MARINETTE, WI

Spring Regional Meetings

April 17 - Ann Arbor & April 18 - Kalamazoo

April 24 - Mt. Pleasant & April 25 - Gaylord

Inclined Plate Settler Clarification Regional Developments

Thomas P. Grubb

Meurer Research

6270 Joyce Drive

Golden, CO 80403

STAINLESS STEEL SUPPORT BEAM

LEVELING WEIR

FLOW CONTROL DECKS EFFLUENT TROUGHS

Plate Settler System Components

SLUDGE COLLECTOR DRIVE

HISTORY OF PLATE SETTLERS

1886 - English Patent

1904 - Hazen’s Theory of Sedimentation

1936 - Plate Settlers Used in Mining Industry

1946 - Camp’s Shallow Depth Sedimentation Theory

1993 - MRI Top Tube Plate Settler Design

Multi-Sectional Settling Tanks developed

to minimize short circuiting

and

maximize flow distribution

Camp’s Shallow Depth Sedimentation Theory

Theory behind High Rate Clarification

3 ft Tube Settlers: Bloomington, IN Inlet baffle directing flow under tubes

Circular thickener sludge collection

3 ft Tubes: Louisville, CO Square btm trough, submerged orifices

2 ft Tubes: Ft. Thomas WTP, KY V-notch troughs 3’ above tubes

Tube Settlers Flow Distribution

MIXERS / FLOCCULATORS

Paddle wheel mixers Vertical turbine mixers

Flocculation Proper floc formation is key to settling

• Vertical impeller mixers: rapid or flash mix for pH adjustment, oxidant and coagulant addition using high particle collisions

• Paddle wheels: medium mixing energy for floc formation, maturation/growth and contaminant adsorption

• Hydraulic mixing: reduce hydraulic energy & distribute flow across basin width

Horizontal Paddle Wheel Flocculators

Vertical Turbine Flocculators Inlet Diffuser

Stage Four:

Hydraulic Mixer

Stage Three Stage Two Stage One Flash Mix

Flocculation Tapered Flocculation for Optimum Contaminant Removal

1000’s 100’s 80 60 40 20 10 0

Rapid Mix

Vertical Turbine

Paddle Wheel

Hydraulic

Flocculation Progressively Lower G-Values form a settlable floc

Flocculation Configuration - Flow Control to Minimize Short Circuiting

•Over Under Baffling

•Ported Baffle Walls

•Serpentine Flow

•Full Width Distribution

WYOMING, MI

INLET DIFUSERS REDIRECT FLOW ACROSS BASIN WIDTH

and REDUCE FLOC SHEAR

PLATE SETTLERS

Advantages of Plate Settlers

T-304 stainless steel lasts indefinitely

No power is required

No pumps, valves or blowers

No moving parts

Very low maintenance

Small Footprint Clarification Process

12MGD Footprint Comparison

Advantages of Plate Settlers

Plate Settler 0.3 gpm/ft2

40’ x 50’

Conventional Sedimentation 0.5 gpm/ft2 SOR 80’ x 208’

Lower cost of land, construction & building. Less space to maintain & smaller building size.

HOW

PLATE SETTLERS

WORK

How Plate Settlers Work

Falling particle sees the “projected area”

of each Plate

Projected plate area overlap

Results – plate settler basin is 1/10th that of conventional basin

Flow Distribution

Stable Laminar Flow Low Reynolds #

& High Froudes #

The settling distance is reduced by 98%, 3.5” compared to 15’ in a conventional basin

3.5"

Fg

Particles migrate to the plate surface along the resultant vector of the two forces – fluid drag (Fd) and gravity (Fg)

Plate settlers provide a “perfect environment” low velocities and no currents (Laminar flow)

How Plate Settlers Work

10’ plate length / 0.022 fps (¼”/sec) = 7.57 minutes residence time in plate

Particle must fall 3.5” vertically in 7.57 minutes = 0.46 in/min plate settling rate

15’ deep basin with 2 hr HRT, 180”/120 minutes = 1.5”/min conventional sedimentation basin settling rate

0.5”/min in plate basin compared to 1.5”/min for the conventional basin

SETTLING

ZONE

SLUDGE ZONE, 10%

INLET

PORTS

TOP TUBE

EFFLUENT COLLECTION ORIFICES

How Plate Settlers Work

Flow Path Through Plate Settlers

1. Flow enters basin high up & travels through inlet channel

2. Flow enters plate settlers through inlet ports and moves

up the plate

3. Top tube contains orifices which distribute flow evenly across the plate

How Plate Settlers Work

Feed Channels

Flow Control

Decks

Cable-Vac

Sludge Collection

Stainless Steel Support Beam

Plate

Cartridge

4.5' W Plate Space = 0.0340" to Achieve 2.0"

Design Head Loss

0.0000

0.0100

0.0200

0.0300

0.0400

0.0500

0.0600

0.0700

0.0800

0.0900

0.1000

0.25 0.5 1 1.5 2 2.5 3 3.5 4 4.5

Plate Spacing Orifice

-1/32" = 3" HL

+1/32" = 1" HL

HEADLOSS (Inches)

Ori

fic

e w

idth

@ 4

.5’L

& 0

.3 g

pm

/sf

The Search for Perfect Flow Distribution

How Plate Settlers Work

The “Pinch Zone”, a Full-Width Plate Orifice

Orifices Insure Even Distribution Across Entire Plate & Basin

How Plate Settlers Work

PLATE SETTLER CALCULATIONS

• Divide the flow in gpm by the loading rate

• Flow = 6,944, Loading Rate = 0.3 gpm/ft²

6,944 gpm/0.3 gpm/ft² =23,147 ft² projected area

Choose the specific loading rate. For example a standard loading rate is 0.3 gpm/ft2

of effective plate area at 90% efficiency.

