Innovative High Rate

swedishstreakMechanics

Feb 22, 2014 (3 years and 7 months ago)

78 views

1

Full
-
Scale Testing of
Innovative High Rate
Filter Media for Plant
Expansion


Bob Raczko, P.E.

United Water

2

UWMX WTP

Location: Manalapan, NJ


Size
: 5 mgd (790 m
3
/hr), but needs to be expanded to 8 mgd (1,260
m
3
/hr) to meet increasing water demands within
next
several years


Plant
Processes:

-
Coagulation/flocculation/two
-
stage
sedimentation/filtration/disinfection/finished
storage/finished water pumping

-
Powdered Activated Carbon (PAC) added to second stage sedimentation for seasonal
taste and odor (T&O) control


Filters
currently are major limiting step in process:

-
6 filters (5 with 1 out of service for backwashing) operate at a nominal rate of
3 gpm/sf
(7.3 m/hr)

-
Based on previous Filtralite testing at Haworth, NJDEP will allow testing up to 7 gpm/sf
(17 m/hr
)

-
Also evaluating larger anthracite/sand media, NJDEP will allow testing up to 5 gpm/sf
(12 m/hr)


If
successful, new media will allow filtration capacity to be expanded
without increasing the number of filters, which will significantly reduce
capital
expenditures

3

HAWORTH WTP


PREVIOUS PILOT TESTING

Compared:


Conventional anthracite/sand


Filtralite


expanded clay media:


Larger size media


Larger macropore size for solids capture


Findings:


Filtralite achieved comparable performance at 7.5 gpm/sf compared
to anthracite/sand at 5 gpm/sf


Filtralite achieved longer filter runs, less headloss development



4

UWMX WTP DEMONSTRATION TESTING

Received approval from NJDEP to modify two filters for demonstration
test:


New underdrains


Provide additional depth for both anthracite/sand and Filtralite
medias


Received approval from NJDEP to conduct demonstration test:


Anthracite/sand


test up to 5 gpm/sf


Filtralite


test up to 7 gpm/sf


Evaluating:


Turbidity


Particle count


Headloss development


Volume Treated, Run Time



5



Parameter


Filter 4

Existing


Filter 5

Filtralite


Filter 6

Anthracite/Sand

Top Layer

12” No. 1 anthracite

21” 2.0 mm
Filtralite

21” 0.95
-
1.05 mm
anthracite

Bottom
Layer

12” 0.45
-
0.55 mm
sand

10” 1.0 mm
Filtralite

10” 0.50
-
〮㘰 浭
s慮a

Support
Gravel

17” (graded)

10” pea gravel

10” pea gravel

FILTER MEDIA SPECIFICATIONS

6

EXISTING MEDIA AND UNDERDRAINS

7

NEW ANTHRACITE/SAND MEDIA

AND UNDERDRAIN

8

FILTRALITE MEDIA AND UNDERDRAIN

9

NEW UNDERDRAIN
-

NOZZLES

10

TESTING TO DATE


Initial Testing (11/10/12


1/12/13):


Target flow ~ 1 mgd


Filter 5 (Filtralite) and Filter 6 (new A/S)


premature turbidity/particle breakthrough,
believed to be caused by PAC addition in second clarifier; Filter 4 (existing filter) is fine


Added PACl as filter aid


Improved turbidity/particle performance


Initially plant operated 16 hr/day (low demands); switched to 24/7 operation on 1/6
(shut down on weekends); turbidity/particle performance more stable; Filter 6 more
stable than Filter 5



1/13/13


1/24/13:


Increased Filter 5, Filter 6 in steps: 1.2 mgd, 1.4 mgd, 1.5 mgd, 1.6 mgd


PACl filter aid continued


Maintained turbidity/particle performance; shorter filter runs (as expected); Filter 6
more stable than Filter 5



Testing stopped on 1/25/13:


High TDS in raw water (road salting)


