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Operation of aeration systems for biological treatment is well documented as requiring the bulk of
energy in wastewater treatment plants (WWTP). Figure 1 shows the electricity requirements for the
primary operation n in an activated sludge facility. Aeration contributes 50
50-70%
70% of the energy
requirements in the plant. With so much of the energy use in a WWTP concentrated at the aeration
system it is a logical target for energy conservation.
Historically aeration systems have been designed with general guidelines of system performance.
For diffused aeration, design criteria of 5.0 to 6.7% per meter (1.52 to 2.05% per foot) has been
applied universally with little considerat
consideration
ion of total cost of ownership (TCO). The following are key
factors in TCO, and may affect the optimized design of an aeration system:
Proper optimization of WWTP operating cost for minimum TCO requires a thorough evaluation of
diffuser system technology and selection of most appropriate diffuser type and diffuser design for
EACH application. General rules of design for diffuser efficiency are no longer acceptable as
thorough analysis results in major savings to the end user.
To date no effective method or easy to apply procedure for integrated aeration system optimization
is available for routine application by design engineers. Process model programs, such as
BioWin, use general rules of design for mechanical performance. They also give no indication to
total operating cost or payback on investments. An aeration system analysis that integrates the
key variables affecting cost can deliver major savings in annual operating costs and savings for
minimum TCO.
EDI has recognized the opportunity for savings for WWTP operation by developing and applying
"rational design" procedures for optimizing total aeration system design. EDI’s Integrated Diffused
Aeration Design Procedures incorporate a 4-phase analysis to develop engineered solutions for
type of diffusers, number of diffusers, and blower sizing.
To perform the optimized design calculations, it is necessary to have process design information
and physical site information. EDI Aeration Design Form provides a summary of many of the
necessary design criteria (Appendix A).
In addition to the project design data, a clear confirmation of factors such as biological treatment
process is required to establish a rational design. The treatment process selected has a major
impact on aeration system optimization. Examples may include the following common treatment
applications:
Note: Proper SOTE performance will incorporate multiple factors influencing performance such as:
1. Standard test conditions. Multiple standards exist, including ASCE and German ATV
standards.
2. Density of diffusers (number of diffusers per area of tank, or membrane area per area of tank).
3. Airflow rate per diffuser.
4. Water depth and diffuser submergence.
5. Type of diffuser platform (Disc, Tube, Panel, StreamLine™).
6. Diffuser Arrangement, such as grid, roll, or other
The initial aeration system optimization calculations begin with a EDI’s Design Brief computation.
This computation uses the project data in Phase I to find the overall oxygen demand in the system.
The second half of the Design Brief uses the diffuser performance found in Phase II to calculate
the airflow requirements and proper diffuser count required in the aeration basin. This calculation
creates one design point of diffuser numbers, one air flow rate/diffuser; and total system air flow.
Output from this initial Design Brief calculation can confirm the basic system feasibility for aeration
to meet O2 demands of the process. Mixing criteria are also established based on the process and
basin geometry. It is now possible to use multiple iterations of Design Brief calculations to
establish an aeration performance envelope for the project.
The Design Brief is the work vehicle used to establish performance profiles for SOTE, air volumes,
and number of diffusers as described below. This set of aeration profiles can be particularly useful
in developing blower sizing, motor and electrical switch gear sizing, plus the basis of future
evaluations of total cost of ownership.
Multiple designs from Phase III (design briefs) can be used to create an SOTE performance profile
when SOTE is plotted versus number of diffuser units. These same multiple designs from Phase
III also allow us to establish the air flow Performance Profile with air volume plotted versus the
number of diffusers. Both curves are typically plotted together as shown in Figure 3. Note:
Curves are independent and they do not show the optimum design point where they
intersect. Separate calculations or evaluations are required to find the optimum total aeration
solution.
1. Range of SOTE or Air Volume design opportunities by changing the quantity of diffuser
applied.
2. Total air volume based on a preliminary selection of operating SOTE or preferred number
of diffusers.
3. Comparison of energy mixing limits (i.e., airflow per basin floor area, or airflow per basin
volume) versus possible operating airflows.
4. Allows selection of energy efficiency to match existing compressor/blower units or size
limits. Also enables sizing blowers to stay within unit Hp (Kw) limits for the site, by
selecting the number of diffusers to deliver the desired air volume.
Note: These performance curves for each diffuser platform are imbedded into the
Proprietary EDI Process Design Brief calculations. If running a separate or manual set of
iterations these SOTE curves must be established or obtained from the diffuser
manufacturer.
A. Create Curve of SOTE % versus number of 9-inch disc units for design diffuser
submergence.
B. Create curve of total air volume versus number of 9-inch discs for process
oxygenation (Note mixing limited cases may need to be reviewed).
C. Compute the energy cost/year based on $10/Kw and assumed blower efficiency of
70% plotted versus number of 9-inch discs.
7. Select optimum diffuser design point to meet the project design objectives (i.e., Select the
number of diffusers).
The integrated aeration system optimization allows the project "Total Cost of Ownership" to be
developed. This incorporates present worth or net present value calculations over the design life of the
project. The cost of ownership calculations again require iterative procedures to create the NPV
"Opportunity" for savings, and is an in-depth analysis beyond the basic diffuser/blower optimization
program shown here.