TPS

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THERMALPR O C E S SSYSTEMS

Your Class A Solutionfor Biosolids ManagementThermal Process Systems

1841 E. Summit St.Crown Point, IN 46307 USA

Phone: (219) 663-1034Fax: (219) 663-7248

E-Mail: engineering@thermalprocess.comthermalprocess.com

Biosolids Management Process Comparison Matrix

PROCESS

Recycle Stream Off-Gas

Class AProduct

SignificantNutrient

LowCOD

HighVolume

Reduction

Low toModerateEnergy

Use Ammonia MethaneReduced

SulfurRetrofitPotential

SimpleOperation

ThermAer™

ConventionalATAD

AnaerobicDigestion

LimeStabilization

ThermalDrying

CapitalCost

Moderate

Moderate

Moderate

High

Very High

LowComposting

Thermal Process Systems was founded by

experienced wastewater treatment

professionals who understand first hand the

complex issues of biosolids processing and

re-use. Hindered by the compromises that were

necessary with existing systems — and the

inability of these processes to meet industry

demand — they formed their own company

focused exclusively on biosolids management.

Their first challenge: to develop a more reliable,

more efficient process for the production of

high quality biosolids. The result is the

proprietary ThermAer™ process. ThermAer™

has been subjected to rigorous field testing in

full-scale operating systems, and pilot testing at

various sites since 1995. It has exceeded every

customer expectation.

In addition to the proprietary ThermAer™

Process, Thermal Process Systems has also

established relationships with the most

respected equipment manufacturers in the

industry today. It is an unmatched combination,

offering you complete systems integration, from

retrofit to ground up installation and control.

The experience to know what works.The innovation to make it work better.

Contact us today for a no obligation analysis of yourbiosolids management needs (219) 663-1034

THERMALPR O C E S SSYSTEMS

TPS

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The First Advanced AerobicBiosolids Reduction System

Beneficial re-useThis is the challenge faced by environmental

professionals today. You appreciate the advantages

of using biological processes to treat the soluble

organic wastes of your company or municipality.

But how can you cost-effectively manage the

by-products to produce consistently stable, high-

quality biosolids, completely free of pathogens and

offensive odors? Finally, you have a no-compromise

solution at a price you can afford.

Historical perspectiveVarious anaerobic and aerobic digestion processes

are in use today. Each has its limitation. For example,

natural aerobic digestion processes release heat,

as well as water and carbon dioxide — all desired

results. However, at typical mesophilic operating

temperatures, roughly 20-40°C, the process

is inefficient, resulting in instability with minimal

pathogen kill and limited solids reduction. ThermAer™

was introduced several years ago to improve the

results of the aerobic digestion process. ThermAer™

takes advantage of highly efficient thermophilic

organisms, naturally present in wastewater,

optimizing the environment for them to proliferate

and dominate. This increases the temperature of

the sludge as the thermophiles feed on other

microorganisms. At these higher temperatures the

food source is broken down, releasing the soluble

substrate material contents and providing a feast for

the thermophiles. The metabolism of the thermophiles

is extremely high, yet the net yield is low. The result

is a significant reduction in volatile solids and the

production of a pathogen- and odor-free end product.

ThermAer™ installation in Morehead, KY.

TPS

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Advancedthermophilic biosolidstreatment

TM

clean& green

A revolutionary processthat delivers the results you want —without the side effectsThermal Process Systems’ proprietary ThermAer™

biosolids reduction system is the second

generation in Autothermal Thermophilic Aerobic

Digestion (ATAD) technology. It gives you the

best of all worlds — a high quality pathogen-

free product — plus controlled foam, the

elimination of foul odors through prevention or

treatment as appropriate, and superior reduction

of volatile solids. ThermAer™ is the only

Autothermal Thermophilic Truly Aerobic Digestion

process. On the following pages you will see how

the ThermAer™ difference can make all the

difference in your process.

Superior volatile solids reductionNo one has to tell you about the complexities

of biosolids disposal today: stringent landfill

permit requirements, reduced land application

availability, costly dewatering requirements,

and increasing tipping fees. Now, thanks to

ThermAer,™ you have a solution.

• ThermAer™ destroys 60-70% of volatile

solids. It also increases dewatering

cakesolids as much as 25-30%. You get

a higher quality product reducing volume

by up to 70%, saving on your trucking

and disposal costs.

• The nutrient and moisture content in

ThermAer™ biosolids is ideal for direct

land application as well as composting

applications — biosolids disposal options

not readily available with other processes.

Assured “Class A” qualityat a “Class B” priceYou need a quality product to compete for

access to today’s limited land application and

reuse markets. With ThermAer™ you’re assured

of Class A solids classification under USEPA

Part 503 regulations, giving you unrestricted

use of your biosolids. You will achieve a

nutrient-rich, high-quality product unmatched

by any other process. ThermAer™ biosolids

have no offensive odors and, because they are

free of pathogens, you can be confident of their

stability and safety during handling and storage.