Plant switched to Aquifer Storage and Recovery (ASR) wells

11

0
500
1000
1500
2000
2500
3000
3500
11/13/12
11/15/12
11/17/12
11/19/12
11/21/12
11/23/12
11/25/12
11/27/12
11/29/12
12/1/12
12/3/12
12/5/12
12/7/12
12/9/12
12/11/12
12/13/12
12/15/12
12/17/12
12/19/12
12/21/12
12/23/12
12/25/12
12/27/12
12/29/12
12/31/12
1/2/13
1/4/13
1/6/13
1/8/13
1/10/13
1/12/13
1/14/13
1/16/13
1/18/13
1/20/13
1/22/13
1/24/13
Volume Treated (MG)

Volume Treated


(minimum flow 1 mgd, max
turbidity
0.05 ntu)

Filter 4
Filter 5
Filter 6
Filter
Aid
Started
12/4

24/7
Operatio
n Started
1/6


1.2

1.4

1.2

1.4
1

1.4

1.4
1

1.5

1.5

1.5

1.6

1.6

Note: 1. Filters 5,6 flows

were 1 mgd on 1/19

12

0
1
2
3
4
5
6
7
8
11/13/12
11/15/12
11/17/12
11/19/12
11/21/12
11/23/12
11/25/12
11/27/12
11/29/12
12/1/12
12/3/12
12/5/12
12/7/12
12/9/12
12/11/12
12/13/12
12/15/12
12/17/12
12/19/12
12/21/12
12/23/12
12/25/12
12/27/12
12/29/12
12/31/12
1/2/13
1/4/13
1/6/13
1/8/13
1/10/13
1/12/13
1/14/13
1/16/13
1/18/13
1/20/13
1/22/13
1/24/13
Headloss (ft)

Headloss

(to end of run)

Filter 4
Filter 5
Filter 6
Filter
Aid
Started
12/4


24/7
Operatio
n Started
1/6


13

0
10
20
30
40
50
60
70
0.9
1
1.1
1.2
1.3
1.4
1.5
Run
Time
(Hours)

Flow (MGD)

Run
Time
vs Flow

Filter 4
Filter 5
Filter 6
14

INITIAL TESTING OBSERVATIONS

Filter 5 (Filtralite):


Lowest Headloss Development


Can operate at higher flowrates


Concern with stability of turbidity/particle performance


Filter 6 (new anthracite/sand):


Lower headloss development than Filter 4 (existing media)


Can operate at higher flowrates


More stable turbidity/particle performance than Filter 5 (Filtralite)

15

TESTING 4/22/13


9/14/13


Longer term (two
-

three week) operation at each flowrate



Goal is to establish acceptable performance at flowrate of 1.5
-

1.6 mgd
in order to be able to high rate filters and avoid need to provide
additional filters



Eliminating need for additional filters would save approx. $3 million in
capital costs



Also evaluate performance w/o filter aid (is media seasoned?)


16

0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
Flow (mgd)

Average Flowrate

(while target flow maintained)

Filter 4
Filter 5
Filter 6
ASR Blending started 8/22

17

0
1000
2000
3000
4000
5000
6000
Volume Treated (Thous Gal)

Volume Treated

(while target flow maintained)

Filter 4
Filter 5
Filter 6
ASR Blending started 8/22

18

0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
Headloss (ft)

Headloss

(while target flow maintained)

Filter 4
Filter 5
Filter 6
ASR Blending started 8/22

19

0
20
40
60
80
100
120
140
Run Time (hr)

Run Time

(while target flow maintained)

Filter 4
Filter 5
Filter 6
ASR Blending started 8/22

20

0
20
40
60
80
100
120
140
0.9
0.95
1
1.05
1.1
1.15
1.2
1.25
1.3
1.35
1.4
Run Time (hr)

Flow (mgd)

