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Energy Efficiency in MBR Systems Brian Codianne 1.

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Presentation on theme: "Energy Efficiency in MBR Systems Brian Codianne 1."— Presentation transcript:

1 Energy Efficiency in MBR Systems Brian Codianne 1

2 Designing Enviroquip® MBR Systems Energy Efficiency - Goals and Strategies Energy Efficiency Energy Expended per volume of water treated Units of measure: kWh/m 3

3 Impact of Improving Energy Efficiency Designing Enviroquip® MBR Systems Energy Efficiency - Goals and Strategies 1 kwh/m^3 saves $110,000

4 Non-MBR Loads Loads needed for support of biology, independent of permeate production  Mixers  MLR Pumps  Process Air Blowers MBR Loads Loads based on the rate of permeate production  Permeate Pumps  MBR Scour Air Blowers MBR Loads vs. Non-MBR Loads Designing Enviroquip® MBR Systems Energy Efficiency - Goals and Strategies

5 ES SMU (Single Deck) SMU Scour Air Energy Usage EK SMU (Double Deck) (Type 510 Cartridge) RW SMU (Double Deck) (Type B2-515 Cartridge) SP SMU (Modules) KUBOTA = 0.22 – 0.40 kWh/m 3 EQ MBR = 0.13 – 0.18 kWh/m 3 KUBOTA = 0.73 kWh/m 3 Integration of New Kubota Products Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

6 Impact of SMU Evolution on Energy gpd at 14.7 gfd kWh/m3 at 14.7 gfd EK-400EW-400RW-400 Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

7 Energy Pro TM Configuration Proportional Aeration Configuration Provide Aeration and Permeate Turndown for Off-Design Point Operations Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

8 Energy Pro TM PA AX SB FC MBR INF EFF 1/3 of capacity at low flow 2/3 of capacity at medium flow Full capacity at high flow MBR Zones Automatically Brought Online to Incrementally Match Demand Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

9 Proportional Aeration Low Intensity at Low Flux Medium Intensity at Medium Flux High Intensity at High Flux.5QQ2Q MBR Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

10 Impact of Proportional Aeration on SMU Energy gpd at 14.7 gfd kWh/m3 at 14.7 gfd (Kubota) EK-400EW-400RW-400 kWh/m3 at 14.7 gfd (EQ Prop Air) Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

11 1Q 2Q 3Q 6:0012:0018:00 24:00 Low Intensity Medium Intensity High Intensity PA AX SB FCFC INF EFF MBR Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

12 Avg. SBR Energy Usage (0.80kWh/m 3 ) Enviroquip MBR Energy Usage Actual Total Plant Energy Usage at Design AAF (1.5 MGD) Dundee, MI – Efficiency and Turndown Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

13 Delphos, OH – Efficiency and Turndown (Energy Audit Excerpt) Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

14 Pump Assisted Gravity Configurations Maximizing Efficiency at Design Points Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

15 Permeate Collection Methods Gravity P Pumped Pumping Energy to Convey Permeate Low SWD No Pumping Costs High SWD Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

16 Pump Assisted Gravity (PAG) PAG is ~25% more energy efficient than gravity or pumped systems Lower blower discharge pressure Pumps only used to resolve air lock/high TMP P Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

17 EQProSim ™ Inputs Diurnal Flows Working Volume (EQ) Permeate Capacity Output Minute to Minute Status Total Run Times Accurate Energy Prediction Use system modeling to optimize controls and hydraulic balancing Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

18 EQProSim ™ Design Optimization Determine Optimum EQ volume for diurnal flows (hydraulic balance, energy) Prediction of energy consumption at design and off-design points Cost-benefit analysis of using various configurations (EnergyPro TM, Proportional Aerations, etc.) Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

19 High Efficiency Blowers Turbo and next-generation PD blowers 15-30% less energy than traditional PD blowers Added Benefits Integrated VFDs (lower MCC cost) Integrated pressure and flow sensors Smaller footprint (less building costs) Incorporating evolving technologies and configurations Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

20 EK SMU (DD) Optimize SRT/MLSS Biomonitoring 2001 MBR System Energy Usage EW SMU Proportional Aeration Pump-Assisted Gravity +20% Efficiency RW SMU Energy Pro™ PAD-K +40% Efficiency SP SMU ECOBLOX™ microBLOX™ % Efficiency ?? Designing Enviroquip® MBR Systems Energy Efficiency – MBR Strategies

21 Designing Enviroquip® MBR Systems Energy Efficiency – Overall Strategies Improving Non-MBR Efficiencies Mixers Optimizing mixer speeds/energy input to match process needs Ovivo LM Mixers Mixed Liquor Recycle Installing turn-down in pumping rates for seasonal changes in flows Process Aeration Maximizing fine bubble SOTE to reduce aeration energy Minimizing energy burned through control valves (basin SWDs) Improve blower/FCV interactions – Most Open Valve Control

22 Compounding Factors Running at higher than necessary DO If pre-aeration basin DO is 6 mg/l instead of 2 mg/l – 84% more energy consumption Running at a higher aeration header set point than necessary In a 16’ SWD basin, each additional.1 psig = 1.25% more energy In an 8’ SWD basin, each additional.1 psig = 2.6% more energy Balancing differing basin SWDs with FCVs on the same aeration headers First basin at 16’ + second basin at 15’ = 6% expended energy across FCV First basin at 10’ + second basin at 9’ = 10% expended energy across FCV First basin at 16’ + second basin at 8’ = 87% expended energy across FCV Inability to turn-down mixed-liquor recycle flow rates MLR rate based on daily Q total. Operating at 50% capacity = need for 50% of MLR Operating with less efficient equipment Older PD blowers compared to newer turbofan blowers = 10% - 30% additional energy Designing Enviroquip® MBR Systems Energy Efficiency – Theory vs. Reality

23 Analysis of Energy-Related Alternatives Cost/benefits of: Energy Pro™ and Proportional Aeration Configurations Segregation of aeration systems by operating depths Installation of mixed liquor recycle flow turn down Installation of mixers sized for basin Utilization of higher-efficiency motors and technologies Utilize Ovivo as a Design Resource Designing Enviroquip® MBR Systems Energy Efficiency – Designing for Reality

24 Thank You Brian Codianne Senior Technologist, MBR Systems


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