Upload
others
View
1
Download
0
Embed Size (px)
Citation preview
Development, Challenges, and
Validation of a High Efficiency
UV Unit
Wayne M. Emery, P.E.
Calgon Carbon Corp
Presentation Outline
Introduction
System Details
Delta Wings
Case Study
Title 22
System Sizing
Installations
Closing Remarks
Who is Calgon Carbon?
We solve customer purification
and separation problems with
a variety of technologies
World’s Largest Producer of
Granular Activated Carbon
Diverse Product Portfolio
900+ employees
240 patents
10 sales offices – 6 countries
14 manufacturing facilities – 6
countries
Revenues: > $500 M
On New York Stock Exchange
(CCC)
60 + Years of Experience in
Water Treatment
UV Technologies Division
25 year track record in UV water
treatment
UV products for treating
contaminated water, wastewater,
drinking water and ballast water
Pioneered the use of UV
technology for the inactivation of
Cryptosporidium and Giardia in
drinking water
> 500 installations
Located and manufactured in the
Pittsburgh, PA area
Calgon Carbon’s UV Technologies
Drinking Water Disinfection – to inactivate pathogenic bacteria, viruses, and protozoa (Cryptosporidium and Giardia control)
Wastewater Disinfection – to reduce chlorine discharge into the environment
Advanced Oxidation – to destroy toxic chemical contaminants
Ballast Water Treatment – to remove or kill invasive species transported by marine vessels
Calgon Carbon’s UV History
Started in Advanced Oxidation (MP + Hydrogen Peroxide): 1985, acquired by CCC in 1996
Progressed to Drinking Water with MP: 1997, CCC innovation
Entered Wastewater Market with LP: 2004, CCC acquisition 2004
Entered Ballast Water Market (MP UV and filtration): 1995, acquired by CCC 2010
How Should You Want Your System
Designed?
Use advanced science and technology to develop products
Bioassay validated products – true sizing and performance verification, not just “manufacturer’s claims”
Make sure the system won’t have to be ‘upgraded’ due to performance or design issues
Use high powered lamps for WW open channel – basis for low O&M and smallest footprint
Focus on real Cost of Ownership for lowest 20 year Net Present Value
8 lamps per rack, max.
Interchangeable design
Individually isolated
Designed to comply with
IP67 for intermittent
submergence
Cleaning system is
electrically driven
minimizing number of
components
Two cable assemblies
per rack each powering
4 lamps
Technical Details – Lamp Rack
Lamp
Data
Technical Details – Lamp 520 W low pressure high output pellet amalgam lamp
Up to 205 W of UVc output
Coated lamp for longer life, 12,000 hour guarantee
Pre-heat start configuration to reduce the effects of cycling due to
process conditions such as Sequential Batch Reactors
Continuous heat configuration for power savings and extended lamp
life
UV sensor, factory
calibrated to DVGW
reference standard
One sensor per UV
bank
Value used in dose
calculation to allow
maximum turn-down
when Dose Pacing
enabled
Maximize energy
savings
Technical Details – UV Sensor
Designed to comply
with NEMA 4X (IP 65)
ratings
Each supplied with main
breaker and lockable
doors
Operator Station on
front door allows
Operators to view PDC
status and control PDC
manually, if required
Technical Details – PDC
Each Ballast drive one lamp
Variable output 60 to 100%
Powered by single phase
220 - 277VAC, 60 Hz
Interchangeable, addressed
via slot in card cage
Individual lamp failure
indication reported locally via
LED and remotely at SCC
System Power Factor > 0.98
at full power
Complies with Current Total
Harmonics Distortion
guidelines specified in IEEE
519-1992 standards
Technical Details – Ballast
UV System Control Center
Allen Bradley
CompactLogix or
ControlLogix PLC
Allen Bradley
PanelView Plus
600/1000/1500
Standard Designs
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 0.5 1 1.5 2 2.5 3
Re
lati
ve
Irr
ad
ian
ce
Distance from Lamp, in
65%T
55%T
Irradiance drops off exponentially with distance
from the lamps
Background
Relative Irradiance at the center point between 4 lamps in a square lamp array vs.
lamp spacing between adjacent lamps in the array
Center point has
the lowest intensity
x
x
0%
5%
10%
15%
20%
25%
30%
2 2.5 3 3.5 4 4.5 5
Re
lati
ve
Irr
ad
ian
ce
at
Ce
nte
r P
oin
t
Spacing Between Lamps, in
65%T
55%T
Relative Irradiance in Lamp Array
To maintain the same hydraulic efficiency, the flow per
lamp must be proportional to the Lamp Power
Lamp spacing must be increased to limit the pressure
drop due to the increased flow per lamp (velocity)
Increased lamp spacing results in poor dose distribution
and hence lower hydraulic efficiency
We calculate a limit of approx. 300 Watts per lamp for 3
to 4 inch spacing at 55 and 65%T, respectively
HOW DO WE ACHIEVE ACCEPTABLE HYDRAULIC
EFFICIENCY WHEN WE HAVE CONFLICTING
REQUIREMENTS.
The Challenge with Higher Power
Amalgam Lamps
Design an open channel UV disinfection
system with 500 to 600 Watt lamps that:
Complies with NWRI guidelines
Produces a high MS2 RED at relatively low
flows
Optimizes hydraulics efficiency due to larger
lamp spacing required for higher power
lamps
Design Requirements
Mixing devices - Delta Wings
Create large scale counter-
rotating vortices.
