Sanitaire ICEAS

Xylem Water Solutions

Presentation Overview

• Intro & Experience• Why SBR? Why ICEAS? • Process Applications• ICEAS Process• ICEAS Operating Cycles• The ICEAS Advantages• ICEAS Process Control and

SIMS• Case Studies

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Our Mission

Sanitaire

Wastewater

Reuse

To Provide Cost Effective Biological Treatment Solutions to meet the Wastewater and Water Reuse Needs of Our Customers

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ICEAS

Intermittent Cycle Extended Aeration SystemDeveloped in Australia to Meet the Needs of Sparsely Populated Areas

ICEAS

Single Basin

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Depth of Experience

•Over 800 ICEAS/SBR facilities operating.•Flows from 10,000 GPD (38 m3/d) up to 130 MGD (492,000 m3/d).•Municipal and select Industrial applications.•Effluent quality guaranteed to 10/10/5/1 (BOD/TSS/TN/TP) w/out tertiary filtration.

Jefferson City, MO11 MGD Average Daily Flow, 50 MGD Peak Flow

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Why SBR?

When SBR is the Best Technology:

– BNR Requirements– Infinite available anaerobic and aerobic time settings

– High Peak to Average Flow Ratio (5:1)– Won’t wash out solids– Can operate with Second Storm

– Limited Land Availability– Uses less tanks, and smaller footprint than CAS

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Why ICEAS?

Advanced SBR Technology•Continuous Flow•Uniform Loading to all Basins•System Uses “Phase” Approach Compared

To Individual Tanks Used In A ConventionalActivated Sludge Process

•Aeration & Clarification in the Same Basin•Time-based Control System•Superior components

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• Domestic & Industrial Wastewater Treatment• BOD & TSS Removal• Nitrification & Denitrification• Biological Phosphorus Removal (BPR)

Process Applications

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Nominal Loading Rates: 15 – 20 lb BOD/1000 ft3F:M Ratio: 0.03 – 0.085 lb BOD/lb VSSSludge Age: 15 – 25 Days (warmer temps)

20 – 35 Days (cooler temps)HRT: 18 – 24 HoursSludge Yield: 0.65 or higher

ICEAS Typical Design Parameters

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1. React 2. Settle

3. Decant Treated Effluent

Continuous Flow of

Screened and Degritted Influent

Waste Sludge

ICEAS Operating Cycle

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ICEAS Process: Basin Layout

Pre-React Zone• Usually 12-15% of Basin Volume• Acts as Biological Selector• Discourages Filamentous Growth• Propagates Floc Formers• Allows for Continuous Flow• MLSS Concentration about ½ that of Main React Zone

• Continuous Supply of Carbon, Necessary for Bio-P Reactions

Main React Zone• Length to Width Ratio- Usually 3:1- Minimum 2:1

• Plug Flow Pattern• Top Water Level ~ 12-18+ feet

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ICEAS Basin Cross Section

Draw Down•Difference Between Top and Bottom Water Level

•Limited to 1/3 of TWL or Maximum 6 ft

•Function of Peak Flow and Cycle Times

Sludge Blanket

Buffer ZoneDrawdown

Buffer Zone• Typically 3 ft• Acts as

Safety Factor (20% when TWL = 15’)

• Occupied by Sludge Blanket if SVI > 150

Sludge Blanket• Function of

F:M Ratio• Function of

Influent Loading

• Target SVI = 150

• Chemical Sludge for Bio-P Removal Must be Included

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What About Short Circuiting?• Does NOT occur• Pre-react Zone HRT

- 3 hours @ ADF- Pre-react HRT > 2 hr period of Settle and Decant

• Basin Configuration- Proximity of decanters to downstream side of pre-react wall- Hydraulic displacement of clarified liquid required

• Existing Installations- Superior effluent quality even during storm conditions

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•Nitrification (NIT)•BOD & TSS Removal•Ammonia Nitrogen•Partial Denitrification

Typically Used For DomesticSewage

ICEAS NIT Operating Cycle

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ICEAS NDNP Operating Cycle

• Nitrification-Denitrification (NDN)

• Nitrogen removal• Bio-P removal

Stringent effluent requirements

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ICEAS Cycle Capabilities

• For higher peak to average flow ratios, can use second storm cycle

• For higher strength waste streams, can increase cycle time to accommodate more air per day

