APPENDIX A
Preliminary
Design Report (
Water Research Foundation Project #3114:
Innovative Applications of Treatment Processes for Spent Filter Backwash
PRELIMINARY DESIGN REPORT
SPENT FILTER BACKWASH EQUALIZATION
SPENT FILTER BACKWASH TREATMENT EVALUATION
EXECUTIVE
SUMMARY
Introduction
Pilot studies were conducted at the Utah Valley Water
Purification Plant (WPP) located in
The reader should note that the cost and footprint estimates
assumed that a new building would be constructed to hold the new processes.
Since this report will be part of the Foundation report and will hence be
viewed by other utilities, it was determined that it would be better to show
these estimates for completely new facilities rather than incorporating more
site specific conditions necessary for a retrofit option. For the WPP, although
there is room to locate the new facilities as indicated, another alternative
would have been to retrofit the new facilities into the south end of the
The reader should also note that each manufacturer was only able
to conduct testing during one time period. In May 2007 Leopold tested one
process, and in July and August 2007 Siemens successfully tested two SFBW
treatment processes. Since untreated SFBW characteristics were different in the
two time periods, the reader should exercise caution in comparing results from one
manufacturer to another since they were not compared side-by-side, although it
is appropriate to compare the two processes from Siemens to one another since
they were treating the same SFBW. Furthermore, results are presented in the Foundation
report in a separate
Summary of Findings
Performance of the pilot tested processes are summarized in Table A.1. Table A.2 summarizes cost and footprint estimates derived from these findings.
These results demonstrate that 2,000 ft2 of space is necessary for a ClariDAF system comprised of two 2,000 gpm treatment trains designed at 14 gpm/ft2 nominal (i.e., manufacturer) clarification rate and 16 minutes flocculation time, including all space required for flocculation, clarification, chemical feed, air saturation, and other assorted appurtenances. This is about 2.5 times smaller than the area needed for existing treatment (5,000 ft2). The estimated size of the new building to house these facilities is about 3,500 ft2 compared with the current 7,650 ft2 building, or less than half the size of the existing building. Therefore, though nominally a 14 gpm/ft2 system when you consider only clarification area, when you consider the entire footprint impact, the rate expressed relative to the required area for treatment (assuming one train out of service) is 2,000 gpm for a 2,000 ft2 area, or 1.00 gpm/ft2, versus 0.40 gpm/ft2 for the existing SFBW treatment system (2,000 gpm for 5,000 ft2 treatment area, including area for one train out of service). Relative to the entire 3,500 ft2 building the rate for ClariDAF is 0.57 gpm/ft2, versus 0.26 gpm/ft2 for the existing 7,650 ft2 treatment building. Furthermore, if the Utah Valley WPP evaluates addition of thickening and dewatering facilities in the future (along with a separate evaluation of whether to add DAF to main processes prior to filtration), the solids from the ClariDAF are expected to be high enough (3 to 4 percent solids) that solids from this SFBW treatment process can go directly to dewatering without requiring additional thickening capacity. By contrast, residuals from existing SFBW treatment would probably require thickening prior to being sent to dewatering processes.
