701.114 730 008 00 technology and operation

8/8/2019 701.114 730 008 00 Technology and Operation

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PROTECTING THEPROTECTING THE BLUEBLUE PLANETPLANET

Technology & OperationTechnology & Operation

TRAINING

Davi JanssensProcess Engineer

Inbev Omsk


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Table of contents

1. Design

2. Process conditions and parameters

3. Reporting

4. Trouble shooting

5. Cost drivers

6. Formulas for WWTP process

7. Technology UASB

8. Technology Lucas


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1.1. Good brewery housekeeping

Limited water consumption per hl beer producedLimited pollution load per hl beer produced

No significant spent grains discharge to the WWTPNo significant surplus yeast discharge to the WWTPNo significant kieselguhr discharge to the WWTPNo oil discharge to the WWTPCleaning & disinfecting agents: biodegradable + low concentratedProper waste management

- Gradual discharge high loaded wastewaters

- Gradual discharge caustic/acid solutions

-

Temperature < 40C

1.Design


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1.2. Design: Influent Characteristics brewery wastewater

Parameter Units Design

Maximum flow rate m3/day 8.650

Peak flow m3

/h 720Water temperature C 25

pH - 6-12

BOD5 mg/l < 2.320

CODtot mg/l < 4.000

COD load kg/day 34.600

Total nitrogen mg N/l 30-50

Total P mg P/l 10-20

TSS mg/l 500-700

Sulphates mg/l < 100


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1.2. Design: Influent Characteristics malting wastewater


Maximum flow rate m3/day 900

Peak flow m3

/batch 90

pH - 6-12

BOD5 mg/l < 500

CODtot mg/l < 850

COD load kg/day 775

Total nitrogen mg N/l 40-50

Total P mg P/l 10-20

TSS mg/l 200-500


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1.2. Design: Influent Characteristics rainwater


Maximum flow rate m3/day 198

Peak flow m3/h 100

BOD load kg/day 61,6

COD load kg/day 132


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1.3. Expected effluent quality

Parameter Unit Guaranteed Expected

TSS mg/l 250 50

pH 6,5-9 6,5-9

BOD5 mg/l 150 50

CODtot mg/l 180 100

Phosphate mg/l 4,5 4,5

Ntot mg/l 18 15

Nnitrate mg/l 9 5

Sulphite mg/l 0 0


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Mesophilic temperature-activity correlation

0 10 20 30 40 50

Temperature

Bio

degradation

rate

1.4. T [C] vs. biodegradation


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2.1. Process parameters UASB

-Flow rate : < 10.000 m/d

-Min. hydraulic retention time (h):-Buffer tank = 14,4 h-UASB = 9,3 h

-Upflow velocity :


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- COD-load: 17.500 kg COD/d per reactor

- Organic (or Volumetric) loading: design Vb = 9 kg COD/m.day

- Amount COD fed per m active volume per day

Active volume = Reactor volume = 1.944 m

UASB: 17.500/1.944 = 9 kgCOD/m.day

Max.Vb = 10 kg COD/m.day (at 36C)


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- F/M or Sludge loading

Avg. sludge concentration:1,5-6 % DS = 15-60 g/l

Sb = 0,15 0,6 kg COD/kg DS.day

- Feed to Micro-organisms: amount COD fed/kg DS of biomass.day

Organic loading/sludge concentration

UASB: < 1 kg COD/kg DS.day

- F/Mo Effluent quality q or F/Mq Effluent quality o

- F/Mo Sludge production o (typically: < 0,05 kg DS/kg CODremoved)

- Organic load o Biogas production o (typically: 0,3 0,4 Nm

biogas/kg CODremoved)


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2.2. Process conditions UASB

pH

- UASB effluent: 6,5 < pH < 7,5

- Methanogenesis = very pH-sensitive !!!

Temperature

- UASB: Range: 25 38 C (mesophilic)

Optimum: 32 37 C

- TCo 10C reaction velocity doubles

Nutrients- UASB: COD/N/P = 400/5/1

Oxygen- UASB: NO O2 allowed


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Good contact between substrate and biomass good mixing !!!