• For 3 or 4 basin system, can adjust decant duration to allow for continuous decant

• Decanter lowers at variable rates for normal, storm and second storm to allow for greater flexibility

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ICEAS Process Advantages

• Continuous Flow• Time Based Control System• Reduced Capitol Cost• Reduced O&M Cost• Expansion Opportunities

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Process Advantages: Continuous Flow

• Equal Flow and Load to ALL Basins at ALL Times• Diurnal Variations Received by ALL Basins• Biomass Characterized the Same in ALL Basins• Simplifies Process Adjustments • Allows for Single Basin Operation During Times of

Maintenance or Periods of Low Flow

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Process Advantages: Time Based Control System

• Effective Control of Process Cycles• High Flow Capability Without Solids Washout• Operator Friendly – Simplicity of Operation• System Uses “Phase” Approach• Handles Flow Variations Better than Flow Based Systems

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Process Advantages:Reduced Capitol Cost

Compared to SBR:– Smaller Footprint

– Less Volume Required(10-30%)

– Less Headloss– Active Decanter

– Built in emergency overflow

– Fewer Tanks– No Pre-or Post- EQ Tanks

– Less Equipment– No Influent Valves

Compared to CAS:– Smaller Footprint

– Less Volume Required– Fewer Tanks

– No Primary or Secondary Clarifiers

– Less Equipment– No Return Sludge Pumps– No Return Sludge Piping

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Process Advantages:Reduced O&M Cost

Highly Effective Sanitaire Aeration – Energy Savings of up to 60%

Easy-to-Access Equipment– Decanter is accessible from walkway– Pumps and mixers are on guide rails

Single Basin Operation– Can lead to 50% power savings with reduced loadings– No need for flow storage space when servicing a basin

Low Power Requirements– 2 Basin, 1.5 mgd, NIT cycle ~ 1,400 KWH/Day ~ 58 KWH/H– 2 Basin, 1.5 mgd, NDN Cycle ~ 1,700 KWH/Day ~ 71

KWH/H

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Process Advantages:Expansion Opportunities

Increased Loading – Phased expansion by

adding additional basins Future BNR Requirements

– Oversize initial basin size by 20%

– Increase blower capacity– Address location for future

mixers– Include BNR upgrade in

program cycle

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The Control System is the nucleus of the process, which operates the following equipment:

• Decanters• Aeration and Sludge Holding Tank

Blowers• Motorized Air Control Valves• Motorized Influent Valves • Waste Sludge Pumps • Submersible Mixers• Influent Pumps• Post Equalization Pumps• Chemical Feed System• Ancillary Controls • Drum Filters

ICEAS Process Control Systems

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Process Control CapabilitiesFeature

Plant controls designed, tested and built

Detailed electrical drawings

Library of standardized software blocks

BenefitProvides single point responsibility which results in minimal issues during commissioning and plant operation

Clearly identify all terminal connections

Proven basis of design

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The ICEAS Control System consists of the following equipment.

•Main control panel

Programmable Logic Controller (PLC)

Human Machine Interface (HMI)

•Motor Control Center (MCC) to house

•Instruments for analytical process, level, and flow measurement•Plant wide SCADA system to monitor and control the entire process

•Reporting Software for plant data

•SIMS (sludge inventory management system)

Control System Overview

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Control Switches & Pilot Lights Operation:

•Hand-OFF-AUTO for each device •Hand position is hardwired outside of PLC no interlocks

•Auto position will respond the PLC program with interlocks

•Pilot light will indicate equipment is running or at end of travel position

ICEAS Control System

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Plant Wide SCADA Integration System

FeatureWe have the technical competence to provide a solution

Process experts supported by fully staffed Electrical Engineering Department

BenefitCustomer is provided with a comprehensive solution ICEAS supplier takes full responsibility to insure proper plant operation including ancillary equipment

Accurate intuitive graphics and controls of the ICEAS process and ancillary equipment

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Plant Wide SCADA Integration System Advantages

FeatureCommon platform for all electrical hardware and software equipment

Coordinate Ancillary Controls

O&M files stored on the desk top PC as part of the SCADA system

Full trending for each process variable

BenefitUniformity of equipment; same look and feel for operator Optimize the performance of the influent and effluent equipment

Operator has ready access to technical information

Detailed information on overall performance of the system

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SIMS – Solids Inventory Management System

