Use of Biowin for Process Troubleshooting / Design for a Unique WastewaterOWEA Plant Operations and Lab Analysis Workshop

W. James Gellner

Outline

• Introduction / Problem Overview– Plant Issues– Biowin Overview

• Special Sampling• Simulations for Plant Troubleshooting• Simulations for Upgrade Design• Summary / Conclusions

Plant Overview

• Turkey processing plant• 37,000 turkeys per day• Direct discharge permit• Repeated ammonia and

solids violations led to IDEM Agreed Order

• ATS hired to perform CPE

Plant Schematic

PROCESSING PLANT(Kill Through Deboning

– Including All Screening)

CLARIFICATION TANK

(0.22 MG)

DISINFECTION (UV)

RAS

WAS

EFFLUENT

ACTIVATED SLUDGE TANK

(0.83 MG)

ANAEROBIC LAGOONS / FLOW

EQUILIZATION(2.24 MG, 8.52 MG)

AEROBIC LAGOONS / BACKUP FLOW EQUILIZATION

(9.07 MG)

TERTIARY FILTRATION(Schrelber

Fuzzy Filter, 0.4 microns) CASCADE

AERATION

EMERGANCYBYPASS

CHEMICAL ADDITION (pH & Alkalinity Control,

Hydrated Lime)

Effluent Requirements

Parameter 30 Day Concentration (mg/l)

Daily Concentration (mg/l)

BOD5 20 30Total Suspended Solids 20 30

Ammonia (summer) 0.93 1.85Ammonia (winter) 1.77 3.54

Oil and Grease 10 15E coli 125/100 mls 235/100 mls

pH > 6.0 S.U. and < 9.0 S.U.Dissolved Oxygen > 6 mg/l winter

> 5 mg/l summer

Influent Loadings

Parameter Average Daily MaximumFlow 0.61 MGD 1.20 MGD

BOD5 3860 lb/day (760 mg/l) 8060 lb/dayCOD 8190 lb/day (1610 mg/l) 13300 lb/dayTSS 1120 lb/day (220 mg/l) 2070lb/dayNH3 790 lb/day (155 mg/l) 1620 lb/day

Alkalinity 3120 lb/day (610 mg/l) 5280 lb/day

ATS / Hazen and Sawyer

• 11/2008• CPE / Process Evaluation

– Detailed sampling & analysis

• DAF implementation• Design of improvements

Ammonia / Solids Violations

• Repeated (inconsistent operations)• Overwasting of biological solids• Lagoon solids slugs• Overfeed of lime to biological system• Poor settling – filaments• “FLIP!”

BioWin Overview

• Full plant simulation software• ASDM – Activated Sludge/Anaerobic

Digestion (IWA) • Graphical user interface

– User friendly, Windows style• Requires detailed characterization

Influent (Eff ANA#2) Schreiber MLSS Tank Final Clarifier

WAS

FC EffluentRAS Mixer

RAS/WAS Splitter

Influent Mixer

Lime

BioWin Overview (cont)• Steady state / dynamic

simulations• Tailored to domestic

waste• Ability to

import/export data• Allows multiple

simulations for what-if and process sizing analysis

Why Use Biowin?

• Process troubleshooting tool– Evaluate effect of solids on system performance

• Operations staff education– Simulations provide good examples for

operations staff• Design tool

– Size / optimize new processes for improvements

Special Sampling

• Characterize influent• Capture process

conditions• Allow for accurate

representation of process performance

COD Components

Total COD

Biodegradable

Soluble Particulate

Unbiodegradable

Soluble Particulate

TKN Components

Total TKN

Free Ammonia Organic Nitrogen

Biodegradable

Soluble Particulate

Unbiodegradable

Soluble Particulate

“The Filtration Tree”

Symbol Filter RepresentationXX Not filtered Represents total sample (with

particulate and soluble)XG Glass fiber –

1.5 micronTraditional breakpoint between particulate and soluble

XM Membrane filter – 0.45 micron

Difference between XM and XG represents colloidal

XF Flocculated / filtered with 0.45 micron

Used to estimate readily biodegradable material (COD)

