Water / Wastewater Treatment Engineering a Solution


Golden Flake brought in ADI Systems to engineer a solution. The problem was somewhat complicated by the fact that the plant is landlocked in its position, being in the Birmingham inner city. There was no room for site expansion, and little available room for a conventional activated-sludge facility with the footprint requirements for spray fields that would be required to process the plant’s wastewater flow.


ADI Systems recommended the implementation of a membrane bioreactor (MBR) system to treat the raw wastewater following the vibrating screens.


The ADI-MBR process, based on technology developed by ADI Systems and Kubota Corporation, is a form of activated sludge technology that uses a submerged membrane barrier to perform the liquids/solids separation and reactor biomass retention functions, instead of gravity clarification, which eliminated problems associated with sludge settling and separation.


The MBR process also fits on compact sites while providing consistent, high quality effluent that can be reused in certain applications.


Golden Flake representatives liked the MBR approach as the treated wastewater (effluent) from the MBR system could then be discharged into the Upper Valley Creek, adjacent to the property, no longer requiring the need and expense of discharging wastewater to the county sewer system.


ADI Systems commissioned a 350-gallon MBR pilot plant onsite at Golden Flake using a small stream of their pre-screened wastewater. The MBR pilot plant operated for three months to demonstrate and evaluate ADI-MBR technology for treating Golden Flake’s wastewater.


The MBR pilot study was a success and demonstrated that ADI-MBR technology was easy to operate, could consistently meet the effluent limits, and produce a direct discharge quality effluent while being situated on a site with a compact footprint.


“The technology is really what sold us,” explains Jones. “We toured a couple MBR facilities in Georgia that were using the Kubota submerged-membrane technology, and we were very impressed by what we saw. The quality of the effluent leaving the MBR for discharge into the stream would meet the requirements of the Alabama Department of Environmental Management.”


“The system also fits in to a very compact and small footprint,” continues Jones. “This is what we needed for our site.”


Membrane Bioreactor System


The ADI-MBR system provides a near-absolute barrier to suspended solids and allows for operation at higher mixed liquor suspended solids (MLSS) concentrations (typically 10,000 to 18,000 mg/L versus 2,000-5,000 mg/L as in conventional activated sludge systems) resulting in longer solids retention times, less waste sludge production and a much smaller footprint.


The ADI-MBR system at Golden Flake


consists of a pre-aeration tank and two membrane basins, each equipped with double-decker submerged membrane units (SMU).


The MBR system is also equipped with aeration blowers, a re-aeration chamber, pumps, instrumentation and controls. The total package includes a control building with a dewatering press/conveyor system, automatic composite samples, laboratory, office and PLC systems.


During operation of the ADI-MBR system, treated effluent is passed through the membranes via a slight suction, and then aerated to meet the DO limit prior to discharge to the adjacent stream. Waste activated sludge is dewatered onsite with a screw press and the sludge cake is removed for disposal.


“Membrane treatment technologies are often employed when higher quality effluents are required,” says Mike McDermaid, Project Manager for ADI Systems. “Additionally, the ADI-MBR system is ideal when available plant footprint is very limited, and when the wastewater characteristics make conventional gravity settling technologies difficult or ineffective.”


“The ADI-MBR process results in a robust, ultra- compact treatment system, occupying significantly less footprint compared to a conventional activated sludge treatment system,” continues McDermaid. “We felt this would be a very suitable application for Golden Flake.”


The ADI-MBR system at Golden Flake provides a design hydraulic retention time of approximately


1 day, and is designed for a daily influent flow rate of up to 400,000 gpd. The system treats pre-screened wastewater with BOD and TSS concentrations that range from 1000 to 10,000 mg/L and 200 to 12,000 mg/L, respectively.


System Implementation


The new ADI-MBR system began construction in February 2009, became operational in August 2009, and consistently produces effluent that is lower than effluent discharge limits set by the Alabama Department of Environmental Management: <2ppm TSS, (<30 ppm TSS limit); <5 ppm BOD,


(<10ppm BOD limit); <1 ppm NH3-N (<1.5 ppm NH3-N limit); and >6 ppm DO (>6ppm DO limit).


Up to 250 gallons per minute of clean,


high-quality effluent is released into Upper Valley Creek, and serves to enhance the downstream riparian environment by improving the oxygenation of the water flow within the small watercourse.


