mbr-the reliable solution for difficult to treat wastewaters€¦ · 2 nesowea industrial waste...

© 2014 General Electric Company. All rights reserved

OWEA NE Industrial Waste Seminar February

20th 2014

Presenter: Brian Arntsen Richfield,

Ohio

MBR-The reliable solution for difficult to treat Wastewaters

2NESOWEA Industrial Waste Seminar

Feb 20th, 2014

Presentation Overview

• MBR

• Zeeweed* 500 membranes

• HPI Case Studies

• Food & Beverage Case Studies

• Zeeweed® Experience

* Trademark of the General Electric Company may be registered in one or more countries


Feb 20th, 2014

ZeeWeed MBR

• Advanced technology that combines ultrafiltration (UF) membranes with biological treatment

• Brings conventional clarification, aeration and filtration together into a single step


Feb 20th, 2014

ZeeWeed MBR

8,000 to 10,000 mg/l

Bioreactor Membrane(liquid/solids separation)

Hi-Rate Biological Treatment

• large capacity throughput

• compact footprint

• advanced treatment

• simpler, more reliable process

Absolute / Positive Filter• high degree of biomass/solids control• consistently high effluent quality• lower operator attention - less components

Influent

Filtrate

(Effluent

)

6

NESOWEA Industrial Waste Seminar Feb 20th, 2014

ZeeWeed = Consistent High Quality Effluent

Achievable ZeeWeed

Treatment Results

BOD5 < 2 mg/L

TSS < 2 mg/L

NH3-N < 0.05 mg/L*

TN < 3 mg/L*

TP < 0.05 mg/L*

Turbidity < 0.1 NTU

Fecal Coliform 0 cfu/100 mL**

SDI < 3* With appropriate biological design ** After disinfection

ZeeWeed MBR selected by the City of Corona, CA for its small footprint and the ability to meet Title 22 discharge regulations

Reusing the majority of their existing infrastructure, the city of Woodstock, GA converted a 0.5 MGD (1,893 m3/d) SBR into a 2 MGD (7,570 m3/d) ZeeWeed MBR

Zeeweed 500 Membranes


Feb 20th, 2014

What is a Membrane?

Membranes are engineered thin barriers or films of material that allow certain substances to pass by a size exclusion mechanism related to the size of the pores on the membrane surface

Rejected Matter

Permeate Permeate

Membrane

Permeable Matter

SupportMaterial


Feb 20th, 2014

Membrane Filtration

Conventional Treatment


Feb 20th, 2014

ZeeWeed Family of Membranes

Unsupported immersed

Ideal for large scale potable, tertiary, desalination pre-treatment, and media filter retro-fit

Reinforced immersed

For very challenging raw water qualityIdeal for MBR

500 Series 1000 Series 1500 Series

Unsupported pressurized

Ideal for small scale potable, tertiary, and desalination pre-treatment applicationsIdeal for industrial process water, make-up and reuse applications


Feb 20th, 2014

Reinforced Membranes are the Key to Superior Effluent Quality

Hollow strands of porous plastic fibers with billions of microscopic pores on the surface

Pores form a physical barrier to impurities but allow pure water molecules to pass

Membrane layer integrated with a support braid, resulting in unmatched fiber ruggedness Membrane