Similar evaluations for the
CONTRAFAST process indicates that the required footprint for two 2,000 gpm
treatment trains is 1,800 ft2, or 1.11 gpm/ft2 for the
nominal 8.5 gpm/ft2 facility when expressed relative to total
footprint impact for treatment instead of only clarification area. The Trident
Table A.1
Summary of SFBW treatment results discussed
in this report
City |
Median untreated turbidity (ntu) |
Nominal clarification rate (gpm/ft2) |
Residuals concentration (percent solids) |
Information source |
Polymer needed? |
Pilot- or Full-scale? |
95 percent <2 ntu |
May 2007 |
|||||||
Existing tubes |
100 |
0.45 |
~0.5 |
This study |
* |
Full |
Yes |
ClariDAF |
100 |
14 |
4.4 |
This study |
Yes |
Pilot |
Yes |
July and August 2007 |
|||||||
Existing tubes |
100 |
0.92 |
~0.5 |
This study |
* |
Full |
Yes |
CONTRAFAST |
100 |
12 |
>5 |
This study |
Yes |
Pilot |
Yes |
Trident (tubes only) |
100 |
3 |
~0.3 |
This study |
Yes |
Pilot |
Yes |
Trident (tubes + AC) |
100 |
18 |
~0.3 |
This study |
Yes |
Pilot |
Yes |
*Impact of treatment without flocculation not reported
Table A.2
Estimated cost and footprint for high-rate
SFBW treatment at
Description |
ClariDAF |
CONTRAFAST |
Trident |
Tubes (existing) |
Design conditions |
|
|||
Number of treatment trains |
2 |
2 |
3 |
2 |
Capacity per treatment train (gpm) |
2,000 |
2,000 |
1,050 |
2,000 |
Nominal clarification rate (gpm/ft2) |
14 |
8.5 |
15 |
1.5 |
Flocculation time (min) |
16 |
8.4** |
HH |
15 |
Cost* |
|
|||
Capital ($ million) |
9.3 |
7.6 |
10.6 |
n/a |
O&M ($ thousand/yr) |
180 |
110 |
200 |
n/a |
Net Present Worth ($ million)H |
11.4 |
8.9 |
13.0 |
n/a |
Footprint (ft2) |
|
|||
Treatment only |
2,000 |
1,800 |
2,600 |
5,000 |
Building |
3,500 |
3,500 |
3,500 |
7,650 |
Additional thickening required prior to dewateringI |
no |
no |
yes |
yes |
Clarification rate (gpm/ft2)' |
|
|||
Nominal (i.e., manufacturer) |
14 |
8.5 |
15 |
1.5 |
Relative to “treatment” footprint |
1.00 |
1.11 |
0.81 |
0.40 |
Relative to “building” footprint |
0.57 |
0.57 |
0.57 |
0.26 |
*December 2007 dollars, includes cost of new building and associated appurtenances
H20 years, six percent interest
IAssume thickened solids prior to dewatering have to be >1 percent solids
'One train out of service
**Solids contact time (i.e., detention time in reactor tank)
HHNot applicable
EXISTING FACILITIES
The Central Utah
Water Conservancy District’s (CUWCD) Utah Valley Water Purification Plant (WPP)
located in
Provided by CUWCD, September 2007
Figure A.1
Provided by CUWCD, September 2007
Figure A.2
The existing
SFBW treatment facilities include a 325,000-gallon equalization basin (separate
from the 152,000-FTW equalization basin) designed to handle two consecutive
backwashes. Polymer is added to equalized SFBW prior to an in-line static
mixer, and then flow is diverted to one or both of two parallel trains with
two-stage flocculation and a sedimentation basin with tube settlers in each
train. One train employs chain and flight collectors for residuals and is
operated most of the time. The other train has a traveling bridge sludge
collection system that has not been functioning properly and was not being used
at the time of the studies for this project. Each side of the existing facility
has a capacity to process about 2,000 gpm (1.48 gpm/ft2, or ~3 mgd)
of SFBW. Untreated SFBW turbidity frequently exceeds several hundred ntu while
treated SFBW is typically <2 ntu when polymer is used. The treated effluent
is recycled to rapid mix at the head of the plant while solids gravity flow to
drying beds. Figure A.3 is a schematic of the existing SFBW handling processes.
Figure A.4 shows a plan view of the SFBW treatment building labeled the
For future design considerations, a 2,000 gpm SFBW treatment system was chosen to replace current capacity. The sizing and costing including two, 2,000 gpm units as is the existing case.