Your best solution for biosolids managementNow, for the first time you have a reliable, realistic solution to the increasingly difficult problem ofbiosolids processing, reuse and disposal. With the ThermAer™ Process you achieve:

Reduces capital and operating costsYour savings in operating and capital expense

can often more than justify your decision to

specify ThermAer.™ It’s the ideal solution

to upgrade your current system or as the

heart of your new installation.

Superior cost-effectivenessCompare the benefits of the ThermAer™

process to the operational and maintenance

costs of any other installed biosolids

management system. You simply won’t find

a more cost-effective combination.

Process FlexibilityNow you can meet required volatile solids

destruction and pathogen kill rates with greater

process flexibility. Unlike other systems, you

no longer need a series of operations in

multiple reactors to achieve a stable product.

You can achieve the desired results either in

a single reactor, or if you currently have multiple

reactors, you can, if you choose, put them

to more productive use either as series or

parallel systems.

Downstream efficiency and synergyThe ThermAer™ process reduces volatile solids

and improves dewaterability, resulting in much

smaller mass and volume. This significantly

decreases the size and costs of unit processes

required for “further treatment” downstream

(such as dewatering, drying, etc.), while

increasing their efficiency.

Control Panel — Delphos, OH. An IntegratedControl Package provides the flexibility tooperate the processes by a simple touch onthe screen.

Your system will be custom-engineered to fit your

needs exactly, whether you would like to retrofit

your existing basins — or integrate ThermAer™ into

your new system. In typical installations, such as

the one illustrated here, you will have the flexibility

to continuous or batch feed the process daily, after

thickening the feed material.

Positive Displacement Blowers —Delphos, OH. Positive displacement blowersallow for the flexibility of varying the liquiddepth in the reactors.

Assured product quality – with no compromisesWith the patented ThermAer™ Process, you can achieve the results you want without compromisingyour quality or cost objectives. The system delivers superior volatile solids reduction, extremely lowodor and pathogen reduction in any reactor configuration – and, where required or desired, assuredEPA Class A certification.

Tank Wall isdesigned to retainheat generatedin the process.

Field-Proven BiofiltAer™ The Thermal Process Systems field-proven

biofilter technology is specifically designed to efficiently and reliably

remove ammonia, a natural by-product of superior VS reduction. The

BiofiltAer™ is included as an integral component of the system.

Jet Aeration System — Industrial Facility,Lafayette, IN. Bottom-up Jet Aeration Systemprovides more efficient mixing in the reactorwith 3-4% solids concentration or more.

Pump Gallery — Yorkville, IL. ConventionalOut-of-Basin Pumps are already familiar tooperating and maintenance staff.

Pump Gallery — Delphos, OH. Out-of-BasinPumps mounted at grade for an easy access.

TPS

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Thickener6.8%

SNDR™

2.6% TS pH 6.5-6.8

~35-40°C

• Primary and/or secondary thickened before feeding to ThermAer™ Reactor(s)

• Jet Aeration • High Oxygen Transfer

• Independent mixing and oxygen delivery control

• Hydraulic foam control • Full Automation • Varying liquid depths

• Single reactor system for nitrification and denitrification

• Integrated control strategy for pH, temperature and ORP

• Headspace utilized as a natural scrubber

• High temperature and intense mixing ruptures the cell walls of incoming waste stream

• Foam production, an indication of degradation of proteins, controlled by hydraulicfoam control cones

• Very low yield, an indication of highvolatile solids reduction

5,000 kg

• Greatly reduces the overall dewatering costs • Mesophilic conditioning and optimum pH

provide suitable conditions for nitrificationand denitrification

• No external alkalinity required• Conditioning in SNDR™ reduces ammonia,

soluble COD, and overall chemical andpolymer consumption

2,500 kg

1,900 kg

6.5 Cubic Meters

27-30% Solids * Destruction data based upon the representative

observed values at Yorkville Bristol Sanitary District

ThermAer™

3.4% TS pH 8-8.5

~65-70°C

Coagulant

CentrifugePolymer

Granulated dewatered biosolids at Yorkville BristolSanitary District, IL. Volume reduction greatlyincreases the storage capacity while reducingtransportation and disposal costs.

TPS ThermAer™ ProcessOverall Flow Schematic* TPS

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ThermAer™ Jet Aeration SystemMatching oxygen supply to process demands

Today the rules have changed...For the first time you can precisely match oxygen

delivery to oxygen demand, thanks to the

revolutionary ThermAer™ process featuring a

patented flexible-flow Jet Aeration System.

You get all these benefits and more:

• Extremely high oxygen transfer

efficiencies at low air/liquid ratio.

