HYPERDIVE Mixing- and Aeration System

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H Y P E R D I V E ®- M i x i n g - a n d

A e r a t i o n S y s t e m

Fluid mechanicallyoptimized

High oxygen input

Excellent mixing

Low energyconsumption

Robust construction

Low maintenance

Easy to install

u m w e l t u n dv e r f a h r e n s t e c h n i k

The growing pollution of our environment is a problem which concerns all of us.

For years water pollution, in particular, has continued to grow in threatening proportions.

Water is turning into a more and more limited resource. As a consequence, forward-looking

technologies are desperately needed for water and wastewater treatment.

With great commitment INVENT is dedicated to the development and implementation

of such technologies, thus creating powerful products which contribute greatly

to the preservation of the water quality of our groundwater, rivers and lakes.

The protection, the preservation and, where necessary, the restoration of our environment

will remain one of the most important tasks of our society in the future.

INVENT takes on responsibility in this field,

with innovative environmental and process engineering.

i n n o v a t i o n f o r n a t u r e

H Y P E R D I V E ®

Submers ib le Mixer/ Aerator

INVENT develops, produces andglobally implements innovativecomponents, systems and processesfor the treatment of water and waste-water.

In water and wastewater treatmentseveral process steps are applied.In combination they form a completesystem.It is important to distinguish betweenphysical, physical/chemical andbiological processes. The biologicalstage represents the heart of theplant. Here carbon and nitrogencompounds are biologically decom-posed. The basis for this process isthe effective mixing and efficienttransfer of oxygen, so that the biolo-gically active bacteria can workeffectively.

INVENT specializes in exactly thisfield and, with its innovativeproducts, is one of the world’sleaders in the area of mixing andaeration technology for the waterand wastewater treatment industry.

In addition to the task of introducing oxygen, it also fulfilsthe important function of mixingand avoiding sedimentation.Due to the mechanical aerationmethod, the oxygen transferperformance is nearly as highin wastewater as it is in pure water.

Leaders inMix ing and Aerat ion

3 out of 4 HYPERDIVE ® Mixing & Aeration Systems at an industrial wwtp in the Netherlands (Oil & Gas Industry)

The HYPERDIVE® Mixing and Aeration

System was developed and opti-mized especially for demandingapplications in municipal andindustrial wastewater treatmentplants. It provides efficient oxygentransfer and optimal mixing duringthe biological stage. Compared toconventional systems, it possessesthe following advantages:


An Overv iew

The Task

The task of mixing and aerationsystems for biological wastewatertreatment is to add large amounts ofoxygen into the wastewater with thelowest possible energy consumption.At the same time, the wastewatershould be intensively mixed so thatthe oxygen concentration and theactivated sludge flocs are alwaysuniformly distributed throughout thecomplete reactor, and sedimentationcan be completely avoided.

For an efficient oxygen supply, airor gas bubbles of optimum size mustbe generated. Only in this way canthe introduced oxygen amounts beused in the best possible way.This optimal bubble size is dependenton the depth at which the air is intro-duced. In order to achieve longretention times of the bubbles in thetank, the air should be introduced atthe greatest possible depth.The generation of bubbles shouldtherefore take place close to the tankbottom rather than at the watersurface.

Even after many years, the aerationperformance is not diminished. Thesystem’s pressure loss remains constantly low.Aerosol development and noiseemission are eliminated.The system can be installed simply and quickly, even in a filled tank.

There are multiple areas ofapplication for the HYPERDIVE

®

Mixing and Aeration System.In principle, it can be used for allaeration tasks, especially in allvariations of the activated sludgeprocess, such as:

For BOD/COD reduction and nitrification in conventional activated sludge plantsIn Membrane Bio Reactor plants(MBR)In Sequencing Batch Reactor plants (SBR)In swing zones with facultativedenitrification/nitrificationIn pure oxygen plantsFor BOD/COD reduction as wellas nitrification in carousel tanks,oxidation ditches or aerated ponds

The areas of application, thefunctionality, the construction andfurther technical details of the HYPER-D IVE

® Mixing and Aeration Systemare described in the followingparagraphs.