Provided by CUWCD, September 2007
Figure A.3
Provided by CUWCD, September 2007
Figure A.4
HIGH
Figure A.5
illustrates the variation in the number of backwash events each month from
October 2005 until September 2006. The pilot studies for this project were
planned to coincide with periods when the amount of available SFBW was expected
to be greatest between May 1 and
Detailed results of the pilot studies are available in the final report for Foundation Project #3114. Portions of the findings are presented below, as well as cost and footprint estimates for construction of new systems at the Utah Valley WPP as an alternative to the existing SFBW treatment system. Each of the existing SFBW treatment system clarifiers have a surface area of 1,350 ft2 and a capacity of 2,000 gpm (2.88 mgd), resulting in a maximum clarification rate of 1.48 gpm/ft2.
The following
costs and footprint estimates are based on including a new building. One reason
for this assumption was that since the report was to be included in a report to
be viewed by other utilities, it might be better to show as an example the cost
for a new system rather than a site specific retrofit. However, other utilities
looking to add similar high-rate processes may be able to further reduce cost
and footprint impacts by retrofitting these new processes into existing
buildings. In fact, at the Utah Valley WPP a logical place to install new SFBW
treatment facilities would be to demolish the currently unused portion of the
SFBW reclamation facility (the side with traveling bridge sludge collection),
and locate the replacement SFBW treatment facilities in this part of the
existing building. However, for purposes of this report it was felt desirable
to impose as few site specific limitations as possible, like would be needed to
evaluate retrofit option, since it was hoped that other utilities reading this
report could evaluate costs for a generic, complete facility, without a great
deal of site specific implications associated with the developed costs and
footprint. In order to show an example of the impact of site specific
limitations, the costs and footprint estimates developed for the
Figure A.5 Number of filter
backwash events per month at the
Option A: ClariDAF
ClariDAF is a high rate dissolved air flotation system designed by Leopold. ClariDAF system components and schematic are depicted Figures A.6 through A.8, including a photo of the pilot trailer set-up at the Utah Valley WPP during May 2007 (Figure A.7).
Provided by
Figure A.6 ClariDAF schematic
Figure A.7 ClariDAF pilot trailer at
Provided by
Figure A.8 ClariDAF pilot schematic
ClariDAF is a high-rate DAF process which can operate at loading rates of 8 to 15 gpm/ft2. Clarification rates for this system are based on flow per square foot area occupied by the effluent laterals located at the bottom of the DAF cell. The ClariDAF system utilizes a rapid mix zone where polymer may be added followed by one or more flocculation basins and a DAF Cell. An internal angled baffle wall create a recirculation effect throughout the DAF Cell which increases bubble density and efficient flotation for removal of the “float”. The clarified water exits the system through the laterals and into an effluent channel while the sludge blanket is mechanically skimmed into a collection channel.
Pilot testing results depicted in Figures A.9 to A.10 demonstrated that acceptable performance was achieved at rates up to 14 gpm/ft2. Based on these results, a design loading rate of 14 pm/ft2 with a 16 min flocculation time was chosen for a 2,000 gpm matching the existing system the at Utah Valley WPP. Pilot testing demonstrated the need for a polymer to meet treated water goals of <2 ntu.
