water waste processing - february 2015

SOLUTIONS FOR WATER-PROCESS PROFESSIONALS

Food & bev reuse treatments

Remote site data transmission

Active mixing solves problems

INCLUDING:

February 2015www.waterwaste.com

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Write In 101

In This Issue

Productivity Perspectives 4

Remote-site data transmission defl ectsregulatory runaround 6Broadband wireless extends municipalitys fi ber-ring multi-

megabit throughput to miles-away treatment sites.

Water-reuse treatment options in food & beverage 12Whys and wherefores, from biological and disinfection treat-

ments to membranes and osmosis.

Active mixing solves rural utilityice-buildup problems 18Someone once said, Water bodies, like human bodies, re-

quire good circulation to function properly.

How is solids-separation controlled inprimary wastewater treatment? 20Primary clarifi ers, air-fl otation units and Imhoff settlers are

amongst equipment options.

News in Brief 22

New Product Spotlight 24

Advertiser Index 24

Group Publisher, Michael C. Christian

Ph: 908-507-5472Email: [email protected]

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SOLUTIONS FOR WATER-PROCESS PROFESSIONALS

6

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Write In 102

According to a U.S. Geological Survey

report from last November, the federal sci-

ence agency found that water use dropped

to 355 billion gallons a day in 2010. In 2005,

national water use was 410 billion gallons

per day. A nation of 309 million in 2010

used as much water as 205 million people

45 years ago. California reduced its water

use 17 percent from 2005 to 2010.

In other news, during December last,

Congress unanimously passed the Water

for the World Act and it was immediately

signed by President Obama. In statistics

repeated near ad infinitum by the media, its

noted that nearly 750 million people around

the world dont have access to clean water

and 2.5 billion people dont have access to

a toilet.

The law is said to strengthen and clarify

the 2005 Water for the Poor Act, associated

with the late Senator Paul Simon of Illinois,

who, early recognizing the emergence of

water issues on the global stage, released

the book Tapped Out in 1998, one year

after his Senate retirement.

Recognizing insight

In a recent story in The Southern Il-

linoisan, John Oldfield, chief executive of

WASH Advocates, seemed to put a good

face on the bills lack of funding when he

was quoted as noting its hugely bi-partisan

support. According to the newspaper

story, previous versions of the bill called for

spending as much as $8 billion over the

next five years to meet the acts mandates.

In its present enacted form, only about $2

million is needed over the same period.

The bill will ensure U.S. aid dollars are

devoted to international projects that pro-

vide first-time access to safe drinking water.

Of course, the newspaper account also

points out, the omnibus spending plan

passed by Congress and signed into law

by President Obama last December in-

cludes a $17.5 billion bump for U.S. water

access and sanitation projects, bringing

the minimum U.S. spending levels for such

projects to $382.5 million, though millions

more is spent annually.

Further information on the legislations

details is included in a recent article found

in the High Plains/Midwest AG Journal, and

based on staff and wire reports.

In regards to water infrastructure, the web

site story says, the bill increases funding

in several priority areas, including the U.S.

Army Corps of Engineers construction ac-

count, which was increased by $514 billion

above the administrations request, includ-

ing $112 million in additional for the Inland

Waterway Trust Funds projects.

Overall, says the website story, The Army

Corps of Engineers fared well, with a $921

million increase in its Civil Works account

and $47.5 million increase to operations &

maintenance.

The less fortunate

Headed in the opposite direction, ac-

cording to an article by Jack Rasmus on

the website counterpunch, is the EPAs

funding, which in the bill was reduced

another $60 million, having already been

reduced 21 percent below 2010 levels. He

also notes the Clean Water Acts regulatory

scope was shrunk to exempt ponds and

irrigation systems, although this may be a

perfectly reasonable action.

Also included in the omnibus spending

plan is legislation to create 15 manufactur-

ing innovation sites across the U.S. at a

federal government cost of $30 million a

year for the next 10 years.

Its assumed here that, depending on

what local regions are awarded the funding,

the efforts also could be aimed at process

industries, especially food & beverage,

and not just the manufacture of discrete

products. The hubs support a network of

public-private partnerships involving col-

leges, universities and goods makers to en-

sure the availability of fully trained workers,

which is something the editors have been

hearing an awfully lot about lately.

Go between the lines to glean the bottom lines

Kevin Parker, Editorial [email protected]

By Kevin Parker, Editorial Director


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Write In 103

Since 1848, the city of Georgetown

has been found about 30 miles north of

Austin, the Texas state capital.

Yet the towns population has almost

doubled, to 52,000, in the last 12 years.

Workers and dependents from major

Austin employers including the state

government and University of Texas, and

high-tech companies, including Dell,

Apple and Intel are among those re-

sponsible for the growth.

All these people need water and sewers

and electricity and roads.

Thats where Georgetown Utility Sys-

tems, a department in the City of George-

towns municipal government, comes

in. The pace of growth makes providing

services a tall order, says Ron Marrow, a

Georgetown transmission and distribution

supervisor.

Its not enough to just keep up with

the citys growing number of citizens,

because that would mean were always

behind the curve, he says. We have to

stay ahead of the growth and that takes

good planning.

