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This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 690323

Horizon 2020 research and innovation programme

Project: No 690323 SMART-Plant

Full project title:

Scale-up of low-carbon footprint material recovery techniques

in existing wastewater treatment plants (SMART-Plant)

DeliverableD3.2

Construction and commissioning of the

SidestreamSMARTechs

Due date of deliverable: 31 May 2017

Actual submission date: 04 Oct 2017

Ref. Ares(2017)4843381 - 04/10/2017

Project: No 690323

SMART-Plant D3.2

DOCUMENT INFORMATION:

Deliverable Number D3.2 Title: Construction and commissioning of the

Sidestream SMARTechs

Work Package Number WP3 Title: Side- and Down-stream SMARTechnologies

Due date of deliverable Contractual M6 Actual M6

Version number 1.0

Format Pdf file

Creation date 15/05/2017

Version date 20/09/2017

Type R DEM DEC OTHER ETHICS

Dissemination Level PU Public CO Confidential

Rights

Copyright “SMART-Plant Consortium”.

During the drafting process, access is generally limited to the SMART-Plant

Partners.

Responsible author

Name:

Paolo Pozzato, Davide

Savio, Monica

Miglioranza

E-mail:

[email protected];

[email protected],

[email protected]

Partner: SCAE Phone: +39 0444 360 533

Other authors

Name:

Constantinos Noutsopoulos,

Simos Malamis, Daniel Mamais,

Andreas Andreadakis, Evangelos

Statiris

Partner: NTUA

Name: Nicola Frison, David Bolzonella Partner: UNIVR

Name: Daniele Renzi Partner: ATS

mailto:[email protected]

mailto:[email protected]

Project: No 690323

SMART-Plant D3.2

Name:

Ioanna Droubogianni, Dimitra

Kollia, Panagiotis Lalis, George

Zarras

Partner: AKTOR

Brief Description Deliverable 3.2 is part of WP3 which is related to side- and down-stream

SMARTechnologies. More specifically D3.2 focuses in three sidestream

SMARTechnologies that are integrated in the existing conventional sewage

sludge treatment line to provide more energy efficiency for the i) removal of

nitrogen, ii) recovery of phosphorus and iii) recovery of PHA. The D3.2 is to the

construction and the commissioning of the sidestream SMARTechs.

Keywords sidestream Smartechs, construction, commissioning

Version log Revision history

Rev. No. Issue Date Modified by Comments

Version 1 03/10/2017 Francesco Fatone Minor revision by Coordinator before

submission

Project: No 690323

SMART-Plant D3.2

TABLE OF CONTENTS

Document Information: ......................................................................................................................... 2

Table of Contents ................................................................................................................................... 4

List of Tables .......................................................................................................................................... 5

List of Figures ......................................................................................................................................... 5

Executive Summary ................................................................................................................................ 6

Abbreviations ......................................................................................................................................... 9

1. Introduction ............................................................................................................................. 11

2. SMARTech4a - Sidestream SCENA ........................................................................................... 13

2.1 Technical description of the SMARTech 4A ............................................................................. 13

2.2 List of the electromechanical equipment ................................................................................ 16

2.3 Practical instructions for the operation of SMARTech 4A ....................................................... 23

2.1 Integrability of the Smartech 4a in existing WWTPs ............................................................... 25

2.2 Drawings ‘as built’ .................................................................................................................... 27

2.3 Picture report ........................................................................................................................... 28

3. SMARTech4b - Sidestream THERMAL HYDROLYSIS-SCENA ..................................................... 32

3.1 Technical description of the SMARTech 4B ............................................................................. 32


3.3 Practical instructions for the operation of SMARTech 4B ....................................................... 39

3.1 Integrability of the Smartech 4b in existing WWTPs ............................................................... 42


3.3 Pictures report ......................................................................................................................... 44

4. SMARTech5 - Sidestream SCEPPHAR ....................................................................................... 52

4.1 Technical description of the SMARTech 5 ............................................................................... 52


4.2 Practical instructions for the operation of SMARTech 5 ......................................................... 66

4.3 Integrability of the Smartech 5 in existing WWTPs ................................................................. 72


4.5 Pictures report ......................................................................................................................... 74

Project: No 690323

SMART-Plant D3.2

LIST OF TABLES

Table 1 Specification of the grinder for the mixed primary sludge. .................................................... 16

Table 2 Specification for the installation of the dynamic thickening .................................................. 16

Table 3 Specification of the fermentation unit .................................................................................... 18

Table 4 Specification for the installation of the screw-press separator for the mixed sludge fermentation ........................................................................................................................................ 19

Table 5 Specification of the Short-Cut Sequencing Batch Reactor ...................................................... 19

Table 6 Operation of the fermentation unit ........................................................................................ 23

Table 7 Operation of the screw-press separator ................................................................................. 24

Table 8 Operation of the short-cut Sequencing Batch Reactor. .......................................................... 25

Table 9 Major units and specifications of the electro-mechanical equipment ................................... 36

Table 10 Basic features of automation in the operation of pilot plant system. .................................. 40

Table 11 List of electromechanical equipment and FLOW DIRECTION of the Salsnes Filter .............. 54

Table 12 List of tanks, electromechanical equipment, sensors and FLOW DIRECTION of the Sequencing Batch Fermentation Reactor ............................................................................................ 55

Table 13 List of tanks, electromechanical equipment, sensors and flow direction of the ultrafiltration unit ....................................................................................................................................................... 57

Table 14 Specification of the crystallization unit ................................................................................. 57

Table 15 List of tanks, electromechanical equipment, sensors and flow direction of the nitritation unit.............................................................................................................................................................. 59

Table 16 List of tanks, electromechanical equipment, sensors and flow direction of the PHA-accumulating biomass selection SBR ................................................................................................... 61

Table 17 List of tanks, electromechanical equipment, sensors and flow direction of the accumulation SBR ....................................................................................................................................................... 64

Table 18 Operation of the SF1000 ....................................................................................................... 66

Table 19 Operation of the fermentation unit ...................................................................................... 67

Table 20 Operation unit of the ultrafiltration unit .............................................................................. 68

Table 21 Operation of the crystallizer ................................................................................................. 68

Table 22 Operation of the nitritation unit ........................................................................................... 70

Table 23 Operation of the selection SBR ............................................................................................. 71

Table 24 Operation of the accumulation SBR ...................................................................................... 72

LIST OF FIGURES

Figure 1 Deliverables of WP3 related to sidestream SMARTechs. ...................................................... 11

Figure 2 P&id of the Smartech 4a ........................................................................................................ 13

Figure 3 SMARTech 4a - Dynamic thickener of the sewage sludge ..................................................... 28

Figure 4 SMARTech 4a – Screw-press for S/L of the fermentation sewage sludge ............................. 28

Figure 5 SMARTech 4a – Accumulation tank for the fermentation liquid of mixed sludge ................ 29

Figure 6 SMARTech 4a – Different views of the fermentation ............................................................ 29

Figure 7 SMARTech 4a - Electrical Panel and air compressor of Smartech 4a .................................... 30

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SMART-Plant D3.2

Figure 8 SMARTech 4a -Tank for the acculation of the anaerobic supernatant and influent pump of the scSBR .............................................................................................................................................. 30

Figure 9 SMARTech 4a - Air diffusion system of the scSBR ................................................................. 31

Figure 10 Flow diagram of Psittalia WWTP with SMARTech 4b .......................................................... 32

Figure 11 Major units of SMARTech 4b and their interconnections ................................................... 33

Figure 12. Plan view of SMARTech 4B ................................................................................................. 44

Figure 13 Plan view of SMARTech 4B .................................................................................................. 45

Figure 13 3D drawing of SMATech 4B ................................................................................................. 45

Figure 15 SMARTech 4B – construction phase .................................................................................... 46

Figure 16 SMARTech 4B – construction phase .................................................................................... 46

Figure 17 SMARTech 4B – construction phase – installation of reject water storage tanks ............... 47

Figure 18 SMARTech 4B – construction of raw and treated reject water networks ........................... 47

Figure 19 SMARTech 4B – overview of feed pump, decanting pump and decanting network ........... 48

Figure 20 SMARTech 4B – overview of feed pump and decanting pump ........................................... 48

Figure 21 SMARTech 4B – decanting system ....................................................................................... 49

Figure 22 SMARTech 4B – chemicals and substrate dosing pumps .................................................... 49

Figure 23 SMARTech 4B – chemicals and substrate storage tanks ..................................................... 50

Figure 24 SMARTech 4B – installation of on-line probes .................................................................... 50

Figure 25 SMATech 4B – hydraulic testing of the SBR ......................................................................... 51

Figure 26 SMATech 4B –testing of the aeration system of the SBR .................................................... 51

Figure 27 P&id of the Smartech 5. ....................................................................................................... 52

Figure 28 SMARTech 5 - Integrated container with rotating belt filter intalled ................................. 74

Figure 29 SMARTech 5 - Hopper for the cellulosic primary sludge .................................................... 75

Figure 30 SMARTech 5 - Installation of the Smartech 5 ...................................................................... 75

Figure 31 SMARTech 5 - (a) Sequencing Batch Fermentation Reactor during the installation; (b) Sequencing Batch Fermentation Reactor placed in the platform ....................................................... 76

Figure 32 Ultrafiltration unit ................................................................................................................ 76

Figure 33 SMARTech 5 - Ultrafiltration system (right side) and crystallizer (right side) ..................... 77

Figure 34 SMARTech 5 - Left side,Nitritation, Selection and Accumulation SBRs; Right side, ultrafiltration system and cristallizer. .................................................................................................. 77

Figure 35 SMARTech 5 - Air diffusion system for the nitritation, selection and accumulation SBR. .. 78

Figure 36 SMARTech 5 - Hydraulic testing ........................................................................................... 78

Figure 37 SMARTech 5 – Testing of the air diffusion system. ............................................................. 79

Figure 38 SMARTech 5 – Screenshot of the PLC control panel ........................................................... 79

EXECUTIVE SUMMARY

Deliverable 3.2 is part of WP3 which is related to side- and down-stream SMARTechnologies. More

specifically D3.2 focuses in three sidestream SMARTechnologies that are integrated in the existing

conventional sewage sludge treatment line to provide more energy efficiency for the i) removal of

Project: No 690323

SMART-Plant D3.2

nitrogen, ii) recovery of phosphorus and iii) recovery of PHA. The D3.2 is to the construction and the

commissioning of the sidestream SMARTechs.