Fiber

Electron microscope view of membrane surface


Feb 20th, 2014

The ZeeWeed 500 System

Fibre


Feb 20th, 2014

Basic MBR Production Train

1. Biological reactor

2. Membranes

3. Permeate pump & air blower

4. Control panel

5. Permeate & air piping1

2 4

3

5

HPI Case Studies


Feb 20th, 2014

HPI Wastewater Experience

Client & Location Start up

Size (gpd) Application

Marathon Oil, MI, USA 2015 4,610,000 MBR

Eagle Ford, TX, USA 2015 187,000 MBR

PETROBRAS COMPERJ, Brazil

2014 4,762,000 MBR

CCRL, SK, Canada 2014 2,300,000 MBR+HERO

Novokuibyshevsk, Russia 2013 15,900,000

MBR

Antipinsky, Russia 2013 2,400,000 MBR

TANECO Phase I, Russia 2011 4,500.000 MBR +EDR+RO

PETROBRAS REVAP, Brazil 2010 1,904,000 MBR

SASOL, South Africa 2006 3,300,000 ZW+RO WW

MARATHON OIL, KY, USA 2003 50,000 MBR,

PEMEX, Minatitlan, Mexico 2001 6,800,000 UF + RO


Feb 20th, 2014

TANENCO, Russia-4.5MGD

REJECT STREAM

Pumped down oil well

ADF = 35 m3/h

TDS-25000-35000 ppm

MBR Permeate

Recycled to Cooling Tower

ADF = 1400 m3/h

TDS/ Conductivity = 400 ppm

“Less salty”

wastewater

Rain overflow

from landfill,

etc.

ADF = 1400 m3/h

TDS = less 1000 (400) ppm

COD = 80-200 ppm

BOD = 40-50 ppm

“Salty” wastewater

Desalter,

desalination, CT

blowdown

EDR 5 x 1 array

Permeate

Recycled to

Cooling Tower

ADF = 665 m3/h

TDS - less 250 ppm

ADF = 700 m3/h

TDS = less 2200 (1500)

ppm

COD = 80-200 ppm

BODtot = 40-50ppm

MBR I

2 lines

• DAF, API Separators upstream; not in GE Scope

• Prefer AC filters before EDR to absorb residual COD

MBR II/2

2 lines

MBR II/1

2 lines

1-st “a” Phase – MBR 1 – September

2011;

1-st “b” Phase – 3 EDR+RO – October-

November 2011;

2-d Phase – MBR II + 2 EDR+RO - 2012

ADF = 35 m3/h,

TDS - less 50 ppm

ADF = 70 m3/h,

TDS- less 11000

ppm

RO 2 modules

ADF = 700 m3/h

TDS - less 1250 (to 1650)

ppm

Cl - less 80-200 ppm

SO4 - less 350 ppm

ADF = 630 m3/h,

TDS=200 ppm


Feb 20th, 2014

TANENCO, Russia-4.5MGDParameters Influent MBR I Effluent

MBR I

Influent to

the EDR

(request)

EDR+RO

permeate

water

Target

effluent

BODtot, mg/l 40-50 <5-10 <5-10

COD, mg/l 80-200 <50!!! <50!!! <50!!!

TSS, mg/l <20 <5 <5

NH4-N, mg/l <16 <1 <1 <1

NO3-N, mg/l - <9,1 <9,1 <9,1

TKN, mg/l <20 - -

TN, mg/l <20 <10 <10

TP, mg/l 0,5 * <1 *

Oil, mg/l <10 <1,5 <2 <1,5

Chlorides, mg/l <500 <500 <350 <350

Sulphates, mg/l <250 250 <200 <200

Sulphides, mg/l 2 Not

detectable0

TDS, mg/l <2200 (real

1500)

<2200 1250** <250 <250

Sio2, mg/l <1* - effluent P depends on influent P, on addition P nutrient dosing and the use of P removal system

** - system will allow to meet the guaranteed product quality for increase of TDS to 1620 mg/l


Feb 20th, 2014

REVAP Refinery, Brazil- 1.9MGD

Located in Sao Paolo, Brazil

Largest MBR in refinery in Latin America

Capacity: 1.9 MGD (7,200 m3/d)

Commissioned July 2010

ZeeWeed MBRTM for Water reuse

ZW 500dTM 4 trains x 3 cassettes x 48modules

Spare Space: 1 Cassette per train


Feb 20th, 2014

PETROBRAS REVAP Refinery, BrazilFeed Characteristics and Required Effluent Quality

Parameter unit Raw Water

for WS (300)