Special Sampling Overview

• 3 days for each event• Composite sampling• Process grabs at 9am and 9pm• Total of ~ 400 samples and

analysis• Special sampling performed in

June (prior to DAF) and in September 2009 (after temp DAF installation)

Sampling Schematic

GRAB

COMPOSITE

PROCESSING PLANT(Kill Through Deboning

– Including All Screening) INSTALLED

DAF CLARIFICATION TANK

(0.22 MG)

DISINFECTION (UV)

RAS

WAS

EFFLUENT

SAMPLE LEGEND

ACTIVATED SLUDGE TANK

(0.83 MG)

ANAEROBIC LAGOONS / FLOW

EQUILIZATION(2.24 MG, 8.52 MG)

AEROBIC LAGOONS / BACKUP FLOW EQUILIZATION

(9.07 MG)

TERTIARY FILTRATION(Schrelber

Fuzzy Filter, 0.4 microns) CASCADE

AERATION

DAFSLUDGE

EMERGANCYBYPASS

CHEMICAL ADDITION (pH & Alkalinity Control,

Hydrated Lime)

Special Sampling Results

Constituent 1st Sampling EventUnfiltered (mg/l)

2nd Sampling EventUnfiltered (mg/l)

TSS 165 154COD 1513 1294BOD5 623 520

CBOD5 529 421TKN 221 234NH3 129 183

NOxN 0.5 0.43NO2N 0 0.05

TP 34.8 36.6PO4P 10.4 11.7Ca+2 28.4 91.1Mg+2 10.3 13.8

Influent FractionsDefault 1st event 2nd event

Fbs - Readily biodegradable (including Acetate) [gCOD/g of total ] 0.27 0.560 0.515

Fac - Acetate [gCOD/g of readily biodegradable ] 0.15 0.000 0Fxsp - Non-colloidal slowly biodegradable [gCOD/g of slowly

degradable ] 0.5 0.150 0.27Fus - Unbiodegradable soluble [gCOD/g of total ] 0.08 0.083 0.058

Fup - Unbiodegradable particulate [gCOD/g of total ] 0.13 0.283 0.29Fna - Ammonia [gNH3-N/gTKN] 0.75 0.582 0.606

Fnox - Particulate organic nitrogen [gN/g Organic N] 0.5 0.250 0.25Fnus - Soluble unbiodegradable TKN [gN/gTKN] 0.02 0.020 0.02

FupN - N: ratio for unbiodegradable part. [gN/gCOD] 0.035 0.035 0.035Fpo4 - Phosphate [gPO4-P/gTP] 0.75 0.297 0.32

FupP - P: ratio for influent unbiodegradable part. [gP/gCOD] 0.011 0.560 0.515

Biowin Setup

• June 2009 data used for troubleshooting• September 2009 data used for process sizing

Influent (Eff ANA#2) Schreiber MLSS Tank Final Clarifier

WAS

FC EffluentRAS Mixer

RAS/WAS Splitter

Influent Mixer

Lime

DAF - Future

“Lime Solids” Scenarios

• Lime feed varied to increase CaCO3 solids in reactor

• CaCO3 model• pH modeling turned off to accommodate

precipitate model

Influent (Eff ANA#2) Schreiber MLSS Tank Final Clarifier

WAS

FC EffluenRAS Mixer

RAS/WAS Splitter

Influent Mixer

Lime

“Lime Solids” Results

0

2

4

6

8

10

12

14

16

18

0

20

40

60

80

100

120

140

160

180

0.00 500.00 1,000.00 1,500.00 2,000.00 2,500.00

VSS

SRT

(Day

s)

Cla

rifie

r Effl

uent

NH

3N (m

g/L)

MLVSS (mg/L)

Effluent NH3

VSS SRT (days)

MLSS = 4500 mg/lTemperature = 10.2 deg C

CaCO3 Solids = 3500 mg/l

CaCO3 Solids = 2500 mg/l

“Lagoon Solids” Scenarios

• Influent solids of 100, 160, 300, 600, 1000– Ratio’d solids in influent fractions & COD

• MLSS of 2000 & 3500 mg/l• Three different temperatures• No change in soluble constituents

