Design Presentation
- 1. Wastewater Management Process Design and Economic Considerations
- 2. Presentation Outline • Introduction of Project • Process Description and Results – PFD – Process Units • Neutralization Reactors • Hydrocyclones • Primary Clarification • Reverse Osmosis • Waste Disposal • Economics • Conclusion • References • Data Tables/Equations/Resources
- 3. Project Introduction • Plant location: MN • Produces:Metals • Current market conditions makes plant construction feasible. • Plant construction delays due to EPA regulations, TDS ≤ 10 ppm • High flow rate and total TDS concentration promotes creative solution
- 5. Pass 1 Equipments Used Process description Ozone Treatment Removal of Fe and Mn Clarifier Flocculant and polymer addition Multimedia Filter Total suspended solid removal Reverse Osmosis Unit Membrane filteration
- 6. Pass 2 & 3 Equipments Used Process description Neutralization Reactors Addition of lime Hydrocyclone 90% solid removal (CaCO3,CaSO4) Clarifier Flocculant and Polymer addition Reverse Osmosis Unit Membrane filteration
- 7. Experimental Design • Geochemical modeling Aqueous geochemical modeling Equilibrium concentrations (or activities) of chemical species in solution Saturation indices (SI's) of solid phases in equilibrium with a solution. Design software used PHREEQ from USGS Calculation of the effects of mixing of waters, Saturation index of the compounds higher than 1 precipitate out Changing the solution's temperature, Eh, or pH, etc
- 8. Jar testing: simulating the coagulation/flocculation process Flocculants and polymers were bought from integrated engineers Selection based on the highest amount of flocks formed per amount of flocculants added. Conductivity test for testing the presence of inorganics dissolved in the mixture
- 9. Ozone Contact Tank • Addition of Ozone - 100% Removal - Manganese and Iron • Separated out in later steps.
- 10. Reactor Clarifier • Addition of flocculants to remove dissolved solids • Flocculants settle and are removed • Removed flocculants are sent to the landfill • Pass 1 will be 96,200 gal with a detention time of 2 hr • Pass 2 will be 26,500 gal with a detention time of 1.5 hr • Pass 3 will be 8,500 gal with detention time of 1.5 hr
- 11. Sand Filter • Either dual coal-sand or tri- media coal-sand-garnet. • It has an effective high rate filtration process with long filter runs. • It is a proven and widely accepted filtration process. • Helps remove more suspended solids before going to the RO unit. • Sized for 800gpm • Area 80.0 ft2 • Backwash velocity calculated after filter media is chosen.
- 12. Reverse Osmosis Unit 1 Example Staged RO Unit • Modeled as three parallel units with ten stages – 800 gal∙min-1 feed flow – 60% Recovery – 10 mg∙L-1 Permeate Concentration • Special Design Parameters – High inlet flow requires multiple stages/passes – Antiscalent addition – High flux yields high pressure inlet flow
- 13. Reverse Osmosis Unit 2 Unit 3 • Modeled as three parallel • Modeled as three parallel units with seven stages units with five stages – 320 gal∙min-1 feed flow – 128 gal∙min-1 feed flow – 60% Recovery – 50% Recovery – 10 mg∙L-1 Permeate – 10 mg∙L-1 Permeate Concentration Concentration – 192 gal∙min-1 permeate – 192 gal∙min-1 permeate flow flow – 12.3% membrane recovery – 12.9% membrane recovery – 99.3% solute rejection – 99.5% solute rejection
- 14. Neutralization Reactor • Reverse Osmosis Unit Feed – Highly saturated • Addition of Lime – Stabilize pH – Aid in removal of salts • Gypsum • Calcium Carbonate • Aragonite • Artinite • Calcite • Chrysotile • Design • Clinoenstatite - Modeled as circular up flow • Diopside clarifier • Huntite • Hydromagnesite - Using same equations as the • Magnesite Ozone Contact Tank • Sepiolite • Talc • Tremolite
- 15. Hydrocyclones • Removes solids in the waste stream • The removed solids are land filled • 16 in. with1,600 hp shaft will be used for Pass 2 • 12 in. with 360 hp shaft will be used for Pass 3
- 16. Reactor Clarifier • Addition of flocculants to remove dissolved solids • Flocculants settle and are removed • Removed flocculants are sent to the landfill • Pass 1 will be 96,200 gal with a detention time of 2 hr • Pass 2 will be 26,500gal with a detention time of 1.5 hr • Pass 3 will be 8,500 gal with detention time of 1.5 hr
- 17. Landfill design • Hazardous waste landfill must have a double linear • Can not be located in wetland on a floodplain • Cover is placed on top when landfill is closed • All leachate is collected and treated
- 18. Gypsum Removal • Removal by vacuum belt filtration • Can be run using just gravity or with a pressure drop. • Drying rates up to 80%.