Run Time vs Flow

4/22/13
-

8/24/13

Filter 4
Filter 5
Filter 6
21

0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0
20
40
60
80
100
120
140
160
180
Time
15-Jul-13 03:45:00
15-Jul-13 07:30:00
15-Jul-13 11:15:00
15-Jul-13 15:00:00
15-Jul-13 18:45:00
15-Jul-13 22:30:00
16-Jul-13 02:15:00
16-Jul-13 06:00:00
16-Jul-13 09:45:00
16-Jul-13 13:30:00
16-Jul-13 17:15:00
16-Jul-13 21:00:00
17-Jul-13 00:45:00
17-Jul-13 04:30:00
17-Jul-13 08:15:00
17-Jul-13 12:00:00
17-Jul-13 15:45:00
17-Jul-13 19:30:00
17-Jul-13 23:15:00
18-Jul-13 03:00:00
18-Jul-13 06:45:00
18-Jul-13 10:30:00
18-Jul-13 14:15:00
18-Jul-13 18:00:00
18-Jul-13 21:45:00
19-Jul-13 01:30:00
19-Jul-13 05:15:00
19-Jul-13 09:00:00
19-Jul-13 12:45:00
19-Jul-13 16:30:00
19-Jul-13 20:15:00
20-Jul-13 00:00:00
20-Jul-13 03:45:00
20-Jul-13 07:30:00
20-Jul-13 11:15:00
20-Jul-13 15:00:00
20-Jul-13 18:45:00
20-Jul-13 22:30:00
21-Jul-13 02:15:00
21-Jul-13 06:00:00
21-Jul-13 09:45:00
21-Jul-13 13:30:00
21-Jul-13 17:15:00
21-Jul-13 21:00:00
Turbidity (ntu)

Particle Count (counts/ml)

Filter 4
-

7/15
-

7/22

[
2
-

µm]

[>3-5µm]
[>5-7µm]
[>7-10µm]
[>10-15µm]
[>15µm]
Turbidity
22

0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
0.180
0
10
20
30
40
50
60
70
80
90
Time
15-Jul-13 03:45:00
15-Jul-13 07:30:00
15-Jul-13 11:15:00
15-Jul-13 15:00:00
15-Jul-13 18:45:00
15-Jul-13 22:30:00
16-Jul-13 02:15:00
16-Jul-13 06:00:00
16-Jul-13 09:45:00
16-Jul-13 13:30:00
16-Jul-13 17:15:00
16-Jul-13 21:00:00
17-Jul-13 00:45:00
17-Jul-13 04:30:00
17-Jul-13 08:15:00
17-Jul-13 12:00:00
17-Jul-13 15:45:00
17-Jul-13 19:30:00
17-Jul-13 23:15:00
18-Jul-13 03:00:00
18-Jul-13 06:45:00
18-Jul-13 10:30:00
18-Jul-13 14:15:00
18-Jul-13 18:00:00
18-Jul-13 21:45:00
19-Jul-13 01:30:00
19-Jul-13 05:15:00
19-Jul-13 09:00:00
19-Jul-13 12:45:00
19-Jul-13 16:30:00
19-Jul-13 20:15:00
20-Jul-13 00:00:00
20-Jul-13 03:45:00
20-Jul-13 07:30:00
20-Jul-13 11:15:00
20-Jul-13 15:00:00
20-Jul-13 18:45:00
20-Jul-13 22:30:00
21-Jul-13 02:15:00
21-Jul-13 06:00:00
21-Jul-13 09:45:00
21-Jul-13 13:30:00
21-Jul-13 17:15:00
21-Jul-13 21:00:00
Turbidity (ntu)

Particle Count (counts/ml)

Filter
5
-

7
/
15
-

7
/
22

[
2
-

µm]

[>3-5µm]
[>5-7µm]
[>7-10µm]
[>10-15µm]
[>15µm]
Turbidity
23

0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
0.180
0
50
100
150
200
250
300
350
Time
15-Jul-13 03:45:00
15-Jul-13 07:30:00
15-Jul-13 11:15:00
15-Jul-13 15:00:00
15-Jul-13 18:45:00
15-Jul-13 22:30:00
16-Jul-13 02:15:00
16-Jul-13 06:00:00
16-Jul-13 09:45:00
16-Jul-13 13:30:00
16-Jul-13 17:15:00
16-Jul-13 21:00:00
17-Jul-13 00:45:00
17-Jul-13 04:30:00
17-Jul-13 08:15:00
17-Jul-13 12:00:00
17-Jul-13 15:45:00
17-Jul-13 19:30:00
17-Jul-13 23:15:00
18-Jul-13 03:00:00
18-Jul-13 06:45:00
18-Jul-13 10:30:00
18-Jul-13 14:15:00
18-Jul-13 18:00:00
18-Jul-13 21:45:00
19-Jul-13 01:30:00
19-Jul-13 05:15:00
19-Jul-13 09:00:00
19-Jul-13 12:45:00
19-Jul-13 16:30:00
19-Jul-13 20:15:00
20-Jul-13 00:00:00
20-Jul-13 03:45:00
20-Jul-13 07:30:00
20-Jul-13 11:15:00
20-Jul-13 15:00:00
20-Jul-13 18:45:00
20-Jul-13 22:30:00
21-Jul-13 02:15:00
21-Jul-13 06:00:00
21-Jul-13 09:45:00
21-Jul-13 13:30:00
21-Jul-13 17:15:00
21-Jul-13 21:00:00
Turbidity (ntu)

