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This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 690323
Horizon 2020 research and innovation programme
Project: No 690323 SMART-Plant
Full project title:
Scale-up of low-carbon footprint material recovery techniques
in existing wastewater treatment plants (SMART-Plant)
DeliverableD3.2
Construction and commissioning of the
SidestreamSMARTechs
Due date of deliverable: 31 May 2017
Actual submission date: 04 Oct 2017
Ref. Ares(2017)4843381 - 04/10/2017
Project: No 690323
SMART-Plant D3.2 Page 2
DOCUMENT INFORMATION:
Deliverable Number D3.2 Title: Construction and commissioning of the
Sidestream SMARTechs
Work Package Number WP3 Title: Side- and Down-stream SMARTechnologies
Due date of deliverable Contractual M6 Actual M6
Version number 1.0
Format Pdf file
Creation date 15/05/2017
Version date 20/09/2017
Type R DEM DEC OTHER ETHICS
Dissemination Level PU Public CO Confidential
Rights
Copyright “SMART-Plant Consortium”.
During the drafting process, access is generally limited to the SMART-Plant
Partners.
Responsible author
Name:
Paolo Pozzato, Davide
Savio, Monica
Miglioranza
E-mail:
Partner: SCAE Phone: +39 0444 360 533
Other authors
Name:
Constantinos Noutsopoulos,
Simos Malamis, Daniel Mamais,
Andreas Andreadakis, Evangelos
Statiris
Partner: NTUA
Name: Nicola Frison, David Bolzonella Partner: UNIVR
Name: Daniele Renzi Partner: ATS
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SMART-Plant D3.2 Page 3
Name:
Ioanna Droubogianni, Dimitra
Kollia, Panagiotis Lalis, George
Zarras
Partner: AKTOR
Brief Description Deliverable 3.2 is part of WP3 which is related to side- and down-stream
SMARTechnologies. More specifically D3.2 focuses in three sidestream
SMARTechnologies that are integrated in the existing conventional sewage
sludge treatment line to provide more energy efficiency for the i) removal of
nitrogen, ii) recovery of phosphorus and iii) recovery of PHA. The D3.2 is to the
construction and the commissioning of the sidestream SMARTechs.
Keywords sidestream Smartechs, construction, commissioning
Version log Revision history
Rev. No. Issue Date Modified by Comments
Version 1 03/10/2017 Francesco Fatone Minor revision by Coordinator before
submission
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SMART-Plant D3.2 Page 4
TABLE OF CONTENTS
Document Information: ......................................................................................................................... 2
Table of Contents ................................................................................................................................... 4
List of Tables .......................................................................................................................................... 5
List of Figures ......................................................................................................................................... 5
Executive Summary ................................................................................................................................ 6
Abbreviations ......................................................................................................................................... 9
1. Introduction ............................................................................................................................. 11
2. SMARTech4a - Sidestream SCENA ........................................................................................... 13
2.1 Technical description of the SMARTech 4A ............................................................................. 13
2.2 List of the electromechanical equipment ................................................................................ 16
2.3 Practical instructions for the operation of SMARTech 4A ....................................................... 23
2.1 Integrability of the Smartech 4a in existing WWTPs ............................................................... 25
2.2 Drawings ‘as built’ .................................................................................................................... 27
2.3 Picture report ........................................................................................................................... 28
3. SMARTech4b - Sidestream THERMAL HYDROLYSIS-SCENA ..................................................... 32
3.1 Technical description of the SMARTech 4B ............................................................................. 32
3.2 List of the electromechanical equipment ................................................................................ 35
3.3 Practical instructions for the operation of SMARTech 4B ....................................................... 39
3.1 Integrability of the Smartech 4b in existing WWTPs ............................................................... 42
3.2 Drawings ‘as built’ .................................................................................................................... 44
3.3 Pictures report ......................................................................................................................... 44
4. SMARTech5 - Sidestream SCEPPHAR ....................................................................................... 52
4.1 Technical description of the SMARTech 5 ............................................................................... 52
4.1 List of the electromechanical equipment ................................................................................ 54
4.2 Practical instructions for the operation of SMARTech 5 ......................................................... 66
4.3 Integrability of the Smartech 5 in existing WWTPs ................................................................. 72
4.4 Drawings ‘as built’ .................................................................................................................... 74
4.5 Pictures report ......................................................................................................................... 74
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LIST OF TABLES
Table 1 Specification of the grinder for the mixed primary sludge. .................................................... 16
Table 2 Specification for the installation of the dynamic thickening .................................................. 16
Table 3 Specification of the fermentation unit .................................................................................... 18
Table 4 Specification for the installation of the screw-press separator for the mixed sludge fermentation ........................................................................................................................................ 19
Table 5 Specification of the Short-Cut Sequencing Batch Reactor ...................................................... 19
Table 6 Operation of the fermentation unit ........................................................................................ 23
Table 7 Operation of the screw-press separator ................................................................................. 24
Table 8 Operation of the short-cut Sequencing Batch Reactor. .......................................................... 25
Table 9 Major units and specifications of the electro-mechanical equipment ................................... 36
Table 10 Basic features of automation in the operation of pilot plant system. .................................. 40
Table 11 List of electromechanical equipment and FLOW DIRECTION of the Salsnes Filter .............. 54
Table 12 List of tanks, electromechanical equipment, sensors and FLOW DIRECTION of the Sequencing Batch Fermentation Reactor ............................................................................................ 55
Table 13 List of tanks, electromechanical equipment, sensors and flow direction of the ultrafiltration unit ....................................................................................................................................................... 57
Table 14 Specification of the crystallization unit ................................................................................. 57
Table 15 List of tanks, electromechanical equipment, sensors and flow direction of the nitritation unit.............................................................................................................................................................. 59
Table 16 List of tanks, electromechanical equipment, sensors and flow direction of the PHA-accumulating biomass selection SBR ................................................................................................... 61
Table 17 List of tanks, electromechanical equipment, sensors and flow direction of the accumulation SBR ....................................................................................................................................................... 64
Table 18 Operation of the SF1000 ....................................................................................................... 66
Table 19 Operation of the fermentation unit ...................................................................................... 67
Table 20 Operation unit of the ultrafiltration unit .............................................................................. 68
Table 21 Operation of the crystallizer ................................................................................................. 68
Table 22 Operation of the nitritation unit ........................................................................................... 70
Table 23 Operation of the selection SBR ............................................................................................. 71
Table 24 Operation of the accumulation SBR ...................................................................................... 72
LIST OF FIGURES
Figure 1 Deliverables of WP3 related to sidestream SMARTechs. ...................................................... 11
Figure 2 P&id of the Smartech 4a ........................................................................................................ 13
Figure 3 SMARTech 4a - Dynamic thickener of the sewage sludge ..................................................... 28
Figure 4 SMARTech 4a – Screw-press for S/L of the fermentation sewage sludge ............................. 28
Figure 5 SMARTech 4a – Accumulation tank for the fermentation liquid of mixed sludge ................ 29
Figure 6 SMARTech 4a – Different views of the fermentation ............................................................ 29
Figure 7 SMARTech 4a - Electrical Panel and air compressor of Smartech 4a .................................... 30
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SMART-Plant D3.2 Page 6
Figure 8 SMARTech 4a -Tank for the acculation of the anaerobic supernatant and influent pump of the scSBR .............................................................................................................................................. 30
Figure 9 SMARTech 4a - Air diffusion system of the scSBR ................................................................. 31
Figure 10 Flow diagram of Psittalia WWTP with SMARTech 4b .......................................................... 32
Figure 11 Major units of SMARTech 4b and their interconnections ................................................... 33
Figure 12. Plan view of SMARTech 4B ................................................................................................. 44
Figure 13 Plan view of SMARTech 4B .................................................................................................. 45
Figure 13 3D drawing of SMATech 4B ................................................................................................. 45
Figure 15 SMARTech 4B – construction phase .................................................................................... 46
Figure 16 SMARTech 4B – construction phase .................................................................................... 46
Figure 17 SMARTech 4B – construction phase – installation of reject water storage tanks ............... 47
Figure 18 SMARTech 4B – construction of raw and treated reject water networks ........................... 47
Figure 19 SMARTech 4B – overview of feed pump, decanting pump and decanting network ........... 48
Figure 20 SMARTech 4B – overview of feed pump and decanting pump ........................................... 48
Figure 21 SMARTech 4B – decanting system ....................................................................................... 49
Figure 22 SMARTech 4B – chemicals and substrate dosing pumps .................................................... 49
Figure 23 SMARTech 4B – chemicals and substrate storage tanks ..................................................... 50
Figure 24 SMARTech 4B – installation of on-line probes .................................................................... 50
Figure 25 SMATech 4B – hydraulic testing of the SBR ......................................................................... 51
Figure 26 SMATech 4B –testing of the aeration system of the SBR .................................................... 51
Figure 27 P&id of the Smartech 5. ....................................................................................................... 52
Figure 28 SMARTech 5 - Integrated container with rotating belt filter intalled ................................. 74
Figure 29 SMARTech 5 - Hopper for the cellulosic primary sludge .................................................... 75
Figure 30 SMARTech 5 - Installation of the Smartech 5 ...................................................................... 75
Figure 31 SMARTech 5 - (a) Sequencing Batch Fermentation Reactor during the installation; (b) Sequencing Batch Fermentation Reactor placed in the platform ....................................................... 76
Figure 32 Ultrafiltration unit ................................................................................................................ 76
Figure 33 SMARTech 5 - Ultrafiltration system (right side) and crystallizer (right side) ..................... 77
Figure 34 SMARTech 5 - Left side,Nitritation, Selection and Accumulation SBRs; Right side, ultrafiltration system and cristallizer. .................................................................................................. 77
Figure 35 SMARTech 5 - Air diffusion system for the nitritation, selection and accumulation SBR. .. 78
Figure 36 SMARTech 5 - Hydraulic testing ........................................................................................... 78
Figure 37 SMARTech 5 – Testing of the air diffusion system. ............................................................. 79
Figure 38 SMARTech 5 – Screenshot of the PLC control panel ........................................................... 79
EXECUTIVE SUMMARY
Deliverable 3.2 is part of WP3 which is related to side- and down-stream SMARTechnologies. More
specifically D3.2 focuses in three sidestream SMARTechnologies that are integrated in the existing
conventional sewage sludge treatment line to provide more energy efficiency for the i) removal of
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SMART-Plant D3.2 Page 7
nitrogen, ii) recovery of phosphorus and iii) recovery of PHA. The D3.2 is to the construction and the
commissioning of the sidestream SMARTechs.
A brief description of the sidestream Smartechs involved in WP3 is reported below:
SMARTech 4a focuses in the integration of conventional biogas recovery from sewage sludge with
sidestream energy-efficient and compact nitrogen removal and phosphorus recovery. It applies the
Short-Cut Enhanced Nutrient Abatement system (SCENA) which integrates the following processes:
(o) dynamic thickening of the mixed sludge, (i) acidogenic fermentation of cellulosic sludge to
produce VFAs as carbon source, and (ii) via nitrite nitrogen and phosphorus removal (by P-
bioaccumulation) from sludge reject water using an SBR. In this configuration, nitrogen is removed
through the bioprocesses of nitritation/denitritation, and Enhanced Biological Phosphorus removal
(EBPR) is accomplished via nitrite through the alternation of anaerobic/aerobic/anoxic conditions.
