Construction and commissioning of the - Horizon 2020 research and innovation programme Project: No 690323 SMART-Plant
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This project has received funding from
the European Union’s Horizon 2020
Ref. Ares(2017)4843381 - 04/10/2017
research and innovation programme
under grant agreement No. 690323
Horizon 2020 research and innovation programme
Project: No 690323 SMART-Plant
Full project title:
Scale-up of low-carbon footprint material recovery techniques
in existing wastewater treatment plants (SMART-Plant)
DeliverableD3.2
Construction and commissioning of the
SidestreamSMARTechs
Due date of deliverable: 31 May 2017
Actual submission date: 04 Oct 2017
Project: No 690323
DOCUMENT INFORMATION:
Construction and commissioning of the
Deliverable Number D3.2 Title:
Sidestream SMARTechs
Work Package Number WP3 Title: Side- and Down-stream SMARTechnologies
Due date of deliverable Contractual M6 Actual M6
Version number 1.0
Format Pdf file
Creation date 15/05/2017
Version date 20/09/2017
Type R DEM DEC OTHER ETHICS
Dissemination Level PU Public CO Confidential
Rights Copyright “SMART-Plant Consortium”.
During the drafting process, access is generally limited to the SMART-Plant
Partners.
Responsible author Paolo Pozzato, Davide pozzato@scaevicenza.it;
Name: Savio, Monica E-mail: tecnico@scaevicenza.it,
Miglioranza segreteria@scaevicenza.it
Partner: SCAE Phone: +39 0444 360 533
Other authors Constantinos Noutsopoulos,
Simos Malamis, Daniel Mamais,
Name: Partner: NTUA
Andreas Andreadakis, Evangelos
Statiris
Name: Nicola Frison, David Bolzonella Partner: UNIVR
Name: Daniele Renzi Partner: ATS
SMART-Plant D3.2
Project: No 690323
Ioanna Droubogianni, Dimitra
Name: Kollia, Panagiotis Lalis, George Partner: AKTOR
Zarras
Brief Description Deliverable 3.2 is part of WP3 which is related to side- and down-stream
SMARTechnologies. More specifically D3.2 focuses in three sidestream
SMARTechnologies that are integrated in the existing conventional sewage
sludge treatment line to provide more energy efficiency for the i) removal of
nitrogen, ii) recovery of phosphorus and iii) recovery of PHA. The D3.2 is to the
construction and the commissioning of the sidestream SMARTechs.
Keywords sidestream Smartechs, construction, commissioning
Version log Revision history
Rev. No. Issue Date Modified by Comments
Minor revision by Coordinator before
Version 1 03/10/2017 Francesco Fatone
submission
SMART-Plant D3.2
Project: No 690323 TABLE OF CONTENTS Document Information: ......................................................................................................................... 2 Table of Contents ................................................................................................................................... 4 List of Tables .......................................................................................................................................... 5 List of Figures ......................................................................................................................................... 5 Executive Summary................................................................................................................................ 6 Abbreviations ......................................................................................................................................... 9 1. Introduction ............................................................................................................................. 11 2. SMARTech4a - Sidestream SCENA ........................................................................................... 13 2.1 Technical description of the SMARTech 4A ............................................................................. 13 2.2 List of the electromechanical equipment ................................................................................ 16 2.3 Practical instructions for the operation of SMARTech 4A ....................................................... 23 2.1 Integrability of the Smartech 4a in existing WWTPs ............................................................... 25 2.2 Drawings ‘as built’ .................................................................................................................... 27 2.3 Picture report ........................................................................................................................... 28 3. SMARTech4b - Sidestream THERMAL HYDROLYSIS-SCENA ..................................................... 32 3.1 Technical description of the SMARTech 4B ............................................................................. 32 3.2 List of the electromechanical equipment ................................................................................ 35 3.3 Practical instructions for the operation of SMARTech 4B ....................................................... 39 3.1 Integrability of the Smartech 4b in existing WWTPs ............................................................... 42 3.2 Drawings ‘as built’ .................................................................................................................... 44 3.3 Pictures report ......................................................................................................................... 44 4. SMARTech5 - Sidestream SCEPPHAR ....................................................................................... 52 4.1 Technical description of the SMARTech 5 ............................................................................... 52 4.1 List of the electromechanical equipment ................................................................................ 54 4.2 Practical instructions for the operation of SMARTech 5 ......................................................... 66 4.3 Integrability of the Smartech 5 in existing WWTPs ................................................................. 72 4.4 Drawings ‘as built’ .................................................................................................................... 74 4.5 Pictures report ......................................................................................................................... 74 SMART-Plant D3.2
