Www.toscano.es DUMO Ultralyzer technology to optimize WWTP process DUMO Ultralyzer technology to optimize WWTP process Increasing profits through ultrasonic

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DUMO Ultralyzer technology to optimize WWTP process

Increasing profits through ultrasonic disintegration

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1.About Toscano.

2.Ultrasound science.

3.Ultrasound engineering.

4.Ultrasonic disintegration of biosolids.

5.References.

6.R&D.

7.Conclusions.

Index

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1. About Toscano

• Manufacturer and distributor of water, industry and environmental equipments.

• Development leads to water sector.

• More than 4,000 m2 of installations.

Our company

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1. About Toscano

• R&D. • Agreements with

Universities and Public Administrations.

• High production capacity (smd, robots…).

• Laboratory and testing bench.

… our company

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Experience with DUMO Ultralyzer technology

• Toscano is the designer, manufacturer and provider of DUMO© Ultralyzer technology.

• 11 reference sites have been installed since 2005.

• This year more than 20 projects have been submitted for tender.

1. About Toscano

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2. Ultrasound science

Physics principles: some types of oscillations

Ball on a spring

Pendulum Rotation earth

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Physics principles: waves

The ball starts to oscillate as soon as it is pushed (perturbated).

Pulse

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Oscillation

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In terms of physics a wave is a perturbation that propagates through a medium.

Ball movement over time describes a wave.

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Time

- - - - - - - - - -

A

a = A·sen(ωt) // ω = 2π·f

For one complete oscillation T, the frequence f is the number of oscillations per second, termed as f = T-1

A complete oscillation takes a T time (Period)

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Acoustic waves: types

Ultrasound AcousticInfrasound

20 Hz 20 kHz

• Sound is a wave where excited magnitude is pressure (vertical axis is A = P).

• Ultrasound is a type of acoustic wave where the frequence is higher than 20 kHz (human limit).

• In the same way as sound, ultrasound needs a medium to propagate (wastewater or sludge).

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Ultrasonic waves

• Successive pressures (+) and (-) cause particles movement and wave propagation.

• (A) is the amplitude and determines power (P), (P = E/t, E = mω2A2/2) and intensity I (I = P/S), measured in (W/cm2).

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Ultrasonic Cavitation

• When pressures (+) and (-) take place under frequences about 20 kHz and intensities between 25 and 50 W/cm2, the medium breaks and produces small bubbles.

• This phenomenon is known as Ultrasonic Cavitation.

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2. Ultrasound scienceCreation and implosion of the cavitation bubbles

• Ultrasonic cavitation is the process consisting of bubble creation, growth, and collapse by implosion.

• Cavitation bubbles can reach internal temperatures about 5,000 ºC and pressures about 500 bar.

• These extreme conditions are controlled and used to disintegrate biomass → DUMO Ultralyzer.

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Electrical energy

Piezoelectrical crystal

Ultrasonic wave

3. Ultrasound engineeringHow can we produce ultrasonic waves?

• Piezoelectricity: a pressure wave pushes on the piezoelectric crystal inducing internal crystal vibration, which causes electrical voltage at the crystal surface. This phenomenon is reversible and used to generate ultrasound waves.

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3. Ultrasound engineeringDUMO Ultralyzer parts: GENERATOR

• Transform the inlet electric signal (240 Vac, 50 Hz) into a sinusoidal wave (900 Vrms at 20 kHz).

• Able to adapt automatically to all conditions in order to maintain constant the oscillating unit amplitude.

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3. Ultrasound engineering

Receives electrical signal, transforms into acoustic for transfering to the medium. It has three parts:

• Converter: receives electrical signal and transforms into acoustic.

• Booster: Amplifies the signal.• Sonotrode: Transfers the acoustic

energy to the medium (sludge).

Booster

Converter

Sonotrode

DUMO Ultralyzer parts: OSCILLATING UNIT

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• Inside reactor body acoustic waves impact on the sludge.

• Each standard unit is split into 5 zones corresponding to 5 oscillating units.

DUMO Ultralyzer parts: REACTOR BODY

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3. Ultrasound engineeringTaking advantage of each cavitation zone

• Each split zone is calculated to receive maximum cavitation dosage.

