Power Generation and Oxygen Transfer Analyses for Micro Hydro-Turbine Installed in Wastewater Treatment Aeration Tank

This study targets one of the major energy consumers in the U.S. It suggests a new mechanical system that can recover a portion of the energy in Wastewater Treatment Plants (WWTPs). The proposed system entails a hydro-turbine installed above the air diffuser in the aeration tank to extract the water-bubble current's kinetic energy and converts it to electricity. Observing the optimum location of the turbine required multiple experiments where turbine height varies between 35% and 95% (water height percentages above the diffuser), while varying the airflow between 1.42 L/s (3 CFM) and 2.12 L/s (4.5 CFM) with a 0.24 L/s (0.5 CFM) increment. Additionally, three water heights of 38.1 cm (15”), 53.4 cm (21”), and 68.6 cm (27”) were considered to study the influence of the water height. It was noticed that the presence of the system has an adverse effect on the Standard Oxygen Transfer Efficiency (SOTE). Therefore, a small dual-blade propeller was installed right above the diffuser to directly mix the water in the bottom of the tank with the incoming air to enhance the SOTE. The results showed that the maximum reclaimed power was obtained where the hydro-turbine is installed at 65% - 80% above the diffuser. A reduction of up to 7.32% in SOTE was observed when the setup was placed inside the tank compared to the tank alone. The addition of the dual-blade propeller showed an increase in SOTE of 7.27% with a power loss of 6.21%, ensuring the aeration process was at its standards.

Optimizing Power Reclamation of Micro Hydro Turbines in WWTPs Aeration Basins

This study investigates the optimum operating conditions and design configurations that can optimize the power reclaimed by small hydro turbines derived by the rising water-bubble current. The rising current is generated by the compressed air introduced by the diffusers at the bottom of aeration basins of Wastewater Treatment Plants (WWTPs). While optimizing the power production, the standard oxygen transfer efficiency (SOTE) is monitored since it is a significant parameter that cannot be sacrificed in the operation of WWTPs. Using one set of turbine blades, it was found out that the highest velocity is obtained in the upper half of the water column (70% - 80%). In contrast, the lowest velocities were obtained just above the air diffuser and at the water surface. Testing started with using a single turbine (ST) to determine the location of the optimum power reclaimed at each tested airflow (1.18, 1.42, 1.65, and 1.89 L/s). Then using double turbine (DT) and triple turbine (TT) to compare their performance to the ST’s maximum power increased power reclamation. The maximum percentage of increase in power reclamation for DT is 19.59%, while it is 20.24% in the case of TT. At a commonly used airflow in WWTPs (1.42 L/s), the optimum configurations of DTs and TTs were selected to investigate the effect of having the proposed setup on the SOTE. For membrane diffusers, DTs and TTs limited the dispersion of the air bubbles in the tank, therefore, reducing the SOTE (8.3% for DT and 3.7% for the TT). The ceramic and sharp-nub diffusers were also tested versus rubber membrane ones to determine the effect of using the ceramic and sharp-nub diffusers on the power reclamation and SOTE. Ceramic diffusers neither achieve higher power reclamation than the membrane nor increases the SOTE. In contrast, sharp-nub diffusers increase the SOTE for all configurations compared to membranes, but this came into account of power reclamation, where sharp-nub diffusers cause a DT and a TT to produce less power than ST does.

The Changing and Distribution Laws of Oxygen Transfer Efficiency in the Full-Scale IFAS Process

The integrated fixed-film activated sludge (IFAS) process has been widely used in the upgrading of wastewater treatment plants (WWTPs). The oxygen transfer efficiency (αOTE) is of great significance to the design and operation of the IFAS process. The carrier filling ratio (CFR) and aeration type are two critical factors affecting αOTE and standard oxygen transfer efficiency (αSOTE). However, the distribution and changing laws of αOTE and αSOTE in the full-scale IFAS process areunclear. To optimize the operation of a WWTP and to improve the αOTE of the aeration systems, several off-gas tests were conducted under different aeration types and different CFRs. The results show that for the aerobic tank investigated (the ratio of length and width was 8:1), the αOTE and the αSOTE of the middle of the aeration systems were higher than those of the other two sides. However, the reason for the low αOTE at the beginning and the end of the tank may be different. Coarse-bubble aeration systems had a lower αOTE and almost the same oxygenation capacity (αSOTE) as the fine-bubble aeration systems under constant CFR (43%). The average αSOTE (18.7–28.9%) of the hybrid aeration systems increased with increasing CFR (7.7–57.7%), and different locations exhibited different degrees of change. The results reveal the distribution and changing law of the αOTE of aeration systems in the IFAS process, and attention should be paid to the improvement of the OTE of the plug-flow IFAS process.

