screening and consequences - mi-wea.org - grant presentation.pdfplugging heat exchangers all raw...
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Presentation
for
MWEA Process Committee Seminar
November 6, 2013
SCREENING AND CONSEQUENCES
Tom Grant, Hubbell Roth and Clark
Sandra Diorka, Delhi Charter Township
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Need for Project
Class A Sludge Anaerobic Digestion System Heat
Exchangers Plugging
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Plugging Heat Exchangers
All raw sludge is macerated such that fibers, plastics,
etc. are relatively small, about ¼” wide x 3” to 6”
long
During sludge recirculation and pumping through 1
1/4” and 3” diameter heat exchanger tubes, small
pieces become entwined and form ropes that plug the
heat exchangers
Heat exchangers required cleaning every other day
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Plugging Heat Exchangers
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Existing Not Effective
Existing headworks grinding with capture was not
effectively removing screenable materials from
wastewater
Requires seasonal cleaning of primary clarifiers and
disposal of wet settlings to drying beds
Causing early wear on POTW equipment
Excessive labor spent removing rags from all process
equipment
Wasting pumps
Telescopic valves
Decant valves
Digester heat exchangers
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Existing Not Effective
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Existing Not Effective
Removal of about 40 pounds wet material per day
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New Screen Selection:
Site Visits, Round 1
Traditional bar screens
Visited Michigan WWTPs to view their headworks
screens:
South Lyon, ¼” bar
Grand Rapids, ¼” bar
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Bar Screen Observations
During site visits noticed:
Bar screens had excessive pass through
Equipment had grease balls and strings hanging
Resulting screenings were very dirty
Bar screen room and environment was gross
Primaries, aeration tanks, and secondaries had floaters
Conclusion: Bar screens are not so good. What else
can we get?
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Pilot Testing at POTW
How do we pick between round holes and slots (bar
screen)? How big should the holes be?
Devised an in house experiment
Fabricated a slide gate with four different “screens”
built in
1/8 inch round hole (perforated plate)
1/4 inch round hole
1/4 inch “bar” hole
Window screen (around 1mm hole size)
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Pilot Testing at POTW
Placed each gate in the influent channel for a
specified time
Weighed the material collected
Window screen was considered “100%” capture
Roughly 8000 pounds per day
Round holes collected roughly 4 times the amount of
material as the bar or slot shaped openings
Conclusion: We want round holes!!
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New Screen Selection:
Site Visits, Round 2
North Kent, 1 to 3 mm drum screen
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New Screen Selection:
Site Visits, Round 2
Kalamazoo, 6 mm
bandscreen
Flow Out
Screen entrance is
sealed to channel
Flow In
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Discovered and Purchased
U.K. Study
Purchased “National Screen Evaluation Facility, Inlet
Screen Comparative Report” performed between
1999 and 2011 by the UK Water Industry Research
Installed and compared the performance of 27 different
headworks treatment products
Finescreen
Stepscreen
Combined screen (bar or round with processing)
Bandscreen
Reported % capture of material
Maintenance frequency
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Finescreen
•Screen rotates
around to carry
stuff to the top
•Can have round
or bar openings
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Stepscreen
•Like a fine screen
•Steps move and
transport stuff to the
top – body of the
screen holds still
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Discovered and Purchased
U.K. Study
Bandscreens showed the best performance
Highest screen capture rate
Lowest risk of “pass through” or “carry over” because of
seal between opening and the channel
Study showed two brands had the highest screen capture
rate
Screens incorporating slots or bar spacing showed the
lowest performance
Conclusion: We want one of the bandscreens with
the highest capture rate!
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Site Visits
Round 3
Made a three day trip to visit four additional screens
Ishpeming, MI – Jones and Atwood band, 6 mm holes
Sheboygan, WI – Brackett Green band, 6 mm holes
Madison, WI – Brackett Green band, 6 mm holes
Fond du Lac, WI – JWC Fine Screen, 3 mm holes
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Site Visits
Ishpeming
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Site Visits
Sheboygan
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The Final Decision
How did we decide?
The cleanest end product
3mm because
Madison had 6mm hole size with the same type of heat
exchanger
Heat exchangers still plugged
Fond du Lac had 3mm hole size with the same type of
heat exchanger
Heat exchangers did NOT plug!!
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What Happened After ?
Heat exchangers no longer routinely cleaned
Primaries have no rags or floating “salad”
Grease hauled less often (contains only grease)
Aeration tanks do not have to be “skimmed”
No more condoms
Wasting pumps no longer need to be routinely
cleaned
Sludge storage decant valves have remained clean
Telescopic valves no longer have to be cleaned
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Screenings Production
0
200
400
600
800
1000
1200
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70.0
72.0
74.0
76.0
78.0
80.0
82.0
84.0
86.0
88.0
Before After
Raw Sludge % Volatile
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0
50
100
150
200
250
300
350
400
450
500
Grit Production
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Before – NOT Gritty
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After – Actually Grit
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Engineering and Construction
Design Engineering
2 screens, each handle 6 mgd, bypass/overflow
manually cleaned channel 5 mgd
Tight site – fit between existing influent screw
pumps, grit tank and primary clarifiers
Existing hydraulic grade line is fixed
Poor soils for building & channels foundation
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Tight Site
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Poor Soils
Helical Screw Piles Foundation
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Construction
Extended schedule due to piles, originally June 2012
completion, first screen started in October 2012
Alternate bypass
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Construction
Gravity Bypass
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Construction
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Construction
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Construction
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Construction
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Results
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Results
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Questions??