Development, Challenges, and

Validation of a High Efficiency

UV Unit

Wayne M. Emery, P.E.

Calgon Carbon Corp

Presentation Outline

Introduction

System Details

Delta Wings

Case Study

Title 22

System Sizing

Installations

Closing Remarks

Who is Calgon Carbon?

We solve customer purification

and separation problems with

a variety of technologies

World’s Largest Producer of

Granular Activated Carbon

Diverse Product Portfolio

900+ employees

240 patents

10 sales offices – 6 countries

14 manufacturing facilities – 6

countries

Revenues: > $500 M

On New York Stock Exchange

(CCC)

60 + Years of Experience in

Water Treatment

UV Technologies Division

25 year track record in UV water

treatment

UV products for treating

contaminated water, wastewater,

drinking water and ballast water

Pioneered the use of UV

technology for the inactivation of

Cryptosporidium and Giardia in

drinking water

> 500 installations

Located and manufactured in the

Pittsburgh, PA area

Calgon Carbon’s UV Technologies

Drinking Water Disinfection – to inactivate pathogenic bacteria, viruses, and protozoa (Cryptosporidium and Giardia control)

Wastewater Disinfection – to reduce chlorine discharge into the environment

Advanced Oxidation – to destroy toxic chemical contaminants

Ballast Water Treatment – to remove or kill invasive species transported by marine vessels

Calgon Carbon’s UV History

Started in Advanced Oxidation (MP + Hydrogen Peroxide): 1985, acquired by CCC in 1996

Progressed to Drinking Water with MP: 1997, CCC innovation

Entered Wastewater Market with LP: 2004, CCC acquisition 2004

Entered Ballast Water Market (MP UV and filtration): 1995, acquired by CCC 2010

How Should You Want Your System

Designed?

Use advanced science and technology to develop products

Bioassay validated products – true sizing and performance verification, not just “manufacturer’s claims”

Make sure the system won’t have to be ‘upgraded’ due to performance or design issues

Use high powered lamps for WW open channel – basis for low O&M and smallest footprint

Focus on real Cost of Ownership for lowest 20 year Net Present Value

Typical System

8 lamps per rack, max.

Interchangeable design

Individually isolated

Designed to comply with

IP67 for intermittent

submergence

Cleaning system is

electrically driven

minimizing number of

components

Two cable assemblies

per rack each powering

4 lamps

Technical Details – Lamp Rack

Lamp

Data

Technical Details – Lamp 520 W low pressure high output pellet amalgam lamp

Up to 205 W of UVc output

Coated lamp for longer life, 12,000 hour guarantee

Pre-heat start configuration to reduce the effects of cycling due to

process conditions such as Sequential Batch Reactors

Continuous heat configuration for power savings and extended lamp

life

Technical Details –

Cleaning System

UV sensor, factory

calibrated to DVGW

reference standard

One sensor per UV

bank

Value used in dose

calculation to allow

maximum turn-down

when Dose Pacing

enabled

Maximize energy

savings

Technical Details – UV Sensor

Designed to comply

with NEMA 4X (IP 65)

ratings

Each supplied with main

breaker and lockable

doors

Operator Station on

front door allows

Operators to view PDC

status and control PDC

manually, if required

Technical Details – PDC

Each Ballast drive one lamp

Variable output 60 to 100%

Powered by single phase

220 - 277VAC, 60 Hz

Interchangeable, addressed

via slot in card cage

Individual lamp failure

indication reported locally via

LED and remotely at SCC

System Power Factor > 0.98

at full power

Complies with Current Total

Harmonics Distortion

guidelines specified in IEEE

519-1992 standards

Technical Details – Ballast

UV System Control Center

Allen Bradley

CompactLogix or

ControlLogix PLC

Allen Bradley

PanelView Plus

600/1000/1500

Standard Designs

Weir

Level Control Gate

Level Control

Motorized Weir Gate

Delta Wings

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 0.5 1 1.5 2 2.5 3

Re

lati

ve

Irr

ad

ian

ce

Distance from Lamp, in

65%T

55%T

Irradiance drops off exponentially with distance

from the lamps

Background

Relative Irradiance at the center point between 4 lamps in a square lamp array vs.

lamp spacing between adjacent lamps in the array

Center point has

the lowest intensity

x

x

0%

5%

10%

15%

20%

25%

30%

2 2.5 3 3.5 4 4.5 5

Re

lati

ve

Irr

ad

ian

ce

at

Ce

nte

r P

oin

t

Spacing Between Lamps, in

65%T

55%T

Relative Irradiance in Lamp Array

To maintain the same hydraulic efficiency, the flow per

lamp must be proportional to the Lamp Power

Lamp spacing must be increased to limit the pressure

drop due to the increased flow per lamp (velocity)

Increased lamp spacing results in poor dose distribution

and hence lower hydraulic efficiency

We calculate a limit of approx. 300 Watts per lamp for 3

to 4 inch spacing at 55 and 65%T, respectively

HOW DO WE ACHIEVE ACCEPTABLE HYDRAULIC

EFFICIENCY WHEN WE HAVE CONFLICTING

REQUIREMENTS.

The Challenge with Higher Power

Amalgam Lamps

Design an open channel UV disinfection

system with 500 to 600 Watt lamps that:

Complies with NWRI guidelines

Produces a high MS2 RED at relatively low

flows

Optimizes hydraulics efficiency due to larger

lamp spacing required for higher power

lamps

Design Requirements

Mixing devices - Delta Wings

Create large scale counter-

rotating vortices.