Project: No 690323 LIST OF TABLES Table 1 Specification of the grinder for the mixed primary sludge. .................................................... 16 Table 2 Specification for the installation of the dynamic thickening .................................................. 16 Table 3 Specification of the fermentation unit.................................................................................... 18 Table 4 Specification for the installation of the screw-press separator for the mixed sludge fermentation ........................................................................................................................................ 19 Table 5 Specification of the Short-Cut Sequencing Batch Reactor ...................................................... 19 Table 6 Operation of the fermentation unit ........................................................................................ 23 Table 7 Operation of the screw-press separator ................................................................................. 24 Table 8 Operation of the short-cut Sequencing Batch Reactor. .......................................................... 25 Table 9 Major units and specifications of the electro-mechanical equipment ................................... 36 Table 10 Basic features of automation in the operation of pilot plant system. .................................. 40 Table 11 List of electromechanical equipment and FLOW DIRECTION of the Salsnes Filter .............. 54 Table 12 List of tanks, electromechanical equipment, sensors and FLOW DIRECTION of the Sequencing Batch Fermentation Reactor ............................................................................................ 55 Table 13 List of tanks, electromechanical equipment, sensors and flow direction of the ultrafiltration unit ....................................................................................................................................................... 57 Table 14 Specification of the crystallization unit ................................................................................. 57 Table 15 List of tanks, electromechanical equipment, sensors and flow direction of the nitritation unit .............................................................................................................................................................. 59 Table 16 List of tanks, electromechanical equipment, sensors and flow direction of the PHA- accumulating biomass selection SBR ................................................................................................... 61 Table 17 List of tanks, electromechanical equipment, sensors and flow direction of the accumulation SBR ....................................................................................................................................................... 64 Table 18 Operation of the SF1000 ....................................................................................................... 66 Table 19 Operation of the fermentation unit ...................................................................................... 67 Table 20 Operation unit of the ultrafiltration unit .............................................................................. 68 Table 21 Operation of the crystallizer ................................................................................................. 68 Table 22 Operation of the nitritation unit ........................................................................................... 70 Table 23 Operation of the selection SBR ............................................................................................. 71 Table 24 Operation of the accumulation SBR ...................................................................................... 72 LIST OF FIGURES Figure 1 Deliverables of WP3 related to sidestream SMARTechs. ...................................................... 11 Figure 2 P&id of the Smartech 4a ........................................................................................................ 13 Figure 3 SMARTech 4a - Dynamic thickener of the sewage sludge ..................................................... 28 Figure 4 SMARTech 4a – Screw-press for S/L of the fermentation sewage sludge............................. 28 Figure 5 SMARTech 4a – Accumulation tank for the fermentation liquid of mixed sludge ................ 29 Figure 6 SMARTech 4a – Different views of the fermentation ............................................................ 29 Figure 7 SMARTech 4a - Electrical Panel and air compressor of Smartech 4a .................................... 30 SMART-Plant D3.2
Project: No 690323 Figure 8 SMARTech 4a -Tank for the acculation of the anaerobic supernatant and influent pump of the scSBR .............................................................................................................................................. 30 Figure 9 SMARTech 4a - Air diffusion system of the scSBR ................................................................. 31 Figure 10 Flow diagram of Psittalia WWTP with SMARTech 4b .......................................................... 32 Figure 11 Major units of SMARTech 4b and their interconnections ................................................... 33 Figure 12. Plan view of SMARTech 4B ................................................................................................. 44 Figure 13 Plan view of SMARTech 4B .................................................................................................. 45 Figure 13 3D drawing of SMATech 4B ................................................................................................. 45 Figure 15 SMARTech 4B – construction phase .................................................................................... 46 Figure 16 SMARTech 4B – construction phase .................................................................................... 46 Figure 17 SMARTech 4B – construction phase – installation of reject water storage tanks............... 47 Figure 18 SMARTech 4B – construction of raw and treated reject water networks ........................... 47 Figure 19 SMARTech 4B – overview of feed pump, decanting pump and decanting network ........... 48 Figure 20 SMARTech 4B – overview of feed pump and decanting pump ........................................... 48 Figure 21 SMARTech 4B – decanting system ....................................................................................... 49 Figure 22 SMARTech 4B – chemicals and substrate dosing pumps .................................................... 49 Figure 23 SMARTech 4B – chemicals and substrate storage tanks ..................................................... 50 Figure 24 SMARTech 4B – installation of on-line probes .................................................................... 50 Figure 25 SMATech 4B – hydraulic testing of the SBR ......................................................................... 51 Figure 26 SMATech 4B –testing of the aeration system of the SBR .................................................... 51 Figure 27 P&id of the Smartech 5. ....................................................................................................... 52 Figure 28 SMARTech 5 - Integrated container with rotating belt filter intalled ................................. 74 Figure 29 SMARTech 5 - Hopper for the cellulosic primary sludge .................................................... 75 Figure 30 SMARTech 5 - Installation of the Smartech 5 ...................................................................... 75 Figure 31 SMARTech 5 - (a) Sequencing Batch Fermentation Reactor during the installation; (b) Sequencing Batch Fermentation Reactor placed in the platform ....................................................... 76 Figure 32 Ultrafiltration unit ................................................................................................................ 76 Figure 33 SMARTech 5 - Ultrafiltration system (right side) and crystallizer (right side) ..................... 77 Figure 34 SMARTech 5 - Left side,Nitritation, Selection and Accumulation SBRs; Right side, ultrafiltration system and cristallizer. .................................................................................................. 77 Figure 35 SMARTech 5 - Air diffusion system for the nitritation, selection and accumulation SBR. .. 78 Figure 36 SMARTech 5 - Hydraulic testing ........................................................................................... 78 Figure 37 SMARTech 5 – Testing of the air diffusion system. ............................................................. 79 Figure 38 SMARTech 5 – Screenshot of the PLC control panel ........................................................... 79 EXECUTIVE SUMMARY Deliverable 3.2 is part of WP3 which is related to side- and down-stream SMARTechnologies. More specifically D3.2 focuses in three sidestream SMARTechnologies that are integrated in the existing conventional sewage sludge treatment line to provide more energy efficiency for the i) removal of SMART-Plant D3.2
