Current Trends in Digester Mixing Technologies Becky Daugherty Brian Hemphill
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1 Current Trends in Digester Mixing Technologies Becky Daugherty Brian Hemphill rc0406sfbs.ppt
2 Outline Importance of Digester Mixing Digester Mixing Technologies Current Trends Case Studies Design Considerations Q & A rc0406sfbs.ppt 2
3 Digester without Mixing Short Circuiting Out Stratification Scum Mat Buildup In Grit Accumulation Out In rc0406sfbs.ppt 3
4 Importance of Good and Reliable Mixing in Digesters Provides Uniform Environment for Microbes Maintains Contact Between Active Biomass and Incoming Feed Sludge Enhances Biological Reaction Rates Improves VSS Reduction Efficiency Increases Gas Production more pronounced at lower HRTs Reduces Short-Circuiting Reduces Process Upsets Improves Operating Safety Margin rc0406sfbs.ppt 4
5 Mixing Design Parameters Digester volume turnover time (DVTT) =(tank volume/pump capacity) Does not consider velocity ( power) Unit power (UP) = (pump horsepower/tank volume/1000) Lack of consistency re HP calculation RMS velocity gradient (VGT or G) = (pump power/tank volume/sludge viscosity) Better but difficult to apply rc0406sfbs.ppt 5
6 Mixing Design Parameters Best approach is probably CFD modeling This is expensive and not definitive Complications: Inlet feed and outlet hydraulics likely play a big role There is natural mixing that occurs due to gas production Nearly impossible to get real world side-by-side realistic comparisons rc0406sfbs.ppt 6
7 Digester Mixing Technologies Gas Mixing Mechanical Mixing Pump Mixing rc0406sfbs.ppt 7
8 Gas Mixing Compressed Digester Gas Recirculated through the Digester Unconfined Mixing Sequential discharge to individual lances Confined Mixing Eductor tube acts as gas lift pump to recirculate digester contents Bubble gun generates large bubbles that act as a gas lift pump rc0406sfbs.ppt 8
9 Gas Mixing Unconfined System Compressed Digester Gas Recirculated through Gas Lances Sequential Discharge to Individual Lances using Rotary Valve Gas/liquid Mixing Plume Increases in Diameter as it Rises to the Surface Courtesy of US Filter rc0406sfbs.ppt 9
10 Gas Mixing Unconfined System Housing Heater Rotary Valve Low Pressure Regulator Courtesy of US Filter rc0406sfbs.ppt 10
11 Gas Mixing Unconfined System Gas Discharge Lance Removable while Digester is in Service Courtesy of US Filter rc0406sfbs.ppt 11
12 Gas Mixing Confined System Eductor Tubes Release Compressed Gas inside Digester Eductor Tube acts as a Gas Lift Pump Creates Upward Mixing Pattern rc0406sfbs.ppt 12
13 Gas Mixing Confined System Bubble Gun Generation every 3 to 4 seconds per Mixer Turbulence Created at Surface Prevents Scum Buildup GasTake-off Gas Compressor Compressed GasLine Courtesy of Infilco rc0406sfbs.ppt 13
14 Mechanical Mixing Non-clog, Axial Flow Propellers Often Located Inside Vertical Draft Tubes (a.k.a. Draft Tube Mixing) Provides Tangential Mixing Pattern inside Digester Reversible Mixing Pattern Roof Mounted Equipment Optional Heat Exchanger Jacket Courtesy of US Filter rc0406sfbs.ppt 14
15 Mechanical Mixing Draft Tubes Internal Roof Mounted External Platform Mounted Courtesy of OTI rc0406sfbs.ppt 15
16 Mechanical Mixing Draft Tubes Optional Heat Exchanger Jacket (in lieu of External Heat Exchangers) Axial Flow Propeller Courtesy of OTI rc0406sfbs.ppt 16
17 Mechanical Mixing Installations Internally Mounted Externally Mounted Courtesy of Westech rc0406sfbs.ppt 17
18 Vertical Linear Mixers (VLM) rc0406sfbs.ppt 18
19 Gresham LMM Installation rc0406sfbs.ppt 19
20 Pump Mixing Axial Flow, Screw Centrifugal, or Chopper Type Pumps Draw Sludge from Bottom or Top of Digester High-velocity Discharge through Nozzles Perimeter Nozzles Internal Nozzles Continuous or Intermittent Operation Courtesy of Vaughan/Rotamix rc0406sfbs.ppt 20
21 Pump Mixing Nozzle Design Alternatives Digester Mixing Nozzle Digester Mixing Nozzle Perimeter-Mounted Nozzles Internal Floor-Mounted Nozzles rc0406sfbs.ppt 21
22 Pump Mixing Perimeter Nozzles rc0406sfbs.ppt 22
23 Pump Mixing Internal Nozzles Chopper Pump with Internal Mixing Nozzles Courtesy of Vaughan/Rotamix rc0406sfbs.ppt 23
24 Pump Mixing Internal Nozzles Courtesy of Vaughan/Rotamix rc0406sfbs.ppt 24
25 Current Trends bjd405cwea.ppt 25
26 1983 ASCE Nationwide Survey of Anaerobic Digesters 90 WWTPs from 39 States Responded Active mixing was found to be the most significant factor in reducing volatile solids 13 WWTPs reported Inadequate Mixing but still reported >50% VSS Reduction rc0406sfbs.ppt 26
