BIO-CEL -MCP: Verfahrensprinzip und Referenzen. Dr.-Ing. Christoph Thiemig

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1 BIO-CEL -MCP: Verfahrensprinzip und Referenzen Dr.-Ing. Christoph Thiemig

2 Inhalt 1. Begriffsdefinitionen MBR 2. Theoretischer Hintergründe zum Mechanical Cleaning Process MCP 3. Ergebnisse aus 2 Jahren Pilotanlagenbetrieb 4. Ökonomische Vorteile 5. Schlussfolgerungen 2

3 Begriffsdefinitionen Term Crossflow Cake layer; cake layer formation Backdiffusion Fouling Scaling Expression Scouring of membrane by air Formation of particles on the membrane caused by the filtration process. By crossflow removed cake layer Pollution of membrane by organic compounds which cannot be removed by backdiffusion. Removable by oxidizing cleaning agents. Pollution of membrane by anorganic compunds. Removable by acidic cleaning agents. 3

4 Begriffsdefinitionen Term Unit Expression Flow Q L/s or m³/h Hydraulic througput per time (specific) permeate flux I L/(m²*h) Flow in respect to presently active membrane surface Transmembrane Pressure TMP Permeability Perm (=I/TMP) bar, mbar, kpa L/(m²*h*bar) Depression on suction side of membrane during filtration process. TMP is usually directly proportional to flux Parameter to determine the condition of the membrane. Perm is calculated by the ratio of flux/tmp How to judge the condition of your filtration: - Check TMP at a fixed Flux, or - Calculate Permeability 4

5 Über- und unterkritischer Fluss Filtration Fluss Pause Überkritischer Fluss Kritischer Fluss 0 Unterkritischer Fluss Zeit TMP konstanter TMP während der Filtration ansteigender TMP während der Filtration DSB = Deckschichtbildung RS = Resuspendierung Dicke der Deckschicht Deckschicht konstant δ DS = f(v p ) (DSB = RS) Deckschicht ansteigend δ DS = f(v p,t) (DSB > RS) Deckschicht sinkend δ DS = f(v p,t) (RS > DSB)

6 Hintergrund und Geschichte Beginn der Untersuchungen von MICRODYN- NADIR im Jahre 2006 Literaturrecherche Diplomarbeit im Jahre 2007 mit unterschiedlichen Granulaten Verfahren zur Patentierung eingereicht in 2008 Weitergehende Forschungsaktivitäten Technische Universität Darmstadt Fachhochschule Osnabrück Kontinuierlicher Pilotanlagenbetrieb

7 Prozess

8 Prozess MCP-Granulat (derzeit)

9 Prozess

10 Prozess MCP-Granulat BIO-CEL -MCP Grundidee des Wirbelschichtreaktors Granulat wird dem Belebtschlamm zugegeben Aufströmung erfolgt über Crossflow-Belüftung Dichte des Granulates~ 1 keine Absetzprozesse

11 Prozess MN Pilotanlage

12 Ergebnisse der Laborversuche

13 Ergebnisse der Laborversuche

14 Ergebnisse der Laborversuche Flux: LMH 40 days non-stop

15 Ergebnisse der Laborversuche Referenz MCP Betriebszeit 700 d 700 d Gesamtdurchsatz 2262 m³ 2700 m³ Differenz m³ (+ 19 %) Mittlerer Fluss 16.6 LMH 19.8 LMH Peak-Fluss 25 LMH 40 LMH

16 Ergebnisse der Laborversuche Entscheidend: Peak-Fluss 25 LMH 40 LMH (+ 60 %) Design is based on peak-flux (e.g. stormwater) Example: 1,000 m³/h peak flow Standard MBR (25 LMH) 40,000 m² Membrane MCP-MBR (40 LMH) 25,000 m² Membrane Please take in mind: Design also based on average flux both fluxes are relevant Application with high peak factor of highest interest!

17 Ergebnisse der Laborversuche Rejection Measurement New Membrane Rejection > 90 % After 18 month of operation with MCP Rejection 94 % After 24 month of operation with MCP Rejection 90 %

18 Ergebnisse der Laborversuche SEM Images

19 Economic Efficiency Calculation Economic Efficiency Calculation 1. Invest Cost 2. Operational Cost 3. Comparison Overview / general Example 10,000 PE 2,000 m³/d, peak 167 m³/h (0.5 MGD, peak 1 MGD)

20 Economic Efficiency Calculation Invest Membrane area Standard MBR 25 L/(m² h) peak flow MCP-MBR 35 L/(m² h) peak flow Cost difference about 25 % Example PE: Standard-MBR 352,000 MCP-MBR 264,000

21 Economic Efficiency Calculation Invest (Membrane area)

22 Economic Efficiency Calculation Invest Membrane area Lifetime Standard MBR 8a (?) MCP-MBR 6a 8a (?) Annual cost Standard MBR 352,000 / 8a = 44,000 /a MCP-MBR 264,000 / 6a = 44,000 /a 8 year lifetime: MCP-MBR 264,000 / 8a = 33,000 /a

23 Economic Efficiency Calculation Invest All others with benefit for MCP-MBR Filtration Tank Volume Installation cost (manpower, handling, ) Chemicals infrastructure Crossflow aeration blowers. Not to be considered!

24 Economic Efficiency Calculation Invest Membrane area (10,000 PE)

25 Economic Efficiency Calculation Invest Rejection of MCP Depends on system and size ( C.Thiemig) For 10,000 PE Example about 10,000 Lifetime 10a 1,000 /a annual cost MCP Granulates Invest and replacement For 10,000 PE Example about 2,000 Exchange 1/a 2,000 /a annual cost

26 Economic Efficiency Calculation Operational Energy Demand Standard-MBR 0.48 kwh/m³ MCP-MBR 0.36 kwh/m³ 25% less cost for energy Example PE Standard-MBR 350,000 kwh/a (35,000 /a) MCP-MBR 260,000 kwh/a (26,000 /a)

27 Economic Efficiency Calculation Operational Cost Chemicals and Manpower for cleaning Maintenance Cleaning Standard-MBR 14d, 250 ppm Cl + 120d, 1000 ppm CA MCP-MBR 28d, 250 ppm Cl (disinfection) Intensive Cleaning Standard-MBR 1a, 500 ppm Cl + 1a, 2500 ppm CA MCP-MBR no intensive cleaning Example 10,000 PE Standard-MBR 1,900 /a (chemicals) 2,800 /a (manpower) MCP-MBR 140 /a (chemicals)

28 Economic Efficiency Calculation Conclusion MCP-Process shows advantages in invest (less membrane area) AND operational cost (less energy and chemicals demand)

29 Conclusion The granulates remove the fouling layer by enhanced mechanical effects No chemical cleaning during 2 year continuous operation sustainable process Superior effluent quality, no changing in turbidity, COD-removal,

30 Conclusion The MCP has a positive effect on membrane performance (results from MN pilot scale): non-stop operation: 24h/d for 2 years Average flux: 19.8 L/(m² h) (11.7 gfd) 20 % higher average flux compared to reference line Peak Flux 40 L/(m² h) (23.6 gfd) period of 16 days (non-stop, 24h/d) 60 % higher compared to reference line Importand for Design! Less Membrane Area required!

31 Conclusion Investigation of membranes after 2 year continuous MCP: SEM: membrane still in good condition Rejection of membrane: unchanged Cost efficient process: Less membrane area required Invest cost and membrane exchange cost Less chemicals, lower energy demand Operational cost

32 Thank you very much! W W W. M I C R O D Y N - N A D I R. C O M

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