Beruflich Dokumente
Kultur Dokumente
Introduction
Case Studies
Anoxic Zone Mixing
Channel Mixing
Theory and Criteria
Mixing Theory
Design Criteria
Recommendations
Introduction
Flow Equalization Tanks
Headworks Wet Wells
Flow Distribution Boxes
Aeration Tanks & Channels
Anoxic and Anaerobic Reactors
Final Effluent (Re‐aeration)
Disinfection tanks
Sludge Digesters
Processes with Chemical Addition
Mixing is a typical process in wastewater
treatment
Introduction
Why Do We Mix?
Keep solids in suspension
Enhance mass transfer and microbial
kinetics
Improve chemical reaction with pollutants
Provide aeration / odor control
Improve effective residence time, decrease
short‐circuiting
Mixing is an important process in wastewater
treatment.
Introduction
How Do We Mix?
Draft Tubes
By Kocamemi
There are different solutions/equipment
for mixing.
Introduction
Mixing exists in most plants
Mixing consumes a lot of energy
Design criteria vary
There are a lot of over designed/operated
mixers
Process performance requires adequate
mixing
Sustainability depends on everybody’s effort.
Introduction
Heavy/high density solids have been
removed;
Following typical criteria might waste
energy: opportunities to improve
Types of mixing:
Rapid mixing
Continuous mixing
Outline
Introduction
Case Studies
Anoxic Zone Mixing
Channel Mixing
Theory and Criteria
Mixing Theory
Design Criteria
Recommendations
Case Study 1
Plant wet weather peak flow 63 MGD
Upstream grit removal and primary
treatment with EDIs
Aeration tank volume: 5.4 MG with two
trains
Four anoxic zones, volume is 44,800 ft3 for
each zone, dimensions: 94 ft (L) X 30 ft (W)
X 15.9 ft (D)
Expected MLSS concentrations: 2,000 to
5,500 mg/L
How to provide best anoxic mixing design?
Case Study 1
Coarse bubble diffusers were excluded
due to concerns of oxygen introduction
Submersible mixers: ABS and Flygt
Invent HYPERCLASSIC Mixer
Floating Mixers: Siemens and AquaDDM®
Mixing Zone Mixing Energy
Design Mixer Size Total Power Annual Energy
Reference Volume (1,000 Input (Hp/1,000
Iterations (Hp) Draw (Hp) Cost*
cubic feet) cubic feet)
MetCalf & Eddy
1 20 (17 Hp) 22.4 0.75 136 $53,300
Recommendation
Manufacturer's Design
3 5 22.4 0.22 40 $15,700
Criteria
Similar Projects by
4 3 22.4 0.13 24 $9,400
Others
* Plant average electricity cost is $0.06/kwh; electricity price inflation is not considered.
VFD was excluded from design
Two‐speed motor is not available
Easy change out of mixer impellers
Manufacturer physical lab and CFD
modeling were not conclusive
Fort Collins Drake Facility in Colorado:
15 Hp/MG, or 0.11 Hp/1,000 cubic feet
Big mixers could cause tank bottom
concrete deterioration over time.
Decision: To conduct full scale testing at one
half of the anoxic zones during construction.
Case Study 1
Pulsed Large Bubble Mixing
Mixed liquor channel with MLSS =
2,000‐5,500 mg/L
Channel volume: 33,480 ft3
Channel Dimensions: 944 ft (L) X 15 ft
(W) X 6 ft (D)
Case Study 2
1) Main aeration blowers with a throttling
valve – pressure drop of 3 to 4 psi
2) Mechanical mixers – too many units
3) New dedicated blowers – capital cost
4) Existing PD blowers and coarse bubble
diffusers
5) Existing PD blowers and retractable fine
bubble diffusers
Case Study 2
Design Channel
Design Air Demand Blower Power Annual Energy
Reference Criteria Bottom Area
Options 2 2 (scfm) Draw (Hp) Cost*
(scfm/ft ) (ft )
Typical Manufacturer
1 0.12 14,166 1700 60 $23,530
Recommendations
Lower Limit of Mixing
2 0.06 14,166 850 30 $11,760
Requirements
* Plant average electricity cost is $0.06/kwh; electricity price inflation is not considered.
Outline
Introduction
Case Studies
Anoxic Zone Mixing
Channel Mixing
Theory and Criteria
Mixing Theory
Design Criteria
Recommendations
Theory and Criteria
A measurement of mixing effectiveness
G is an average number – not homogeneous
Mixing creates circulation (velocity) and shear
Given V and µ, P needs to increase to increase G
Theory and Criteria
Radial‐flow impeller in a baffled tank
Theory and Criteria
Axial‐flow impeller in a baffled tank
Theory and Criteria
Mixing Theory – Velocity Gradient
CFD Modeling of a mixing tank 23
Mixing Theory – Velocity Gradient
CFD Modeling of a mixing tank
24
Mixing Theory – Power Number
Different mechanical
impellers has
different power
draw and mixing
effect.
25
Theory and Criteria
For mixing for solids suspension, consider
the following factors:
Tank Dimensions
Baffles
The impeller: material, shape
Settling velocity of solids: specific gravity,
size, etc.
Solids concentration
Temperature
Difficult to quantity; a highly empirical process.
Theory and Criteria
Different
mechanical
impellers have
different power
draws and
mixing effects.
Theory and Criteria
Design Criteria
Anoxic Zone Mixing Requirements:
MetCalf & Eddy: 0.75 to 1.50 Hp / 1,000 ft3
WEF MOP8: 0.45 to 0.75 Hp / 1,000 ft3
Manufacturer's Criteria: 0.22 Hp / 1,000 ft3
Theory and Criteria
Design Criteria
Better understanding and better design
(e.g., big blade low speed mixers)
Lower density of solids to suspend/mix
Better tank/channel geometry
Baffle design
Bulk flow velocity to be considered!
Why Less Power Is Possible?
For anoxic and anaerobic reactors, By Jared Wray, P.E., and Daniel Alper, KSB, 2012
Outline
Introduction
Case Studies
Anoxic Zone Mixing
Channel Mixing
Theory and Criteria
Mixing Theory
Design Criteria
Recommendations
Recommendations
Design and operate beyond published
design criteria
How to improve mixing efficiency:
Low speed big diameter mixers
Conduct physical models
Conduct CFD Modeling
Install Baffles
Install VFD or two‐speed motors
Recommendations
Improvement Process:
Compare current mixing power input with
design criteria and other facilities
Identify and analyze possible improvement
alternatives
• Calculate Capital Improvement Costs
• Calculate Energy Savings
• Determine Payback Period
Verify feasibility
Design and implement the improvement
Summary
Mixing is typical, important, and energy
consuming
Mixing design needs careful analysis,
rather than just following design criteria
Mixing energy saving opportunities
might be available after primary
treatment
Significant savings can be achieved by
careful design and operation