RECONSTRUCTION OF THE LARGEST DWTP IN THE CZECH REPUBLIC – OZONE

TREATMENT SYSTEM

Radka Hušková1, Jiri Benes2, Philip Page3, Florian Axt4

1. Pražské vodovody a kanalizace, a.s., Praha, Czech Republic

2. DISA, v.o.s, Brno, Czech Republic
3. Statiflo International Ltd, Macclesfield, Cheshire, United Kingdom
4. ITT Water & Wastewater Herford GmbH, Germany

Abstract
This paper is outlining the reconstruction of ozonization unit at the WTP Želivka (Czech Republic)
and describes the way of ozone water mixing, experiences gained in design, start up and operation
of a state of the art ozonization system.

Key-words: Water treatment plant, ozone, ozonization, mixing, dissolving, gas dispersion system

Introduction
The Zelivka water treatment plant (see Figure 1) is the nation’s largest site, completed in 1972,
providing drinking water mainly for Prague. The site is currently serving approx. 73 % of Prague´s
demand for potable water. Also, some regions of Central Bohemia are being supplied with water
from the site. The site is currently operated by PVK, belonging to a VEOLIA Water group.

WTP Želivka – General Site Information

Source of water surface water from reservoir Svihov
Reservoir surface 14.32 km2
Reservoir capacity 266.6 mil. m3
Average depth 18 m
Max. depth 53.6 m
Site capacity max. 7 m3/s
Site capacity average 3.5 m3/s
Population served 1.2 mil. in Prague and approx. 400,000
in greater Prague region
Ozone dose typical 1.0-1.5 mg/l
General raw water quality characteristics see table 1

The treatment process consists of a coagulation step (Al2(SO4)3) and sand filtration, pH
stabilization using lime, followed by post-ozonation. The final treatment step is chlorination. The
finished potable water from WTP Zelivka pumped approx. 52 km into the main reservoir of
Jesenice and then distributed to the end users.
 Figure 1: DWTP Zelivka and reservoir Svihov

Table 1 Basic parameters of raw water for WTP Želivka (average value over year 2010)
Average
Parameter Unit value
Escherichia coli CFU/100ml 1
Coliform bacteria CFU/100ml 2
Alga count cells/ml 370
Total organic carbon mg/l 4.58
Nitrate mg/l 31
Fluoride mg/l 0.11
Al mg/l 0.01
CODMn mg/l 3.69
Chloride mg/l 16.1
Conductivity mS/m 27.2
Mn mg/l 0.05
Pesticides (sum parameter, 29)* ng/l 190.13
pH - 7.35
PAH(sum parameter,6) ng/l 0.87
Sulphates mg/l 33
Na mg/l 11.8
Ca mg/l 25.7
Ca, Mg mmol/l 0.92
Turbidity ZFn 1.01
Fe mg/l 0.04
Absorbance (254 nm) - 0.136
*Main contribution represents Terbuthylazine with max. conc. 150 ng/l
Process description – the old ozone system
The post-ozonation system, initially erected in 1991, consisting of only one ozone generator with a
capacity of 36 kg/hr and three introduction points were used. The air-fed generator supplied ozone
into three separate treatment lines utilizing co-current and counter-current ozone dissolution
chambers with bubble diffusers spaced in the chambers. Each of treatment lines consisted of two
dissolution chambers (counter-current and co-current) followed by an ozone contact basin
providing sufficient contact time for disinfection. The dimensions of the each dissolution chamber
are approx. 15 m (width) x 2.8 (length) x 8 m (depth).
The pressurized ozone gas was introduced by 477 bubble diffusers installed at the bottom of each
dissolution chamber allowing the bubbles rising upwards. The ozone containing off-gas was
treated by three thermal ozone destructors, allowing thermal decomposition of the ozone to
oxygen, and was finally vented to the atmosphere.

The main reasons for the plant upgrade

1. No duty & stand-by ozone generating system. Frequent system shut downs, mainly due to
the necessity for cleaning and repairs of the old ozone generator. This caused serious
problems to the plant operator to assure the proper final water quality without ozone
treatment.
2. Clogging of bubble diffusers. Some had to be replaced, some removed and piping outlets
blended.
3. Different clogging rates causing different ozone transfer efficiencies.
4. Low overall efficiency, at approx. 60 – 65 %
5. Varying ozone dissolution rate in separate treatment lines leading to an unstable final
,especially biological (algae), quality of potable water in the spring period when water in the
dam is mixed due to the increasing temperature caused by ice melting.