Figure A.9
Figure A.10
Option A would
consist of two, 2,000gpm ClariDAF systems to match current SFBW treatment
capabilities. The new system (two units) would have a total footprint of
approximately 32 ft by 63 ft or 2,000 ft2 which is 2.5 times smaller
than the existing 5,000 ft2 system. Cost calculations are listed in
Table A.3 below. Costs include
construction of a new 3,500 ft2 (50 ft by 70 ft) concrete building,
ClariDAF basin walls, ClariDAF equipment, instrumentation, controls, pumps, and
a polymer feed system. Figure A.11 illustrates the potential footprint of a new
building north of the main process flocculation basins and east of the existing
SFBW (
Table A.3
New ClariDAF SFBW treatment system cost
analysis
Item |
Capital cost ($) |
O&M cost ($/yr) |
20-yr present worth ($) |
New ClariDAF treatment facility |
9,300,000 |
180,000 |
11,400,000 |
Figure A.11
Provided by
Figure A.12
Provided by
Figure A.13
Option B: CONTRAFAST
The CONTRAFAST
is a high rate solids contact process manufactured by Siemens Water
Technologies. This process involves internal and external recirculation of
solids originating in the untreated water. Untreated water and treatment
chemicals first enter a mixed solids contact module, followed by a gravity
clarification module using tubes. Clarified water passes through the tubes and
a portion of the solids collected in the clarification module are recirculated
to the solids contact module. Clarification rates cited by the manufacturer
typically are expressed relative to the surface area of clarification, but do not
take into account total footprint. This
report discusses findings relative to the clarification area, and also relative
to total footprint. Solids produced from these processes are typically on the
order of 3 to 5 percent, or perhaps higher. As with DAF, these solids may not
need thickening prior to dewatering, which is of course desirable and will
reduce the net impact on plant footprint due to adding one of these processes
for SFBW treatment. Figure A.14 depicts the pilot unit evaluated in July and August
2007 including mixing in the center solids contact zone and then clarification
via tube settlers in the clarification zone. Figure A.15 is a photo of the
pilot testing equipment installed at the Utah Valley WPP during July and August
2007 (CONTRAFAST is the tall module to left of Trident
Pilot testing results in Table A.4 and Figures A.16 and A.17 show that acceptable performance was achieved at rates up to 12 gpm/ft2. The process may have been capable of achieving acceptable performance at higher rates, but this was the upper hydraulic limit for the pilot unit tested. Based on these results, a CONTRAFAST design loading rate of 8.5 gpm/ft2 for the 2,000 gpm systems at Utah Valley WPP was used. Testing also demonstrated the need for polymer to meet treated water goals of <2 ntu.
Provided by Siemens Water Technologies, September 2007
Figure A.14 CONTRAFAST
schematic
Figure A.15 Siemens pilot equipment used at
