WWOA Conference @ Wisconsin Dells

Session D: MIXING --Wednesday, Oct. 7, 2015

How to Reduce the Operating Cost of Your Wastewater Treatment Plant with Efficient Mixing Authors: Ken Neu, MS Environmental / Health Products & Service, LLC

Sam Kondo, PhD Star Burst Technology, LLC

Contents of Presentation

Introduction-various mechanical & high pressure pulsed air mixing

Introduction of Low Pressure (plant) Pulsed Air Mixing

Benefits of Low Pressure Large Bubble Pulsed Air Mixing

Case Study: Ridgeville, IN—Star Burst Mixing with Aeration

BioP Mixing Demonstration Study @ MMSD—South Shore Plant

Waster & Wastewater Treatment Solutions

KEN NEU, M.S.

ENVIRONMENTAL / HEALTH

PRODUCTS & SERVICE

PO Box 21 P. O. BOX 101

Richfield, WI 53076 PHILLIPS, WI 54555

Business Cell: 262-628-1300

E-MAIL: ken-ehs@juno.com

Offered by: KEN NEU, M.S.

ENVIRONMENTAL / HEALTH PRODUCTS & SERVICE PO Box 21 P. O. BOX 101

Richfield, WI 53076 PHILLIPS, WI 54555 Business Cell: 262-628-1300

E-MAIL: ken-ehs@juno.com

High-speed

Mixer

Slow-speed

Vertical Mixer

---- Power of Large Bubble Pulsed Air Mixing---- -----Minimum Energy Consumption and Maintenance-----

• Pulsed Air mixer systems are ideal for wastewater treatment chambers (aerobic, anoxic and anaerobic), sludge storage tanks, open channels, equalization tanks, and digesters, both anaerobic and aerobic.

• Equally well suited for water treatment applications, such as flocculation basins, disinfection chambers, treated water storage AND for industrial & agricultural mixing applications.

Effective Mixing Zone 0.5 to 1 feet/sec

4 to 6 feet /sec

- 10 feet for 12”Mixer - 20 feet for BC101

General Concept- Pulsed Bubble Mix Example: Early Version- Star Burst Mixer

Pulse Air Mixing – How It Works

Harness the power of large bubbles for highly energy- efficient complete mixing.

Use short, powerful bursts of compressed air or gas (digester, etc.) through engineered mixers.

Large bubbles lift liquid with air/gas blending the contents.

Creates a VERY powerful upward force as pulsed air bursts are released (less energy to mix than high or low speed mechanical mixers—US Dept. of Energy noticed)

Mixing liquid with Bubble - DOE evaluated Pulsed Air Mixing in 1999 as an - Innovative Technology.

- Report title page: below

- Pulsair Systems, Inc--1999 - Pulsed Hydraulics, Inc. (PHI)--2004 - EnviroMix, Inc -- 2008

Three similar Pulsed Air Mixer products –All use high-pressure compressed air develo

This is a typical installation of Pulsair cited from their

website.

Less Electricity Usage - Promoted by US EPA

PHI Design/Specifications

Every PHI Hydro-Pulse mixing solution is custom designed and engineered to

meet the unique requirements of each customer's mixing application. The PHI

mixing system uses air supplied by a compressor (blower air cannot be used

as the PHI system requires relatively high psi) which creates the source of the

Hydro-Pulse. The air then goes through a MAC valve which is contained in a

valve enclosure and then through piping to the forming plates which are

installed at the bottom of the mixing basin. The amount of air required is

determined by the size and shape of the tank, the tank contents, and the number of forming plates installed.

- 5 – 15 HP rotary screw compressor and the reserve tank

- Control Panel with solenoid valves, timers,…

- SS Piping - Floor mounted nozzles in a tank

- Floor mounted SS nozzles

Less Electricity Usage – PulsAir, Phi, BioMx

These are a series of pictures of released bubbles from the Pulsair nozzle.