Particle Count (counts/ml)

Filter
6
-

7
/
15
-

7
/
22

[
2
-

µm]

[>3-5µm]
[>5-7µm]
[>7-10µm]
[>10-15µm]
[>15µm]
Turbidity
24

OBSERVATIONS
4
/
22
/
13


9
/
14
/
13


Medias appear to be seasoned (generally operate without filter aid)


Filter
5 (Filtralite):


Lowest Headloss Development


Can operate at higher flowrates


Concern with stability of turbidity/particle
performance; susceptible
to changes (hydraulic, water quality), especially near end of run


Filter 6 (new anthracite/sand):


Lower headloss development than Filter 4 (existing media)


Can operate at higher flowrates


More stable turbidity/particle performance than Filter 5 (Filtralite)


25

FUTURE WORK


Continue testing at higher rates (currently at
1.4
mgd)



Plant is currently on a blend of surface water and ASR water because
of low streamflow

and need to maintain passing flow. This results in
high run times and volumes treated, which are not representative.



Will evaluate higher flowrates when plant is back on full surface
water (no ASR)



Consider addition of small layer of sand (about
4
inches) to Filter
5
(Filtralite) to see if that improves stability of turbidity/particle
performance

26

THANK YOU!


Any Questions?

27

0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
0.090
0.100
0
5
10
15
20
25
30
35
40
45
50
Time
05-Jan-13 03:45:00
05-Jan-13 07:30:00
05-Jan-13 11:15:00
05-Jan-13 15:00:00
05-Jan-13 18:45:00
05-Jan-13 22:30:00
06-Jan-13 02:15:00
06-Jan-13 06:00:00
06-Jan-13 09:45:00
06-Jan-13 13:30:00
06-Jan-13 17:15:00
06-Jan-13 21:00:00
07-Jan-13 00:45:00
07-Jan-13 04:30:00
07-Jan-13 08:15:00
07-Jan-13 12:00:00
07-Jan-13 15:45:00
07-Jan-13 19:30:00
07-Jan-13 23:15:00
08-Jan-13 03:00:00
08-Jan-13 06:45:00
08-Jan-13 10:30:00
08-Jan-13 14:15:00
08-Jan-13 18:00:00
08-Jan-13 21:45:00
09-Jan-13 01:30:00
09-Jan-13 05:15:00
09-Jan-13 09:00:00
09-Jan-13 12:45:00
09-Jan-13 16:30:00
09-Jan-13 20:15:00
10-Jan-13 00:00:00
10-Jan-13 03:45:00
10-Jan-13 07:30:00
10-Jan-13 11:15:00
10-Jan-13 15:00:00
10-Jan-13 18:45:00
10-Jan-13 22:30:00
11-Jan-13 02:15:00
11-Jan-13 06:00:00
11-Jan-13 09:45:00
11-Jan-13 13:30:00
11-Jan-13 17:15:00
11-Jan-13 21:00:00
Turbidity (ntu)

Particle Count (counts/ml)

Filter
4
-

1
/
5
-

1
/
12

[
2
-

µm]