Project: No 690323 nitrogen, ii) recovery of phosphorus and iii) recovery of PHA. The D3.2 is to the construction and the commissioning of the sidestream SMARTechs. A brief description of the sidestream Smartechs involved in WP3 is reported below: SMARTech 4a focuses in the integration of conventional biogas recovery from sewage sludge with sidestream energy-efficient and compact nitrogen removal and phosphorus recovery. It applies the Short-Cut Enhanced Nutrient Abatement system (SCENA) which integrates the following processes: (o) dynamic thickening of the mixed sludge, (i) acidogenic fermentation of cellulosic sludge to produce VFAs as carbon source, and (ii) via nitrite nitrogen and phosphorus removal (by P- bioaccumulation) from sludge reject water using an SBR. In this configuration, nitrogen is removed through the bioprocesses of nitritation/denitritation, and Enhanced Biological Phosphorus removal (EBPR) is accomplished via nitrite through the alternation of anaerobic/aerobic/anoxic conditions. SMARTech4b aims to the integration of the enhanced biogas recovery (by thermal hydrolysis) of sewage sludge with sidestream energy-efficient and compact nitrogen removal and phosphorus recovery. It applies and optimize the Short-Cut Enhanced Nutrient Abatement processfor the treatment of reject water with a very high ammonium nitrogen content (>1.2 gN/L) due to the pre- treatment of sewage sludge through thermal hydrolysis. In order to increase the biodegradable COD/N and COD/P ratios reject water from primary sludge gravity thickeners will be used. Alternatively, sodium acetate will be also employed to increase the readily biodegradable COD in reject water in order to efficiently remove nitrogen through short-cut nitrification/denitrification and to accumulate phosphorus in sludge through enhanced biological P removal via denitritation or aerobically. SMARTech4b is designed to treat approximately 2-3 m3/d of reject water from sludge dewatering facilities. Based on the design, alternative operational conditions can be employed depending on the type of external substrate provided. An SBR with an effective volume of at least 9 m3 will be installed and be equipped with aeration system, mixing apparatus, probes and meters for automatic control of the process. The SBR will be fed with sludge liquors form the dewatering unit and from primary sludge thickening unit. The sludge liquors before being fed to the SBR will be collected in two storage tanks. Three chemical dosing units will also be installed in order to provide SMART-Plant D3.2
Project: No 690323 i) for sodium acetate addition (as a complementary external substrate), and ii) for pH control of the process. SMARTech5 enables the integration of conventional biogas recovery from sewage sludge with the energy-efficient nitrogen removal from sludge reject water and the recovery of PHA and struvite. It applies the Short-Cut Enhanced Phosphorus and PHA Recovery concept (SCEPPHAR), which was conceived as a modified version of SCENA for WWTPs larger than 150 kPE. It accounts of the following sub-processes: (i) acidogenic fermentation of cellulosic primary sludge for the production of VFAs and the release of nitrogen and phosphorus in soluble forms (ammonia and phosphate); (ii) solid and liquid separation of the fermentation products and recovery of struvite form the sewage sludge fermentation liquid by the addition of Mg(OH)2 to favour phosphorus precipitation; (iii) ammonium conversion to nitrite accomplished in a SBR; (iv) selection of PHA storing biomass in a SBR by the alternation of aerobic feast conditions and followed by anoxic famine conditions for denitritation driven by internally stored PHA as carbon source; (v) PHA accumulation using a fed-batch reactor to maximize the cellular PHA content of the biomass harvested from the selection stage. SMART-Plant has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 690323. SMART-Plant D3.2
Project: No 690323 ABBREVIATIONS AOB Ammonia Oxidizing Bacteria BNR Biological nutrient removal BOD5 Biochemical oxygen demand CHP Combined heat and power COD Chemical oxygen demand DO Dissolved oxygen DS Dissolved solids EBPR Enhanced Biological Phosphorus removal GHG Green house gases MLSS Mixed liquor suspended solids MLVSS Mixed liquor volatile suspended solids NH4-N Ammonium nitrogen NLR Nitrogen loading rate NOB Nitrite Oxidizing Bacteria ORP Oxidation-reduction potential OTR Oxygen transfer rate PHA Polyhydroxyalkanoates PLC Programmable logic controller SBR Sequencing Batch Reactor SCENA Short-Cut Enhanced Nutrient Abatement process SCEPPHAR Short-Cut Enhanced Phosphorus and PHA Recovery concept SL-DS Sludge liquor-Dewatered sludge SMART-Plant D3.2
Project: No 690323 SL-PS Sludge liquor-Primary sludge SOTE Diffuser efficiency SOTR Standard oxygen transfer rate SRT SVI Sludge volume index TN Total nitrogen TP Total phosphorus ΤS Total solids TSS Total suspended solids VFAs Volatile fatty acids VSS Volatile suspended solids WAS Waste Activated Sludge WWTP Wastewater Treatment Plant SMART-Plant D3.2
Project: No 690323
1. INTRODUCTION
Deliverable 3.2 is part of WP3. WP3 main objective is to test and validate both side- and downstream
SMARTechnologies. More specifically WP3 includes 1) three Sidestream SMARTechs that will
integrate the existing conventional and enhanced biogas recovery from sewage sludge aiming at the
energy-efficient removal of nitrogen, recovery of phosphorus and PHA and 2) two Downstream
SMARTechs that will process the resource rich sludge to recycle raw material for following reuse in
agricultural and construction sectors.
WP3 consists of five tasks:
Task 3.1 enabling sidestream SMARTech 4a with a duration of 42 months
Task 3.2 enabling sidestream SMARTech 4b with a duration of 42 months
Task 3.3 enabling sidestream SMARTech 5 with a duration of 42 months
Task 3.4 enabling downstream SMARTech A with a duration of 30 months
Task 3.5 enabling downstream SMARTech B with a duration of 30 months
In the context of WP3 six deliverables are foreseen. Deliverables 3.1-3.3 & 3.5 are related to the three
sidestream SMARTechs. The short title of each of the deliverables and their month of delivery is
illustrated in Figure 1.
Figure 1 Deliverables of WP3 related to sidestream SMARTechs.
The present report is the second of these series of deliverables. D3.2 presents the costruction,
installation and commissioning of the sidestream Smartetech.