1. SS circular nozzle of Pulsair 2. Compressed air is released by manipulating a timer and a solenoid valve.

3. Some bubbles become 4” in diameter. 4. Some bubbles enlarge to 6” in diameter.

(1/6) Less Electricity Usage – PulsAir, Phi, BioMx

Toroidal Bubble Mixer

Mixers

Pulsed Bubble Mixer

Submersible High-speed

Mixer

Vertical Slow-speed

Mixer

1.84 HP 15.8 HP

7.3 HP 4.2 HP

Intermittent Large Bubble Pulsed Air Mixers—the competitors

US Department of Energy-1999--Innovative Technology Summary Report

Star Burst Technology– Indiana— 1998 to present

Sam Kondo, PhD. developer-inventor of LOW PRESSURE PULSED BUBBLE Geyser Pump-2001 (sold 4500 units from 2001 to 2012)

Evolution of LOW PRESSURE PULSED BUBBLE Star Burst Mixer-2012

Pulsair Systems, Inc ----1999 (high pressure pulsed bubble)

PHI --State of Washington—2004 (high pressure pulsed bubble)

Enviromix—South Carolina---2008 (high pressure pulsed bubble)

Mixer Comparison

Could it be that Star Burst Low Pressure Mixer may be 75 to 97 % less power cost than a High-Speed Mixer ??

Kondo comparison between StarBurst mixer and other bubble mixers (Randall & Randall 2012)

Bubble Mixer x 30: EDM = 10 ft 7.32 HP

StarBurst 12” Mixer x 30: EDM = 10 ft 1.6 HP

○ Effective Diameter of Mixing (EDM) is typically 10 feet. ○ Mixing in a tank of 41 ft x 55 ft x 24 ft (404,000 gallons)

Kondo comparison between StarBurst mixer and other bubble mixers (Randall & Randall

2012)

StarBurst 18” Mixer x 12: EDM = 10 ft 1.8 HP StarBurst Mixer BC101 x

3 EDM = 21-26 ft 2.2 HP

StarBurst Mixer (BC101 x 1, DC101 x 4): EDM = (56ft, 17 ft) 2.3 HP

○ EDM’s of StarBurst Mixer is 10, 17, 21, 26, 31, 36, 38 & 56 feet.

Low Pressure Pulsed Air - How It Works - Bubble Creation

• Installed at the bottom of a tank; Low-pressure (facility) air is fed from a blower to the mixer. – If water depth is 10 ft., air pressure needed is 4.3 psi. – If water depth is 20 ft., air pressure needed is 8.6 psi.

• Air is accumulated within an air capture cylinder in the mixer until the air level reaches the bottom of the air cylinder;

• When air/water interface in the cylinder reaches the bottom of the cylinder, the air pocket is broken;

• -All accumulated air is instantly released from the air cylinder, forced out due to the static pressure of the water. The period of bubble release is very short (< 1/16 second). Air release in a very short time creates a TOROIDAL (rolling circumference)bubble 4 ft. diameter from a 12” mixer.

Low Pressure Advantages

Slightly Compressed gas: Air, Nitrogen or Digester Gas

Electrical power: limited to the power required to produce

the low-pressure gas source (blower)

CAN use (low pressure) plant air supply---NO

SEPARATE COMPRESSOR REQUIRED

Low Pressure Pulsed Bubble Mixing

–How It Works-- Simple & Easy Control

• Intensity of the mixing: --Simple-- control the air volume

to mixer (hand valve or automated)

• Interval between bubbles & bubble size are the key

features of the low pressure (Star Burst) Mixer

• Air Pulse production frequency desired is determined

based on a number of variables:

– viscosity of fluid being mixed, flow rate, depth & volume of the basin.

Low Pressure Pulsed Air Mixing Advantages

Mixing intensity can be different for each basin,

section of a basin, or application using PLANT OR

FACILITY AIR.

