GE Water & Process Technologies

Application of UF/MBR Technology for Industrial Wastewater Reuse

Eur. Ing. Simon Morris CEng, CEnv, CSci, MIChemE

Envirolink Northwest – April 2nd 2008

2 /Connelly /

Water ReuseWater recycling = Reusing treated wastewater for beneficial

purposes

Good environmental policy, but high-quality effluent required

Main beneficial uses: boiler feedwater pretreatment, cooling tower make-up, toilet fixture flushwater, irrigation, groundwater recharge

3 /Connelly /

Water Reuse Drivers

Reduced allowable discharge flows and loads to downstream treatment facilities

Increasing water purchase and discharge costs

Regional water scarcity, less availability for process use

Focus on better environmental stewardship

Irrigation

Process Water

Aquifer Recharge

4 /Connelly /

Membranes for Water ReuseAdvances in membrane technology have made water reuse a technically-feasible & cost-effective solutionMembranes can reclaim effluents to almost ultra-pure quality & generate significant cost savings

Wastewater reclamation with low pressure membrane technologies is significantly cheaper than RO desalination to produce water for irrigationMembranes can directly treat activated sludge (MBR) or can be used to polish secondary effluent (tertiary treatment)A 220,000 sq. ft. bank/office building in Houston

was one of the first of its kind to use an on-site membrane reuse system (1985)

5 /Connelly /

Membranes are Rapidly Replacing Conventional Technology

Conventional Treatment19th century technology Large land requirementCoarse filtration, no physical barrierNeed multiple steps for coarse filtrationLabor and chemical intensiveDependent on chlorine for disinfection

ZeeWeed Membrane TreatmentModern and continuously improvingCompact footprint; Allows for expansion Physical barrier means higher quality water at all timesSingle step provides simpler operationFully automated with minimal chemicals

6 /Connelly /

Immersed hollow fibreconstructionReinforced membrane structureOutside-in operationPVDF Chemistry• Oxidant resistant

(500,000 ppm-hr Cl2)• Wide pH range

–Filtration: 5 to 9.5 pH–Cleaning: 2 to 11 pH

Compatible with coagulants & PACNSF61 certified

MembraneFiber

Electron microscope view of membrane surface

The ZeeWeed 500 UF Membrane

7 /Connelly /

Biological reactor

ZeeWeed membranes

The ZeeWeed MBR ProcessCIP system

RAS pump

Permeate pump

8 /Connelly /

ZeeWeed = Consistent High Quality Effluent

< 2.2 CFU/100 mL**Fecal Coliform

Achievable ZeeWeedTreatment Results

< 3SDI

< 0.1 NTUTurbidity< 0.05 mg/L*TP< 3 mg/L*TN< 0.05 mg/LNH3-N< 1 mg/LTSS< 2 mg/LBOD5

* With appropriate biological design ** After disinfection

ZeeWeed MBR selected by the City of Corona, CA for its small footprint and the ability to meet Title 22 discharge regulations

Reusing the majority of their existing infrastructure, the city of Woodstock, GA converted a 0.5 MGD (1,893 m3/d) SBR into a 2 MGD (7,570 m3/d) ZeeWeed MBR

9 /Connelly /

Water Reuse Product Line-up

•ZeeWeed® Membrane Bioreactor (MBR)

•ZeeWeed® Tertiary Filtration (direct filtration of secondary effluent)

•Both ZeeWeed® MBR and Tertiary systems may be combined with Reverse Osmosis (RO) for higher quality effluent reuse applications

10 /Connelly /

MBR Reuse Case Studies

11 /Connelly /

Combining Industrial Reuse with Municipal Wastewater Treatment

ZeeWeed® MBR and tertiary filtration produce a high quality effluent suitable for direct reuse

Growing interest by industries to use nearby municipal WWTP effluent as a replacement for surface water in various process applications

