Report 103
Report 103
Report 103
=
|
|
.
|
\
|
p
P
o
P
i
P
net
P
2
4.3.8 Determination of Calculated Parameters
4.3.8.1 Pressure Calculations
The net operating pressure (P
net
) for the RO systems was calculated according to the following
equation:
(1)
Where,
P
net
= net operating pressure (psi)
P
i
= pressure at the inlet of the pressure vessel (psi)
P
o
= pressure at the outlet of the pressure vessel (psi)
P
p
= permeate pressure
= net osmotic pressure of the feed and permeate (psi)
The integrated averaging factor (IAF) assuming 100 percent salt rejection can be used to estimate
the osmotic pressure as follows:
Where,
f
= osmotic pressure of the feed stream (psi)
IAF = 1.386 (for 50 percent recovery)
For the RO membranes, the following approximate rule of thumb can be used:
- 1,000 mg/L NaCl solution 11.5 psi of osmotic pressure,
- A correlation between NaCl and conductivity can be assumed (1mho of conductivity =
1 mg/L NaCl).
f
IAF t t = A
20
P
ON
OFF ON
Net
Q
t
t t
Q
|
|
.
|
\
|
=
The transmembrane pressure (TMP) for the Kubota MBR provided in this report is the average
driving pressure required to filter water through the upper and lower membrane banks at the
given flow rate plus piping resistance. The TMP of each membrane bank was calculated by
subtracting the dynamic pressure measured during filtration from the static head in the
membrane tank.
TMP= (P
d-upper
+ P
d lower
)/2 P
s
(2)
Where:
P
d-upper
= Dynamic Pressure measured in the upper membrane bank at given flow rate (psi)
P
d-lower
= Dynamic Pressure measured in the lower membrane bank at given flow rate (psi)
P
s
= Static Pressure Measured during Relaxation (psi)
TMP for US Filter MBR System was based on:
TMP= (P
suction
- P
permeate
) (3)
Where:
P
suction
= Pressure measured at point X in membrane tank on the suction side of the
membrane (psi)
P
permeate
= Pressure measured at point X in the membrane tank on the permeate side of
the membrane (psi)
4.3.8.2 Flow Calculations
The net permeate rate for the Mitsubishi, Zenon and Kubota MBR can be calculated using the
equation:
(4)
Where,
Q
NET
= net permeate rate (gpm)
t
ON
= the time the MBR membrane is in production (min)
t
OFF
= the time the MBR membrane is in relaxation (min)
Q
p
= Permeate flow rate (gpm)
Please note: this calculation assumes the loss of flow during cleaning in place (CIP) and
intermittent maintenance cleans is negligible.
21
BP ON
BP ON P
NET
t t
V t Q
Q
+
=
A
Q
J
p
1440
=
( ) 20 0239 . 0
20 @
=
T
e J C J
The US Filter/Jet Tech MBR employed backpulsing to minimize fouling. The net permeate rate
for this system was calculated with the equation:
(5)
Where,
V
BP
= volume of water backpulsed (gallons)
t
BP
= time of backpulse (min)
4.3.8.3 Flux Calculation
The flux of the RO membranes and the MBR membranes can be calculated as follows:
(6)
Where,
J = Membrane flux (gfd)
A = Total membrane surface area (ft
2
)
4.3.8.4 Temperature Correction
Low-pressure membrane fluxes are normally temperature corrected to 20C, and RO membranes
are corrected to 25C. The membrane fluxes for the MBR membranes can be temperature
corrected with the following formula:
(7)
Where,
T = feed water temperature (C)
The RO membranes were temperature corrected according to manufacturers correction factors.
22
Net
SP
P
J
J =
|
|
.
|
\
|
=
f
P
c
c
R 1 100
60
=
NET
Q
V
HRT
4.3.8.5 Specific Flux
The specific flux is the relationship between flux and the net operating pressure. The
relationship is defined by the formula:
(8)
Where,
J
SP
= specific flux (gfd/psi)
Likewise, the temperature-corrected specific flux can be calculated using the temperature
corrected flux.