• Efficiency = 90%, Projected Area = 23,147 ft²

23,147/0.9 = 25,719 ft² effective projected area

Divide the projected area by the efficiency to get

effective projected settling area

Calculation for 10 MGD (6,944 GPM):

Plate Settler Calculations

Sizing Calculation Example

• 4.5’W x 10’L plate @ 55o(cos55) x 0.9 = 23.23 ft² • Effective Projected Area Required = 23,147 ft²

• 25,719 / 23.23 = 1,107 plates

Divide the effective projected settling area by

the area of each plate to get # of plates

FABRICATION &

INSTALLATION

Manufacture frames and supports

PLATE SETTLER FABRICATION

PLATE SETTLER FABRICATION

Inclined Plates installed into frames @ 550

PLATE SETTLER INSTALLATION

Load onto flatbed trucks for shipping

PLATE SETTLER INSTALLATION

Install Beams & Crane Plate Cartridges into Position

PLATE SETTLER INSTALLATION

Plate Cartridges are Secured to the Beams

PLATE SETTLER INSTALLATION

Troughs are Lowered into Position

PLATE SETTLER INSTALLATION

Weirs are Leveled and Installation is Complete

Rapid Mix, Flocculation, Hydraulic Baffling, Plate Clarification and Sludge Removal

Frederick MD

PLATE CLARIFICATION SYSTEM

INCLINED PLATE SETTLER

INSTALLATIONS BENTON HARBOR, MI

MUSKEGON, MI SOUTH HAVEN, MI

WYOMING, MI MARINETTE, WI

BENTON HARBOR, MI

2010

2 Basins

12 MGD

40’L x 30’W x 15’D

0.3 gpm/sf @90%

BENTON HARBOR, MI

BENTON HARBOR, MI

Horizontal Reels

Ported Floc Baffle

15’L x 30’W x 15’WD

40 min@ 6 MGD

1st : 3 HP

2nd: 2 HP

3rd : 1 HP

BENTON HARBOR, MI

Inlet Flow Diffusers

G-Values, sec-1

1st : 70

2nd : 45

3rd : 20

4th : Hydraulic

BENTON HARBOR, MI 4 Rows, 6 MGD

150 Plates/Row

600 Plates/Basin

5 Orifice/plate

MUSKEGON, MI Two (2) Basins

86’L x 50’W x 17.3’D

20 MGD/Basin Design

6 MGD/Basin Average

0.24 gpm/sf Loading

2-50 NTU Raw Water

MUSKEGON, MI 2006

393 Plates/Row

2,358 Plates/Basin

9.55’L x 4.5’W Plates

6 Orifice/plate

MUSKEGON, MI 3 Troughs/Basin

45’L x 24”W x 28” D

4,650 gpm Capacity each

MUSKEGON, MI

MUSKEGON, MI

MUSKEGON, MI

MUSKEGON, MI

SOUTH HAVEN, MI 2009

2 Basins

29’L x 28’W

7 MGD, 9.7MGD Peak

0.3 gpm/sf @ 100%

SOUTH HAVEN, MI 1st Stage

3rd Stage 4th Stage

G-Values, sec-1

1st : 60

2nd : 40

3rd : 30

4th : 15

13.5’ L x 13.5’W

14.5’ WD

32 min@ 3.5 MGD

1st & 2nd: 2 HP

3rd & 4th: 1 HP

SOUTH HAVEN, MI 78 Plates/Cartridge

4 Cartridges/Basin

312 Plates, 4.5’ x 10’

SOUTH HAVEN, MI 2 Troughs/Basin

18”W x 18”D

2,000 gpm/trough

6 Orifice/plate

SOUTH HAVEN, MI Hoseless Cable-Vac™ Sludge Collector

¼ HP Reel-to-Reel Cable Drive

WYOMING, MI

Serpentine Flow Horizontal Reel Flocculators

WYOMING, MI 2010

3 Basins

86’L x 64’W x 16’D

30 MGD/Basin

0.30 gpm/sf @ 80%

WYOMING, MI

2009 - 2010

8 Rows of 4 Cartridges/Row

98 Plates/Cartridge = 3,136 Plates/Basin

8 Troughs/Basin, 22”W x 19”D x 85’L each

2,600 gpm capacity/trough

WYOMING, MI

MARINETTE, WI 2010

2 Basins

37’L x 22’W x 16’D

3.25 MGD/Basin

Expandable to 4.1 MGD

0.30 gpm/sf

8-100 NTU Raw Water

MARINETTE, WI 1st Stage

70 sec-1 G, 1.5 HP 2nd Stage

45 sec-1 G, 0.75 HP 3rd Stage

20 sec-1 G, 0.5 HP

Coagulant: Sumalchlor 50 or AquaHawk 607, Chlorine @ 0.5 ppm average, 3-6 max

29 min. HRT @ 3.25 MGD

MARINETTE, WI

Future Plate Capacity

Sludge Collector Cable Drive

MARINETTE, WI

Plate Support Beam

Hoseless Cable Driven Sludge Collector

Miramar WTP, San Diego, CA Four 55 MGD Basins

220 MGD

Largest Stainless Steel Inclined

Plate Settler Installation in USA

Inclined Plate Settler Clarification Regional Developments

Thomas P. Grubb

Meurer Research

6270 Joyce Drive

Golden, CO 80403

THANK YOU QUESTIONS?