• Thermal conservation with low

air/liquid ratio.

• Independent control of oxygen transfer

and mixing.

• Variable liquid and air flow enhances

temperature control.

• Higher shear mixing of viscous

mixed liquor.

• “Retrofitability” to virtually any

basin/tank geometry.

Horsepower When You Need It.Energy Savings When You Don’t.Unlike conventional ATAD systems, ThermAer™

monitors and controls your process throughout

the cycle. Using proprietary technology available

only with ThermAer,™ aerobic conditions are

maintained at all times. The benefits of this

revolutionary concept over conventional ATAD

systems have been proven through several years

of full-scale operating experience:

• Optimized energy input.

• More efficient mixing from the bottom up

— providing the most effective mixing

intensity for 3-4% solids mixed liquor.

• Managed and controlled foam production.

• Eliminating the production of reduced

sulfur compounds which may cause

offensive odors.

ThermAer™ Assures Process StabilityThermAer provides stable process assurance and consistently highquality product. Thermal Process Systems has proven that certainprocess variables directly correlate, allowing them to be used as areliable means of control.

-30mV

-250 to -350 mV

18%

5-10%

65˚C

58˚C

Off-Gas O2

ORP

Temp

ORP Response

-30mV

Headspace Oxygen Content

18%

Uniform Temperature Increase

Typical Curves After Feed Cycle

A typical batch feed operation will yield similar response curves for ORP,Headspace Oxygen Content, and Temperature. A dip is normal prior tothe burn cycle and immediately following each batch feed. Notice therapid rise to normal conditions, which is repeatable. Thermal ProcessSystem’s patented control technology is based on the proven correlationbetween ORP, temperature, and other variables in the batching process.

“Mirror Image”

Independent research has proven that Oxygen Uptake Rate (OUR) andOxidation Reduction Potential (ORP) are inversely proportional, makingthis relationship a highly reliable control variable.

Conventional systems provide onlyone level of oxygen supply duringthe entire process, regardless ofthe level of activity in the reactor.

The ThermAer™system monitors theoxygen demand constantly throughthe use of oxidation reductionpotential (ORP). Based on thiscondition, VFDs adjust liquid flowrate and oxygen delivery to matchthe actual needs of the process thusassuring oxygen is available whenneeded thus saving horsepower andenergy. This assures you a morestable and complete digestionprocess in the reactor.

How Does it Work —and Will it Work for You?Whether you are upgrading your present system

or planning a new one, you can’t afford to

overlook the exceptional benefits offered only

by ThermAer.™

• Flexibility. ThermAer™ is easily adapted

to optimize most existing or proposed

design schemes, mechanical equipment

and processes, including:

• Virtually any tank size and geometry.

• Various thickening and/or dewatering

equipment.

• Unique site conditions and space

considerations.

• A Wide Variety of process flow schemes,

including single or multiple reactors.

• Reliability. ThermAer™ has consistently

met the most stringent demands for safety

and reliable performance in the field.

For example:

• Flexible Options for maintaining tight

temperature control at all times.

ThermAer’s advanced jet aeration

technology allows variations in air flow,

liquid pumping, or both.

• Optimum Foam Control through the

stability of the aerobic process and

the unique foam control system. The Splash

Cone™ and adequate headspace in the

reactor assure absolute foam management.

• Safer, Easier, Less-Frequent

Maintenance because there are no

moving parts inside the basin.

• Optimum Pump Life thanks to ThermAer’s

innovative process, allowing your pumps

to meet precise aeration requirements

at low speeds.

• Consistent Process Performance. Since

the thermophilic organisms are maintained

in their ideal environment at all times,

you’re assured that they are always hearty

and resilient.

• Simplicity. For all its sophistication,

ThermAer™ requires very little attention and

is remarkably easy to operate. Your operators

can perform waste and feed with less than an

hour per day of their attention. Your start-up

will also be smooth and easy, with minimal

training for your operations and maintenance

personnel. The major components (pumps

and blowers), as well as the monitoring and

testing devices should already be familiar to

them. You may even specify the automation

level you prefer — an integrated control

package or any number of other systems.

RECIRCULATEDLIQUID

EntrainedLiquid

High Velocity Jet Plume

AIR

500

400

300

200

100

0

0

-100

-200

-300

-400

OUR is Inversely Proportional to ORP

ORP

(mV)

Oxyg

enUp

take

Rate

(mg/

L-Hr

)

ORP OUR

Exclusive Jet Aeration SystemMonitors and Controls Air Flowand Liquid Pumping

Thermophiles require oxygen — and lots of it — to thrive and

consume excess food. But the exact amount of oxygen they

need for optimum performance is not constant. It varies

widely depending upon the stage the process may be in.

