Industrial Utility Efficiency

Wastewater

Air Compressor Design Considerations for a Successful Compressed Gas Mixing Project

By Chris Ahnen, Director of Engineering, EnviroMix

Compressed Gas Mixing provides uniform mixing of water or wastewater tank contents by firing programmed, short-duration, high-intensity bursts of compressed air through engineered nozzles located near the tank floor. Mixing parameters – including pressure, sequence, duration and frequency – may be adjusted, either through operator input or automatic process feedback, to optimize power use and deliver ideally mixed conditions.

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20 Years of Case Studies: Plants Sharing Best Practices

Edited by Troy Dreier, Senior Editor, Compressed Air Best Practices® 

For 20 years, Compressed Air Best Practices® Magazine has published articles focused on helping manufacturers reduce power demand, lower water consumption, and improve the performance of compressed air, cooling, blower and industrial vacuum systems. In this article, we highlight a sampling of those stories across the following industries: Plastics and Packaging Food and Beverage Automotive and Transportation Cement, Building Materials, and Mining Metals, Pulp, and Paper Pharmaceuticals, Healthcare, and Research Wastewater Treatment
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Choosing the Best Wastewater Mixing System - How Compressed Gas Mixing Overcomes Daunting Challenges

By Sarah Elger, P.E., Director of Strategy and Marketing and John Koch, P.E., Vice President of Technology, EnviroMix Inc.

When selecting a mixing technology, wastewater treatment plants (WWTPs) and their consultant engineers must consider numerous factors, balancing specific treatment demands with plant priorities and ultimately choosing the technology that best suits their needs and specifications. Compressed gas mixing (CGM) is often the best solution, allowing designers to circumvent many challenges that alternative technologies either create or cannot overcome.
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When Mixing is the Goal, Why Would You Aerate? Compressed Gas Mixing Provides an Alternative Approach

By David Lauer, P.E., EnviroMix

At the beginning of the 20th century, biological wastewater treatment — more specifically, the activated sludge process — was developed and became widely accepted as the treatment method for municipal wastewater, helping to protect our lakes and rivers from pollutants and support public health. In 1947, the Committee on Development of Uniform Standards for Sewage Works was created by the group known as the Great Lakes – Upper Mississippi River Board of State and Provincial Public Health and Environment Managers.
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Fayetteville Wastewater Treatment Plant Lowers Operational Costs, Increases Efficiencies

By Mike Grennier, Compressed Air Best Practices® Magazine

The plant upgrades, in combination with a progressive management strategy, allows the plant to consume less energy and reduce its reliance on outside contractors for biosolids removal, resulting in total operational savings of approximately $60,000 per year. The plant is also positioned to efficiently manage the area’s wastewater for decades to come.
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Pure & Enriched: The Advantages of Using Oxygen in Wastewater Treatment Processes

By Vince Hartley, Airgas, an Air Liquide Company

Wastewater treatment processes have come a long way in the past century, but demand continues to grow for more reliable and efficient treatment technologies. As a result, industry professionals are searching for an all-encompassing solution to enhance their treatment plants and processes. One of the purest environmental aids on the market is oxygen.
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From Wastewater Agitation to Air Compressor Controls-Food Processor Finds 74% Savings Potential

By Ron Marshall, Marshall Compressed Air Consulting

As many well know, system measurement is essential to ensuring a compressed air system is running efficiently and effectively, with good air quality and adequate pressure. This is also well understood by a multi-national food company (name has been withheld to protect the innocent) who started a focused effort to measure and improve their compressed air systems in their many processing plants worldwide.
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Study Proves Potential Energy Savings of AODD Pump Controls

By Compressed Air Best Practices® Magazine

Air-operated double diaphragm (AODD) pumps are common to many manufacturing facilities. As estimated by veteran compressed air auditor Hank van Ormer of Air Power USA, approximately 85 to 90 percent of plants in the United States have AODD pumps. They are used for all kinds of liquid transfer applications, like those found in chemical manufacturing, wastewater removal, and pumping viscous food products.
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PTFE Membrane Bubble Diffusers Reduce Demand on Aeration Blowers

By Doreen Tresca, Stamford Scientific International, Inc.