- 19. Gypsum • Produce approximately 600kg per day. • Widely used product. – Plaster ingredient – Fertilizer and soil conditioner – Plaster of Paris • Approximately 90% of gypsum is used in the manufacture of wallboard for residential and non- residential applications. • Sharp rise in gypsum prices likely in 2012 due to housing industry coming back after recession.
- 20. Vacuum BeltFilter, $389,081 Economics Multimedia .00 Filter, $160,000.00 Flocculation Clarifier, $798,600 00 Hydrocyclone, $34, • No future estimate 084.00 Reverse Osmosis, $790,000 Neutralization – not significant in production .00 Clarifier, $651,425. 00 of profitable material. • Gypsum – produced and sold to offset some of the cost. Chemica Capital Cost, $3,292,489. • Energy Cost Cost, $2,823,190. 88 00 – Evaporator • $9million per year Operating and Maintenance Cost, $1,560,654. 00
- 21. Recomendations • Flocculants and polymers for Clarifiers • Automated process • Pilot plant for the process • Scaling up the process according to fluctuation
- 22. Conclusions • Reverse Osmosis unit over other ideas – Evaporator – Recrystallizer – Carbon nano-tubes • Should now be EPA compliant • Profitability associated with other areas of the mine
- 23. References • BRUCE HUTTON, I. K. (2007). OPERATING AND MAINTENANCE EXPERIENCE AT THE. Johanusburg: Anglo steel. • Brunfelt, P. C. (2012, April). Project Discussion. (A. Shah, Interviewer) • Iverson, D. (2012, April). Cost of the Reverse Osmosis. (A. shah, Interviewer) • NETAFIM USA. (2010). Hydrocyclone separators for gold mine. Fresno, CA 93727: NETAFIM USA. • Russell, D. (2012, April). Cost Of antiscalent Spectraguard 350. (A. Shah, Interviewer) • SHARMA, J. R. (May 2010). DEVELOPMENT OF A PRELIMINARY COST ESTIMATION METHOD FOR. Arlington: THE UNIVERSITY OF TEXAS AT ARLINGTON. • Kahan, I (2009) “eMalahleni Water Reclamation Plant – Towards Zero Waste” WISA Membrane Technology, Conference 2009 • Kawamura, S. (2000). Integrated Design and Operation of Water Treatment Facilities. John Wiley & Sons, Inc., New York. • Groudev, Stoyan. "Safe Management of Mining Waste and Waste Facilities." http://www.safemanmin.eu/. N.p., 2008. Web. 30 Apr 2012. • LaGrega, Michael. Hazardous Waste Management. 2nd. waveland press inc, 2010.