- UASB: Upflow velocity + gas production

turbulence mixing


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2.3. Process parameters SBR

-Flow rate : < 10.000 m/d

-Surface area outer compartments: 3 x 440 m

- Max. upflow settler compartment: 0,95 m/h

flow rate/surface area

= [417 m/h]/[440 m] = 0,95 m/h


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- COD-load : < 5000 kg COD/d

- BOD-load : < 3000 kg BOD/d

- Active volume : Reactor volume x [% aerobic or anoxic]

= 7.200 m x 62,5%

= 4.500 m

- Design volumetric load Vb : 1,1 kg COD/m/d

0,68 kg BOD/m/d

= amount organics fed per m active volume per day

Influent

Effluent

Aerobic Filling

Accumulation

Aerobic React

RegenerationDecanting

PHASE 1

PHASE 2PHASE 3


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- Design sludge concentration : 6 kg MLSS/m

- Design sludge load or F/M : 0,185 kg COD/kg MLSS/d

0,11 kg BOD/kg MLSS/d

= amount organics fed per kg activated sludge per day

- F/Mo Effluent quality q or F/Mq Effluent quality o

- F/Mo Sludge production o (typically: < 0,2-0,3 kg DS/kg CODremoved)

Sludge growth rate too high

Slow-growing nitrifying biomass outcompeted!

F/M < 0,15 kg BOD/kg MLSS/d = OK


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2.4. Process conditions SBR

pH

- LUCAS effluent: 6,5 < pH < 8,5

- Nitrification = very pH-sensitive !!!

Temperature

- LUCAS: Range: 15 38 C (mesophilic)

Optimum: 32 37 C

- TCo 10C reaction velocity doubles

- Nitrification = very TC-dependent !!!

Oxygen- SBR: D.O. > 1 mg O2/l

in aerobic phasesnot in anoxic and sedimentation phases


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Good contact between substrate and biomass good mixing !!!

- SBR: Mechanical mixing by submersible mixers and

floating aerators

- Especially important during anoxic phases!!!


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3. Reporting

3.1. Influent & balancing

Whats coming in ?

- influent flow rate

- influent COD & BOD

- influent pH

- influent N

- TSS, P, SO4, of the raw WW

Whats happening in the equalization tank ?- Do we obtain a stable feed water quality?


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3.2. UASB

Whats happening in the anaerobic reactor ?

- COD reduction

- TSS - Settleable solids in effluent

- VFA & pH

- Temperature

- Acid/Caustic consumption

- DS in reactor (sludge gradient?)

- Granular sludge

- Biogas production } 0,3 0,4 m/kgCODrem


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Whats happening (continued)

- Daily Flow Rate (m/day)

- COD load (kg/day) UASB

- COD removal efficiency UASB

- F/M UASB

- Effluent quality UASB: COD, TSS, BOD, pH,

- Sludge wasting: yes/no?


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3.3. LUCAS

Whats happening in the aerobic reactors ?

- COD reduction

- N-removal: Nitrification/Denitrification- TSS - Settleable solids in effluent

- pH &Temperature

- MLSS in reactors (typical 4-7 g/l)

- Sludge wasting: yes/no?

- Sludge settleability (target: SV < 800 ml & SVI < 150-200 ml/l)

- Daily flow rate (m/d) & organic load (kg COD/d)

- F/M

- Biological effluent quality: COD, TSS, BOD, NH4, pH, COD-

removal, N-removal


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3.4. Analyses: follow-up

Analysis Influent AnaerobicEffluent

FinalEffluent

Sludge

Flow Daily Daily Daily Daily (wasted)

pH Daily Daily Daily

Oxygen concentration Daily

CODtotal Daily Daily Daily

CODfiltered 3 x/week Daily

VFA 3 x/week 3 x/week

TSS 3 x/week Daily 3 x/week

Nitrogen total + NH4+-N

+ NO3

-N

3 x/week 3 x/week

Phosphorus total + PO43--P 3 x/week 3 x/week

MLSS or DS Daily

Temperature Daily Daily Daily Daily

SV/SVI Weekly 2 x/week


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4. Troubleshooting

4.1. Wastewater quality

-BOD/COD ratio > 65 % ?