4.3.8.6 Salt Rejection
The salt rejection for the RO membranes was calculated using the following equation:
(9)
Where,
R = rejection (%)
c
p
= permeate conductivity (mhos)
c
f
= feed conductivity (mhos)
4.3.8.7 Hydraulic Retention Time
The hydraulic retention time (HRT) for the MBR pilot units was calculated using the formula:
(10)
Where,
HRT = Hydraulic retention time (hours)
V = MBR volume (gallons)
23
W W W
R
Q
V
X Q
VX
SRT = =
7
...
7 2 1
7
= = =
+ + +
=
n n n
day
SRT SRT SRT
SRT
4.3.8.8 Sludge Retention Time
The sludge retention time (SRT) is defined as the total mass of activated sludge in the
MBR divided by the mass flow rate of activated sludge being removed. In order to calculate the
SRT of the MBRs, the reactors are treated as an ideal continuously stirred tank reactor (CSTR).
Under this assumption, concentration of activated sludge in the MBR will be the same as the
concentration in the waste stream and the equation will simplify as follows:
(11)
Assuming that XR is equal to X
W
.
Where,
SRT = sludge retention time (days)
X
R
= volatile suspended solids in the reactor (mg/L)
X
W
= volatile suspended solids in the waste stream (mg/L)
Q
W
= waste stream flow rate (gpd)
The seven-day SRT (SRT
7-day
) is calculated by averaging the SRT over 7 previous days as
follows:
(12)
Where,
SRT
7-day
= the 7 day average SRT
N = day
24
1 =
=
NET
R
NET
NET R
Q
Q
Q
Q Q
RR
1 =
=
NET
R
NET
NET membrane R
Q
Q
Q
Q Q
RR
4.3.8.9 Recycle Ratio
The recycle ratio (RR) for MBR systems operating with anoxic and aerobic tanks is defined as
the ratio of the flow of MLSS from the aerobic tank to the anoxic tank, divided by the net
permeate rate. The Kubota MBR was the only MBR system operated with an anoxic and aerobic
tank. During operation of the Kubota MBR, MLSS was pumped from the anoxic tank to the
aerobic tank and returned to the anoxic tank by gravity. Accordingly, only the flow rate from the
anoxic to aerobic tank was recorded. As a result, the RR for Kubota MBR was calculated as
follows:
(13)
Where,
RR = Recycle Ratio
Q
R
= Flow Rate from the anoxic tank (gpm)
Because the US Filter and Zenon MBR systems were equipped with an aerobic tank and separate
membrane tank, the RR was determined as the ratio of the flow rate of MLSS from the
membrane tank to the aerobic tank divided by the net permeate rate. The RR for these two MBR
systems were calculated as follows:
(14)
Where,
RR = Recycle Ratio
Q
R-membrane
= Flow Rate from the membrane tank to the aerobic tank (gpm)
25
4.3.9 Chemical Additions
4.3.9.1 Antiscalant Addition for RO Membranes
In order to control inorganic scaling on the RO membranes an antiscalant product was used
1
.
The antiscalant was added in-line; upstream of the RO membranes at the manufacturers
recommended dosage of 2.0 ppm using a chemical-metering pump
2
.
4.3.9.2 Chloramine Addition for RO Membranes
In order to control biological fouling on the RO membranes, a 1.0 mg/L chloramine residual was
maintained in the MBR effluent during portions of the study. Chloramines were formed in-situ
by dosing free chlorine, followed by ammonia (3.9/1 Cl
2
/NH
4
ratio). The chemicals were added
using chemical metering pumps
3
.
4.3.10 Chemical Cleaning of Membranes
All chemical cleanings were performed in accordance to the manufacturers recommended
protocol. These protocols are provided in Appendix B.
Mitsubishi and Kubota MBR systems were cleaned in-line (CIL) the presence of MLSS by
introducing chemicals to the inside of the membranes through the permeate lines. Chemicals
passed from the inside to the outside of the membranes by gravity.
Zenon and US Filter membranes were cleaned in place (CIP) by first transferring MLSS present
in the membrane tank to the aerobic tank. This allowed for the membranes to be soaked in the
direct presence of chemicals. Maintenance cleans were performed on the Zenon membranes
twice per week using a 250 ppm NaOCl and once per week using 2 percent citric acid solution.