Effluent Quality

Influent Flow M3/h 300

Temp. (min/ max) ° C 25 / 32 25 / 35*

CODtotal mg/L 850 (peak +20 %) ≤ 60**

BOD5 mg/L 230 ≤ 5

TSS mg/L < 5 n/a

TN mg/L n/a ≤ 20

TKN mg/L 90 n/a

NH3-N mg/L 80 ≤ 1

TP mg/L n/a ≤ 1

Turbidity NTU n/a ≤ 1

pH - 7 - 10 6.5 – 7.5

Alkalinity mg/L 30 75

Oil & Grease mg/L < 5 ≤ 1

* max. bioreactor temperature

**biodegradable COD is assumed to be

93%


Feb 20th, 2014

REVAP Refinery, Brazil- 1.9MGD

Source: Petrobras

API separator + DAF + Nutshell filter

Nutshell filter as a safety factor and polishing unit

for the removal of free-oil

Robust Equalization tank with no cascading to

bioreactor


Feb 20th, 2014

Marathon Oil, Kentucky- 50,000 gpdLocated in Catlettsburg, KY

Commissioned: August 2003

Marathon Oil is a wholesale supplier of gasoline, asphalt, and other oil-based products.

• Site is the Marine River Terminal

• Owned and operated by Marathon Oil (formerly Marathon Ashland Petroleum)

• Located on the Ohio River

• Services barges that carry petroleum to various refineries

• Problems meeting discharge criteria began in 2001 at the barge treatment operations


Feb 20th, 2014

Marathon Oil, Kentucky- 50,000 gpd

Initial system: equalization + dissolved air floatation (DAF)

Difficult wastewater - contains solids, oil and grease, aromatic hydrocarbons (including the “BTEX” compounds), metals, BOD and occasionally arsenic.

• Early 2002: pilot study performed using ZeeWeed Pilot proved to be very successful

• Removed COD, BOD, TSS

• Also removed “BTEX” compounds and heavy metals to acceptable levels.


Feb 20th, 2014

Marathon Oil, Kentucky- 50,000 gpd

• Plant successfully commissioned in less than one year:

• Grit removal system (heavy solids removal)

• Oil / water separator

• MBR consists of 1 train x 2 cassettes x 11 elements

• Sludge is wasted from recirculation line to filter press, thickened & hauled off-site.

Full-Scale System


Feb 20th, 2014

PEMEX Refinery, Mexico- 6.8 MGD

Design WW flow rate of 300 L/s (6.8 MGD)

Treatment includes:

• Dissolved air flotation

• Conventional Biological Treatment

• ZeeWeed Tertiary Filtration

• Reverse Osmosis

Overall water recycle efficiency is approximately 70% based on RO permeate

• One of Mexico’s largest refineries (173,200 bpd)

• Located in Minatitlan, Mexico

• WW treatment allows for recycle

PEMEX Minatitlan


Feb 20th, 2014

PEMEX Refinery, Mexico- 6.8 MGDZeeWeed system design:

• Peak Flow – 300 L/s ( 6.8 MGD)

• Recovery- 90 to 95%

• 7 parallel trains of ZW500b (6 operating + 1 standby)

• 11 cassettes per train (expandable to 15)

Effluent Quality Requirements:

• TSS < 1 mg/l

• Turbidity < 0.1 NTU

• SDI < 3


Feb 20th, 2014

PEMEX Refinery, Mexico- 6.8 MGDGE Process Trains

Membrane Building


Feb 20th, 2014

Membranes Immersed in Process Tank @ 85,000 mg/L FOG After Upset!

Cassette Fully Restored After Recovery Cleaning!

