Basic Design Concepts of MBR - otcoinc.org

Basic Design Concepts Basic Design Concepts

of MBRof MBR

Class III & Class IV OTCO WorkshopClass III & Class IV OTCO Workshop

Wednesday August 15, 2007Wednesday August 15, 2007

Terry M. Gellner, P.ETerry M. Gellner, P.E

CT Consultants, IncCT Consultants, Inc

OutlineOutline

�� Types of MembranesTypes of Membranes

�� MBR WWTP and General Sizing CriteriaMBR WWTP and General Sizing Criteria

�� Common Terms and DefinitionsCommon Terms and Definitions

�� Review of Hollow Fiber and Flat Plate Review of Hollow Fiber and Flat Plate

ComponentsComponents

�� WhatWhat’’s on the Horizons on the Horizon

Referenced TextReferenced Text

Membrane Systems Membrane Systems

For Wastewater For Wastewater

TreatmentTreatment

byby

Water Water

Environment Environment

FederationFederation

Referenced WWTPReferenced WWTP

�� Cauley Creek WWTP Cauley Creek WWTP –– GeorgiaGeorgia

�� Forsyth WWTP Forsyth WWTP –– GeorgiaGeorgia

�� Savannah WWTP Savannah WWTP -- GeorgiaGeorgia

�� Hyrum WWTP Hyrum WWTP –– UtahUtah

�� Hampton WWTP Hampton WWTP –– GeorgiaGeorgia

�� Delphos WWTP Delphos WWTP –– OhioOhio

�� Mt Sterling WWTP Mt Sterling WWTP –– KentuckyKentucky

�� Green Castle WWTP Green Castle WWTP -- IndianaIndiana

Membrane Bioreactor SystemsMembrane Bioreactor Systems

√√ Types of MembranesTypes of Membranes






Membrane ClassificationsMembrane Classifications

Microfiltration

(MF)

Ultrafiltration

(UF)

Nonofiltration

(NF)

Reverse

Osmosis (RO)

MBR Performance

Comparison of Membrane Filtration ProcessesComparison of Membrane Filtration Processes

Contaminants Rejected

General Process CharacteristicsGeneral Process Characteristics

MF and UFMF and UF

�� Low PressureLow Pressure

�� Size ExclusionSize Exclusion

�� Pathogenic bacteria and Pathogenic bacteria and some virusessome viruses

�� MBR Systems, polishing MBR Systems, polishing and post treatment and post treatment

NF and RONF and RO

�� Higher PressureHigher Pressure

�� Size Exclusion plus Size Exclusion plus

diffusion chargediffusion charge

�� Pathogenic bacteria, Pathogenic bacteria,

viruses, dissolved solids viruses, dissolved solids

and ionsand ions

�� Secondary polishing and Secondary polishing and

post treatmentpost treatment

Typical Types of MembranesTypical Types of Membranes

Nozzle

Membrane Panel

Spacer

Membrane Sheet

Microstructure

Reinforced

Structure

Biomass

Effluent

Hollow

Fiber



√√ MBR WWTP and General Sizing CriteriaMBR WWTP and General Sizing Criteria





MBR?MBR?

�� A membrane bioreactor (MBR) is a combination A membrane bioreactor (MBR) is a combination

of suspended growth activated sludge biological of suspended growth activated sludge biological

treatment and membrane filtration equipment treatment and membrane filtration equipment

performing the critical solids/liquid separation performing the critical solids/liquid separation

function that is traditionally accomplished using function that is traditionally accomplished using

secondary clarifiers and filters.secondary clarifiers and filters.

Conventional Activated SludgeConventional Activated Sludge

MBR Activated SludgeMBR Activated Sludge

Process Overview SchematicProcess Overview Schematic

Process Units and Sizing CriteriaProcess Units and Sizing Criteria

�� Preliminary TreatmentPreliminary Treatment

�� ScreeningScreening

�� Grit/Grease RemovalGrit/Grease Removal

�� Activated Sludge ProcessActivated Sludge Process

�� Aeration TankAeration Tank

�� Membrane BioreactorMembrane Bioreactor

�� Biological Nutrient RemovalBiological Nutrient Removal

�� Post TreatmentPost Treatment

�� DisinfectionDisinfection

�� Post AerationPost Aeration

Preliminary TreatmentPreliminary Treatment

�� Screening Screening

�� Type Type

One Dimensional One Dimensional –– Bar type (Slotted) Bar type (Slotted)

