GRAVITOX a fundamental approach to aeration design

Dr. Son Le & Ian Carline

The Carbon Crunch

Technology Solutions for the Water Industry

Haweswater House, 4th March 2009

GRAVITOX a fundamental approach to aeration design

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Dr. Son Le & Ian Carline

Asset Management & Regulation UNITED UTILITIES PLC, Warrington WA5 3LP
Email MS.Lee@uuplc.co.uk; web http://enzymichydrolysis.com/

GRAVITOX development Overview 1. Background 2. Introduction to Aeration 3. GRAVITOX Concept 4. Theoretical considerations 5. Experimental programme 6. Summary

Background
UK Government target for CO2 emissions: 20% below 1990 levels by 2010 60% reduction by 2050 real progress by 2020 (1.2MtC pa) UU target for CO2 emissions: 37M to achieve 8% reduction 2012 50% reduction by 2035 60% reduction by 2050
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Framing the challenge

UU Group GHG emissions 1990 - 2050
600000

T o n n es o f CO 2e

500000 400000 300000 200000 100000 0 1990 1994 2000 2005 2010 2015 2020 2025 2030 2035 2040 2045 2050

Year
Actual carbon emissions (1990-2005) and projections to 2020 Linear reduction of 60% from 1990 baseline Impact of mitigation activities to 2020
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Delivering our carbon strategy to 2050

488,000 tCO2e
CHP and IPM = 38,000 tCO2e Cost = 37m Wind = 80,000 tCO2e Cost = 80m

Low carbon technology = 80,000 tCO2e Cost = ??

What we are doing: Reducing footprint of existing assets Extending renewable energy Embracing R&D and innovation

170,000 tCO2e = TBD

122,000 tCO2e

Energy Use Analysis

Source: Yorkshire Water

Activated sludge aeration accounts for 55.6% of the energy used in sewage treatment

Introduction to Aeration
The purpose of aeration is two-fold: 1) Supply oxygen to microorganisms 2) Mixing to provide contact between microorganisms and nutrients

Coarse bubble aerators

orifice types

Maximum oxygen transfer efficiency (OTE) 0.75% per foot of depth

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Static tube

Surface Mechanical Aerators

Fine Bubble Aerators

FLEXIBLE MEMBRANE DIFFUSER (DISC & TUBE)

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Oxygen Transfer Efficiency Common aeration systems

Typical Oxygen Transfer Rates (kgO2/kWh , EPA 1984) Diffuser Type Clean water Activated sludge Coarse Bubble Diffusers 1.2 0.96 Fine Bubble Diffusers 3.9 1.76 Surface Mechanical Aerators 1.8 1.53 Submerged Turbine Aerators 1.2 1.02 Jet Aerators 1.68 1.26

These values represent OTE of 8 to 15% only

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DEEPSHAFT Process
Typical energy efficiency 5 - 8 kg O2/kWh RAS (42-67% OTE)

Influent

FE

Clarifier SAS
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GRAVITOX Development
Deep-Shaft efficiency without the high capital Simple Retrofit existing ASP assets Problems Bubble generation Aerated sludge pumping Bubble behaviour / Flow Distribution Performance data

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GRAVITOX Concept
GRAVITOX (Gravity Oxygenator)

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Theoretical considerations

Energy Demand Bubble Formation Bubble Transport Hydrodynamics Oxygen transfer Performance Prediction

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Energy considerations
bubble generation

Total power demand P = BG+BT+ST+M

BG = Bubble Generation BT = Bubble Transport ST = Sludge Transport M = Mixing Power

Mixing

Bubble transport

Sludge transport

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Bubble Formation
Film pressure
Laplace-Young (surface tension )
1,000.00 100.00 kJ/m3 10.00 1.00 0.10 0.01 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 bubble dia (mm) Bubble Surface energy

Work done
in creating a bubble (bubble surface energy)

W = PV (Nm or J)

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Bubble Transport
(1) Overcoming buoyancy E = force acting on bubble x depth ( Archimedes' principle, single bubble) Depth h (m)

(bubble volume basis, = air density) (2) Isothermal Compression

work done dragging bubbles from top to bottom

W = W1 + W2
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Bubble Hydrodynamics
After formation, a bubble rapidly accelerates to its terminal velocity

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Oxygen Transfer

For a given depth, oxygen transfer only depends on gas hold up ratio

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Performance Prediction
GRAVITOX DEVELOPMENT Process Model Version 1.3a ( 4th February 2008)
Bioreactor Working volume, L Flow L/h 116,667 Flow Ml/d PE 10,036 700,000 2.80 GRAVITOX ASP plant

INFLUENT
(settled sewage)

mg/L 215 300 50 27 6

g/h
25,083 35,000 5,833 3,150 700

EFFLUENT BOD <5 mg/l COD <30 mg/l SS <10 mg/l Ammoniacal N <1 mg/l Total P <1 mg/l sludge at 3,500 mg/L MLSS
501.20 weight basis vol basis (L/h) 10.45 g/d (80%VS)

BOD COD SS Ammoniacal N Total P

Oxygen consumed Oxygen transfer efficiency Oxygen supply requirement Air supply requirement

18,813 50.00% 37,625 163,587 126,812 Baseline power requirement in kW (ASP with FBDA)

Power rating 3 kW Energy saving 70% (over FBDA)

GRAVITOX Design parameters Sludge feed (m3/h) : 422 Air/water ratio : 0.3 Pipe diameter (cm) : 40 Depth (m) : 50 Pressure drop (m) : 0.5 21

Experimental programme
Bench Scale Research Design
600L Acrylic tank. U tube setup Aerator and Pump on sep shafts Air and Water Flow meters. Power meter

Operating Parameters
Monitor: bubble generation, bubble size and distribution. Measure: Aerator & Pump efficiency Pressure (Head) Power consumption Contact time (Flow rate)
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Bench Scale Research

Bubble Generation

Marine Bubbler

Axial Flow Bubbler

50mm, 70mm and 110mm Produced good Good Flow low head coarse bubbles flow (5mm) Okay head 2-3 meters Okay bubble quantity and size

Centrifugal bubbler
Produced good bubble quantity and size.

CF+AF Bubbler
Planned for work with composite bubblers.
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Prototype development

15m3 Bioreactor (200 PE) 100m and 30m boreholes with U-tubes (50mm ID) 0.3 to 8.5 bar tests BOD/SS/NH3/P (15/30/5/1)

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Construction of Prototype Test Plant

Boreholes - Ground Source Solutions. Refit old ASP plant -Newton Industrial

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2 metres

Metal U Tube at bottom 50mm internal diameter

Metal casing required for first 30m to protect hole.

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What's Next ?

Prototype Test Plant delivery (end March 09). Baseline performance data (conventional ASP with FBDA, 1-2 months ) GRAVITOX prototypes testing & optimisation (6-9 months)

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SUMMARY GRAVITOX development Part of UU strategy to deliver carbon savings to 2050 Target 75% energy reduction
(potential reduction 82,000tCO2 pa, 16% UU Group)

2007 Concept 2008 Prototype R&D 2009 Prototype testing & optimisation 2010 Demonstration & Roll out
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Thank you
ACKNOWLEDGEMENTS The authors would like to thank United Utilities PLC for permission to present this work. This paper represents the opinion the authors and does not necessarily represent the view of their employers. The GRAVITOX development is supported by the Carbon Trust (Project reference:076-068 Low carbon sewage treatment).

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