“Lagoon Solids” Results - Winter

0

20

40

60

80

100

120

140

160

100 167 300 600 1000

Schr

iebe

r Tan

k Ef

flue

nt N

H3N

(mg/

L)

Schreiber Tank Influent TSS (mg/L)

Steady State Simulations with Influent Q (0.6 MGD) and T=9.74oC

3,500 mg/L MLSS 2,000 mg/L MLSS

“Lagoon Solids” Results - Average

0

10

20

30

40

50

60

70

80

100 167 300 600 1000

Schr

iebe

r Tan

k Ef

flue

nt N

H3N

(mg/

L)

Schreiber Tank Influent TSS (mg/L)

Steady State Simulations with Influent Q (0.6 MGD) and T=17.73oC

3,500 mg/L MLSS 2,000 mg/L MLSS

“Lagoon Solids” Results - Summer

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

100 167 300 600 1000

Schr

iebe

r Tan

k Ef

flue

nt N

H3N

(mg/

L)

Schreiber Tank Influent TSS (mg/L)

Steady State Simulations with Influent Q (0.6 MGD) and T=26.07oC

3,500 mg/L MLSS 2,000 mg/L MLSS

Process Recommendations

• Permanent DAF – effluent 100 mg/l TSS• LSI control strategy• Denitrification tank / WAS Storage

– Increase / recover alkalinity– Prevent “float”

• Chemical feed / flocculation / splitter• New settling tank• NRCY / RAS Pump Station

Reactor Sizing Simulations

• Added denitrification reactor to Biowin• Evaluated COD removal and NO3 reduction

Inf (Eff ANA#2) Schreiber Tank FC

WAS

FC EffRAS Mixer

RAS/WAS Splitter

Inf & NRCY Mixer

Lime

DAF Solids (back to lagoon)

DAF Anoxic_1Carbon Bypass Splitter NRCY SplitterCarbon Bypass Mixer

Reactor Sizing - Effluent Nitrate

Anoxic Reactor Hydraulic Retention Time (based on Q =

0.61)Simulated Effluent Nitrate

Concentration (mg/l)0 hrs (no anoxic zone) 185

4 hrs 1206 hrs 938 hrs 7916 hrs 59

NOTES:MLSS = 3000 mg/lTemp = 9.74 deg CInternal recyle rate of 300 % of influent flow rate

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

4 6 8 16

Filt

ered

CO

D C

onsu

med

in A

noxi

c R

eact

or, (

ppd,

CO

D-X

G)

Anoxic HRT (hours, Inf Q)

3,000 mg/L MLSS - T=9.74oC

3,000 mg/L MLSS - T=17.73oC

Reactor Sizing COD Consumption

COD Removed = 550 mg/l

COD Removed = 700 mg/l

Reactor Sizing – Effluent Ammonia

0

30

60

90

120

150

180

210

240

270

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

3,000 2,750 2,500 2,250 2,000

Sim

ulat

ed C

lari

fier

Eff

luen

t NO

3, (m

g/L

Sim

ulat

ed C

lari

fier

Eff

luen

t NH

3N, (

mg/

L)

MLSS (mg/L)

Efflent NH3N- w/o AX

Efflent NH3N - AX HRT = 6hrs

Efflent NO3N - w/o AX

Efflent NO3N - AX HRT = 6hrs

Q = 0.61 MGDAnoxic HRT = 6 hoursTemperature = 9.74 deg C

Reactor Sizing – Internal Recycle

0

20

40

60

80

100

120

140

0% 50% 100% 200% 300%

FC E

fflu

ent N

O3N

, (m

g/L)

NRCY (%, Inf Q)

Q = 0.61 MGDAnoxic HRT = 6 hoursTemperature = 9.74 deg C

Reactor Design

Current Status

• Under construction• Complete by 3/31/2011

Summary / Conclusions

• Biowin useful as a tool in both troubleshooting and design– Illustrative tool– Multiple simulations allows for process

optimization• Effectiveness of model dependent on

characterization• Tailored to domestic, but can be “flexed” for

industrial wastes and unique sidestreams

Questions?

jgellner@hazenandsawyer.com