A simple turn of the air control valve (automated or

not) changes mixing intensity

Typically, these valve settings are set once for optimal

performance for each application and not changed

unless the operating conditions change.

Star Burst Advantages-Unique Toroidal Bubble

• A Huge air release in a very short time creates a toroidal vortex bubble 4 feet in diameter from the 12” mixer.

• The bubble rolls at the periphery & “wraps up” any filaments or elongated microbe clusters to create a dense microbe mass.

• Well suited for anoxic/anaerobic/BNR applications due to small surface to large volume ratio of 4’dia. bubble.

• 4’ toroidal vortex bubble is a standard & unique feature of Star Burst mixers.

Low pressure at the center of Toroidal Vortex

Pressure wave of fast moving fluid (20 feet/sec for StarBurst Mixer)

Rotation of fluid in toroid

- The Most Efficient Mixing Energy with the Least Applied Energy

http://hirabayashi.wondernotes.jp/2014/09/23/ CFD by Dr. Jun Hirabayashi

Vortex is formed when air volume is proper.

When air volume is too big, continuous bubbling occurs.

Toroidal Vortex

Toroidal

Vortex

Here’s what happens when Ellen learns about toroidal vortex bubbles/rings…

Rolling Motion Created by Toroidal Vortex Let’s take a closer look at the rolling motion created by a toroidal bubble. Watch the bottle cap as they drop it into the vortex.

Toroidal

Vortex

The StarBurst Mixer In Action

Toroidal

Vortex

Star Burst Advantages: Maintenance Simplified

• Multiple basins; different processes can often be mixed utilizing the same air source: Low Pressure Plant/Facility Air.

• No moving parts below water level. Low Pressure Plant Air Blower & valves are above water level, allowing quick and easy access.

• (Automated controls not required, may be added, if desired)

Toroidal Bubble Granular Activated Sludge (using Star Burst Mixers)

(10 inch transfer pipe from Aeration Tank to Clarifier) Less Maintenance, Faster Settling, Less Chemical for Coagulation

Ridgeville, IN—After Renovation

--Granular Activated Sludge--Advantages

• “Granular Activated Sludge” can be cultivated as the Star Burst Mixer operates with its unique toroidal bubble rolling action.

• Benefits of Granular Activated Sludge:

– Settling velocity of the sludge is increased up to 10 times faster than ordinary AS;

– Clarifier capacity may be increased with greater settling rates

– Sludge volume may be decreased due to increased sludge density

– With BPR, biological P release & uptake occurs as normal and may be enhanced.

– Granular Activated Sludge stays in suspension in anaerobic zone w/ Star Burst mix

– Dense solids = less polymer use = cost savings.

– Conversion to “Granular Activated Sludge” using Star Burst mixers may be possible in conventional AS systems & aerobic digestion tanks

Advantages Summary— Star Burst Low Pressure Pulsed Air Mixer

Durable- all PVC engineered construction; worry-free operation Lowest energy & air pressure requirements of all competitors

Lower maintenance than all competitors

Lowest capital cost of all competitors

Enhanced Oxygen Transfer efficiency (OTE) may be possible

when pulsed air mixers are used in conjunction with fine bubble aeration. The fine bubbles stay longer in water due to the mixer agitation.

Star Burst Mixers replace multiple mechanical mixers or other mixing devices, and their energy and maintenance requirements

Case Study: Ridgeville, IN WWTP 100,000 gpd Extended Aeration Activated Sludge Package Plant

The 2008 plant was having difficulty meeting permit. (Very Limited turn-down capability as built vs. 20 yr. design)

Renovations were done in early 2014 to improve performance. Some fine bubble diffusers were removed.

Star Burst Mixers were added.

Result: Plant performance increased.

Secondary effect: Energy use-- dramatically reduced.

Is this system proven in the field?