The RO membranes were cleaned using 0.1 percent sodium hydroxide. The chemical solution
was mixed using RO permeate in an external cleaning skid which consisted of a 100 gallon
chemical tank, a heating element and a centrifugal pump. The solution was recycled through the
RO concentrate line back to the membrane cleaning tank at a rate of 4-6 gpm for 1 hour. Next,
the membranes were allowed to soak for 1 hour. Finally, the cleaning solution was completely
drained from the membranes and the system was brought back on-line.
1
King Lee Technologies, Pretreatment Plus 0100, San Diego, CA
2
LMI Milton Roy, Model P121, Acton, MA
3
LMI Milton Roy, Model P121, Acton, MA
26
4.4 Water Quality
4.4.1 On-site water quality analyses
4.4.1.1 Temperature
The temperatures of the aerobic tank of the MBR systems were monitored using in-line
temperature gages and a DO probe
4
, these values were periodically field verified using an
alcohol thermometer. The temperature of the RO influent was determined using an in-line
temperature gauge
5
.
4.4.1.2 pH
A desktop pH meter
6
, was used throughout the study to determine pH of the raw wastewater,
primary effluent, MBR effluent and MLSS. The meter was calibrated daily using a 3 point
calibration with buffers 4, 7, and 10. The calibration was confirmed daily using a laboratory
check standard.
4.4.1.3 Turbidity
The turbidity of the MBR effluents was determined using an on-line turbidimeter
7
. On-line
measurements were periodically verified using a bench top turbidimeter
8
.
4.4.1.4 Silt Density Index (SDI)
Silt density index (SDI) analyses were performed on the MBR effluents using a SDI machine
9
.
The SDI machine filtered water through a disposable 0.45-m filter. The SDI value was
determined by periodic monitoring of the flow rate through the filter, at a constant pressure, over
a 15-minute period.
4
YSI Model 55, Yellow Springs, OH
5
ReoTemp, San Diego, CA
6
Fisher Scientific International Inc. Accumet Research AR15, Hampton NH
7
Hach Co., Model 1720D, Loveland, CO
8
Hach Co, Model 2100N, Loveland, CO
9
Chemetek, FPA-2000, Portland, OR
27
4.4.1.5 UV-254 Absorbency
Samples collected for TOC analysis were also analyzed for UV-254 absorbency using a
spectrophotometer
10
.
4.4.1.6 Conductivity
On-line conductivity of the RO influent and effluent was also monitored using on-line
conductivity meters
11
. Measured values were compared with daily conductivity results from the
laboratory to ensure continued accuracy.
4.4.1.7 Free and Total Chlorine Residual
The total chlorine residual of RO influent was monitored using grab samples and a colorimetric
test kit
12
.
4.4.2 Laboratory Water Quality Analyses
All laboratory water quality analysis were performed at one of the following locations: Point
Loma Laboratory (PL Lab), the City of San Diego Water Quality Laboratory at Alvarado,
Calscience Environmental Laboratories (CEL Lab) or the City of San Diego Marine Micro Lab.
Table 4-4 summarizes the detection limits and methods used for all of the laboratory analyses
that were performed.
4.4.3 Sampling Protocol/Frequency
All water quality samples were collected as grab samples using sample containers provided from
the corresponding laboratory. All samples were transported to the lab in a cooler and were
processed within the allowable holding period. During sampling, sample ports were allowed to
flush before samples were collected. All microbial samples were collected using aseptic
techniques. The sample ports were flamed and flushed before a sample was collected.
4.4.4 Quality Assurance/Quality Control
Appropriate measures were taken at the pilot site in order to attain the highest amount of quality
control and quality assurance. Appendix C contains a technical memorandum documenting the
quality assurance/quality control (QA/QC) that was performed throughout the study.