1 out of 4 HYPERDIVE ® Mixing & Aeration Systems

at an industrial wwtp in the Netherlands (Oil & GasIndustry)

BOD: Biological oxygen demand

COD: Chemical oxygen demand


An Overv iew

An intensive mixing is highly im-portant for the optimal and safeoperation of an activated sludgeplant. The influence of mixing on thepurification capacity of a plant isquite often underestimated. However,it is easily understandable that - forexample - sedimentation on the tank’sbottom, not only diminishes theavailable reactor volume, but alsorepresents oxygen depression and asource of toxins due to the mostlyanaerobic digestion. Besides reducedperformance, this leads to poorsedimentation qualities of the sludgeflocs in the secondary sedimentationtank.

Poor mixing, however, also leads tooxygen gradients in the activatedsludge tank. This in turn reduces theoxygen supply performance, as thedriving concentration gradient isreduced. Furthermore, such non-homogeneous occurrences create aproblem for the usual single-pointoxygen measurements which areusually located in the upper part ofthe basin, where the oxygen concen-tration tends to be higher than in therest of the basin. All in all, theavailable basin volume is not usedto the maximum.

Ef f i c i ent and re l iab le

To summarize, what is required isa system which fulfils the abovedemands with regard to optimalbubble sizes and homogenousmixing, which furthermore can beused in various applications, and isof sturdy construction and resistantto wear and tear.

Oxygen distribution with insufficient mixing - poorpurification performance

Oxygen distribution with good mixing &homogenization - excellent purification performance


The So lut ion

Schematicrepresentation of the

HYPERDIVE ® Mixing

& Aeration System

air header

The So lut ion

The INVENT HYPERDIVE®-Mixing and

Aeration System is a fluid-mechani-cally optimized mechanical aerationsystem with a hyperboloid-shapedmixer body which is installed closeto the bottom, and a submergeddrive. In contrast to other products,it was developed not only for thepurpose of oxygen input but also forthe purpose of mixing, and is tailor-made especially for carrying out thisdouble task.

The way the hyperboloid mixer/aera-tor functions can be seen in theillustration below. The hyperboloidmixer/aerator is pictured with its threemain components, the submergeddrive, the hyperboloid mixer bodyand the cage/foot construction. It isshown in a typical activated sludgetank, which, depending on the typeof treatment plant, can be rectangularor circular, naturally, other shapes oftank are also possible - for example,carousel tanks or aerated lagoons canbe equipped with the HYPERDIVE

®

Mixing and Aeration System.

The hyperboloid mixer/aeratorrotates close to the bottom and itseight integrated and specially opti-mized motion fins thus produce abottom flow which is directedradially outwards. Particularly atthe bottom, this flow is highlyturbulent and thus effectively whirlsup any deposits. Along the walls,the flow rises upwards and carriesall particles until they are just belowthe water surface. The overall flowwhich forms in the activated sludgetank produces an intensive mixingof the activated sludge.

Highest e f f i c i encythrough opt ima l des ign

drive shaft

micro-vortices hyperboloidmixer-body

motion fins shear finsring sparger

stream lines process air linesubmerged drive


The So lut ion

The oxygen concentration is distributed homogeneously throughout the tank.The activated sludge flocs areoptimally supplied with oxygento their core. (cf. diagram) Thisimproves the sludge quality immensely – especially the sedimentation qualities in thesecondary sedimentation tanks.The activated sludge flocs aredistributed throughout the tank,and sedimentation is eliminated.Production of aerosol and theassociated hygienic and aesthetic problems no longer occur. Protective covers are unnecessary.