ZeeWeed® MBR effluent from the Redlands, CA WWTP is used at the local power plant

ZeeWeed® tertiary effluent from the Gold Bar, AB WWTP is reused in the neighboring Petro-Canada refinery

12 /Connelly /

ABR Wietzendorf, Germany (0.6 MGD)Potato Starch Production

Overview• ZeeWeed® UF for MBR/RO reuse of

potato processing wastewater• Phase 1 commissioned in July 2002• Phase 2 commissioned in Sept 2003• ZeeWeed® 500 membranes

Key Features• ZeeWeed® permeate feeds RO• RO water reused in the process

for washing potato starch • Permeate COD ＜85 mg/l • Permeate TKN ＜10 mg/l • Permeate PO4-P ＜1.5 mg/l

13 /Connelly /

Chungwa Picture Tube III, Taiwan (1.1 MGD)TFT-LCD Manufacturing

Overview• Third of 5 ZeeWeed® UF systems for

MBR/RO reuse within the plant• Commissioned in March 2003• 4 trains of ZeeWeed® 500 membranes

Key Features• RO permeate reused in the process• Consistent effluent quality in spite of

highly variable COD load • Permeate COD ＜35.2 mg/l (97+%

removal)• Permeate BOD ＜6.5 mg/l

14 /Connelly /

Major Food Manufacturer, UK (1,600 m3/day)Multi-product facility

Overview• Client expanded facility but was

unable to obtain additional potable water volumes from municipality (availability and hydraulic issues)

• Solution is to reuse effluent for non-product purposes on site

• ZeeWeed® UF for MBR/RO reuse of fruit, vegetable and meat processing wastewater

• Currently undergoing commissioning

Key Features• ZeeWeed® permeate feeds RO• <3 SDI, <0.2 NTU, <5 TSS• RO water reused at various

locations on-site

15 /Connelly /

Tertiary Reuse Case Studies

16 /Connelly /

Yanshan Petrochemical, China (6.9 MGD)Petrochemical Refining

Overview• ZeeWeed® UF for tertiary

treatment and reuse of petroleum wastewater

• Commissioned in July 2004• ZeeWeed® 500 membranes

Key Features• Four trains ZeeWeed® UF• ZeeWeed® permeate feeds RO

for demineralized process water• Permeate TSS ＜1 mg/l • Permeate Turbidity ＜0.2 NTU • Permeate SDI ＜3

17 /Connelly /

PEMEX Minatitlán Oil Refinery, Mexico (7 MGD)Petroleum Refining

Overview• ZeeWeed® UF tertiary pre-

treatment to Reverse Osmosis treating refinery effluent

• Commissioned in November 2001• ZeeWeed® 500 membranes

Key Features• Seven independent ZeeWeed® UF

trains• Small footprint reduced installation

costs and allowed the entire plant to be fit in existing space

• TSS < 1 mg/L • SDI of < 3.0 • Turbidity of < 0.1 NTU

18 /Connelly /

E.C. Katowice, Poland (1.4 MGD)Power Production

Overview• Treats secondary effluent from

municipal WWTP for use as Katowice Power Plant cooling circuit feedwater

• Commissioned in October 1999• ZeeWeed® 500 membranes

Key Features• Three trains ZeeWeed® UF • Design performance:

•NTU < 0,05 mg/l•SDI < 1•Particles < 15 per ml•Bacterial count = nd

19 /Connelly /

Bedok, Singapore (11.25 MGD)Semiconductor Manufacturing

Overview• Treats secondary effluent from

municipal WWTP for pre-treatment to RO for water re-use

• Commissioned in November 2002• ZeeWeed® 500 membranes

Key Features• Five trains ZeeWeed® UF • Supply high quality product water

to wafer-fab industry• Design performance:

•Turbidity < 0.2 NTU•SDI < 3•90% Recovery

20 /Connelly /

Bedok, Singapore (11.25 MGD)UF System Gallery and Interactive Visitor Center

21 /Connelly /

Bedok, SingaporeDriver: Water Re-Use

22 /Connelly /

Bedok, SingaporeExterior Building

23 /Connelly /

Bedok, SingaporeUltrafiltration Gallery

24 /Connelly /

Bedok, SingaporeRO Gallery

25 /Connelly /

ConocoPhilips, UK• Early 2004: ConocoPhilips European Power

commissions the largest combined heat & power (CHP) plant in Europe at South Killingholme, North Lincolnshire, UK

• The £350m, 730 MW plant supplies electricity & steam to the neighbouring ConocoPhilipsHumber & TotalFinaElf Lindsey refineries

• The two refineries combined account for 25% of the UK’s current refining capacity

• Humber is the third largest refinery in the UK• Excess electricity exported to the National

Grid• Consent given in August 2006 to increase

CHP plant capacity further to 1,230 MW

26 /Connelly /

ConocoPhilips, UKCHP plant & refinery synergies:• Humber refinery’s power and heat

supply upgraded to meet future growth• CHP makes use of refining by-products

such as waste gas which would otherwise be flared off

• Existing refinery wastewater is treated and reused for cooling tower makeup in the CHP plant

27 /Connelly /

ConocoPhilips, UK• Existing MMF/GAC/RO system not

working well (frequent RO elementcleaning)

• Improved solution required by 2007

• June – Sept 2005: pilot trial showed effectiveness of ZeeWeed 500 UF membrane to reduce SDI & organic load suitable for RO pretreatment• SDI < 1.9 throughout the pilot

• GE awarded the project in Q1 2006

28 /Connelly /

ConocoPhilips, UK• System treats combined wastewater flows

from the Humber Oil Refinery & Lindsey Oil Refinery

• Wastewater consists of refinery desalters, API separators and sour water strippers

• System also designed to treat cooling tower blow down & municipal raw wastewater

• ZeeWeed® UF tertiary treatment system installed upstream of the RO membranes, replacing MMF / GAC

• DAF upstream of the UF membranes

29 /Connelly /

ConocoPhilips, UK• UF configuration: 4 x 25% trains of ZeeWeed®

• Peak feed flow: 575 m3/hr (3.6 MGD)• Average feed flow: 500 m3/hr (3.2 MGD)

15 mg/LFOG3,000 µsConductivity3,800 cells/mL, seasonalAlgae30 mg/L (~5 mg/L with DAF)TOC46 mg/L (~5 mg/L with DAF)TSS50 NTU (~2 NTU with DAF)Turbidity

ValueParameter

Influent Wastewater Characteristics

30 /Connelly /

ConocoPhilips, UK

<0.1 NTUTurbidity90%Recovery

<3 SDI<1 mg/LTSS3-5 mg/LTOC450 m3/hr (2.85 MGD)Design permeate flow517.5 m3/hr (3.28 MGD)Peak permeate flow

ValueParameter

UF Permeate (RO Feed) Quality

31 /Connelly /

Nanjing Automobile Corporation (NAC), UKAutomobile manufacturing facility

Overview• £53M acquisition of MG Rover Group in 2005• Re-opened Longbridge manufacturing plant in

2007 to produce MG TF sports car• DAF plus ZeeWeed® UF for tertiary wastewater

treatment to enable reuse on site• System delivered and commissioned 2007

Key Features• 32 m3/hr ZeeWeed® 1000

package plant• Feed to RO unit• RO water reused at various

locations on-site

32 /Connelly /

GE Wastewater Treatment System Advantages…

…turning waste products into valuable resources

Eliminate discharge finesReduce wastewater treatment costsReduce clean water purchase costsSecure new source of process waterAchieve higher level of facility self-sufficiencyAchieve Zero Liquid Discharge via reusing wastewater Allow clients to become an environmental steward in their community

Questions?

Simon.Morris1@ge.com