7 - Inclined Plate Settler Clarification
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Transcript of 7 - Inclined Plate Settler Clarification
MARINETTE, WI
Spring Regional Meetings
April 17 - Ann Arbor & April 18 - Kalamazoo
April 24 - Mt. Pleasant & April 25 - Gaylord
Inclined Plate Settler Clarification Regional Developments
Thomas P. Grubb
Meurer Research
6270 Joyce Drive
Golden, CO 80403
STAINLESS STEEL SUPPORT BEAM
LEVELING WEIR
FLOW CONTROL DECKS EFFLUENT TROUGHS
Plate Settler System Components
SLUDGE COLLECTOR DRIVE
HISTORY OF PLATE SETTLERS
1886 - English Patent
1904 - Hazen’s Theory of Sedimentation
1936 - Plate Settlers Used in Mining Industry
1946 - Camp’s Shallow Depth Sedimentation Theory
1993 - MRI Top Tube Plate Settler Design
Multi-Sectional Settling Tanks developed
to minimize short circuiting
and
maximize flow distribution
Camp’s Shallow Depth Sedimentation Theory
Theory behind High Rate Clarification
3 ft Tube Settlers: Bloomington, IN Inlet baffle directing flow under tubes
Circular thickener sludge collection
3 ft Tubes: Louisville, CO Square btm trough, submerged orifices
2 ft Tubes: Ft. Thomas WTP, KY V-notch troughs 3’ above tubes
Tube Settlers Flow Distribution
MIXERS / FLOCCULATORS
Paddle wheel mixers Vertical turbine mixers
Flocculation Proper floc formation is key to settling
• Vertical impeller mixers: rapid or flash mix for pH adjustment, oxidant and coagulant addition using high particle collisions
• Paddle wheels: medium mixing energy for floc formation, maturation/growth and contaminant adsorption
• Hydraulic mixing: reduce hydraulic energy & distribute flow across basin width
Horizontal Paddle Wheel Flocculators
Vertical Turbine Flocculators Inlet Diffuser
Stage Four:
Hydraulic Mixer
Stage Three Stage Two Stage One Flash Mix
Flocculation Tapered Flocculation for Optimum Contaminant Removal
1000’s 100’s 80 60 40 20 10 0
Rapid Mix
Vertical Turbine
Paddle Wheel
Hydraulic
Flocculation Progressively Lower G-Values form a settlable floc
Flocculation Configuration - Flow Control to Minimize Short Circuiting
•Over Under Baffling
•Ported Baffle Walls
•Serpentine Flow
•Full Width Distribution
WYOMING, MI
INLET DIFUSERS REDIRECT FLOW ACROSS BASIN WIDTH
and REDUCE FLOC SHEAR
PLATE SETTLERS
Advantages of Plate Settlers
T-304 stainless steel lasts indefinitely
No power is required
No pumps, valves or blowers
No moving parts
Very low maintenance
Small Footprint Clarification Process
12MGD Footprint Comparison
Advantages of Plate Settlers
Plate Settler 0.3 gpm/ft2
40’ x 50’
Conventional Sedimentation 0.5 gpm/ft2 SOR 80’ x 208’
Lower cost of land, construction & building. Less space to maintain & smaller building size.
HOW
PLATE SETTLERS
WORK
How Plate Settlers Work
Falling particle sees the “projected area”
of each Plate
Projected plate area overlap
Results – plate settler basin is 1/10th that of conventional basin
Flow Distribution
Stable Laminar Flow Low Reynolds #
& High Froudes #
The settling distance is reduced by 98%, 3.5” compared to 15’ in a conventional basin
3.5"
Fg
Particles migrate to the plate surface along the resultant vector of the two forces – fluid drag (Fd) and gravity (Fg)
Plate settlers provide a “perfect environment” low velocities and no currents (Laminar flow)
How Plate Settlers Work
10’ plate length / 0.022 fps (¼”/sec) = 7.57 minutes residence time in plate
Particle must fall 3.5” vertically in 7.57 minutes = 0.46 in/min plate settling rate
15’ deep basin with 2 hr HRT, 180”/120 minutes = 1.5”/min conventional sedimentation basin settling rate
0.5”/min in plate basin compared to 1.5”/min for the conventional basin
SETTLING
ZONE
SLUDGE ZONE, 10%
INLET
PORTS
TOP TUBE
EFFLUENT COLLECTION ORIFICES
How Plate Settlers Work
Flow Path Through Plate Settlers
1. Flow enters basin high up & travels through inlet channel
2. Flow enters plate settlers through inlet ports and moves
up the plate
3. Top tube contains orifices which distribute flow evenly across the plate
How Plate Settlers Work
Feed Channels
Flow Control
Decks
Cable-Vac
Sludge Collection
Stainless Steel Support Beam
Plate
Cartridge
4.5' W Plate Space = 0.0340" to Achieve 2.0"
Design Head Loss
0.0000
0.0100
0.0200
0.0300
0.0400
0.0500
0.0600
0.0700
0.0800
0.0900
0.1000
0.25 0.5 1 1.5 2 2.5 3 3.5 4 4.5
Plate Spacing Orifice
-1/32" = 3" HL
+1/32" = 1" HL
HEADLOSS (Inches)
Ori
fic
e w
idth
@ 4
.5’L
& 0
.3 g
pm
/sf
The Search for Perfect Flow Distribution
How Plate Settlers Work
The “Pinch Zone”, a Full-Width Plate Orifice
Orifices Insure Even Distribution Across Entire Plate & Basin
How Plate Settlers Work
PLATE SETTLER CALCULATIONS
• Divide the flow in gpm by the loading rate
• Flow = 6,944, Loading Rate = 0.3 gpm/ft²
6,944 gpm/0.3 gpm/ft² =23,147 ft² projected area
Choose the specific loading rate. For example a standard loading rate is 0.3 gpm/ft2
of effective plate area at 90% efficiency.