During the aeration mode, air orgas is blown under the hyperboloidmixer body. This is realized via aseparate process air line which endsin a specially designed spargersystem under the hyperboloid mixerbody. There the air escapes andmeets the specially shaped undersideof the hyperboloid mixer body, whichis equipped with so-called dispersingtunnels and special shear fins. Asthe hyperboloid mixer body rotates,the air in the dispersing tunnels ismixed intensively with the waste-water and is chopped into finebubbles by the shear fins.The main flow then transports thesefine bubbles radially outwards anddistributes them throughout the wholetank.

In summary, this optimized methodof mechanical aeration with com-bined mixing possesses the followingadvantages:

Optimally sized bubbles are produced and particularly highretention times are achieved, because of the air introductionat the tank bottom and radial distribution.High oxygen transfer andyield levels are therefore achieved.

There is no noise emission.The energy, installation and maintenance costs and thus theoperating costs are reduced toa minimum.The system is absolutely non-clogging, there is no wear of membranes and no increase inloss of pressure.

Anaerobic sludge floc (small amount of active biomass and poor sludge settleability)/ Aerobic sludge floc (largeamount of active biomass and excellent sludge settleability)

active biomass active biomass

inactive biomassinactive biomass

O2 -concentration O2 -concentration

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Des ign and Mater ia l Se lec t ion

Robust and proven

hyperboloidmixer body

foot construction

process air hose

drive unit


As illustrated in the accompanyingexploded drawing, the hyperboloidmixer/aerator is made up of threemain components which are pre-cisely fitted to each other: the sub-merged drive unit, the hyperboloidmixer body and the cage with footconstruction.

Drive unitThe submerged drive sits on top ofthe cage construction and is directlyconnected to the hyperboloid mixerbody via a stainless steel flange.The drive unit consists of a sub-mersible electric motor, a gear-reducer and a mechanical seal.

Only energy-saving and robustmotors, heavy-duty gear-reducersand reliable mechanical seals fromleading manufacturers are used.High service factors are selected forthe gear-reducers and the calculatedbearing life expectancy is more than100,000 hours.ring sparger

cage construction

stainless steel flange

lifting gear



HYPERDIVE ® Mixing & Aeration System ready

for shipment


Cage ConstructionThe cage construction consists ofa heavy base construction with astainless steel cage mounted uponit. The base construction is alwaysmade from a solid steel constructioncoated with epoxy resin. This givesthe HYPERDIVE

® Mixing and AerationSystem the necessary weight toguarantee that it always remains inits position.

Furthermore the base, through itsshape, also supports the developmentof a flow beneath the hyperboloidmixer body which is favourable tothe aeration and mixing process.The stainless steel cage also includesthe air collection and distributioninto the sparger.

Process Air Hose/ SpargerSystemThe process air hose provides theair from the air header outside thebasin to the HYPERDIVE

® Mixing andAeration System. It is connected tothe air manifold which is integratedinto the cage construction. The mani-fold distributes it into the four legs,and from there the air is introducedinto the special sparger system.

Hyperboloid Mixer BodyThe hyperboloid mixer body,developed out of the INVENTlaboratories in accordance with themost up-to-date knowledge of fluidmechanics, is manufactured usinghigh-quality fibre-reinforced plastic.The use of the most modern fibre-reinforced composites makes possiblethe construction of a high-strength,corrosion-resistant and lightcomponent.

The complete hyperboloid mixer notonly produces a favourable flow fieldbut is also absolutely non-cloggingbecause of the optimal shape andthe motion fins, which are seamlesslyintegrated into the mixer body.

Fins are moulded not just on theupper side but also on the undersideof the mixer body. The ones on topserve to transport the fluid, andtherefore the mixing, and those be-low generate the bubbles. We callthis INVENT Double F in Technology®.

The sparger system is made so asto prevent clogging. It is responsiblefor the pre-distribution of the airunder the mixer body. The pressu-rised air, or gas, that is used mustbe supplied from outside by meansof a suitable blower system.


