Innovation and Value-Added Benefits Behind East Chicago’s Membrane Treatment Facility

August 1, 2012

Indiana’s Newest Filtration Facility; East Chicago

Eric Horvath, PE and Kara M. Boyles, PhD, PE

Presentation Overview

• Project Drivers

• Value Engineering

• Membrane Procurement

• Membrane Design

• New WTP Overview

• Start-Up Challenges

• Lessons Learned

Project Drivers • Marquette Plan for

Redevelopment

– Indiana Lakefront Communities

– Project to Reclaim the Lakeshore

• Age and Condition of Existing Plant

Existing Water Treatment Plant

Existing Water Treatment Plant

• WTP Built in 1964 • 24 MGD • Conventional Sand

Filtration • Aluminum Sulfate

Coagulation • 6 MG Finished Water

Storage • Located near Lakefront

Existing & Future WTP Sites

Existing Water Plant

New WTP Site Existing

Brownfield

Project Considerations • Time is of the Essence

– No Further Investment at Existing WTP

– Move Redevelopment Forward

• Clear Site for Redevelopment

– Relocation of Raw Water Pump Station

• Constrained Budget

• Flow 20 MGD Initial & 30 MGD Future

• Meet LT2ESWTR Bin 2

• Minimize Flow to Sanitary Sewers

• Investigate Zebra Mussel Treatment

• No Gaseous Chlorine at Proposed

WTP

Value Engineering • City Unhappy with $70M Price Tag

– Fresh Look at Design – Potential Cost Savings – Increased Functional Ability

• Team Reviewed Collected Data • 294 Creative Concepts Developed • 24 Concepts Further Developed • Optimal Combinations of Concepts to

Form 4 Alternatives Pressure Membrane

Submerged Membrane Traditional Gravity Filters

Treatment Alternatives

• Low Cost Alternative • Pressure Membrane • Submerged Membrane • Conventional Filtration

Treatment Alternatives Process Flow Diagram

RESIDUALS EQUALIZATION (Required by All)

A. Concrete Equalization Basin – Gravity Filters

B. Concrete Equalization Basin – Membranes

RESIDUALS DISCHARGE A. Inclined Plate Settler with

Recycle to Head of Plant B. Inclined Plate Settler with

Discharge to Sanitary Sewer. C. Discharge to Sanitary Sewer

Solids to Sanitary Sewer

RAW WATER SOURCE A. Indirect Withdrawal B. Zebra Mussel Control in Existing Intake C. Existing Intake With No Zebra Mussel Control

RAW WATER PUMP STATION

(Not Required for Indirect Withdrawal)

A. Vertical Turbine Pumps B. Submersible Pumps

FLOCCULATION & CLARIFICATION

A. Rapid Mix & Flocculation (Filtration C & D) B. Rapid Mix, Flocculation & Inclined Plate Settlers (Filtration A & B) C. Ballasted Clarification

FILTRATION (Required by All)

A. Concrete Gravity Filter B. Rectangular Steel Gravity Filter C. Pressure Membranes D. Submerged Membranes

DISINFECTION (Required by All)

A. UV Disinfection / Sod. Hypo B. Sodium Hypochlorite

TRANSFER PUMP STATION

(Required for Pre-stressed Concrete Ground

Storage)

GROUND STORAGE (Required by All)

A. Pre-stressed Concrete Ground Storage B. Below-grade Concrete Storage

HIGH SERVICE PUMPING (Required by All)

Preferred Alternative Process Flow Diagram

RESIDUALS EQUALIZATION

Concrete Equalization Basin

for Membranes

RESIDUALS DISCHARGE

Inclined Plate Settler with Recycle to Head of Plant

Recycle Water to Head of Plant

Solids to Sanitary Sewer

RAW WATER SOURCE

Existing Intake With No Zebra Mussel

Control

RAW WATER PUMP STATION

Vertical Turbine Pumps

FLOCCULATION & CLARIFICATION

In-Line Flocculation

FILTRATION

Pressure Membranes

DISINFECTION

Sodium Hypochlorite

GROUND STORAGE Pre-stressed Concrete Ground Storage

HIGH SERVICE PUMPING To Distribution System

Membrane Procurement

• Request for Proposals • Financial Criteria – Total Present

Worth – Membrane Equipment Capital Cost – Non-Equipment Capital Cost – Present Worth of Operating Cost – PW Cost of Membrane Replacement –