A brief description of the sidestream Smartechs involved in WP3 is reported below:

SMARTech 4a focuses in the integration of conventional biogas recovery from sewage sludge with

sidestream energy-efficient and compact nitrogen removal and phosphorus recovery. It applies the

Short-Cut Enhanced Nutrient Abatement system (SCENA) which integrates the following processes:

(o) dynamic thickening of the mixed sludge, (i) acidogenic fermentation of cellulosic sludge to

produce VFAs as carbon source, and (ii) via nitrite nitrogen and phosphorus removal (by P-

bioaccumulation) from sludge reject water using an SBR. In this configuration, nitrogen is removed

through the bioprocesses of nitritation/denitritation, and Enhanced Biological Phosphorus removal

(EBPR) is accomplished via nitrite through the alternation of anaerobic/aerobic/anoxic conditions.

SMARTech4b aims to the integration of the enhanced biogas recovery (by thermal hydrolysis) of

sewage sludge with sidestream energy-efficient and compact nitrogen removal and phosphorus

recovery. It applies and optimize the Short-Cut Enhanced Nutrient Abatement processfor the

treatment of reject water with a very high ammonium nitrogen content (>1.2 gN/L) due to the pre-

treatment of sewage sludge through thermal hydrolysis. In order to increase the biodegradable

COD/N and COD/P ratios reject water from primary sludge gravity thickeners will be used.

Alternatively, sodium acetate will be also employed to increase the readily biodegradable COD in

reject water in order to efficiently remove nitrogen through short-cut nitrification/denitrification and

to accumulate phosphorus in sludge through enhanced biological P removal via denitritation or

aerobically. SMARTech4b is designed to treat approximately 2-3 m3/d of reject water from sludge

dewatering facilities. Based on the design, alternative operational conditions can be employed

depending on the type of external substrate provided. An SBR with an effective volume of at least 9

m3 will be installed and be equipped with aeration system, mixing apparatus, probes and meters for

automatic control of the process. The SBR will be fed with sludge liquors form the dewatering unit

and from primary sludge thickening unit. The sludge liquors before being fed to the SBR will be

collected in two storage tanks. Three chemical dosing units will also be installed in order to provide

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SMART-Plant D3.2

i) for sodium acetate addition (as a complementary external substrate), and ii) for pH control of the

process.

SMARTech5 enables the integration of conventional biogas recovery from sewage sludge with the

energy-efficient nitrogen removal from sludge reject water and the recovery of PHA and struvite. It

applies the Short-Cut Enhanced Phosphorus and PHA Recovery concept (SCEPPHAR), which was

conceived as a modified version of SCENA for WWTPs larger than 150 kPE. It accounts of the following

sub-processes: (i) acidogenic fermentation of cellulosic primary sludge for the production of VFAs

and the release of nitrogen and phosphorus in soluble forms (ammonia and phosphate); (ii) solid and

liquid separation of the fermentation products and recovery of struvite form the sewage sludge

fermentation liquid by the addition of Mg(OH)2 to favour phosphorus precipitation; (iii) ammonium

conversion to nitrite accomplished in a SBR; (iv) selection of PHA storing biomass in a SBR by the

alternation of aerobic feast conditions and followed by anoxic famine conditions for denitritation

driven by internally stored PHA as carbon source; (v) PHA accumulation using a fed-batch reactor to

maximize the cellular PHA content of the biomass harvested from the selection stage.

SMART-Plant has received funding from the European Union’s Horizon 2020 research and

innovation programme under grant agreement No 690323.

Project: No 690323

SMART-Plant D3.2

ABBREVIATIONS

AOB Ammonia Oxidizing Bacteria

BNR Biological nutrient removal

BOD5 Biochemical oxygen demand

CHP Combined heat and power

COD Chemical oxygen demand

DO Dissolved oxygen

DS Dissolved solids

EBPR Enhanced Biological Phosphorus removal

GHG Green house gases

MLSS Mixed liquor suspended solids

MLVSS Mixed liquor volatile suspended solids

NH4-N Ammonium nitrogen

NLR Nitrogen loading rate

NOB Nitrite Oxidizing Bacteria

ORP Oxidation-reduction potential

OTR Oxygen transfer rate

PHA Polyhydroxyalkanoates

PLC Programmable logic controller

SBR Sequencing Batch Reactor

SCENA Short-Cut Enhanced Nutrient Abatement process

SCEPPHAR Short-Cut Enhanced Phosphorus and PHA Recovery concept

SL-DS Sludge liquor-Dewatered sludge

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SMART-Plant D3.2

SL-PS Sludge liquor-Primary sludge

SOTE Diffuser efficiency

SOTR Standard oxygen transfer rate SRT

SVI Sludge volume index

TN Total nitrogen

TP Total phosphorus

ΤS Total solids

TSS Total suspended solids

VFAs Volatile fatty acids

VSS Volatile suspended solids

WAS Waste Activated Sludge

WWTP Wastewater Treatment Plant

Project: No 690323

SMART-Plant D3.2

1. INTRODUCTION

Deliverable 3.2 is part of WP3. WP3 main objective is to test and validate both side- and downstream

SMARTechnologies. More specifically WP3 includes 1) three Sidestream SMARTechs that will

integrate the existing conventional and enhanced biogas recovery from sewage sludge aiming at the

energy-efficient removal of nitrogen, recovery of phosphorus and PHA and 2) two Downstream

SMARTechs that will process the resource rich sludge to recycle raw material for following reuse in

agricultural and construction sectors.

WP3 consists of five tasks:

Task 3.1 enabling sidestream SMARTech 4a with a duration of 42 months

Task 3.2 enabling sidestream SMARTech 4b with a duration of 42 months

Task 3.3 enabling sidestream SMARTech 5 with a duration of 42 months

Task 3.4 enabling downstream SMARTech A with a duration of 30 months

Task 3.5 enabling downstream SMARTech B with a duration of 30 months

In the context of WP3 six deliverables are foreseen. Deliverables 3.1-3.3 & 3.5 are related to the three

sidestream SMARTechs. The short title of each of the deliverables and their month of delivery is

illustrated in Figure 1.

Figure 1 Deliverables of WP3 related to sidestream SMARTechs.

The present report is the second of these series of deliverables. D3.2 presents the costruction,

installation and commissioning of the sidestream Smartetech.

Project: No 690323

SMART-Plant D3.2

D3.2 is structured in four chapters and annexes, including this introduction, which presents the

objectives of this report and its structure. For each technology, the report is structurized a technical

of the SMARTech is

1- Technical description of the SMARTech 4a, 4b and 5;

2- List of the electromechanical equipment 4a, 4b and 5;

3- Practical instructions for the operation of SMARTech 4a, 4b and 5;

4- Drawings ‘as built’

5- Picture reports

Finally, Annex presents the executive drawing “as built” of the three Smartechs.

Project: No 690323

SMART-Plant D3.2

2. SMARTECH4A - SIDESTREAM SCENA

2.1 Technical description of the SMARTech 4A

The Smartech 4a is an innovantive technology aiming the via-nitrite nitrogen phosphorus removal

from the anaerobic supernatant. The overall system can be described according to the following

integrated operational units:

1) (alkaline) fermentation of thickened sewage sludge at mesophilic conditions (37°C) for the

on-site production of best available carbon source (BACS), which is the optimal mix of volatile fatty

acids;

2) A solid/liquid separation of the fermented sewage sludge by a screw press;

3) A Sequencing Batch Reactor (SBR) for the short cut biological nitrogen removal and

phosphorus recovery via-nitrite through the dosage of the sewage sludge fermentation liquid.

Figure 2 P&id of the Smartech 4a

The optimization of the Smatech 4a was carried out during the design phase by the implementation

of the dynamic thickening of the mixed sewage sludge, which allows the increase of the organic

loading rate and the reduction of the sludge volume fed to the anaerobic digestor and the

fermentation unit. The dynamic thickener (SCAE) allows the thickening of up to 100 m3 of sewage

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SMART-Plant D3.2

sludge per day, according with a flowrate of 20 m3/h. The final concentration of the sewage sludge

will be around 5% (Total Solid based) thanks to the addition of a polyelectrolyte solution (0.8% of

active compound) by a dedicated machine. Around 10 m3 of thickened sludge fed the fermentation

unit, which has a total volume of 50 m3. The fermentation process works at around 30°C thanks to

the heater fed to the biogas produced from the full scale anaerobic digestor. A constant hydraulic

retention time of 5 days is controlled by two pneumatic and opposite valves, which are able to divert

the flowrate of the thickened sewage sludge to the fermentation unit or to the digestor according

with set-point level achieve in the fermentation unit. The solid/liquid separation of the fermented

sewage sludge is carried out by a screw-press (SCAE) able to produce around 2-4 m3/h of

fermentation liquid rich of volatile fatty acids. The liquid fractio is stored in a storage tank of 20 m3

to make it available for the further utilization during the anaerobic and anoxic phase of the scSBR.

The solid fermented fraction (13-15% total solids based) is not disposed due to the still high biogas

production potential, but it is mixed with the thickened mixed sludge which fed the anaerobic

digestor.

The scSBR has a maximal working volume of 70 m3, which allow the treatment of the daily flowrate

of anaerobic supernant produced after the dewatering operation of the anaerobic digestate under

3-4 cycles. The scSBR is equipped with a mixing system having a nominal power of 1.5 kW. The

aeration system consist of a volumetric blower (nominal power 11 kw) and n°80 diffusers (INVENT)

able to provide around 500 m3/h of compressed air at 400 mbar of pressure, in order to provide an

oxygen transfer efficiency up to 15%. The dissolved oxygen concentration in the bulk will be

controlled during the aerobic phase at 1.5 mg/L by a Variable Frequency Device (VFD) to module the

air flowrate of the blower.

There are two centrifugal pumps from FLYGHT manufacturer with capacity of 70 and 65 m3/h

respectively for the feeding and discharge of the scSBR. In each cycle, the feeding pump feeds

automatically around 10-15 m3 of anaerobic supernatant, which is taken directly from the storage

tank of 90 m3. The latter has a capacity to store enough anaerobic supernant for 2-2.5 days, which

takes into account the days when the WWTP of Carbonera is not supervised from the operators

(week-end) or when the dewatering operation are not taking placed. At the end of the cycle, the

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centrifugal sumberged pump installed at 0.8 m from the bottom of the scSBR allows the discharge of

the treated anaerobic supernatant in the headworks of the main WWTP.

The SBR is equipped with sensors from HACH-LANGE company which are based on a floating

chamber. The sensors allows the monitoring of several parameters and by them also the control of

the nitrogen forms, so to control the cycle lenght. The sensors installed are: pH, Dissolved Oxygen

(DO), Conductivity (COND), Oxydation Reduction Potential (ORP), Mixed Liquor Suspended Solids

(MLSS).