• The effect is optimized through flow movement inside the reactor body.

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3. Ultrasound engineeringMost effective cavitation: horn type sonotrode

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3. Ultrasound engineeringCavitation effect over sonotrode

New sonotrode

Sonotrode after 1.5 to

2 years

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3. Ultrasound engineeringCavitation effect over biomass

• Cavitation causes from deagglomeration up to cell lysis.

• This effect is the basis of the DUMO Ultralyzer technology.

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3. Ultrasound engineeringDUMO Ultralyzer sizing

• Flow rate to treat is about 30 to 50% of the total TWAS.

• Each 5 kW unit can treat up to 30 m3/d (= 1.25 m3/h) of TWAS → 4 kWh/m3.

• Reactor body volume is only 29 litres, which means a real advantage in term of space.

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3. Ultrasound engineeringAn example of common sizing

Consider a typical WwTW with the following parameters:

• Qraw = 1,000 m3/h (Qmax = 1,500 m3/h) → 105 population.

• Primary sludge: 6,000 kg/d @ 10 g/l.• Secondary sludge: 4,250 kg/d @ 6,7 g/l (sludge to sonicate).• Thickener mixed sludge: 10,250 kg/d @ 52 g/l → 195 m3/d.• Anaerobic digester: V = 4,500 m3, HRT = 25 d, VSdeg = 45%.

It is only necessary 5 kW unit for each 200 m3/d of mixed sludge…!!!

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Applications 2º CLARIFIERBIOLOGICAL REACTOR

BLENDED SLUDGE

THICKENED PRIMARY SLUDGE

WAS THICKENER

DIGESTER

• DUMO Ultralyzer works on sludge and water lines.

• Sludge line is for anaerobic digestion(1) and denitrification(2).

• Water line is for bulking & foaming.

TWAS

RAS


(1)

(2)

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4. Ultrasonic disintegration of biosolidsHydrolysis: the limited step in anaerobic digestion

Ultrasonic disintegration is the solution to solve conventional hydrolysis step (8 to 10 days) which takes place in 90 seconds when sonicated.

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4. Ultrasonic disintegration of biosolidsEffect of sonication on sludge water phase

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4. Ultrasonic disintegration of biosolidsDegree of Disintegration: DDCOD

• Centrifugation of the sonicated and non sonicated sludge between 10 and 30 min at 40,000 g.

• Filtration through a 0.45 μm membrane (soluble).• COD measurement.• Reference disintegration is 22 hours at 20 °C with 0.5

molar NaOH (alkaline disintegration).• DDCOD= [ΔCODUS / ΔCODNaOH] * 100 [%].

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4. Ultrasonic disintegration of biosolidsIncrease in anaerobic VS degradation

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4. Ultrasonic disintegration of biosolidsHow much energy is required for an adequate DDCOD?

y = 1.5x

y = 0.9x

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Lleida TWAS

average results for other TWAS samplesLinear (Lleida TWAS)

Linear (average results for other TWAS samples)

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4. Ultrasonic disintegration of biosolidsIncreasing the anaerobic digestion performance

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4. Ultrasonic disintegration of biosolidsOptimum conditions in the anaerobic digester

• WAS thickened between 3 and 6%. (Although it is possible to work from 1% to 9%).

• HRT (Hydraulic Retention Time) ≤ 35 days.• VS degradation (digestion performance) ≤ 50%.• Biogas production ≤ 0,45 Nm3/Kg MVfed.

• Standard costs in biosolids for disposal, energy and polymer purchase.

• The others parameters (pH, Tª, etc…) remain as in the conventional operation.

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4. Ultrasonic disintegration of biosolidsTypical example for a 20 - 25 HRT days digestion

• Increase in VS degradation: 20 - 35%.• Increase in biogas production: 20 - 35%.• Reduction in sludge production: 15 - 30%.• Increase in sludge dewatering: 10 - 20%.• Reduction in sludge viscosity: 40 - 50%.• Complete elimination of the problems associated

with the filamentous micro organisms inside the anaerobic digester.