27 1983 Survey Results Pump Mixing 32% Mechanical Mixing 20% Gas Mixing 48% rc0406sfbs.ppt 27
28 2005/06 Carollo Survey 55 WWTPs in 6 Western States Responded WWTP Capacities Between 3 and 320 mgd PS/TWAS was Most Common Feed Sludge VSS Reduction Varied Between 44 and 68% (50 to 55% Most Common) HRT Varied Between 15 and 45 Days (Median was 20 Days) rc0406sfbs.ppt 28
29 2005/06 Survey Results Pump Mixing 45% Mechanical Mixing 15% No Mixing 2% Gas Mixing 38% rc0406sfbs.ppt 29
30 Survey Comparison Pump Mixing 32% 1983 Survey 2005/06 Survey Pump Mixing 45% Gas Mixing 48% Mechanical Mixing - 20% Gas Mixing 38% Mechanical Mixing - 15% No Mixing 2% rc0406sfbs.ppt 30
31 2005/06 Survey Frequency of Problems Frequency of Problems, % Gas Mixing Mechanical Mixing Pump Mixing rc0406sfbs.ppt 31
32 2005/06 Survey Reported Problems Gas Mixing Compressor failure/extensive maintenance Pipe leaking Pipe plugging Digester foaming Poor mixing rc0406sfbs.ppt 32
33 2005/06 Survey Reported Problems Mechanical Mixing Impeller ragging Vibration problems rc0406sfbs.ppt 33
34 2005/06 Survey Reported Problems Pump Mixing Foaming Pump Clogs rc0406sfbs.ppt 34
35 Digester Mixing Rating Rating System Score of 1 to 5 (1 = worst, 5 = best) Average Ratings Gas Mixing Mechanical Mixing Pump Mixing rc0406sfbs.ppt 35
36 Survey Summary Increasing Trend in Use of Pump Mixing Pump Mixing is Often the Simplest Retrofit Alternative Lowest cost alternative in most cases O&M Concerns are Key Drivers for Selection of Mixing Technology rc0406sfbs.ppt 36
37 Case Studies bjd405cwea.ppt 37
38 Case Studies Monterey, CA 30 mgd design ADWF 4 86-ft diameter digesters Unconfined gas mixing system using discharge lances rc0406sfbs.ppt 38
39 Case Studies Monterey, CA Concerns with existing system Routine and unexpected leaks in digester gas piping Significant maintenance requirements on digester gas compressors High water requirement on digester gas compressors (50,000 gallons per day) Outdated electrical system Replacement parts were difficult to find Improper mixing resulted in significant solids accumulation at bottom of digesters Required frequent cleaning rc0406sfbs.ppt 39
40 Case Studies Eugene, OR 49 mgd design ADWF 3 85-ft diameter digesters Unconfined gas mixing system using diffuser rings rc0406sfbs.ppt 40
41 Case Studies Eugene, OR Concerns with existing system Incomplete mixing active volume of digesters only 63% of total volume based on tracer study Replacement parts for the compressed digester gas system are difficult to obtain rc0406sfbs.ppt 41
42 Case Studies Economic Comparison Installed Cost Similar for the three systems (±10%) Maintenance Cost Highest for gas mixing system Based on operator input and results from 2005/06 survey Can vary based on plant-specific factors Power cost Lowest for pump mixing system operated intermittently rc0406sfbs.ppt 42
43 Case Studies Non-Economic Comparison Mixing Technology Advantages Disadvantages Gas Mixing Mechanical Draft Tube Mixing External Pump Mixing No moving equipment submerged Low explosive hazard Mixer can reverse pump flow Multiple mixers provide added reliability Low explosive hazard Easier equipment access Chopper pumps macerate rags and debris Lower maintenance Explosive gas hazard Compressor operation and maintenance Potential for gas leaks Can contribute to digester foaming Lower mixing efficiency Large wall penetrations Roof mounted motors are more difficult to maintain Prone to clogging with rags Piping/nozzles inside digester (difficult to access) rc0406sfbs.ppt 43
44 Case Studies Plant Specific Factors Struvite (NH 4 MgPO 4 ) build-up Precipitation can lead to clogged pipes Struvite deposits most often occur at locations of local turbulence (pipe fittings, valves, pumps) Energy Costs Peak demand charges can influence equipment s life cycle cost rc0406sfbs.ppt 44
45 Case Studies Monterey, CA High energy cost shifted economic to favor the use of intermittent pump mixing Rotamix system has been installed in one of four digesters and has been operating for 4 months Eugene, OR Struvite concerns shifted the analysis to favor the use of external draft tubes 3 digesters were converted rc0406sfbs.ppt 45
46 Design Considerations bjd405cwea.ppt 46
47 Pump Mixing Design Considerations Provide 1 or 2 Pumps per Digester Size Pump based on 8 Turnovers per day (or 1 turnover every 3 hours) Pump Venting needed for Intermediate Operation Provide 1 to 2 Mixing Nozzles per 100,000 cf of Volume Size Nozzle for discharge velocity between 20 to 30 fps Size Digester Piping between 5 to 8 fps Check Pump hp is within 0.2 to 0.3 hp/1,000 cf rc0406sfbs.ppt 47