All the signal from the sensor are first collected by the controller SC1000 (HACH-LANGE) and then

transfer to a Programmable Logic Controller (PLC, SIEMENS) via a modbus protocol. The data can be

also recorded and used from the remote system of ATS. The control algortims installed in the PLC

provides the control of the electrical equipments, including the lenght of each phases, the automatic

dosage of the carbon source and the variable frequency driver to control the right dissolved oxygen

during aerobic phase.

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SMART-Plant D3.2

2.2 List of the electromechanical equipment

Table 1 Specification of the grinder for the mixed primary sludge.

GRINDER

CODE DESCRIPTION Unit Value

TR1 Grinder m3/h 20

rpm 270

Hz 50

Description

The grinder is used as for the size reduction of the coarse material present in the mixed sludge. The grinder has 4 self-sharpening cutting blades with a grid having a maximal pore size of 24 mm and 445 cm2 of surface. The maximal operating pressure is 2 bar.

Table 2 Specification for the installation of the dynamic thickening

DYNAMIC THICKENING

CODE DESCRIPTION Unit Flowrate

ID Dynamic thickening m3/h 20

List of electromechanical equipment included

CODE DESCRIPTION Flowrate Intalled power

CONTROL

P4 Feeding ID 20 m3/h 7.5

P7 Emulsion dosage 0-600 L/h -

P8 Poly solution dosage 2 m3/h 1.1

P16 Washing ID pump 5 m3/h 5.5

P05 Feeding DA, POI, FRM 6 m3/h 4

FLOW Feeding from (F)/ Discharge to (D) PUMP CODE

Configuration 1: PRI -> ID -> FRM; Configuration 2: PRI -> ID -> POI; Configuration 3: PRO ->ID-> DA

F1:P04 F2:P07, P08 D1: P05 D2: gravity

SENSORS INSTALLED

Code M012

Description Measurement of the total solids of the mixed sludge

Technical description Probe with combined light infrared absorption for measuring turbidity and suspended solids Independent of the color of the water sample (suitable for waste activated sludge, primary sludge,

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SMART-Plant D3.2

etc).

Component and configuration Configuration: insertion probe with steel probe body; Lenght of cable: 10 meters Technical data: photometer with double IR detector Method of measurement: Turbidity measurement according to DIN EN 27027; Measure Solids, equivalent to DIN 38414 Measurement range: Turbidity: 0.001 - 4.000; Total Solids: 0.001 - 50.0 g / l Accuracy: 1.0% turbidity, ± 0.001 FNU Coeff. Var process: 1.0% according to DIN 38402 Response Time: 0.5 s <T90 <5 min (adjustable) Measurement range: 0.3 s Sample temperature: from + 2 ° C to + 40 ° C Dimensions: (D * L) 60 * 200 mm Weight approx. 2.4 kg

Code M013

Description Measurement of the total solids of the thickened mixed sludge

Technical description Probe with combined light infrared absorption for measuring turbidity and suspended solids Independent of the color of the water sample (suitable for waste activated sludge, primary sludge, etc).


Other equipments included

- Pipe connection flange for inline installation (steel stainless) - System inline/highline fastening system for insertion into no-pressure pipe, steel AISI 304

Project: No 690323

SMART-Plant D3.2

Table 3 Specification of the fermentation unit

FERMENTATION UNIT

CODE DESCRIPTION Size Value

FRM Fermentation unit Diamete 4 m

Height 4 m



CONTROL

P05 Feeding FRM 6 m3/h 7.5 Based on status of V3 and V4

P09 Discharge FRM 6 m3/h 0.55

MX5 Mixer FRM - 1.5 Manual switch on/off

HH Heater 55 (daily needs of biogas)

14.7 kW thermic power

The biogas is taken from the full scale anerobic digestion of sewage sludge


FRM -> PC F1:P05 D1:P09

SENSORS INSTALLED

Code M010

Description Measurement oft he pH and temperature of the fermentation unit (FRM)

Technical description Differential type digital sensor for the measurement of pH and temperature. Electrode not in contact with the liquid bulk.

Component and configuration Material of the electrode: glass; Type of probe: submerged Sensor body: steel Range of measurement: 0 - 14; T=-5° C a 50° C Time of response: pH: < 5 s; T: < 2 min Reference electrode for the control of the impedence of the liquid bulk Lenght of the cable: 10 metri Dimensions: 350 x 44 mm (diameter)


- Fixing system for pH, size 1" steel AISI316

Project: No 690323

SMART-Plant D3.2

Table 4 Specification for the installation of the screw-press separator for the mixed sludge fermentation

SCREW PRESS SEPARATOR

CODE DESCRIPTION Unit Flowrate

PC Screw Press for sludge fermentation dewatering

m3/h 2-4

List of electromechanical equip-ment included


CONTROL

P09 Feeding DA, POI, FRM 6 m3/h 4 Controlled by frequency inverted and leve ultrasonic

P13 Poly solution dosage 0.32 Controlled by frequency inverted and leve ultrasonic

P11 Solid fraction fermentation sludge

0.6-3.2 m3/h 5.5 Controlled by frequency inverted and leve ultrasonic

P10 Liquid fraction fermentation liquid

2-5 m3/h 1.4 Controlled by min/max level sensor M022


FRM-> PC -> SCENA (Liquid fractio) FRM ->PC -> POI (Solid fraction)

F1: P09; F2: P13 D1: P11; D2: P10

POLYELECTROLITE MACHINE

CODE DESCRIPTION Flowrate VALUE

PP2 Machine for preparation of polyelectrolyte solution

m3/h



CONTROL

P7 Emulsion dosage 0-600 L/h 0.5

P8 Poly solution dosage 1.1


PP2 -> FRM PP2 -> ID

F1: P7; D1: P8 D2:

Table 5 Specification of the Short-Cut Sequencing Batch Reactor

Project: No 690323

SMART-Plant D3.2

SHORT-CUT SEQUENCING BATCH REACTOR

CODE DESCRIPTION Size Value

scSBR Short-Cut Sequencing Batch Reactor

Max working Volume

70 m3

Surface 8 x 2.9 m

Height 3.2 m



CONTROL

P1 Feeding scSBR 49 m3/h 1.8 Switch on during the filling phase (control by the PLC)

MX3 Mixer scSBR - 1.5 Switch on during the filling, anaerobic and anoxic phase. (control by the PLC)

BL1 Blower scSBR 170 ÷ 520 m3/h 11 Switch on aerobic phase. (control by the PLC)

P2 Discharge scSBR 70 m3/h 1.35 Switch on during the discharge phase (control by the PLC)

P12 Carbon source 5 m3/h 0.98 Switch on during the anaerobic and anoxic phase (control by the PLC)

P03 Purge 5 m3/h 2.2 Manual switch on/off


FRM -> PC F1:P05 D1:P09

INSTALLED SENSORS

Code DO002

Description Measurement of dissolved oxygen of the selection SBR unit (R006)

Technical description The measurement method is based on the emission of luminescent radiation by a special substance (luminophore) that is excited by light blue emitted by a LED and returning to the normal state emits light red. A photodiode measures the time needed to return to the quiescent state, inversely proportional to the concentration of oxygen present on the luminophore.

Component and configuration - Measuring principle: luminescent optic - Measurement range: 0 to 20.00 mg / L (ppm) O2, 0 to 200% saturation - Accuracy: 0-5 mg / L O2 ± 0.1 mg / L, 5-20 mg / L O2 ± 0.2 mg / L; Temperature: ± 0.2 ° C - Repeatability: ± 0.1mg / L - Resolution: 0.01 mg / L (ppm) O2 / 0.1% saturation

Project: No 690323

SMART-Plant D3.2

- Response time (at 20 ° C): T90 <40 s, T95 <60 s - Calibration: 2 year factory guaranteed and linked to CAP - Operating temperature: 0 ° C to 50 ° C - Storage temperature: -20 ° C to 70 ° C (95% relative humidity) - Max pressure range: 10 bar - Sensor connector: 1 "NPT external thread - Cable length: 10 m - Sensor CAP material: acrylic - Body Probe Materials: CPVC, Polyurethane, Viton®, Noryl®, Stainless Steel 1.4404 (AISI 316L) - Degree of protection: IP68 - Dimensions (L x W): 48.25 mm x 254 mm

Other equipments included PVC mounting kit for LDOsc® probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - red tube closure cap

Code ORP003

Description Measurement of the oxidation-reduction potential of the selection SBR unit R006

Technical description Differential type digital sensor for the measurement of oxidation-reduction potential. Electrode not in contact with the liquid bulk.

Component and configuration Electrode: Platinum Sensor body: AISI 316 stainless steel Probe Type: Immersion Measuring range: from -2000 to +2000 mV; T = -5 ° C to 70 ° C Response Time (T90): ORP: <5 s; T: <2 min Auto Diagnostics: Measurement and reference electrode impedance control Lenght of cable: 10 m Power supply: from sc100 or sc1000 controller Temperature conditions: -20 to 50 ° C Pressure: max. 6.9 bar Template Provider: Automatic NTC 300 Calibration: by process and / or with std buffer solutions Dimensions: 271.3 x 44 mm (length x diameter) Mounting: with chain or with immersion tube Weight: approx. 1 Kg


PVC mounting kit for pH probe Includes:

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- PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - brown tube closure cap

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2.3 Practical instructions for the operation of SMARTech 4A

The dynamic thinkening is fed using the volumetric pump P04 with a flow rate of 20 m3/h. To prevent

clogging due to tatters or other inert materials, a grinder by vogelsang company is installed before

the pump P04. However, in case of mantenance or techical problems, the P04 can be replaced by the

parent installed volumetric pump P06. The thickened mixed sludge (50 gTSS/L) is pumped using a

volumetric pump at 6 m3/h. The influent flowrate and the total solid concentration of the influent

mixed sluge are monitored by the inline sensors M012 (TSS) and M014 (Qf) respectively. A solution

of polyelectrolite is provided using the volumetric pump P09, where the flowrate is automatically

adjusted according with the registered total solids concentration of the influent and thickened mixed

sludge using the inline sensors M013 (TSS) and M015 (Qdig) respectively. Every day, 10 m3/d of

fermented sludge are discharge from the fermentation unit using the P09 and then fed with fresh 10

m3/d of thickened mixed sludge using the P05. The feeding and discharge of the fermentation unit

are controlled by the level sensor M009 and based on two opposite pneumatic valves (V3 and V4).

At minimun fixed level, the pneumatic valve V4 is kept closed, while the pneumatic valve V3 is open,

so to allow the feeding of thickened. The duration of the feeding is 1.7 hours. Once the maximal level

of the fermentation unit is achieved, the valve V3 close and V4 open.