PEMEX Refinery, Mexico- 6.8 MGD

Food & Beverage


Feb 20th, 2014

Food & Beverage wastewater reuseSite Location Start

up

Flow,

gpd

MBR/Tert Description

Frito Lay, Casa Grande, AZ 2010 648,000 MBR Potato Processing

Farm Frites, Lommel, Belgium

2008 158,500 MBR/RO Potato Starch

ADM Cedar Rapids, IA 2008 3,500,000 MBR Biofuels

Premier Foods, UK 2007 424,000 MBR/RO Vegetable canning

Nestle, Anderson IN 2007 1,135,000 MBR Ready-to-drink

Citrosuco, Brazil 2007 126,800 MBR/RO Orange Juice

ADM Decatur, IL 2004

2006

Ph.1:

5,000,000

Ph.2:

6,000,000

Tertiary UF Oilseed Products

Cooperl, Lamballe, France 2003

2004

Ph. 1: 274,700

Ph. 2: 359,300

MBR/RO Pork Processing

ABR Wietzendorf, Germany 1996

2002

2003

Ph. 1: 126,800

Ph. 2: 253,600

Ph. 3: 570,611

MBR

MBR/RO

Potato starch


Feb 20th, 2014

Nestle Anderson, Indiana- 1.14 MGDNesquick/Coffeemate wastewater• New $360M factory and distribution center for

Nestle’s Beverage division

• 880,000 square foot facility produces ready-to-drink milk products like Nesquick and Coffee-Mate products

• Limited existing sewer flows

• Downstream POTW capacity was insufficient to treat increased organic & solids load

• Solution: 1.14 MGD MBR

• Commissioned in Summer 2008

• Up to 80% of the MBR permeate is reused for non-product contact applications eg. cooling tower makeup


Feb 20th, 2014

Frito Lay, Casa Grande, AZ- 0,65 MGD Potato Snack Manufacturer

• Corporate goal in late 2007 to move to “Net Zero” environmental footprint with one of Frito Lay’s nearly 40 manufacturing plants

• The 188,000 ft2 Casa Grande facility, built in 1984, was selected

• Products include Lay’s potato chips, Fritos corn chips, Tostitos tortilla chips, Doritos tortilla chips, and Cheetos cheese-flavored snacks.

• Plant to be operated with renewable energy and recycled water: 80+% reduction of water, electricity

• First existing food manufacturing site in the US to achieve LEED EB Gold certification

• Water solution: MBR, commissioned in summer 2008 + RO for process water recovery & reuse

• Average flow: 648,000 gpd

• RO water reused for rinse and wash water in the chip making process


Feb 20th, 2014

Frito Lay, Casa Grande, AZ- 0,65 MGD

Bioreactor Centrifuge Building


Feb 20th, 2014

Frito Lay, Casa Grande, AZ- 0,65 MGD

Process Blowers Membrane Train


Feb 20th, 2014

Basic American Foods ID – 0,75 MGD

Key Project Design Issues:

• Treating wastewater from potato processing

• Nitrification/Denitrification for direct discharge

• Complete Design/Build project

• Commissioned in March 2003

• Price: $US 5.1M


Feb 20th, 2014

Basic American Foods ID – 0,75 MGD

Erection of Bioreactor Tank


Feb 20th, 2014

Basic American Foods, Blackfoot, ID

Installation of ZeeWeed Tank


Feb 20th, 2014

ADM, Decatur Illinois- 6MGDOilseed Processing

One of the world’s largest processors of oilseeds, soybeans, corn, wheat and cocoa

WWTP: anaerobic treatment / aerobic treatment / dissolved air flotation / settling / tertiary treatment with membranes (ZW-500c)

5 MGD (3,470 gpm) tertiary ZeeWeed System to recycle secondary effluent to cooling towers (part of the treated water is reused for cooling tower makeup water; the rest is sent to sewer)

Phase 1: commissioned in March 2004. Price: $US 3.5M

Expanded to 6 MGD (4,200 gpm)

Provided savings in cooling tower chemicals of > $ 1 M per year

In the words of the operator; Brad Crookshank, “The cooling towers have never run better”


Feb 20th, 2014

ADM, Decatur Illinois- 6MGD


Feb 20th, 2014

ADM, Cedar Rapids, IA –3.5MGDEthanol Production Wastewater• Dry corn milling plant with an initial

production of 275M gal per year

• Marks ADM’s investment to expanding its biofuels capability

• 3.5 MGD MBR to treat wastewater from the facility

• MBR permeate is used for cooling tower makeup, like the previous tertiary system in Decatur, IL