-No toxic compounds ?

> heavy metals, (mineral) oil, antibiotics, cleaning agents

-No sand, no kieselguhr (inert!!!)

-No yeast, no spent grains

-TC < 40C ?

-No organic overload ?

-No pH-shocks ?

-COD/SO4 > 10


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4.2. Troubleshooting table

Rosarbrewery Omsk: Follow-up data: roubleshooting

Analysis Range Actionifoutofrange

pH pr e-heating/correction tank (BUF06/7.00.00)

6,5-7,5 Check pH anaerobic effluent tank (BUF10.00.00):6,5-7,5OK Checkdosing units of caustic and acid

Check pHprobe aftercorrection tank and in anaerobic effluent

Check pH in the brewery and culling pump pit

Notify the brewery

Temperature pre-heating/correction tank(BUF 06/7.00.00)

25-38C Stop feeding towards UASB (UAB 08/09.00.00) UASB into recirculation

Check temperature anaerobic effluent tankCheck working external heat exchanger

Check pump PUM 06.01.00

Check internal heat exchangerCheck working reintegrated boilerCheck temperature heating agent reintegrated boiler

Check insulation of the tanks

Notify the brewery

Inlet flow 0-8650 m/day Check level in balancing tank (BUF 05.00.00)

Check level and level switches in all pump pitsCheck COD-load (max. 34,6 ton COD/day)

Check TSS-load (max. 6055 kg TSS/day)Notify the Brewery

CODin < 4000 mg/l Check COD-load (max.34,6ton COD/day)Check COD in all pump pitsCheck working rotative sieves

Notify the brewery

VFAin 150-750 mg /l Check CODinCheck pH in balancing tankCheck HRT

TSSin 500 - 700 m g/l Check TSS in all pumppits

Check function rotative sieve if RS=OK Notify the brewery; Check

COD/TSS >5


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Recirculation flow (FIT08/09.00.50) < 260 m/h per

UASB

Adjust upflow velocity;

Check inlet flowCheck level balance and pre-heating/correction tank

Check COD loadSwitch to stand-by pump

pH anaerobic eff luent tank (BUF 10.00.00) 6,5- 7,5 Adjust pH-setpoint NaOH/HCl-dosing in correction tank

Check pHprobe anaerobic effluent tankCheck dosing units

Check granularsludge

Temperature anaerobic effluent tank (BUF10.00.00)

25-38C Check T (C) in balance and pre-heating/correction tank

Check working external heat exchangerCheck pump PUM 06.01.00

Check internal heat exchangerCheck working reintegrated boiler

Check temperature heating agent reintegrated boilerCheck temperature reading

Check insulation of the tanks

CODanaerobic effluent < 1000 m g/l Check UASB COD-removal: >75% OK

Check CODinCheck COD-load

Check biogasproduction

VFAanaerobic effluent < 200 mg/l Golden rule:

>250mg/l: decrease feed flow of the UASB

>500 mg/l: Stop feed flow;

Check pH of Anaerobic effluent and preheating/correction tank

TSSanaerobic effluent < 200 mg/l Check TSSinCheck biogas productionCheck granularsludge UASB (DS)

Check recirculation flow (upflow velocity)Check 3-phase separators and PPS

Biogas production < 500 Nm/day Check COD-load < 34,6 ton COD/day

Check influent flowCheck 3-phase separators and PPS

Check granularsludge UASB

Forward flush < 10% of initialvalues

Flush/clean until initial values are reached


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pH SBRs (AER 11/12/13.00.00) 6,5-8,5 Check pH in Anaerobic effluent tank

Check pH in balancing and pre-heating/correction tank

Check dosing units

DO SBRs (AER 11/12/13.00.00) > 0,5 mg/l Check COD load < 34,6 ton COD/day

Check DO probesCheck working aerators

Check MLSS in SBR

MLSS (sludge concentration) SBRs (AER

11/12/13.00.00)