Table 6 Operation of the fermentation unit

Operation phase Parameter that defines the phase duration according to PLC design

Equipment in working mode during this phase controlled by PLC

Filling (1 per day) Level max The valve V3 open while the valve V4 is closed

Decanting (1 per day) Level min The valve V4 open while the valve V3 is closed

The screw press is fed using a volumetric pump with a maximal flowrate of 2-4 m3/h. The solid and

liquid separation of the mixed sludge fermentation results on two main stream: solid and liquid. The

liquid is pumped by a centrifugal pump using the storage tank of the carbon source. The solids

fraction is pumped by to the post dynamic thickening using the volumetric pump P11. The P9 is

controlled by the level of the fermentation. Every day, the screw press accomplishes the solid/liquid

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separation until when the minimun level of the fermentation unit is achieved. The fermentation liquid

produced is relaunched by the pump P10 from a temporary tank to the final storage tank of 20 m3

for its further application to the scSBR. The P10 is turned on when the level of the carbon source is

between the minimun and maximal level of the M022. The P10 stops the operation as soon as the

maximal level M011 is achieved. The eventual excess of carbon source production is drained by the

overflow and so discharged in the mainstream.

Table 7 Operation of the screw-press separator



Filling Operation according to the level MIN and MAX of the fermentation unit

P9

Relunch of the liquid fraction

Operation according to M022 P10

Discharge solid fraction Operation according to M011 P11

The scSBR is fed with around 40 m3/d of anaerobic supernatant using the suberged centrifugal pump

P01. The carbon source is provided by the volumetric pump P12. The effluent from the scSBR is

discharged using the submerged centrifugal pump P02. The waste activated sludge is withdrawn from

the scSBR using the P03. The anaerobic supernatant from the dewatering operation of the digestate

is sent by gravity in the equalization tank. The level M001 controlled the operation of two pneumatic

valve V13 and V14: at the minimal level achieved, the V13 is closed and V14 is opened, while at the

maximal level achieved the V13 is opened and V14 is closed. The daily flowrate of anaerobic

supernatant provided to the scSBR is divided in three or four cycle. The level M002 determines the

minimal and the maximal level achievable in the scSBR. Six sensors are installed in the reactor:

conductivity (M003), pH (M004), ORP (M005), DO (M006), MLSS (M007) and N2O (M008). Among

them, DO is used to control the compressor through VDF, while conductivity and pH are used to

control the lenght of the aerobic phase, the amount of carbon source and the lenght of the anoxic

phase. The other sensors are not included in the control algorithm of the system but are recorded in

the PLC.

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Table 8 Operation of the short-cut Sequencing Batch Reactor.



Filling Timer or/and Level meter SBR mixing device Sludge liquors feeding pumps

Anaerobic phase (1 phase for each cycle)

Time based control

SBR mixing device Monitoring of the process parameters (pH, ORP, Conductivity, Oxygen, N2O, MLSS)

Aerobic phase (1-2 phases during each cycle)

Time based controlled for the Min and Max lenght of the phase; Real time control based on conductivity and pH

Frequency of the blower control by a PID algoritm

Anoxic phase (1-2 phases during each cycle)

Time based controlled for the Min and Max lenght phases Dosage of the carbon source according with the conductivity; End of the phase according with pH signals

SBR mixing device; Carbon source feeding;

Settling Timer -

Decanting Timer or/and Level meter Disharge pump

WAS removal Timer or/and Level meter Decanting pump SBR mixing device

2.1 Integrability of the Smartech 4a in existing WWTPs

Integrability issues Smartech 4a

Technical Feasibiliy

1. Should new facilities always be

considered during the design and

implementation of the Smartech?

No. Preliminary designs should be always performed in

order to consider the recovery of disused tanks or the

conversion of the existing facilities in the WWTPs. In

particular, the Smartech 4a was designed considering

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the conversion of existing tanks dedicated to the

storage of liquid waste.

2. Does the implementation of the

Smartech imply a substantial change of

the present flowscheme of the WWTP?

No, if the Smartech 4a takes advantage of existing

works, only minor changes of piping connection are

required, which do not represent substantial changes

of the WWTPs.

3. Could the Smartech negatively impact

on the final discharge of the main

WWTP?

No, the Smartech will positively impact on the final

discharge, because the treated effluent from Smartech

4a is supposed to contain up to 90% less nitrogen and

30-60% less phosphorous compared with raw

anaerobic supernatant. However, even if the

technology does not perform as expected, the effluent

will be treated in the main WWTPs before its final

discharge in the water body.

Acceptability of the Smartech

1. Is the Smartech 4a well accepted

among the operators?

The Smartech 4a is considered by operators an

integrated and useful compartment of the WWTP and

the personnelle are used to operate and take care of

it.

2. Are specific skills and/or tranings

required for the operators?

No additional specific trainings are requireds. The

knowledge and expertize already held by the

operators of the main WWTP are also sufficient and

adequate to operate in the Smartech 4a. The latter in

fact uses the same equipments typically adopted also

by conventional biological processes.

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Bureaucratic issues

1. Did Smartech 4a require a specific

authorization for its implementation?

Yes. The authorization for its implementation was

asked to the Regional Authority (see the attachment).

Are there any standards, regulations or

references applicable?

No, the Smartech 4a does not need to conform to

specific regulation. However, if new facilities are

implemented, the competent autority may ask to

respect the standards of the “landscaping regulation”.

However, regulations could significantly change based

on the country where the plant is operating.

2.2 Drawings ‘as built’

The drawings of the units are reported in the following annexes:

• Drawing 1: P&id of the Smartech 4a

• Drawing 2: Fermentation unit

•

• Drawing 3: Layout of the Smartech 4a

• Drawing 4: Dynamic Thickening

• Drawing 5: Screw press separator

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2.3 Picture report

Figure 3 SMARTech 4a - Dynamic thickener of the sewage sludge

Figure 4 SMARTech 4a – Screw-press for S/L of the fermentation sewage sludge

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Figure 5 SMARTech 4a – Accumulation tank for the fermentation liquid of mixed sludge

Figure 6 SMARTech 4a – Different views of the fermentation

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Figure 7 SMARTech 4a - Electrical Panel and air compressor of Smartech 4a

Figure 8 SMARTech 4a -Tank for the acculation of the anaerobic supernatant and influent pump of the scSBR

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Figure 9 SMARTech 4a - Air diffusion system of the scSBR

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3. SMARTECH4B - SIDESTREAM THERMAL HYDROLYSIS-SCENA

3.1 Technical description of the SMARTech 4B

The SMARTech 4b pilot system is an innovative nutrient removal process via nitrite which is

integrated in the Psyttalia WWTP in order to manage the reject water produced from the dewatering

process of the plant. The SMARTech 4b shall treat separately the reject water of the dewatering

process to biologically remove nitrogen and phosphorus and then recycle it back to the inlet of the

WWTP (Figure 3.1). This process also takes advantage of the readily biodegradable COD which is

contained in the reject water of the primary thickened sludge in order to provide part of the carbon

source which is required to remove nutrients from dewatered sludge.

Figure 10 Flow diagram of Psittalia WWTP with SMARTech 4b

Figure 10 illustrates the major units of the pilot system along with their interconnections. The core

of SMARTech 4B is the bioreactor (SBR). The SBR is a rectangular tank with dimensions

[2.00x2.30x2.40] [WxLxH] and 9m3 maximum active volume. The construction material is stainless

steel AISI 304L.

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Figure 11 Major units of SMARTech 4b and their interconnections

The SBR is equipped with a mixing apparatus in order to provide a minimum mixing capacity of 8

W/m3. The mixer manufacturer is SEKO (Italy) and it is a slow speed 200rpm mixer with 220mm

propeller, stainless steel shaft and PVC body.

The effective depth of the reactor will be at least 1.5 m (during the aeration phases) in order to allow

for an oxygen transfer efficiency to the order of 8-10%. An aeration system with diffusers has been

installed in order to meet the oxygen requirements of the system. The aeration system consists of a

side channel air compressor from MAPRO International with maximum capacity of 252 m3/h at 200

mbar and fine bubble AEROSTRIP diffusers Type T provided by Aquaconsult. The transfer efficiency

of the diffusers is in the order of 100 m3/m2 h.

The SBR will be fed with sludge liquors from the dewatering unit and from the primary sludge

thickening unit. The sludge liquors upstream the SBR will be collected in two storage tanks (one for

each type of sludge liquors). There are two transfer pumps from NETZSCH manufacturer with capacity

of 5 m3/h each, which feed the storage tanks in automatic mode, in order to keep the necessary

volume of slugde liquors in the storage tanks. Each tank provides a storage capacity of min 2 d, with

an effective volume to the order of 8 m3 each. Both storage tanks are made of polyethylene, black

color, with roof manhole. Each of these storage tanks is equipped with a submersible centrifugal

pump (two in total) from LOWARA manufacturer for continuous mixing of the content.

Each type of sludge liquors will be fed into the SBR with the use of an eccentric screw pump. The

installed feeding pump is from NETZSCH manufacturer and it is driven by VFD (frequency converter).

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The maximum capacity of the pump is 7 m3/h. The selection of the capacity of this pump is based on:

i) the maximum daily flow rate of the sludge liquors (3 m3/d for the SL-DS and 2.65 m3/d for the SL-

PS), ii) the minimum number of 3 cycles per day and iii) the duration of fill phase of 15 min. A second

eccentric screw pump, from NETZSCH manufacturer and also driven by VFD has been installed in

order to provide decanting of treated sludge liquors from the SBR and the removal of the surplus

activated sludge as well. The waste activated sludge will be collected temporarily in a rectangular

storage tank made of polyethylene and of volume 1m3, which is sufficient for 2 days storage of sludge

removed.

A solution of acetic acid (in the form of sodium acetate) will be added to the reactor to meet the

biodegradable organic carbon requirements. The external organic carbon system consists of a

storage tank with an active volume of 1 m3 and it is sufficient for more than 7 days storage capacity.

The tank is made of polyethylene and it is placed in an appropriate leakage basin. It is equipped with

a mixer from SEKO manufacturer. A dedicated diaphragm, adjustable flow-rate dosing pump from

DOSEEURO AP manufacturer with a capacity of 200 L/h is installed in order to transfer the sodium

acetate solution from the storage tank to SBR.

It is expected that under normal conditions there will not be any need for pH control for the pilot

system. However, as the performance of especially the nitritation – denitritation processes is highly

dependent on the pH and the fact that under transient conditions (especially during start-up) there

might be a need for pH control, a pH control system has been installed in the pilot system. The pH

control system consists of an acid dosing system and a base dosing system. The acid (in the form of

sulfuric acid) dosing system consists of a storage tank with a volume of 1 m3 and a diaphragm,

adjustable flow-rate dosing pump from DOSEEURO AP manufacturer with a capacity of 50 L/h. A

separate similar dosing system is provided for the addition of the base (in the form of sodium

hydroxide). Both chemicals storage tanks are placed in a leakage basin.