The final effluent produced by the ADI-MBR system is clean enough to reuse for certain applications, such as site irrigation. The waste activated sludge from the ADI-MBR system is pumped through an on-site dewatering press to reduce the overall sludge volume to 20,000 pounds per week, which is then trucked upstate for farm fertilisation.


“The entire ADI-MBR treatment system is automated,” explains Jones. “Our maintenance supervisor can completely control the whole system from one location in the plant or from his home on a laptop. Every pump and motor can be controlled from the computer screen. This provides a control flexibility we did not have before.”


One of the biggest benefits of the ADI-MBR system is that Golden Flake is no longer discharging primary treated wastewater into the county sewer system, and is no longer paying escalating surcharges for its wastewater discharge. “The ADI-MBR technology has given us excellent results. The effluent quality we are discharging – the effluent is almost crystal clear – has allowed us to completely eliminate our dependence on the county sewer system and the escalating water surcharges we were having to pay each month.”


About ADI Systems


ADI Systems Inc. is a technology and design-build company that provides a wide range of wastewater treatment systems to industrial companies worldwide. In addition to generic technologies, ADI Systems provides proprietary and patented anaerobic and aerobic biological waste treatment technologies. ADI Systems Inc. is an operating company within ADI Group Inc. ADI Group is an employee-owned company established in 1945 and has grown steadily over the past 65 years. Its engineers, scientists, technicians and support staff have experience working on more than 200 projects in 30 countries around the globe.


Flow Meter Web Demo Now Online


McCrometer’s (USA) new online product demo makes it easier than ever to understand the application and low cost of ownership advantages of the hot tap full profile insertion FPI MagTM Flow Meter.


As the successor to McCrometer’s popular Multi-Mag Insertion Flow Meter, the new FPI Mag is the industry’s only multi-electrode, hot tap, full profile insertion flow meter delivering a continuous total flow profile similar to a full-bore mag meter. The FPI Mag delivers unique benefits in terms of performance, ease of installation, low maintenance and value.


The enhanced design of the new Full Profile Insertion Flow Meter features additional sensing electrodes for increased sensitivity and is now packaged in a heavy-duty 316 stainless steel sensor body for maximum structural integrity. The sensor is coated with a NSF certified 3M fusion-bonded epoxy coating for operational longevity.


The FPI Mag with hot tap installation addresses the ever increasing need for municipalities to provide uninterrupted service, while improving process control and ensuring delivery accountability. The Full Profile Insertion Flow Meter from McCrometer installs without interrupting service, de-watering lines, cutting pipe or welding flanges. Installation costs are reduced by eliminating the need for heavy equipment or extensive manpower. The FPI Mag is the industry’s most economical flow metering solution for medium and large line sizes, reducing installed costs by more than 45 percent.


The FPI Mag meter’s compact insertion design fits in confined spaces with limited access and offers total accessibility. The flow meter can be removed in pipes under pressure for easy inspection, cleaning, calibrating or verification with McCrometer’s own NIST traceable Calibration Lab. It is particularly cost-effective for retrofit applications replacing flow meters or in sites never metered before.


Unlike all other insertion mag meters, the FPI Mag Flow Meter’s multi-electrode sensor design compensates for variable flow profiles, including swirl, turbulence and low-flow conditions. Multiple electrodes placed across the entire sensor body continuously measure and report the average flow rate over the full diameter of pipe.


The Full Profile Insertion Flow Meter is available for line sizes from 4 to 138 inches and rivals the performance of a full bore electromagnetic flow meter. With highly stable measurement, the FPI Mag features accuracy of ±1% of reading ± 0.03 ft./sec zero stability from 0.3 to 20 ft/s velocity range. The flow sensor comes pre-calibrated from McCrometer’s NIST traceable Calibration Lab and requires no recalibration in the field.


With no moving parts and a single-piece design, the FPI Mag’s multi-electrode sensor contains nothing to wear or break, and it is generally immune to clogging by sand, grit or other debris. The FPI Mag supports liquid flow measurement requirements in municipal water and effluent wastewater treatment. Typical municipal water applications include: wells, booster stations, effluent, filter balancing and backwash, pumping stations, UV dosing and potable water distribution.


Reader Reply Card No 11


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www.pollutionsolutions-online.com • February / March 2011


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