- 24. Appendix
- 26. RO Unit 1 Data Sheet From Total in Pass 1 2 3 4 5 6 7 8 9 10 RO1:1 Stage 1 Flow Vo (gal/min) 266.667 243.318 222.014 202.575 184.839 168.655 153.888 140.414 128.120 116.902 116.902 xxxxxxxxx Recovery 0.0876 0.0876 0.0876 0.0876 0.0876 0.0876 0.0876 0.0876 0.0876 0.0876 0.0876 0.0876 Permeate flow (gal/min) 23.348 21.304 19.438 17.736 16.183 14.766 13.473 12.294 11.217 10.235 160.00 480.00 Concentrate Flow (gal/min) 243.318 222.014 202.575 184.839 168.655 153.888 140.414 128.120 116.902 106.667 106.667 320.00 TDS Conc (g/gal) 3.595 3.9363 4.3104 4.7204 5.1697 5.6622 6.2019 6.7934 7.4416 8.1521 8.1521 8.1521 TDS Perm (g/gal) 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 HRLE- HRLE- HRLE- HRLE- HRLE- HRLE- HRLE- HRLE- HRLE- HRLE- Membrane 440i 440i 440i 440i 440i 440i 440i 440i 440i 440i HRLE-440i HRLE-440i Area ft^2 440 440 440 440 440 440 440 440 440 440 4400 13200 Flux (gal/ft^2*day) 76.413 69.722 63.618 58.048 52.965 48.328 44.096 40.235 36.713 33.498 52.364 52.364 Moles Feed 0.092 0.101 0.110 0.121 0.132 0.145 0.159 0.174 0.190 0.209 0.209 0.209 Moles Permeate 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 Osmotic Pressure, Feed (atm) 5.936 6.500 7.118 7.795 8.536 9.350 10.241 11.218 12.288 13.461 13.461 13.461 ΔΠ (atm) 5.738 6.301 6.919 7.596 8.338 9.151 10.042 11.019 12.089 13.262 13.262 13.262 ΔP (atm) 101.254 93.454 86.441 80.155 74.544 69.561 65.163 61.313 57.980 55.135 74.500 74.500
- 27. RO Unit 1 Ion Balances From H:1 From C:1 1 2 3 4 5 6 7 8 9 10 Final mol/gal mol/gal mol/gal mol/gal mol/gal mol/gal mol/gal mol/gal mol/gal Element g/gal g/gal Feed Feed Feed Feed Feed Feed Feed Feed Feed mol/gal Feed g/gal K 0.037850 0.034244 0.000876 0.000959 0.001050 0.001150 0.001260 0.001379 0.001511 0.001655 0.001813 0.001986 0.086 Na 0.189250 0.171221 0.004379 0.004795 0.005251 0.005750 0.006298 0.006897 0.007555 0.008275 0.009065 0.009931 0.429 Mg 0.803785 0.727214 0.018600 0.020366 0.022301 0.024422 0.026747 0.029295 0.032087 0.035148 0.038501 0.042177 1.823 Ca 0.227100 0.205466 0.005255 0.005754 0.006301 0.006900 0.007557 0.008277 0.009066 0.009931 0.010878 0.011917 0.515 Sr 0.001514 0.001370 0.000035 0.000038 0.000042 0.000046 0.000050 0.000055 0.000060 0.000066 0.000073 0.000079 0.003 Ba 0.000114 0.000103 0.000003 0.000003 0.000003 0.000003 0.000004 0.000004 0.000005 0.000005 0.000005 0.000006 0.000 CO3 0.006359 0.005753 0.000147 0.000161 0.000176 0.000193 0.000212 0.000232 0.000254 0.000278 0.000305 0.000334 0.014 HCO3 1.616195 1.462230 0.037399 0.040950 0.044842 0.049107 0.053781 0.058904 0.064519 0.070672 0.077416 0.084807 3.665 CL 0.075700 0.068489 0.001752 0.001918 0.002100 0.002300 0.002519 0.002759 0.003022 0.003310 0.003626 0.003972 0.172 SO4 0.946250 0.856107 0.021896 0.023975 0.026254 0.028751 0.031488 0.034487 0.037775 0.041377 0.045326 0.049653 2.146 SiO2 0.018925 0.017122 0.000438 0.000480 0.000525 0.000575 0.000630 0.000690 0.000755 0.000828 0.000907 0.000993 0.043 B 0.001893 0.001712 0.000044 0.000048 0.000053 0.000058 0.000063 0.000069 0.000076 0.000083 0.000091 0.000099 0.004 CO2 0.048599 0.043970 0.001125 0.001231 0.001348 0.001477 0.001617 0.001771 0.001940 0.002125 0.002328 0.002550 0.110 Total 3.9735 3.5950 0.0919 0.1007 0.1102 0.1207 0.1322 0.1448 0.1586 0.1738 0.1903 0.2085 8.152