Aeration tanks use bubble diffusers to distribute oxygen within the wastewater. Fine bubble diffusers, or those that produce a large amount of very small air bubbles, first began to become popular in the 1980s, as they had a much higher efficiency than coarse bubble diffusers. Fine bubble diffusers generally feature a membrane that allows airflow to pass from the piping system on the floor of the tank through the body of the diffuser and the membrane, providing oxygen into the wastewater for treatment.
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Pneumatic Control in Modular Wastewater Treatment Plants

By Compressed Air Best Practices® Magazine

The design of wastewater treatment plants is changing, and it has something to do with LEGO® bricks. More specifically, it has to do with how large and complex LEGO structures are built. If you follow the instructions carefully, you build module after module, eventually piecing them together to create a fully functional and cohesive unit.
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Turbo Blowers Generate Significant Energy Savings at Victor Valley Wastewater

By Robert Lung for the U.S. Department of Energy Better Plants Program

A replacement strategy for air compressors and blowers integrated into a system-level approach towards energy efficiency can deliver significant energy savings and optimize equipment performance. At the Victor Valley Wastewater Reclamation Authority, a blower replacement project yielded annual energy savings of more than 928,000 kWh and $98,000 in energy costs, while improving the reliability of its secondary treatment process. In addition, the agency qualified for important incentives from its electric utility — significantly improving the project economics and resulting in a 2.94-year payback.
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High Speed Bearing Technologies for Wastewater Treatment Applications

By Aleksandra Irving PE and Joseph Ibets PE, The Spencer Turbine Company

High speed bearing technology is applicable for aeration blowers operating at much higher speeds than the typical 60Hz, 3600RPM for cast multistage units. High Speed Turbo (HST) units are usually single stage (though some utilize multiple cores) and rotate from 15,000 to 50,000RPM. At such high speeds, standard roller bearings cannot offer the industry standard L10 bearing life. Two types of bearing technologies have come to dominate the wastewater treatment market for these types of machines: airfoil and magnetically levitated. Often the two technologies are compared as equals, however, in many significant ways they are not.
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Kaeser Rotary Screw Blowers for Wastewater Aeration

By Rod Smith, Compressed Air Best Practices® Magazine

Compressed Air Best Practices® Magazine interviewed Frank Mueller (President) and Stephen Horne (Blower Product Manager) from Kaeser Compressors. Kaeser Compressors continues to grow both in the U.S. and internationally. We currently employ approximately 4800 people globally. In order to support the demand and maintain our superior quality and quality service levels, we continue to invest in people, facilities and technology.
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Remote Diagnostics for Water Filtration Systems

By Craig Correia, Process Automation Industry Manager, Festo Corporation

Productivity is more reliable when equipment can be monitored to detect incipient failures and take corrective action before the plant goes down. But many devices, such as analog control valves, pneumatic valve terminals and field sensors, often do not offer diagnostic feedback, or it is not being used. This white paper describes how this problem is being addressed, and includes an example of pneumatic valve terminals that can monitor, among other things, open load or coil currents at the specific valve and pressure inside the valve terminal.
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Magnetic Bearings: An Attractive Force for Energy-efficiency

By Mark Hinckley, Director Strategic Projects, SKF Strategic Industries

With sustainability and energy-efficiency targets tougher than ever, magnetic bearings are drawing the attention of engineers in many industries, offering a whole range of advantages from increased performance to extended lifespan.
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Advanced Automation Lowers Labor Cost and Improves Performance at the Las Palmas, California, Waste Water Treatment Plant

By Nate Ventress, Process Automation Specialist, Western Region, Festo

Recently the capacity of the Las Palmas, California, waste water treatment operations were expanded by combining two plants and making one centralized filtration center. The new center expanded the flow capacity from 162,000 Gallons per Day (GPD) combined to 288,000 GPD when the manually controlled reclaimed water operations were updated to a state-of-the-art automated system. Reclaimed water from the plant irrigates local community green spaces. The new automated system ensures lower labor costs, consistent quality, and peak efficiency in the process of reclaiming waste water for irrigation.
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Q&A: APG-Neuros and Turbo Blower Technology