SMARTech4b aims to the integration of the enhanced biogas recovery (by thermal hydrolysis) of
sewage sludge with sidestream energy-efficient and compact nitrogen removal and phosphorus
recovery. It applies and optimize the Short-Cut Enhanced Nutrient Abatement processfor the
treatment of reject water with a very high ammonium nitrogen content (>1.2 gN/L) due to the pre-
treatment of sewage sludge through thermal hydrolysis. In order to increase the biodegradable
COD/N and COD/P ratios reject water from primary sludge gravity thickeners will be used.
Alternatively, sodium acetate will be also employed to increase the readily biodegradable COD in
reject water in order to efficiently remove nitrogen through short-cut nitrification/denitrification and
to accumulate phosphorus in sludge through enhanced biological P removal via denitritation or
aerobically. SMARTech4b is designed to treat approximately 2-3 m3/d of reject water from sludge
dewatering facilities. Based on the design, alternative operational conditions can be employed
depending on the type of external substrate provided. An SBR with an effective volume of at least 9
m3 will be installed and be equipped with aeration system, mixing apparatus, probes and meters for
automatic control of the process. The SBR will be fed with sludge liquors form the dewatering unit
and from primary sludge thickening unit. The sludge liquors before being fed to the SBR will be
collected in two storage tanks. Three chemical dosing units will also be installed in order to provide
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SMART-Plant D3.2 Page 8
i) for sodium acetate addition (as a complementary external substrate), and ii) for pH control of the
process.
SMARTech5 enables the integration of conventional biogas recovery from sewage sludge with the
energy-efficient nitrogen removal from sludge reject water and the recovery of PHA and struvite. It
applies the Short-Cut Enhanced Phosphorus and PHA Recovery concept (SCEPPHAR), which was
conceived as a modified version of SCENA for WWTPs larger than 150 kPE. It accounts of the following
sub-processes: (i) acidogenic fermentation of cellulosic primary sludge for the production of VFAs
and the release of nitrogen and phosphorus in soluble forms (ammonia and phosphate); (ii) solid and
liquid separation of the fermentation products and recovery of struvite form the sewage sludge
fermentation liquid by the addition of Mg(OH)2 to favour phosphorus precipitation; (iii) ammonium
conversion to nitrite accomplished in a SBR; (iv) selection of PHA storing biomass in a SBR by the
alternation of aerobic feast conditions and followed by anoxic famine conditions for denitritation
driven by internally stored PHA as carbon source; (v) PHA accumulation using a fed-batch reactor to
maximize the cellular PHA content of the biomass harvested from the selection stage.
SMART-Plant has received funding from the European Union’s Horizon 2020 research and
innovation programme under grant agreement No 690323.
Project: No 690323
SMART-Plant D3.2 Page 9
ABBREVIATIONS
AOB Ammonia Oxidizing Bacteria
BNR Biological nutrient removal
BOD5 Biochemical oxygen demand
CHP Combined heat and power
COD Chemical oxygen demand
DO Dissolved oxygen
DS Dissolved solids
EBPR Enhanced Biological Phosphorus removal
GHG Green house gases
MLSS Mixed liquor suspended solids
MLVSS Mixed liquor volatile suspended solids
NH4-N Ammonium nitrogen
NLR Nitrogen loading rate
NOB Nitrite Oxidizing Bacteria
ORP Oxidation-reduction potential
OTR Oxygen transfer rate
PHA Polyhydroxyalkanoates
PLC Programmable logic controller
SBR Sequencing Batch Reactor
SCENA Short-Cut Enhanced Nutrient Abatement process
SCEPPHAR Short-Cut Enhanced Phosphorus and PHA Recovery concept
SL-DS Sludge liquor-Dewatered sludge
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SL-PS Sludge liquor-Primary sludge
SOTE Diffuser efficiency
SOTR Standard oxygen transfer rate SRT
SVI Sludge volume index
TN Total nitrogen
TP Total phosphorus
ΤS Total solids
TSS Total suspended solids
VFAs Volatile fatty acids
VSS Volatile suspended solids
WAS Waste Activated Sludge
WWTP Wastewater Treatment Plant
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1. INTRODUCTION
Deliverable 3.2 is part of WP3. WP3 main objective is to test and validate both side- and downstream
SMARTechnologies. More specifically WP3 includes 1) three Sidestream SMARTechs that will
integrate the existing conventional and enhanced biogas recovery from sewage sludge aiming at the
energy-efficient removal of nitrogen, recovery of phosphorus and PHA and 2) two Downstream
SMARTechs that will process the resource rich sludge to recycle raw material for following reuse in
agricultural and construction sectors.
WP3 consists of five tasks:
Task 3.1 enabling sidestream SMARTech 4a with a duration of 42 months
Task 3.2 enabling sidestream SMARTech 4b with a duration of 42 months
Task 3.3 enabling sidestream SMARTech 5 with a duration of 42 months
Task 3.4 enabling downstream SMARTech A with a duration of 30 months
Task 3.5 enabling downstream SMARTech B with a duration of 30 months
In the context of WP3 six deliverables are foreseen. Deliverables 3.1-3.3 & 3.5 are related to the three
sidestream SMARTechs. The short title of each of the deliverables and their month of delivery is
illustrated in Figure 1.
Figure 1 Deliverables of WP3 related to sidestream SMARTechs.
The present report is the second of these series of deliverables. D3.2 presents the costruction,
installation and commissioning of the sidestream Smartetech.
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D3.2 is structured in four chapters and annexes, including this introduction, which presents the
objectives of this report and its structure. For each technology, the report is structurized a technical
of the SMARTech is
1- Technical description of the SMARTech 4a, 4b and 5;
2- List of the electromechanical equipment 4a, 4b and 5;
3- Practical instructions for the operation of SMARTech 4a, 4b and 5;
4- Drawings ‘as built’
5- Picture reports
Finally, Annex presents the executive drawing “as built” of the three Smartechs.
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2. SMARTECH4A - SIDESTREAM SCENA
2.1 Technical description of the SMARTech 4A
The Smartech 4a is an innovantive technology aiming the via-nitrite nitrogen phosphorus removal
from the anaerobic supernatant. The overall system can be described according to the following
integrated operational units:
1) (alkaline) fermentation of thickened sewage sludge at mesophilic conditions (37°C) for the
on-site production of best available carbon source (BACS), which is the optimal mix of volatile fatty
acids;
2) A solid/liquid separation of the fermented sewage sludge by a screw press;
3) A Sequencing Batch Reactor (SBR) for the short cut biological nitrogen removal and
phosphorus recovery via-nitrite through the dosage of the sewage sludge fermentation liquid.
Figure 2 P&id of the Smartech 4a
The optimization of the Smatech 4a was carried out during the design phase by the implementation
of the dynamic thickening of the mixed sewage sludge, which allows the increase of the organic
loading rate and the reduction of the sludge volume fed to the anaerobic digestor and the
fermentation unit. The dynamic thickener (SCAE) allows the thickening of up to 100 m3 of sewage
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sludge per day, according with a flowrate of 20 m3/h. The final concentration of the sewage sludge
will be around 5% (Total Solid based) thanks to the addition of a polyelectrolyte solution (0.8% of
active compound) by a dedicated machine. Around 10 m3 of thickened sludge fed the fermentation
unit, which has a total volume of 50 m3. The fermentation process works at around 30°C thanks to
the heater fed to the biogas produced from the full scale anaerobic digestor. A constant hydraulic
retention time of 5 days is controlled by two pneumatic and opposite valves, which are able to divert
the flowrate of the thickened sewage sludge to the fermentation unit or to the digestor according
with set-point level achieve in the fermentation unit. The solid/liquid separation of the fermented
sewage sludge is carried out by a screw-press (SCAE) able to produce around 2-4 m3/h of
fermentation liquid rich of volatile fatty acids. The liquid fractio is stored in a storage tank of 20 m3
to make it available for the further utilization during the anaerobic and anoxic phase of the scSBR.
The solid fermented fraction (13-15% total solids based) is not disposed due to the still high biogas
production potential, but it is mixed with the thickened mixed sludge which fed the anaerobic
digestor.
The scSBR has a maximal working volume of 70 m3, which allow the treatment of the daily flowrate
of anaerobic supernant produced after the dewatering operation of the anaerobic digestate under
3-4 cycles. The scSBR is equipped with a mixing system having a nominal power of 1.5 kW. The
aeration system consist of a volumetric blower (nominal power 11 kw) and n°80 diffusers (INVENT)
able to provide around 500 m3/h of compressed air at 400 mbar of pressure, in order to provide an
oxygen transfer efficiency up to 15%. The dissolved oxygen concentration in the bulk will be
controlled during the aerobic phase at 1.5 mg/L by a Variable Frequency Device (VFD) to module the
air flowrate of the blower.
There are two centrifugal pumps from FLYGHT manufacturer with capacity of 70 and 65 m3/h
respectively for the feeding and discharge of the scSBR. In each cycle, the feeding pump feeds
automatically around 10-15 m3 of anaerobic supernatant, which is taken directly from the storage
tank of 90 m3. The latter has a capacity to store enough anaerobic supernant for 2-2.5 days, which
takes into account the days when the WWTP of Carbonera is not supervised from the operators
(week-end) or when the dewatering operation are not taking placed. At the end of the cycle, the
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SMART-Plant D3.2 Page 15
centrifugal sumberged pump installed at 0.8 m from the bottom of the scSBR allows the discharge of
the treated anaerobic supernatant in the headworks of the main WWTP.
The SBR is equipped with sensors from HACH-LANGE company which are based on a floating
chamber. The sensors allows the monitoring of several parameters and by them also the control of
the nitrogen forms, so to control the cycle lenght. The sensors installed are: pH, Dissolved Oxygen
(DO), Conductivity (COND), Oxydation Reduction Potential (ORP), Mixed Liquor Suspended Solids
(MLSS).
All the signal from the sensor are first collected by the controller SC1000 (HACH-LANGE) and then
transfer to a Programmable Logic Controller (PLC, SIEMENS) via a modbus protocol. The data can be
also recorded and used from the remote system of ATS. The control algortims installed in the PLC
provides the control of the electrical equipments, including the lenght of each phases, the automatic
dosage of the carbon source and the variable frequency driver to control the right dissolved oxygen
during aerobic phase.
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2.2 List of the electromechanical equipment
Table 1 Specification of the grinder for the mixed primary sludge.
GRINDER
CODE DESCRIPTION Unit Value
TR1 Grinder m3/h 20
rpm 270
Hz 50
Description
The grinder is used as for the size reduction of the coarse material present in the mixed sludge. The grinder has 4 self-sharpening cutting blades with a grid having a maximal pore size of 24 mm and 445 cm2 of surface. The maximal operating pressure is 2 bar.
Table 2 Specification for the installation of the dynamic thickening
DYNAMIC THICKENING
CODE DESCRIPTION Unit Flowrate
ID Dynamic thickening m3/h 20
List of electromechanical equipment included
CODE DESCRIPTION Flowrate Intalled power
CONTROL
P4 Feeding ID 20 m3/h 7.5
P7 Emulsion dosage 0-600 L/h -
P8 Poly solution dosage 2 m3/h 1.1
P16 Washing ID pump 5 m3/h 5.5
P05 Feeding DA, POI, FRM 6 m3/h 4
FLOW Feeding from (F)/ Discharge to (D) PUMP CODE
Configuration 1: PRI -> ID -> FRM; Configuration 2: PRI -> ID -> POI; Configuration 3: PRO ->ID-> DA
F1:P04 F2:P07, P08 D1: P05 D2: gravity
SENSORS INSTALLED
Code M012
Description Measurement of the total solids of the mixed sludge
Technical description Probe with combined light infrared absorption for measuring turbidity and suspended solids Independent of the color of the water sample (suitable for waste activated sludge, primary sludge,
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etc).