SMART-Plant D3.2Project: No 690323 D3.2 is structured in four chapters and annexes, including this introduction, which presents the objectives of this report and its structure. For each technology, the report is structurized a technical of the SMARTech is 1- Technical description of the SMARTech 4a, 4b and 5; 2- List of the electromechanical equipment 4a, 4b and 5; 3- Practical instructions for the operation of SMARTech 4a, 4b and 5; 4- Drawings ‘as built’ 5- Picture reports Finally, Annex presents the executive drawing “as built” of the three Smartechs. SMART-Plant D3.2
Project: No 690323 2. SMARTECH4A - SIDESTREAM SCENA 2.1 Technical description of the SMARTech 4A The Smartech 4a is an innovantive technology aiming the via-nitrite nitrogen phosphorus removal from the anaerobic supernatant. The overall system can be described according to the following integrated operational units: 1) (alkaline) fermentation of thickened sewage sludge at mesophilic conditions (37°C) for the on-site production of best available carbon source (BACS), which is the optimal mix of volatile fatty acids; 2) A solid/liquid separation of the fermented sewage sludge by a screw press; 3) A Sequencing Batch Reactor (SBR) for the short cut biological nitrogen removal and phosphorus recovery via-nitrite through the dosage of the sewage sludge fermentation liquid. Figure 2 P&id of the Smartech 4a The optimization of the Smatech 4a was carried out during the design phase by the implementation of the dynamic thickening of the mixed sewage sludge, which allows the increase of the organic loading rate and the reduction of the sludge volume fed to the anaerobic digestor and the fermentation unit. The dynamic thickener (SCAE) allows the thickening of up to 100 m3 of sewage SMART-Plant D3.2
Project: No 690323 sludge per day, according with a flowrate of 20 m3/h. The final concentration of the sewage sludge will be around 5% (Total Solid based) thanks to the addition of a polyelectrolyte solution (0.8% of active compound) by a dedicated machine. Around 10 m3 of thickened sludge fed the fermentation unit, which has a total volume of 50 m3. The fermentation process works at around 30°C thanks to the heater fed to the biogas produced from the full scale anaerobic digestor. A constant hydraulic retention time of 5 days is controlled by two pneumatic and opposite valves, which are able to divert the flowrate of the thickened sewage sludge to the fermentation unit or to the digestor according with set-point level achieve in the fermentation unit. The solid/liquid separation of the fermented sewage sludge is carried out by a screw-press (SCAE) able to produce around 2-4 m3/h of fermentation liquid rich of volatile fatty acids. The liquid fractio is stored in a storage tank of 20 m3 to make it available for the further utilization during the anaerobic and anoxic phase of the scSBR. The solid fermented fraction (13-15% total solids based) is not disposed due to the still high biogas production potential, but it is mixed with the thickened mixed sludge which fed the anaerobic digestor. The scSBR has a maximal working volume of 70 m3, which allow the treatment of the daily flowrate of anaerobic supernant produced after the dewatering operation of the anaerobic digestate under 3-4 cycles. The scSBR is equipped with a mixing system having a nominal power of 1.5 kW. The aeration system consist of a volumetric blower (nominal power 11 kw) and n°80 diffusers (INVENT) able to provide around 500 m3/h of compressed air at 400 mbar of pressure, in order to provide an oxygen transfer efficiency up to 15%. The dissolved oxygen concentration in the bulk will be controlled during the aerobic phase at 1.5 mg/L by a Variable Frequency Device (VFD) to module the air flowrate of the blower. There are two centrifugal pumps from FLYGHT manufacturer with capacity of 70 and 65 m3/h respectively for the feeding and discharge of the scSBR. In each cycle, the feeding pump feeds automatically around 10-15 m3 of anaerobic supernatant, which is taken directly from the storage tank of 90 m3. The latter has a capacity to store enough anaerobic supernant for 2-2.5 days, which takes into account the days when the WWTP of Carbonera is not supervised from the operators (week-end) or when the dewatering operation are not taking placed. At the end of the cycle, the SMART-Plant D3.2
Project: No 690323 centrifugal sumberged pump installed at 0.8 m from the bottom of the scSBR allows the discharge of the treated anaerobic supernatant in the headworks of the main WWTP. The SBR is equipped with sensors from HACH-LANGE company which are based on a floating chamber. The sensors allows the monitoring of several parameters and by them also the control of the nitrogen forms, so to control the cycle lenght. The sensors installed are: pH, Dissolved Oxygen (DO), Conductivity (COND), Oxydation Reduction Potential (ORP), Mixed Liquor Suspended Solids (MLSS). All the signal from the sensor are first collected by the controller SC1000 (HACH-LANGE) and then transfer to a Programmable Logic Controller (PLC, SIEMENS) via a modbus protocol. The data can be also recorded and used from the remote system of ATS. The control algortims installed in the PLC provides the control of the electrical equipments, including the lenght of each phases, the automatic dosage of the carbon source and the variable frequency driver to control the right dissolved oxygen during aerobic phase. SMART-Plant D3.2
Project: No 690323
2.2 List of the electromechanical equipment
Table 1 Specification of the grinder for the mixed primary sludge.
GRINDER
CODE DESCRIPTION Unit Value
TR1 Grinder m3/h 20
rpm 270
Hz 50
Description
The grinder is used as for the size reduction of the coarse material present in the mixed sludge. The
grinder has 4 self-sharpening cutting blades with a grid having a maximal pore size of 24 mm and 445
cm2 of surface. The maximal operating pressure is 2 bar.
Table 2 Specification for the installation of the dynamic thickening
DYNAMIC THICKENING
CODE DESCRIPTION Unit Flowrate
ID Dynamic thickening m3/h 20
List of electromechanical equipment included
CODE DESCRIPTION Flowrate Intalled CONTROL
power
P4 Feeding ID 20 m3/h 7.5
P7 Emulsion dosage 0-600 L/h -
P8 Poly solution dosage 2 m3/h 1.1
P16 Washing ID pump 3
5 m /h 5.5
P05 Feeding DA, POI, FRM 3
6 m /h 4
FLOW Feeding from (F)/ Discharge to (D) PUMP CODE
Configuration 1: PRI -> ID -> FRM; F1:P04
Configuration 2: PRI -> ID -> POI; F2:P07, P08
Configuration 3: PRO ->ID-> DA D1: P05
D2: gravity
SENSORS INSTALLED
Code M012
Description Measurement of the total solids of the mixed sludge
Technical description
Probe with combined light infrared absorption for measuring turbidity and suspended solids
Independent of the color of the water sample (suitable for waste activated sludge, primary sludge,
SMART-Plant D3.2Project: No 690323 etc). Component and configuration Configuration: insertion probe with steel probe body; Lenght of cable: 10 meters Technical data: photometer with double IR detector Method of measurement: Turbidity measurement according to DIN EN 27027; Measure Solids, equivalent to DIN 38414 Measurement range: Turbidity: 0.001 - 4.000; Total Solids: 0.001 - 50.0 g / l Accuracy: 1.0% turbidity, ± 0.001 FNU Coeff. Var process: 1.0% according to DIN 38402 Response Time: 0.5 s
Project: No 690323
Table 3 Specification of the fermentation unit
FERMENTATION UNIT
CODE DESCRIPTION Size Value
FRM Fermentation unit Diamete 4m
Height 4m
List of electromechanical equipment included
CODE DESCRIPTION Flowrate Intalled CONTROL
power
P05 Feeding FRM 3
6 m /h 7.5 Based on status of V3 and V4
P09 Discharge FRM 3
6 m /h 0.55
MX5 Mixer FRM - 1.5 Manual switch on/off
HH Heater 55 (daily 14.7 kW The biogas is taken from the
needs of thermic full scale anerobic digestion of
biogas) power sewage sludge
FLOW Feeding from (F)/ Discharge to (D) PUMP CODE
FRM -> PC F1:P05
D1:P09
SENSORS INSTALLED
Code M010
Description Measurement oft he pH and temperature of the fermentation
unit (FRM)
Technical description
Differential type digital sensor for the measurement of pH and temperature. Electrode not in
contact with the liquid bulk.