By Rod Smith, Compressed Air Best Practices® Magazine

Compressed Air Best Practices® Magazine interviewed Mr. Omar Hammoud, the CEO and President of APG-Neuros. APG-Neuros was founded in 2006 in Quebec as a result of seeing an opportunity for innovation in the North American blower market. Our mission is to distribute, manufacture, provide aftermarket support and continued development of high-efficiency turbo blowers and complete Aeration Systems for the municipal and industrial markets in North America and Europe.
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Evaluating Different Blower Technologies on a Wire-to-Air Basis

By Andrew Balberg, Business Development Manager–Low Pressure, Atlas Copco

In the absence of official third party specifications on energy efficiency, it is difficult to evaluate and compare blower technologies fairly and effectively. The lack of readily available evaluation tools leads to misinformation and unfair comparisons between technologies. Further, the performance verification process is difficult to prove.
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DO Control System and Turbo Blowers Optimize Energy Use at a WWTF

By Jack Troidl, P.E., Woodard & Curran

Every municipality and utility is facing the reality of rising energy costs. In 2010, the Town of Billerica, MA, which is located 22 miles northwest of Boston with a population of just under 40,000 residents, engaged Process Energy Services and Woodard & Curran to conduct an energy evaluation of the Town’s Wastewater Treatment Facility (WWTF) and pump station systems sponsored by National Grid. The objective of the evaluation was to provide an overview of each facility system to determine how electrical energy and natural gas were being used at the facility and to identify and develop potential costsaving projects.
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Screw Blowers and Membrane Bioreactor Treat Wastewater at a Bottling Plant

By Richard Stukey

The right ingredients and processes are essential for manufacturing flavorful beverages that contribute to the company’s bottom line. But what happens to all those other “ingredients” that aren’t part of the recipe? Cleaning up those unwanted ingredients from bottling plant wastewater can consume large amounts energy, time and money—and become a distraction from the company’s primary goal of manufacturing beverages.
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Improved Aeration Efficiency through Design and Control

By Matthew Gray, Senior Process Engineer and Steve Kestel, Lead Systems Engineer, BioChem Technology, Inc.

With the recent and future increases of the cost of energy, operating a wastewater treatment plant (WWTP) as efficiently as possible has become one of the most important factors that operators and managers are facing today. The implementation of a properly designed aeration control system has been reported by the United Sates Environmental Protection Agency to reduce aeration energy by 25 to 40 percent.
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O₂ Automation: The Future of Bubble Mixing?

Compressed Air Best Practices® Magazine interviewed Kris Drewry from O₂ Automation and Pulsed Hydraulics Inc.

We have industrial accounts where we mix chemicals and acids. Our favorite is blending wine and spirits using compressed nitrogen. The old way to blend was to use “air rousing.” This was done by installing rows of perforated pipes in the bottom of the tank and attaching an air pipe to this grid. Since the typical mixing cycle was 45 minutes, copious amounts of air and energy were used.
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Aeration Energy Offers Opportunities to Save

By Jess Burgess, Consortium for Energy Efficiency

Aeration systems at wastewater treatment facilities present significant, cost-effective energy savings opportunities. Aeration—the introduction of air into the wastewater stream to support anaerobic bacteria and mixing—is a key function at the majority of wastewater treatment facilities in North America. Aeration accounts for 25-60 percent of total energy consumption at wastewater treatment facilities , and a significant piece of operating budgets sector-wide.
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Adaptive Control for Low Pressure Wastewater Treatment Air Systems

By Roy Stuhlman, Kaeser Compressors, Consultant and an instructor for the Compressed Air Challenge® and Stephen Horne, Kaeser Compressors for the Compressed Air Challenge®

In recent years, there have been many changes in wastewater treatment. Most modern processes control three cycles: DO, NH4, and NO3, and all of the processes require high volumes of air. Undeniably, the low pressure air system uses more electrical power than the rest of the wastewater treatment plant combined. The blower packages in these systems can be equipped with low noise enclosures, fixed speed or variable speed drives, and can include all the instrumentation needed for self-protection.
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Black & Veatch Provides Guidance to WWTP Design

By Rod Smith, Compressed Air Best Practices® Magazine

Compressed Air Best Practices® Magazine interviewed Ms. Julie Gass P.E., Lead Process Mechanical Engineer, from Black & Veatch on trends in the wastewater treatment industry especially pertaining to new technology aeration blowers and energy efficiency.
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