A new system – alternatives considered

Several alternatives were considered for a new system proposal. The goal was to set a new
standard by building the most sufficient, technologically sophisticated system and employing state-
of-the-art technologies causing no/minimum civil modifications. A comprehensive process study
was run in order to find out the optimal solution in terms of:
a) Duty only, or duty-standby ozone generator concept
b) Capacity of ozone generator/generators
c) Feed gas for ozone generator/generators options
d) Ozone dissolution technology
e) Key parameters, the new system has to meet
f) Reconstruction process planning, i.e. reconstruction running in parallel with the existing
system in operation, or reconstruction done after a shutdown and removal of existing
system
Different sources of technical information and expertise were used including proposals and studies
done by market leaders in the relevant technologies. Also, a visit to a similar treatment plant in
Germany was organized: This allowed to share the experiences and to determine the “best
practice” solution.
New system specification
Following a lengthy period, in which several studies, cost analysis and proposals were carried out.
The final system configuration was chosen collectively by the owner, trustee and operator of the
WTP Zelivka. The following priorities were applied during the decision making process, before the
final decision was taken:
1. Efficiency of ozone generating process and ozone dissolution process
2. A new system had to be installed with a minimum of civil modifications to the existing site
3. A low system maintenance requirement
 4. Reliability and robustness of system and its components
5. Low investment cost required
6. Low operating cost required
Also, the following pre-conditions needed to be fulfilled:
a) The reconstruction has to be divided into two phases
b) During the first phase (one ozone generator plus two treatment lines) will start as soon as
the existing system will stop and be removed. The duration of the period for installation a
commissioning of this first stage was strictly limited and in fact was given by a historically
gained water quality data. In other words, the season in which site can be operated without
ozone treatment is short and was given to the main contractor as the available time for the
phase one. After this time a new ozone system (phase one) had to be complete, functional
and meeting all the parameters.
c) Second phase (one ozone generator plus one treatment line) will commence as the first
phase scope was complete and fully operational.
The new system incorporates following technologies and components:
Feed gas system
Oxygen from LOX tanks was selected the best option for this application. The main benefits are
shown below, being the best option from a level of user comfort point of view:
elimination of maintenance requirements on dry air-preparation or PSA oxygen preparation
systems
virtually zero maintenance cost are required
elimination of need for investment into dry air-preparation or PSA oxygen preparation
systems
the best option in terms of operation costs per €/kg O3 produced
the solution from a health & safety point of view

Ozone generator system

Two (2) new ozone generators are used, each of capacity at 16 kg O3/hr producing ozone from
oxygen at 12 wt% concentration. The two (2) state-of the-art ITT WEDECO, PDO ozone
generators was selected as the best option available. The main technical parameters are:
Manufacturer ITT Water & Wastewater
Country of origin Germany
Type PDO 1000
HV electrodes used EFFIZON HP®
Feed gas oxygen using LOX tanks
Nominal capacity 16 000 g/hr
Nominal concentration 179 g/Nm3
Turndown ratio 5 – 100 %
Gas flow rate nominal 90 Nm3/hr
Nominal operating power 152 kWh/h
Specific power consumption 9.5 kW/kg ozone produced
HV electrodes guarantee 10 (ten) years of operation
 Figure 2: line up of new WEDECO PDO 1000 ozone generators at Zelivka site

Following possible operation modes had to be considered in control and regulation concept:
a) Generator #1 duty, generator #2 stand-by, or vice versa
b) Both generators running in parallel

Each generator is controlled by an internal PLC with a MODBUS RT connection for data exchange
line enabling communication, control and visualization through the operator panel of central control
system of water site.
Each ozone generator is powered and controlled by its own power supply system (PSU). The PSU
enclosure is providing the required working conditions for all electrical devices of the ozone
generator.
Each generator is equipped with high concentration ozone analyzers and necessary control
devices for fully automatic adjustment of ozone production accordingly to the required ozone dose
and water flow rate.

Ozone distribution
The ozone will be introduced at six (6) individual introduction points. The amounts of ozone
required at each individual point may vary depending on the varying water flow rates. The control is
achieved by six (6) automated gas distribution systems.
The gas distribution system (GDA) works as the peripheral of the ozone generator. This means,
signals from all control devices of GDA are connected to PLC of the ozone system and settings are
then optimized for each introduction point. Also, an internal safety module (to avoid the flooding the
ozone generators with water from injector) is integrated into each GDA system.
 Figure 3 and 4: spacing of introduction points and detail of one WEDECO GDA unit

Ozone dissolution
As noted above, the selection of an ozone dissolution method was one of key aspects of a new
system design. Following thorough studies were undertaken considering the following alternatives:
a) Bubble diffusers
b) In-line radial diffusers
c) Gas dispersion system using static mixers

