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RAUBIOXON PLUS Pipe Aerator

Technical Information 316 TI-E


Technical modifications reserved
Contents Page

1. Areas of application _________________________________________________________________________ 1

2. RAUBIOXON PLUS pipe aerator _______________________________________________________________ 2


2.1 Components 2
2.2 Material property of silicone membrane 2
2.3 Product range 2
2.3.1 Pipe aerator 2
2.3.2 Pipe aerator with non-return valve 2
2.3.3 Pipe aerator with 11/4" internal thread 3
2.4 Marking 3

3. Advantages of RAUBIOXON PLUS pipe aerator __________________________________________________3

4. Accessories ________________________________________________________________________________ 3
4.1 Stainless steel rod 3
4.2 Adaptor for square air distribution pipes 3
4.3 Adaptor for round air distribution pipes 4
4.4 Air distribution pipe (air header) 4
4.4.1 Square air distribution pipe 4
4.4.2 Round air distribution pipe 4
4.5 End cap 5
4.6 Assembly adaptor 5
4.7 Stainless steel clamp 5
4.7.1 Pipe clamp distance 5

5. Delivery make-up ____________________________________________________________________________6

6. Design of aeration system ____________________________________________________________________6


6.1 General 6
6.2 Diagrams 7
6.3 Oxygen transfer tests 7

7. Assembly __________________________________________________________________________________ 8
7.1 General 8
7.1.1 Storage 8
7.1.2 Inspection 8
7.1.3 Preparation for assembly 8
7.2 RAUBIOXON PLUS pipe aerator 8
7.2.1 Positioning of pipe aerator 8
7.2.2 Assembly of the pipe aerators 9
7.2.3 Arrangement of pipe aerator 9

8. Commencement of operation ________________________________________________________________ 10


8.1 Commissioning 10
8.2 Oxygen transfer measurement 10
8.3 Idle time, prior to continuous operation 10

9. Operation __________________________________________________________________________________10
9.1 General 10
9.2 Air supply 10
9.3 Maintenance/cleaning 10
9.4 Warranty 10

10. Project questionnaire _______________________________________________________________________ 11


1. Areas of application

The RAUBIOXON PLUS pipe aerator system was specially developed for fine bubble aeration of municipal
wastewater in biological treatment processes. It can be operated with an airflow rate of between 2 - 12mN3
/h*ma and is suitable for both continuous and intermittent operation.

Refurbishment with RAUBIOXON pipe aerators at Wittenberg STP in 1998

Moreover, RAUBIOXON PLUS pipe aerators have also shown to produce excellent results in the following
industrial applications:

• Food industry such as production of milk, chocolate, starch and meat


• Beverage industry
• Leather processing
• Paper production
• Textile cleaning
• Mineral oil processing

Refurbishment with RAUBIOXON pipe aerators at Nestle Ltd in Spain in 1998

However, RAUBIOXON PLUS pipe aerators are not suitable for industries, which produce wastewater
containing the following types of chemicals:

1. Organic solvents
2. Strong acids
3. Strong alkaline

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2. RAUBIOXON PLUS pipe aerator

RAUBIOXON PLUS is an enhanced version of RAUBIOXON pipe aerator. It comes with a new silicone
rubber membrane, which has a higher tear strength and anti-microbial property.

2.1 Components

RAUBIOXON PLUS pipe aerator comprises a support pipe made of RAU-PP (polypropylene), a membrane
made of RAU-SIK (silicone rubber), which is fixed to the support pipe by two stainless steel clips and an
EPDM seal.

2.2 Material property of silicone membrane

RAUBIOXON PLUS silicone membrane does not contain plasticizer.


It is permanently elastic and therefore does not harden or become
brittle. It is resistant to high temperature. Moreover, it is also suitable
for certain industrial wastewater treatment plants. The patented anti-
microbial property of the silicone rubber membrane inhibits incrustation.
As a result, there is substantial energy saving due to small increase of
back pressure.

