Indiana s Newest Filtration Facility; East Chicago

Transcription

1 Indiana s Newest Filtration Facility; East Chicago Innovation and Value-Added Benefits Behind East Chicago s Membrane Treatment Facility Eric Horvath, PE and Kara M. Boyles, PhD, PE August 1, 2012

2 Presentation Overview Project Drivers Value Engineering Membrane Procurement Membrane Design New WTP Overview Start-Up Challenges Lessons Learned

3 Project Drivers Marquette Plan for Redevelopment Indiana Lakefront Communities Project to Reclaim the Lakeshore Age and Condition of Existing Plant

4 Existing Water Treatment Plant

5 Existing Water Treatment Plant WTP Built in MGD Conventional Sand Filtration Aluminum Sulfate Coagulation 6 MG Finished Water Storage Located near Lakefront

6 Existing & Future WTP Sites Existing Water Plant New WTP Site Existing Brownfield

7 Project Considerations Time is of the Essence No Further Investment at Existing WTP Move Redevelopment Forward Clear Site for Redevelopment Relocation of Raw Water Pump Station Constrained Budget Flow 20 MGD Initial & 30 MGD Future Meet LT2ESWTR Bin 2 Minimize Flow to Sanitary Sewers Investigate Zebra Mussel Treatment No Gaseous Chlorine at Proposed WTP

8 Value Engineering City Unhappy with $70M Price Tag Fresh Look at Design Potential Cost Savings Increased Functional Ability Team Reviewed Collected Data 294 Creative Concepts Developed 24 Concepts Further Developed Optimal Combinations of Concepts to Form 4 Alternatives Pressure Membrane Traditional Gravity Filters Submerged Membrane

9 Treatment Alternatives Low Cost Alternative Pressure Membrane Submerged Membrane Conventional Filtration

10 Treatment Alternatives Process Flow Diagram RESIDUALS EQUALIZATION (Required by All) A. Concrete Equalization Basin Gravity Filters B. Concrete Equalization Basin Membranes RESIDUALS DISCHARGE A. Inclined Plate Settler with Recycle to Head of Plant B. Inclined Plate Settler with Discharge to Sanitary Sewer. C. Discharge to Sanitary Sewer Solids to Sanitary Sewer RAW WATER SOURCE A. Indirect Withdrawal B. Zebra Mussel Control in Existing Intake C. Existing Intake With No Zebra Mussel Control RAW WATER PUMP STATION (Not Required for Indirect Withdrawal) A. Vertical Turbine Pumps B. Submersible Pumps FLOCCULATION & CLARIFICATION A. Rapid Mix & Flocculation (Filtration C & D) B. Rapid Mix, Flocculation & Inclined Plate Settlers (Filtration A & B) C. Ballasted Clarification FILTRATION (Required by All) A. Concrete Gravity Filter B. Rectangular Steel Gravity Filter C. Pressure Membranes D. Submerged Membranes DISINFECTION (Required by All) A. UV Disinfection / Sod. Hypo B. Sodium Hypochlorite TRANSFER PUMP STATION (Required for Pre-stressed Concrete Ground Storage) GROUND STORAGE (Required by All) A. Pre-stressed Concrete Ground Storage B. Below-grade Concrete Storage HIGH SERVICE PUMPING (Required by All)

11 Preferred Alternative Process Flow Diagram RESIDUALS EQUALIZATION Concrete Equalization Basin for Membranes RESIDUALS DISCHARGE Inclined Plate Settler with Recycle to Head of Plant Recycle Water to Head of Plant Solids to Sanitary Sewer RAW WATER SOURCE Existing Intake With No Zebra Mussel Control RAW WATER PUMP STATION Vertical Turbine Pumps FLOCCULATION & CLARIFICATION In-Line Flocculation FILTRATION Pressure Membranes DISINFECTION Sodium Hypochlorite GROUND STORAGE Pre-stressed Concrete Ground Storage HIGH SERVICE PUMPING To Distribution System

12 Membrane Procurement Request for Proposals Financial Criteria Total Present Worth Membrane Equipment Capital Cost Non-Equipment Capital Cost Present Worth of Operating Cost PW Cost of Membrane Replacement 20 yr Non-Financial Criteria Layout and Assembly for Ease of O&M Technical and Performance Information

13 Membrane Procurement Competitive Membrane Proposals Option for Vendor to Propose One Submerged System and One Pressure System Pressure Proposals from Pall and Siemens Submerged Proposals from GE and Siemens