A1

A3

A5 A7

A9

Flow Equalization

Sludge Holding

A4

A2

A6 A8

A10 C1 C2 C4

Train 1 Train 2

Raw Sewage

C3

Ridgeville WWTP, IN

Case Study: Ridgeville, IN WWTP Number and size of units: Two trains, 50,000 GPD (each)

Detention time: 24.6 hrs.

Organic Loading: 10.24 lb.-BOD/1000 cu ft

Type of aeration equipment: Fine Bubble Diffusers

Air /blowers: 450 cfm/Three, 200 cfm at 5 psi

Air required: BOD: 65.4 cfm

NH3-N: 12.3 cfm

Mixing: 73.3 cfm

RAS: 24.0 cfm

Case Study: Ridgeville, IN WWTP Clarifier 2-rectangular dual hopper/each train

12’ W c 24’ L x 15’ SWD

Surface Settling Rate: 173.6 [GPD/ft.2] for 0.1 MGD

Weir overflow rate = 3061 GPD/lf/tank at 0.3 MGD Peak hourly flow

RAS two 3” Closed Bottom Star Burst Pumps/ea. train

Aerobic Sludge Holding Tank: Two, one per train:

Air supply = 30 cfm/1000 cu, 27.5 cfm/tank

Effluent BOD = 25 mg/L Ammonia = 5.0 mg/L

Ridgeville WWTP Ridgeville WWTP, IN - BEFORE

12” and 18” StarBurst Mixer

Ridgeville WWTP

Effluent BOD = <4.0 mg/L Ammonia = 0.4 mg/L

Ridgeville WWTP, IN - AFTER

Oxygen Transfer Efficiency is enhanced by the combination of fine bubble diffuser + Mixer

High DO Tank - FBD + Mixer

StarBurst Granular Activated Sludge (10 inch transfer pipe from Aeration Tank to Clarifier)

Less Maintenance, Faster Settling, Less Chemical for Coagulation

Ridgeville, IN—After Renovation

Case Study: Ridgeville, IN WWTP Treated vs. Raw WW-Observed Microscopic View of Granular Activated Sludge

30 Minute Settleometer

Here’s a short video of our Granular Activated Sludge in a Settleometer…

Quick Settling Sludge

Case Study: Ridgeville, IN WWTP

MLSS Settleometer 30 min SVI

Case Study: Ridgeville, IN WWTP

ExtendedAerationSizeofBlower [HP] 35

ElectricityCost [$/year] 17,154

GranularActivatedSludge

SizeofBlower [HP] 8

ElectricityCost [$/year] 3,92123%

Electricity Cost: Before and after Renovation:

After renovation, the operation blower is reduced from 35 HP to less than 8 HP (77% R).

Case Study: Ridgeville, IN WWTP

Conclusions:

The combined fine bubble WITH Star Burst intermittent mixing:

Creates an optimum environment for high treatment levels,

Good environment for biological nutrient removal capability,

Toroidal Bubble = Granular Activated Sludge & Improved floc settling,

Reduction of operating energy as a side benefit,

Low maintenance cost-no moving parts below water

Reduction of polymer use due to better settling floc.

BioP Mixing Demonstration Study @ MMSD

—South Shore Wastewater Treatment Facility

Aeration Tank # 25 was outfitted with twelve (12) 18” Star Burst Low Pressure Pulsed Air Mixers on June 14, 2015. An anaerobic zone was created of roughly the beginning 50’ of a +350’ Long aeration channel.

BioP Mixing Demonstration Study @ MMSD —South Shore Wastewater Treatment Facility

BioP had been successful when aeration was stopped in the initial section of aeration basins. However, solids accumulations occurred in the unaerated section of tanks.

Mixing Goals:

Maintain MLSS in suspension in the first 47 feet of an aeration basin; no solids accumulation of negative consequence.

Maintain dissolved oxygen in anaerobic condition

(textbook indicates 0.3 mg/l DO or less).