Material Properties Standard Unit Value


Shore hardness DIN 53505 Shore A 60 –5
Density DIN 53479 g/cm3 1.19
Tensile strength DIN 53504 SII N/mm2 ‡9
Elongation at break DIN 53504 SII % ‡ 450
Tear strength ASTM-D624B N/mm ‡ 50

2.3 Product range

2.3.1 Pipe aerator


C = 43mm,
D = 63mm

EPDM seal

Article no. Overall length A (mm) Effective length B (mm) Weight (kg)
294702 550 500 0.9
294712 800 750 1.2
294722 1050 1000 1.5

2.3.2 Pipe aerator with non-return valve


C = 43mm,
D = 63mm

Article no. Overall length A (mm) Effective length B (mm) Weight (kg)
291716 550 500 0.9
291726 800 750 1.2
291736 1050 1000 1.5

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2.3.3 Pipe aerator with 11/4" internal thread
D = 63mm

Article no. Overall length A (mm) Effective length B (mm) Weight (kg)
291898 550 500 0.9
291918 800 750 1.2

2.4 Marking

REHAU RAUBIOXON PLUS Brand name


64 x 1.5 Diameter and wall thickness
Date Date of production
Number Production number

3 Advantages of RAUBIOXON PLUS pipe aerator

The advantages of RAUBIOXON PLUS pipe aerator are as follows:

• Permanently elastic RAU-SIK membrane


• High temperature resistance
• No hardening/brittleness
• Low susceptibility to incrustation
• Suitable for industrial wastewater treatment plants
• Suitable for intermittent operation
• High oxygen utilisation
• Bubble size of 1.5 to 2mm at the membrane surface
• Low buoyancy aeration unit
• Self sealing when air supply is cut off
• Quick and robust installation
• Economical conversion of existing systems

4 Accessories

4.1 Stainless steel rod

RAUBIOXON PLUS pipe aerator can be installed easily in pairs. One end of the pipe aerator has a threaded
insert. Two pipe aerators can be connected using a M10 threaded stainless steel rod. Depending on the size
of the air distribution pipe, the following rods are used.

Article no. Threaded rod length (mm) For air distribution pipes
279888 210 80x80x2
279898 230 100x100x3
279908 250 120x120x3

4.2 Adaptor for square air distribution pipes

If the diameter of the opening in the square air distribution pipe is not 45mm, a PVC adaptor ring with
EPDM seal is to be added onto the pipe aerator to ensure that the connection to the air distribution pipe is
tight. Depending on the size of the opening, the following adaptors are used:

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Article no. size of opening (mm)
284550 35
284157 40
240073 50
284560 55
PVC adaptor ring

Flat EPDM seal, art. 248337, is required to be used together with the adaptor, art. 240073 while
EPDM seal, art. 284449 is to be used together with adaptor, art. 284157, 284550 and 284560. With the
addition of such adaptor on each side of the air distribution pipe, the length of the threaded rod has to be
increased by about 20mm.
4.3 Adaptor for round air distribution pipes
To connect the pipe aerator to round air distribution
pipe, a PP adaptor with EPDM seal is required.

Article no. Pipe DN


233511 80
233521 100 Adaptor for round pipe

As a result of using the adaptor, the length of the threaded rod has to be increased follows:

Article no. Threaded rod length (mm) Pipe DN


236684 255 80
236694 275 100

4.4 Air distribution pipe (air header)

There are two types of air distribution pipes, namely square stainless steel pipe, grade 304 or higher
and round uPVC pipes. The air distribution pipes are usually mounted with its centre at a distance of
approximately 200mm from the tank base.