The SBR is equipped with a piezoelectric level transmitter from ENDRESS+HAUSER company and

several analytical field instruments such as pH, ORP, DO, Temperature, Conductivity, NH4-N, NO2-

N/NOx-N from the WTW company. All the instrumentation will be collected in a common controller

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WTW MIQ, which will be interconnected with PLC via Profibus DP interface. All the storage tanks will

be equipped with suitable level switches.

All electrical and automation equipment, including motor starters, variable frequency drives and PLC,

have been installed into a stainless steel IP55 enclosure (2000x600x600mm) from SABO

manufacturer, forming the Motor Control Center (MCC) of the pilot plant system. The electric power

supply is at 400VAC/3–phase and the control voltage at 24VDC. The process automation (e.g. feeding,

aeration, decanting, was, chemical dosing) will be carried out in automatic mode by the CPU PLC but

there is also an HMI device (touch panel) for controlling the equipment manually and monitoring all

measured values from instrumentation locally. Finally, the MCC will be ready for interconnection to

an external PC for data acquisition.


The technical specifications of the major units and the electro-mechanical equipment installed at

the site are presented in Table 3.1.

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Table 9 Major units and specifications of the electro-mechanical equipment

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3.3 Practical instructions for the operation of SMARTech 4B

The operation of SMARTech 4B includes a series of actions and settings which can be divided in the

following categories:

• Preparation of chemicals to be dosed in the reactor

• Selection of the automation mode and definition of the set points

• Calibration of on-line probes

Preparation of chemicals

Three types of chemicals will be used during the operation of SMARTech 4B: the substrate, the acid

and the base for pH control. Among these the acid-base chemicals will be supplied as ready to use

solutions with the already specificed characteristics and therefore no specific actions will be needed

from the operators of the system. The only care will be to send a notice for refill the chemicals tanks

upon signal of low level.

Substrate as sodium acetate will be dosed to the reactor automatically. The preparation of the

solution in the respective tank will be undertaken by the operator of the system. The solution wiil be

prepared by adding sodium acetate powder to the tank in order to reach an acetic acid content of

200 kg/m3.

Selection of automation mode

SMARTech 4b is equipped with online monitoring meters and a programmable logic controller (PLC)

which will provide operational flexibility and applicability of different control strategies.

Online probes of dissolved oxygen, pH, temperature, conductivity, oxidation-reduction potential,

NH4-N, NOx and a level meter have been installed into the surface of SBR unit and real time

information on the performance of the system will be obtained and transferred to the online

controller every 1 minute. The PLC is interconnected to an external PC for data acquisition.

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All the major units of the electro-mechanical equipment such as the SBR mixer apparatus and the

mixing devices of storage tanks, feeding, dosing and decanting pumps and the air blower are

connected to the PLC which control their operation according to predefined parameters or schedule.

The main operational strategy that will be established is based on time schedule and online sensors

measurements. More specifically, every SBR cycle has a number of distinct phases. For each phase a

variety of functions and processes have been programmed under the regulations of the PLC according

to the automation plan. Table 10 describes the basic features of the automation to control the

operation pf the system.

Table 10 Basic features of automation in the operation of pilot plant system.

Operation phase Parameter that defines the

phase duration according to PLC

design

Equipment in working mode

during this phase controlled by

PLC

Filling Timer or/and Level meter SBR mixing device

Sludge liquors feeding pumps

Anaerobic phase

(1-2 phases during each

cycle)

Timer

SBR mixing device

pH adjustment system

acid/base dosing pumps

Aerobic phase


cycle)

Main operation: Timer or/and

NH4-N sensor measurements

Alternativelly: pH set point or pH

slope

Air blower



Control of blower flow rate

Anoxic phase


cycle)

Main operation: Timer or/and

NOx sensor measurements

Alternativelly: ORP slope or pH

set point or pH slope

SBR mixing device

Substrate feeding pumps



Settling Timer -

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Decanting Selected valve of decanding

pump

Decanting pump

SAS removal Selected valve of decanting pump Decanting pump

SBR mixing device

Based on the design of the automation system the operator is able to choose the number of each

phase (e.g. anaerobic, anoxic, aerobic) during each cycle as well as their sequence. The maximum

number of process functions/phases that can be selected in each cycle is eight (two anaerobic, three

anoxic and three aerobic).

Filling phase is starting upon setting the feeding pump on. The duration of the feeding phase is

primarily based on the set point of the level meter. For safety reasons the maximum duration of this

phase can also be regulated by a timer.

The duration of the anaerobic phase is primarily regulated by a timer. During this phase, the PLC will

set up the SBR mixing system and if necessary will control the pH adjustment system providing acid

or base solution from the storage tanks using two dosing pumps. It is expected that under transient

conditions and especially during start-up there will be a need for pH control to the desired set points

by providing sulfuric acid or sodium hydroxide.

During the aerobic phase the PLC will activate the aeration system while the mixing system will

ceased operation as adequate mixing will be provided by the diffusers. The air flow rate provided by

the blower will be regulated according to the desired set point of dissolved oxygen in the reactor.

The duration of the aerated period will be controlled either by a timer or by a critical value of NH4-N

sensor (or both). The automation system provides also alternative control functions of the duration

of this phase based either on the pH set point or on pH slope. During the aerated phases pH control

can be impleened (if desired) by regulating the acid/base dosing system.

Following the aerobic phase, the anoxic phase will start with the end of aeration and the addition of

external carbon source (fiilling). In order to meet the biodegradable organic carbon requirements for

denitritation procces the automation system will be set to provide adequate volumes of primary

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sludge liquor or acetate or a mix of the two substrates. A maximum of three dinstict anoxic phases

can be implemented during each cycle and their duration will be controlled by either a timer or by

reaching a pre-defined value of NOx sensor (or both). Furthermore, alternative control strategies can

also be choosen by the operator based on set points defined for ORP, pH and pH slope. During each

anoxic phase the PLC will maintain open the mixing system and will also provide pH control.

The surplus activated sludge (SAS) removal will take place either during aerobic or during anoxic

phase in the form of mixed liquor in order to keep the desried sludge age.

After the last anoxic period in each cycle, the PLC will stop the mixing system and sedimentation

phase will take place for a pre-selected time period. Every cycle will end up with decanting. The PLC

will control the volume of supernatant that the decanting pump will remove from the SBR unit either

by a timer or by the level meter measurements.

In view of the above, the operator selects the mode of automation and specifies the set points

directly on the screen pf PLC.

Calibration of on-line probes

Calibration of the on-line probes will take place on a weekly basis. In this context the operator will

collect activated sludge samples which will be analyzed for pH, conductivity, ORP, NH4-N, NO2-N, NOx-

N and the results will be compared with the on-line measurements for validation. Upon significant

deviations calibration of the on-line probes will take place.

3.1 Integrability of the Smartech 4b in existing WWTPs

Integrability issues Smartech 4b

Technical Feasibility

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New facilities are required for the development of the

Smartech4b since new systems are developed to treat the

sludge reject water, which includes storage tanks,

sequencing batch reactor, control and automation, pumps,

aerators and other auxiliary equipment.


Smartech imply a substantial

change at the present flowscheme

of the WWTP?

Smartech4b does not require excessive interventions.

However, some intervention is required in the sludge

treatment line in order to direct the reject water from

thickening and dewatering first to the Smartech4b

technology and the treated effluent from Smartech4b to

the inlet of the WWTP. These interventions are considered

to be rather small.

3. Could the Smartech negatively

impact on the final discharge of the

main WWTP?

No. The Smartech4b is expected to positively affect the

final discharge of the WWTP by reducing the nutrient load

which is sent to the main wastewater treatment line. Even

if the technology does not perform as expected in terms of

nutrient removal, the treated effluent from Smartech4b is

returned back to the inlet of the WWTP. So in the worst

case scenario it will not affect the final discharge of the

WWTP. Within the project, Smartech4b is applied as a small

pilot to a very large WWTP. So its actual effect in the

treated effluent is negligible.


1. Is the Smartech 4b well accepted


The personnel of the plant including the operators are very

much interested in Smartech4b. The companies which are

in charge for the operation of the WWTP (EYDAP SA and

AKTOR SA) are participating as partners in the project.

2. Are specific skills and/or

trainings required for the

operators?

The knowledge, expertise and skills of the operators is

sufficient to manage Smartech4b and no training is

required.

Bureaucratic issues

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1. Did Smartech 4b require a

specific authorization for its

implementation?

Smartech4b is a pilot system developed within the

premises of the water utility participating the project.

Therefore, no licence is required.

2. Are there any standards,

regulations or references

applicable?

Smartech4b does not need to conform to any standards or

regulations.



• Drawing 3.4.1: Layout of the Smartech 4b

• Drawing 3.4.2: Cross section of the pilot Smartech 4b

• Drawing 3.4.3: P&I of the pilot SMARTech 4b

3.3 Pictures report

Figure 12. Plan view of SMARTech 4B

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Figure 13 Plan view of SMARTech 4B

Figure 14 3D drawing of SMATech 4B

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Figure 15 SMARTech 4B – construction phase

Figure 16 SMARTech 4B – construction phase

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Figure 17 SMARTech 4B – construction phase – installation of reject water storage tanks

Figure 18 SMARTech 4B – construction of raw and treated reject water networks

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Figure 19 SMARTech 4B – overview of feed pump, decanting pump and decanting network

Figure 20 SMARTech 4B – overview of feed pump and decanting pump

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Figure 21 SMARTech 4B – decanting system

Figure 22 SMARTech 4B – chemicals and substrate dosing pumps

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Figure 23 SMARTech 4B – chemicals and substrate storage tanks

Figure 24 SMARTech 4B – installation of on-line probes

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Figure 25 SMATech 4B – hydraulic testing of the SBR

Figure 26 SMATech 4B –testing of the aeration system of the SBR

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4. SMARTech5 - SIDESTREAM SCEPPHAR

4.1 Technical description of the SMARTech 5

The Smartech 5 performs the SCEPPHAR process (Short Cut Enhanced Phosphorus and PHA Recovery)

which allows the via-nitrite nitrogen removal and, at the same time, recovers struvite and PHA from

the acidogenic fermentation liquid of cellulosic sewage sludge. The first SCEPPHAR system was

developed at the University of Verona (Frison et al., 2015) and uses real cellulosic sewage sludge from

the municipal wastewater treatment plant in an oxic-anoxic via-nitrite system, which saved energy

compared to other systems that are operated under complete aerobic conditions.