Two Dimensional Two Dimensional –– Perforated holePerforated hole

�� Capture Mode Capture Mode

�� Size 1, 2 or 3 mmSize 1, 2 or 3 mm

�� OperationOperation

Grit and GreaseGrit and Grease

�� Types observedTypes observed

�� VortexVortex

�� Aerated GritAerated Grit

�� HeadcellHeadcell

�� Partical SizePartical Size

�� Grease/ScumGrease/Scum

Activated Sludge ProcessActivated Sludge Process

�� Permitted Design CriteriaPermitted Design Criteria

�� Flow RatesFlow Rates

�� Pollutant Loadings Pollutant Loadings

�� CBOD, TSS, TKN, NH3, TP, TNCBOD, TSS, TKN, NH3, TP, TN

�� Biological Nutrient RemovalBiological Nutrient Removal

�� Basin Types and Volumes Basin Types and Volumes

Membrane Bioreactor SizingMembrane Bioreactor Sizing

�� Membranes are Hydraulically RestrictedMembranes are Hydraulically Restricted�� Low FlowLow Flow

�� Average Daily FlowAverage Daily Flow

�� Maximum Daily Sustained Flow Maximum Daily Sustained Flow

�� Peak Instantaneous FlowPeak Instantaneous Flow

�� Membrane design flowMembrane design flow

�� Operating MLSS ConcentrationOperating MLSS Concentration

�� TemperatureTemperature

�� Equalization Equalization

Post TreatmentPost Treatment

�� DisinfectionDisinfection

�� Chemical Chemical

�� Ultraviolet Disinfection Open ChannelUltraviolet Disinfection Open Channel

�� Ultraviolet Disinfection Close ConduitUltraviolet Disinfection Close Conduit

�� Is disinfection needed?Is disinfection needed?

�� Post AerationPost Aeration

Hyrum WWTPHyrum WWTP

UV DisinfectionUV Disinfection

Savannah WWTP Savannah WWTP

DisinfectionDisinfection

Typical Permeate SampleTypical Permeate Sample

Permeate QualityPermeate Quality

�� Water reuse is popularWater reuse is popular




√√ Common Terms and DefinitionsCommon Terms and Definitions




Gross FluxGross Flux

The volume of water that passes through a The volume of water that passes through a

membrane per unit time and per unit surface area membrane per unit time and per unit surface area

of the membrane. Flux is often normalized based of the membrane. Flux is often normalized based

on temperature. on temperature.

Instantaneous Permeate Flow /Surface Area Instantaneous Permeate Flow /Surface Area

Net FluxNet Flux

�� The total Permeated Flow over 24 hours divided The total Permeated Flow over 24 hours divided

by the total surface area expressed in gallons per by the total surface area expressed in gallons per

minute per square foot. minute per square foot.

�� Total Permeate Flow/ Surface AreaTotal Permeate Flow/ Surface Area

Total Surface AreaTotal Surface Area

�� The total surface area represents the total The total surface area represents the total

membrane surface area available for treatment in membrane surface area available for treatment in

a membrane system.a membrane system.

Transmembrane PressureTransmembrane Pressure

�� The difference between average/concentrate The difference between average/concentrate

pressure and the permeate pressure is the driving pressure and the permeate pressure is the driving

force. The TMP is a means to assess fouling.force. The TMP is a means to assess fouling.

TMP = feed pressure TMP = feed pressure –– permeate pressurepermeate pressure

FoulingFouling

�� The build up of impurities on the membranes The build up of impurities on the membranes

such as colloidal materials. Fouling reduces flux such as colloidal materials. Fouling reduces flux

through the membrane and increase the TMP.through the membrane and increase the TMP.

�� Micro fouling is the build up of impurities in the Micro fouling is the build up of impurities in the

membrane pores.membrane pores.

BioFilmBioFilm

�� A thin layer of sludge on the membrane. A thin layer of sludge on the membrane.

Biofilm occurs on all membranes. Some Biofilm occurs on all membranes. Some

manufacturers rely on biofilm. Other choose to manufacturers rely on biofilm. Other choose to

ignore it. ignore it.

BiohydraulicsBiohydraulics

�� Term developed by Enviroquip. Bio hydraulics Term developed by Enviroquip. Bio hydraulics

is the interrelationship between the BIOis the interrelationship between the BIO--logical logical

process and the HYDRAULIC characteristics of process and the HYDRAULIC characteristics of

the membranes. the membranes.