4.4.1 Square air distribution pipe

adaptor for square air distribution pipe

Material: SS 304 (standard)


Dimensions: 80x80x2, 100x100x3, 120x120x3

4.4.2 Round air distribution pipe

adaptor for round air distribution pipe

Material: uPVC
Dimensions: ø90x6.7, ø110x8.2

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4.5 End cap

Should there be a need to install pipe aerator on


one side of the air distribution pipe only, end cap
made of PP, art. 291858 can be used to seal off
the other end.
End cap

4.6 Assembly adaptor

For the assembly of pipe aerator, an assembly


adaptor made of stainless steel, art. 248287 is
required.
Assembly adaptor
4.7 Stainless steel clamp

When uPVC pipes are used as air distribution pipe,


they have to be secured to the tank base using
stainless steel clamps made of SS 304.
Article no. uPVC pipe DN
236704 80
236714 100

Stainless steel clamp


4.7.1 Pipe clamp distance

The distance between pipe clamps varies according to the size and depth of wastewater as shown in
the following 4 charts:

Pipe clamp distance for tank with 3m water depth Pipe clamp distance for tank with 4m water depth
Pipe clamp distance (mm)
Pipe clamp distance (mm)

uPVC pipe PN 16 according to DIN 8061/62 (DN) uPVC pipe PN 16 according to DIN 8061/62 (DN)

Pipe clamp distance for tank with 5m water depth Pipe clamp distance for tank with 6m water depth
Pipe clamp distance (mm)

Pipe clamp distance (mm)

uPVC pipe PN 16 according to DIN 8061/62 (DN) uPVC pipe PN 16 according to DIN 8061/62 (DN)

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5. Delivery make-up

Article no. Effective length (mm) Packing unit (pcs) Carton size (mm)
294702/291716/291898 500 25 375 x 375 x 555
294712/291726/291978 750 25 375 x 375 x 805
294722/291736 1000 25 375 x 375 x1055

6. Design of aeration system

6.1 General

It is the purpose of each design to supply the required amount of oxygen into the wastewater under a
given set of conditions in the most economical way, taking into consideration the investment and
operating cost.

The basis for the design are the aerator characteristic values in clean water, which are based on
standard condition (1013 mbar or 101.3 kPa, 200C). See diagrams 3 and 4.

Through calculation and factors obtained empirically the aerator characteristic values are adjusted to the
actual available conditions.

For example, the wastewater temperature and air pressure are taken into consideration as they
influence the oxygen saturation concentration, increased content on dissolved salts and surface active
substances (Tenside), flow, arrangement and size of the non-aerated zones.

Please contact our technical application department with your specific problem and provide information
by filling up the project questionnaire found in section 10.

Diagram 1 shows the relationship between pressure loss of the pipe aerator and specific air flow rate.
Diagram 2 shows the relationship between pressure loss of the pipe aerator with non-return valve and
specific air flow rate.

6.2 Diagrams

Pressure loss of RAUBIOXON pipe aerator, measured in air


Pressure loss (mbar)

specific air flow rate (mN3/h*ma)

Diagram 1
Pressure loss of RAUBIOXON pipe aerator with non-return valve,
measured in air
Pressure loss (mbar)

specific air flow rate (mN3/h*ma)


Diagram 2

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Specific Oxygen Absorption of RAUBIOXON Pipe Aerator at 3.6m immersion depth

SOA (gO2/mN3m)

Aerator density 10%


Aerator density 20%
Aerator density 30%

Air flow rate (mN3/h*ma)

Diagram 3

Specific Oxygen Absorption (SOA) of RAUBIOXON pipe aerator

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◆ Aerator density 30% airflow rate 8/10mN3/h*m
25
◆ Aerator density 20% airflow rate 8mN3/h*m
24 ◆ ▲ Aerator density 20% airflow rate 10mN3/h*m

23 Aerator density 10% airflow rate 8mN3/h*m


◆ Aerator density 10% airflow rate 10mN3/h*m
22 ▲

SOA (gO2/mN3m)

21

20 ◆

19

18 ◆

17 ▲

16

15

14
3 4 5 6 7 8 9 10 11 12 13

Immersion depth of pipe aerator (m)

Diagram 4

The diagrams for specific oxygen absorption apply to measurements in tank with clean water under
standard conditions with constant area aeration with a tolerance of +/- 10%.