Component and configuration
Material of the electrode: glass;
Type of probe: submerged
Sensor body: steel
Range of measurement: 0 - 14; T=-5° C a 50° C
Time of response: pH: < 5 s; T: < 2 min
Reference electrode for the control of the impedence of the liquid bulk
Lenght of the cable: 10 metri
Dimensions: 350 x 44 mm (diameter)
Other equipments included
- Fixing system for pH, size 1" steel AISI316
SMART-Plant D3.2Project: No 690323
Table 4 Specification for the installation of the screw-press separator for the mixed sludge
fermentation
SCREW PRESS SEPARATOR
CODE DESCRIPTION Unit Flowrate
PC Screw Press for sludge m3/h 2-4
fermentation dewatering
List of electromechanical equip-ment included
CODE DESCRIPTION Flowrate Intalled CONTROL
power
P09 Feeding DA, POI, FRM 3
6 m /h 4 Controlled by frequency
inverted and leve ultrasonic
P13 Poly solution dosage 0.32 Controlled by frequency
inverted and leve ultrasonic
P11 Solid 3
fraction 0.6-3.2 m /h 5.5 Controlled by frequency
fermentation sludge inverted and leve ultrasonic
P10 Liquid fraction 2-5 m3/h 1.4 Controlled by min/max level
fermentation liquid sensor M022
FLOW Feeding from (F)/ Discharge to (D) PUMP CODE
FRM-> PC -> SCENA (Liquid fractio) F1: P09;
FRM ->PC -> POI (Solid fraction) F2: P13
D1: P11;
D2: P10
POLYELECTROLITE MACHINE
CODE DESCRIPTION Flowrate VALUE
PP2 Machine for preparation of m3/h
polyelectrolyte solution
List of electromechanical equipment included
CODE DESCRIPTION Flowrate Intalled CONTROL
power
P7 Emulsion dosage 0-600 L/h 0.5
P8 Poly solution dosage 1.1
FLOW Feeding from (F)/ Discharge to (D) PUMP CODE
PP2 -> FRM F1: P7;
PP2 -> ID D1: P8
D2:
Table 5 Specification of the Short-Cut Sequencing Batch Reactor
SMART-Plant D3.2Project: No 690323
SHORT-CUT SEQUENCING BATCH REACTOR
CODE DESCRIPTION Size Value
scSBR Short-Cut Sequencing Batch Max working 70 m3
Reactor Volume
Surface 8 x 2.9 m
Height 3.2 m
List of electromechanical equipment included
CODE DESCRIPTION Flowrate Intalled CONTROL
power
P1 Feeding scSBR 3
49 m /h 1.8 Switch on during the filling
phase (control by the PLC)
MX3 Mixer scSBR - 1.5 Switch on during the filling,
anaerobic and anoxic phase.
(control by the PLC)
BL1 Blower scSBR 3
170 ÷ 520 m /h 11 Switch on aerobic phase.
(control by the PLC)
P2 Discharge scSBR 70 m3/h 1.35 Switch on during the discharge
phase (control by the PLC)
P12 Carbon source 3
5 m /h 0.98 Switch on during the anaerobic
and anoxic phase (control by
the PLC)
P03 Purge 3
5 m /h 2.2 Manual switch on/off
FLOW Feeding from (F)/ Discharge to (D) PUMP CODE
FRM -> PC F1:P05
D1:P09
INSTALLED SENSORS
Code DO002
Description Measurement of dissolved oxygen of the selection SBR unit (R006)
Technical description
The measurement method is based on the emission of luminescent radiation by a special substance
(luminophore) that is excited by light blue emitted by a LED and returning to the normal state emits
light red. A photodiode measures the time needed to return to the quiescent state, inversely
proportional to the concentration of oxygen present on the luminophore.
Component and configuration
- Measuring principle: luminescent optic
- Measurement range: 0 to 20.00 mg / L (ppm) O2, 0 to 200% saturation
- Accuracy: 0-5 mg / L O2 ± 0.1 mg / L, 5-20 mg / L O2 ± 0.2 mg / L; Temperature: ± 0.2 ° C
- Repeatability: ± 0.1mg / L
- Resolution: 0.01 mg / L (ppm) O2 / 0.1% saturation
SMART-Plant D3.2Project: No 690323 - Response time (at 20 ° C): T90
Project: No 690323 - PVC pole (Ø 40mm, length 2 meters) - 1 "NPT sensor adapter - swivel spindle - brown tube closure cap SMART-Plant D3.2
Project: No 690323
2.3 Practical instructions for the operation of SMARTech 4A
The dynamic thinkening is fed using the volumetric pump P04 with a flow rate of 20 m3/h. To prevent
clogging due to tatters or other inert materials, a grinder by vogelsang company is installed before
the pump P04. However, in case of mantenance or techical problems, the P04 can be replaced by the
parent installed volumetric pump P06. The thickened mixed sludge (50 gTSS/L) is pumped using a
volumetric pump at 6 m3/h. The influent flowrate and the total solid concentration of the influent
mixed sluge are monitored by the inline sensors M012 (TSS) and M014 (Qf) respectively. A solution
of polyelectrolite is provided using the volumetric pump P09, where the flowrate is automatically
adjusted according with the registered total solids concentration of the influent and thickened mixed
sludge using the inline sensors M013 (TSS) and M015 (Qdig) respectively. Every day, 10 m3/d of
fermented sludge are discharge from the fermentation unit using the P09 and then fed with fresh 10
m3/d of thickened mixed sludge using the P05. The feeding and discharge of the fermentation unit
are controlled by the level sensor M009 and based on two opposite pneumatic valves (V3 and V4).
At minimun fixed level, the pneumatic valve V4 is kept closed, while the pneumatic valve V3 is open,
so to allow the feeding of thickened. The duration of the feeding is 1.7 hours. Once the maximal level
of the fermentation unit is achieved, the valve V3 close and V4 open.