3 - 6 g/l

3000-6000 m g/l

< 3 g/l:

Check SV SBR

Stop sludge wasting

> 6 g/l:Check TSS/COD final effluent

Check SV SBR

Start sludge wasting

SV SBRs (AER 11/12/13.00.00) < 800 ml/l Check MLSS/SVI in SBR

Check TSS/COD final effluentCheck sludge microscopically (filaments?; higherorganisms?)

pH final effluent 6,5-9 Check pH in the SBRs

Check pH anaerobic effluent tankCheck pH balancing and pre-heating/correction tank

Check dosing unitsNotify the brewery

COD final effluent < 180 mg/l Check COD of the influent

Check loads of anaerobic and aerobic treatmentCheck settlement in the SBRs

Check pH in pre-heating/correction tankCheck temperature in pre-heating/correction tank

TSS final effluent < 250 mg/l Check SV in SBRs

Check TSS influentCheck TSS afterUASB

Notify the brewery

Sludge concentration after rotating drum(DED 19.03.00)

5-7% < 4 %:

Check polymer preparation/dosing/consum ption

Check working drumCheck MLSS SBRs/check feedflow of drum


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4.3. Influent

- pH bioreactor out of range

Acid/Caustic dosing

Increase anaerobic effluent recycling

- Overload

Feed flow rate q

- Temperature too high (> 38C) Omit hot fluxes from WW

By-pass heat exchanger


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Golden Rule

VFA > 250 mg/l feed

VFA > 500 mg/l stop feed4.4. UASB

Anaerobic Digestion: hydrolysis, acidogenesis, acetogenesis,methanogenesis

- pH anaerobic effluent out of range Dosing caustic/acid Check for TSS and/or COD-overload

- increase VFA anaerobic effluent reduce/stop feeding increase of recirculation

- increase TSS anaerobic effluent check DS in reactor (sludge gradient) reduce upflow velocity reduce TSS in influent organic overload? biogas production o


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4.5. Anaerobic effluent

Increase in effluent-COD and/or -BOD

- Biodegradability changed?

- Organic overload?

- Dead zones in reactor (not enough mixing/turbulence)

- Nutrient deficit (N, P, micronutrients)

- TSS wash-out => surface load q

=> sludge wasting

=> overload biogas boost

=> TSS influent

- Intoxication (pH, H.M., oil, detergent )


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4.6. LUCAS

Respect design load

- Organic load (kg COD/day): design aeration system

- Hydraulic load (m/day): design sedimentation tank

Overload removal efficiency

- Organic overload Failure aeration odour nuisance

- Hydraulic overload Insufficient pump capacity Upflow velocity - Sludge wash out


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Aerobic Digestion:

- pH effluent out of range

Check dosing units Check pH influent and anaerobic effluent

- Increase COD effluent Check COD load Check efficiency anaerobic treatment

-Increase TSS effluent Check MLSS in SBR

Check influent TSS Check efficiency mechanical pre-treatment Check pressurizing system effluent gutters


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4.7. Aerobic effluent

Increase of final effluent-COD and/or -BOD


- Organic overload (Sb < 0,25-0,5 kgCOD/kgMLSS.d)? O2 deficiency?

- Dead zones in reactor (not enough mixing)


- TSS wash-out => settling phase

=> sludge wasting

=> TSS influent

=> Filamentous bulking

Chlorination (5-20 g Cl/kgMLSS.d)

- Intoxication (pH, H.M., oil, detergent, TC )


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4.8. Final effluent

Increase in final effluent-COD and/or -BOD


- Organic overload?

- Lack of oxygen (DO < 1 mg/l)?


- TSS wash-out => sludge concentration too high

=>settleability changed

=> sludge wasting

=> TSS influent

- Intoxication (pH, Heavy metals, oil, detergent, etc.)


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5. Cost drivers

5.1. Cost drivers

Cost drivers ?