Figure 27 P&id of the Smartech 5.

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The SCEPPHAR system is composed by seven different operative units, controlled by a CPU-PLC with

electro levels and time-based control. Each unit is fed and emptied by pumps or pneumatic valve

systems, depending on the type of unit. The list of the different units is reported below:

1) R001-> SF1000-Salsnes Filter

2) R002-> Fermentation unit

3) R003-> Ultrafiltration

4) R004-> Crystallizer

5) R005-> Nitritation SBR

6) R006-> Selection SBR

7) R007-> PHA Accumulation

The Salsnes filter (R001) consists in a belt dynamic filter with a fine mesh size less than 350µm for

the filtration of 450 m3/d of degritted municipal wastewater. The aim is the separation of cellulosic

primary sludge. The best mesh size will be selected during the start-up of the filter. In order to achieve

around 50% of the suspended solids removal, polielectrolyte will be add to favour the coagulation of

the organic matter. The pumps flowrates are controlled by a variable frequency drive (VFD), while

the starting and turning off is controlled by level and time-based control. The fermentation process

accomplishes the production of volatile fatty acids (VFAs), which represents the carbon precursors

for the PHAs production. Mesophilic or thermophilic fermenting conditions may be setted by the

electrical heating system. The solid-liquid (S/L) separation system is composed by a ultrafiltration unit

(UF) provided with ceramic membrane, which allows the solid/liquid separation of the fermented

cellulosic primary sludge. An efficient solid/liquid separation is required in order to easier handle the

solid fraction of fermented sludge and at the same time to recover the maximal amount of liquid

fraction which contains VFAs and nutrients. A clean liquid is also important to enhance the purity of

the struvite recovered. The permeate produced by the filtration of the fermented cellulosic mixed

sludge is composed by a liquid rich in volatile fatty acids and nutrients like nitrogen and phosphorus.

The crystallization reaction allows the recovery of phosphorus in the struvite form (NH4MgPO4·6H2O).

The anaerobic superantant is fed into the nitritation reaction (R005) using the pump P108 (flowrate

5 m3/h) and then after the nitritation, the effluent is discharge into the tank Tk008. Nitrite is later

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used as electron acceptor by the PHA storing biomass in the selection SBR (R006). PHA-accumulating

biomass selection is essential to obtain a microbial community capable of synthetize and hyper-

accumulate PHAs and at the same time, remove nitrogen via-nitrite. To achieve this result, biomass

is subjected to feast and famine conditions. During the feast phase, PHA are synthetized and

accumulated by the biomass, while under famine conditions nitrites are used as electron acceptor

from the PHAs degradation, thus promoting the microbial growth of denitrificants and PHA storing

organisms. The accumulation bioprocess allows the achievement of maximum rates of PHA storage

under feast conditions. Carbon source is provided at intervals to the biomass; at the end of PHA

accumulation, biomass activity is interrupted through the dosage of a quencher. The SBR are

equipped with sensors from HACH-LANGE company which are based on a floating chamber. The

sensors allows the monitoring of several parameters and by them also the control of the nitrogen

forms, so to control the cycle lenght. The sensors installed are: pH, Dissolved Oxygen (DO),

Conductivity (COND), Oxydation Reduction Potential (ORP), Mixed Liquor Suspended Solids (MLSS)

and for nitrous oxide emission (N2O).


Table 11 List of electromechanical equipment and FLOW DIRECTION of the Salsnes Filter

SF 1000

List of electro-mechanicals installed

CODE DESCRIPTION INSTALLED POWER (kW)

FLOWRATE (m3/h)

CONTROL

P100 Inlet centrifuge pump 2.4 54 VFD/electro level/time based

P101 Cellulosic primary sludge pump

1.5 3 VFD/electro level/time based

P102 Polyelectrolyte dosing pump

1 5 VFD/Electro level/time based

List of sensors

CODE TYPE OF SENSOR COMMENTS

LC002 Electro level (3 levels) Min (1 and 2)-max control of the fermenter

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FLOW DIRECTION

FLOW Feeding from (F)/ Discharge to (D)

PUMP CODE

R001 (SF1000) F1: WW influent->R001 F2: TK000->R001 D1: R001->R002 D2: R001->mainstream

F1: P100 F2: P102 D1: P101 D2: gravity

Table 12 List of tanks, electromechanical equipment, sensors and FLOW DIRECTION of the Sequencing Batch Fermentation Reactor

SEQUENCING BATCH FERMENTATION REACTOR

Tanks volumes

CODE DESCRIPTION UNITS VALUE

R001 Sequencing batch fermentation reactor

m3 2.6

TK003 Alkalinity source L 25

List of electromechanical equipment


FLOWRATE CONTROL

M2 Fermenter mixer 200 rpm 2 x Blade diameter 500mm

1.5 - NO

P101 Cellulosic primary sludge pump

1.5 3 m3/h VFD/electro level/time based

P104 Base-dosing pump - 50 L/h Time based/pH sensor

P105 Fermented sludge centrifuge pump

20 m3/h VFD/Time based/electro level

HE100 Heater kW 1.5 Temperature set-point

VP001 Pneumatic valve - - Electro level

FLOW DIRECTION


PUMP CODE

R002 (SBFR) F1:R001->R002 F2:TK003->R002 D1:R002->R003 D2:R002->drains

F1:P101 F2:P104 D1: P105 D2: gravity (VP001)

SENSORS INSTALLED

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Code TS001

Description Measurement of the total solid concentration of the cellulosic primary sludge influent in the fermentation unit (R002)

Technical description Probe with combined light infrared absorption for measuring turbidity and suspended solids Independent of the color of the water sample (suitable for waste activated sludge, primary sludge, etc).



- Pipe connection flange for inline installation (steel stainless) - System inline/highline fastening system for insertion into no-pressure pipe, steel AISI 304

Code pH001

Description Measurement oft he pH and temperature of the fermentation unit R002

Technical description Differential type digital sensor for the measurement of pH and temperature.



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- Fixing system for pH, size 1" steel AISI316

Table 13 List of tanks, electromechanical equipment, sensors and flow direction of the ultrafiltration unit

ULTRAFILTRATION UNIT

Tanks volumes


TK004 Permeate tank L 100

R002 Sequencing Batch Fermentation Reactor

m3 2.6



FLOWRATE CONTROL

VP1 Pneumatic valve - -

P105 Recycling pump (Fermented sludge centrifuge pump)

24 m3/h VFD/Time based/electro level

FLOW DIRECTION


PUMP CODE

R003 (UF) F1:R002->R003 D1:R003->TK004 D2:R003->R002

F1:P105 D1: gravity D2: gravity

Code VP1

Description Pneumatic valve for the backwash of the UF unit

Technical description

• Body and flanges made of aluminum or stainless steel • Sealing element in various types of elastomer, up to 170 ° C • Maximum fluid pressure to be intercepted up to 6 bar (depending on the execution) • Control pressure: 2 bar higher than the pressure of the fluid to be intercepted • Possibility of threaded attachments and execution in different materials

Table 14 Specification of the crystallization unit

CRYSTALLIZATION UNIT

Tanks volumes


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R004 Crystallization unit L 50

TK004 Permeate tank L 100

TK005 Carbon source storage tank m3

TK006 Base tank (Mg(OH)2) L 25



FLOWRATE

CONTROL

M3 Crystallizer mixer (140 rpm Blade diameter 200mm)

0.18 - Time based/electro level

P106 Influent pump 200 L/h Time based/electro level

P107 Base-dosing pump (Mg(OH)2)

- 10 L/h pH sensor

FLOW DIRECTION


PUMP CODE

R004 (Crystallizer) F1:TK004->R004 F2:TK006->R004 D1:R004->struvite tank D2: R004->TK005

F1:P106 F2: P107 D1: gravity (VM015) D2: gravity

SENSOR INSTALLED

CODE TYPE OF SENSOR COMMENTS

LC003 Electro level (2 levels) Min-Max control of the permeate tank

Code pH003

Description Measurement of the pH and temperature of the crystallization unit R004


Component and configuration Material of the electrode: glass; Type of probe: submerged Sensor body: steel Range of measurement: 0 - 14; T=-5° C a 50° C Time of response: pH: < 5 s; T: < 2 min Reference electrode for the control of the impedence of the liquid bulk Lenght of the cable: 10 m

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Dimensions: 350 x 44 mm (diameter)

Table 15 List of tanks, electromechanical equipment, sensors and flow direction of the nitritation unit

NITRITATION SEQUENCING BATCH REACTOR

Tanks volumes


R005 Nitritation SBR m3 1.4

TK007 Anaerobic supernatant storage tank m3 90

TK009 Alkalinity L 25

TK008 Nitrified supernatant storage tank m3 1.4



FLOWRATE

CONTROL

P108 Anaerobic supernatant feeding pump

0.75 5 m3/h Time based/electro level

P109 Base-dosing pump 10 L/h pH sensor

P114 Nitritation SBR emptying pump

0.75 5 m3/h Time based/ Electro level

B1 Blower 0.7 200 L/min Dissolved oxygen

B2 Blower 0.7 200 L/min Dissolved oxygen

FLOW DIRECTION


PUMP CODE

R005 (Nitritation SBR) F1:TK007->R005 F2:TK009->R005 D1:R005->TK008 D2: R005->drains

F1: P108 F2: P109 D1: P114 D2: manual valve (VM020)

SENSORS INSTALLED

Code COND001

Description Measurement of the conductivity of the nitritation SBR (R005)

Technical description Submerged inductive conductivity digital probe. The inductive principle adopted ensures precision, long service life and applicability in aggressive and heavy application.

