energy efficiency and capacity increase for aerobic treatment

Jaeger Group of Companies

Energy efficiency and capacity increase for aerobic treatment

Delivering customer value based on

40 years experience in fine bubble aeration

20 years innovation in IFAS textile fixed bed technology

40 Years of Innovation: Rubber. Jäger. Diffuser.

At the beginning of the 1970’s aeration

systems did not longer meet the

requirements of waste water treatment

entirely.

So Arnold Jäger developed cooperating with

the leading German wastewater treatment

plants the first rubber membrane diffuser.

Since 1975, Gummi-Jäger produced more

than 40 Millions membranes and diffusers

Arnold Jäger and his sons took out more

than 30 patents on aeration technology in

Europe and the USA.

The R&D team of the Jaeger Group

perpetually works to improve the aeration

technology. „„

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 2

We grew up with rubber

Since 1942 application-oriented advisory

service, material-oriented construction and

system related development are the key for

the Jäger Group’s success.

Our competence and efficiency continuously

raised according to the customers’ demands.

Our success is based on continuous product

innovation, advice independent from the

material as well as a friendly, competent

service and zero-defect philosophy

competent service.

The family business in its 3rd generation

operates worldwide and is a qualified partner

in the field of automotive, environmental and

agricultural industry as well as in machine

and plant engineering and crude oil

exploration.

© Jäger Umwelttechnik GmbH

25.02.2015 / Slide 3

Global presence in niche markets

25.02.2015 /

© Jäger- Unternehmensgruppe

Mechanical EngineeringRenewable Energy

Automotive Waste Water Treatment Agricultural TechnologyExploration Technology

Jäger Umwelt-Technik GmbH & Co. KG

Sales 5 Mio. Euro

Staff 7 Environmental Engineers

2 Sales & Marketing

10 Manufacturing staff

Locations Hannover (HQ) Germany

Vienna Austria

Bangkok Thailand

22 partners worldwide

Jäger Rubber & Plastics /(Shenzhen) Ltd.

Sales 3 Mio. Euro


10 Sales & Marketing

25 Manufacturing Staff

Locations Shenzhen (PRC)

Facts & Figures of the “Waste Water” group 2012


25.02.2015 / Seite 5

Characterization of wastewater

„normal“ inflow and„normal“

Concentration

„normal Load“ (e.g.

Dryweather)

Low inflowand low

Concentration

Low Load(e.g. Nights)

High inflowand high

Concentration

High Load(e.g. Surg)

high inflowand low

Concentration

„normale Load“ (e.g.

Rain Weather)

© Cleartec Water Management GmbH

25.02.2015 / Seite 6

Energy efficiency and capacity increase

IFAS (integrated fixed film activated sludge) textile fixed bed

combined with

Ultra fine bubble aeration


25.02.2015 / Slide 7

WWTP – Flow Chart

25.02.2015 / Slide 8

WWTP - Biological Stage


25.02.2015 / Seite 9

Conventional Activated Sludge Tank with suspended Biomass

Suspended heterotrophe

(for C-Elimination)

Suspended autotroph

(for Nitrification)

C

C

C

C

C

N

N

N

N

N

N

N

IFAS – Explanation


25.02.2015 / Seite 10

IFAS process (Integrated Fixed Film Activated Sluge) ActivatedSludge tank with Cleartec System

suspended combined with sessile biomass

IFAS textile fixed bed combined with ultra fine bubble aeration


25.02.2015 / Seite 11

Cleartec – a closer look

1 Growth stripes

2 Biofilm, sessile biomass

3 Flexibility

4 removal of old biomass

5 bacterial metabolism processes

6 aeration

7 vertical flow

8 suspended biomass

25.02.2015


/ Slide 12

Textile fixed bed: 2 basic materials


25.02.2015 / Seite 13

3-dimensional BioCurlz

6 laces per unit

Specific surface:

32m²/m²

2-dimensional BioTextile

flat woven fabric

Specific surface:

23m²/m²

2-dimensional Cleartec - fabric

25.02.2015 / Slide 14


3-dimensional BioCurlz

25.02.2015 / Slide 15


IFAS Cleartec Biotextile (1)


25.02.2015 / Seite 16

Significant expansion (up to 100%) with little

or no additional aerobic volume

Increased Biological Nutrient Removal

(BNR)

Improved solids settling (typical SVI’s less

than 80)

Greater resistance to hydraulic solids washout

Increased resilience to shock loading

Reduced solids flow to clarifiers, increasing

clarifier capacity

Up to 50% less energy than other

MBBR/Moving Bed IFAS systems

MBBR: OC 4-6 mg/l

Cleartec: OC <2 mg/l

IFAS impact on FST

Sludge from convantional ASTSVI 120 - 150

Sludge form IFAS ASTSVI 70 – 100


25.02.2015 / Seite 17

Normal settlement of Sludge Faster settlement, moresludge can be returned in lesstime

Comparison MBBR vs. Cleartec IFAS technology


25.02.2015 / Seite 18

The nature of the Cleartec

fixed-bed system results in

effective treatment without the

concerns associated with

moving bed systems.