- 28. RO Unit 2 Data Sheet From Total in Pass 1 2 3 4 5 6 7 RO2:1 Stage 2 Flow Vo (gal/min) 106.66 93.575 82.098 72.025 63.188 55.435 48.634 xxxxxx xxxxxxxxx Recovery 0.1227 0.1227 0.1227 0.1227 0.1227 0.1227 0.1227 0.1227 0.1227 Permeate flow (gal/min) 13.0872 11.4815 10.0728 8.8369 7.7527 6.8015 5.9670 63.9997 192.00 Concentrate Flow (gal/min) 93.5795 82.0980 72.0252 63.1883 55.4355 48.6340 42.6670 42.6670 128.00 TDS Conc (g/gal) 5.82192139 6.6308 7.5529 8.6038 9.8018 11.1673 12.7238 12.7238 12.7238 TDS Perm (g/gal) 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 HRLE- Membrane HRLE-440i HRLE-440i HRLE-440i HRLE-440i HRLE-440i HRLE-440i HRLE-440i 440i HRLE-440i Area ft^2 440 440 440 440 440 440 440 3080 9240 Flux (gal/ft^2*day) 42.831 37.576 32.966 28.921 25.373 22.260 19.528 29.922 29.922 Moles Feed 0.149 0.170 0.193 0.220 0.251 0.286 0.325 0.325 0.325 Moles Permeate 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 Osmotic Pressure, Feed (atm) 9.613 13.139 14.966 17.048 19.422 22.128 25.212 25.212 25.212 ΔΠ (atm) 9.415 12.940 14.767 16.850 19.224 21.929 25.013 25.013 25.013 Δp (atm) 62.953 59.910 55.974 53.001 50.939 49.754 49.424 62.416 62.416
- 29. RO Unit 2 Ion Balances From H:2 From C:2 1 2 3 4 5 6 7 Total mol/gal mol/gal mol/gal mol/gal mol/gal mol/gal Element g/gal g/gal Feed Feed Feed Feed Feed Feed mol/gal Feed g/gal K 0.08583 0.08185 0.00209 0.00238 0.00272 0.00309 0.00352 0.00402 0.00458 0.179 Na 0.42915 0.40924 0.01047 0.01192 0.01358 0.01547 0.01762 0.02008 0.02288 0.894 Mg 1.82268 1.73813 0.04446 0.05063 0.05767 0.06570 0.07485 0.08527 0.09716 3.799 Ca 0.51498 0.49109 0.01256 0.01431 0.01629 0.01856 0.02115 0.02409 0.02745 1.073 Sr 0.00343 0.00327 0.00008 0.00010 0.00011 0.00012 0.00014 0.00016 0.00018 0.007 Ba 0.00026 0.00025 0.00001 0.00001 0.00001 0.00001 0.00001 0.00001 0.00001 0.001 CO3 0.01442 0.01375 0.00035 0.00040 0.00046 0.00052 0.00059 0.00067 0.00077 0.030 HCO3 1.83246 1.74745 0.04469 0.05090 0.05798 0.06605 0.07525 0.08573 0.09768 3.819 CL 0.17166 0.16370 0.00419 0.00477 0.00543 0.00619 0.00705 0.00803 0.00915 0.358 SO4 1.07287 1.02310 0.02617 0.02980 0.03395 0.03867 0.04406 0.05019 0.05719 2.236 SiO2 0.04291 0.04092 0.00105 0.00119 0.00136 0.00155 0.00176 0.00201 0.00229 0.089 B 0.00429 0.00409 0.00010 0.00012 0.00014 0.00015 0.00018 0.00020 0.00023 0.009 CO2 0.11020 0.10509 0.00269 0.00306 0.00349 0.00397 0.00453 0.00516 0.00587 0.230 Total 6.105 5.822 0.149 0.170 0.193 0.220 0.251 0.286 0.325 12.724
- 30. RO Unit 3 Data Sheet Total in Pass 1 2 3 4 5 From RO3:1 Stage 3 Flow Vo (gal/min) 42.667 37.144 32.336 28.150 24.506 xxxxxx xxxxxxxxx Recovery 0.1294 0.1294 0.1294 0.1294 0.1294 0.1294 0.1294 Permeate flow (gal/min) 5.523 4.808 4.186 3.644 3.172 21.333 64.00 Concentrate Flow (gal/min) 37.144 32.336 28.150 24.506 21.334 21.334 64.00 TDS Conc (g/gal) 9.318 10.698 12.283 14.103 16.195 16.195 16.195 TDS Perm (g/gal) 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 0.03785 Membrane HRLE-440i HRLE-440i HRLE-440i HRLE-440i HRLE-440i HRLE-440i HRLE-440i Area ft^2 440 440 440 440 440 2200 6600 Flux (gal/ft^2*day) 18.075 15.736 13.699 11.925 10.382 13.963 13.963 Moles Feed 0.2383 0.2736 0.3142 0.3607 0.4142 0.4142 0.4142 Moles Permeate 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 0.00102 Osmotic Pressure, Feed (atm) 15.386 17.664 20.282 23.288 26.742 26.742 26.742 ΔΠ (atm) 15.186 17.465 20.082 23.089 26.542 26.542 26.542 ΔP (atm) 37.781 37.134 37.206 37.995 39.519 43.996 43.996