10
Hach Co., DR/4000U spectrophotometer, Loveland, CO
11
Myron L Company, Series 750
12
Hach Co., Test Kit Model CN-80, Loveland, CO
29
5. Results and Discussion Phase-I: Operation
of New MBR Systems
5.1 MBR Operating Conditions Phase I (Part 1)
During Phase I (Part 1) pilot testing, the US Filter and Kubota MBR systems were operated on
raw wastewater from the PLWTP. The US Filter system was initially operated with an aerobic
tank and membrane tank having a combined HRT of 7.6 hours at a flux of 11.5 gfd (19.8 L/hr-
m2). Later, the operating level of the aerobic tank was lowered and the flux was increased to
14.5 (24.9 L/hr-m2). These changes reduced the combined HRT to 6.0 hours. Throughout Part
1 investigations, US Filter MBR was operated with an average internal recycle ratio (RR) of 6.
A mixed liquor wasting routine was implemented to allow an SRT
7-day
of 9 days and MLSS
concentrations of 912 grams per liter (g/L). The HRT and SRT
7-day
data are presented in Figure
5-1; mixed liquor suspended solids (MLSS) and mixed liquor volatile suspended solids
(MLVSS) concentrations are presented in Figure 5-2. As shown, on several occasions during
Part 1 testing the MLSS measured in aerobic tank dropped below 4,000 mg/L. This was due to a
glitch in the pilot system, which allowed feed water to fill the aerobic tank above the high level
set point. After each occurrence, it was necessary to drain the aerobic tank back to the normal
operating level before bringing the system back on line, effectively wasting the accumulated
solids.
The DO measured in the aerobic tank and system air flow rates are presented in Figure 5-3. The
upper graph shows the DO was consistently between 24 mg/L during the first 1,349 hours (56
days) of operation. Following this period, the membrane flux was increased. This resulted in a
steady decrease in the DO to values < 0.5 mg/L. To avoid anoxic conditions, the flux was
reduced back to 11.5 gfd (19.8 L/hr-m2). Accordingly, the DO in the aerobic tank resumed to
values between 3-5 mg/L. After 2,620 hours (109 days) of operation, the blower on the system
was modified to increase the fine air flow rate to the aerobic tank from 25 to 45 scfm (0.7 to 1.3
m
3
/min). Following this modification, the flux was increased back to 14.5 (24.9 L/hr-m2) and
the DO was maintained between 2-4 mg/L. The increase of fine air flow to the membrane tank is
illustrated in the lower graph of Figure 5-3. Also shown, the coarse air flow to the membrane
tank was steady at 9 scfm for the entire testing period. The DO was reduced again after 4,302
hours
(179 days) of operation when the flux was increased to values ranging from 19-24 gfd
(32.2-40.7 L/hr-m2).
The Kubota MBR was operated with aerobic and anoxic tanks using Type 510 flat sheet
membranes under following conditions: flux= 14.5 gfd (24.9 L/hr-m2); HRT=5.1 hours; RR= 4.
The mixed liquor wasting rate was set to achieve an SRT of 11days and a MLSS concentration
between 12-14 g/L. The HRT and SRT
7-d
values are presented in Figure 5-4. The DO
30
concentrations measured in the aerobic tank are presented in Figure 5-5. As shown, DO in the
aerobic tank was consistently between 1.2 and 2.4 mg/L. The MLSS and MLVSS concentrations
measured in the aerobic tank and the MLVSS wasting rate are presented in Figure 5-6. The
upper graph shows that after 1,670 hours (70 days) of operation, the system was drained
resulting in a significant decrease in the MLSS concentration. As a result, the DO measured in
the aerobic tank increased to 5.4 mg/L. However, as shown in Figure 5-5, the DO gradually
decreased to target of 2 mg/L due to growth of MLSS. After this occurrence, the system was
restarted and the MLSS were allowed to increase to 17.8 g/L. At that time, the daily wasting
schedule was resumed to meet the target MLSS concentration of 12-14 g/L. As shown in the
lower graph, the normal wasting rate required to meet the solids target was between 16-20
kilograms (kg) VSS / day.