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Component and configuration Probe Material: PEEK Probe Type: For Immersion with Steel Body Measuring range: 250 μS to 2.5 S / cm Measuring principle: Inductive Accuracy: +/- 1% of reading value or +/- 0.004 mS / cm Temperature Accuracy: +/- 0.2 ° C Reproducibility: <0.2% Response Time (T90): Cond .: <2 s; T: <2 min Sensor cable: 10 mt cable with quick connector for connection to series controller or extender cable Protection rating: IP68 Operating temperature: - 20/+50 ° C Thermocomputer: Automatic PT100 Calibration: Process or Electrical Dimensions: 405 x 42 mm (length x diameter) Mounting: with chain or with immersion tube

Other equipments included PVC Mounting Kit for Conductivity Probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - Purple tube closure cap

Code pH003

Description Measurement of the pH and temperature of the nitritation unit R005



Other equipments included PVC mounting kit for pH probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - brown tube closure cap

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Code DO001

Description Measurement of dissolved oxygen of the nitritation SBR unit R005


Component and configuration - Measuring principle: luminescent optic - Measurement range: 0 to 20.00 mg / L (ppm) O2, 0 to 200% saturation - Accuracy: 0-5 mg / L O2 ± 0.1 mg / L, 5-20 mg / L O2 ± 0.2 mg / L; Temperature: ± 0.2 ° C - Repeatability: ± 0.1mg / L - Resolution: 0.01 mg / L (ppm) O2 / 0.1% saturation - Response time (at 20 ° C): T90 <40 s, T95 <60 s - Calibration: 2 year factory guaranteed and linked to CAP - Operating temperature: 0 ° C to 50 ° C - Storage temperature: -20 ° C to 70 ° C (95% relative humidity) - Max pressure range: 10 bar - Sensor connector: 1 "NPT external thread - Cable length: 10 m - Sensor CAP material: acrylic - Body Probe Materials: CPVC, Polyurethane, Viton®, Noryl®, Stainless Steel 1.4404 (AISI 316L) - Degree of protection: IP68 - Dimensions (L x W): 48.25 mm x 254 mm


Table 16 List of tanks, electromechanical equipment, sensors and flow direction of the PHA-accumulating biomass selection SBR

BIOMASS SELECTION SEQUENCING BATCH REACTOR

Tanks volumes


R006 Selection SBR m3 2.9

TK008 Nitrified supernatant storage tank m3 1.4

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TK005 Carbon source storage tank m3 1



FLOWRATE

CONTROL

P110 Nitrified supernatant feeding pump

0.75 5 Time based/electro level

P111 Carbon source pump 0.75 5 Time based

M4 Selection SBR mixer (90 rpm Blade diameter: 500mm)

0.75 0.75 Time based

B3 Blower 0.95 60 m3/h VFD/Dissolved oxygen/time-based

VP105 Pneumatic valve (discharge treated anaerobic supernatant)

- - Electro level/time-based

FLOW DIRECTION


PUMP CODE

R006 (Selection SBR) F1:TK008->R006 F2:TK005->R006 D1:R006->R007 D2: R006->drains D3: R006->drains

F1: P110 F2: P111 D1: manual valve (VM032) D2: Pneumatic valve (VP105) D3: manual valve (VM026)

INSTALLED SENSORS

Code DO002



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Component and configuration - Measuring principle: luminescent optic - Measurement range: 0 to 20.00 mg / L (ppm) O2, 0 to 200% saturation - Accuracy: 0-5 mg / L O2 ± 0.1 mg / L, 5-20 mg / L O2 ± 0.2 mg / L; Temperature: ± 0.2 ° C - Repeatability: ± 0.1mg / L - Resolution: 0.01 mg / L (ppm) O2 / 0.1% saturation - Response time (at 20 ° C): T90 <40 s, T95 <60 s - Calibration: 2 year factory guaranteed and linked to CAP - Operating temperature: 0 ° C to 50 °C - Storage temperature: -20 ° C to 70 ° C (95% relative humidity) - Max pressure range: 10 bar - Sensor connector: 1 "NPT external thread - Cable length: 10 m - Sensor CAP material: acrylic - Body Probe Materials: CPVC, Polyurethane, Viton®, Noryl®, Stainless Steel 1.4404 (AISI 316L) - Degree of protection: IP68 - Dimensions (L x W): 48.25 mm x 254 mm


Code ORP003

Description Measurement of the oxidation-reduction potential of the selection SBR unit R006

Technical description Differential type digital sensor for the measurement of oxidation-reduction potential. Electrode not in contact with the liquid bulk.

Component and configuration Electrode: Platinum Sensor body: AISI 316 stainless steel Probe Type: Immersion Measuring range: from -2000 to +2000 mV; T = -5 ° C to 70 ° C Response Time (T90): ORP: <5 s; T: <2 min Auto Diagnostics: Measurement and reference electrode impedance control Lenght of cable: 10 m Power supply: from sc100 or sc1000 controller Temperature conditions: -20 to 50 ° C Pressure: max. 6.9 bar Template Provider: Automatic NTC 300

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Calibration: by process and / or with std buffer solutions Dimensions: 271.3 x 44 mm (length x diameter) Mounting: with chain or with immersion tube Weight: approx. 1 Kg


PVC mounting kit for pH probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - brown tube closure cap

Table 17 List of tanks, electromechanical equipment, sensors and flow direction of the accumulation SBR

ACCUMULATION SEQUENCING BATCH REACTOR

Tanks volumes


R007 Accumulation SBR m3 1

TK005 Carbon source storage tank m3 1

TK010 Thickening of PHA-rich biomass L 50

TK011 Quenching chemical L 25



FLOWRATE

CONTROL

P111 Carbon source feeding pump

0.75 5 m3/h Time based

P113 Quenching chemical pump

10 Time based

B7 Blower 200 L/min Time based

FLOW DIRECTION


PUMP CODE

R007 (Accumulation SBR) F1:TK005->R007 F2:R006->R007 F3:TK011->R007 D1:R007->TK010

F1: P111 F2: manual valve (VM032) F3: P113 D1: manual valve (VM036)

INSTALLED SENSORS

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Code DO002



Component and configuration - Measuring principle: luminescent optic - Measurement range: 0 to 20.00 mg / L (ppm) O2, 0 to 200% saturation - Accuracy: 0-5 mg / L O2 ± 0.1 mg / L, 5-20 mg / L O2 ± 0.2 mg / L; Temperature: ± 0.2 ° C - Repeatability: ± 0.1mg / L - Resolution: 0.01 mg / L (ppm) O2 / 0.1% saturation - Response time (at 20 ° C): T90 <40 s, T95 <60 s - Calibration: 2 year factory guaranteed and linked to CAP - Operating temperature: 0 ° C to 50 ° C - Storage temperature: -20 ° C to 70 ° C (95% relative humidity) - Max pressure range: 10 bar - Sensor connector: 1 "NPT external thread - Cable length: 10 m - Sensor CAP material: acrylic - Body Probe Materials: CPVC, Polyurethane, Viton®, Noryl®, Stainless Steel 1.4404 (AISI 316L) - Degree of protection: IP68 - Dimensions (L x W): 48.25 mm x 254 mm


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4.2 Practical instructions for the operation of SMARTech 5

The SF1000 is fed by a centrifugal pump (P100) with a flowrate ranging from 30 to 54 m3/h. It has

been estimated that P100 will work between 8 to 15 hours per day, according with the fixed flowrate

of the influent. The SF1000 is discharged discontinuously through a centrifugal pump (P101) with a

flowrate of 3m3/h. It has been estimated that P101 will work from 8 to 15hours per day. The Salsnes

Filter (R001) turns on at preselected time by the operator, but only if the electro level sensor (LC002)

of the sequencing batch fermenter reactor (SBFR) detects the “MIN 2” level, to avoid undesired

feedings. The flowrate of the wastewater inlet pump (P100) is adjust by acting on the variable

frequency drive. The sludge pump (P101) turns on when the loading hopper achieve the maximal

level (P101). If required, the polyelectrolyte pump (P102) can be turned on and regulated by the

operator by acting on the VFD. The cellulosic primary sludge pump (P101) feeds the SBFR (R001). The

Salsnes Filter will work until the electro level sensor (LC002) of the sequencing-batch fermentation

reactor will detect the “MAX” level. Once the fermenter is fed to the maximum level, the Salsnes

Filter (R001), the wastewater inlet pump (P100), the cellulosic primary sludge pump (P101) and, if

turned on, the polyelectrolyte pump (P102), will be turned off until the starting time is reached.

Table 18 Operation of the SF1000



Feeding of wastewater Pre-selected time by the operator P100

Sieved westewater Discharge by gravity -

Cellulosic mixed sludge Pump controlled by the level sensor installed in the loadin hopper

P101

Polyelectrolite dosage Pre-selected flowrate according with the desired total solid concentration in the cellulosic mixed sludge

P102

The SBFR is fed discontinuously by the cellulosic primary sludge pump (P101) with a flowrate of

3m3/h. The feeding time ranges from 8 to 15 h, depending on the working flowrate of the P100

(SF1000 feeding pump). The SBFR is discharged by the centrifuge pump P105, which fed the

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ultrafiltration system (R003). It has been estimated that the discharge of the SBFR will take about 5-

6 h per day. The Sequencing Batch Fermentation Reactor (R001) is heated by an electrical heater of

1.5 kW, while the working temperature can be set by the operator. The influent pH is buffered

through the addition of an alkaline solution (e.g. NaOH) by a dosing pump (P104) according with time

based or pH control. The fermenting cellulosic sludge is mixed 24 h per day by a 2.2 kW mixer (M2).

The inlet suspended total solids are measured through an in-line probe (TS001). The feeding is

controlled by two different levels (LC002) which are recognized (“MAX” and “MIN2”). The “MAX”

level sets the maximal working capacity of the SBFR, while the level “MIN2” (LC002) allows the

switching on of the SBFR feeding pump (P101). The level sensor (LC002) detects the “MIN1” level,

the fermented sludge centrifuge pump (P105) is turned off and filtrationis stopped. The volume of

fermented sludge between the levels “MIN1” and “MIN2” is drained through the pneumatic valve

(VP001) installed in the bottom of the fermentation unit.

Table 19 Operation of the fermentation unit



Feeding Pump turned on from MIN2 to MAX level

P101

Mixer Manual turn on/off M2

Electrical heating system Temperature control by a thermostat

HE1

Discharge Ultrafiltration operates between MAX and MIN1 level. Pneumatic valve open between MIN1 and MIN2 level.

P105, VP1

The sludge pump (P105) for the recirculation of the fermented cellulosic sludge is turned on at pre-

selecte time. The flowrate of P105 can be set by the operator through a variable frequency drive (up

to 25 m3/h) and the duration of the ultrafiltration last for about 5-6 hours per day. The permeate is

collected in a permeate storage tank (TK004) by gravimetric flux and the permeate flowrate is

showed on Q101 flowmeter. The working pressure of the ultrafiltration system can be modified by

acting a manual valve (VM009) located on the recirculation pipe (PI 001); the flowrate of the P105 is

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showed on the Q100 flowmeter, the electro level sensor (LC002) within the sequencing batch

fermentation unit indicates “MIN1” level: when this level is reached, P105 is turned off and filtration

process stops.

Table 20 Operation unit of the ultrafiltration unit



Feeding Feeding pump switch on according with setted time by the operators. Feeding pump switch off according with fixed time lenght by the operators or minimun level achieved (MIN2)

P105, LC002

Concentrate fermented cellulosic mixed sludge

Recycled back to the fermentation unit (R002).