Table A.4
Summary of
Date |
Duration (hours) |
Rate (gpm/ft2) |
Recycle (percent) |
Polymer dose (mg/L) |
Turbidity (ntu) |
Treated turbidity ≤ 2 ntu (percent) |
Particles >2 µm (particles/mL) |
||||||
Start |
End |
Raw |
Treated |
Median |
95th Percentile |
Max |
Mean |
||||||
Impact of polymer dose (Cytec 1883) |
|||||||||||||
08/30 |
08/30 |
|
2.25 |
8.0 |
7.3 |
none |
0.0 |
4.96 |
37.5 |
4,778 |
8,419 |
8,637 |
4,837 |
08/30 |
08/30 |
|
1.50 |
8.0 |
7.3 |
1.5 |
3.5 |
0.36 |
100.0 |
2,196 |
2,705 |
2,759 |
2,166 |
08/30 |
08/30 |
|
1.25 |
8.0 |
7.3 |
3.0 |
4.9 |
0.43 |
100.0 |
2,774 |
2,810 |
2,818 |
2,715 |
Impact of rate (gpm/ft2) |
|||||||||||||
07/18 |
07/21 |
|
39.00 |
4.0 |
9.0 |
0.9 |
90.7 |
0.71 |
95.3 |
377 |
932 |
5,389 |
444 |
07/23 |
07/26 |
|
47.25 |
5.0 |
7.0 |
1.0 |
98.2 |
0.78 |
95.5 |
638 |
1,324 |
10,979 |
746 |
07/26 |
08/03 |
* |
57.75 |
6.0 |
6.0 |
2.0 |
60.9 |
0.84 |
96.4 |
984 |
3,497 |
16,188 |
1,338 |
08/06 |
08/07 |
* |
12.50 |
6.4 |
9.0 |
3.0 |
43.4 |
0.68 |
100.0 |
1,311 |
1,713 |
1,762 |
1,255 |
08/06 |
08/14 |
* |
7.00 |
7.0 |
8.5 |
3.0 |
107.8 |
0.81 |
100.0 |
1,797 |
3,252 |
3,419 |
1,917 |
08/07 |
08/16 |
* |
36.50 |
8.0 |
7.3 |
3.3 |
44.4 |
0.90 |
98.0 |
1,732 |
2,584 |
2,948 |
1,727 |
08/14 |
08/16 |
* |
18.25 |
9.0 |
6.5 |
3.5 |
41.8 |
1.03 |
99.0 |
2,173 |
3,448 |
3,723 |
1,922 |
08/17 |
08/28 |
* |
28.00 |
10.0 |
7.5 |
3.5 |
14.5 |
0.89 |
95.1 |
2,067 |
6,859 |
9,487 |
3,149 |
08/29 |
08/30 |
* |
17.25 |
12.0 |
6.2 |
3.0 |
8.6 |
0.73 |
100.0 |
2,974 |
4,926 |
5,490 |
3,176 |
08/30 |
08/30 |
|
1.50 |
14.0 |
5.4 |
4.0 |
3.7 |
2.78 |
35.8 |
5,117 |
8,137 |
8,659 |
5,261 |
*Not continuous between these two date
Figure A.16
Figure A.17
Option B would
consist of two, 2,000-gpm CONTRAFAST systems to match current SFBW treatment
capabilities. The new system would have a total footprint of approximately 55
ft by 33 ft or 1,800 ft2 which is one third the size of the existing
5,000 ft2 system. Cost calculations are listed in Table A.5. Costs include construction of a new 3,500 ft2
(50 ft by 70 ft) concrete building, CONTRAFAST equipment, instrumentation,
controls, pumps, and a polymer feed system. Figure A.18 illustrates the
potential footprint of a new building north of the main process flocculation
basins and east of the existing SFBW (
Table A.5
New CONTRAFAST SFBW treatment system cost
analysis
Item |
Capital cost ($) |
O&M cost ($/yr) |
20-yr present worth ($) |
New CONTRAFAST treatment facility |
$7,600,000 |
$114,000 |
$8,900,000 |
Figure A.18
Provided by Siemens Water Technologies, September 2007
Figure A.19
Provided by Siemens Water Technologies, September 2007
Figure A.20
Option C: Trident
Trident
The Trident
Provided by Siemens Water Technologies, September 2007
Figure A.21 Trident
Provided by Siemens Water Technologies, September 2007
Figure A.22 Trident
Pilot testing
results in Table A.6 and Figures A.23 and A.24 show that acceptable performance
was achieved at rates up to 18 gpm/ft2. Based on these results, a