- 31. RO Unit 3 Ion Balances From R:3 From C:3 1 2 3 4 5 Total Element g/gal g/gal mol/gal Feed mol/gal Feed mol/gal Feed mol/gal Feed mol/gal Feed g/gal K 0.17888 0.17190 0.00440 0.00505 0.00580 0.00665 0.00764 0.2988 Na 0.89439 0.85948 0.02198 0.02524 0.02898 0.03327 0.03821 1.4938 Mg 3.79866 3.65038 0.09336 0.10719 0.12307 0.14132 0.16227 6.3446 Ca 1.07327 1.03137 0.02638 0.03029 0.03477 0.03993 0.04585 1.7926 Sr 0.00716 0.00688 0.00018 0.00020 0.00023 0.00027 0.00031 0.0120 Ba 0.00054 0.00052 0.00001 0.00002 0.00002 0.00002 0.00002 0.0009 CO3 0.03005 0.02888 0.00074 0.00085 0.00097 0.00112 0.00128 0.0502 HCO3 1.90952 1.83498 0.04693 0.05388 0.06187 0.07104 0.08157 3.1893 CL 0.35776 0.34379 0.00879 0.01010 0.01159 0.01331 0.01528 0.5975 SO4 1.11799 1.07435 0.02748 0.03155 0.03622 0.04159 0.04776 1.8673 SiO2 0.08944 0.08595 0.00220 0.00252 0.00290 0.00333 0.00382 0.1494 B 0.00894 0.00859 0.00022 0.00025 0.00029 0.00033 0.00038 0.0149 CO2 0.22968 0.22071 0.00565 0.00648 0.00744 0.00854 0.00981 0.3836 Total 9.696 9.318 0.2383 0.2736 0.3142 0.3607 0.4142 16.195
- 32. Surface Complexation Principles • Fully considers variable charge surfaces. # of sorption of sites is constant but their individual charge, & total surface charge, vary as a function of solution composition • Similar to aqueous complexation/speciation • A mix of anions, cations & neutral species can sorb • Accounts for electrostatic work required to transport species through the “diffuse layer” (similar to an activity coefficient correction) Gouy-Chapman theory
- 33. Surface complexation equations • 1st deprotonation 2nd deprotonation reaction: reaction: SOH + SOH 0 H+ SOH 0 SO- H+ 2 SOH 0 H app SO H app K a1 K a2 SOH 2 SOH 0 Divalent cation complexation SOH 0 M 2+ SOM + H+ app SOM H K M SOH 0 M2
- 35. Sand Filter
- 36. Hydrocyclones
- 38. RO Design Equations • π is the osmotic pressure, atm • i = Van’t Hoff factor • Cs = solute concentration, mol∙L-1 • R = Universal Gas Constant, L∙atm∙mol-1∙K-1 • T = absolute temperature, K • πp, osmotic pressure of the permeate side, atm • πf is the osmotic pressure on the feed side, atm
- 39. RO Design Equations • Jp = permeate flux, gal∙ft-2∙day-1 • qp = permeate flow, gal∙day-1 • Am is the membrane surface area, ft2 • Aw = membrane water permeability coefficient ,gal∙ft-2∙day-1∙atm-1 • ΔP = Pressure drop in atm.
Editor's Notes
- #10: Ozone neutralization mixer is in place to help draw out and facilitate the precipitation of Manganese and Iron. Integrated Design and Operation of Water Treatment Facilities, 2nd edition by Susumu Kawamura.
- #18: Hazardous landfill are required by the EPA to have 2 liner system. It is also required to have a leachate collection system and above the first liner and to have a leak detection system above the 2nd liner. Landfill also can not be located in a floodplain , wetland or near a source of open water. When the landfill is no longer in use a permanent cover is placed on top. This cover consists of vegetation, soil, a drainage layer, and geomembrane. There is also a vent to allow gas release and prevent pressure build up in the landfill. The collected leachate can either be re-injected into the landfill, treated on site or Sources : hazardous waste book, http://www.biutec.at/safemanmin/pdf/D31_Rev20080922.pdf,
- #37: Sources: Charts are from Netafilm
- #38: Sources: assumptions from Kawamura (2000) in shurma