Yet surprisingly, conventional ATAD systems disregard these

variations, providing only a single rate of oxygen supply — an

inflexibility that requires a cumbersome multi-reactor process

to produce a single pathogen-free batch.

You’ll Appreciate the Difference...Use the chart on the back cover to compare

ThermAer™ to the most common methods

currently used for biosolids management.

Then, give us a call at Thermal Process

Systems. We will be happy to discuss your

needs and arrange an on-site visit to

evaluate your situation.

Oxygen Supply

TPS

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Storage Nitrification Denitrification Reactor*(SNDR™)

The importance of producing a high-quality

cake and reducing recycle constituents cannot

be overstated. With the advent of Storage

Nitrification Denitrification Reactor (SNDR™),

thermophilic sludges can be dewatered more

economically, producing a very high-quality

end product. Mesophilic conditioning prior

to dewatering reduces the soluble COD

fraction in the digested biosolids. The SNDR™

provides optimum temperature, pH, alkalinity

and aeration conditions for nitrification and

denitrification of digested biosolids. The SNDR™

improves dewaterability, cake quality and

reduces recycle concentrations.

Nitrification and Denitrification are controlled in

the SNDR™ by monitoring the pH, temperature,

and ORP. Since nitrification is inhibited at

temperatures above 35°C, this reactor is

operated in order to fully optimize the growth

rate of these specialized microorganisms.

pH set points can be used to control the

nitrification and denitrification process by

creating an aerobic or anoxic condition as

warranted. Because a reduction of total alkalinity

accompanies nitrification, the pH of the system

provides an ideal method of control.

Typical variation of ORP and pH in the SNDR™

• Utilizes air cooling to lower the

temperature of the liquid contents.

• Lower temperature and pH provide

the optimum conditions for the

scrubbing action in the headspace

of the tank.

• Provides Nitrifiers and Denitrifiers

in the centrate to continuously

re-seed the activated sludge

basin system.

SNDR™ Advantages• Lower Conditioning CostsReduction in soluble COD, ammonium,

and VFAs in the SNDR™ significantly

reduces the chemical demand for

dewatering operations.

• Lower Nutrient RecycleNitrification and denitrification in the

SNDR™ greatly reduce the ammonium

concentration in the recycle streams.

• Single Reactor SystemNitrification and denitrification is carried

out in a single tank.

• No External Alkalinity RequiredCO2 released during ThermAer™ digestion

generates carbonate and bi-carbonate

alkalinity. When transferred to the SNDR™

this alkalinity is utilized for nitrification,

therefore eliminating the requirement for

any external alkalinity source.

• Simple Control StrategyA Control strategy based on ORP,

temperature and pH controls the overall

process in SNDR.™

• Lower Disposal CostsSNDR™ provides an additional 10-15%

VS reduction in addition to already

high VS destruction in ThermAer.™ The

SNDR™ further reduces the biosolids to

be hauled from the facility.

• Full AutomationAutomation includes automatic waste,

feed, aeration, nitrification and

denitrification. The system can be

operated with minimal assistance.

The SNDR™:• Reduces ammonium and soluble COD

fraction in recycle stream.

• Provides optimum conditions for

nitrification and denitrification in a

single reactor system.

• Provides additional aeration to reduce

the oxidative demand and lowers

odor potential.

• Provides additional 10-15% VSR,

thus reduces sludge mass to be

hauled from the facility.

Quality BiosolidsCake Nutrient Data*Total Nitrogen 1.50%

Organic Nitrogen 1.25%

Phosphorus (P) 1.00%

Potassium (K) 1.50%

Sodium (Na) 0.03%

Calcium (Ca) 1.05%

Magnesium (Mg) 0.15%

BiofiltAer™

Simplicity• Odor control fan

• Primary humidification chamber

• Secondary humidification chamber

• Air redistributors

• Biofiltration chamber

BiofiltAer™ has:• The ability to remove high

ammonia concentrations during

upset conditions.

• No additional requirements

for nutrients.

• Low operating cost.

• Minimal head losses.

• Minimal electrical requirements.

• Low re-acclimation time.

• Inorganic layer for longer media life.

• Root wood media for biological

culture to attach and thrive.

Centrate Data*TSS ~150 mg/L

NH3 as N ~300 mg/L

COD ~2000 mg/L

Phosphorus ~30 mg/L

BOD ~200 mg/L

*Based on the representative sample analyzedfrom Yorkville Bristol Sanitary District

Land application site in Three Rivers, MI

BiofiltAer™ in Brunswick County, NC

BiofiltAer™ odor control unitin Bowling Green, OH.

BiofiltAer™ ensures that noodors are present on site.*Patent Pending

pH-ORP vs Time

6.45

6.5

6.55

6.6

6.65

6.7

6.75

pH

–120

–100

–80

–60

–40

–20

0

pHORP

ORP

TPS

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