Component and configuration Configuration: insertion probe with steel probe body; Lenght of cable: 10 meters Technical data: photometer with double IR detector Method of measurement: Turbidity measurement according to DIN EN 27027; Measure Solids, equivalent to DIN 38414 Measurement range: Turbidity: 0.001 - 4.000; Total Solids: 0.001 - 50.0 g / l Accuracy: 1.0% turbidity, ± 0.001 FNU Coeff. Var process: 1.0% according to DIN 38402 Response Time: 0.5 s <T90 <5 min (adjustable) Measurement range: 0.3 s Sample temperature: from + 2 ° C to + 40 ° C Dimensions: (D * L) 60 * 200 mm Weight approx. 2.4 kg
Code M013
Description Measurement of the total solids of the thickened mixed sludge
Technical description Probe with combined light infrared absorption for measuring turbidity and suspended solids Independent of the color of the water sample (suitable for waste activated sludge, primary sludge, etc).
Component and configuration Configuration: insertion probe with steel probe body; Lenght of cable: 10 meters Technical data: photometer with double IR detector Method of measurement: Turbidity measurement according to DIN EN 27027; Measure Solids, equivalent to DIN 38414 Measurement range: Turbidity: 0.001 - 4.000; Total Solids: 0.001 - 500.0 g / l Accuracy: 1.0% turbidity, ± 0.001 FNU Coeff. Var process: 1.0% according to DIN 38402 Response Time: 0.5 s <T90 <5 min (adjustable) Measurement range: 0.3 s Sample temperature: from + 2 ° C to + 40 ° C Dimensions: (D * L) 60 * 200 mm Weight approx. 2.4 kg
Other equipments included
- Pipe connection flange for inline installation (steel stainless) - System inline/highline fastening system for insertion into no-pressure pipe, steel AISI 304
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Table 3 Specification of the fermentation unit
FERMENTATION UNIT
CODE DESCRIPTION Size Value
FRM Fermentation unit Diamete 4 m
Height 4 m
List of electromechanical equipment included
CODE DESCRIPTION Flowrate Intalled power
CONTROL
P05 Feeding FRM 6 m3/h 7.5 Based on status of V3 and V4
P09 Discharge FRM 6 m3/h 0.55
MX5 Mixer FRM - 1.5 Manual switch on/off
HH Heater 55 (daily needs of biogas)
14.7 kW thermic power
The biogas is taken from the full scale anerobic digestion of sewage sludge
FLOW Feeding from (F)/ Discharge to (D) PUMP CODE
FRM -> PC F1:P05 D1:P09
SENSORS INSTALLED
Code M010
Description Measurement oft he pH and temperature of the fermentation unit (FRM)
Technical description Differential type digital sensor for the measurement of pH and temperature. Electrode not in contact with the liquid bulk.
Component and configuration Material of the electrode: glass; Type of probe: submerged Sensor body: steel Range of measurement: 0 - 14; T=-5° C a 50° C Time of response: pH: < 5 s; T: < 2 min Reference electrode for the control of the impedence of the liquid bulk Lenght of the cable: 10 metri Dimensions: 350 x 44 mm (diameter)
Other equipments included
- Fixing system for pH, size 1" steel AISI316
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SMART-Plant D3.2 Page 19
Table 4 Specification for the installation of the screw-press separator for the mixed sludge fermentation
SCREW PRESS SEPARATOR
CODE DESCRIPTION Unit Flowrate
PC Screw Press for sludge fermentation dewatering
m3/h 2-4
List of electromechanical equip-ment included
CODE DESCRIPTION Flowrate Intalled power
CONTROL
P09 Feeding DA, POI, FRM 6 m3/h 4 Controlled by frequency inverted and leve ultrasonic
P13 Poly solution dosage 0.32 Controlled by frequency inverted and leve ultrasonic
P11 Solid fraction fermentation sludge
0.6-3.2 m3/h 5.5 Controlled by frequency inverted and leve ultrasonic
P10 Liquid fraction fermentation liquid
2-5 m3/h 1.4 Controlled by min/max level sensor M022
FLOW Feeding from (F)/ Discharge to (D) PUMP CODE
FRM-> PC -> SCENA (Liquid fractio) FRM ->PC -> POI (Solid fraction)
F1: P09; F2: P13 D1: P11; D2: P10
POLYELECTROLITE MACHINE
CODE DESCRIPTION Flowrate VALUE
PP2 Machine for preparation of polyelectrolyte solution
m3/h
List of electromechanical equipment included
CODE DESCRIPTION Flowrate Intalled power
CONTROL
P7 Emulsion dosage 0-600 L/h 0.5
P8 Poly solution dosage 1.1
FLOW Feeding from (F)/ Discharge to (D) PUMP CODE
PP2 -> FRM PP2 -> ID
F1: P7; D1: P8 D2:
Table 5 Specification of the Short-Cut Sequencing Batch Reactor
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SHORT-CUT SEQUENCING BATCH REACTOR
CODE DESCRIPTION Size Value
scSBR Short-Cut Sequencing Batch Reactor
Max working Volume
70 m3
Surface 8 x 2.9 m
Height 3.2 m
List of electromechanical equipment included
CODE DESCRIPTION Flowrate Intalled power
CONTROL
P1 Feeding scSBR 49 m3/h 1.8 Switch on during the filling phase (control by the PLC)
MX3 Mixer scSBR - 1.5 Switch on during the filling, anaerobic and anoxic phase. (control by the PLC)
BL1 Blower scSBR 170 ÷ 520 m3/h 11 Switch on aerobic phase. (control by the PLC)
P2 Discharge scSBR 70 m3/h 1.35 Switch on during the discharge phase (control by the PLC)
P12 Carbon source 5 m3/h 0.98 Switch on during the anaerobic and anoxic phase (control by the PLC)
P03 Purge 5 m3/h 2.2 Manual switch on/off
FLOW Feeding from (F)/ Discharge to (D) PUMP CODE
FRM -> PC F1:P05 D1:P09
INSTALLED SENSORS
Code DO002
Description Measurement of dissolved oxygen of the selection SBR unit (R006)
Technical description The measurement method is based on the emission of luminescent radiation by a special substance (luminophore) that is excited by light blue emitted by a LED and returning to the normal state emits light red. A photodiode measures the time needed to return to the quiescent state, inversely proportional to the concentration of oxygen present on the luminophore.
Component and configuration - Measuring principle: luminescent optic - Measurement range: 0 to 20.00 mg / L (ppm) O2, 0 to 200% saturation - Accuracy: 0-5 mg / L O2 ± 0.1 mg / L, 5-20 mg / L O2 ± 0.2 mg / L; Temperature: ± 0.2 ° C - Repeatability: ± 0.1mg / L - Resolution: 0.01 mg / L (ppm) O2 / 0.1% saturation
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- Response time (at 20 ° C): T90 <40 s, T95 <60 s - Calibration: 2 year factory guaranteed and linked to CAP - Operating temperature: 0 ° C to 50 ° C - Storage temperature: -20 ° C to 70 ° C (95% relative humidity) - Max pressure range: 10 bar - Sensor connector: 1 "NPT external thread - Cable length: 10 m - Sensor CAP material: acrylic - Body Probe Materials: CPVC, Polyurethane, Viton®, Noryl®, Stainless Steel 1.4404 (AISI 316L) - Degree of protection: IP68 - Dimensions (L x W): 48.25 mm x 254 mm
Other equipments included PVC mounting kit for LDOsc® probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - red tube closure cap
Code ORP003
Description Measurement of the oxidation-reduction potential of the selection SBR unit R006
Technical description Differential type digital sensor for the measurement of oxidation-reduction potential. Electrode not in contact with the liquid bulk.
Component and configuration Electrode: Platinum Sensor body: AISI 316 stainless steel Probe Type: Immersion Measuring range: from -2000 to +2000 mV; T = -5 ° C to 70 ° C Response Time (T90): ORP: <5 s; T: <2 min Auto Diagnostics: Measurement and reference electrode impedance control Lenght of cable: 10 m Power supply: from sc100 or sc1000 controller Temperature conditions: -20 to 50 ° C Pressure: max. 6.9 bar Template Provider: Automatic NTC 300 Calibration: by process and / or with std buffer solutions Dimensions: 271.3 x 44 mm (length x diameter) Mounting: with chain or with immersion tube Weight: approx. 1 Kg
Other equipments included
PVC mounting kit for pH probe Includes:
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- PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - brown tube closure cap
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2.3 Practical instructions for the operation of SMARTech 4A
The dynamic thinkening is fed using the volumetric pump P04 with a flow rate of 20 m3/h. To prevent
clogging due to tatters or other inert materials, a grinder by vogelsang company is installed before
the pump P04. However, in case of mantenance or techical problems, the P04 can be replaced by the
parent installed volumetric pump P06. The thickened mixed sludge (50 gTSS/L) is pumped using a
volumetric pump at 6 m3/h. The influent flowrate and the total solid concentration of the influent
mixed sluge are monitored by the inline sensors M012 (TSS) and M014 (Qf) respectively. A solution
of polyelectrolite is provided using the volumetric pump P09, where the flowrate is automatically
adjusted according with the registered total solids concentration of the influent and thickened mixed
sludge using the inline sensors M013 (TSS) and M015 (Qdig) respectively. Every day, 10 m3/d of
fermented sludge are discharge from the fermentation unit using the P09 and then fed with fresh 10
m3/d of thickened mixed sludge using the P05. The feeding and discharge of the fermentation unit
are controlled by the level sensor M009 and based on two opposite pneumatic valves (V3 and V4).
At minimun fixed level, the pneumatic valve V4 is kept closed, while the pneumatic valve V3 is open,
so to allow the feeding of thickened. The duration of the feeding is 1.7 hours. Once the maximal level
of the fermentation unit is achieved, the valve V3 close and V4 open.
Table 6 Operation of the fermentation unit
Operation phase Parameter that defines the phase duration according to PLC design
Equipment in working mode during this phase controlled by PLC
Filling (1 per day) Level max The valve V3 open while the valve V4 is closed
Decanting (1 per day) Level min The valve V4 open while the valve V3 is closed
The screw press is fed using a volumetric pump with a maximal flowrate of 2-4 m3/h. The solid and
liquid separation of the mixed sludge fermentation results on two main stream: solid and liquid. The
liquid is pumped by a centrifugal pump using the storage tank of the carbon source. The solids
fraction is pumped by to the post dynamic thickening using the volumetric pump P11. The P9 is
controlled by the level of the fermentation. Every day, the screw press accomplishes the solid/liquid
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separation until when the minimun level of the fermentation unit is achieved. The fermentation liquid
produced is relaunched by the pump P10 from a temporary tank to the final storage tank of 20 m3
for its further application to the scSBR. The P10 is turned on when the level of the carbon source is
between the minimun and maximal level of the M022. The P10 stops the operation as soon as the
maximal level M011 is achieved. The eventual excess of carbon source production is drained by the
overflow and so discharged in the mainstream.