Marrow and a team of three have

charge of communications and con-

nectivity across the municipalitys water,

waste and electrical infrastructure. To their

endeavors, they bring to bear a wealth of

experience with the citys infrastructure

and its environment.

Fast look back

For years the utility used the 900 MHz

radio spectrum in monitoring components

in its water, sewage and electrical distri-

bution systems, i.e., using SCADA data

communications with speeds of 9600 bits/

sec. However, Marrow says, the 900 MHz

radio communications werent always

reliable given an approximately 300

square-mile coverage area.

Hot weather was an especial problem.

The area is known for long, hot summers.

Average temperatures often top 100 de-

grees F in July and August. Temperature

highs near 90 degrees F are common well

into October.

A seemingly trivial temperature-related

failure can have significant consequences.

Heat-caused atmospheric changes

can disrupt radio data transmissions,

Marrow says. Whenever it got hotter than

90 degrees F, for example, communica-

tions from a remote wastewater lift station

would fail. Wed send a technician to take

data readings every four hours. If there

was an overflow, the actual environmental

impact might not be all that big, but the

regulatory reporting would be huge, so

wed make sure someone monitored it in

person.


IT-based automation

Remote-site data transmission deflects regulatory runaroundBroadband wireless extends municipalitys fiber-ring multi-megabit throughput to miles-away treatment sites

The 900 MHz radio spectrum wasn't always reliable when it came to use of SCADA for supervisory control of water distribution systems.

Long, hot summers were an

especial challenge.

Write In 104


IT-based automation

Another issue was the star topology of

the 900 MHz radio network. All the remote

radios transmitted back to one central ra-

dio, Marrow says. If that central radio went

down, so would all our communications.

Big step taken

Marrow and his team designed, devel-

oped and deployed a redundant, 1.0 Gbps

fiber ring network for the citys SCADA com-

munications. Its multi-megabit bandwidth

eventually would enable broadband com-

munications that include video surveillance,

voice-over-IP and remote, on-demand WiFi

hotspots for municipal field workers.

In the aftermath of the project, however,

their most immediate concern was cost-ef-

fectively connecting remote water treatment

stations with the new fiber ring.

Installation of in-ground fiber can cost up

to $25,000 per mile. Extending the citys

fiber to its wastewater lift stations, up to

seven miles away, wasnt economically fea-

sible. Instead, broadband wireless would

be used to extend the municipalitys fiber

ring multi-megabit throughput out to the

remote sites.

Alternative options for doing so included

using 1) a commercial cellular network, but

that came with monthly charges; 2) 802.11

WiFi, but that came with limited range; and

3) 802.16e WiMAX, using the 4.9 GHz spec-

trum that the U.S. Federal Communications

Commission (FCC) allocated to public

safety and municipal uses, and which also

allows for mobile connectivity.

While WiMAX over the 4.9 GHz band

delivers the range needed, it requires FCC

licensing, something which isnt done with-

out expert support. This is where Siemens

reengaged with the municipality.

Devising devices

Deploying the municipalitys fiber ring

included installation of scores of Siemens

RUGGEDCOM RS900G Layer 2 switches,

part of Siemens harsh-environment com-

munications portfolio. The RS900G is an

environmentally hardened, fully managed

Ethernet switch that provides dual-fiber

optical Gigabit Ethernet ports with Gigabit

uplink ports, and 128-bit encryption.

In all, Georgetown had more than 200 of the

devices deployed in its fiber network, includ-

ing routers and media converters. It only

made sense to keep all the iMAX components

in the family, too, Marrow says.

Marrows Siemens contacts understood

what was involved in extending the fiber

rings broadband throughput to the remote

sites. WiMAX technology also presented

some line-of-sight challenges in connecting

wastewater lift stations typically placed

in low-lying areas amid Georgetowns

rolling, tree-covered terrain.

We not only needed help securing our

FCC license, we also needed some excel-

lent RF engineering, system design and

integration, Marrow says.

Integrator introduction

For these services, Marrow contacted

Alpha Omega Wireless, an Austin-based

'If wed have an overflow, the actual environmental impact might

not be all that big, but the regulatory reporting would be huge.'

www.waterwaste.com | Water/Waste Processing | February 2015 9

Write In 105

systems integrator and Siemens-certified in-

dustrial wireless solution provider. Marrow met

with Joe Wargo, founder and president, and

Kelly Ice, business development manager.

Alpha Omega Wireless compiled require-

ments to define a point-to-multipoint 4.9 GHz

WiMAX solution as well as a comprehensive

deployment and commissioning plan. In ad-

dition, they processed the paperwork needed

for the citys FCC license to use the 4.9 GHz

spectrum.

The solution includes three components, all

with rugged performance features to withstand

harsh weather conditions: the WIN 7249 small

form-factor base station, for 4.9 GHz radio

transmissions; the WIN 5249 outdoor sub-

scriber unit, also for the 4.9 GHz spectrum;

and the RP100 single-port 802.3xx Power-over-

Ethernet (PoE) injector, which powers the other

two devices.