6.3 Oxygen transfer tests

Oxygen transfer ability and yield can often be proven by corresponding tests. The oxygen transfer
measurements are in most cases carried out in clean water according to the absorption method.
Chemicals are added to the water in order to remove all oxygen present in it. Through the aeration
system, oxygen is introduced; the concentration increases from zero up to maximum saturation. Out of
the resulting concentration curve, the oxygen transfer capacity is calculated. By using the output of the
compressor as a reference, the specific energy consumption of the so-called oxygen efficiency is
calculated.

The conduct of transfer measurement in Germany is regulated by the working paper M209 of the
Wastewater Technical Association (ATV). It is, however, necessary for the project owner and supplier

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The conduct of transfer measurement in Germany is regulated by the working paper M209 of the
Wastewater Technical Association (ATV). It is, however, necessary for the project owner and supplier to
agree explicitly on certain parameter such as, for example, the permissible tolerance.
Specific Oxygen Utilization rate
RAUBIOXON pipe aerator

Ribbon aeration
Zonal aeration
Separate mixing
Sheet aeration (foils)

The values apply to universal


aeration with an utilisation density
of 29.7% at an immersion depth
of 3.60m.
Source : Gutachten TH Darmstadt
to agree explicitly on certain parameter such as, for example, the permissible tolerance.

7. Assembly

7.1 General

7.1.1 Storage

The aerators are to be stored in their original packaging, in a dry, ventilated room, in compliance with
DIN 7716.

7.1.2 Inspection

Every pipe aerator, especially the aerator tube, must be checked for damage and tight fixing of the clips.

7.1.3 Preparation for assembly

After the air supply pipe work has been assembled and the air distribution pipes connected to it, the pipe
work should be cleared of other foreign bodies by blowing pressurized air through it for about 10 minutes.
When this has been carried out, the pipe aerator can be assembled to the air distribution pipes. Object
such as stones, pieces of wood etc. are to be removed from the treatment tank.

7.2 RAUBIOXON PLUS pipe aerator

7.2.1 Positioning of pipe aerator

• Square distribution pipe


Holes with ø 45mm (-0/+1mm) are to be made on both sides of the square air distribution pipe so that
the pipe aerators can be fitted.

• Round uPVC pipe


Holes with ø 30mm (-0/+0.5mm) and ø 5.0 (-0/+0.5mm) are to be made along the axis on both sides
of the uPVC pipe as shown below:

These holes must lie on the same axis (maximum deviation – 0.5mm)! The air distribution pipes have to
be adjusted in relation to one another, both horizontally and vertically. Proper function of the pipe aerator
depends on precise positional adjustment.

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7.2.2 Assembly of the pipe aerators

A special adaptor is used for the assembly of the RAUBIOXON


PLUS pipe aerators. It is to be used together with a torque
wrench with 1/2" square bit. A screwdriver with a shaft diameter
of between 5 to 6mm can be placed in the slot in the opposite
pipe aerator so that it does not rotate during tightening of the
Assembly adaptor
pipe aerators.

A pair of RAUBIOXON PLUS pipe aerators can be assembled


as follows:

• The M10 threaded rod is screwed into the female threaded


insert of the pipe aerator until is hand tight (about 1 cm
deep). Lubricants should not be applied onto the sealing
surfaces!
Threaded rod screwed into the pipe
• The two pipe aerators are assembled together using a aerator
torque wrench with the assembly adaptor on one end and
the screwdriver inserted in the slots of the pipe aerator at
the other end.

Note:
The tightening of the pipe aerator cannot be carried out
by holding onto the pipe aerator tube as the pipe aerator
tube will be twisted. This is not permitted!
Assemble with torque wrench
• The pipe aerator is fixed in position by using a screwdriver.
The screwdriver should be held in an upright position.

• The other pipe aerator is to be tightened using a torque


wrench with a torque of 35 Nm.