The STATIFLO gas dispersion system (GDS) was selected as the best option for ozone dissolution
into water.
Throughout the project preparation period, STATIFLO International Ltd., and their Czech distributor
DISA v.o.s have prepared several system proposals with various layouts and arrangements of
pre-dispersion and contacting devices. The main goal was to optimize the design and to optimize
the use of ozone for disinfection process. This allowed meeting the limitations given by the
engineering contractor. The final design of gas dispersion system was able to meet all critical
parameters as requested:
Maximum pressure drop of 100 mm at a peak flow of 1285 l/s
The ozone transfer efficiency at min. 95% based on mass transfer balance inlet and
measured off gas concentration
No civil modifications of dissolution chambers

Each of those six (6) units is bolted against the chamber wall and floor and open at each end. The
vertical and horizontal baffles provided were directing the flow through the contactors. The
ozonated sidestream water is introduced to the centerline of the contactor inlet. One of the
limitations to the design of system was that no new openings could have been provided in the
existing walls of the tanks. The only access into inlet sections for material and people was through
existing DN 1200 pipes. This means, that design and fabrication of contactors had to be done in
segments displaceable through DN 1200 pipes.
Each of six (6) pre dispersion units consists of:
Water pump
Ozone jet pump
Pre-dispersion mixer
Interconnecting pipework and valves,

Figure 5: Layout of 2 GDS systems per one inlet chamber

 Figure 6 : Contactor inlet (one of six)

Figure 7: contactor outlet (one of six)

Ozone destruction
For off-gas treatment as a safety measure, five (5) WEDECO COD ozone destruction systems
were supplied. Each catalytic COD system consists of:
- Catalytic ozone destructor
- Gas extraction fan
- Electrical panel
- Ozone analyzer of in off gas (destructor inlet)
- Ozone analyzer of in off gas (destructor outlet)
- Demister
- Interconnecting piping and cabling
Each unit was fully assembled, instrumented, piped and cabled on a skid.

Figure 9: WEDECO COD (one of five) ozone destructor with off gas ozone analyzers

Testing – old system versus new system in comparisons, measurements results

The first trials were conducted in early 2010. The target of the trials was to verify the efficiency of a
new technology in the light of process parameters required in various operational modes. The most
likely operational mode was tested and a final water quality was checked. Tests results showing
the comparisons between the new system and the old one operated in a comparable time period of
2009 are shown in the attached graphs.
The results obtained came out from the tests performed in the normal operation when verifying
min. and max. ozone doses. The results clearly show higher efficiency of the new system in the
organic matter removal represented by A254, CODMn.

Graph 1: Dependence A254 reduction on ozone dosage

 Graph 2: Dependence CODMn reduction on ozone dosage

The two graphs (1 & 2) above show, that in order to achieve the same effect, with the old ozone
system 30% higher ozone mass would be required.
Certain pesticides in the raw water are a critical raw water quality parameter in a spring time period
of year. Therefore, the attention was paid to their reduction through the efficient use of ozone.
When ozone system had to be shut off, the concentration of pesticides in treated water and raw
water was on the same level.
The data obtained since the beginning of 2010 show a significant effect of a new ozone system on
pesticides reduction (see Graph 3). The reduction efficiency is shown in the graphs attached in
Graph 4.

Graph 3: Dependence sum of pesticides reduction on residual ozone

 Graph 4: Ozone Effect on Terbuthylazine removal during 2010

Graph 5: Dependence of ozone transfer efficiency per line (range 97-99.5%) on required residual ozone
concentration per line (range 0.3-0.4 mg/l O3); : Line 1, 2, 3
Operational cost
The data obtained regarding the electrical energy and oxygen cost demonstrated that a substantial
saving in operational costs can be obtained: 50% savings in specific operation cost per 1 kgO3
produced were achieved.
The site operator is aware of the fact, that the ideal solution specifically for the Zelivka plant would
be a combination of ozone with active carbon filtration. This is not feasible due to the existing
hydraulics of the site. Therefore the site operator is utilizing ozone in a suitable dosage in order to
meet all critical quality parameters of water.

Conclusion
The thorough project preparation and a good cooperation between the owner, trustee, operator,
engineering contractor, mechanical contractor and suppliers, two ozone systems using GDS for
ozone dissolution were successfully installed and started. It is obvious; the design concept realized
is highly reliable and able to meet the strict process parameters in a wide range of operational
modes. The test results indicate the whole process improvement. One of the main benefits is the
high ozone transfer efficiency rate with its positive effect on a finished water quality and operation
cost.
The key thing from an operator (PVK) point of view is, the complete ozone system was
reconstructed before spring period when water in the reservoir Svihov is mixed. It is the state-of-
the-art type of technology and provides desired duty & standby system concept.
The operator would like to thank to all the parties involved in the preparation and realization stage
of the whole DWTP Zelivka ozone system project.