Shaft Mounted Advanced Reactor Technology

System Details

The SMART unit design comprises of a very heavy duty steel drive shaft, together with a steel outer skeleton. The shaft and outer skeleton combine to make a structure that is both strong and reliable.

Whilst the SMART unit is not a Rotating Biological Contactor (RBC) according to the conventional understanding of the term, the design of the SMART unit responds to the failure modes observed by the authoritative Cranfield study Manufacturing High Quality Rotating Biological Contactors for the UK Water industry with simple but intelligent and robust improvements that enhance the designs already proven reliability.

Shaft failure, for example, and consequent downtime and cost for replacement has been eliminated through the lessons learned during extensive field testing on more than 20 full size units over the last decade. The subsequent enhancements to the design allow for the most adverse operating conditions in any region throughout the world. In addition to the substantial nature of the SMART unit steel structural components - which allows a generous corrosion allowance - the steel components are coated to some of the most exacting standards in the industry, and match or exceed ISO standards for wastewater treatment equipment.

Where applications demand it, the SMART unit can be manufactured in materials such as 316 stainless steel.

Indeed, should truly exotic materials be required then Bluewater Bio is able, using state of the art computer modelling and simulation software, to incorporate these requirements.

Steel Skeleton

In addition to extensive field testing on numerous full size units, state of the art Finite Element methods have been used to analyse component and assembly integrity under worst case conditions.

System Details

The SMART media is the heart of the HYBACS process, the proprietary polymer mesh extrusion combines a huge bioactive volume with robust design.

Each of the 12 cassettes are protected by the steel outer skeleton and is designed to withstand a minimum of 8 years continuous operation before requiring replacement.

The mesh plates are held in place by precision moulded polypropylene couplings. The couplings are, in turn, mounted on stainless steel tie bars.

The couplings accurately locate the mesh plates, and uniformly distribute the forces transmitted to the mesh media, thereby minimising stresses and ensuring long term reliability.

In the event that the removal of a cassette is required, then the modular design of the assembly facilitates this.

Typically a complete cassette can be replaced in a matter of hours should the need arise.

The Smart Media

Maintenance of a SMART unit could not be simpler with the only consumable items being routine oil changes for the geardrive and greasing of the main shaft bearings neither of which requires specialist skills.

Reduced maintenance

Versatility

SMART units are proven on installations globally for the treatment of both municipal and a wide range of industrial effluents.

The SMART unit is a high performance carbon removal unit which, when deployed as an integral part of Bluewater Bios patented HYBACS process, can also form the core of a high performance and cost effective nutrient removal system.

The SMART unit utilises a unique three dimensional mesh media onto which the fixed film biomass adheres. The unique nature of the three dimensional mesh media is such that the vast majority of the attached film is biologically active.

Tank For installations in smaller works, each SMART is normally supplied as a self contained unit within an epoxy coated steel tank, complete with flanged inlet and outlet connections. Where SMART units are installed in larger works it is generally more cost effective to directly install the units into lanes within a concrete structure with each lane comprising of up to six SMARTs.

GRP Cover A GRP cover is supplied with every rotating assembly, which provides protection for both operational personnel and for the rotating biomass. As standard the covers are supplied in Bluewater Bios corporate colours, however Clients colour requirements are generally able to be incorporated at no additional cost.

Rotating Assembly The rotating assembly forms the core of the SMART unit, carrying the mesh media cassettes. The assembly is rigorously and robustly engineered to ensure long term reliable operation, whilst ensuring ease of maintenance should the need arise in the years ahead.

Media Cassettes The media cassettes form the biological engine room of the SMART unit. The standard SMART unit, Model 302, comprises of twelve cassettes each comprising of fifteen mesh plates. The plates are located using precision moulded spacer couplings, which in turn are supported on high quality stainless steel tie bars.

Geardrive Bluewater Bio has chosen Sumitomo as our Engineering Partner for the SMART unit geardrive. Sumitomos buddy box has numerous advantages, not least of which are its rugged shaft mounted design and global product support.