48 Mechanical Mixing (Draft Tubes) Design Considerations Provide minimum of 4 External Mixers on Digesters greater than 70 ft in diameter Consider Both Upflow and Downflow Mixing in Design of Draft Tubes Consider Insulating Exposed External Draft Tubes Provide Mixer Motors rated for Class I Div 1 service Check Total Mixer hp is within 0.2 to 0.3 hp/1,000 cf rc0406sfbs.ppt 48
49 Gas Mixing Design Considerations Don t do it unless you have to! Consider Pump Mixing or Mechanical Mixing Systems instead rc0406sfbs.ppt 49
50 Q & A bjd405cwea.ppt 50
51 rc0406sfbs.ppt 51
52 Digester Mixing Selection Factors affecting selection of digester mixing technology Digester size Digester shape Sludge type (primary, secondary, or mixed) Mixing system reliability rc0406sfbs.ppt 52
53 Digester Mixing Technology Cost Comparison Gas Mixing Mechanical Mixing Pump Mixing Equipment Cost $97,000 $300,000 $147,000 Notes: (1) Based on vendor quotes for an 80-foot diameter digester (2) Includes associated piping costs. (3) Does not include installation costs. rc0406sfbs.ppt 53
54 Other Observations Use of Mechanical Mixing in Egg- Shaped Digesters Difficult to Retrofit Using Draft Tubes Large sidewall penetrations Selection of Pump Mixing for Cylindrical Digesters rc0406sfbs.ppt 54
55 Comparison of Digester Pump Mixing Alternatives Perimeter-Mounted Nozzles Three nozzles located around each tank perimeter to create spiral mixing pattern Five side wall penetrations per tank Requires more piping and larger diameter piping Proven Carollo design $904,000 w/outdoor pumps Internal Floor- Mounted Nozzles Four floor-mounted nozzles inside each tank to produce a dual-zone mixing pattern Two sidewall penetrations per tank Requires less piping and smaller diameter piping Vendor guarantee on mixing $714,000 w/outdoor pumps rc0406sfbs.ppt 55
56 Mixing Pump Location Evaluation Outdoor Installation (adjacent to each digester) Indoor Installation (w/in digester control building) Advantages Simplifies construction sequencing (shorter construction period) Less piping required Readily accessible for O&M needs Equipment protected from weather All pumps centrally located in one area Disadvantages Aesthetics and noise concerns Electrical equipment needs to be Class I, Div 2 minimum when located adjacent w/in 10 of digester More complex construction sequencing (longer construction period) More piping required in tunnel areas Electrical equipment needs to be Class I, Div 2 minimum when located inside building May trigger upgrade of electrical equipment inside building to meet Class I, Div 2 requirements ($50,000 to $250,000) rc0406sfbs.ppt 56
57 Pump Mixing Axial Flow, Screw Centrifugal, or Chopper Type Pumps Draw Sludge from Bottom or Top of Digester High-velocity Discharge through Nozzles Perimeter Nozzles Internal Nozzles Continuous or Intermittent Operation Courtesy of Vaughan/Rotamix rc0406sfbs.ppt 57
58 Digester Mixing Cost Comparison Item Confined Gas Mixing Mechanical Mixing Pump Mixing Installed Cost $880,000 $785,000 $745,000 Present Worth of O&M Cost $268,000 $209,000 $89,000 Total Present Worth Cost Notes: $1,148,000 $994,000 $834,000 (1) Based on vendor quotes for an 85-foot diameter digester. (2) Based on present value of 20 years of annual costs at 6% interest. (3) Based on an estimated O&M labor week of $50/hour depending on complexity of the equipment: 9 hrs/week for gas mixing, 7 hrs/week for mechanical mixing, 3 hrs/week for pump mixing. rc0406sfbs.ppt 58
59 Comparison of Surveys Frequency of Problems Frequency of Problems, % Gas Mixing Mechanical Mixing /2006 Pump Mixing rc0406sfbs.ppt 59
60 Design Criteria Comparison for an 85-ft Diameter Digester with 27-ft SWD Item Confined Gas Mixing Mechanical Mixing Pump Mixing Manufacturer Infilco OTI Vaughan/Rotamix Number of Compressors 1 N/A N/A Number of Mixers N/A 4 N/A Number of Pumps N/A N/A 1 Energy, hp (total) (1) 37.5 (2) Energy Input, hp/1,000 cf (2) Turnover Rate, minutes (3) Notes: (1) Based on equipment manufacturer s design for continuous operation using four mixers at rated 10 hp. (2) Based on equipment manufacturer s design for intermittent operation (2 hours on/off cycle), which is equivalent to 50% of the rated 75 hp mixing pump. (3) Adjusted value considering nozzle entrained flow velocity of 40 fps. rc0406sfbs.ppt 60
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