[>3-5µm]
[>5-7µm]
[>7-10µm]
[>10-15µm]
[>15µm]
Turbidity
28

0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
0
50
100
150
200
250
300
350
400
450
Time
05-Jan-13 03:45:00
05-Jan-13 07:30:00
05-Jan-13 11:15:00
05-Jan-13 15:00:00
05-Jan-13 18:45:00
05-Jan-13 22:30:00
06-Jan-13 02:15:00
06-Jan-13 06:00:00
06-Jan-13 09:45:00
06-Jan-13 13:30:00
06-Jan-13 17:15:00
06-Jan-13 21:00:00
07-Jan-13 00:45:00
07-Jan-13 04:30:00
07-Jan-13 08:15:00
07-Jan-13 12:00:00
07-Jan-13 15:45:00
07-Jan-13 19:30:00
07-Jan-13 23:15:00
08-Jan-13 03:00:00
08-Jan-13 06:45:00
08-Jan-13 10:30:00
08-Jan-13 14:15:00
08-Jan-13 18:00:00
08-Jan-13 21:45:00
09-Jan-13 01:30:00
09-Jan-13 05:15:00
09-Jan-13 09:00:00
09-Jan-13 12:45:00
09-Jan-13 16:30:00
09-Jan-13 20:15:00
10-Jan-13 00:00:00
10-Jan-13 03:45:00
10-Jan-13 07:30:00
10-Jan-13 11:15:00
10-Jan-13 15:00:00
10-Jan-13 18:45:00
10-Jan-13 22:30:00
11-Jan-13 02:15:00
11-Jan-13 06:00:00
11-Jan-13 09:45:00
11-Jan-13 13:30:00
11-Jan-13 17:15:00
11-Jan-13 21:00:00
Turbidity (ntu)

Particle Count (counts/ml)

Filter
6
-

1
/
5
-

1
/
12

[
2
-

µm]

[>3-5µm]
[>5-7µm]
[>7-10µm]
[>10-15µm]
[>15µm]
Turbidity
29

0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
0.180
0.200
0
100
200
300
400
500
600
Time
05-Jan-13 03:45:00
05-Jan-13 07:30:00
05-Jan-13 11:15:00
05-Jan-13 15:00:00
05-Jan-13 18:45:00
05-Jan-13 22:30:00
06-Jan-13 02:15:00
06-Jan-13 06:00:00
06-Jan-13 09:45:00
06-Jan-13 13:30:00
06-Jan-13 17:15:00
06-Jan-13 21:00:00
07-Jan-13 00:45:00
07-Jan-13 04:30:00
07-Jan-13 08:15:00
07-Jan-13 12:00:00
07-Jan-13 15:45:00
07-Jan-13 19:30:00
07-Jan-13 23:15:00
08-Jan-13 03:00:00
08-Jan-13 06:45:00
08-Jan-13 10:30:00
08-Jan-13 14:15:00
08-Jan-13 18:00:00
08-Jan-13 21:45:00
09-Jan-13 01:30:00
09-Jan-13 05:15:00
09-Jan-13 09:00:00
09-Jan-13 12:45:00
09-Jan-13 16:30:00
09-Jan-13 20:15:00
10-Jan-13 00:00:00
10-Jan-13 03:45:00
10-Jan-13 07:30:00
10-Jan-13 11:15:00
10-Jan-13 15:00:00
10-Jan-13 18:45:00
10-Jan-13 22:30:00
11-Jan-13 02:15:00
11-Jan-13 06:00:00
11-Jan-13 09:45:00
11-Jan-13 13:30:00
11-Jan-13 17:15:00
11-Jan-13 21:00:00
Turbidity (ntu)

Particle Count (counts/ml)

Filter
5
-

1
/
5
-

1
/
12

[
2
-

µm]

[>3-5µm]
[>5-7µm]
[>7-10µm]
[>10-15µm]
[>15µm]
Turbidity
30

0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
11/13/12
11/15/12
11/17/12
11/19/12
11/21/12
11/23/12
11/25/12
11/27/12
11/29/12
12/1/12
12/3/12
12/5/12
12/7/12
12/9/12
12/11/12
12/13/12
12/15/12
12/17/12
12/19/12
12/21/12
12/23/12
12/25/12
12/27/12
12/29/12
12/31/12
1/2/13
1/4/13
1/6/13
1/8/13
1/10/13
1/12/13
1/14/13
1/16/13
1/18/13
1/20/13
1/22/13
1/24/13
Flowrate (mgd)

Average Flowrate


(to end of run)

Filter 4
Filter 5
Filter 6