Table 6 Operation of the fermentation unit
Operation phase Parameter that defines the phase Equipment in working
duration according to PLC design mode during this phase
controlled by PLC
Filling (1 per day) Level max The valve V3 open while
the valve V4 is closed
Decanting (1 per day) Level min The valve V4 open while
the valve V3 is closed
The screw press is fed using a volumetric pump with a maximal flowrate of 2-4 m3/h. The solid and
liquid separation of the mixed sludge fermentation results on two main stream: solid and liquid. The
liquid is pumped by a centrifugal pump using the storage tank of the carbon source. The solids
fraction is pumped by to the post dynamic thickening using the volumetric pump P11. The P9 is
controlled by the level of the fermentation. Every day, the screw press accomplishes the solid/liquid
SMART-Plant D3.2Project: No 690323
separation until when the minimun level of the fermentation unit is achieved. The fermentation liquid
produced is relaunched by the pump P10 from a temporary tank to the final storage tank of 20 m3
for its further application to the scSBR. The P10 is turned on when the level of the carbon source is
between the minimun and maximal level of the M022. The P10 stops the operation as soon as the
maximal level M011 is achieved. The eventual excess of carbon source production is drained by the
overflow and so discharged in the mainstream.
Table 7 Operation of the screw-press separator
Operation phase Parameter that defines the Equipment in working mode
phase duration according to PLC during this phase controlled by
design PLC
Filling Operation according to the level P9
MIN and MAX of the
fermentation unit
Relunch of the liquid Operation according to M022 P10
fraction
Discharge solid fraction Operation according to M011 P11
The scSBR is fed with around 40 m3/d of anaerobic supernatant using the suberged centrifugal pump
P01. The carbon source is provided by the volumetric pump P12. The effluent from the scSBR is
discharged using the submerged centrifugal pump P02. The waste activated sludge is withdrawn from
the scSBR using the P03. The anaerobic supernatant from the dewatering operation of the digestate
is sent by gravity in the equalization tank. The level M001 controlled the operation of two pneumatic
valve V13 and V14: at the minimal level achieved, the V13 is closed and V14 is opened, while at the
maximal level achieved the V13 is opened and V14 is closed. The daily flowrate of anaerobic
supernatant provided to the scSBR is divided in three or four cycle. The level M002 determines the
minimal and the maximal level achievable in the scSBR. Six sensors are installed in the reactor:
conductivity (M003), pH (M004), ORP (M005), DO (M006), MLSS (M007) and N2O (M008). Among
them, DO is used to control the compressor through VDF, while conductivity and pH are used to
control the lenght of the aerobic phase, the amount of carbon source and the lenght of the anoxic
phase. The other sensors are not included in the control algorithm of the system but are recorded in
the PLC.
SMART-Plant D3.2Project: No 690323
Table 8 Operation of the short-cut Sequencing Batch Reactor.
Operation phase Parameter that defines the phase Equipment in working
duration according to PLC design mode during this phase
controlled by PLC
Filling Timer or/and Level meter SBR mixing device
Sludge liquors feeding
pumps
Anaerobic phase Time based control SBR mixing device
(1 phase for each cycle) Monitoring of the process
parameters (pH, ORP,
Conductivity, Oxygen,
N2O, MLSS)
Aerobic phase Time based controlled for the Min Frequency of the blower
(1-2 phases during each and Max lenght of the phase; control by a PID algoritm
cycle) Real time control based on
conductivity and pH
Anoxic phase Time based controlled for the Min SBR mixing device;
(1-2 phases during each and Max lenght phases Carbon source feeding;
cycle) Dosage of the carbon source
according with the conductivity;
End of the phase according with
pH signals
Settling Timer -
Decanting Timer or/and Level meter Disharge pump
WAS removal Timer or/and Level meter Decanting pump
SBR mixing device
2.1 Integrability of the Smartech 4a in existing WWTPs
Integrability issues Smartech 4a
Technical Feasibiliy
1. Should new facilities always be No. Preliminary designs should be always performed in
considered during the design and order to consider the recovery of disused tanks or the
implementation of the Smartech? conversion of the existing facilities in the WWTPs. In
particular, the Smartech 4a was designed considering
SMART-Plant D3.2Project: No 690323
the conversion of existing tanks dedicated to the
storage of liquid waste.
2. Does the implementation of the No, if the Smartech 4a takes advantage of existing
Smartech imply a substantial change of works, only minor changes of piping connection are
the present flowscheme of the WWTP? required, which do not represent substantial changes
of the WWTPs.
3. Could the Smartech negatively impact No, the Smartech will positively impact on the final
on the final discharge of the main discharge, because the treated effluent from Smartech
WWTP? 4a is supposed to contain up to 90% less nitrogen and
30-60% less phosphorous compared with raw
anaerobic supernatant. However, even if the
technology does not perform as expected, the effluent
will be treated in the main WWTPs before its final
discharge in the water body.
Acceptability of the Smartech
1. Is the Smartech 4a well accepted The Smartech 4a is considered by operators an
among the operators? integrated and useful compartment of the WWTP and
the personnelle are used to operate and take care of
it.
2. Are specific skills and/or tranings No additional specific trainings are requireds. The
required for the operators? knowledge and expertize already held by the
operators of the main WWTP are also sufficient and
adequate to operate in the Smartech 4a. The latter in
fact uses the same equipments typically adopted also
by conventional biological processes.
SMART-Plant D3.2Project: No 690323
Bureaucratic issues
1. Did Smartech 4a require a specific Yes. The authorization for its implementation was
authorization for its implementation? asked to the Regional Authority (see the attachment).
Are there any standards, regulations or No, the Smartech 4a does not need to conform to
references applicable? specific regulation. However, if new facilities are
implemented, the competent autority may ask to
respect the standards of the “landscaping regulation”.
However, regulations could significantly change based
on the country where the plant is operating.