The utility-grade gear works in environments

subject to high electromagnetic interference

(EMI), extreme temperatures and environ-

mental pollutants. Its also been put through

accelerated-stress testing, including highly

accelerated life testing (HALT) and highly ac-

celerated stress screen (HASS), both designed

to find defects before environmental conditions

do. These tests enable Siemens to provide

five-year warranties for the RUGGEDCOM port-

folio of network components.

Today, Georgetown enjoys a reliable, future-

The utility-grade gear used to enable

the remote reporting capabilities has been extensively subjected to accelerated stress

testing.

Previous top: Licensed 4.9 GHz wireless capability augmented the city's mission-critical broadband network.Previous bottom:The challenge was to connect remote water treatment sites with faster, more reliable data transmission.

ready, high-bandwidth wireless network.

Its developers claim thousands of dollars

in labor cost-savings along with hundreds

of thousands of dollars in cost-avoidance

for just the first deployment phase, which

took just two days.

The base station was installed in one of

the citys outlying, 120-foot water towers. It

delivered a clear line of sight to subscriber

units installed at four water-treatment sta-

tions, the farthest more than five miles away.

What followed was faster

Marrow says he was amazed at the dif-

ference in transmission speeds apparent

when he used his laptop to log into the

4.9 GHz SCADA data stream. It was like

night and day, he says. Before, the data

speeds were so slow. Its like going from

a pipe a quarter-inch wide to one thats

six-inches wide.

Marrow was pleased with the imple-

mentation by Alpha Omega Wireless,

backed by Siemens service and support.

We test all the radio components as

soon as they arrive to ensure each one

works to its specification, says Ice. Then

we follow our proprietary project manage-

ment methodology, which we built on the

rigorous standards of the Project Man-

agement Institute.

The city no longer need dispatch a

technician to hand-log data at wastewater

lift stations whenever outdoor temperature

breaks 90 degrees, as it does more than

30 times a year. That saves thousands of

dollars.

Thats not to mention the technicians

discomfort to be inside an enclosure

gathering the data, while the suns baking

down on you, Marrow says.


IT-based automation

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It pales though in comparison to the

citys avoidance of hundreds of thou-

sands of dollars in capital costs, if it had

pushed fiber out to the remote sites.

Siemens and Alpha Omega Wireless

had the expertise, responsiveness and

consultative approach right for the proj-

ect. They worked well together and the

support was good, he says. Through-

out it all, we felt our backs were covered.

No matter what issue might arise, we

knew both companies would respond

as one.

Siemens AG is a German multi-national

corporation headquartered in Berlin

and Munich. It is the largest engineer-

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involvement with industrial automation

and digitization, the company says it is a

global powerhouse positioned along the

electrification value chain from power

generation, transmission and distribu-

tion to smart grid applications and the

efficient application of electrical energy.

Siemens

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Write In 200

Highly accelerated life testing

(HALT) and highly acceler-

ated stress screen (HASS) are

both designed to find defects

before environmental condi-

tions do.

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Write In 107

In a food & beverage facility, water is for

make-up of cooling towers and boilers,

and for equipment washing and production

input. Water provision may involve connec-

tion to a municipal system; extraction from

the local natural water supply, such as a

ground well; or reclamation from process-

facility wastewater via reuse treatment,

lowering freshwater requirements.

Water resources were taken for granted

for decades, but now are seen critical for

companies, communities and govern-

ments, as issues of environmental sustain-

ability, both globally and in local context,

come to the fore.

Only 2.5 percent of the worlds water

is fresh, and much of that is trapped in

glaciers and snowfields. One estimate says

only about 1 percent of this freshwater is

accessible, i.e., available for everyday

use. In another estimate, if current trends

continue, global freshwater demand will

exceed supply by a staggering 40 percent

in 2030.

By reducing source-water requirements,

any food & beverage company lessens its

environmental impact. Many companies

also realize substantial cost savings from

water-related investments.

Other benefits of water reuse include

1) enhanced sustainability practices; 2)

more appropriate water-quality standards

for food & beverage processes; and 3)

mitigated business risk through lessened

dependency on external water sources.

Water reuse is growing around the world.

Read further to understand more about its

deployment, including issues bearing on

investment decisions.

Terms & definitions

Wastewater is typically discharged into a

collection network, to be treated by publicly

owned treatment works (POTW) or under

the national pollutant discharge elimination

system (NPDES).

In the U.S., publicly owned facilities

are the business of local governments or

municipalities, and treat domestic sewage,

not industrial wastewater. Some industrial

facilities are permitted to discharge water

to public treatment works if they follow

pretreatment processes such as for solids

removal, biochemical oxygen demand

(BOD) reduction and pH adjustment.

Public treatment works are sensitive to

industrial discharge due to potential impact

on facility operations. Many require corpo-

rations to pull permits for discharge and

charge significant fees. In addition, fines

and other penalties can be imposed for

discharge permit violations.

The discharge of water into a river, lake,

creek or other body of water falls under the

purview of the national pollutant discharge

elimination system, a division of the EPA,

already mentioned. Companies looking to

discharge wastewater through the national

discharge system need water more heavily

treated than if discharged to public treat-

ment works.

