for energy efficient operation & improved process control

Excellence in aeration control -for energy efficient operation & improved process control

Hassan Ragab, Alterous – Partner of BINDER Group

1

© BinderGroup Germany

Existing wastewater treatment plants have following needs:

▪ Treatment capacity – growing population, increaseconnection rate

▪ Effluent quality – re-use for irrigation

▪ Check in needs for • refurbishment of existing equipment

• expansion (new tanks, new technologies e.g. MBBR)

Actual Situation

EGYPT

2


Challenges:▪ comparable higher investment costs▪ proper design of components & system integration▪ Skills of operational staff

Chances:▪ high quality effluent (re-use agriculture)▪ digestation o sludge reduces load to biological treatment of 1/3▪ energy efficient operation & very low carbon footprint▪ sustainable investment

Technologies

Wastewater treatment in activated sludge plants

3


15%

11%

4%4%

1%Aeration

Solid Handling

WW Pumping &Primary Clarifier

Secondary Clarifier& RAS Pumping

Lighting & Bldgs

Headworks

4

Total Energy Consumption in WWTPs

Data from WEF MOP 32 (2009)

Aeration65%


4

We focus on aeration!

5

Blower1

Flow meter2

Control valve3

Control system 6

Sensors (DO, NH4-N, NO3-N) 5

Diffuser, Mixer4

Biological Aeration System

Components Aeration System

Aeration System


Target values for efficient systems: <15 kWh/ PE/ year for the aeration system<25 kWh/ PE/ year for the whole plant

6

Valve-Control-Massflow - VACOMASS®▪ Thermal mass flow meters

▪ Jet control valves – Patented, pressure recovery up to 75%

▪ Diaphragm control valves

▪ Aeration controller, flexcontrol including “flex algorithm” with Artificial Intelligence (AI)

Specially designed for biological process in wastewater treatment industry

VACOMASS® Product Line

Patented


Patented

WWTP Songshen Phase I (CN)

Stable DO-Control in tank 1, zone M3 (start-up 2018)

13.11.2018 14.11.2018 15.11.2018 16.11.2018 17.11.2018 18.11.2018

DO-ACT mg/l DO-SET mg/l Stroke % 1.7 +/- 0.3 mg/l

7


0,1640,174

0,1470,128 0,123 0,120 0,120

0,000

0,050

0,100

0,150

0,200

0,250

3月 4月 5月 6月 7月 8月 9月

Energy consumption of blowers

FINE TUNINGBEFORE START UP

energy consumption reduced for 28.4%

March April May June July August September


Reduction in energy consumption of blower

8


Total nitrogen concentration in the effluent is reduced for 20%

TIME May June July August September October

AVG 10.66 11.53 10.46 9.93 8.24 8.81

MAX 14.33 13.07 11.63 12.39 10.39 10.91

MIN 8.88 8.90 8.10 6.11 6.26 6.93

9


Improvement of effluent quality


10

Improvement due to PI2D-AI and ABAC

C-Dosing 22.4 %

COD reduction 24.3 %

NH4 reduction 30.4 %

NO3 reduction 52.9 %

Energy savings 19.0 %5-month comparison

Water inflow 30,000 m³/d2 lines – 2 zones each


Reduction of chemical´s consumptionResults: reduction of total nitrogen in the effluent with 19% less energyconsumption plus 22% savings in chemicals


▪ Advanced aeration controller• Automatic parameter adjustment through AI

• Eliminates disturbing factors due to load changes

• Control, maintenance and monitoring functions

▪ High control quality• Typical max. DO-deviation +/- 0.3 mg/l

▪ Proven improvement total N• Precise aeration control: 15 – 30 %

▪ Proven energy savings• Precise aeration control: 10 – 40 %• Precise control valve, low Δ p: 5 – 15%• Sliding header pressure: 8 – 10 %• Ammonia-based DO-SET: 8 – 20 %

Process safety

Equipment safety

Energy savings Control quality

Quality features of aeration control

Summary results

Conclusions


11

Target value15 kWhr/ PE/ year

Actual reality> 50 kWhr/ PE/ year

12

Worldwide References

Amsterdam (NL)

Vienna (AUT)*

Auckland (NZ)*

Ulm (GER)

Gent (BE)*

Shanghai (CN)*

Dortmund (GER)

Milano (IT)

Hamburg (GER) Berlin (GER)

Arnhem (NL)

Beijing (CN)*

Singapore (SGP)

© BinderGroup GermanyMunich (GER)*

Cleveland (USA)

13

Many thanks for your attention!

Do you have any questions?


14

Manuela CharatjanManager Process Engineering

Binder GmbHBuchbrunnenweg 1889081 Ulm, GermanyTel. +49 731 18998 - [email protected]

Your direct contact to us!

Hassan RagabCEO

ALTEROUS 2008 Al-Batha TowerBuhierah Cornish RoadP.O. Box 60699, Sharjah, UAETel. +971 50 626 [email protected] www.alterous.com

Please feel free to contact us directly


for energy efficient operation & improved process control

Documents

Transcript of for energy efficient operation & improved process control