- Energy

- Chemicals

- Sludge production

- Labour (fixed cost)

- Maintenance (fixed cost)

The better the anaerobic WWTP is working, the less energy is

consumed, the more biogas/energy is produced, the less sludge is

produced


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Anaerobic WWTP:

- Low energy consumption (0,3 kWh/kgCOD)

- Produces biogas = green energy

- Low sludge production (+/- 0,05 kg DS/kgCOD)

Aerobic WWTP:

- High energy consumption (1,1 kWh/kgCOD)

- High sludge production (+/- 0,2 kg DS/kgCOD)


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Chemicals: depends on the pH of the incoming WW.

Consumption of caustic can be reduced by

recycling anaerobic effluent.

Sludge:

- Low sludge growth

- Anaerobic excess sludge is pumped in small quantities to a

storage tank in anticipation of dewatering or transport


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5.2. Advantages aerobic treatment

-Possibility of nutrient removal (N & P)

- Bio-N and P-removal

- Higher COD-removal efficiency

Necessary to remove last 20 % ofCOD

Low effluent COD

- Heat-range: 0 - 40C

- Short start-up

- Very robust process


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6. Formulas for WWTP processes

- Active Volume

- HRT = hours

- Volumetric Load: Vb = kg COD/m*day

- Sludge Load: Sb = kg COD/kg MLSS*day

- Removal Efficiency in % (COD, BOD, N, P, )

- Sludge Age = days

-Surface Load = m/h

-Biogas production


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Active Volume [m]:

Active Volume = Total Volume Sedimentation Volume

Sedimentation Volume = Passive Volume

HRT [hours]:.

Time span H2O-molecule present in reactor

hourmQinmVtotal

hoursHRT /

!


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/

/__*)(/

mkgDSmVactive

daykgCODLoadDayOrganicdaySSVkgMLkgCODSb

v

/__*/

mVactive

daykgCODLoadDayOrganicdaymkgCODVb !

Sb or F/M (kg COD/kg DS*day)

Vb (kg COD/m*day)

Organic day load (kg COD/day) = Qin (m/day) x CODin (kg COD/m)


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/_/__

/

mkgsludgeDSwasteddaymFlowWasteSludge

mkgDSreactormVtotaldaysMCRT

v

v

!

Removal efficiency [%]

- COD, BOD, N, P,

- Correlation amount X Enters WWTP vs. amount X Discharged

- X-removal efficiency (%) = (Xinfluent - Xeffluent)/Xinfluent

Sludge age or MCRT [days]- Residence time sludge in bioreactor

.


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_

//

mSurfaceSettling

hmQfeedhmVs !

Surface load = Upflow velocity [m/h]

- Design outer compartments for settling & discharge

- Minimum settling velocity sludge floc

.


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_

//

mSurfaceSettling

hmQrecirchmVs !

Surface load = Upflow velocity [m/h]

- Design UASB surface

- Minimum settling velocity sludge granule

.

Biogas production [Nm/h]

- 0,3-0,4 Nm/kg bCOD; 25 MJ/Nm- CH4 (65-85%);CO2 (15-35%); H2S (1000-9000 ppm); H2;

NH3;N2 and VOCs


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UASB

SeparationbafflesEffluent weir

Gasdome

Feed Loops

Reci cul i l

Reactor urface

m

U

P

F

L

O

W

Upflow Velocity

(m/h)/m =m/h

UASB

SeparationbafflesEffluent weir

Gasdome

Feed Loops

Recirculation Flow

m/h

Reactor urface

m

U

P

F

L

O

W

U

P

F

L

O

W

Upflow Velocity

(m/h)/m =m/h

7. TechnologyUA B


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8. Technology SBR

I fl t

ffl t

Aero ic illi g

Acc m latio

Aero ic eact

ege eratioeca ti g

PHASE1

PHASE2PHASE3


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4 steps occurring in SBR:

- Accumulation (feeding + aeration)

- Regeneration (only aeration)

- Settling

- Discharge

Sludge wasting always during discharge phase


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