As a government-regulated system,


Filtration & membranes

Water-reuse treatment options in food & beverageWhys and wherefores, from biological and disinfection treatments to membranes and osmosis

Reclamation from process-

facility wastewater via reuse

treatment lowers freshwater

requirements.

Table 1

strict permit requirements govern this type

discharge.

In fact, these standards often are more

stringent than those imposed for reuse. Vio-

lations of discharge requirements can result

in EPA-issued punitive fi nes and consent

decrees, which subject plants to routine

inspections to ensure standards compli-

ance. Should mandated provisions not

be followed, a company could also fi nd

itself paying for environmental damage

remediation.

Whether discharging wastewater

through POTW or NPDES, a company

should consider its full cost of wastewater

disposal when evaluating treatment and

reuse.

The technology of reuse

Commercial technologies for waste-

water treatment in reuse applications

include 1) conventional treatment to re-

move solids, and adjust pH and chlorine

levels, or 2) advanced processes that

fi lter and oxidize water, delivering higher

quality. These methods are more fl ex-

ible as to the how and where of recycled

water use.

Conventional solid waste removal can

include use of screens, dissolved-air

fl otation and primary clarifi ers, fi lters,

biological treatment via conventionally-

activated sludge, chlorination and pH

adjustment, reducing solids and Bio-

chemical Oxygen Demand (BOD). It pro-

vides minimal disinfection and, for some

reuse applications, such as turf irrigation,

conventional treatment may be all that is

needed.

Advanced technologies can remove

contaminants that conventional treat-

ments cant and are applied based on

specifi c needs, including the following:

microfi ltration or ultrafi ltration

membranes for solids and bacteria

removal

sequencing-batch or membrane-

bioreactors for biological nutrient

removal

reverse osmosis for removal of dis-

solved organics or salts

oxidation and disinfection to remove


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trace contaminants and pathogens

adsorption or ozone-enhanced

biological active filtration to remove

dissolved organics and contaminants

These advanced treatments can be

roughly categorized as either "biological" or

"disinfection."

Biological treatment further includes two

subcategories: sequencing batch reactor

(SBR) and membrane bioreactor (MBR).

In general, sequence-batching needs less

capital investment, but a membrane biore-

actor can cost less to operate.

Both combine biological treatment with

membrane filtration to 1) provide a high

quality effluent and 2) meet stringent nutri-

ent limits for phosphorus and nitrogen.

For a more detailed comparison of SBR to

MBR, refer to Table 1.

Kinds of disinfection

Disinfection treatment comes in three

types: chlorine, ultraviolet (UV) and ozone.

The most basic is chlorine disinfection.

Here, water is filtered with hypochlorite

to generate chlorine residual to inactivate

pathogens such as bacteria.

UV technologies are chemical-free

and need less contact time than chlorine

disinfection. In these systems, water is

channeled through a reactor that emits

UV light at low wavelengths to destroy the

DNA structures of microorganisms, includ-

ing bacteria, viruses, yeasts and molds.

Virtually any liquid can be used with this

technology, so it is often found in beverage-

processing plants.

However, UV is sensitive to water clarity.

Higher clarity water requires less energy

to treat, and as a result, pretreatment of

wastewater is common in systems where

UV disinfection is used.

Ozone and advanced oxidation process-

es (AOP) are powerful oxidation treatment

technologies that generate hydroxyl radi-

cals, the strongest oxidant used in water

treatment. AOP is an ideal disinfection

approach to treat recalcitrant contaminants

not removed by other technologies. AOP

and ozone technologies are commonly

coupled with other filtration technologies.

Table 2 outlines a cost-benefit analysis of

common disinfection technologies.

Membranes & osmosis

In addition to biological and disinfection

techniques, other advanced treatments are

used either separately or in conjunction to

fulfill wastewater discharge requirements.

Membrane filtration, including microfiltra-

tion and ultrafiltration, is for suspended-sol-

ids removal in food & beverage processing.

The technologies remove some pathogens,

viruses and bacteria. See the table below

for a breakdown of filtration types.

Multiple treatment options are avail-

able for specific needs a variety of

conventional and advanced treatment

processes can be configured for any

facility and tailored to be fit-for-purpose

depending on the application.

Choose equipment that results in

long-term benefits A plants total

water and wastewater costs are signifi-

cant and will continue to rise. Employ-

ing the correct reuse technologies can

result in both hard and soft savings for

your organization, including reduc-

tion in supply risk and environmental

benefits.

Collect the necessary information

to start the process Now that youve

decided to start reusing water, the first

step is to define some objectives. Con-

sider both financial and environmental

goals.

THE REUSE TAKEAWAY

Types of Filtration

Table 2

PROCESSING ONLINEConnect with

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Write In 116

In reverse osmosis, salts and many dissolved organics are

removed through a Reverse osmosis is used for highest-quality

reuse water, such as high-pressure boiler feedwater or for low

salt and contaminant levels. Reverse osmosis is expensive and

generates a concentrate brine wastestream that must be man-

aged via proper disposal.

Treating water is only the first step to ensuring wastewater is

recycled and reused efficiently and effectively within a plant. It is

important for organizations to also consider the transportation

and storage costs of water reuse.