Ins ta l la t ion and Operat ion

Insta l la t ion

The HYPERDIVE®-Mixing and

Aeration System is constructed insuch a way that it can be easily andquickly installed. It is normally de-livered to the construction site in apreassembled state.Depending on the means oftransportation, the client might haveto assemble a few parts before thewhole unit can be installed. Oncethe HYPERDIVE

® Mixing and AerationSystem is fully assembled, a dry runis executed to carry out final checks.After that the HYPERDIVE

® Mixingand Aeration System can be liftedup with a crane and be positionedin the basin without draining thebasin.

1.-2.: Installation of a HYPERDIVE ®

Mixing & Aeration System

3.-5.: Installation of a HYPERDIVE ®

Mixing & Aeration System

Low operat iona l costsdue to low energy consumpt ion

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Ins ta l la t ion and Operat ion

Low maintenance costs

Operat ion

After a short dry run and a checkof the direction of rotation, the hyper-boloid mixer/aerator can startoperating without any further work.It is designed for permanentoperation and does not requireintense maintenance work, exceptfor an occasional inspection of thegear reducer and the mechanicalseal. For this procedure, whichusually has to be executed every 2years, the HYPERDIVE

® Mixing andAeration System is pulled out of thebasin and serviced outside the basinin a dry position.

Graphical representation ofthe 4 different installation steps

HYPERDIVE ® Mixing & Aeration System in

operation in an industrial wwtp in Sweden(Pulp & Paper Industry)

HYPERDIVE ® Mixing & Aeration System

during installation in a municipal wwtpin Middle East


Lay-out and Des ign

Lay-out and Des ignThe lay-out and design of an optimummixing and aeration system is a verycomplex task. It requires a largeamount of competence, know-howand experience.Above all, it is important to considerthe entire system and to understandthe complete process in addition tothe standard parameters, to incor-porate this information, and to inte-grate the aeration system optimallyinto the complete process.

Competent and exper ienced

In the case of industrial plants, forexample in the paper and the petro-chemical industries, it can also beimportant to understand the pro-duction process to a certain degree,because this significantly influencesthe wastewater composition.

INVENT’s approach is to focus on thecustomer and to always try and offerobjectively the best solution. Whenstrictly put into practice this meansnot just offering one single systembut instead selecting from the outsetthe most suitable one for the appli-cation at hand, from a range ofmixing and aeration systems, mem-brane and further aeration systems.The selection of the suitable systemis the first and most important stepin the planning and designing of aplant. If the wrong system is chosen,it inevitably leads to a solution whichis only partially suitable and therebyto a restricted performance of theplant and to increased costs.

Through many years of intensiveresearch and development work inthe field of mixing and aerationtechnology, INVENT has been able todevelop a range of products, whichoptimally cover every application.Therefore you can always rely ongetting the best solution from INVENTand not just the only one available.

Typical characteristics of a HYPERDIVE ®Mixing &

Aeration System

Typical gassed power characteristics

INVENT design engineers


The Laboratory

Cont inous improvementand qua l i ty contro l

The use of a characterization methoddeveloped by INVENT allows us tocharacterize and lay out aerationsystems with just a few measure-ments.These high-level quality controlprocedures provide an assurance ofquality that you should expect fromsuperior products for water andwastewater treatment.

The LaboratoryIn the INVENT laboratories inErlangen, all INVENT products arecontinuously developed and impro-ved. The most modern equipment,measuring methods and analyticaldevices are available for this task.In order to determine fluid mechani-cal parameters, scale models areexamined and optimized with thehelp of laser and ultrasound measu-ring methods. Chemical analyseshelp to examine mixed processeson micro and macro scale.

Standard methods, recommendedby DWA1 or ASCE2 are used to mea-sure the mass transfer.Measuring instruments appropriatefor taking measurements on large-scale plants are available. The„bubble size” - an important para-meter for the lay-out of aerationsystems - is determined with opticalmeasuring methods.