5.2 MBR Operating Conditions Phase I (Part 2)
At the end of Part 1 testing, the feed piping to the US Filter and Kubota MBR systems were
modified to supply advanced primary effluent. Next the membranes from each MBR system
were cleaned in accordance to the manufacturers protocol. The RO membranes on the Kubota
MBR RO skid were also cleaned prior to beginning Part 2 testing. Due to the lower organic
content of the advanced primary effluent it was necessary to establish new sludge wasting rates
for each MBR system to maintain the target MLSS during Part 2 testing.
The US Filter MBR system was operated under similar operating conditions as Part 1 testing,
including combined HRT = 6.0 hours; Flux = 14.5 gfd, RR = 6; fine air flow rate = 45 scfm;
coarse air flow rate = 9 scfm and MLSS= 9-12 g/L. However, the mixed liquor wasting rate
required to maintain the target MLSS gave an SRT
7-day
between 30-40 days. The MLSS and
normal sludge wasting rate for Part 1 and Part 2 testing are presented in Figure 5-2. As shown in
the lower graph, the normal sludge wasting necessary to maintain the MLSS between 9-12 g/L
was much less during Part 2 (0.7-2.0 kg VSS/day) than Part 1 (4.0-6.0 kg VSS/day). Also, the
DO during Part 2 was consistently measured to be between 5-7 mg/L. The decreased wasting
rate necessary to maintain target MLSS and the increase in DO are both associated with the
lower organic content of advanced primary effluent as compared to raw wastewater.
The Kubota MBR system was also operated under similar operating conditions as Part 1,
including combined HRT = 5.1 hours; Flux = 14.5 gfd, and RR = 4. However, the target MLSS
was reduced to 9-12 g/L and the mixed liquor wasting rate required to meet this goal resulted in a
SRT of 18 days (9 days Part 1). As shown in Figure 5-5, the DO in the aerobic tank during Part
2 was much higher than Part 1 and ranged from 3.5 5.5 mg/L.
31
5.3 Membrane Performance
5.3.1 MBR Pilot Plants
The membrane performance of the US Filter MBR during Phase I testing is presented in Figure
5-7. As indicated, after 1,182 hours (49 days) of operation, several chlorinated backwashes were
employed to disinfect the permeate piping. This reduced the TMP, measured at 11.5 gfd
(19.8 L/hr-m2), from 1.3 to 0.93 psi (0.09 to 0.06 bar). Over the next 1,438 hours (60 days) of
operation, the TMP increased to 1.62 psi (0.11 bar). As indicated, after 2,620 hours (109 days)
of operation, the permeate flux was increased from 11.5 to 14.5 gfd (19.8 to 24.9 L/hr-m2). This
caused the TMP to increase from 1.62 to 2.14 psi (0.11 to 0.15 bar). After 2,954 hours
(123 days) of operation the system was cleaned using chlorine, which reduced the TMP,
measured at 14.5 gfd, from 3.17 to 2.04 psi (0.22 to 0.14 bar). Post cleaning, the system was
operated for approximately 11 days during which time no fouling was observed. At this time,
the system was cleaned again using both acid and chlorine. This cleaning reduced the TMP from
2.12 to 1.34 psi. Such results indicate that acid was more effective than chlorine in cleaning the
membranes. This is expected due to the presence of ferric chloride in the raw wastewater. In the
presence of alkalinity, ferric chloride undergoes a hydrolysis reaction, which forms ferric
hydroxide causing a red precipitate. When discharging the spent acid solution, it was observed
to have a reddish color indicating ferric chloride. Following the cleaning, the MBR was operated
at 14.5 gfd (24.9 L/hr-m2) for nearly 1,000 hours (42 days), during which time the TMP
increased from 1.34 to 2.7 psi. The system was then cleaned again using acid and chlorine which
reduced the TMP to 0.9 psi. After the cleaning, the system was brought back on line and the flux
was increased to 19-24 gfd. During operation at high flux rates the TMP increased dramatically.
Such results indicate the rate of fouling observed on the US Filter membranes, as measured by
rate of TMP increase, increased with increased flux. This data also suggests the critical flux of
the membrane is 15 gfd. Lastly, during Part 2 testing on advanced primary, the US Filter MBR
system was operated for 1,000 hours (42 days) at 14.5 gfd during which time minimal fouling
was observed. Such results indicate the US Filter system can operate successfully on advanced
primary effluent containing polymer and coagulant residual.