Table 7 Operation of the screw-press separator
Operation phase Parameter that defines the phase duration according to PLC design
Equipment in working mode during this phase controlled by PLC
Filling Operation according to the level MIN and MAX of the fermentation unit
P9
Relunch of the liquid fraction
Operation according to M022 P10
Discharge solid fraction Operation according to M011 P11
The scSBR is fed with around 40 m3/d of anaerobic supernatant using the suberged centrifugal pump
P01. The carbon source is provided by the volumetric pump P12. The effluent from the scSBR is
discharged using the submerged centrifugal pump P02. The waste activated sludge is withdrawn from
the scSBR using the P03. The anaerobic supernatant from the dewatering operation of the digestate
is sent by gravity in the equalization tank. The level M001 controlled the operation of two pneumatic
valve V13 and V14: at the minimal level achieved, the V13 is closed and V14 is opened, while at the
maximal level achieved the V13 is opened and V14 is closed. The daily flowrate of anaerobic
supernatant provided to the scSBR is divided in three or four cycle. The level M002 determines the
minimal and the maximal level achievable in the scSBR. Six sensors are installed in the reactor:
conductivity (M003), pH (M004), ORP (M005), DO (M006), MLSS (M007) and N2O (M008). Among
them, DO is used to control the compressor through VDF, while conductivity and pH are used to
control the lenght of the aerobic phase, the amount of carbon source and the lenght of the anoxic
phase. The other sensors are not included in the control algorithm of the system but are recorded in
the PLC.
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Table 8 Operation of the short-cut Sequencing Batch Reactor.
Operation phase Parameter that defines the phase duration according to PLC design
Equipment in working mode during this phase controlled by PLC
Filling Timer or/and Level meter SBR mixing device Sludge liquors feeding pumps
Anaerobic phase (1 phase for each cycle)
Time based control
SBR mixing device Monitoring of the process parameters (pH, ORP, Conductivity, Oxygen, N2O, MLSS)
Aerobic phase (1-2 phases during each cycle)
Time based controlled for the Min and Max lenght of the phase; Real time control based on conductivity and pH
Frequency of the blower control by a PID algoritm
Anoxic phase (1-2 phases during each cycle)
Time based controlled for the Min and Max lenght phases Dosage of the carbon source according with the conductivity; End of the phase according with pH signals
SBR mixing device; Carbon source feeding;
Settling Timer -
Decanting Timer or/and Level meter Disharge pump
WAS removal Timer or/and Level meter Decanting pump SBR mixing device
2.1 Integrability of the Smartech 4a in existing WWTPs
Integrability issues Smartech 4a
Technical Feasibiliy
1. Should new facilities always be
considered during the design and
implementation of the Smartech?
No. Preliminary designs should be always performed in
order to consider the recovery of disused tanks or the
conversion of the existing facilities in the WWTPs. In
particular, the Smartech 4a was designed considering
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the conversion of existing tanks dedicated to the
storage of liquid waste.
2. Does the implementation of the
Smartech imply a substantial change of
the present flowscheme of the WWTP?
No, if the Smartech 4a takes advantage of existing
works, only minor changes of piping connection are
required, which do not represent substantial changes
of the WWTPs.
3. Could the Smartech negatively impact
on the final discharge of the main
WWTP?
No, the Smartech will positively impact on the final
discharge, because the treated effluent from Smartech
4a is supposed to contain up to 90% less nitrogen and
30-60% less phosphorous compared with raw
anaerobic supernatant. However, even if the
technology does not perform as expected, the effluent
will be treated in the main WWTPs before its final
discharge in the water body.
Acceptability of the Smartech
1. Is the Smartech 4a well accepted
among the operators?
The Smartech 4a is considered by operators an
integrated and useful compartment of the WWTP and
the personnelle are used to operate and take care of
it.
2. Are specific skills and/or tranings
required for the operators?
No additional specific trainings are requireds. The
knowledge and expertize already held by the
operators of the main WWTP are also sufficient and
adequate to operate in the Smartech 4a. The latter in
fact uses the same equipments typically adopted also
by conventional biological processes.
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Bureaucratic issues
1. Did Smartech 4a require a specific
authorization for its implementation?
Yes. The authorization for its implementation was
asked to the Regional Authority (see the attachment).
Are there any standards, regulations or
references applicable?
No, the Smartech 4a does not need to conform to
specific regulation. However, if new facilities are
implemented, the competent autority may ask to
respect the standards of the “landscaping regulation”.
However, regulations could significantly change based
on the country where the plant is operating.
2.2 Drawings ‘as built’
The drawings of the units are reported in the following annexes:
• Drawing 1: P&id of the Smartech 4a
• Drawing 2: Fermentation unit
•
• Drawing 3: Layout of the Smartech 4a
• Drawing 4: Dynamic Thickening
• Drawing 5: Screw press separator
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2.3 Picture report
Figure 3 SMARTech 4a - Dynamic thickener of the sewage sludge
Figure 4 SMARTech 4a – Screw-press for S/L of the fermentation sewage sludge
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Figure 5 SMARTech 4a – Accumulation tank for the fermentation liquid of mixed sludge
Figure 6 SMARTech 4a – Different views of the fermentation
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Figure 7 SMARTech 4a - Electrical Panel and air compressor of Smartech 4a
Figure 8 SMARTech 4a -Tank for the acculation of the anaerobic supernatant and influent pump of the scSBR
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Figure 9 SMARTech 4a - Air diffusion system of the scSBR
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3. SMARTECH4B - SIDESTREAM THERMAL HYDROLYSIS-SCENA
3.1 Technical description of the SMARTech 4B
The SMARTech 4b pilot system is an innovative nutrient removal process via nitrite which is
integrated in the Psyttalia WWTP in order to manage the reject water produced from the dewatering
process of the plant. The SMARTech 4b shall treat separately the reject water of the dewatering
process to biologically remove nitrogen and phosphorus and then recycle it back to the inlet of the
WWTP (Figure 3.1). This process also takes advantage of the readily biodegradable COD which is
contained in the reject water of the primary thickened sludge in order to provide part of the carbon
source which is required to remove nutrients from dewatered sludge.
Figure 10 Flow diagram of Psittalia WWTP with SMARTech 4b
Figure 10 illustrates the major units of the pilot system along with their interconnections. The core
of SMARTech 4B is the bioreactor (SBR). The SBR is a rectangular tank with dimensions
[2.00x2.30x2.40] [WxLxH] and 9m3 maximum active volume. The construction material is stainless
steel AISI 304L.
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Figure 11 Major units of SMARTech 4b and their interconnections
The SBR is equipped with a mixing apparatus in order to provide a minimum mixing capacity of 8
W/m3. The mixer manufacturer is SEKO (Italy) and it is a slow speed 200rpm mixer with 220mm
propeller, stainless steel shaft and PVC body.
The effective depth of the reactor will be at least 1.5 m (during the aeration phases) in order to allow
for an oxygen transfer efficiency to the order of 8-10%. An aeration system with diffusers has been
installed in order to meet the oxygen requirements of the system. The aeration system consists of a
side channel air compressor from MAPRO International with maximum capacity of 252 m3/h at 200
mbar and fine bubble AEROSTRIP diffusers Type T provided by Aquaconsult. The transfer efficiency
of the diffusers is in the order of 100 m3/m2 h.
The SBR will be fed with sludge liquors from the dewatering unit and from the primary sludge
thickening unit. The sludge liquors upstream the SBR will be collected in two storage tanks (one for
each type of sludge liquors). There are two transfer pumps from NETZSCH manufacturer with capacity
of 5 m3/h each, which feed the storage tanks in automatic mode, in order to keep the necessary
volume of slugde liquors in the storage tanks. Each tank provides a storage capacity of min 2 d, with
an effective volume to the order of 8 m3 each. Both storage tanks are made of polyethylene, black
color, with roof manhole. Each of these storage tanks is equipped with a submersible centrifugal
pump (two in total) from LOWARA manufacturer for continuous mixing of the content.
Each type of sludge liquors will be fed into the SBR with the use of an eccentric screw pump. The
installed feeding pump is from NETZSCH manufacturer and it is driven by VFD (frequency converter).
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The maximum capacity of the pump is 7 m3/h. The selection of the capacity of this pump is based on:
i) the maximum daily flow rate of the sludge liquors (3 m3/d for the SL-DS and 2.65 m3/d for the SL-
PS), ii) the minimum number of 3 cycles per day and iii) the duration of fill phase of 15 min. A second
eccentric screw pump, from NETZSCH manufacturer and also driven by VFD has been installed in
order to provide decanting of treated sludge liquors from the SBR and the removal of the surplus
activated sludge as well. The waste activated sludge will be collected temporarily in a rectangular
storage tank made of polyethylene and of volume 1m3, which is sufficient for 2 days storage of sludge
removed.
A solution of acetic acid (in the form of sodium acetate) will be added to the reactor to meet the
biodegradable organic carbon requirements. The external organic carbon system consists of a
storage tank with an active volume of 1 m3 and it is sufficient for more than 7 days storage capacity.
The tank is made of polyethylene and it is placed in an appropriate leakage basin. It is equipped with
a mixer from SEKO manufacturer. A dedicated diaphragm, adjustable flow-rate dosing pump from
DOSEEURO AP manufacturer with a capacity of 200 L/h is installed in order to transfer the sodium
acetate solution from the storage tank to SBR.
It is expected that under normal conditions there will not be any need for pH control for the pilot
system. However, as the performance of especially the nitritation – denitritation processes is highly
dependent on the pH and the fact that under transient conditions (especially during start-up) there
might be a need for pH control, a pH control system has been installed in the pilot system. The pH
control system consists of an acid dosing system and a base dosing system. The acid (in the form of
sulfuric acid) dosing system consists of a storage tank with a volume of 1 m3 and a diaphragm,
adjustable flow-rate dosing pump from DOSEEURO AP manufacturer with a capacity of 50 L/h. A
separate similar dosing system is provided for the addition of the base (in the form of sodium
hydroxide). Both chemicals storage tanks are placed in a leakage basin.
The SBR is equipped with a piezoelectric level transmitter from ENDRESS+HAUSER company and
several analytical field instruments such as pH, ORP, DO, Temperature, Conductivity, NH4-N, NO2-
N/NOx-N from the WTW company. All the instrumentation will be collected in a common controller
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WTW MIQ, which will be interconnected with PLC via Profibus DP interface. All the storage tanks will
be equipped with suitable level switches.
All electrical and automation equipment, including motor starters, variable frequency drives and PLC,
have been installed into a stainless steel IP55 enclosure (2000x600x600mm) from SABO
manufacturer, forming the Motor Control Center (MCC) of the pilot plant system. The electric power
supply is at 400VAC/3–phase and the control voltage at 24VDC. The process automation (e.g. feeding,
aeration, decanting, was, chemical dosing) will be carried out in automatic mode by the CPU PLC but
there is also an HMI device (touch panel) for controlling the equipment manually and monitoring all
measured values from instrumentation locally. Finally, the MCC will be ready for interconnection to
an external PC for data acquisition.
3.2 List of the electromechanical equipment
The technical specifications of the major units and the electro-mechanical equipment installed at
the site are presented in Table 3.1.
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Table 9 Major units and specifications of the electro-mechanical equipment
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3.3 Practical instructions for the operation of SMARTech 4B
The operation of SMARTech 4B includes a series of actions and settings which can be divided in the
following categories:
• Preparation of chemicals to be dosed in the reactor
• Selection of the automation mode and definition of the set points
• Calibration of on-line probes
Preparation of chemicals
Three types of chemicals will be used during the operation of SMARTech 4B: the substrate, the acid
and the base for pH control. Among these the acid-base chemicals will be supplied as ready to use
solutions with the already specificed characteristics and therefore no specific actions will be needed
from the operators of the system. The only care will be to send a notice for refill the chemicals tanks
upon signal of low level.