• Thereafter, the RAUBIOXON PLUS pipe aerator is to be


further tightened until one of the aerator tube groove
appears at the top. The pipe aerator is allowed to be
further tightened by at most half a turn. Align with screwdriver

Note:
An imaginary line between the two aerator-tube
grooves may deviate from the vertical by –10oC.

• If the EPDM seal is not compressed evenly, the tightening


process has to be repeated.

7.2.3 Arrangement of pipe aerator

If RAUBIOXON PLUS pipe aerators 1000mm are used in tanks


of certain geometry, sometimes, as a result of overflowing Positioning of pipe aerator

water, the pipe aerator can start to oscillate. This can result
in negative effects on the entire pipe aerator unit. Therefore,
when designing a layout of RAUBIOXON PLUS pipe aerators
1000mm, the direction of the overflow should be +/-45o to
the long axis of the pipe aerator. This is essential for pipe
aerators 1000mm only but not 500mm and 750mm.

Layout of RAUBIOXON PLUS pipe


aerator 1000mm

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8. Commencement of operation

8.1 Commissioning

A trial of the system should be carried out as soon as possible after fitting, with the tank filled with
clean water. The system should be checked for air tightness, section by section, with a maximum
depth of 20 cm of water above the pipe aerators. Leaks are revealed when, after a brief period, the air
supply is cut off. Air bubbles then rise where the seal is poor (depending on system pressure).
Work that can cause damage to the aerators (such as painting, welding, concrete sealing etc.) must not
be carried out in the area of the treatment tank.

8.2 Oxygen transfer measurement

Prior to taking oxygen transfer readings, the aerating process is to be continued for a period of at
least 48 hours at a specific air flow rate of at least 8mN3/hma in order to ensure that the aerators
function properly. Otherwise, the latest version of the wastewater purification regulations, ATV M209,
apply.

8.3 Idle time, prior to continuous operation

If the aerators are not put into operation immediately following the trial, then the depth of water above the
aerators is to be increased to 1m. This depth of water must be maintained until the equipment is finally
put into operation. Keep an eye on water evaporation. If the aerators heat up due to exposure to
sunshine, the starting torque is to be checked once more prior to putting into operation. If there is frost,
the depth of water above the aerators must be at least 10% of the minus temperature (in metres).
Example: at -200C, water depth above aerators = 2m

9. Operation

9.1 General

Water temperature must be between 5 and 30ºC. Higher temperatures are possible. However, it is
necessary to consult the manufacturer beforehand.

9.2 Air supply

The air supply system has to be free of oil, dust and solvent and must include a filtration system. The air
supply system must comply with local Health and Safety legislation. Dust filters for ambient dust are to
be designed to achieve 90% filtration in conformity with EN 779, filter class G4. Air temperature at inlets
may not exceed 80oC. Higher temperatures may be permitted in consultation with the manufacturer.
The pipe aerator can be operated with an air supply of between 2 - 12mN3/h*ma.

9.3 Maintenance/cleaning

If the treatment tank is drained or the aerator system is pulled up, care is to be taken that the deposits
on the aerator tubes do not dry out, i.e. the aerators are to be immediately cleaned. Dried deposits will
impair aerator performance. Occasionally, there might be process-related deposits, which can be removed
in their initial stages. It is therefore necessary to check for such deposits regularly, right from the start,
and to determine an appropriate cleaning cycle. Mechanical cleaning can be carried out using high
pressure water jet on the pipe aerator, which are covered by about 10cm of water. Also, an air flow rate
of 4 to 5m3N/hma should be applied when cleaning is carried out.

9.4. Warranty

Warranty is given according to our current warranty declaration.

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Authorised Dealer:-

SBS Enviro Concepts


Mumbai: Tel:91.22.27546130 / 91.9373333854;
Delhi: Tel:91.11.1294081688 / 91.9899770124
Email:sbsenviro@gmail.com,sbsenviro1@youtele.com
Web:-www.sbsenviro.com

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