No Media Migration in

basins or Media Loss into

the discharge waters

No Additional Aeration

Energy required for

Mixing

No requirement for fine

screening

No degradation to sludge

settle ability

MBBR

Moving bed reactor

Cleartec® textile installed in SS

frames with integrated aeration

Materialsmall moving polymer carriers,

cylindrical shaped, foamed

Polypropylen filaments woven to 3D

laces or2D fabric

Installation movable, free floatingflexible, fixed cages with integrated

aerators

Type of aerators coarse - fine bubble fine - mirco fine bubble

Energy consumption

High, high airflow required to prevent

settlement of carriers

OC > 5 mg/l

Low, low airflow to control thickness of

biofilm

OC 1,2 - 1,8 mg/l

Installation fixed, bottom mountedretrievable, integrated in cages, can be

lifted easy

Maintenancedewatering of tank and separation of

media required

cages with textile & aerators can be

lifted aside the tank, easy & safe access

to aerators

Specific surface for biomass

settlementup to 1.200 m²/m³ 600 - 1.000 m²/m³

Volume displacement of

fixed bedhigh (70% ) very low (<10%)

Energy consumption high low

middle - high high

agglomeration of carriers at outlet

(downstream)

fine screen required

additional clarifier capacity required

High resistance agains hydraulic shock

load

resistant against clogging / 3D perfusion

Improved slude settlement velocity/no

additional clarifier capacity required

Investment costs low middle

Technical

description

Pro

cess

de

scri

pti

on

Ae

rati

on

sys

tem

Process stability

Upgrade of WWTP Geiselbullach, Munich Germany (1)

TYPE OF WWTP Municipal

MAXIMUM FLOW 80. 000 m³/d

CAPACITY 250. 000 PE

BIOLOGICAL STAGE 2 lanes

2 anox tanks

2 anaerobic tanks

2 aerobic tanks

OPERATION upstream denitrification

Bio-P (additional P-precipation)

TREATMENT Nitrification

Denitrification

Bio-P


25.02.2015 / Seite 19

Stömungs-

Simulation

BioWin-

Simulation

C:/Users/ajaeger.AJH/Desktop/USB Stick JUT CWM 11_2013/Biowin Präsentation.pptx#1. PowerPoint-Präsentation

Position of the Cages in the aeration tanks


25.02.2015 / Seite 20

Retrofitting of WWTP Geiselbullach, Munich Germany (2)

1987: Start up

1995: Higher legal requirements in N-elimination led the operator to experiment

with different fixed-bed systems.

1996: Our initial development of a retiform textile media was installed.

2012: The IFAS system still provided the required effluent quality. But the aluminum

metal cages were corroded and failed.

2013: After more than 17 years of operation retrofit of the complete aeration system

1987

(without Cleartec®)

2013

(with Cleartec®)

ParameterInflow

[mg/l]

Effluent

[mg/l]

Biological

efficiency

[%]

Inflow

[mg/l]

Effluent

[mg/l]

Biological

efficiency

[%]

COD 310 53 82,9 543 22 95,9

BOD5 172 11 93,5 207 1,9 99,1

NH4-N 3632 11,1 32

3,04* 90,5

0,35** 98,9

*January-December

**Mai-October (consent value by legal requirement)


25.02.2015 /

Upgrade of WWTP Geiselbullach, Munich Germany (3)


25.02.2015 / Seite 22

Geiselbullach: High diffuser density equally spaced


25.02.2015 / Seite 23

Geiselbullach: Retrievable cages with IFAS textile and integrated diffusers


25.02.2015 / Seite 24

Geiselbullach: Pilot cage aeration tank

25.02.2015 / Slide 25


Geiselbullach: Biofilm / sessile biomass3 days after commissioning @ TS 6 g/l

25.02.2015 / Slide 26


WWTP Geiselbullach – Results of the commisioning phase

25.02.2015 / Slide 27


Biofilm / sessile biomass

2 Month after contact with waste water

Thick biofilm

Complete flow / no blocking

No redworms

No EPS

Suspended solids / TS 6 g/l

Comparison of Aeration Systems: Surface aerators (1)