Substrate as sodium acetate will be dosed to the reactor automatically. The preparation of the
solution in the respective tank will be undertaken by the operator of the system. The solution wiil be
prepared by adding sodium acetate powder to the tank in order to reach an acetic acid content of
200 kg/m3.
Selection of automation mode
SMARTech 4b is equipped with online monitoring meters and a programmable logic controller (PLC)
which will provide operational flexibility and applicability of different control strategies.
Online probes of dissolved oxygen, pH, temperature, conductivity, oxidation-reduction potential,
NH4-N, NOx and a level meter have been installed into the surface of SBR unit and real time
information on the performance of the system will be obtained and transferred to the online
controller every 1 minute. The PLC is interconnected to an external PC for data acquisition.
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All the major units of the electro-mechanical equipment such as the SBR mixer apparatus and the
mixing devices of storage tanks, feeding, dosing and decanting pumps and the air blower are
connected to the PLC which control their operation according to predefined parameters or schedule.
The main operational strategy that will be established is based on time schedule and online sensors
measurements. More specifically, every SBR cycle has a number of distinct phases. For each phase a
variety of functions and processes have been programmed under the regulations of the PLC according
to the automation plan. Table 10 describes the basic features of the automation to control the
operation pf the system.
Table 10 Basic features of automation in the operation of pilot plant system.
Operation phase Parameter that defines the
phase duration according to PLC
design
Equipment in working mode
during this phase controlled by
PLC
Filling Timer or/and Level meter SBR mixing device
Sludge liquors feeding pumps
Anaerobic phase
(1-2 phases during each
cycle)
Timer
SBR mixing device
pH adjustment system
acid/base dosing pumps
Aerobic phase
(1-3 phases during each
cycle)
Main operation: Timer or/and
NH4-N sensor measurements
Alternativelly: pH set point or pH
slope
Air blower
pH adjustment system
acid/base dosing pumps
Control of blower flow rate
Anoxic phase
(1-3 phases during each
cycle)
Main operation: Timer or/and
NOx sensor measurements
Alternativelly: ORP slope or pH
set point or pH slope
SBR mixing device
Substrate feeding pumps
pH adjustment system
acid/base dosing pumps
Settling Timer -
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Decanting Selected valve of decanding
pump
Decanting pump
SAS removal Selected valve of decanting pump Decanting pump
SBR mixing device
Based on the design of the automation system the operator is able to choose the number of each
phase (e.g. anaerobic, anoxic, aerobic) during each cycle as well as their sequence. The maximum
number of process functions/phases that can be selected in each cycle is eight (two anaerobic, three
anoxic and three aerobic).
Filling phase is starting upon setting the feeding pump on. The duration of the feeding phase is
primarily based on the set point of the level meter. For safety reasons the maximum duration of this
phase can also be regulated by a timer.
The duration of the anaerobic phase is primarily regulated by a timer. During this phase, the PLC will
set up the SBR mixing system and if necessary will control the pH adjustment system providing acid
or base solution from the storage tanks using two dosing pumps. It is expected that under transient
conditions and especially during start-up there will be a need for pH control to the desired set points
by providing sulfuric acid or sodium hydroxide.
During the aerobic phase the PLC will activate the aeration system while the mixing system will
ceased operation as adequate mixing will be provided by the diffusers. The air flow rate provided by
the blower will be regulated according to the desired set point of dissolved oxygen in the reactor.
The duration of the aerated period will be controlled either by a timer or by a critical value of NH4-N
sensor (or both). The automation system provides also alternative control functions of the duration
of this phase based either on the pH set point or on pH slope. During the aerated phases pH control
can be impleened (if desired) by regulating the acid/base dosing system.
Following the aerobic phase, the anoxic phase will start with the end of aeration and the addition of
external carbon source (fiilling). In order to meet the biodegradable organic carbon requirements for
denitritation procces the automation system will be set to provide adequate volumes of primary
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sludge liquor or acetate or a mix of the two substrates. A maximum of three dinstict anoxic phases
can be implemented during each cycle and their duration will be controlled by either a timer or by
reaching a pre-defined value of NOx sensor (or both). Furthermore, alternative control strategies can
also be choosen by the operator based on set points defined for ORP, pH and pH slope. During each
anoxic phase the PLC will maintain open the mixing system and will also provide pH control.
The surplus activated sludge (SAS) removal will take place either during aerobic or during anoxic
phase in the form of mixed liquor in order to keep the desried sludge age.
After the last anoxic period in each cycle, the PLC will stop the mixing system and sedimentation
phase will take place for a pre-selected time period. Every cycle will end up with decanting. The PLC
will control the volume of supernatant that the decanting pump will remove from the SBR unit either
by a timer or by the level meter measurements.
In view of the above, the operator selects the mode of automation and specifies the set points
directly on the screen pf PLC.
Calibration of on-line probes
Calibration of the on-line probes will take place on a weekly basis. In this context the operator will
collect activated sludge samples which will be analyzed for pH, conductivity, ORP, NH4-N, NO2-N, NOx-
N and the results will be compared with the on-line measurements for validation. Upon significant
deviations calibration of the on-line probes will take place.
3.1 Integrability of the Smartech 4b in existing WWTPs
Integrability issues Smartech 4b
Technical Feasibility
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1. Should new facilities always be
considered during the design and
implementation of the Smartech?
New facilities are required for the development of the
Smartech4b since new systems are developed to treat the
sludge reject water, which includes storage tanks,
sequencing batch reactor, control and automation, pumps,
aerators and other auxiliary equipment.
2. Does the implementation of the
Smartech imply a substantial
change at the present flowscheme
of the WWTP?
Smartech4b does not require excessive interventions.
However, some intervention is required in the sludge
treatment line in order to direct the reject water from
thickening and dewatering first to the Smartech4b
technology and the treated effluent from Smartech4b to
the inlet of the WWTP. These interventions are considered
to be rather small.
3. Could the Smartech negatively
impact on the final discharge of the
main WWTP?
No. The Smartech4b is expected to positively affect the
final discharge of the WWTP by reducing the nutrient load
which is sent to the main wastewater treatment line. Even
if the technology does not perform as expected in terms of
nutrient removal, the treated effluent from Smartech4b is
returned back to the inlet of the WWTP. So in the worst
case scenario it will not affect the final discharge of the
WWTP. Within the project, Smartech4b is applied as a small
pilot to a very large WWTP. So its actual effect in the
treated effluent is negligible.
Acceptability of the Smartech
1. Is the Smartech 4b well accepted
among the operators?
The personnel of the plant including the operators are very
much interested in Smartech4b. The companies which are
in charge for the operation of the WWTP (EYDAP SA and
AKTOR SA) are participating as partners in the project.
2. Are specific skills and/or
trainings required for the
operators?
The knowledge, expertise and skills of the operators is
sufficient to manage Smartech4b and no training is
required.
Bureaucratic issues
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1. Did Smartech 4b require a
specific authorization for its
implementation?
Smartech4b is a pilot system developed within the
premises of the water utility participating the project.
Therefore, no licence is required.
2. Are there any standards,
regulations or references
applicable?
Smartech4b does not need to conform to any standards or
regulations.
3.2 Drawings ‘as built’
The drawings of the units are reported in the following annexes:
• Drawing 3.4.1: Layout of the Smartech 4b
• Drawing 3.4.2: Cross section of the pilot Smartech 4b
• Drawing 3.4.3: P&I of the pilot SMARTech 4b
3.3 Pictures report
Figure 12. Plan view of SMARTech 4B
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Figure 13 Plan view of SMARTech 4B
Figure 14 3D drawing of SMATech 4B
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Figure 15 SMARTech 4B – construction phase
Figure 16 SMARTech 4B – construction phase
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Figure 17 SMARTech 4B – construction phase – installation of reject water storage tanks
Figure 18 SMARTech 4B – construction of raw and treated reject water networks
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Figure 19 SMARTech 4B – overview of feed pump, decanting pump and decanting network
Figure 20 SMARTech 4B – overview of feed pump and decanting pump
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Figure 21 SMARTech 4B – decanting system
Figure 22 SMARTech 4B – chemicals and substrate dosing pumps
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Figure 23 SMARTech 4B – chemicals and substrate storage tanks
Figure 24 SMARTech 4B – installation of on-line probes
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Figure 25 SMATech 4B – hydraulic testing of the SBR
Figure 26 SMATech 4B –testing of the aeration system of the SBR
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4. SMARTech5 - SIDESTREAM SCEPPHAR
4.1 Technical description of the SMARTech 5
The Smartech 5 performs the SCEPPHAR process (Short Cut Enhanced Phosphorus and PHA Recovery)
which allows the via-nitrite nitrogen removal and, at the same time, recovers struvite and PHA from
the acidogenic fermentation liquid of cellulosic sewage sludge. The first SCEPPHAR system was
developed at the University of Verona (Frison et al., 2015) and uses real cellulosic sewage sludge from
the municipal wastewater treatment plant in an oxic-anoxic via-nitrite system, which saved energy
compared to other systems that are operated under complete aerobic conditions.
Figure 27 P&id of the Smartech 5.
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The SCEPPHAR system is composed by seven different operative units, controlled by a CPU-PLC with
electro levels and time-based control. Each unit is fed and emptied by pumps or pneumatic valve
systems, depending on the type of unit. The list of the different units is reported below:
1) R001-> SF1000-Salsnes Filter
2) R002-> Fermentation unit
3) R003-> Ultrafiltration
4) R004-> Crystallizer
5) R005-> Nitritation SBR
6) R006-> Selection SBR
7) R007-> PHA Accumulation
The Salsnes filter (R001) consists in a belt dynamic filter with a fine mesh size less than 350µm for
the filtration of 450 m3/d of degritted municipal wastewater. The aim is the separation of cellulosic
primary sludge. The best mesh size will be selected during the start-up of the filter. In order to achieve
around 50% of the suspended solids removal, polielectrolyte will be add to favour the coagulation of
the organic matter. The pumps flowrates are controlled by a variable frequency drive (VFD), while
the starting and turning off is controlled by level and time-based control. The fermentation process
accomplishes the production of volatile fatty acids (VFAs), which represents the carbon precursors
for the PHAs production. Mesophilic or thermophilic fermenting conditions may be setted by the
electrical heating system. The solid-liquid (S/L) separation system is composed by a ultrafiltration unit
(UF) provided with ceramic membrane, which allows the solid/liquid separation of the fermented
cellulosic primary sludge. An efficient solid/liquid separation is required in order to easier handle the
solid fraction of fermented sludge and at the same time to recover the maximal amount of liquid
fraction which contains VFAs and nutrients. A clean liquid is also important to enhance the purity of
the struvite recovered. The permeate produced by the filtration of the fermented cellulosic mixed
sludge is composed by a liquid rich in volatile fatty acids and nutrients like nitrogen and phosphorus.
The crystallization reaction allows the recovery of phosphorus in the struvite form (NH4MgPO4·6H2O).