Trident
Table A.6
Date |
Test duration (hours) |
Ferric sulfate dose (mg/L) |
Polymer type |
Median |
Percent
of results <2
ntu |
|||||||||
Polymer dose (mg/L) |
Rate |
Turbidity |
Particles
>2µm |
|||||||||||
Start |
End |
Tube |
AC |
Raw |
Tube |
AC |
Tube |
AC |
Tube |
AC |
||||
(gpm/ft2) |
(ntu) |
(particles/mL) |
(percent) |
|||||||||||
Impact
of rate |
||||||||||||||
07/19 |
07/21 |
23.0 |
|
Cytec
A100 |
0.10 |
3.0 |
9.0 |
100.3 |
0.26 |
0.22 |
1,467 |
1,507 |
99.1 |
100.0 |
07/23 |
07/26 |
50.0 |
|
Cytec
A100 |
0.12 |
4.0 |
12.0 |
80.6 |
0.59 |
0.26 |
2,432 |
1,626 |
92.0 |
96.2 |
07/30 |
08/15 |
73.0 |
|
Cytec
A110 |
0.35 |
5.0 |
15.0 |
93.9 |
0.71 |
0.35 |
2,078 |
1,752 |
86.3 |
95.2 |
08/08 |
08/13 |
22.3 |
|
Cytec
A110 |
0.35 |
6.0 |
17.9 |
112.9 |
0.99 |
0.48 |
3,505 |
1,306 |
90.0 |
96.9 |
08/13 |
08/14 |
5.3 |
|
Cytec
A110 |
0.35 |
6.9 |
20.7 |
63.5 |
5.22 |
3.20 |
5,232 |
4,082 |
12.5 |
41.2 |
Impact
of Cytec A110 polymer dose |
||||||||||||||
08/15 |
08/15 |
2.5 |
|
Cytec
A110 |
0.00 |
5.0 |
15.1 |
57.3 |
7.10 |
1.73 |
7,696 |
No
data |
18.1 |
52.4 |
08/15 |
08/15 |
1.3 |
|
Cytec
A110 |
0.09 |
4.9 |
14.8 |
81.6 |
0.69 |
0.68 |
1,333 |
No
data |
100.0 |
100.0 |
08/15 |
08/15 |
5.0 |
|
Cytec
A110 |
0.18 |
5.0 |
15.0 |
72.2 |
0.34 |
0.32 |
774 |
No
data |
89.3 |
76.6 |
07/30 |
08/15 |
73.0 |
|
Cytec
A110 |
0.35 |
5.0 |
15.0 |
93.9 |
0.71 |
0.35 |
2,078 |
1,752 |
86.3 |
95.2 |
08/06 |
08/06 |
4.0 |
|
Cytec
A110 |
0.60 |
5.0 |
15.1 |
31.8 |
0.93 |
0.41 |
1,009 |
1,529 |
95.5 |
93.3 |
Impact
of ferric sulfate dose (plus polymer) |
||||||||||||||
08/06 |
08/06 |
4.0 |
0 |
Cytec
A110 |
0.60 |
5.0 |
15.1 |
31.8 |
0.93 |
0.41 |
1,009 |
1,529 |
95.5 |
93.3 |
08/06 |
08/06 |
2.8 |
5 |
Cytec
A110 |
0.60 |
5.0 |
15.1 |
40.7 |
2.00 |
0.63 |
640 |
1,434 |
50.0 |
82.3 |
08/06 |
08/06 |
4.8 |
10 |
Cytec
A110 |
0.60 |
5.0 |
14.9 |
86.7 |
1.74 |
0.81 |
1,192 |
3,325 |
63.3 |
90.3 |
08/06 |
08/06 |
1.0 |
20 |
Cytec
A110 |
0.48 |
4.9 |
14.8 |
207.4 |
2.54 |
0.43 |
5,103 |
2,888 |
43.3 |
88.0 |
Impact
of polymer type |
||||||||||||||
07/27 |
07/27 |
5.8 |
|
Cytec
1986 |
0.66 |
3.9 |
11.8 |
27.0 |
0.73 |
0.29 |
2,611 |
1,988 |
89.5 |
100.0 |
07/23 |
07/26 |
50.0 |
|
Cytec
A100 |
0.12 |
4.0 |
12.0 |
80.6 |
0.59 |
0.26 |
2,432 |
1,626 |
92.0 |
96.2 |
Figure A.23 Impact of Trident
Figure A.24 Impact of polymer dose on
Trident
Option C would
consist of three 1,050-gpm Trident
Figure A.25
illustrates the potential footprint of a new building north of the main process
flocculation basins and east of the existing SFBW (
A significant
footprint savings could be achieved by eliminating the Buffer Tank basin on the
end of the Trident
Table A.7
New Trident
Item |
Capital Cost ($) |
O&M Cost ($/yr) |
20-yr Present Worth ($) |
New
Trident |
10,600,000 |
204,000 |
13,000,000 |
Figure A.25
Provided by Siemens Water Technologies, September 2007
Figure A.26
Utah Valley WPP Trident
Provided by Siemens Water Technologies, September 2007
Figure A.27 Utah Valley WPP Trident