2.2 Drawings ‘as built’
The drawings of the units are reported in the following annexes:
• Drawing 1: P&id of the Smartech 4a
• Drawing 2: Fermentation unit
•
• Drawing 3: Layout of the Smartech 4a
• Drawing 4: Dynamic Thickening
• Drawing 5: Screw press separator
SMART-Plant D3.2Project: No 690323 2.3 Picture report Figure 3 SMARTech 4a - Dynamic thickener of the sewage sludge Figure 4 SMARTech 4a – Screw-press for S/L of the fermentation sewage sludge SMART-Plant D3.2
Project: No 690323 Figure 5 SMARTech 4a – Accumulation tank for the fermentation liquid of mixed sludge Figure 6 SMARTech 4a – Different views of the fermentation SMART-Plant D3.2
Project: No 690323 Figure 7 SMARTech 4a - Electrical Panel and air compressor of Smartech 4a Figure 8 SMARTech 4a -Tank for the acculation of the anaerobic supernatant and influent pump of the scSBR SMART-Plant D3.2
Project: No 690323 Figure 9 SMARTech 4a - Air diffusion system of the scSBR SMART-Plant D3.2
Project: No 690323 3. SMARTECH4B - SIDESTREAM THERMAL HYDROLYSIS-SCENA 3.1 Technical description of the SMARTech 4B The SMARTech 4b pilot system is an innovative nutrient removal process via nitrite which is integrated in the Psyttalia WWTP in order to manage the reject water produced from the dewatering process of the plant. The SMARTech 4b shall treat separately the reject water of the dewatering process to biologically remove nitrogen and phosphorus and then recycle it back to the inlet of the WWTP (Figure 3.1). This process also takes advantage of the readily biodegradable COD which is contained in the reject water of the primary thickened sludge in order to provide part of the carbon source which is required to remove nutrients from dewatered sludge. Figure 10 Flow diagram of Psittalia WWTP with SMARTech 4b Figure 10 illustrates the major units of the pilot system along with their interconnections. The core of SMARTech 4B is the bioreactor (SBR). The SBR is a rectangular tank with dimensions [2.00x2.30x2.40] [WxLxH] and 9m3 maximum active volume. The construction material is stainless steel AISI 304L. SMART-Plant D3.2
Project: No 690323 Figure 11 Major units of SMARTech 4b and their interconnections The SBR is equipped with a mixing apparatus in order to provide a minimum mixing capacity of 8 W/m3. The mixer manufacturer is SEKO (Italy) and it is a slow speed 200rpm mixer with 220mm propeller, stainless steel shaft and PVC body. The effective depth of the reactor will be at least 1.5 m (during the aeration phases) in order to allow for an oxygen transfer efficiency to the order of 8-10%. An aeration system with diffusers has been installed in order to meet the oxygen requirements of the system. The aeration system consists of a side channel air compressor from MAPRO International with maximum capacity of 252 m 3/h at 200 mbar and fine bubble AEROSTRIP diffusers Type T provided by Aquaconsult. The transfer efficiency of the diffusers is in the order of 100 m3/m2 h. The SBR will be fed with sludge liquors from the dewatering unit and from the primary sludge thickening unit. The sludge liquors upstream the SBR will be collected in two storage tanks (one for each type of sludge liquors). There are two transfer pumps from NETZSCH manufacturer with capacity of 5 m3/h each, which feed the storage tanks in automatic mode, in order to keep the necessary volume of slugde liquors in the storage tanks. Each tank provides a storage capacity of min 2 d, with an effective volume to the order of 8 m3 each. Both storage tanks are made of polyethylene, black color, with roof manhole. Each of these storage tanks is equipped with a submersible centrifugal pump (two in total) from LOWARA manufacturer for continuous mixing of the content. Each type of sludge liquors will be fed into the SBR with the use of an eccentric screw pump. The installed feeding pump is from NETZSCH manufacturer and it is driven by VFD (frequency converter). SMART-Plant D3.2
Project: No 690323 The maximum capacity of the pump is 7 m3/h. The selection of the capacity of this pump is based on: i) the maximum daily flow rate of the sludge liquors (3 m3/d for the SL-DS and 2.65 m3/d for the SL- PS), ii) the minimum number of 3 cycles per day and iii) the duration of fill phase of 15 min. A second eccentric screw pump, from NETZSCH manufacturer and also driven by VFD has been installed in order to provide decanting of treated sludge liquors from the SBR and the removal of the surplus activated sludge as well. The waste activated sludge will be collected temporarily in a rectangular storage tank made of polyethylene and of volume 1m3, which is sufficient for 2 days storage of sludge removed. A solution of acetic acid (in the form of sodium acetate) will be added to the reactor to meet the biodegradable organic carbon requirements. The external organic carbon system consists of a storage tank with an active volume of 1 m3 and it is sufficient for more than 7 days storage capacity. The tank is made of polyethylene and it is placed in an appropriate leakage basin. It is equipped with a mixer from SEKO manufacturer. A dedicated diaphragm, adjustable flow-rate dosing pump from DOSEEURO AP manufacturer with a capacity of 200 L/h is installed in order to transfer the sodium acetate solution from the storage tank to SBR. It is expected that under normal conditions there will not be any need for pH control for the pilot system. However, as the performance of especially the nitritation – denitritation processes is highly dependent on the pH and the fact that under transient conditions (especially during start-up) there might be a need for pH control, a pH control system has been installed in the pilot system. The pH control system consists of an acid dosing system and a base dosing system. The acid (in the form of sulfuric acid) dosing system consists of a storage tank with a volume of 1 m3 and a diaphragm, adjustable flow-rate dosing pump from DOSEEURO AP manufacturer with a capacity of 50 L/h. A separate similar dosing system is provided for the addition of the base (in the form of sodium hydroxide). Both chemicals storage tanks are placed in a leakage basin. The SBR is equipped with a piezoelectric level transmitter from ENDRESS+HAUSER company and several analytical field instruments such as pH, ORP, DO, Temperature, Conductivity, NH4-N, NO2- N/NOx-N from the WTW company. All the instrumentation will be collected in a common controller SMART-Plant D3.2
Project: No 690323 WTW MIQ, which will be interconnected with PLC via Profibus DP interface. All the storage tanks will be equipped with suitable level switches. All electrical and automation equipment, including motor starters, variable frequency drives and PLC, have been installed into a stainless steel IP55 enclosure (2000x600x600mm) from SABO manufacturer, forming the Motor Control Center (MCC) of the pilot plant system. The electric power supply is at 400VAC/3–phase and the control voltage at 24VDC. The process automation (e.g. feeding, aeration, decanting, was, chemical dosing) will be carried out in automatic mode by the CPU PLC but there is also an HMI device (touch panel) for controlling the equipment manually and monitoring all measured values from instrumentation locally. Finally, the MCC will be ready for interconnection to an external PC for data acquisition. 3.2 List of the electromechanical equipment The technical specifications of the major units and the electro-mechanical equipment installed at the site are presented in Table 3.1. SMART-Plant D3.2