Pumps and pressures

Treatment and pumping systems are primary energy con-

sumers within a water or wastewater loop. Sizing a system

appropriately and selecting equipment to meet requirements is

critical to life-cycle energy savings.

Pumps both transport and boost pressure in a system.

Water is moved from one spot to another for treatment, storage

purposes or use. Pressure boosting is needed for treatments,

including reverse osmosis, where water moves through a

membrane at specific pressures. Many reuse applications, such

as irrigation and equipment washing, also require pressure-

boosting.

Pumps and piping impact considerably the energy con-

sumed over a systems lifecycle. Pumps should be selected

to operate at their best efficiency point (BEP) and plumbing

engineered to minimize friction loss. Xylem estimates that a wa-

ter reuse system with improperly sized piping and pumps can

increase energy consumption by 200 to 300 percent.

Write In 109

With increasing droughts and

water-related anomalies, water

reuse must be front and center

for food & beverage plants bent

on sustainability and a secure

water supply. It speaks also to a

greater focus on social respon-

sibility and water stewardship. In

part, due to public indices such

as the Dow Jones Sustainability

Index, companies are investing

more heavily in sustainability

than ever before and are better

managing their water use.

Another driver of water reuse

is health and safety mandates.

Food & beverage operations

must comply with the FDA, as

well as EPA and other relevant

regulatory bodies. Standards put

in place by these organizations to

regulate wastewater quality vary,

but apply in some form to all

plants, regardless of size. For ex-

ample, in 2012, the EPA released

a document outlining state and

federal water reuse guidelines for

all industries, including food and

beverage processing.

Xylem, Inc.

www.xyleminc.com

Write In 201

Reuse treatments found in the food & beverage industry may be biological, as with use of a batch reactor or bioreactor, or may involve disinfection, using chlorine, UV or ozone based technologies.

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Write In 111

It seemed like every year after its potable

storage tank was constructed way back in

1972, the town of Lyons, Michigan, faced

icing problems, town officials admit.

With a population of nearly 800 men,

women and children, rural Lyons, found

near the center of the state, today over-

comes winter ice cake problems without

lifting or lowering its tank-water levels,

ensuring residents have full-strength water

pressure and fire-protection flow.

Ice-cake problems start with the fact that

leaving water quiescent in potable water-

storage tanks can lead to thermal strati-

fication, biofilms, excessive disinfection

byproducts and disinfectant residual loss.

Winter-ice formation in distribution-system

reservoirs also is challenging for water utili-

ties in colder climates.

With active mixing, stratification is

forestalled because inflow water circulates

throughout the entire tank, as water is

pulled in the tank bottom, where the dens-

est layers are, and transported directly to

the top of the tank.

Common enough situation

Thick ice layers often form on storage

tanks surfaces during prolonged subfreez-

ing weather. Steel tank seams can expand

during ice formation, causing water leak-

age or structural damage. Interaction of

ice chunks with inflows and outflows may

further damage tanks.

According to Susan Craft, a department

of public works superintendent, at one

point ice damage took out the cathodic

protection of Lyons tank. During the course

of renovating that single pedestal tank,

Craft consulted with Dixon Engineering of

Lake Odessa, Michigan on whether a more

definitive solution might be available.

The outcome was that today Lyons has

a GridBee GS-12 mixer from Dickinson,

North Dakota-based Medora Corp. for its

potable water tank. Craft reports that from

that point on, ice buildup in the tank was

a thing of the past, and furthermore, do-

ing year-round active mixing significantly

improved chlorine residuals.

Passive mixing so 'old school'

Most potable water storage tanks were

specified before circulation and mixing

water-quality benefits were fully appreci-

ated. Tanks were specified with excess stor-

age capacity for fire protection, adequate

water pressure and in anticipation of future

growth. Daily usage was relatively small in

relation to this excess capacity, again limit-

ing the benefits of passive mixing. Another

limitation of passive mixing is that tanks

have single-pipe influent-effluent designs,

with the ingress-egress point typically

located at the tank base.

Insufficient mixing allows water to ther-

mally stratify within a tank. During freezing

weather, temperatures in the lower portion


Mixing & blending

Active mixing solves rural utility ice-buildup problemsSomeone once said, Water bodies, like human bodies, require good circulation to function properly.

In Lyons, the 100,000-gallon capacity tower was "too small to lower the level much during the winter" and risk compromising fire-flow capacity. As a result, ice cake became the reality.

Stratification is forestalled

because inflow water circulates

through the entire tank, moving

what's at the bottom to the top.


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Write In 112

of the water column are warmest. Groundwater, typically sourced

at about 11 degrees C, as infl uent water, is the primary source of

heat. When infl uent volumes are low, infl uent water temperature

declines quickly to 3-5 degrees C. The most recently introduced

water stays in the lower portion of the water column because

water density is greatest at about 4 degrees C. Water tempera-

tures in the tank decline with increasing elevation until ice forms

wall-to-wall on the surface. Subsurface ice continues to form,

often reaching thicknesses of one to two feet.