Demonstration Phase 1: June 14-July 25 (1-2 bursts/ min/mixer & 7-8 bursts/min/mixer), drain tank, examine mixers, tank floor, repair air leak.

Demonstration Phase 2: August 27 – Ongoing (3-5 bursts/min/mixer)

A-O Process for phosphorus removal

Phosphorus absorption by PAO (Phosphorus

Accumulating Organisms) Phosphorus

Release

Plan View

Side View

BioP Mixing Demonstration Study @ MMSD —South Shore Wastewater Treatment Facility

Twelve (12) Star Burst Mixers Installed: 15 minutes/ mixer w/4 sets-3/8” SS anchor bolts. (< 4 hrs. to install mixers) Mixers DO NOT touch diffuser pipe or diffuser. Star Burst mixer air cylinder captures & releases existing diffuser air. Of 278 Sanitaire Diffusers in 1st aeration grid section, 266 diffusers plugged, 12 diffusers utilized as mixer air source.

Transport of mixers to jobsite & installation materials/plugging diffusers was $ 2,500 = $ 208/mixer. (mixer cost, mixer installation & diffuser plugging labor was not included in above cost)

StarBurst Mixer at MMSD

BioP Mixing Demonstration Study @ MMSD —South Shore Wastewater Treatment Facility

Twelve (12) Star Burst Mixers were installed over existing Sanitaire diffusers on June 14, 2015. Anaerobic zone volume is 160,000 gallons=21,333 cu ft

LOW PRESSURE Plant Air is the only

mixer air source. Mixer pulsed air rate

average for demonstration

period 2 from 8/27-9/11 = 4.4 bursts/min = 24.8 CFM @ 6.7 psi

No Baffle Wall between AN and A Zones

Light Weight, Anchored Heavy Weight, not Anchored

Renovation takes a ½ day

(1) (2) (3) (4) (5) (6) (

D Drain the Basin Clean the Basin Unused FBD to be plugged (270) Cover the unplugged FBD with the Mixer Anchor the Mixer Fill the tank with water to check air leak Completed!!!

No Special Air Supply

Lines

Low Pressure

Air

No Cleaning

No Baffle Wall

Basin 25 installation and Bio-P

BioP Mixing Demonstration Study @ MMSD —South Shore Wastewater Treatment Facility

Star Burst mixers in action anaerobic zone-tank #25 Future Goal: Flow adjustments will fine-tune treatment process. Baffle walls to prevent aerated water backflow into the anaerobic zone may NOT be needed.

Toroidal Vortex for Complete Mixing at Low DO Tank

At MMSD’s South Shore plant, Basin # 25: Intermittent Toroidal Bubble mixing significantly increased MLSS suspension-----with No settled sludge at the corner of the tank.

Toroidal Bubble

DO, ORP and Phosphorus in Basin 25

2 Bursts/min 7 Burst/min SCFM

7 Bursts/min MLSS

2500 SCFM

Only 2.3% of total air supplied to aeration basin #25 was used for anaerobic zone mixing

Complete Mixing !!!

2 Bursts/min 7 Burst/min MLSS, DO

Sludge Accumulation?

Basin 25 with Star Burst Mixers Basin 26 with FBD

Accumulated Sludge at 26th Basin

40-50% solids contents at the bottom of 26th Basin

No Sludge Accumulation in 25th Basin

Estimated 3,000 mg/L solids at the bottom of 25th Basin

BioP Mixing Demonstration Study @ MMSD-SS WWTF- Star Burst Mixer Study Phase 2 (8/27-9/11) Basin #25

Sample Location Ortho-P, mg/l

Inf. to basin 25 (PCE) 5.55

# 25 - Anoxic 1 15.37

# 25 - Anoxic 2 10.63

# 25 - Anoxic 3 8.17

Basin End 0.37

Plant Eff. 0.30

Significant P release in Anaerobic zone, average of 7 data sets.