The Power Reclamation of Utilizing Micro-Hydro Turbines in the Aeration Basins of Wastewater Treatment Plants

Upgrading the aeration basin technology can improve the oxygen transfer efficiency (OTE), while keeping the energy consumption at its minimum level. Therefore, this paper introduces a new idea of installing micro-propeller turbines in the aeration basin of a wastewater treatment plant (WWTP) to extract power from the high-velocity location in the water column. This extracted power can be used to operate a mixer at the top of the membrane to induce the mixing in that region, which will drive the less oxygenated wastewater into the water column. The rest of the extracted power will rotate microturbine rotors for electric power generation. By applying the proposed microturbines to the 13 audited facilities, it was demonstrated to achieve a gross annual energy-savings of 3,836.9 MWh, a gross annual cost-saving of $260,497, and total CO2 emissions that would be reduced by 2,714 metric tons/year. Generally, the addition of the proposed microturbines can save up to 15.7% of the annual plant electricity consumption (1.3–12.8% of the plant annual electricity bills).

Three decades of oxygen transfer tests in clean water in a pilot scale test tank with fine-bubble diffusers and the resulting conclusions for WWTP operation

We summarized the experience from three decades of oxygen transfer testing and aeration research at the Technical University of Darmstadt to validate the oxygen transfer efficiency of modern fine-bubble diffusers. A total of 306 oxygen transfer tests in clean water of 65 different fine-bubble diffusers, carried out in the same test tank under identical test conditions, were analysed and compared with previous results. As a result, we could show that the performance of fine-bubble aeration systems has increased by 17% over the last three decades. Therefore, modern well-designed and operated aeration systems can achieve specific standard oxygen transfer efficiency (SSOTE) values between 8.5 and 9.8% · m−1. Additionally, a comparison of various diffuser types and diffuser densities was done. Based on the new results, an exemplary cost/benefit analysis for a 100,000 PE WWTP shows the calculation of an optimized diffuser density with respect to investment and operating costs.

The influence of the design of the mixing device on the efficiency of mass transfer during pneumo-mechanical aeration of wastewater

Аэрация при очистке сточных вод является самым энергоемким процессом. Затраты на обеспечение биологической очистки кислородом составляют около 60% в структуре себестоимости очистки. Таким образом, эффективность массообмена и снижение расхода воздуха является актуальной задачей для предприятий, которые стремятся повысить экономическую эффективность своей деятельности. Цель данной работы – определить эффективность пневмомеханической системы аэрации с использованием турбинной мешалки и разработанной авторами новой конической мешалки, а также сравнить эффективность диспергирования газа в пневматической и пневмомеханической системах аэрации. В качестве критерия для сравнения выбран показатель SOTE (Standard Oxygen Transfer Efficiency), который является основным технологическим параметром, позволяющим сравнивать эффективность различных аэрационных систем. Второй критерий эффективности – показатель SAE (Standard Aeration Efficiency) – отношение количества растворенного в жидкости кислорода к количеству используемой электроэнергии. В результате проведенных экспериментальных исследований установлено, что коническая мешалка по скорости насыщения воды кислородом работает также эффективно, как и турбинная, потребляя при этом гораздо меньше электроэнергии. С разработкой конического колеса вследствие низкого сопротивления лопастей перемешивание в системе «газ – жидкость» возможно в аппаратах больших размеров, что особенно актуально для аэротенков с небольшой глубиной при биологической очистке сточных вод в условиях, когда эффективность пневматической системы существенно снижается.