Sanitaire pioneered for the ICEAS system and is offered as part of our integrated solution

Algorithm was developed within the ICEAS PLC Logic

Intuitive graphics display for ease of operation and trending

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Case Studies

Kimmswick MO: medium plant, converted to BNR

Jefferson City MO: medium plant

Newville, PA: <2 mg/l TN, without filters

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Rock Creek SD - Kimmswick, MO WWTP

• Sewer District from 1979 condensed in 1999 • 32 square miles newly formed sewer district boundary• 8,000 dwelling units (approx. 22,000 PE)• Replace 14 treatment plants and 17 miles of interceptor• 2010 MWEA Plant of the Year

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ICEAS Process Selection

• Selected on basis of footprint, peak flow capability, proven effluent quality

• Oxidation Ditch ruled out due to site constraint

• MBR excessive cost

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Rock Creek SD - Kimmswick, MO WWTP• Four (4) Basin ICEAS NIT Design• Mississippi River discharge permit

30/30 BOD/TSS (<5/5/1 average typical)

• 4.8 MGD, 3.5 peaking factor• Four basins, 129’ x 63’ x 18’• Three 100 H.P. blowers. Two “duty”

blowers and one stand-by• Commissioned Sept 2004• Sanitaire provided complete ICEAS

equipment, SHT aeration, SIMS, SCADA and plant wide integration

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Cost Effective Ownership at Kimmswick

Treatment Plant Capital Cost (2002) = $2.12/gal. treated

Total Project cost $22M USD •$3.9M Engineering and other construction costs•$10.2M WWTP•$7.9M Interceptors

Operations Budget = $1.4M•$155,000 annual electricity spend (treatment, pumping, operations building)

Current median user charge $78/quarter

Plant Staff•1 Operations Supt•1 Lab Director•4 Maintenance •3 Operators

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Master Plan Upgrade - 2010

Original ICEAS design accommodated future nutrient removal• Denite Mix time• Basins size

Current Facility Plan (implemented 2011):• Submersible Mixers for enhanced nitrogen removal

• UV disinfection (future)• Controls Systems Modifications• Study current nutrient removal

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Controls Systems Modifications for NDN

• Reprogramming to decanters, PLC and SCADA

• Starters, control panel from original construction

• Install and terminate mixers• Possible chemical dosing for

Phosphorus

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Jefferson City WWTP, MO

•50,000 PE•Bar Screen/Grit removal/effluent pumping•Four (4) basin ICEAS – NIT process •11 MGD Average Daily Flow, 50 MGD Peak Flow.•$25 million project cost.•Startup 2002.•Effluent quality to 15/15/5 mg/l (BOD/TSS/NH3-N).

Jefferson City, MO

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Jefferson City WWTP, MO

• 2007 Plant of the Year > 1.0 MGD• 2007 William D. Hatfield winner Dave Erwin • 2007 Crystal Crucible winner Clara Haenchen• 2004 Laboratory Analyst Excellence winner Clara Haenchen

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Newville Borough, PA

Influent Wastewater Characteristics and Site Conditions

ADWF 600,000 gpd

PDWF 900,000 gpd

PWWF 1,300,000 gpd

BOD5 Conc. (at 20°C) 250 mg/L

BOD Loading 1251 lb/day

TSS Conc. 250 mg/L

TSS Loading 1251 lb/day

NH3-N Conc. 40 mg/L

NH3-N Loading 200 lb/day

Total Phosphorus Conc. 8 mg/L

Total Phosphorus Loading 40 lb/day

Alkalinity required (minimum) 169 mg/L

Wastewater Temperature 10 to 20 °C

ICEAS NDNP Process: 2-basin

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Newville Borough PA

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Newville Borough, PA

Effluent Quality Requirements

BOD5 Conc. (at 20°C) 10 mg/L

TSS Conc. 10 mg/L

NH3-N Conc. 1 mg/L

Total Nitrogen Conc. 8 mg/L

Total Phosphorus Conc.* 1 mg/L

*May require chemical addition.

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Sanitaire Customer Service• Proven process• Complete system approach• Cost Effective ownership• Provide top quality Customer Service• Work as a Team to Guarantee Success

- Design- Construction- Operation- After Sale Support and Training

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Questions?

www.sanitaire.com/us

Sanitaire, a xylem brand

9333 N. 49th St. Brown Deer WI

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