• WWTP commissioned by end 2008


Feb 20th, 2014

Citrosuco, Santos-SP, Brazil –0,13MGD

Project Background

• Citrosuco is one of the world’s largest producers of fresh & concentrated orange juice

• 20,000 tonnes of oranges harvested daily

• Citrosuco has 2 factories, one in Mattão and the other in Limeira, both a few hours outside of São Paolo

• Together, both plants process ~100,000 oranges per minute – roughly 2,000 tonnes of orange juice concentrate per day, or 280,000 tonnes annually

• Two-thirds is exported to Europe

Plant Entrance


Feb 20th, 2014

Citrosuco, Santos-SP, Brazil –0,13MGDConfiguration

• MBR will be located at the port of Santos-SP, where 30,000 tonnes of concentrate is stored prior to being exported in cooled tanker ships

• Total MBR feed is 126,800 gpd (480 m3/d)

• 82,400 gpd (312 m3/d) is sent through an RO

• Water is reused for cleaning equipment contacted by juice

• The remainder, 44,400 gpd (168 m3/d) of MBR permeate is reused for cleaning the second line areas not coming into contact with juice

• MBR configuration is 4 cassettes x 32 modules

• Contract value is ~$US 1M

Loading Dock

Zeeweed MBR Experience


Feb 20th, 2014

MBR-Versatile Technology for Virtually All Wastewater Treatment Applications

Double your plant’s capacity within the same footprint Traverse City, MI

Enclose and blend your plant with the local surroundings Cauley Creek, GA

Greenfield Plants

Retrofits

Treat and reuse your plant’s effluent for irrigation American Canyon, CA

Water Reclamation


Feb 20th, 2014

Proven Solutions for Plants of All Sizes

GE has the proven experience to deliver MBR plants of any size, from small pre-engineered, quick delivery systems to the world’s largest operating plants.

< 2,000 GPD > 90 MGD


Feb 20th, 2014

Project TechnologyCommissioning

DateADF/MDF (mgd)

Seine Aval (Acheres), France GE/ZENON 2016 57.6 / 91.9

Macau, China GE/ZENON 2014 35.9 / 48.6

Riverside, CA, USA GE/ZENON 2014 32.0 / 48.0

Brightwater, WA, USA GE/ZENON 2011 31 / 45

Visalia, CA, USA GE/ZENON 2014 22.0/ 44.0

North Las Vegas, NV, USA GE/ZENON 2011 25 / 35

Ballenger McKinney ENR WWTP, MD,

USAGE/ZENON 2013 15 / 34.8

Cox Creek WRF, MD, USA GE/ZENON 2015 15 / 30

Yellow River, GA, USA GE/ZENON 2011 18.3 / 29.3

Cannes (Aquaviva), France GE/ZENON 2013 15.6 / 27.9

Busan City, Korea GE/ZENON 2012 26.4 / 26.4

Johns Creek, GA, USA GE/ZENON 2009 10.9 / 24.7

Changi, Singapore GE/ZENON 2014 15.9 / 23.8

Turkmenistan – Polimeks GE/ZENON 2011 18.5 / 23.1

Cleveland Bay, Australia GE/ZENON 2007 7.7 / 19.8

Broad Run WRF, VA GE/ZENON 2008 10 / 18.8

Cairns North, Australia GE/ZENON 2009 5.1 / 15.4

Cairns South, Australia GE/ZENON 2009 5.1 / 15.4

Peoria, AZ GE/ZENON 2008 10.0/15.0

Largest ZeeWeed MBRs


Feb 20th, 2014

Over 400 MGD-years of MBR Experience

ZeeWeed MBR technology offers the most:

• R&D experience

• Membrane manufacturing experience

• System and process design experience

• Commissioning experience

• Operation and maintenance experience

• Service and support experience

• Value

MGD-years = (plant capacity) x (years in operation)


Feb 20th, 2014

Thank You!

mbr-the reliable solution for difficult to treat wastewaters€¦ · 2 nesowea industrial waste...

Documents