The anaerobic superantant is fed into the nitritation reaction (R005) using the pump P108 (flowrate
5 m3/h) and then after the nitritation, the effluent is discharge into the tank Tk008. Nitrite is later
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used as electron acceptor by the PHA storing biomass in the selection SBR (R006). PHA-accumulating
biomass selection is essential to obtain a microbial community capable of synthetize and hyper-
accumulate PHAs and at the same time, remove nitrogen via-nitrite. To achieve this result, biomass
is subjected to feast and famine conditions. During the feast phase, PHA are synthetized and
accumulated by the biomass, while under famine conditions nitrites are used as electron acceptor
from the PHAs degradation, thus promoting the microbial growth of denitrificants and PHA storing
organisms. The accumulation bioprocess allows the achievement of maximum rates of PHA storage
under feast conditions. Carbon source is provided at intervals to the biomass; at the end of PHA
accumulation, biomass activity is interrupted through the dosage of a quencher. The SBR are
equipped with sensors from HACH-LANGE company which are based on a floating chamber. The
sensors allows the monitoring of several parameters and by them also the control of the nitrogen
forms, so to control the cycle lenght. The sensors installed are: pH, Dissolved Oxygen (DO),
Conductivity (COND), Oxydation Reduction Potential (ORP), Mixed Liquor Suspended Solids (MLSS)
and for nitrous oxide emission (N2O).
4.1 List of the electromechanical equipment
Table 11 List of electromechanical equipment and FLOW DIRECTION of the Salsnes Filter
SF 1000
List of electro-mechanicals installed
CODE DESCRIPTION INSTALLED POWER (kW)
FLOWRATE (m3/h)
CONTROL
P100 Inlet centrifuge pump 2.4 54 VFD/electro level/time based
P101 Cellulosic primary sludge pump
1.5 3 VFD/electro level/time based
P102 Polyelectrolyte dosing pump
1 5 VFD/Electro level/time based
List of sensors
CODE TYPE OF SENSOR COMMENTS
LC002 Electro level (3 levels) Min (1 and 2)-max control of the fermenter
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FLOW DIRECTION
FLOW Feeding from (F)/ Discharge to (D)
PUMP CODE
R001 (SF1000) F1: WW influent->R001 F2: TK000->R001 D1: R001->R002 D2: R001->mainstream
F1: P100 F2: P102 D1: P101 D2: gravity
Table 12 List of tanks, electromechanical equipment, sensors and FLOW DIRECTION of the Sequencing Batch Fermentation Reactor
SEQUENCING BATCH FERMENTATION REACTOR
Tanks volumes
CODE DESCRIPTION UNITS VALUE
R001 Sequencing batch fermentation reactor
m3 2.6
TK003 Alkalinity source L 25
List of electromechanical equipment
CODE DESCRIPTION INSTALLED POWER (kW)
FLOWRATE CONTROL
M2 Fermenter mixer 200 rpm 2 x Blade diameter 500mm
1.5 - NO
P101 Cellulosic primary sludge pump
1.5 3 m3/h VFD/electro level/time based
P104 Base-dosing pump - 50 L/h Time based/pH sensor
P105 Fermented sludge centrifuge pump
20 m3/h VFD/Time based/electro level
HE100 Heater kW 1.5 Temperature set-point
VP001 Pneumatic valve - - Electro level
FLOW DIRECTION
FLOW Feeding from (F)/ Discharge to (D)
PUMP CODE
R002 (SBFR) F1:R001->R002 F2:TK003->R002 D1:R002->R003 D2:R002->drains
F1:P101 F2:P104 D1: P105 D2: gravity (VP001)
SENSORS INSTALLED
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Code TS001
Description Measurement of the total solid concentration of the cellulosic primary sludge influent in the fermentation unit (R002)
Technical description Probe with combined light infrared absorption for measuring turbidity and suspended solids Independent of the color of the water sample (suitable for waste activated sludge, primary sludge, etc).
Component and configuration Configuration: insertion probe with steel probe body; Lenght of cable: 10 meters Technical data: photometer with double IR detector Method of measurement: Turbidity measurement according to DIN EN 27027; Measure Solids, equivalent to DIN 38414 Measurement range: Turbidity: 0.001 - 4.000; Total Solids: 0.001 - 500.0 g / l Accuracy: 1.0% turbidity, ± 0.001 FNU Coeff. Var process: 1.0% according to DIN 38402 Response Time: 0.5 s <T90 <5 min (adjustable) Measurement range: 0.3 s Sample temperature: from + 2 ° C to + 40 ° C Dimensions: (D * L) 60 * 200 mm Weight approx. 2.4 kg
Other equipments included
- Pipe connection flange for inline installation (steel stainless) - System inline/highline fastening system for insertion into no-pressure pipe, steel AISI 304
Code pH001
Description Measurement oft he pH and temperature of the fermentation unit R002
Technical description Differential type digital sensor for the measurement of pH and temperature.
Component and configuration Material of the electrode: glass; Type of probe: submerged Sensor body: steel Range of measurement: 0 - 14; T=-5° C a 50° C Time of response: pH: < 5 s; T: < 2 min Reference electrode for the control of the impedence of the liquid bulk Lenght of the cable: 10 metri Dimensions: 350 x 44 mm (diameter)
Other equipments included
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- Fixing system for pH, size 1" steel AISI316
Table 13 List of tanks, electromechanical equipment, sensors and flow direction of the ultrafiltration unit
ULTRAFILTRATION UNIT
Tanks volumes
CODE DESCRIPTION UNITS VALUE
TK004 Permeate tank L 100
R002 Sequencing Batch Fermentation Reactor
m3 2.6
List of electromechanical equipment
CODE DESCRIPTION INSTALLED POWER (kW)
FLOWRATE CONTROL
VP1 Pneumatic valve - -
P105 Recycling pump (Fermented sludge centrifuge pump)
24 m3/h VFD/Time based/electro level
FLOW DIRECTION
FLOW Feeding from (F)/ Discharge to (D)
PUMP CODE
R003 (UF) F1:R002->R003 D1:R003->TK004 D2:R003->R002
F1:P105 D1: gravity D2: gravity
Code VP1
Description Pneumatic valve for the backwash of the UF unit
Technical description
• Body and flanges made of aluminum or stainless steel • Sealing element in various types of elastomer, up to 170 ° C • Maximum fluid pressure to be intercepted up to 6 bar (depending on the execution) • Control pressure: 2 bar higher than the pressure of the fluid to be intercepted • Possibility of threaded attachments and execution in different materials
Table 14 Specification of the crystallization unit
CRYSTALLIZATION UNIT
Tanks volumes
CODE DESCRIPTION UNITS VALUE
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R004 Crystallization unit L 50
TK004 Permeate tank L 100
TK005 Carbon source storage tank m3
TK006 Base tank (Mg(OH)2) L 25
List of electromechanical equipment
CODE DESCRIPTION INSTALLED POWER (kW)
FLOWRATE
CONTROL
M3 Crystallizer mixer (140 rpm Blade diameter 200mm)
0.18 - Time based/electro level
P106 Influent pump 200 L/h Time based/electro level
P107 Base-dosing pump (Mg(OH)2)
- 10 L/h pH sensor
FLOW DIRECTION
FLOW Feeding from (F)/ Discharge to (D)
PUMP CODE
R004 (Crystallizer) F1:TK004->R004 F2:TK006->R004 D1:R004->struvite tank D2: R004->TK005
F1:P106 F2: P107 D1: gravity (VM015) D2: gravity
SENSOR INSTALLED
CODE TYPE OF SENSOR COMMENTS
LC003 Electro level (2 levels) Min-Max control of the permeate tank
Code pH003
Description Measurement of the pH and temperature of the crystallization unit R004
Technical description Differential type digital sensor for the measurement of pH and temperature. Electrode not in contact with the liquid bulk.
Component and configuration Material of the electrode: glass; Type of probe: submerged Sensor body: steel Range of measurement: 0 - 14; T=-5° C a 50° C Time of response: pH: < 5 s; T: < 2 min Reference electrode for the control of the impedence of the liquid bulk Lenght of the cable: 10 m
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Dimensions: 350 x 44 mm (diameter)
Table 15 List of tanks, electromechanical equipment, sensors and flow direction of the nitritation unit
NITRITATION SEQUENCING BATCH REACTOR
Tanks volumes
CODE DESCRIPTION UNITS VALUE
R005 Nitritation SBR m3 1.4
TK007 Anaerobic supernatant storage tank m3 90
TK009 Alkalinity L 25
TK008 Nitrified supernatant storage tank m3 1.4
List of electromechanical equipment
CODE DESCRIPTION INSTALLED POWER (kW)
FLOWRATE
CONTROL
P108 Anaerobic supernatant feeding pump
0.75 5 m3/h Time based/electro level
P109 Base-dosing pump 10 L/h pH sensor
P114 Nitritation SBR emptying pump
0.75 5 m3/h Time based/ Electro level
B1 Blower 0.7 200 L/min Dissolved oxygen
B2 Blower 0.7 200 L/min Dissolved oxygen
FLOW DIRECTION
FLOW Feeding from (F)/ Discharge to (D)
PUMP CODE
R005 (Nitritation SBR) F1:TK007->R005 F2:TK009->R005 D1:R005->TK008 D2: R005->drains
F1: P108 F2: P109 D1: P114 D2: manual valve (VM020)
SENSORS INSTALLED
Code COND001
Description Measurement of the conductivity of the nitritation SBR (R005)
Technical description Submerged inductive conductivity digital probe. The inductive principle adopted ensures precision, long service life and applicability in aggressive and heavy application.
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Component and configuration Probe Material: PEEK Probe Type: For Immersion with Steel Body Measuring range: 250 μS to 2.5 S / cm Measuring principle: Inductive Accuracy: +/- 1% of reading value or +/- 0.004 mS / cm Temperature Accuracy: +/- 0.2 ° C Reproducibility: <0.2% Response Time (T90): Cond .: <2 s; T: <2 min Sensor cable: 10 mt cable with quick connector for connection to series controller or extender cable Protection rating: IP68 Operating temperature: - 20/+50 ° C Thermocomputer: Automatic PT100 Calibration: Process or Electrical Dimensions: 405 x 42 mm (length x diameter) Mounting: with chain or with immersion tube
Other equipments included PVC Mounting Kit for Conductivity Probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - Purple tube closure cap
Code pH003
Description Measurement of the pH and temperature of the nitritation unit R005
Technical description Differential type digital sensor for the measurement of pH and temperature. Electrode not in contact with the liquid bulk.
Component and configuration Material of the electrode: glass; Type of probe: submerged Sensor body: steel Range of measurement: 0 - 14; T=-5° C a 50° C Time of response: pH: < 5 s; T: < 2 min Reference electrode for the control of the impedence of the liquid bulk Lenght of the cable: 10 metri Dimensions: 350 x 44 mm (diameter)
Other equipments included PVC mounting kit for pH probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - brown tube closure cap
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Code DO001
Description Measurement of dissolved oxygen of the nitritation SBR unit R005
Technical description The measurement method is based on the emission of luminescent radiation by a special substance (luminophore) that is excited by light blue emitted by a LED and returning to the normal state emits light red. A photodiode measures the time needed to return to the quiescent state, inversely proportional to the concentration of oxygen present on the luminophore.