• Efficiency = 90%, Projected Area = 23,147 ft²
23,147/0.9 = 25,719 ft² effective projected area
Divide the projected area by the efficiency to get
effective projected settling area
Calculation for 10 MGD (6,944 GPM):
Plate Settler Calculations
Sizing Calculation Example
• 4.5’W x 10’L plate @ 55o(cos55) x 0.9 = 23.23 ft² • Effective Projected Area Required = 23,147 ft²
• 25,719 / 23.23 = 1,107 plates
Divide the effective projected settling area by
the area of each plate to get # of plates
FABRICATION &
INSTALLATION
Manufacture frames and supports
PLATE SETTLER FABRICATION
PLATE SETTLER FABRICATION
Inclined Plates installed into frames @ 550
PLATE SETTLER INSTALLATION
Load onto flatbed trucks for shipping
PLATE SETTLER INSTALLATION
Install Beams & Crane Plate Cartridges into Position
PLATE SETTLER INSTALLATION
Plate Cartridges are Secured to the Beams
PLATE SETTLER INSTALLATION
Troughs are Lowered into Position
PLATE SETTLER INSTALLATION
Weirs are Leveled and Installation is Complete
Rapid Mix, Flocculation, Hydraulic Baffling, Plate Clarification and Sludge Removal
Frederick MD
PLATE CLARIFICATION SYSTEM
INCLINED PLATE SETTLER
INSTALLATIONS BENTON HARBOR, MI
MUSKEGON, MI SOUTH HAVEN, MI
WYOMING, MI MARINETTE, WI
BENTON HARBOR, MI
2010
2 Basins
12 MGD
40’L x 30’W x 15’D
0.3 gpm/sf @90%
BENTON HARBOR, MI
BENTON HARBOR, MI
Horizontal Reels
Ported Floc Baffle
15’L x 30’W x 15’WD
40 min@ 6 MGD
1st : 3 HP
2nd: 2 HP
3rd : 1 HP
BENTON HARBOR, MI
Inlet Flow Diffusers
G-Values, sec-1
1st : 70
2nd : 45
3rd : 20
4th : Hydraulic
BENTON HARBOR, MI 4 Rows, 6 MGD
150 Plates/Row
600 Plates/Basin
5 Orifice/plate
MUSKEGON, MI Two (2) Basins
86’L x 50’W x 17.3’D
20 MGD/Basin Design
6 MGD/Basin Average
0.24 gpm/sf Loading
2-50 NTU Raw Water
MUSKEGON, MI 2006
393 Plates/Row
2,358 Plates/Basin
9.55’L x 4.5’W Plates
6 Orifice/plate
MUSKEGON, MI 3 Troughs/Basin
45’L x 24”W x 28” D
4,650 gpm Capacity each
MUSKEGON, MI
MUSKEGON, MI
MUSKEGON, MI
MUSKEGON, MI
SOUTH HAVEN, MI 2009
2 Basins
29’L x 28’W
7 MGD, 9.7MGD Peak
0.3 gpm/sf @ 100%
SOUTH HAVEN, MI 1st Stage
3rd Stage 4th Stage
G-Values, sec-1
1st : 60
2nd : 40
3rd : 30
4th : 15
13.5’ L x 13.5’W
14.5’ WD
32 min@ 3.5 MGD
1st & 2nd: 2 HP
3rd & 4th: 1 HP
SOUTH HAVEN, MI 78 Plates/Cartridge
4 Cartridges/Basin
312 Plates, 4.5’ x 10’
SOUTH HAVEN, MI 2 Troughs/Basin
18”W x 18”D
2,000 gpm/trough
6 Orifice/plate
SOUTH HAVEN, MI Hoseless Cable-Vac™ Sludge Collector
¼ HP Reel-to-Reel Cable Drive
WYOMING, MI
Serpentine Flow Horizontal Reel Flocculators
WYOMING, MI 2010
3 Basins
86’L x 64’W x 16’D
30 MGD/Basin
0.30 gpm/sf @ 80%
WYOMING, MI
2009 - 2010
8 Rows of 4 Cartridges/Row
98 Plates/Cartridge = 3,136 Plates/Basin
8 Troughs/Basin, 22”W x 19”D x 85’L each
2,600 gpm capacity/trough
WYOMING, MI
MARINETTE, WI 2010
2 Basins
37’L x 22’W x 16’D
3.25 MGD/Basin
Expandable to 4.1 MGD
0.30 gpm/sf
8-100 NTU Raw Water
MARINETTE, WI 1st Stage
70 sec-1 G, 1.5 HP 2nd Stage
45 sec-1 G, 0.75 HP 3rd Stage
20 sec-1 G, 0.5 HP
Coagulant: Sumalchlor 50 or AquaHawk 607, Chlorine @ 0.5 ppm average, 3-6 max
29 min. HRT @ 3.25 MGD
MARINETTE, WI
Future Plate Capacity
Sludge Collector Cable Drive
MARINETTE, WI
Plate Support Beam
Hoseless Cable Driven Sludge Collector
Miramar WTP, San Diego, CA Four 55 MGD Basins
220 MGD
Largest Stainless Steel Inclined
Plate Settler Installation in USA
Inclined Plate Settler Clarification Regional Developments
Thomas P. Grubb
Meurer Research
6270 Joyce Drive
Golden, CO 80403
THANK YOU QUESTIONS?