PermeabilityPermeability

�� The permeability of a membrane is the flux rate The permeability of a membrane is the flux rate

divided by the transmembrane pressure.divided by the transmembrane pressure.

P = Flux / TMPP = Flux / TMP

RecoveryRecovery

�� Recovery is the concept of restoring the Recovery is the concept of restoring the

hydraulic characteristics of the membrane. hydraulic characteristics of the membrane.

Recovery is achieve by membrane cleaning. Recovery is achieve by membrane cleaning.





√√ Review of Hollow Fiber and Flat Plate Review of Hollow Fiber and Flat Plate



Membrane System ComponentsMembrane System Components

�� Feed Stream, RAS and WASFeed Stream, RAS and WAS

�� Air SystemsAir Systems

�� Membranes and HardwareMembranes and Hardware

�� Permeate SystemPermeate System

�� Flux Maintenance SystemsFlux Maintenance Systems

�� Integrity Monitoring SystemIntegrity Monitoring System

�� Programmable Logic ControllerProgrammable Logic Controller

Comparison of Leading Comparison of Leading

ManufacturersManufacturers

�� Hollow Fiber Hollow Fiber -- Zenon Zenon -- General ElectricGeneral Electric

�� Flat Plate Flat Plate -- Kubota Kubota –– Enviroquip a subsidiary of Enviroquip a subsidiary of