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4. Ultrasonic disintegration of biosolidsCost - benefit analysis in Shanganagh WWTP (Ireland)

Parameter Unit Conventional Ultrasound Difference

VS - degradation % 46.29 54.96 8.67

Biogas production Nm3/d 4,254 5,076 823

TS digested load ton/d 12.06 10.93 1.13

Polymer cost €/kg 2.99 2.99 0.00

Disposal cost €/ton 75.00 75.00 0.00

Energy purchase €/kWh 0.11 0.11 0.00

Saving in polymer €/year 92,158 83,501 8,656

Saving in disposal €/year 1,501,067 1,246,731 254,336

Saving in energy €/year 341,596 407,665 66,069

TOTAL ULTRASONIC SAVING PER YEAR (€) 329,062

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• Developed know-how allows a highly detailed engineering.

• Predictive analysis.• Mass Balance calculation.• Engineering design.• Start up and

commissioning.• Training.• Service & support.

4. Ultrasonic disintegration of biosolidsThe engineered solution

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MADRID

SEVILLA MALLORCA

BILBAO

MURCIA

BARCELONACIUDAD REAL

5. References

Spanish installations

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Tablada WWTP

• TWAS flow of 100 m3/d.• 2 anaerobic digesters of 3,300 m3

each one.• HRT of 60 days.• Thickened WAS through DAF.• Installation of one 5 kW ultrasound

reactor since 2006 equiped with all necessary peripherals.

5. References

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• DAF air inside TWAS had to be removed for an effective cavitation.

• A de-aeration tank was designed and installed.

5. References

Tablada WWTP

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5. References

Tablada WWTP

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RESULTS

• WWTP works only with one digester.

• HRT reduced over 50%.

• VS degradation improved 14%.

• Dewatering increased 18%.

5. References

Tablada WWTP

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La Gavia WWTP

• TWAS flow of 240 m3/d.• Anaerobic digestion

volume of 14,500 m3.• VS degradation of 41%.• HRT 24 days.• WAS mechanical

thickening.• 10 kW ultrasonic system

installed in 2007.

5. References

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5. References

La Gavia WWTP

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5. References

La Gavia WWTP

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RESULTS (predicted)

• VS degradation increased up to 57.63%.

• Biogas production increased by 20%.

• Dewatering enhancement of 16.5%.

5. References

La Gavia WWTP

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Arriandi WWTP

• Blended sludge flow of 127 m3/d.• 1 anaerobic digester with foaming

problems inside.• VS degradation of

about 46%.• WAS thickening

through DAF.• 3 kW of ultrasound

since 2009.

5. References

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FLOTADOR

SONICADOR

BOMBA ALIMENTACION

CUADRO

ELECTRICO

AGUA DE

LIMPIEZA

EVACUACIÓN

AGUA LIMPIEZA

ALIMENTACION DUMO

SALIDA DUMO

BOMBA

LIMPIEZA

CAMARA DE MEZCLA

(DEPOSITO+AGITADOR)

TRITURADOR

BOMBA DE TRASVASE

5. ReferencesArriandi WWTP

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RESULTS

• Biogas production increased by 28%.

• Dewatering increased by 8%.• Sludge production reduced

over 21%.• No problems associated with

foaming inside the digester.


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Son Servera WWTP

• 1 anaerobic digester with 2,300 m3 of volume.

• TWAS sonication of 30 m3/d, meaning 50% of TWAS flow rate.

• 5 kW reactor installed in 2008.

5. References

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5. ReferencesSon Servera WWTP

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RESULTS

• Increase in VS degradation by 24%.

• Sludge reduction over 14%.

• 13% of enhancement in dewatering.


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Montornés WWTP

• 1 anaerobic digester with 5,000 m3 of volume.

• VS degradation by 42%.

• TWAS flow of 75 m3/d.

• 4 kW reactor installed in 2010.

5. References

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5. ReferencesMontornés WWTP

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RESULTS

• Increase in VS degradation (biogas production) of 20%.

• Sludge reduction over 15%.

• 12% of enhancement in dewatering.


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Tomelloso WWTP

• 2 anaerobic digesters with 7,000 m3 of total volume.

• VS degradation of 45%.

• TWAS flow of 140 m3/d.