Membrane performance data of the Kubota MBR system measured during Phase I testing is
presented in Figure 5-8. As shown in the upper graph, a sharp increase in TMP was observed
during the initial 788 hour (33 days) of operation following the start up period. During this time
the TMP increased from 1.38 psi (.095 bar) to 5.76 psi (0.4 bar). The manufacturer was notified
and recommended the bottom membrane bank be immediately taken offline to avoid damaging
the membranes. As indicated, this reduced the TMP to 2.52 psi (0.17 bar). Shortly thereafter,
the manufacturer sent field technicians to the pilot site to assess the cause of the fouling.
Accordingly, both membrane banks were removed from the system for observation. Visual
inspection revealed that the flat sheet membranes were covered with reddish-orange precipitate,
indicating the presence of ferric hydroxide. A photograph taken during the inspection is
provided in Appendix D. In addition, the inch permeate line originally used on the pilot unit
was replaced with 2 inch line which is used in standard design of full scale Kubota MBR
systems. It is believed the inch piping may have resulted in flow restriction which increased
the pressure loss on the permeate side of the membranes. The membrane cassettes were replaced
and the membranes were cleaned using chlorine and acid before bringing the system back in
32
service. As shown, following the cleaning, the Kubota MBR operated for over 2,000 hours
(83 days) at a flux of 15 gfd (25.41 L/hr-m2) with a TMP between 1-3 psi (.07-0.21 bar) with
little or no membrane fouling. During Part 2 testing on advanced primary, the Kubota system
was operated for 1,800 hours (75 days) at 15 gfd (25.41 L/hr-m2) during which time TMP was
between 1-2 psi (.07-0.14 bar) with no fouling observed. Such results indicate the Kubota MBR
system can operate successfully on advanced primary effluent containing polymer and coagulant
residual.
5.3.2 RO Pilot Unit
The performance of the Saehan RE 4040 BL RO membranes operating at 10 gfd (16.7 L/hr-m2)
and 50 percent recovery on Kubota MBR effluent is shown in Figure 5-9. As shown, during the
first 252 hours (10.5 days) the system was operated at 12.4 gfd (21 L/hr-m2). However, in order
to simultaneously operate two membrane trains, it was necessary to reduce the flux to 10 gfd
(16.7 L/hr-m2) due to limitations on the quantity of available feed water. During the next
500 hours of operation the net operating pressure increased from 44.6 to 57.5 psi (3.1 to 4.0 bar)
indicating the membranes had fouled. At that time, the membranes were cleaned according to
the manufacturers recommendation using 0.1 percent sodium hydroxide (pH 13). The cleaning
was very effective; reducing the net operating pressure to 34.8 psi at 10 gfd. A similar fouling
trend was observed over the next 300 hours (12.5 days) as the net operating pressure increased to
49.0 psi (3.4 bar). The membranes were cleaned again which reduced the net operating pressure
to 37.7 psi. Prior to this cleaning, the pre-filters on the RO skid were removed from the system
for inspection. It was observed that the pre-filters had undergone a severe discoloration due to
an excessive amount of algae growth, which occurred in the Kubota MBR permeate. A photo
showing the used pre-filters and a new pre-filter is provided in Appendix D. As a result, two
steps were taken to prevent the algae growth in the RO feed water: First, the clear storage tank
and permeate piping of the Kubota MBR system were replaced with opaque material to block
sunlight. Secondly, a dosing pump was installed to allow for the addition of 1-2 mg/L
chloramine to the feed water prior to reaching the RO membranes; prior to this a low pressure
UV system was used as pretreatment. After the changes, the system was cleaned and put in
service at run hour 1,150. As shown, the system operated for over 818 hours (34 days) during
which time the net operating pressure increased from 37.7 to 50 psi indicating chloramine
addition was successful in mitigating RO membrane fouling. The membranes were then cleaned
one last time prior to Part 2 testing. The net operating pressure increased from 37.2 to 46.7 psi
over 700 hours (29.1 days) of operation on Kubota MBR effluent produced from advanced
primary effluent.
