1 full-scale testing of innovative high rate filter media for plant expansion bob raczko, p.e....
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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 m3/hr), but needs to be expanded to 8 mgd
(1,260 m3/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
ParameterFilter 4 Existing
Filter 5Filtralite
Filter 6Anthracite/
SandTop Layer 12” No. 1
anthracite21” 2.0 mm
Filtralite21” 0.95-1.05 mm anthracite
Bottom Layer
12” 0.45-0.55 mm sand
10” 1.0 mm Filtralite
10” 0.50-0.60 mm sand
Support Gravel
17” (graded) 10” pea gravel 10” pea gravel
FILTER MEDIA SPECIFICATIONS
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
11/1
3/12
11/1
6/12
11/1
9/12
11/2
2/12
11/2
5/12
11/2
8/12
12/1
/12
12/4
/12
12/7
/12
12/1
0/12
12/1
3/12
12/1
6/12
12/1
9/12
12/2
2/12
12/2
5/12
12/2
8/12
12/3
1/12
1/3/
13
1/6/
13
1/9/
13
1/12
/13
1/15
/13
1/18
/13
1/21
/13
1/24
/13
0
500
1000
1500
2000
2500
3000
3500
Volume Treated (minimum flow 1 mgd, max turbidity 0.05 ntu)
Filter 4 Filter 5 Filter 6
Volu
me T
reate
d (
MG
)
Filter Aid Started 12/4
24/7 Opera-tion Started 1/6
1.2
1.4
1.2
1.41
1.4
1.41
1.5
1.5
1.5
1.6
1.6
Note: 1. Filters 5,6 flows were 1 mgd on 1/19
12
11/1
3/12
11/1
6/12
11/1
9/12
11/2
2/12
11/2
5/12
11/2
8/12
12/1
/12
12/4
/12
12/7
/12
12/1
0/12
12/1
3/12
12/1
6/12
12/1
9/12
12/2
2/12
12/2
5/12
12/2
8/12
12/3
1/12
1/3/
13
1/6/
13
1/9/
13
1/12
/13
1/15
/13
1/18
/13
1/21
/13
1/24
/13
0
1
2
3
4
5
6
7
8
Headloss(to end of run)
Filter 4 Filter 5 Filter 6
Headlo
ss (
ft)
Filter Aid Started 12/4
24/7 Opera-tion Started 1/6
13
0.9 1 1.1 1.2 1.3 1.4 1.50
10
20
30
40
50
60
70
Run Time vs Flow
Filter 4 Filter 5 Filter 6
Flow (MGD)
Run T
ime (
Hours
)
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
4/26
/201
3
4/30
/201
3
5/4/
2013
5/8/
2013
5/12
/201
3
5/16
/201
3
5/20
/201
3
5/24
/201
3
5/28
/201
3
6/1/
2013
6/5/
2013
6/9/
2013
6/13
/201
3
6/17
/201
3
6/21
/201
3
6/25
/201
3
6/29
/201
3
7/3/
2013
7/7/
2013
7/11
/201
3
7/15
/201
3
7/19
/201
3
7/23
/201
3
7/27
/201
3
7/31
/201
3
8/4/
2013
8/8/
2013
8/12
/201
3
8/16
/201
3
8/20
/201
3
8/24
/201
3
8/28
/201
3
9/1/
2013
9/5/
2013
9/9/
2013
9/13
/201
30
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
Average Flowrate (while target flow maintained)
Filter 4 Filter 5 Filter 6
Flo
w (
mgd)
ASR Blending started 8/22
17
4/26
/201
3
4/30
/201
3
5/4/
2013
5/8/
2013
5/12
/201
3
5/16
/201
3
5/20
/201
3
5/24
/201
3
5/28
/201
3
6/1/
2013
6/5/
2013
6/9/
2013
6/13
/201
3
6/17
/201
3
6/21
/201
3
6/25
/201
3
6/29
/201
3
7/3/
2013
7/7/
2013
7/11
/201
3
7/15
/201
3
7/19
/201
3
7/23
/201
3
7/27
/201
3
7/31
/201
3
8/4/
2013
8/8/
2013
8/12
/201
3
8/16
/201
3
8/20
/201
3
8/24
/201
3
8/28
/201
3
9/1/
2013
9/5/
2013
9/9/
2013
9/13
/201
30
1000
2000
3000
4000
5000
6000
Volume Treated(while target flow maintained)
Filter 4 Filter 5 Filter 6
Volu
me T
reate
d (
Thous G
al)
ASR Blending started 8/22
18
4/26
/201
3
4/30
/201
3
5/4/
2013
5/8/
2013
5/12
/201
3
5/16
/201
3
5/20
/201
3
5/24
/201
3
5/28
/201
3
6/1/
2013
6/5/
2013
6/9/
2013
6/13
/201
3
6/17
/201
3
6/21
/201
3
6/25
/201
3
6/29
/201
3
7/3/
2013
7/7/
2013
7/11
/201
3
7/15
/201
3
7/19
/201
3
7/23
/201
3
7/27
/201
3
7/31
/201
3
8/4/
2013
8/8/
2013
8/12
/201
3
8/16
/201
3
8/20
/201
3
8/24
/201
3
8/28
/201
3
9/1/
2013
9/5/
2013