Component and configuration - Measuring principle: luminescent optic - Measurement range: 0 to 20.00 mg / L (ppm) O2, 0 to 200% saturation - Accuracy: 0-5 mg / L O2 ± 0.1 mg / L, 5-20 mg / L O2 ± 0.2 mg / L; Temperature: ± 0.2 ° C - Repeatability: ± 0.1mg / L - Resolution: 0.01 mg / L (ppm) O2 / 0.1% saturation - Response time (at 20 ° C): T90 <40 s, T95 <60 s - Calibration: 2 year factory guaranteed and linked to CAP - Operating temperature: 0 ° C to 50 ° C - Storage temperature: -20 ° C to 70 ° C (95% relative humidity) - Max pressure range: 10 bar - Sensor connector: 1 "NPT external thread - Cable length: 10 m - Sensor CAP material: acrylic - Body Probe Materials: CPVC, Polyurethane, Viton®, Noryl®, Stainless Steel 1.4404 (AISI 316L) - Degree of protection: IP68 - Dimensions (L x W): 48.25 mm x 254 mm
Other equipments included PVC mounting kit for LDOsc® probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - red tube closure cap
Table 16 List of tanks, electromechanical equipment, sensors and flow direction of the PHA-accumulating biomass selection SBR
BIOMASS SELECTION SEQUENCING BATCH REACTOR
Tanks volumes
CODE DESCRIPTION UNITS VALUE
R006 Selection SBR m3 2.9
TK008 Nitrified supernatant storage tank m3 1.4
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TK005 Carbon source storage tank m3 1
List of electromechanical equipment
CODE DESCRIPTION INSTALLED POWER (kW)
FLOWRATE
CONTROL
P110 Nitrified supernatant feeding pump
0.75 5 Time based/electro level
P111 Carbon source pump 0.75 5 Time based
M4 Selection SBR mixer (90 rpm Blade diameter: 500mm)
0.75 0.75 Time based
B3 Blower 0.95 60 m3/h VFD/Dissolved oxygen/time-based
VP105 Pneumatic valve (discharge treated anaerobic supernatant)
- - Electro level/time-based
FLOW DIRECTION
FLOW Feeding from (F)/ Discharge to (D)
PUMP CODE
R006 (Selection SBR) F1:TK008->R006 F2:TK005->R006 D1:R006->R007 D2: R006->drains D3: R006->drains
F1: P110 F2: P111 D1: manual valve (VM032) D2: Pneumatic valve (VP105) D3: manual valve (VM026)
INSTALLED SENSORS
Code DO002
Description Measurement of dissolved oxygen of the selection SBR unit (R006)
Technical description The measurement method is based on the emission of luminescent radiation by a special substance (luminophore) that is excited by light blue emitted by a LED and returning to the normal state emits light red. A photodiode measures the time needed to return to the quiescent state, inversely proportional to the concentration of oxygen present on the luminophore.
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Component and configuration - Measuring principle: luminescent optic - Measurement range: 0 to 20.00 mg / L (ppm) O2, 0 to 200% saturation - Accuracy: 0-5 mg / L O2 ± 0.1 mg / L, 5-20 mg / L O2 ± 0.2 mg / L; Temperature: ± 0.2 ° C - Repeatability: ± 0.1mg / L - Resolution: 0.01 mg / L (ppm) O2 / 0.1% saturation - Response time (at 20 ° C): T90 <40 s, T95 <60 s - Calibration: 2 year factory guaranteed and linked to CAP - Operating temperature: 0 ° C to 50 °C - Storage temperature: -20 ° C to 70 ° C (95% relative humidity) - Max pressure range: 10 bar - Sensor connector: 1 "NPT external thread - Cable length: 10 m - Sensor CAP material: acrylic - Body Probe Materials: CPVC, Polyurethane, Viton®, Noryl®, Stainless Steel 1.4404 (AISI 316L) - Degree of protection: IP68 - Dimensions (L x W): 48.25 mm x 254 mm
Other equipments included PVC mounting kit for LDOsc® probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - red tube closure cap
Code ORP003
Description Measurement of the oxidation-reduction potential of the selection SBR unit R006
Technical description Differential type digital sensor for the measurement of oxidation-reduction potential. Electrode not in contact with the liquid bulk.
Component and configuration Electrode: Platinum Sensor body: AISI 316 stainless steel Probe Type: Immersion Measuring range: from -2000 to +2000 mV; T = -5 ° C to 70 ° C Response Time (T90): ORP: <5 s; T: <2 min Auto Diagnostics: Measurement and reference electrode impedance control Lenght of cable: 10 m Power supply: from sc100 or sc1000 controller Temperature conditions: -20 to 50 ° C Pressure: max. 6.9 bar Template Provider: Automatic NTC 300
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Calibration: by process and / or with std buffer solutions Dimensions: 271.3 x 44 mm (length x diameter) Mounting: with chain or with immersion tube Weight: approx. 1 Kg
Other equipments included
PVC mounting kit for pH probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - brown tube closure cap
Table 17 List of tanks, electromechanical equipment, sensors and flow direction of the accumulation SBR
ACCUMULATION SEQUENCING BATCH REACTOR
Tanks volumes
CODE DESCRIPTION UNITS VALUE
R007 Accumulation SBR m3 1
TK005 Carbon source storage tank m3 1
TK010 Thickening of PHA-rich biomass L 50
TK011 Quenching chemical L 25
List of electromechanical equipment
CODE DESCRIPTION INSTALLED POWER (kW)
FLOWRATE
CONTROL
P111 Carbon source feeding pump
0.75 5 m3/h Time based
P113 Quenching chemical pump
10 Time based
B7 Blower 200 L/min Time based
FLOW DIRECTION
FLOW Feeding from (F)/ Discharge to (D)
PUMP CODE
R007 (Accumulation SBR) F1:TK005->R007 F2:R006->R007 F3:TK011->R007 D1:R007->TK010
F1: P111 F2: manual valve (VM032) F3: P113 D1: manual valve (VM036)
INSTALLED SENSORS
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Code DO002
Description Measurement of dissolved oxygen of the selection SBR unit (R006)
Technical description The measurement method is based on the emission of luminescent radiation by a special substance (luminophore) that is excited by light blue emitted by a LED and returning to the normal state emits light red. A photodiode measures the time needed to return to the quiescent state, inversely proportional to the concentration of oxygen present on the luminophore.
Component and configuration - Measuring principle: luminescent optic - Measurement range: 0 to 20.00 mg / L (ppm) O2, 0 to 200% saturation - Accuracy: 0-5 mg / L O2 ± 0.1 mg / L, 5-20 mg / L O2 ± 0.2 mg / L; Temperature: ± 0.2 ° C - Repeatability: ± 0.1mg / L - Resolution: 0.01 mg / L (ppm) O2 / 0.1% saturation - Response time (at 20 ° C): T90 <40 s, T95 <60 s - Calibration: 2 year factory guaranteed and linked to CAP - Operating temperature: 0 ° C to 50 ° C - Storage temperature: -20 ° C to 70 ° C (95% relative humidity) - Max pressure range: 10 bar - Sensor connector: 1 "NPT external thread - Cable length: 10 m - Sensor CAP material: acrylic - Body Probe Materials: CPVC, Polyurethane, Viton®, Noryl®, Stainless Steel 1.4404 (AISI 316L) - Degree of protection: IP68 - Dimensions (L x W): 48.25 mm x 254 mm
Other equipments included PVC mounting kit for LDOsc® probe Includes: - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - red tube closure cap
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4.2 Practical instructions for the operation of SMARTech 5
The SF1000 is fed by a centrifugal pump (P100) with a flowrate ranging from 30 to 54 m3/h. It has
been estimated that P100 will work between 8 to 15 hours per day, according with the fixed flowrate
of the influent. The SF1000 is discharged discontinuously through a centrifugal pump (P101) with a
flowrate of 3m3/h. It has been estimated that P101 will work from 8 to 15hours per day. The Salsnes
Filter (R001) turns on at preselected time by the operator, but only if the electro level sensor (LC002)
of the sequencing batch fermenter reactor (SBFR) detects the “MIN 2” level, to avoid undesired
feedings. The flowrate of the wastewater inlet pump (P100) is adjust by acting on the variable
frequency drive. The sludge pump (P101) turns on when the loading hopper achieve the maximal
level (P101). If required, the polyelectrolyte pump (P102) can be turned on and regulated by the
operator by acting on the VFD. The cellulosic primary sludge pump (P101) feeds the SBFR (R001). The
Salsnes Filter will work until the electro level sensor (LC002) of the sequencing-batch fermentation
reactor will detect the “MAX” level. Once the fermenter is fed to the maximum level, the Salsnes
Filter (R001), the wastewater inlet pump (P100), the cellulosic primary sludge pump (P101) and, if
turned on, the polyelectrolyte pump (P102), will be turned off until the starting time is reached.
Table 18 Operation of the SF1000
Operation phase Parameter that defines the phase duration according to PLC design
Equipment in working mode during this phase controlled by PLC
Feeding of wastewater Pre-selected time by the operator P100
Sieved westewater Discharge by gravity -
Cellulosic mixed sludge Pump controlled by the level sensor installed in the loadin hopper
P101
Polyelectrolite dosage Pre-selected flowrate according with the desired total solid concentration in the cellulosic mixed sludge
P102
The SBFR is fed discontinuously by the cellulosic primary sludge pump (P101) with a flowrate of
3m3/h. The feeding time ranges from 8 to 15 h, depending on the working flowrate of the P100
(SF1000 feeding pump). The SBFR is discharged by the centrifuge pump P105, which fed the
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ultrafiltration system (R003). It has been estimated that the discharge of the SBFR will take about 5-
6 h per day. The Sequencing Batch Fermentation Reactor (R001) is heated by an electrical heater of
1.5 kW, while the working temperature can be set by the operator. The influent pH is buffered
through the addition of an alkaline solution (e.g. NaOH) by a dosing pump (P104) according with time
based or pH control. The fermenting cellulosic sludge is mixed 24 h per day by a 2.2 kW mixer (M2).
The inlet suspended total solids are measured through an in-line probe (TS001). The feeding is
controlled by two different levels (LC002) which are recognized (“MAX” and “MIN2”). The “MAX”
level sets the maximal working capacity of the SBFR, while the level “MIN2” (LC002) allows the
switching on of the SBFR feeding pump (P101). The level sensor (LC002) detects the “MIN1” level,
the fermented sludge centrifuge pump (P105) is turned off and filtrationis stopped. The volume of
fermented sludge between the levels “MIN1” and “MIN2” is drained through the pneumatic valve
(VP001) installed in the bottom of the fermentation unit.
Table 19 Operation of the fermentation unit
Operation phase Parameter that defines the phase duration according to PLC design
Equipment in working mode during this phase controlled by PLC
Feeding Pump turned on from MIN2 to MAX level
P101
Mixer Manual turn on/off M2
Electrical heating system Temperature control by a thermostat
HE1
Discharge Ultrafiltration operates between MAX and MIN1 level. Pneumatic valve open between MIN1 and MIN2 level.
P105, VP1
The sludge pump (P105) for the recirculation of the fermented cellulosic sludge is turned on at pre-
selecte time. The flowrate of P105 can be set by the operator through a variable frequency drive (up
to 25 m3/h) and the duration of the ultrafiltration last for about 5-6 hours per day. The permeate is
collected in a permeate storage tank (TK004) by gravimetric flux and the permeate flowrate is
showed on Q101 flowmeter. The working pressure of the ultrafiltration system can be modified by
acting a manual valve (VM009) located on the recirculation pipe (PI 001); the flowrate of the P105 is
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showed on the Q100 flowmeter, the electro level sensor (LC002) within the sequencing batch
fermentation unit indicates “MIN1” level: when this level is reached, P105 is turned off and filtration
process stops.
Table 20 Operation unit of the ultrafiltration unit
Operation phase Parameter that defines the phase duration according to PLC design
Equipment in working mode during this phase controlled by PLC
Feeding Feeding pump switch on according with setted time by the operators. Feeding pump switch off according with fixed time lenght by the operators or minimun level achieved (MIN2)
P105, LC002
Concentrate fermented cellulosic mixed sludge
Recycled back to the fermentation unit (R002).