-

Permeate Collected by gravity to the TK005 -

The feeding pump of the crystallizer (P106) is switched on together with the ultrafiltration system

and operate discontinuously with a flowrate of 200 L/h. During the operation of the ultrafiltration

(R003), the crystallizer mixer (M3) and the crystallizer feeding pump (P106) are switched on. P106 is

switched on only if the electro level sensor (LC003) of the permeate tank (TK004) is not indicating the

“MIN” level;in this case, P106 is not switched on until the achievement of the “MAX” level of the

permeate tank. The crystallizer feeding pump (P106) is switched on/off until the filtrationprocess

stops definitively (reaching of “MIN1” level within R002 unit). At the end of the filtration stage, also

M3 is turned off until the beginning of a new filtration working cycle. pH set-point of the

crystallization reaction can be set by the operator. pH is adjusted by the addition of Mg(OH)2 through

a peristaltic pump (P107): the same pump is controlled by a pH sensor (pH002). The carbon source

after the struvite recovery is collected by gravity in the carbon source storage tank (TK005). The

harvesting of the produced struvite at the end of crystallization process, a manual valve at the bottom

of the R004 should be opened by the operator.

Table 21 Operation of the crystallizer

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Feeding P106

Effluent The permeate overflow the R004 and collected by grativity to the Tk005

-

Harvesting of the struvite Harvesting of the struvite every 2-3 days of full operation

VM015, manual valve

The nitritation SBR (R005) is fed by a centrifuge pump (P108) with a flowrate of 5m3/h. It has been

estimated that the P108 will work around 1h per day.

The nitritation SBR is emptied by a centrifuge pump (P114) with a flowrate of 5 m3/h. It has been

estimated that the P108 will work around 1h per day.

The nitritation bioprocess occurs through a working cycle which is composed by the following phases

(in the same order): idle (0), aerated filling (1), aerobic (2), settling (3) and discharge (4). The duration

of phases 0,2 and 3 is set by the operator. After the idle phase (phase 0), the aerated filling phase (1)

starts and anaerobic supernatant is fed within the nitritation SBR (R005). In concomitance with the

beginning of phase 1, the anaerobic supernatant feeding pump (P108) and blowers (B1 and B2) are

switched on. P108 is controlled by an electro level sensor (LC005). When “MAX” level is detected by

LC005, P108 is turned off and phase 2 (aerobic) starts. During this phase, blowers (B1 and B2) are

switched on and dissolved oxygen (DO) concentration is monitored through a DO probe (DO001). To

control the dissolved oxygen concentration, blower (B2) is switched on/turned off depending on the

DO set-point, while B1 is left on on for all the phase duration. To control the pH of phase 2, an alkaline

solution is fed through a peristaltic pump (P109). This pump is controlled by a pH sensor (pH003)

during all the phase. Monitoring of the same phase is carried out through a conductivity probe

(COND001). At the end of phase 2, settling phase (3) starts and blowers (B1 and B2) are turned off.

When time-limit of the phase is achieved, discharge phase (4) starts and the nitritation SBR emptying

pump (P114) is switched on. This pump is controlled by an electro level sensor (LC005). When “MIN”

level is detected by LC005, P114 is turned off and phase 0 starts (new working cycle). In the table

below are reported the main operation phases of the nitritation SBR

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Table 22 Operation of the nitritation unit




Aerobic phase (1-2 phases during each cycle)

Time based controlled for the Min and Max lenght of the phase;

DO set point control the blowers B1 and B2

Settling Time based -

Decanting Time based or/and Level meter Disharge pump

WAS removal Time based or/and Level meter Decanting pump SBR mixing device

The PHA accumulating biomass selection SBR (R006) is fed by a centrifuge pump (P110) with a

flowrate of 5m3/h. It has been estimated that the P110 will work around 1h per day. The carbon

source is provided by a centrifuge pump (P111) with a flowrate of 5m3/h and it has been estimated

that P111 will work about 0.5h per day. The PHA accumulating biomass selection SBR (R006) is

emptied through a pneumatic valve (VP 105). The selection bioprocess occurs through a working

cycle which is composed by the following phases (in the same order): idle (0), feast (1), famine (2),

settling (3) and discharge (4). The duration of phase 0, 1, 2 and 3 can be set by the operator. After

the idle phase (0), feast phase (1) starts and carbon source feeding pump (P111) is switched on, but

only if the electro level sensor (LC004) of the carbon source storage tank (TK005) is not detecting the

“MIN” level. In concomitance with the beginning of phase 1, also blower (B3) is switched on. P111

control is time-based. When preset time of carbon dosage is reached, P111 is turned off and feast

phase continues until the achievement of maximum preset time. The dissolved oxygen concentration

during the feast phase is set by the operator and is monitored by a DO probe (DO002). Blower

working frequency is controlled through a variable frequency drive, to keep oxygen concentration to

the set-point value. After the achievement of maximum time of feast phase duration, famine phase

(2) starts and blower (B3) is turned off. In concomitance with the beginning of phase 2, mixer (M4) is

switched on, as well as the nitrified supernatant feeding pump (P110). P110 is controlled by an electro

level sensor (LC006). When the “MAX” level is reached, P110 is turned off. Phase 2 continues until

the achievement of maximum time-phase duration. After the famine phase, settling phase (3) starts

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and mixer is turned off. When time-limit of the phase is achieved, discharge phase (4) starts and the

pneumatic valve (VP105) is opened. This valve is controlled by the electro level sensor (LC006). When

the “MIN” level is detected, pneumatic valve is closed and a new working cycle starts (phase 0). The

table below reports the main operations of the selection SBR:

Table 23 Operation of the selection SBR




Aerobic phase (Feast phase) (1 phases during each cycle)

Time based controlled for the Min and Max lenght of the phase; Dosage of the carbon source according with a time based control


Anoxic phase (Famine phase) (1 phases during each cycle)

Time based controlled for the Min and Max lenght phases Dosage of the anaeronic supernatant after nitritation according with a time based control;

SBR mixing device; Anaerobic superantant feeding;

Settling Timer -



The accumulation SBR (R007) is fed manually by the operator through a manual valve (VM032). The

carbon source is provided through a centrifuge pump (P111) with a flowrate of 5m3/h. It has been

estimated that the pump will work. The accumulation SBR (R007) is manually discharged by the

operator through a manual valve (VM036). The accumulation bioprocess is manually activated by the

operator. The accumulation working cycle consists of two different phases (in the following order):

accumulation (1) and quenching (2). The duration of each phase can be set by the operator. When

phase 1 starts, both blower (B7) and carbon source feeding pump (P111) are switched on. P111

control is time-based: the carbon dosage takes place at regular time intervals which duration is

selected by the operator. For each time interval, a carbon dosage (spike) occurs: the carbon source

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feeding duration is set by the operator. The number of intervals (or carbon dosages) can be set by

the operator. When time-limit of the phase is achieved, quenching phase (2) starts and quenching

chemical pump (P113) is switched on. Blower (B7) works for all the duration of the phase. P113

control is time-based and the operating time is set by the operator. When time-limit of quenching

phase is achieved, blower is turned off and working cycle stops. Biomass is harvested in a thickening

tank (TK010) by opening a manual valve (VM036).

Table 24 Operation of the accumulation SBR




Aerobic phase (Feast phase) (1 phases during each cycle)

Time based controlled for the Min and Max lenght of the phase; Dosage of the carbon source according with a time based control


Quencing

Settling Timer -



4.3 Integrability of the Smartech 5 in existing WWTPs

Integrability issues Smartech 5

Technical Feasibiliy




No. Prelimanary designed should be always performed

in order to consider the recovery of disused tanks or

the conversion of existing facilities in the WWTPs.

Morover, around 20% more volume is required for

Smartech 5 compared with Smartech 4a

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Smartech imply a substantial change at

the present flowscheme of the WWTP?

Smartech 5 is a pilot system applied in the sidestream

of the anaerobic digestor and treats less than 10% of

the available anaerobic supernatant. The full scale

implementation of the Smartech 5 implies small and

not substantial changes at the present flowscheme of

the WWTP, such us new pipings for the anaerobic

supernatant and sewage sludge, as well as new

automation to control each stream.

3. Could the Smartech negatively impact

on the final discharge of the main

WWTP?

No, Smartech 5 contributes to improve the quality of

the final effluent, since the treated effluent from

Smartech 5 is supposed to contains up to 90% less

nitrogen compared with raw anaerobic supernatant.

However, even if the technology does not perform as

expected, the effluent will be treated in the main

WWTPs before its final discharge in the water body.


1. Is the Smartech 5 well accepted


The personnelle are used to operate and take care of

the Smartech 5 since it is considered an integrated and

useful compartment of the WWTP.

2. Are specific skills and/or tranings

required for the operators?

No additional specific trainings are required. The

knowledge and expertize already held by the

operators of the main WWTP are sufficient and

adequate for the operation of the Smartech 5. The

latter in fact uses the equipments typically adopted

also for conventional biological processes.

Bureaucratic issues

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1. Did Smartech 5 require a specific

authorization for its implementation?

Yes. The authorization for its implementation was

asked to the Regional Authority (see the attachment).

2. Are there any standards, regulations

or references applicable?

No, the Smartech 5 does not need to conform to

specific regulations.



• Drawing 1: P&id of the SF1000

• Drawing 2: P&id of the Smartech 5

• Drawing 3: Fermentation unt

• Drawing 4: Layout of the Smartech 4a and 5

4.5 Pictures report

SMARTech 5 is reported in the figure below.

Figure 28 SMARTech 5 - Integrated container with rotating belt filter intalled

Project: No 690323

SMART-Plant D3.2

Figure 29 SMARTech 5 - Hopper for the cellulosic primary sludge

Figure 30 SMARTech 5 - Installation of the Smartech 5

Project: No 690323

SMART-Plant D3.2

Figure 31 SMARTech 5 - (a) Sequencing Batch Fermentation Reactor during the installation; (b) Sequencing Batch Fermentation Reactor placed in the platform

Figure 32 Ultrafiltration unit

Project: No 690323

SMART-Plant D3.2

Figure 33 SMARTech 5 - Ultrafiltration system (right side) and crystallizer (right side)

Figure 34 SMARTech 5 - Left side,Nitritation, Selection and Accumulation SBRs; Right side, ultrafiltration system and cristallizer.

Project: No 690323

SMART-Plant D3.2

Figure 35 SMARTech 5 - Air diffusion system for the nitritation, selection and accumulation SBR.

Figure 36 SMARTech 5 - Hydraulic testing

Project: No 690323

SMART-Plant D3.2

Figure 37 SMARTech 5 – Testing of the air diffusion system.

Figure 38 SMARTech 5 – Screenshot of the PLC control panel

horizon 2020 research and innovation programme …smart-plant.eu/uploads/d3_2.pdf · horizon 2020...

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