Location MLSS, mg/l

AN zone- top 5’ 1873

AN zone-middle 5’ 1871

AN zone-bottom 5’ 2035

Ave. 1926

All values +/- 5.6% of Ave = Relatively Well Mixed Vertical Column, average of 7 data sets.

Conclusions

Bio-P release was achieved in the 47’ Star Burst Low Pressure Pulsed Air Anaerobic Mixing Zone with: - Ave DO 0.3 mg/l, - Ave ORP -159 mv Despite vigorous aeration in immediate downstream aeration zone, and NO BAFFLE WALL to prevent higher DO water flow back.

Star Burst Low Pressure pulsed air flow through mixers: Ave 4.4 bursts/min/mixer in the Anaerobic zone-estimated 35.6 SCFM 0.616 HP, o.029 HP/1000 cu. ft., 0.0039 HP/1000 gal mixing volume

Star Burst Low Pressure Mixer Demonstration @ MMSD

South Shore WWTF -- Phase 2 (8/27-9/11- 7 data sets-):

BioP Mixing Demonstration Study @ MMSD SS WWTF Phase 2(8/27-9/11-- 7 data pts-ongoing):

Conclusions—continued

Two types of Aerated Fine Screen on Star Burst mixers worked well without plugging

No sludge accumulation in Basin 25 after 6 weeks operation

Potential Future Goal: Attempt to optimize air distribution with aeration zone valve adjustment to minimize high DO water flow back to anaerobic zone. If this can be successfully achieved, the expense of (full or partial) baffle wall construction may be avoided or at least reduced.

---Star Burst Products---- Airlift Pumps & Pulsed Air Mixers

Environmental /Health Products & Service

Thank You for the opportunity!

Custom Mixing Designs via Scientific and Biological Innovation

Sludge Storage Tank Mixing— Blue River Valley School—Indiana

BC101 Installed in Sludge Tank

The size of the sludge holding tank at Blue River Valley School is:

34' 2" (L) x 15'3" (W) x 10' (D). The volume is 39,000 gallons. Airflow used in this unit is 12.8 CFM @ 4.3 psi. The blower power is 1/3 HP.

Custom Mixing Designs via Scientific and Biological Innovation

Installation of BC101

Installed with a backhoe

BC101 with Extended Exhausts

Burst from 18” Mixer Top View

Albany, IN 5 Horsepower Aerator/Mixer-- 2012

Poor Sludge Consistency = Higher Polymer Consumption during Dewatering

Rotary Vane Compressor of ¼ HP

BEFORE and AFTER Starburst Pump

Before Starburst Pump secondary clarifier water was turbid and scum was observed

12 hrs after Starburst Pump; Transparency of the clarifier became more than 2 feet

After Starburst Pump installation Scum has disappeared

Before: •Clarifier covered by thick scum

Dirty effluent due to sludge overflow

AFTER: • No more floating scum on clarifier • Sludge overflow eliminated • Clarity of water in clarifier exceeds 1 foot

Underwater structure can be seen through.

Star Burst Advantages-Summary

Durable, robust engineered construction; worry-free operation Lowest energy & air pressure requirements of all competitors

Lower maintenance than all competitors

Lowest capital cost of all competitors

Enhanced Oxygen Transfer efficiency (OTE) may be possible when

Star Burst mixers are used in conjunction with fine bubble aeration. The fine bubbles stay longer in water due to the mixer agitation.

Star Burst Mixers replace multiple mechanical mixers or other mixing devices, and their energy and maintenance requirements

Geyser Pump for RAS

(1) Start (2) Air pocket

Fill Period < 1 sec

Fill Period > 1 min

Air

Air

(3) Ejection

Ejection Period

<1 to 10 sec

Air

(4) Suction

Suction Period ~ <1

to 20 sec

Starburst Air-Pulse Mixer / Pump Operating Principal

Custom Mixing Designs via Scientific and Biological Innovation