-
Permeate Collected by gravity to the TK005 -
The feeding pump of the crystallizer (P106) is switched on together with the ultrafiltration system
and operate discontinuously with a flowrate of 200 L/h. During the operation of the ultrafiltration
(R003), the crystallizer mixer (M3) and the crystallizer feeding pump (P106) are switched on. P106 is
switched on only if the electro level sensor (LC003) of the permeate tank (TK004) is not indicating the
“MIN” level;in this case, P106 is not switched on until the achievement of the “MAX” level of the
permeate tank. The crystallizer feeding pump (P106) is switched on/off until the filtrationprocess
stops definitively (reaching of “MIN1” level within R002 unit). At the end of the filtration stage, also
M3 is turned off until the beginning of a new filtration working cycle. pH set-point of the
crystallization reaction can be set by the operator. pH is adjusted by the addition of Mg(OH)2 through
a peristaltic pump (P107): the same pump is controlled by a pH sensor (pH002). The carbon source
after the struvite recovery is collected by gravity in the carbon source storage tank (TK005). The
harvesting of the produced struvite at the end of crystallization process, a manual valve at the bottom
of the R004 should be opened by the operator.
Table 21 Operation of the crystallizer
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Operation phase Parameter that defines the phase duration according to PLC design
Equipment in working mode during this phase controlled by PLC
Feeding P106
Effluent The permeate overflow the R004 and collected by grativity to the Tk005
-
Harvesting of the struvite Harvesting of the struvite every 2-3 days of full operation
VM015, manual valve
The nitritation SBR (R005) is fed by a centrifuge pump (P108) with a flowrate of 5m3/h. It has been
estimated that the P108 will work around 1h per day.
The nitritation SBR is emptied by a centrifuge pump (P114) with a flowrate of 5 m3/h. It has been
estimated that the P108 will work around 1h per day.
The nitritation bioprocess occurs through a working cycle which is composed by the following phases
(in the same order): idle (0), aerated filling (1), aerobic (2), settling (3) and discharge (4). The duration
of phases 0,2 and 3 is set by the operator. After the idle phase (phase 0), the aerated filling phase (1)
starts and anaerobic supernatant is fed within the nitritation SBR (R005). In concomitance with the
beginning of phase 1, the anaerobic supernatant feeding pump (P108) and blowers (B1 and B2) are
switched on. P108 is controlled by an electro level sensor (LC005). When “MAX” level is detected by
LC005, P108 is turned off and phase 2 (aerobic) starts. During this phase, blowers (B1 and B2) are
switched on and dissolved oxygen (DO) concentration is monitored through a DO probe (DO001). To
control the dissolved oxygen concentration, blower (B2) is switched on/turned off depending on the
DO set-point, while B1 is left on on for all the phase duration. To control the pH of phase 2, an alkaline
solution is fed through a peristaltic pump (P109). This pump is controlled by a pH sensor (pH003)
during all the phase. Monitoring of the same phase is carried out through a conductivity probe
(COND001). At the end of phase 2, settling phase (3) starts and blowers (B1 and B2) are turned off.
When time-limit of the phase is achieved, discharge phase (4) starts and the nitritation SBR emptying
pump (P114) is switched on. This pump is controlled by an electro level sensor (LC005). When “MIN”
level is detected by LC005, P114 is turned off and phase 0 starts (new working cycle). In the table
below are reported the main operation phases of the nitritation SBR
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Table 22 Operation of the nitritation unit
Operation phase Parameter that defines the phase duration according to PLC design
Equipment in working mode during this phase controlled by PLC
Filling Timer or/and Level meter SBR mixing device Sludge liquors feeding pumps
Aerobic phase (1-2 phases during each cycle)
Time based controlled for the Min and Max lenght of the phase;
DO set point control the blowers B1 and B2
Settling Time based -
Decanting Time based or/and Level meter Disharge pump
WAS removal Time based or/and Level meter Decanting pump SBR mixing device
The PHA accumulating biomass selection SBR (R006) is fed by a centrifuge pump (P110) with a
flowrate of 5m3/h. It has been estimated that the P110 will work around 1h per day. The carbon
source is provided by a centrifuge pump (P111) with a flowrate of 5m3/h and it has been estimated
that P111 will work about 0.5h per day. The PHA accumulating biomass selection SBR (R006) is
emptied through a pneumatic valve (VP 105). The selection bioprocess occurs through a working
cycle which is composed by the following phases (in the same order): idle (0), feast (1), famine (2),
settling (3) and discharge (4). The duration of phase 0, 1, 2 and 3 can be set by the operator. After
the idle phase (0), feast phase (1) starts and carbon source feeding pump (P111) is switched on, but
only if the electro level sensor (LC004) of the carbon source storage tank (TK005) is not detecting the
“MIN” level. In concomitance with the beginning of phase 1, also blower (B3) is switched on. P111
control is time-based. When preset time of carbon dosage is reached, P111 is turned off and feast
phase continues until the achievement of maximum preset time. The dissolved oxygen concentration
during the feast phase is set by the operator and is monitored by a DO probe (DO002). Blower
working frequency is controlled through a variable frequency drive, to keep oxygen concentration to
the set-point value. After the achievement of maximum time of feast phase duration, famine phase
(2) starts and blower (B3) is turned off. In concomitance with the beginning of phase 2, mixer (M4) is
switched on, as well as the nitrified supernatant feeding pump (P110). P110 is controlled by an electro
level sensor (LC006). When the “MAX” level is reached, P110 is turned off. Phase 2 continues until
the achievement of maximum time-phase duration. After the famine phase, settling phase (3) starts
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and mixer is turned off. When time-limit of the phase is achieved, discharge phase (4) starts and the
pneumatic valve (VP105) is opened. This valve is controlled by the electro level sensor (LC006). When
the “MIN” level is detected, pneumatic valve is closed and a new working cycle starts (phase 0). The
table below reports the main operations of the selection SBR:
Table 23 Operation of the selection SBR
Operation phase Parameter that defines the phase duration according to PLC design
Equipment in working mode during this phase controlled by PLC
Filling Timer or/and Level meter SBR mixing device Sludge liquors feeding pumps
Aerobic phase (Feast phase) (1 phases during each cycle)
Time based controlled for the Min and Max lenght of the phase; Dosage of the carbon source according with a time based control
Frequency of the blower control by a PID algoritm
Anoxic phase (Famine phase) (1 phases during each cycle)
Time based controlled for the Min and Max lenght phases Dosage of the anaeronic supernatant after nitritation according with a time based control;
SBR mixing device; Anaerobic superantant feeding;
Settling Timer -
Decanting Timer or/and Level meter Disharge pump
WAS removal Timer or/and Level meter Decanting pump SBR mixing device
The accumulation SBR (R007) is fed manually by the operator through a manual valve (VM032). The
carbon source is provided through a centrifuge pump (P111) with a flowrate of 5m3/h. It has been
estimated that the pump will work. The accumulation SBR (R007) is manually discharged by the
operator through a manual valve (VM036). The accumulation bioprocess is manually activated by the
operator. The accumulation working cycle consists of two different phases (in the following order):
accumulation (1) and quenching (2). The duration of each phase can be set by the operator. When
phase 1 starts, both blower (B7) and carbon source feeding pump (P111) are switched on. P111
control is time-based: the carbon dosage takes place at regular time intervals which duration is
selected by the operator. For each time interval, a carbon dosage (spike) occurs: the carbon source
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feeding duration is set by the operator. The number of intervals (or carbon dosages) can be set by
the operator. When time-limit of the phase is achieved, quenching phase (2) starts and quenching
chemical pump (P113) is switched on. Blower (B7) works for all the duration of the phase. P113
control is time-based and the operating time is set by the operator. When time-limit of quenching
phase is achieved, blower is turned off and working cycle stops. Biomass is harvested in a thickening
tank (TK010) by opening a manual valve (VM036).
Table 24 Operation of the accumulation SBR
Operation phase Parameter that defines the phase duration according to PLC design
Equipment in working mode during this phase controlled by PLC
Filling Timer or/and Level meter SBR mixing device Sludge liquors feeding pumps
Aerobic phase (Feast phase) (1 phases during each cycle)
Time based controlled for the Min and Max lenght of the phase; Dosage of the carbon source according with a time based control
Frequency of the blower control by a PID algoritm
Quencing
Settling Timer -
Decanting Timer or/and Level meter Disharge pump
WAS removal Timer or/and Level meter Decanting pump SBR mixing device
4.3 Integrability of the Smartech 5 in existing WWTPs
Integrability issues Smartech 5
Technical Feasibiliy
1. Should new facilities always be
considered during the design and
implementation of the Smartech?
No. Prelimanary designed should be always performed
in order to consider the recovery of disused tanks or
the conversion of existing facilities in the WWTPs.
Morover, around 20% more volume is required for
Smartech 5 compared with Smartech 4a
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2. Does the implementation of the
Smartech imply a substantial change at
the present flowscheme of the WWTP?
Smartech 5 is a pilot system applied in the sidestream
of the anaerobic digestor and treats less than 10% of
the available anaerobic supernatant. The full scale
implementation of the Smartech 5 implies small and
not substantial changes at the present flowscheme of
the WWTP, such us new pipings for the anaerobic
supernatant and sewage sludge, as well as new
automation to control each stream.
3. Could the Smartech negatively impact
on the final discharge of the main
WWTP?
No, Smartech 5 contributes to improve the quality of
the final effluent, since the treated effluent from
Smartech 5 is supposed to contains up to 90% less
nitrogen compared with raw anaerobic supernatant.
However, even if the technology does not perform as
expected, the effluent will be treated in the main
WWTPs before its final discharge in the water body.
Acceptability of the Smartech
1. Is the Smartech 5 well accepted
among the operators?
The personnelle are used to operate and take care of
the Smartech 5 since it is considered an integrated and
useful compartment of the WWTP.
2. Are specific skills and/or tranings
required for the operators?
No additional specific trainings are required. The
knowledge and expertize already held by the
operators of the main WWTP are sufficient and
adequate for the operation of the Smartech 5. The
latter in fact uses the equipments typically adopted
also for conventional biological processes.
Bureaucratic issues
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1. Did Smartech 5 require a specific
authorization for its implementation?
Yes. The authorization for its implementation was
asked to the Regional Authority (see the attachment).
2. Are there any standards, regulations
or references applicable?
No, the Smartech 5 does not need to conform to
specific regulations.
4.4 Drawings ‘as built’
The drawings of the units are reported in the following annexes:
• Drawing 1: P&id of the SF1000
• Drawing 2: P&id of the Smartech 5
• Drawing 3: Fermentation unt
• Drawing 4: Layout of the Smartech 4a and 5
4.5 Pictures report
SMARTech 5 is reported in the figure below.
Figure 28 SMARTech 5 - Integrated container with rotating belt filter intalled
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Figure 29 SMARTech 5 - Hopper for the cellulosic primary sludge
Figure 30 SMARTech 5 - Installation of the Smartech 5
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Figure 31 SMARTech 5 - (a) Sequencing Batch Fermentation Reactor during the installation; (b) Sequencing Batch Fermentation Reactor placed in the platform
Figure 32 Ultrafiltration unit
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Figure 33 SMARTech 5 - Ultrafiltration system (right side) and crystallizer (right side)
Figure 34 SMARTech 5 - Left side,Nitritation, Selection and Accumulation SBRs; Right side, ultrafiltration system and cristallizer.
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Figure 35 SMARTech 5 - Air diffusion system for the nitritation, selection and accumulation SBR.
Figure 36 SMARTech 5 - Hydraulic testing