The performance data of the Hydranautics LFC3 RO membrane operating on Kubota MBR
permeate at 50 percent recovery during Phase I testing is shown in Figure 5-10. As shown
during Part 1 testing, the flux was reduced to 10 gfd after 24 hours (1 day) of operation, which
lowered the net operating pressure to 112.5 psi (7.8 bar). The net operating pressure remained
constant for the next 539 hours (22.5 days) of operation. However, over the next 217 hours
(9 days) of operation the pressure increased sharply resulting in a final net operating pressure of
188 psi (13 bar). Following the changes described above to reduce algae growth, the LFC3
operated for over 800 hours (33 days) during which time the net operating pressure only
increased slightly (113 psi to 131 psi). Lastly, during Part 2 testing the LFC3 operated for over
700 hours with minimal fouling.
33
5.4 Water Quality
5.4.1 Raw Wastewater
The results of raw wastewater grab sample analyses conducted by the Point Loma Satellite and
Alvarado Water Treatment Facility Laboratories are presented in Table 5-1. The values shown
are typical of municipal wastewater.
5.4.2 Advanced Primary Effluent
The results of the advanced primary effluent wastewater grab sample analyses conducted by the
Point Loma Satellite and Alvarado Water Treatment Facility Laboratories are presented in Table
5-2.
5.4.3 MBR Pilot Systems
5.4.3.1 Turbidity and Silt Density Index (SDI)
The US Filter MBR effluent on-line turbidity data is provided in Figure 5-11. During Part 1 the
raw wastewater turbidity was between 58-210 NTU. The MBR effluent ranged from
0.01 to 0.12 NTU with average value of 0.03 NTU. During Part 2, the advanced primary effluent
turbidity ranged from 36-130 NTU. MBR effluent ranged from 0.02 to 0.06 NTU with average
value of 0.05 NTU.
The Kubota MBR effluent on-line turbidity data is provided in Figure 5-12. During Part 1, the
raw wastewater turbidity was between 58-210 NTU. The Kubota MBR effluent ranged from
0.05 to 0.13 NTU with average value of 0.08 NTU. During Part 2, the advanced primary effluent
turbidity raged from 36-130 NTU. MBR effluent ranged from 0.06 to 0.13 NTU with average
value of 0.08 NTU. Kubota MBR SDI values measured during Phase I ranged from 0.9-1.1.
5.4.3.2 BOD
5
, COD and TOC
The five-day biochemical oxygen demand (BOD
5
), COD and TOC values for raw wastewater,
advanced primary effluent and the US Filter MBR effluent are shown in Figure 5-13. The
median value of BOD
5
, COD and TOC measured in the raw wastewater was 213 mg/L, 463
mg/L and 40 mg/L, respectively. The organic content of the advanced primary effluent was
significantly lower with median values of BOD
5
and COD measuring 97 mg/L and 216 mg/L,
respectively. The BOD
5
of the US filter effluent was < 2 mg/L for all samples; except at 768
hours of operation when BOD
5
was measured to be 6.7 mg/L. All US Filter MBR effluent TOC
samples were < 10 mg/L and the majority of COD samples measured by the Point Loma Satellite
Lab were < 50 mg/L. Previous studies indicate MBR effluent COD < 20 mg/L. As a result, on
several occasions COD samples were sent to a commercial lab for analysis. The results showed
the average COD in US Filter MBR effluent was 21 mg/L. The discrepancy in COD results
maybe due to the presence of chloride which can elevate results.
34
The BOD
5
, COD and TOC values for raw wastewater, advanced primary effluent and the Kubota
MBR permeate are shown in Figure 5-14. The BOD
5
of the Kubota MBR effluent was 2 mg/L
for all samples. All Kubota MBR effluent TOC samples were < 10 mg/L and the majority of
COD samples measured by the Point Loma Satellite Lab were < 55 mg/L. The average value of
COD measured by Calscience Laboratories was 15 mg/L.