14 Membrane Procurement Schedule Item GE/Zenon Submerged Pall Encased Siemens Submerged Siemens Encased Membrane Equipment Capital Cost $4,469,572 $4,485,704 $4,876,897 $4,515,812 Non-Equipment Capital Cost $1,189,026 $1,217,622 $1,379,756 $1,271,505 Present Worth of Operating Cost $1,585,596 $1,671,308 $1,578,835 $1,465,405 Present Worth of Membrane Replacement Cost $1,040,439 $1,018,134 $1,035,538 $ 985,240 Total Present Worth $8,284,633 $8,392,768 $8,871,026 $8,237,963

15 Membrane Filtration Definition Semi-permeable thin layer of material Slow rate of transfer across the membrane and high pressure drops Very effective

16 RO, NF, UF and MF MEMBRANE DESIGNATION PRESSURE GRADIENT REMOVAL EFFICIENCY PORE DIAMETER

17 Mechanisms of Filtration Mechanical Screening Adsorption Cake Filtration

18 Principles of Membrane Filtration Osmosis Osmotic Pressure

19 Membrane Filtration Theory Water flux: J = Q A = P ( µ )( Rm) Where: J = volumetric flux of water Q = volumetric flow rate of pure water, gal/day A = surface area of clean membrane, ft 2 P = transmembrane pressure µ = dynamic viscosity of water R m = membrane resistance coefficient

20 Membrane Filtration Theory Fouling Flow Adsorption (85-90%) Flux (10-15%) Fouling Layer Permselective Barrier Product Water

21 Biofouling Biofouling is referred as the undesired development of microbial layers on the surface. Biofilm organisms are embedded in a matrix of microbial origin, consisting of extracellular polymeric substances (EPS). EPS & Microbial Growth Microbial Attachment Microbial Colonization Membrane Surface

22 Membrane System Components Membranes Modules Racks Piping

23 Hollow Fiber Flow Path Inside-Out Outside-In

24 Membrane Processes: Operation

25 Pretreatment Coagulation, flocculation, and sedimentation for high raw water turbidity and/or high NOM Where iron and/or manganese are prevalent, oxidation is performed to form precipitate prior to filtration Pre-filtration of particulates To remove large particle fraction, a strainer or bag filter rated at 50 to 500 µm is used for all water sources

26 Cleaning Backwashing with either air or permeate water at preset intervals of 30 to 90 min. Addition of chlorine to backwash water aids in reducing biofouling. Oxidant tolerant membrane material must be selected to employ this technique. Chemical cleaning in place or with modules removed will be required periodically

27 Post-treatment Concentrate High solids concentration High concentration of pathogens Disposal: municipal sewer, ocean discharge, deep well injection

28 Final Plant Design Elements Siemens Pressure Membrane Pilot Testing Test Plan & Protocol Complete Membrane System Includes all ancillary equipment Specific Parameters for Backwash and Maintenance Wash Cold Water and Warm Water Piloting Run at 1.1 times full scale flux

29 Final Plant Design Elements Design Flow Changed to 16 MGD Utilize Existing Intake Zebra Mussel Control using Divers for Cleaning Extension of Raw Water Intake using Jack & Bore / Slurry Microtunneling New Raw Water Pumping Station Vertical Turbine Raw Water Pumps Automatic Self Cleaning Strainers PAC Feed System

30 Final Plant Design Elements New Operations Building Bulk Chemical Storage and Feed Systems Siemens CP Wing Pressure Membranes Mechanical, Electrical, Office and Lab Rooms High Service Pumping Station Future Ultra-Violet Treatment Area Added Package Plate Settlers Membrane Backwash EQ Tank Back Up Power Supply 4 MG Finished Water Storage (w/ Space for Additional 3 MG Tank) Construction Under USACE 219 Grant

31 The New WTP Aerial View

32 Start-up Challenges Finished Water Storage Reservoir Timing of Reservoir Completion Raw and High Service Pumps Motor Vibration Issues Chemical Feed Systems Chemical Compatibility of Materials Utilized Calibration of Pumps Strainers V-notched Openings Plugging

33 Lessons Learned Value Engineering Pays Coordination and Communication are Key One General Contractor Assignment of Owner-Procured Equipment Project Risk Managed Thorough Set of Plans and Specifications Design Staff Active During Construction

34 Thank You Eric Horvath, PE American Structurepoint 211 W. Washington St., Suite 2410 South Bend, IN Kara Boyles, PhD, PE American Structurepoint 211 W. Washington St., Suite 2410 South Bend, IN