Transports the water:
farthest from the lamps in
towards the lamps
close to the lamp moved away
from the lamps
Permits lamps of 500 Watts
and greater to be employed
The Solution - Mixing
Development of mixing
device to increase the
hydraulic efficiency of the
UV reactor
Use patent # 6,015,229,
dated Jan. 18, 2000,
issued to Calgon Carbon
as basis of design
Research & Development
Flow across a delta
wing inclined to the
flow of water
produces two
counter-rotating
vortices
How does a Delta Wing work?
CFD analysis of UV reactor without mixing
High fluence rate
around lamp,
lower fluence
between lamps
CFD Analysis
No Mixing 1 set of Delta Wings 3 sets of Delta Wings
MS2 Concentration as the fluid exits the UV Bank Array
CFD Modeling of Delta Wings
Performance of mixing devices
10
12
14
16
18
20
22
24
0 1 2 3 4
Number of Delta Wings
MS
2 R
ED
mJ
/cm
2
C3500D Research & Development
Pilot system tested with and without
Delta Wings
Worked with the University of Toronto and
GAP Enviro Microbial Services to test the
various combinations
Secondary effluent with MS2 & T1 phage
added as surrogate organisms
UV Transmission ranged from 50 – 70%
using SuperHume™
Pilot Tests
0
20
40
60
80
100
120
140
20 40 60 80 100
Flow
MS
2 R
ED
50%T w/o Delta
60%T w/o Delta
67%T w/o Delta
50%T w Delta
60%T w Delta
67%T w Delta
Pilot Tests with & without Delta
Wings
Pilot test site at Stockton
WWTP, CA
Carollo Engineers as 3rd
Party Engineer
Low dose (T1) and
NWRI (MS2) testing
simultaneously
UVT range: 35 – 74%
Flow range: 0.7 - 4.3
MGD
NWRI Validation
• Peak Flow: 55 MGD
• Average Flow: 38 MGD
• UV Dose: 110 mJ/cm2, 70 mJ/cm2,
50 mJ/cm2
• UVT: 65%
• Total Coliform Permit Limit: 2.2 CFU/100
mL, based on a 7 day median
• Power Cost: $0.12/kWh
• Labor Cost: $50/hour
Case Study – Design Parameters
Type of UV # Channel/Trains # Reactors/Trains Total # Lamps Footprint
110 mJ/cm2
MP 15 2 540 104' x 90'
LPHO A 4 2 4032 120' x 110'
LPHO B 4 4 3072 160' x 50'
C3 500TMD 4 4 1792 140' x 60'
70 mJ/cm2
MP 9 2 324 104' x 55'
LPHO A 3 2 2592 120' x 75'
LPHO B 3 4 1920 150' x 45'
C3 500TMD 3 3 1152 150' x 40'
50 mJ/cm2
MP 12 1 216 63' x 99'
LPHO A 3 2 1728 90' x 60'
LPHO B 3 3 1296 36' x 150'
C3 500TMD 3 2 768 40' x 130'
Equipment & Footprint Decreases
with Increased Efficiency
$0
$200,000
$400,000
$600,000
$800,000
$1,000,000
$1,200,000
$1,400,000
$1,600,000
$1,800,000
$2,000,000
110 70 50
Dose, mJ cm-2
An
nu
al O
&M
Co
st,
$
C 3
50
0
LP
HO
A
MP
MP
MP
C 3
50
0
C 3
50
0
LP
HO
B
LP
HO
A
LP
HO
A
LP
HO
B
LP
HO
B
Efficient C3500D System Allows
for Most Cost Effective O&M
$0
$5,000,000
$10,000,000
$15,000,000
$20,000,000
$25,000,000
$30,000,000
$35,000,000
$40,000,000
$45,000,000
$50,000,000
110 70 50
Dose, mJ cm-2
Lif
e C
yc
le C
os
t, $
C 3
50
0
LP
HO
A
MP
MP
MP
C 3
50
0
C 3
50
0
LP
HO
B
LP
HO
A
LP
HO
A
LP
HO
B
LP
HO
B
Efficient C3500D System Allows
for Most Cost Effective Life Cycle
High LPHO UV lamp output
Optimized lamp spacing overcomes substantial
head loss
Fewer lamps than other LPHO systems
Decreased equipment costs
Decreased installation/construction costs
Decreased O&M costs
C3500D Validation Illustrates
High Level of Disinfection &
Germicidal Efficiency
Check-point Bioassay –
Field Challenges
Channel dimensions
Channel hydraulics
Channel flow distribution
Level Control
Fouling and EOLL design factors
These items are easy to confirm via measurement and
velocity profiling, prior to commencement of check-point
bioassay.
Closing Remarks
C3500D UV SYSTEM
Conditional Acceptance from CDPH
Smallest footprint. Less Lamps to buy, install, and
maintain, leading to lower Capital and O&M costs.
Delta configuration puts the flow where you want it, next
to the lamp.
Proven mechanical only cleaning. No chemicals to buy,
store or leak.
Ballasts are located in the Power Distribution Center as
opposed to the head of the rack. When the channel
floods, the ballasts are kept out of harms way.
This bioassay validated system will meet specified
permit limit – guaranteed.