Organic Nitrogen
Biodegradable
Soluble Particulate
Unbiodegradable
Soluble Particulate
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“The Filtration Tree”
Symbol Filter RepresentationXX Not filtered Represents total sample (with
particulate and soluble)XG Glass fiber –
1.5 micronTraditional breakpoint between particulate and soluble
XM Membrane filter – 0.45 micron
Difference between XM and XG represents colloidal
XF Flocculated / filtered with 0.45 micron
Used to estimate readily biodegradable material (COD)
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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)
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Sampling Schematic
GRAB
COMPOSITE
PROCESSING PLANT(Kill Through Deboning
– Including All Screening) INSTALLED
DAF CLARIFICATION TANK
(0.22 MG)
DISINFECTION (UV)
RAS
WAS
EFFLUENT
SAMPLE LEGEND
ACTIVATED SLUDGE TANK
(0.83 MG)
ANAEROBIC LAGOONS / FLOW
EQUILIZATION(2.24 MG, 8.52 MG)
AEROBIC LAGOONS / BACKUP FLOW EQUILIZATION
(9.07 MG)
TERTIARY FILTRATION(Schrelber
Fuzzy Filter, 0.4 microns) CASCADE
AERATION
DAFSLUDGE
EMERGANCYBYPASS
CHEMICAL ADDITION (pH & Alkalinity Control,
Hydrated Lime)
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Special Sampling Results
Constituent 1st Sampling EventUnfiltered (mg/l)
2nd Sampling EventUnfiltered (mg/l)
TSS 165 154COD 1513 1294BOD5 623 520
CBOD5 529 421TKN 221 234NH3 129 183
NOxN 0.5 0.43NO2N 0 0.05
TP 34.8 36.6PO4P 10.4 11.7Ca+2 28.4 91.1Mg+2 10.3 13.8
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Influent FractionsDefault 1st event 2nd event
Fbs - Readily biodegradable (including Acetate) [gCOD/g of total ] 0.27 0.560 0.515
Fac - Acetate [gCOD/g of readily biodegradable ] 0.15 0.000 0Fxsp - Non-colloidal slowly biodegradable [gCOD/g of slowly
degradable ] 0.5 0.150 0.27Fus - Unbiodegradable soluble [gCOD/g of total ] 0.08 0.083 0.058
Fup - Unbiodegradable particulate [gCOD/g of total ] 0.13 0.283 0.29Fna - Ammonia [gNH3-N/gTKN] 0.75 0.582 0.606
Fnox - Particulate organic nitrogen [gN/g Organic N] 0.5 0.250 0.25Fnus - Soluble unbiodegradable TKN [gN/gTKN] 0.02 0.020 0.02
FupN - N: ratio for unbiodegradable part. [gN/gCOD] 0.035 0.035 0.035Fpo4 - 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
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Biowin Setup
• June 2009 data used for troubleshooting• September 2009 data used for process sizing
Influent (Eff ANA#2) Schreiber MLSS Tank Final Clarifier
WAS
FC EffluentRAS Mixer
RAS/WAS Splitter
Influent Mixer
Lime
DAF - Future
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“Lime Solids” Scenarios
• Lime feed varied to increase CaCO3 solids in reactor
• CaCO3 model• pH modeling turned off to accommodate
precipitate model
Influent (Eff ANA#2) Schreiber MLSS Tank Final Clarifier
WAS
FC EffluenRAS Mixer
RAS/WAS Splitter
Influent Mixer
Lime
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“Lime Solids” Results
0
2
4
6
8
10
12
14
16
18
0
20
40
60
80
100
120
140
160
180
0.00 500.00 1,000.00 1,500.00 2,000.00 2,500.00
VSS
SRT
(Day
s)
Cla
rifie
r Effl
uent
NH
3N (m
g/L)
MLVSS (mg/L)
Effluent NH3
VSS SRT (days)
MLSS = 4500 mg/lTemperature = 10.2 deg C
CaCO3 Solids = 3500 mg/l
CaCO3 Solids = 2500 mg/l
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“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
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“Lagoon Solids” Results - Winter
0
20
40
60
80
100
120
140
160
100 167 300 600 1000
Schr
iebe
r Tan
k Ef
flue
nt N
H3N
(mg/
L)
Schreiber Tank Influent TSS (mg/L)
Steady State Simulations with Influent Q (0.6 MGD) and T=9.74oC
3,500 mg/L MLSS 2,000 mg/L MLSS
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“Lagoon Solids” Results - Average
0
10
20
30
40
50
60
70
80
100 167 300 600 1000
Schr
iebe
r Tan
k Ef
flue
nt N
H3N
(mg/
L)
Schreiber Tank Influent TSS (mg/L)
Steady State Simulations with Influent Q (0.6 MGD) and T=17.73oC
3,500 mg/L MLSS 2,000 mg/L MLSS
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“Lagoon Solids” Results - Summer
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
100 167 300 600 1000
Schr
iebe
r Tan
k Ef
flue
nt N
H3N
(mg/
L)
Schreiber Tank Influent TSS (mg/L)
Steady State Simulations with Influent Q (0.6 MGD) and T=26.07oC
3,500 mg/L MLSS 2,000 mg/L MLSS
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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
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Reactor Sizing Simulations
• Added denitrification reactor to Biowin• Evaluated COD removal and NO3 reduction
Inf (Eff ANA#2) Schreiber Tank FC
WAS
FC EffRAS Mixer
RAS/WAS Splitter
Inf & NRCY Mixer
Lime
DAF Solids (back to lagoon)
DAF Anoxic_1Carbon Bypass Splitter NRCY SplitterCarbon Bypass Mixer
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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 1206 hrs 938 hrs 7916 hrs 59
NOTES:MLSS = 3000 mg/lTemp = 9.74 deg CInternal recyle rate of 300 % of influent flow rate
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0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
4 6 8 16
Filt
ered
CO
D C
onsu
med
in A
noxi
c R
eact
or, (
ppd,
CO
D-X
G)
Anoxic HRT (hours, Inf Q)
3,000 mg/L MLSS - T=9.74oC
3,000 mg/L MLSS - T=17.73oC
Reactor Sizing COD Consumption
COD Removed = 550 mg/l
COD Removed = 700 mg/l
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Reactor Sizing – Effluent Ammonia
0
30
60
90
120
150
180
210
240
270
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
1.80
3,000 2,750 2,500 2,250 2,000
Sim
ulat
ed C
lari
fier
Eff
luen
t NO
3, (m
g/L
Sim
ulat
ed C
lari
fier
Eff
luen
t NH
3N, (
mg/
L)
MLSS (mg/L)
Efflent NH3N- w/o AX
Efflent NH3N - AX HRT = 6hrs
Efflent NO3N - w/o AX
Efflent NO3N - AX HRT = 6hrs
Q = 0.61 MGDAnoxic HRT = 6 hoursTemperature = 9.74 deg C
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Reactor Sizing – Internal Recycle
0
20
40
60
80
100
120
140
0% 50% 100% 200% 300%
FC E
fflu
ent N
O3N
, (m
g/L)
NRCY (%, Inf Q)
Q = 0.61 MGDAnoxic HRT = 6 hoursTemperature = 9.74 deg C
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Reactor Design
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Current Status
• Under construction• Complete by 3/31/2011
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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