In Lyons, the tanks 100,000-gallon capacity further limited

passive mixing. Our tower was too small to lower the level

much during the winter, says Craft, and because we use the

height of the water for pressure, we need to keep it as full as

possible. Plus, lowering water levels compromises fi re-fl ow

capacity. As a result, ice cake became the reality.

Overcoming horizontal layers

Active mixing is based on the simple fact that water in potable

water-storage tanks naturally forms thin horizontal layers. The

heaviest or densest layer is at the bottom, and each layer above

it is progressively lighter.

An active mixer moves infl ow water throughout the entire

water body.

The Gridbee GS-12 sets on the tank fl oor and pulls water

in at a point from one to two inches off the tank fl oor. In other

words, it pulls in water from the very bottom of the tank, where

the densest layers are, and transports it to the top of the tank.

Soon, temperatures are nearly identical throughout the tank and

ice cannot form.

Craft says Lyons uses the mixer year-around to combat prob-

lems from water stratifi cation. Pulling water right off the tank fl oor

ensures the most effi cient mixing of important boundary layers

without disturbing the sediment providing uniform distribu-

tion of disinfectant and uniform water age, as well as preventing

stratifi cation.

According to Craft, I was able

to keep the tank full during the

winter with no icing problems.

And chlorine residual levels are

more consistent. I was having

differing chlorine residuals before

I started mixing, but now its

been evened out in the system.

One sample I pull from a dead-

end has maintained a real even

residual.

Keeping these chlorine residu-

al levels consistent requires less

treatment, which reduces costs.

And improving water quality is,

of course, the ultimate goal for

Lyons and its residents.

Medora Corp., Dickinson,

North Dakota, whose brands

include GridBee and Solar-

Bee, provides mixing, THM

removal and disinfectant boosting

solutions to solve diffi cult prob-

lems in potable water treatment

and storage. GridBee GS-12

mixers are certifi ed to ANSI/NSF

Standard 61, including low-lead

certifi cation, by NSF, UL, CSA or

other qualifying agency. For more

information, call 866-437-8076.

Medora Corp.

www.medoraco.com

Write In 202

Use of an active mixer ensures uniform water temperatures within the tank.

Solids including those suspended,

settle-able or floatable are non-liquid or

fluid substances separated from clarified

wastewater in primary treatment.

Suspended solids are those small, solid

particles that remain so in water, as a col-

loid, or due to the motion of the water.

Settle-able solids are particles that will

settle within a reasonable length of time

assuming little movement. The weight by

volume of settle-able solids is greater than

water.

Floatable solids do so because their

weight by volume is less than that of water.

Primary wastewater treatments that

remove these solids in process containers

include primary clarifiers, air-flotation units

and cone-shape Imhoff settlers. While effec-

tive solids separation supersedes control

of pH and flow or other factors, generic

controls for each process container are

described in the following.

Primary clarifiers

The primary clarifiers most important

function is removing as much settle-able

and suspended material as possible. Unless

removed, organic settle-able solids can

cause a high demand for oxygen (BOD) in

subsequent biological treatment in the plant

or receiving waters.

Many factors influence the settling char-

acteristics of a given clarifier. Most common

include: temperature variation, short circuits,

detention time, weir-overflow rate, surface-

loading rate and solids loading. Three of

these factors are discussed below.

1. Temperature: In general, as water

temperature increases, the settling rate of

particles increases; as temperature decreas-

es, so does the settling rate.

2. Short circuits: As wastewater enters the

settling tank, it should be evenly dispersed

through the entire cross-section of the tank.

It should flow at the same velocity in all

areas toward the discharge end. If veloc-

ity is greater in some sections than others,

short-circuiting may occur.

Short-circuiting also may be caused by

turbulence or density-layer stratification

following from temperature or salinity varia-

tion. Temperature layers can cause short-

circuiting.

3. Detention time: Wastewater should

remain in the clarifier long enough to allow

sufficient solid-particle settling time. If the

tank is too small for the flow quantity and

the particle settling rate, too many particles

will be carried out with the effluent of the

clarifier.


Wastewater Dan

How is solids-separation controlled in primary wastewater treatment?Primary clarifiers, air-flotation units and Imhoff settlers are amongst equipment options

By Daniel Theobald

Air flotation units

The objective of flotation thickening

is to separate solids from the liquid

phase by matching air bubbles to

particles of suspended solids. Four

general methods of flotation are com-

mon, as follows:

1. Dispersed air flotation where

bubbles are generated by mixers or

diffused aerators.

2. Biological flotation where gases

formed by biological activity are used

to float solids.

3. Dissolved air, vacuum flotation

where water is aerated at atmo-

spheric pressure and released under a

vacuum.

4. Dissolved air, pressure flotation

where air is put into solution under

pressure and released at atmospheric

pressure.

The performance of dissolved air-

flotation units depends on; type of

sludge, age of the feed sludge, solids

and hydraulic loadings, air-to-solids

(A/S) ratio, recycle rate, and sludge-

blanker depth.

Operational guidelines are affected

by dissolved air flotation unit sizes.

Performance can be optimized by con-

trolling the air-to-solids ratio, recycle rate

and blanket thickness as variables. These

control variables are affected by solids and

hydraulic loading rates. Controls should

prevent solids or hydraulic loading from

becoming excessive.