Aeration rotors 700mm Aeration rotor 1.000mm


25.02.2015 / Seite 28

Comparison of Aeration Systems: Surface Aerator (2)


25.02.2015 / Seite 29

Comparison of Aeration Systems: Fine bubble diffusers

Line design Area design


25.02.2015 / Seite 30

Comparison of Aeration Systems: Fine bubble diffuser & mixer

Area design + additionally mixers


25.02.2015 / Seite 31

Energy coasts saving in Geselbullach 2014


25.02.2015 / Seite 32

JetFlex® HD Disc Diffuser HD-Series

JetFlex HD™ Disc Diffusers

Type HD 200

HD 270

HD 340

Effective Diameter 184mm / 7ʺ

218mm / 9ʺ

295mm / 12ʺ

Air Flow(depends on type)

1,5 – 4,0 m³/h / 7ʺ

1,5 – 7,0 m³/h / 9ʺ

2,0 – 10,0 m³/h / 12ʺ

Potential retrofit for

(None of these companies are not affiliated with the Jäger Group and the products we manufacture to retrofit these brands are neither original OEM equipment nor are they specifically approved for use by these manufacturers)

Sanitaire®

Nopon®

Aercor®

Envicon®

EDI®


25.02.2015 / Seite 33

Bubble size: Slit Pattern & Sizes

Slit Size Properties

0.5mm – 1.0mm(fine)

(C; E; F; H; P; Q; R, S, U; V; W)

• maximize oxygen transfer and mixing

• operation with low air flow per unit

• large number of diffusers needed

• high pressure loss by an increase of air flow

• high fouling and clogging potential

1.25mm-1.75mm(medium)

(D; G; J; K; L; T)

• adequate oxygen transfer by typical air flow rate

• pressure lost is modest

• reduce fouling potential

• long term service by reducing maintenance frequency

2.0mm – 3.0mm(coarse)(B; M; X)

• operation with high air flow but low oxygen transfer

• also low pressure lost

• minimum fouling or clogging

• special application (e.g. aquiculture)

GapSlit


25.02.2015 / Seite 34

Membrane Material for JetFlex™ Diffusers

Membrane Properties HD, TD TD, SD

EPDM Performance

EPDM Premium

(low plast.)

EPDM Special

(low plast.)

Silicone (VMQ)

Poly-Urethane(PU)

Plasticiser [%] 35 21 16 0 0

Polymer [%] 33 38 45 100 100

Carbon Black [%] 20 22 32 0 0

Others [%] 12 19 7 0 0

Hardness [Shore A] 40 ± 5 47 ± 5 53 ± 5 60 ± 5 N/A

Density [g/cm³] 1.09 ± 0.03 1.17 ± 0.02 1.11 ± 0.03 1.16 ± 0.03 1.18 ± 0.03

Operating Temperature

[°C] Air 5 to +60 5 to +60 5 to +60 +5 to +100 5 to +65

Tensile Strength [MPa] > 6 > 7 > 10 > 9 45

Elongation at Break

[%] > 400 > 400 > 600 > 600 > 600

Tear Strength [N/mm] > 6 > 4,5 > 7 > 35 70

Wall Thickness [mm] 1.9 ± 0.15 1.9 ± 0.15 1.9 ± 0.15 1.5 ± 0.15 0.70 ± 0.05

Application municipal municipal and industrial share industrial municipal and

industrial share


25.02.2015 / Seite 35


25.02.2015 / Seite 36

Material testing of disc membranes (unperforated)

HD 270 EPDM: Burst pressure 550 mbar

TD 65-100 EPDM: Burst pressure 250 mbar

JetFlex® TD Tube Diffusers

JetFlex TD™ Tube Diffusers

Standard Type TD 63

TD 65-2

TD 90-2

Perforated Length 1000mm

750mm

500mm

Bubble Size fine (0,5 - 1,0mm)

medium (1,25 - 1,75mm)

coarse(2,0 - 3,0mm)

Air Flow (according to tube length)

2,0 – 12,0 m³/h


25.02.2015 / Seite 37

JetFlex® SD Strip Diffusers

JetFlex SD™ Strip Diffusers

Standard Type SD180/1500

SD180/2000

Active membrane aerea SD180/1500:0,24 m²

SD180/2000:0,32 m²

Bubble Size ultra fine (0,2 - 1,0mm)

Specific oxygen transfer rate (per m membrane length):

18 – 30 gO2/(Sm³·m)

(depending on bottom coverage and specific air load)