DO Probe The PLC based control system utilised by the SMART unit utilises Dissolved Oxygen concentration of the mixed liquor within the SMART unit as one of the parameters within the control algorithm. Smaller installations will generally utilise one DO probe per unit, however in larger installations the signal from one DO probe may be shared between a number of SMART units. Local SMART Unit Control Panel A number of control panel options are available from Bluewater Bio. The basic specification local SMART Unit Control Panel provides all the core functionality required for operation of a SMART unit. Higher specification control panels are available which incorporate colour touchscreen HMI, additional monitoring, remote diagnostics, etc.

Sparge system Each SMART unit is fitted with an automatic air sparge system, which operates intermittently to remove excess biomass build-up on the mesh media discs. This feature is fully adjustable and is accessed via the SMART Unit Control Panel. Under normal circumstances a small amount of air is taken from the main site aeration system, however a dedicated air sparge blower can be provided.

Development Bluewater Bio is a research driven company, having numerous on-going R&D projects, and is continuously striving to improve the performance of the SMART unit within the particular process it is being applied to - for example the HYBACS process. To this end, and with the Clients agreement, Bluewater Bio may install additional monitoring equipment on either a temporary or permanent basis at no cost to the Client. Optimised for robustness, long-term reliability and serviceability See page overleaf for detailed specifications

Main Components

Summary

SMART Control Panel Data

BwB Control Panels are designed for each specific application. The following is a selection of panels from the most complex and flexible to the more simple and cost effective.

- Included as standardX - Not availableR - Available on request at extra cost * - Depending on the application

RTU - Remote Terminal Unit; ILCP - Integrated Local Control Panel; LCP - Local Control Panel; FP - Field Panel

GENERAL DESCRIPTION RTU ILCP LCP FPInput Voltage 400 V ac 3 Ph+N, 50 Hz, 4 wires

Form Of Separation Form 2

Enclosure Type Stainless Steel R

IP Rating IP 65 *

Cable Entry Bottom Entry

Environment Sewage Treatment Works

Ancillaries Isolator and Emergency Stop fitted on the panel

Weight Panel weight in Kg * 50 40 25EQUIPMENT DESCRIPTION RTU ILCP LCP FPSMART Unit Starter ABB ACS355 VSD 2.2 kW, 3Ph, 5.5 FLC

Compressor Feeder MCB 10 Amp X R X

PLC AB MicroLogix with integrated 24V dc PSU and I/O ModulesAB CompactLogix comprising I/O and Profibus Cards

** X X

XX

HMI Mitsubishi E1151 15" touch screen HMIMitsubishi E11101 10" touch screen HMI

X

R XX

XX

Data Storage 4 GB USB Memory Stick fitted on the HMI X X

DO Probe DO probe comprising Transmitter * *

DO Cleaning Solenoid 24 V dc solenoid valve for probe cleaning air delivery X

Oxygen Monitor Atmospheric Oxygen Probe comprising Transmitter R R R RAir Compressor Air compressor for SMART discs cleaning air supply X R R XAir Sparge Solenoid 24 V dc solenoid valve for discs cleaning air delivery X

Rotation Monitor Ifm-electronic Rotation Monitor X

COMMUNICATION DESCRIPTION RTU ILCP LCP FPSCADA Interface Ethernet port for Clients SCADA connection X

Telemetry VFC for Clients Telemetry X

Ethernet Switch Ethernet Switch for panel network and client SCADA interface R X

Fieldbus Profibus * R R RModem GPRS Modem for remote data transmission and access X X

STANDARDS DESCRIPTION RTU ILCP LCP FPPanel Standards IP65 rated for outdoor installation *

WIMES 3.04 issue 3 (standard clauses) R

LV Directive 2006/95/EC

EMC Directive 2004/108/EC

BS EN 60204-1 Safety of Machinery Electrical equipment of machines

BS EN 60439-1 Low Voltage switchgear & control gear assemblies

BS7671, IEE Wiring Regulations 17th edition

BS EN 60204-1 Safety of Machinery Electrical equipment of machines

United KingdomLondon

Bluewater Bio 105 Wigmore StreetLondonW1U 1QYTelephone: +44 (0)20 7518 1720Fax: +44 (0)20 7493 0071Email: info@bluewaterbio.com