Performance is optimized by conditions

such as those described in the following.

Air-to-solids ratio: An optimum ratio

should be established and maintained.

It is affected by the quantity of air intro-

duced and dissolved into the recycle or

waste-stream, which is in turn critical to

fl otation thickener operation. Enough air

has to be added and dissolved to fl oat

the sludge solids. The most effective way

to do this is introducing air into a pressur-

ized retention tank along with the waste-

stream to be thickened, or along with a

portion of the thickener effl uent stream.

Air also can be dissolved in primary or

secondary effl uent.

Recycle rate and sludge blanket: Both

the rate of effl uent recycle and the thick-

ness of the sludge blanket are opera-

tional controls available to optimize DAF

performance.

Note on Imhoff tanks

Imhoff tanks are rarely constructed to-

day. Your plant may incorporate an Imhoff

tank only if it came online many years

ago, perhaps in the 1980s. Cone-shape

Imhoff settler tanks are unique because

the Imhoff tank combines sedimenta-

tion and sludge digestion in the same

process unit.

If you have specifi c solids separation or

other wastewater queries, please submit a

question by visiting www.ProcessingMag-

azine.com/Ask-the-Wastewater-Expert.

Known in the industry as Wastewater

Dan, Daniel L. Theobald, proprietor of

Environmental Services, is a professional

wastewater and safety consultant/trainer. He

has more than 24 years of hands-on indus-

try experience operating many variants of

wastewater treatment processing units and

is eager to share with others his knowledge

about water conservation. (www.Conserve-

On-Water.com).


To learn more, contact [email protected], visit www.boerger.com or call 612.435.7300

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Write In 113

Experts call for review of US drinking water standards

The U.S. EPA should review its standards

on secondary drinking water contaminants,

according to a paper published in the

American Chemical Society journal Envi-

ronmental Science and Technology.

Authors Andrea Dietrich, professor of civil

and environmental engineering at Virginia

Tech, and Gary A. Burlingame, director

of the Philadelphia Water Department's

Bureau of Laboratory Services, said that

a variety of factors could change con-

sumer perceptions of drinking water quality,

including California's drought conditions,

the increase in hydraulic fracturing and

the country's aging infrastructure of rusty,

degrading pipes.

Dietrich and Burlingame argued that

these and other developments mean that

a critical review and rethink is needed con-

cerning the EPA's secondary standards in

order to maintain consumers' confidence in

tap water as well as in its sensory quality.

These "secondary maximum contaminant

levels" cover substances including alumi-

num, chloride, copper, fluoride, foaming

agents, iron, manganese, silver, sulfate,

total dissolved solids and zinc, as well as

the water's color, odor, pH and corrosivity.

Research by Dietrich and Burlingame

suggests that the current standards for

chloride, copper, iron and manganese

are too high to minimize sensory effects.

Furthermore, they said, the standards

for corrosivity and foaming agents "may

be outdated" and the standard for odor

"requires rethinking as the test does not

correlate with consumer complaints."

Episodes that negatively impact consum-

er confidence and perception of tap water

still occur and may increase, yet second-

ary maximum contaminant levels are not

monitored or enforced nationally. As a

result, there is no systematic collection and

interpretation of consumer feedback.

"Research is necessary to develop stan-

dardized procedures for the collection of

consumer feedback on aesthetic, cosmetic

and technical concerns at individual com-

munity water systems and centralized in

a national database," Dietrich and Burlin-

game said.

Adherence to the EPA's secondary

standards can help maintain production

of palatable water along with consumers'

confidence in their water providers, the

researchers concluded.

Arkansas city agrees to cut sewage discharges

The city of Fort Smith, Arkansas, has

agreed to upgrade its sewer collection and

treatment system to reduce discharges of

raw sewage into local waterways, the U.S.

Environmental Protection Agency (EPA)

announced.

Under a consent decree with the EPA

and the U.S. Department of Justice, Fort

Smith will spend $255 million, plus the cost

of routine operation and maintenance, to

improve its sewer system. This comes after

more than 2,000 discharges of untreated

sewage from its municipal sewage system

over the past 10 years, resulting in more

than 119 million gallons of raw sewage

flowing into local waterways, including the

Arkansas River.

The city will carry out a full assessment

of its sewer system to identify defects and

places where stormwater may be entering

the system. It will also repair all sewer pipe

segments and manholes that are likely

to fail within the next 10 years, develop

projects to improve the performance of

sewers and implement a program to clean

the system of debris such as grease and

tree roots. And a water-monitoring program

will be implemented to establish whether

human waste is entering and being dis-

charged from the city's stormwater system.

Fort Smith will also pay a $300,000 civil

penalty and will spend $400,000 on a pro-

gram to help low-income areas of the city

repair and replace privately-owned portions

of the sewer network.

According to the EPA, this settlement

agreement will substantially reduce the

number of sewage discharges and improve

water quality. It will cut discharges of 3,492

pounds of total suspended solids, 3,343

pounds of biological oxygen demand, 543

pounds of nitrogen and 78 pounds of phos-

phorus from the Fort Smith sewage system

each year.