20 yr • Non-Financial Criteria

– Layout and Assembly for Ease of O&M – Technical and Performance Information

Membrane Procurement • Competitive Membrane

Proposals – Option for Vendor to Propose One

Submerged System and One Pressure System

– Pressure Proposals from Pall and Siemens

– Submerged Proposals from GE and Siemens

Membrane Procurement

Schedule Item GE/Zenon Submerged

Pall Encased

Siemens Submerged

Siemens Encased

Membrane Equipment Capital Cost

$4,469,572 $4,485,704 $4,876,897 $4,515,812

Non-Equipment Capital Cost $1,189,026 $1,217,622 $1,379,756 $1,271,505

Present Worth of Operating Cost

$1,585,596 $1,671,308 $1,578,835 $1,465,405

Present Worth of Membrane Replacement Cost

$1,040,439 $1,018,134 $1,035,538 $ 985,240

Total Present Worth $8,284,633 $8,392,768 $8,871,026 $8,237,963

Membrane Filtration

• Definition

– Semi-permeable thin layer of material

– Slow rate of transfer across the membrane and high pressure drops

– Very effective

RO, NF, UF and MF MEMBRANE

DESIGNATION

PRESSURE GRADIENT

PORE DIAMETER REMOVAL

EFFICIENCY

Mechanisms of Filtration

• Mechanical Screening • Adsorption • Cake Filtration

Principles of Membrane Filtration

Osmosis Osmotic Pressure

Membrane Filtration Theory • Water flux:

Where: – J = volumetric flux of water – Q = volumetric flow rate of pure water, gal/day – A = surface area of clean membrane, ft2 – ∆P = transmembrane pressure – µ = dynamic viscosity of water – Rm = membrane resistance coefficient

))(( mRP

AQJ

µ∆

==

Membrane Filtration Theory • Fouling

Flow (85-90%)

Product Water

Fouling Layer

Permselective Barrier

Flux (10-15%) Adsorption

Biofouling

• Biofouling is referred as the undesired development of microbial layers on the surface.

• Biofilm organisms are embedded in a matrix of microbial origin, consisting of extracellular polymeric substances (EPS).

Membrane Surface

Microbial Attachment

Microbial Colonization

EPS & Microbial Growth

Membrane System Components

• Membranes • Modules • Racks • Piping

Hollow Fiber Flow Path

• Inside-Out • Outside-In

Membrane Processes: Operation

Pretreatment

• Coagulation, flocculation, and sedimentation for high raw water turbidity and/or high NOM

• Where iron and/or manganese are prevalent, oxidation is performed to form precipitate prior to filtration

• Pre-filtration of particulates – To remove large particle fraction, a strainer or bag

filter rated at 50 to 500 µm is used for all water sources

Cleaning

• Backwashing with either air or permeate water at preset intervals of 30 to 90 min.

• Addition of chlorine to backwash water aids in reducing biofouling. Oxidant tolerant membrane material must be selected to employ this technique.

• Chemical cleaning in place or with modules removed will be required periodically

Post-treatment

• Concentrate – High solids concentration – High concentration of pathogens – Disposal: municipal sewer, ocean discharge,

deep well injection

Final Plant Design Elements

• Siemens Pressure Membrane Pilot Testing – Test Plan & Protocol – Complete Membrane System

• Includes all ancillary equipment – Specific Parameters for Backwash and

Maintenance Wash – Cold Water and Warm Water Piloting – Run at 1.1 times full scale flux

Final Plant Design Elements • Design Flow Changed to 16 MGD • Utilize Existing Intake • Zebra Mussel Control using Divers

for Cleaning • Extension of Raw Water Intake

using Jack & Bore / Slurry Micro- tunneling

• New Raw Water Pumping Station – Vertical Turbine Raw Water Pumps – Automatic Self Cleaning Strainers – PAC Feed System

Final Plant Design Elements • New Operations Building

– Bulk Chemical Storage and Feed Systems

– Siemens “CP Wing” Pressure Membranes

– Mechanical, Electrical, Office and Lab

Rooms – High Service Pumping Station – Future Ultra-Violet Treatment Area

Added – Package Plate Settlers

• Membrane Backwash EQ Tank • Back Up Power Supply • 4 MG Finished Water Storage (w/

Space for Additional 3 MG Tank) – Construction Under USACE 219 Grant

The New WTP Aerial View

Start-up Challenges • Finished Water Storage

Reservoir – Timing of Reservoir Completion

• Raw and High Service Pumps – Motor Vibration Issues

• Chemical Feed Systems – Chemical Compatibility of

Materials Utilized – Calibration of Pumps

• Strainers – V-notched Openings Plugging

Lessons Learned

• Value Engineering Pays • Coordination and Communication are Key • One General Contractor • Assignment of Owner-Procured

Equipment • Project Risk Managed • Thorough Set of Plans and Specifications • Design Staff Active During Construction

Thank You

Eric Horvath, PE ehorvath@structurepoint.com American Structurepoint 211 W. Washington St., Suite 2410 South Bend, IN 46601 574.287.2231

Kara Boyles, PhD, PE kboyles@structurepoint.com American Structurepoint 211 W. Washington St., Suite 2410 South Bend, IN 46601 574.287.2231