Air Flow SD180/1500:2,0 – 29,0 m³/h

SD180/2000:2,0 – 38,0 m³/h


25.02.2015 / Seite 38

JetFlex® high efficiency PU strip diffuser


25.02.2015 / Seite 39

Comparison of oxygen transfer rate and operation range


25.02.2015 / Seite 40

10

12

14

16

18

20

22

24

26

28

30

3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

gO

2/S

m³

Sm³/h.diff

Strip Diffuser SD180/2000

Tube Diffuser TD65-2-G1

Disc Diffuser HD340

Retrievable aeration system (strip diffuser)


25.02.2015 / Seite 41

Retrievable aeration system (strip diffuser)


25.02.2015 / Seite 42


25.02.2015 / Seite 43

Three functional zones can be differedwhen viewing an installed Cleartec® cage:

1. The lower sideflow zone:

Place where the diffusers are located.The distance from the diffusers to theBiotextile/BioCurlz should be between 40 –50 cm.

2. The media zone:

The media zone is the area between lowerand upper supporting bar.Within the media zone the flow is assumedto be mainly vertical-upstream.

3. The upper sideflow zone:

The upper sideflow zone lies betweenupper supporting bar and water level ofthe tank.

Functional Zones

Flow Simulation in the aereated Tanks


25.02.2015 / Seite 44

Cages positioning


25.02.2015 / Seite 45

The cages can be distributed in all the tanks with free distancesbetween the cages.

Flow cascade with Biotextil Cleartec


25.02.2015 / Seite 46

Anordnung mehrerer Festbetten


25.02.2015 / Seite 47

Back

Increased efficiency by high diffuser density


25.02.2015 / Seite 48

Distance between diffusers 0.5m 1,0m 2,0m

Bottom coverage [floor area vs. membrane area]

28% 14% 7%

Correction to 100% bottom

coverage

-11% -13% -23%

Air flow rate 224 Sm³/h 272 Sm³/h 341 Sm³/h

Energy consumption 6.4 kW 7.6 kW 10.1 kW

SAE efficiency 3.9 kgO2/kWh 3.3 kgO2/kWh 2.5kgO2/kWh

Different bottom coverage ratios for 25 kgO2/h

Low air flows also help to increase efficiency

Lower air flow rate:

꞊ higher oxygen transfer rate SOTE

꞊ lower headlossin mbar

꞊ less energy con-sumption overall

꞊ lower OPEX

But: higher CAPEX


25.02.2015 / Seite 49

Abstract of References

WWTP Weißenborn

Weißenborn, Germany

Operating since 1999

Municipal, 5.500 PE

New plant with complete nitrification


25.02.2015 / Seite 50

90

20 18

10

50

1510

5

23

3,5 3,7 1,3

0

10

20

30

40

50

60

70

80

90

100

CSB BSB5 Nges NH4-N

[mg

/l]

2008-2010

Legal requirements

Target value

Discharge

Biological efficiency [%]

CSB 93,7

BSB5 98,3

NH4-N 93,1


WWTP- Terrassa

Terrassa, Spain


Municipal, 450.000 PE

Upgrading, Increase of performance (C + N + P)


25.02.2015 / Seite 51


WWTP Kelleramt

Unterlunkhofen, Switzerland


Municipal, 12.800 PE

2013 Upgrade to 21.300 EW

Increase of performance, nitrification


25.02.2015 / Seite 52

Jäger Umwelt-Technik GmbH & Co. KG

Sales 5 Mio. Euro


2 Sales & Marketing

10 Manufacturing staff

Locations Hannover (HQ) Germany

Vienna Austria

Bangkok Thailand

22 partners worldwide

Jäger Rubber & Plastics /(Shenzhen) Ltd.

Sales 3 Mio. Euro


10 Sales & Marketing

25 Manufacturing Staff

Locations Shenzhen (PRC)

Kelleramt Modell in BioWin


25.02.2015 / Seite 53

Spezifikation der Media in dem Modell


25.02.2015 / Seite 54

Spezifikation der Nachklärung in dem Modell


25.02.2015 / Seite 55

Ausgangswerte N, P


25.02.2015 / Seite 56

Presented by:

Thank you for your attention.

Jäger Umwelt-Technik GmbH & Co. KGRuscheplatenstraße 1431137 Hildesheim

Tel. 05121 9138 900Fax. 05121 9138 999

[email protected]

Dipl.-Eng. Samer Alkhaddour

Region Manager (MENA)

25.02.2015


/ Seite 57

Disclaimer: This information is based on our present state of knowledge and is intended to provide general notes on our products and their uses.

It should not therefore be construed as guaranteeing specific properties of the products described or their suitability for a particular application.

Any existing industrial property rights must be observed. The quality of our products is guaranteed under our General Conditions of Sale.

A company of the Jäger Group

energy efficiency and capacity increase for aerobic treatment

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