Project: No 690323 Table 9 Major units and specifications of the electro-mechanical equipment SMART-Plant D3.2 Page 36
Project: No 690323 SMART-Plant D3.2 Page 37
Project: No 690323 SMART-Plant D3.2 Page 38
Project: No 690323 3.3 Practical instructions for the operation of SMARTech 4B The operation of SMARTech 4B includes a series of actions and settings which can be divided in the following categories: • Preparation of chemicals to be dosed in the reactor • Selection of the automation mode and definition of the set points • Calibration of on-line probes Preparation of chemicals Three types of chemicals will be used during the operation of SMARTech 4B: the substrate, the acid and the base for pH control. Among these the acid-base chemicals will be supplied as ready to use solutions with the already specificed characteristics and therefore no specific actions will be needed from the operators of the system. The only care will be to send a notice for refill the chemicals tanks upon signal of low level. Substrate as sodium acetate will be dosed to the reactor automatically. The preparation of the solution in the respective tank will be undertaken by the operator of the system. The solution wiil be prepared by adding sodium acetate powder to the tank in order to reach an acetic acid content of 200 kg/m3. Selection of automation mode SMARTech 4b is equipped with online monitoring meters and a programmable logic controller (PLC) which will provide operational flexibility and applicability of different control strategies. Online probes of dissolved oxygen, pH, temperature, conductivity, oxidation-reduction potential, NH4-N, NOx and a level meter have been installed into the surface of SBR unit and real time information on the performance of the system will be obtained and transferred to the online controller every 1 minute. The PLC is interconnected to an external PC for data acquisition. SMART-Plant D3.2 Page 39
Project: No 690323
All the major units of the electro-mechanical equipment such as the SBR mixer apparatus and the
mixing devices of storage tanks, feeding, dosing and decanting pumps and the air blower are
connected to the PLC which control their operation according to predefined parameters or schedule.
The main operational strategy that will be established is based on time schedule and online sensors
measurements. More specifically, every SBR cycle has a number of distinct phases. For each phase a
variety of functions and processes have been programmed under the regulations of the PLC according
to the automation plan. Table 10 describes the basic features of the automation to control the
operation pf the system.
Table 10 Basic features of automation in the operation of pilot plant system.
Operation phase Parameter that defines the Equipment in working mode
phase duration according to PLC during this phase controlled by
design PLC
Filling Timer or/and Level meter SBR mixing device
Sludge liquors feeding pumps
Anaerobic phase Timer SBR mixing device
(1-2 phases during each pH adjustment system
cycle) acid/base dosing pumps
Aerobic phase Main operation: Timer or/and Air blower
(1-3 phases during each NH4-N sensor measurements pH adjustment system
cycle) Alternativelly: pH set point or pH acid/base dosing pumps
slope Control of blower flow rate
Anoxic phase Main operation: Timer or/and SBR mixing device
(1-3 phases during each NOx sensor measurements Substrate feeding pumps
cycle) Alternativelly: ORP slope or pH pH adjustment system
set point or pH slope acid/base dosing pumps
Settling Timer -
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Decanting Selected valve of decanding Decanting pump
pump
SAS removal Selected valve of decanting pump Decanting pump
SBR mixing device
Based on the design of the automation system the operator is able to choose the number of each
phase (e.g. anaerobic, anoxic, aerobic) during each cycle as well as their sequence. The maximum
number of process functions/phases that can be selected in each cycle is eight (two anaerobic, three
anoxic and three aerobic).
Filling phase is starting upon setting the feeding pump on. The duration of the feeding phase is
primarily based on the set point of the level meter. For safety reasons the maximum duration of this
phase can also be regulated by a timer.
The duration of the anaerobic phase is primarily regulated by a timer. During this phase, the PLC will
set up the SBR mixing system and if necessary will control the pH adjustment system providing acid
or base solution from the storage tanks using two dosing pumps. It is expected that under transient
conditions and especially during start-up there will be a need for pH control to the desired set points
by providing sulfuric acid or sodium hydroxide.
During the aerobic phase the PLC will activate the aeration system while the mixing system will
ceased operation as adequate mixing will be provided by the diffusers. The air flow rate provided by
the blower will be regulated according to the desired set point of dissolved oxygen in the reactor.
The duration of the aerated period will be controlled either by a timer or by a critical value of NH4-N
sensor (or both). The automation system provides also alternative control functions of the duration
of this phase based either on the pH set point or on pH slope. During the aerated phases pH control
can be impleened (if desired) by regulating the acid/base dosing system.
Following the aerobic phase, the anoxic phase will start with the end of aeration and the addition of
external carbon source (fiilling). In order to meet the biodegradable organic carbon requirements for
denitritation procces the automation system will be set to provide adequate volumes of primary
SMART-Plant D3.2 Page 41Project: No 690323
sludge liquor or acetate or a mix of the two substrates. A maximum of three dinstict anoxic phases
can be implemented during each cycle and their duration will be controlled by either a timer or by
reaching a pre-defined value of NOx sensor (or both). Furthermore, alternative control strategies can
also be choosen by the operator based on set points defined for ORP, pH and pH slope. During each
anoxic phase the PLC will maintain open the mixing system and will also provide pH control.
The surplus activated sludge (SAS) removal will take place either during aerobic or during anoxic
phase in the form of mixed liquor in order to keep the desried sludge age.
After the last anoxic period in each cycle, the PLC will stop the mixing system and sedimentation
phase will take place for a pre-selected time period. Every cycle will end up with decanting. The PLC
will control the volume of supernatant that the decanting pump will remove from the SBR unit either
by a timer or by the level meter measurements.
In view of the above, the operator selects the mode of automation and specifies the set points
directly on the screen pf PLC.
Calibration of on-line probes
Calibration of the on-line probes will take place on a weekly basis. In this context the operator will
collect activated sludge samples which will be analyzed for pH, conductivity, ORP, NH4-N, NO2-N, NOx-
N and the results will be compared with the on-line measurements for validation. Upon significant
deviations calibration of the on-line probes will take place.
3.1 Integrability of the Smartech 4b in existing WWTPs
Integrability issues Smartech 4b
Technical Feasibility
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