Transports the water:

farthest from the lamps in

towards the lamps

close to the lamp moved away

from the lamps

Permits lamps of 500 Watts

and greater to be employed

The Solution - Mixing

Development of mixing

device to increase the

hydraulic efficiency of the

UV reactor

Use patent # 6,015,229,

dated Jan. 18, 2000,

issued to Calgon Carbon

as basis of design

Research & Development

Flow across a delta

wing inclined to the

flow of water

produces two

counter-rotating

vortices

How does a Delta Wing work?

CFD analysis of UV reactor without mixing

High fluence rate

around lamp,

lower fluence

between lamps

CFD Analysis

Velocity vectors showing

Vortices generated by Delta Wings

No Mixing 1 set of Delta Wings 3 sets of Delta Wings

MS2 Concentration as the fluid exits the UV Bank Array

CFD Modeling of Delta Wings

Performance of mixing devices

10

12

14

16

18

20

22

24

0 1 2 3 4

Number of Delta Wings

MS

2 R

ED

mJ

/cm

2

C3500D Research & Development

Pilot system tested with and without

Delta Wings

Worked with the University of Toronto and

GAP Enviro Microbial Services to test the

various combinations

Secondary effluent with MS2 & T1 phage

added as surrogate organisms

UV Transmission ranged from 50 – 70%

using SuperHume™

Pilot Tests

PDC

UV Bank

Flow Meter

Valve

Pump

MS2 & T1 Dosing

C3500D Piloting

0

20

40

60

80

100

120

140

20 40 60 80 100

Flow

MS

2 R

ED

50%T w/o Delta

60%T w/o Delta

67%T w/o Delta

50%T w Delta

60%T w Delta

67%T w Delta

Pilot Tests with & without Delta

Wings

Product Finalization

Product Finalization

Pilot test site at Stockton

WWTP, CA

Carollo Engineers as 3rd

Party Engineer

Low dose (T1) and

NWRI (MS2) testing

simultaneously

UVT range: 35 – 74%

Flow range: 0.7 - 4.3

MGD

NWRI Validation

Case Study:

City of Stockton, CA

• Peak Flow: 55 MGD

• Average Flow: 38 MGD

• UV Dose: 110 mJ/cm2, 70 mJ/cm2,

50 mJ/cm2

• UVT: 65%

• Total Coliform Permit Limit: 2.2 CFU/100

mL, based on a 7 day median

• Power Cost: $0.12/kWh

• Labor Cost: $50/hour

Case Study – Design Parameters

Detailed Cost

Analysis

Type of UV # Channel/Trains # Reactors/Trains Total # Lamps Footprint

110 mJ/cm2

MP 15 2 540 104' x 90'

LPHO A 4 2 4032 120' x 110'

LPHO B 4 4 3072 160' x 50'

C3 500TMD 4 4 1792 140' x 60'

70 mJ/cm2

MP 9 2 324 104' x 55'

LPHO A 3 2 2592 120' x 75'

LPHO B 3 4 1920 150' x 45'

C3 500TMD 3 3 1152 150' x 40'

50 mJ/cm2

MP 12 1 216 63' x 99'

LPHO A 3 2 1728 90' x 60'

LPHO B 3 3 1296 36' x 150'

C3 500TMD 3 2 768 40' x 130'

Equipment & Footprint Decreases

with Increased Efficiency

$0

$200,000

$400,000

$600,000

$800,000

$1,000,000

$1,200,000

$1,400,000

$1,600,000

$1,800,000

$2,000,000

110 70 50

Dose, mJ cm-2

An

nu

al O

&M

Co

st,

$

C 3

50

0

LP

HO

A

MP

MP

MP

C 3

50

0

C 3

50

0

LP

HO

B

LP

HO

A

LP

HO

A

LP

HO

B

LP

HO

B

Efficient C3500D System Allows

for Most Cost Effective O&M

$0

$5,000,000

$10,000,000

$15,000,000

$20,000,000

$25,000,000

$30,000,000

$35,000,000

$40,000,000

$45,000,000

$50,000,000

110 70 50

Dose, mJ cm-2

Lif

e C

yc

le C

os

t, $

C 3

50

0

LP

HO

A

MP

MP

MP

C 3

50

0

C 3

50

0

LP

HO

B

LP

HO

A

LP

HO

A

LP

HO

B

LP

HO

B

Efficient C3500D System Allows

for Most Cost Effective Life Cycle

Summary

High LPHO UV lamp output

Optimized lamp spacing overcomes substantial

head loss

Fewer lamps than other LPHO systems

Decreased equipment costs

Decreased installation/construction costs

Decreased O&M costs

C3500D Validation Illustrates

High Level of Disinfection &

Germicidal Efficiency

Title 22

Calgon Carbon receives Conditional

Acceptance for the C3500D from CDPH –

December, 2011

Check-point Bioassay –

Field Challenges

Channel dimensions

Channel hydraulics

Channel flow distribution

Level Control

Fouling and EOLL design factors

These items are easy to confirm via measurement and

velocity profiling, prior to commencement of check-point

bioassay.

Installations

Typical Open Channel Installation

Baker Heights, WV

Eastman, GA

Eastman, GA

Baker Heights, WV

Closing Remarks

C3500D UV SYSTEM

Conditional Acceptance from CDPH

Smallest footprint. Less Lamps to buy, install, and

maintain, leading to lower Capital and O&M costs.

Delta configuration puts the flow where you want it, next

to the lamp.

Proven mechanical only cleaning. No chemicals to buy,

store or leak.

Ballasts are located in the Power Distribution Center as

opposed to the head of the rack. When the channel

floods, the ballasts are kept out of harms way.

This bioassay validated system will meet specified

permit limit – guaranteed.

Thank You