High levels of these pollutants can

reduce oxygen levels in water bodies,

threatening the health of aquatic plants and

animals, for example by causing excessive

algae growth.

IChemE calls for action to cut water usage in food production

More needs to be done to reduce the

amount of water used in food production,

according to the Institution of Chemical

Engineers (IChemE).

The organization estimates that around

90 percent of all freshwater is currently

used by agriculture (70 percent) and indus-

try (20 percent), leaving just 10 percent for

domestic use.

With the global population continuing to

rise and more people moving to a Western-

style diet, increases in food production will

be required to feed the population and that

increased production will need larger water

supplies.

"Estimates suggest that we will need to

produce 60 percent more food by 2050.

Agriculture will need around 19 percent

more water to produce that extra food,"

commented Andy Furlong, IChemE director

of policy.


News in brief


"It is clear that current production meth-

ods are unsustainable and there are

genuine risks of food shortages, rising food

prices, droughts and social unrest for future

generations unless we make more efficient

use of water," he added.

By 2050 around two-thirds of the

world's population will be living in "water

scarce" areas, compared to just seven

percent at present.

IChemE is calling for a global target

to cut the amount of water used in food

production worldwide by 20 percent.

Shutdown strategy saves treatment plant time, money

Engineers in the United Kingdom have

devised a way to shut down an entire

sewage treatment works without using

storm facilities.

Engineering and construction group

Costain said that a team working at

Severn Trent Water's Stratford Milcote

facility developed and trialed the strategy

while installing a new inlet works with

associated screens and handling at the

sewage treatment plant.

Tom Grainger-White, senior site agent

for Costain, explained: "Traditionally when

a treatment works is shut down, foul

water is transferred to tankers and then

transported to other sites. By compil-

ing information such as how wastewater

flowed between the 15 pump stations

that fed the site, and carrying out tests to

check those interactions, we were able to

turn off individual stations.

"This allowed us to increase the time

we could turn off the main treatment

works, and so no tankers were required."

When a faulty valve was discovered at

the water utility's Paddock Lane pump

station, the strategy proved its worth.

Grainger-White said: "Paddock Lane

is a very large pumping station; it's in a

residential area and is almost impossible to

tanker from. But the three trials we carried

out at the Stratford Milcote scheme were

enough to convince everyone that STW

could perform shutdowns further up the

network and so safely replace the valve."

Using information from the shutdown

trials at Milcote, the team was able to safely

replace the faulty valve the next day. Severn

Trent Water estimated that the work cost

around 35,000 ($55,000) less than if over-

pumping had been required.

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Write In 110

Aplus Finetek Sensor, Inc.'s

newest EG series level transmitter,

the EG31, is designed to pre-

cisely measure coolant level in an

evaporator within an industrial air

or water cooled chiller. Accurate

reservoir level control is important

for precise control of refrigerant

flow through the expansion valve.

The Aplus Finetek EG31 also includes a customized installation

mechanism that allows the level transmitter to be installed or

removed without taking the system out of service. The EG31 level

transmitter is currently used by a global leader in the manufac-

ture of large scale industrial chillers.

Aplus Finetek Sensor, Inc.

www.aplusfine.comWrite In 204

Chemical Metering Pumps

Watson-Marlow Pumps Group's

new Qdos 60 chemical metering

pumps expand the Qdos range to

incorporate flow rates from 0.001 to

15 GPH at 100psi and is designed

to reduce chemical metering costs

compared to conventional solenoid

or stepper-driven diaphragm meter-

ing pumps. The Qdos 60 is espe-

cially suited to chemical metering

applications found in larger water treatment plants where flow

demand is greater than that provided by the existing Qdos 30

model and is ideal for disinfection, pH adjustment and floccula-

tion of drinking water, wastewater and industrial process water.

ReNu pumphead technology provides a single, safely con-

tained component for rapid maintenance without the need for

tools. Simple drop-in installation eliminates the need for ancillary

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able metering cut the cost of chemical wastage.

Watson-Marlow Pumps Group

www.wmpg.comWrite In 203

Level Transmitter for Measuring Coolant


Advertiser IndexAmerican Water Works Association (AWWA) ...............................11

Aplus Finetek Sensor, Inc. ..............................................................15

Baldor Electric Company ..................................................................5

Blue-White Industries......................................................................13

Boerger ............................................................................................21

Dwyer Instruments ...............................................Inside Front Cover

Flexicon Corp. .................................................................................10

GEM ...............................................................................................23

Infilco Degremont .............................................. Inside Back Cover

Kaeser Compressors ........................................................................1

Myron L ............................................................................ Back Cover

Process / Flow Network ..................................................................17

Rosedale Products .......................................................................... 7

Rotork ................................................................................................3

Sonitec-Vortisand ............................................................................19

Watson-Marlow Pumps Group .........................................................9

New Product Spotlight

Write In 114

Write In 115

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water waste processing - february 2015

Documents

kaesers screw blower

waterwaste processing

global processing magazine

rotary screw blower

waterreuse treatment

operations manager

water bodies

wastewater treatment