1 DWA: Deutsche Vereinigung für Wasserwirtschaft,

Abwasser und Abfall e. V.2 ASCE: American Society of Civil EngineersQuality control

Oxygen testing in the INVENT Laboratories

H Y P E R C L A S S I C ®H Y P E R D I V E ®

INVENT Products wor ldwide

Chosen references forHyperbolo id Mixer/Aerators

Industrial:

Dow Chemicals,Chemical IndustryDSM, Chemical IndustryQ8 Refinery,Petrochemical IndustryAlpro Milk, Food IndustryArla Foods, Food IndustrySödra Cell, Pulp and Paper IndustrySAPPI, Pulp and Paper IndustryJass Papier, Pulp and Paper IndustryZucchi & Basetti, Textile IndustryMascioni, Textile IndustryDortmunder Union Brauerei, Beverage IndustryRottneros, Paper Industry

Municipal:

Presidente Prudente, BrazilSao José dos Campos, BrazilJabel Ali, U.A.E.Saida, LibanonCaleta Olivia, ArgentinaKA Riedlingen, GermanyKA Isny, GermanyBiomüllvergärung Mühlheiman der Ruhr, Germany

INVENT®, HYPERDIVE® and Doub leF in Techno logy® are registeredtrademarks of INVENT Umwelt- andVerfahrenstechnik AG.

INVENT team meeting

The Serv i ce

How can we support you with theplanning, optimization or moder-nization of your plant, or justgenerally with the realization ofyour ideas? Please ask us aboutit!

In close co-operation with you,the INVENT team will draw up afirst draft and will, if necessary,develop it further together withyou via numerous iterative steps,until all requirements are met.After the order has been placedan experienced team of engineerswill see to it that your project iscarried out on schedule.In accordance with the agreement,we will deliver and install the plantfor you and will also carry out thecommissioning. Our service teamwill reliably take care of allnecessary maintenance work.

Successful worldwide


Further INVENT Products

Profess iona l and innovat ive

Other Productsand Serv i cesINVENT is the market leader formixers, mixing and aeration systems,and membrane aeration systems forthe water and wastewater treatment.Please do not hesitate to ask forinformation about our additionalproduct lines. We would also behappy to offer you complete systemsolutions for your plants, such as acarefully laid-out and adaptedequipment packages. We simulateand optimize your plant with thehelp of appropriate softwarepackages, or else we optimize yourplant or building with regard to fluidmechanics.

We are your specialist partnerfor all questions on water andwastewater treatment.

aerationtechnology

systemsolutions

software-products

research &development

engineering &consulting

Beyond the delivery of componentsand plants, we also offer you generaladvisory and engineering servicesin the field of mixing technology.This can be, for example, the lay-out or optimization of a mixer, orthe experimental examination of astirring tank in a laboratory settingor through numeric simulation.

Furthermore, we carry out large-scaleacceptance tests, whereby usuallythe velocity field, the solid matterconcentration distribution, and theretention time distribution areexamined.

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Middle East Office:INVENT Middle East (FZE)SAIF Office P8-09-07P.O. Box 121720SharjahUnited Arab EmiratesTel: +971 (06) 54 89 139Fax: +971 (06) 54 89 138E-mail: [email protected]

Italy Office:INVENT Aeration Services S.R.L.Via Parravicini 3020052 MonzaItaly Tel: +39 039 2317125Fax: +39 039 2302624E-mail: [email protected]

You can reach us at:

INVENT Umwelt- undVerfahrenstechnik AG

Headquarters:Am Pestalozziring 2191058 ErlangenGermanyTel: +49 (0) 91 31 690 98-0Fax: +49 (0) 91 31 690 98-99E-mail: [email protected]

US Office:INVENT Environmental Technologies, Inc.218 Little Falls RoadUnits 7 & 8Cedar Grove, NJ 07009USATel: +1 973 571 2223Fax: +1 973 571 2474E-mail: [email protected]

Pacific Office:INVENT Pacific Pty. LimitedUnit 3, 1 Trappit PlaceOrange NSWAustralia 2800Tel: +61 408 997 774E-mail: [email protected]

l o c a t i o n s

worldwideA list of our sales partnersabroad is available by requestor on the internet: www.invent-uv.de

Documents

HYPERDIVE Mixing- and Aeration System