EimcoEimco

Cauley Creek WWTP Cauley Creek WWTP -- ZenonZenon

Cauley Creek WWTP Cauley Creek WWTP

Aeration TanksAeration Tanks

Forsyth WWTP Forsyth WWTP -- ZenonZenon

Forsyth WWTPForsyth WWTP

Fine Screening of RASFine Screening of RAS

Savannah WWTPSavannah WWTP

Aeration TanksAeration Tanks

Hollow Fiber Flow SchemeHollow Fiber Flow Scheme

Zenon Zenon –– Membrane RackMembrane Rack

Immersed Membrane TrainImmersed Membrane Train

Cassette

Permeate

Manifold

Air Manifold

Air Separator

Permeate

Pump

Permeate

Header

Process Air SystemProcess Air System


Aeration and MBR BlowersAeration and MBR Blowers

Hollow Fiber Membrane Air SystemHollow Fiber Membrane Air System

Forsyth WWTP Forsyth WWTP

Air and Permeate PipingAir and Permeate Piping

Forsyth WWTP Forsyth WWTP

Pneumatic System CompressorsPneumatic System Compressors

Hollow Fiber Permeate SystemHollow Fiber Permeate System

Hollow Fiber Flux Maintenance Hollow Fiber Flux Maintenance

SystemSystem

�� RelaxRelax

�� Air System with Air PulsingAir System with Air Pulsing

�� Backpulse SystemBackpulse System

�� Chemical CleaningChemical Cleaning

�� BackpulsingBackpulsing

�� Maintenance CleaningMaintenance Cleaning

�� Recovery CleaningRecovery Cleaning


Permeate systemPermeate system

Cauley Creek WWTPCauley Creek WWTP

RAS and Backpulse TankRAS and Backpulse Tank


Permeate SystemPermeate System


Chemical Feed SystemChemical Feed System


Scum Removal System Scum Removal System

Hollow FiberHollow Fiber

Integrity Monitoring SystemIntegrity Monitoring System

�� Anoxic and Aeration Anoxic and Aeration –– Dissolve OxygenDissolve Oxygen

�� Process Air System Process Air System –– Flow and PressureFlow and Pressure

�� MBR Air System MBR Air System –– Flow Flow

�� MBR Tank MBR Tank -- LevelLevel

�� Turbidity Turbidity –– Permeate Permeate

Hyrum WWTP Hyrum WWTP -- KubotaKubota


MBR TankMBR Tank

Hampton WWTP Hampton WWTP -- KubotaKubota

Hampton WWTPHampton WWTP

Delphos WWTP Membrane DeckDelphos WWTP Membrane Deck

Flat Plate Feed Forward Flow Flat Plate Feed Forward Flow

Scheme 1Scheme 1

Flat Plate Membrane Flow Flat Plate Membrane Flow

Scheme 2Scheme 2

Kubota Flat Plate MembraneKubota Flat Plate Membrane

The Kubota panel type MBRThe Kubota panel type MBR

Process Air SystemProcess Air System

Delphos WWTPDelphos WWTP

Process AerationProcess Aeration

Flat Plate Membrane Air SystemFlat Plate Membrane Air System


Membrane Air PipingMembrane Air Piping


Process and MBR BlowersProcess and MBR Blowers


Air System and HardwareAir System and Hardware

Flat Plate Permeate SystemFlat Plate Permeate System


Permeate PipingPermeate Piping


Anoxic TanksAnoxic Tanks

Delphos WWTP Delphos WWTP

Pipe GalleryPipe Gallery


Permeate PumpsPermeate Pumps


Permeate SystemPermeate System

Flat Plate Flat Plate

Flux Maintenance SystemFlux Maintenance System

�� RelaxRelax

�� Air ScourAir Scour

�� Clean In Place Chemical CleaningClean In Place Chemical Cleaning

Flat Plate Air Scour Blow OffFlat Plate Air Scour Blow Off


Chemical SystemChemical System


Chemical Feed ConnectionsChemical Feed Connections

Flat Plate Flat Plate

Integrity Monitoring SystemIntegrity Monitoring System

�� Anoxic Anoxic –– Level and Meter FlowLevel and Meter Flow

�� Process Air System Process Air System –– Flow and PressureFlow and Pressure

�� Air System to MBR Air System to MBR -- FlowFlow

�� Aeration Aeration –– Dissolve Oxygen and NaDHDissolve Oxygen and NaDH

�� MBR Tank MBR Tank –– LevelLevel

�� Permeate Permeate -- TurbidityTurbidity

Turbidity MetersTurbidity Meters

MBR Flow Meter and ValvesMBR Flow Meter and Valves

Programical Logic ControllerProgramical Logic Controller

System ComparisonsSystem Comparisons

�� Hollow FiberHollow Fiber

�� Process Air SystemProcess Air System

�� MBR Air SystemMBR Air System

�� Pneumatic SystemPneumatic System


�� Backpulse SystemBackpulse System

�� Chemical SystemChemical System

�� Tank Drain SystemTank Drain System

�� Integrity SystemIntegrity System

�� PLC SystemPLC System

�� Flat Plate SystemFlat Plate System

�� Process Air SystemProcess Air System

�� MBR Air SystemMBR Air System


�� CIP Chemical SystemCIP Chemical System

�� Integrity SystemIntegrity System

�� PLC ControllerPLC Controller

Hollow Fiber SummaryHollow Fiber Summary

�� Relies on pore size of membrane Relies on pore size of membrane

�� Promotes frequent flux maintenancePromotes frequent flux maintenance

�� Uses regular membrane cleaningUses regular membrane cleaning

�� Promotes support facilities for primary Promotes support facilities for primary

equipmentequipment

�� Promotes multitasking of equipmentPromotes multitasking of equipment

�� Appears more focused on filtering through Appears more focused on filtering through

membranemembrane

Flat Plate SummaryFlat Plate Summary

�� Relies on biofilm to aid in filteringRelies on biofilm to aid in filtering

�� Promotes regular flux maintenancePromotes regular flux maintenance

�� Uses less frequent membrane cleaningUses less frequent membrane cleaning

�� Minimizes on site equipmentMinimizes on site equipment

�� Separates equipment usesSeparates equipment uses

�� Focus is on biohydraulicsFocus is on biohydraulics

Membrane Design ApproachMembrane Design Approach

�� There are more differences than similaritiesThere are more differences than similarities

�� Learn the difference in the technologyLearn the difference in the technology

�� Visit existing plants with design teamVisit existing plants with design team

�� Question the membrane suppliers Question the membrane suppliers

�� The design is site specificThe design is site specific

�� The biology is importantThe biology is important

�� Compare equal systemsCompare equal systems

�� Select the system that suits youSelect the system that suits you







√√ WhatWhat’’s on the Horizons on the Horizon

WhatWhat’’s on the Horizons on the Horizon

�� Application of Application of MBRsMBRs is expandingis expanding

�� Size of plant continues to increaseSize of plant continues to increase

�� More focus on HeadworksMore focus on Headworks

�� Optimizing operations is a point of focusOptimizing operations is a point of focus

�� Hollow Fiber is beginning to look more at Hollow Fiber is beginning to look more at

Biology (TTF & cTOC)Biology (TTF & cTOC)

�� WEF has established a COP WEF has established a COP

QuestionsQuestions

Terry M. Gellner, P.E.Terry M. Gellner, P.E.

CT Consultants, IncCT Consultants, Inc

Basic Design Concepts of MBR - otcoinc.org

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