• 7 kW system installed in 2011.

5. References

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5. ReferencesTomelloso WWTP

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RESULTS

• Start up and commissioning in November 2011.

• Results forecasted in project (19% of improvement in VS degradation).


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5. ReferencesTerrassa WWTP

• First pilot plant has been installed in Spain for improving denitrification process.

• IFAS (Integrated Fixed Film of Activated sludge) reactor with 4 m3 of capacity was installed.

• SRT between 7 and 10 days.• Flow rate of 16 m3/d.• NO3 to remove about 5 mg/l.

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• Denitrification transforms NO3 in N2.

• It is a reduction process in which facultative bacteria, in anoxic regime, use NO3 as acceptor rather than dissolved Oxigen.

• It is necessary a carbon source readily biodegradable.

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COD "RAS"

TN "RAS"

COD/TN - ration "RAS"• Disintegrated sludge is fantastic carbon source readily biodegradable.

• It is necessary to measure COD/TN releasing after sonication.

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• Enzimatic activity is highly increased after sonication, which means better biodegradability.

• Acceleration in TN and WAS production degradation takes place.

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RESULTS

• 5 mg/l of NO3 (all required) removed with one ultrasound system equiped with 1 kW.

• No external carbon source.• Specific WAS reduction of

25 to 30% (Lysis and Cryptic Growth process induced).

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Arrudas ETE - Brazil

5. References

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5. References

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5. References

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Shanganagh WWTP - Ireland

5. References

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Shanganagh WWTP - Ireland

5. References

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Activities carried out and coming soon…

SPAIN IRELAND PORTUGAL BRASIL ISRAEL

Estiviel Swords* Lamego Arrudas** Jerusalem

North of Seville Greystones ADP Onça Haifa

Villapérez WyG Carbono Eficiente Sabesp Be’er Sheva

Bétera Veolia Ireland SIMARSUL Centroprojekt -

Palomares AECOM Águas do Algarve Sanepar -

WWTP tendered, Company contacted or project studing.

5. References

(*) Just awarded. (**) Expansion works of the plant.

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R&D today is engineering for tomorrow…

6. R&D

• Special DUMO Ultralyzer unit has been designed for this purpose.

• One mobile unit with 2 kW of ultrasound power fully equiped is used for different test and proofs.

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R&D today is engineering for tomorrow…

6. R&D

• Different DUMO Ultralyzer applications have been studied.

• Scientific publications about Dewatering and Disinfection have been carried out.

• Promising results were obtained.

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6. R&D

• It is necessary a wide range of particle size to optimize solid - liquid separation.

• Sonication is a good way to change particle size.

• After sonication water inside flocs and cells is easily delibered.

Dewatering

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6. R&D

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1 2 3

Dried matter test after dewatering (%)

1. Mixture of untreated TWAS and PS*

2. Mixture of sonicated TWAS and PS.

3. Mixture of sonicated and untreated TWAS and PS.

(*) Primary Sludge.

IMPORTANT: do not treat 100% of TWAS

Dewatering

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6. R&D

Digested sludge after floculation Digested sludge after disintegration and floculation

Stereo-microscopic image

Dewatering

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6. R&D

• Disintection depends highly on the suspended solids contain (TSS).

• SS can protect bacteria and virus from the UV irradiation (Scattering).

• That leads to a tremendous increase in UV irradiation.

Disinfection

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6. R&D

• Installation was designed to treat water (not sluge) before disinfection process.

• Only 0.11 kWh/m3 of ultrasound dosage it is necessary to avoid scattering.

Disinfection

Sand filter

UV disinfection channel

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6. R&DDisinfection

Evolution in the Total Coliforms elimination

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7. Conclusions.To sum up

• DUMO Ultralyzer represents an innovative, tested, and sustainable technology for water & environment market.

• The available support allows to get quick advantage of the science and the engineering in a full plug & play project.

• State of the art technolgy, in terms of biosolids disintegration, is now accessible.

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Thank you for your attention

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Www.toscano.es DUMO Ultralyzer technology to optimize WWTP process DUMO Ultralyzer technology to optimize WWTP process Increasing profits through ultrasonic