9/9/
2013
9/13
/201
30.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
Headloss (while target flow maintained)
Filter 4 Filter 5 Filter 6
Headlo
ss (
ft)
ASR Blending started 8/22
19
4/26
/201
3
4/30
/201
3
5/4/
2013
5/8/
2013
5/12
/201
3
5/16
/201
3
5/20
/201
3
5/24
/201
3
5/28
/201
3
6/1/
2013
6/5/
2013
6/9/
2013
6/13
/201
3
6/17
/201
3
6/21
/201
3
6/25
/201
3
6/29
/201
3
7/3/
2013
7/7/
2013
7/11
/201
3
7/15
/201
3
7/19
/201
3
7/23
/201
3
7/27
/201
3
7/31
/201
3
8/4/
2013
8/8/
2013
8/12
/201
3
8/16
/201
3
8/20
/201
3
8/24
/201
3
8/28
/201
3
9/1/
2013
9/5/
2013
9/9/
2013
9/13
/201
30
20
40
60
80
100
120
140
Run Time (while target flow maintained)
Filter 4 Filter 5 Filter 6
Run T
ime (
hr)
ASR Blending started 8/22
20
0.9 0.95 1 1.05 1.1 1.15 1.2 1.25 1.3 1.35 1.40
20
40
60
80
100
120
140
Run Time vs Flow4/22/13 - 8/24/13
Filter 4 Filter 5 Filter 6
Flow (mgd)
Run T
ime (
hr)
21
Time 16-Jul-13 05:00:00 17-Jul-13 10:00:00 18-Jul-13 15:00:00 19-Jul-13 20:00:00 21-Jul-13 01:00:000
20
40
60
80
100
120
140
160
180
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
Filter 4 - 7/15 - 7/22
[2-3Hµm] [>3-5µm] [>5-7µm] [>7-10µm] [>10-15µm] [>15µm] Turbidity
Part
icle
Count
(counts
/ml)
Turb
idit
y (
ntu
)
22
Time 16-Jul-13 05:00:00 17-Jul-13 10:00:00 18-Jul-13 15:00:00 19-Jul-13 20:00:00 21-Jul-13 01:00:000
10
20
30
40
50
60
70
80
90
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
0.180
Filter 5 - 7/15 - 7/22
[2-3Hµm] [>3-5µm] [>5-7µm] [>7-10µm] [>10-15µm] [>15µm] Turbidity
Part
icle
Count
(counts
/ml)
Turb
idit
y (
ntu
)
23
Time 16-Jul-13 05:00:00 17-Jul-13 10:00:00 18-Jul-13 15:00:00 19-Jul-13 20:00:00 21-Jul-13 01:00:000
50
100
150
200
250
300
350
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
0.180
Filter 6 - 7/15 - 7/22
[2-3Hµm] [>3-5µm] [>5-7µm] [>7-10µm] [>10-15µm] [>15µm] Turbidity
Part
icle
Count
(counts
/ml)
Turb
idit
y (
ntu
)
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
27
Time 06-Jan-13 06:00:00 07-Jan-13 12:00:00 08-Jan-13 18:00:00 10-Jan-13 00:00:00 11-Jan-13 06:00:000
5
10
15
20
25
30
35
40
45
50
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
0.090
0.100
Filter 4 - 1/5 - 1/12
[2-3Hµm] [>3-5µm] [>5-7µm] [>7-10µm] [>10-15µm] [>15µm] Turbidity
Part
icle
Count
(counts
/ml)
Turb
idit
y (
ntu
)
28
Time 06-Jan-13 06:00:00 07-Jan-13 12:00:00 08-Jan-13 18:00:00 10-Jan-13 00:00:00 11-Jan-13 06:00:000
50
100
150
200
250
300
350
400
450
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
Filter 6 - 1/5 - 1/12
[2-3Hµm] [>3-5µm] [>5-7µm] [>7-10µm] [>10-15µm] [>15µm] Turbidity
Part
icle
Count
(counts
/ml)
Turb
idit
y (
ntu
)
29
Time 06-Jan-13 06:00:00 07-Jan-13 12:00:00 08-Jan-13 18:00:00 10-Jan-13 00:00:00 11-Jan-13 06:00:000
100
200
300
400
500
600
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
0.180
0.200
Filter 5 - 1/5 - 1/12
[2-3Hµm] [>3-5µm] [>5-7µm] [>7-10µm] [>10-15µm] [>15µm] Turbidity
Part
icle
Count
(counts
/ml)
Turb
idit
y (
ntu
)
30
11/1
3/12
11/1
6/12
11/1
9/12
11/2
2/12
11/2
5/12
11/2
8/12
12/1
/12
12/4
/12
12/7
/12
12/1
0/12
12/1
3/12
12/1
6/12
12/1
9/12
12/2
2/12
12/2
5/12
12/2
8/12
12/3
1/12
1/3/
13
1/6/
13
1/9/
13
1/12
/13
1/15
/13
1/18
/13
1/21
/13
1/24
/13
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
Average Flowrate (to end of run)
Filter 4 Filter 5 Filter 6
Flo
wra
te (
mgd)