5.4.3.3 Biological Nutrient Removal
The inorganic nitrogen results including ammonia, nitrate/nitrite and nitrite from the raw
wastewater, advanced primary effluent and US Filter MBR effluent are shown in
Figure 5-15. As shown, the NH
3
-N content of the raw wastewater and advanced primary effluent
were essentially the same with an average value of 27 mg/L. All of the US Filter MBR effluent
samples measured for NH
3
-N during the study were < 2 mg/L with many values below the
detection limit of 0.2 mg/L. Also, the (NO
3
/NO
2
)-N of MBR effluent was consistently above
20 mg/L. Such results indicate the system was completely nitrifying throughout the testing.
Figure 5-17 shows Ortho-phosphate as phosphorus (PO
4
-P) results for analyses conducted on the
raw wastewater, advanced primary effluent and US Filter MBR effluent. As shown, the Ortho-
phosphate (PO
4
) content of the raw wastewater and advanced primary effluent was very low with
values measuring between 0.054- 2.24 mg/L. The US Filter permeate PO
4
ranged from 0.12-
0.65 mg/L. Because the US Filter system was only operating with an aerobic zone it was not
possible for BPR (biological phosphorus removal) to occur.
The inorganic nitrogen results for the Kubota MBR system are shown in Figure 5-16. As shown,
during Part 1, the Kubota MBR successfully removed ammonia, nitrate and nitrite to values
< 1 mg/L N. Such results indicate the system was fully nitrifying and denitrifying during this
time period. However, during Part 2 testing the amount of NO
3
/NO
2
in the Kubota effluent
increased. For example, during Part 1 all values were < 1 mg/L but during Part 2 values ranged
from 3.4 6.8 mg/L. Such results indicate that denitrification was decreased during operation on
advanced primary effluent. This observation is believed to have resulted from excess DO in the
MBR system due to the lower organic content of the advanced primary effluent. During Part 2
testing, the minimum air required for membrane scouring resulted in DO measured in the aerobic
to be between 3-5 mg/L. Introduction of DO into the anoxic zone would slow down the
denitrification process. Figure 5-18 shows PO-P results for analyses conducted on the Kubota
MBR system. During Part 1, the majority of the feed wastewater samples ranged from
0.2 1.5 mg/L, while the Kubota effluent was consistently below 0.1 mg/L. These results
indicate BPR was occurring in the anoxic zone of the Kubota MBR system. However, during
Part 2 the PO
4
in the Kubota effluent increased to values ranging from 0.2-0.4 indicating a
decline in BPR. The decrease in BPR is directly related to the partial loss of denitrification also
observed during Part 2 testing. The presence of NO
3
in the anoxic tank created an anoxic
environment that was not conducive to BPR.
35
5.4.3.4 Total Coliform, Fecal Coliform, Total Coliphage
The results of total coliform, fecal coliform and total coliphage analyses conducted on the feed
wastewater and US Filter MBR effluent are presented in Figure 5-19. Initial results from Part 1
testing showed total and fecal coliform rejections (3-5 log) were obtained with total coliform
permeate levels (MPN/100 ml) ranging from 230 to 3,000 and fecal coliform permeate levels
(MPN/100 ml) ranging from 22 to 230. However, after 1700 hours of operation, higher total and
fecal coliform rejections (4-7 log) were achieved, with total coliform permeate levels ranging
from 2 to 240 MPN/100 ml and fecal coliform permeate levels below 10 MPN/100 ml. The
enhanced removal may be due to pore plugging of a portion of the larger pores within the
membrane pore size distribution. Lastly, the US Filter MBR obtained 3-4 log rejection of natural
coliphage throughout the testing period.
Several measures were taken during the study to determine the cause of high total and fecal
coliform counts measured in the US filter MBR effluent. These included: disinfecting the
permeate side of the membrane, replacing the permeate sample location; taking samples at
different times in the filtration cycle and taking samples just after cleaning the membranes.
Overall, results showed that total and fecal counts were higher in samples taken just after a
backwash and just following a membrane cleaning. A possible explanation of the results
follows. First, the permeate piping became contaminated during backwashing due to the
presence of algae and bacterial growth which occurred in the permeate storage tank. Second,
cleaning the membranes removed the dynamic layer formed on the membrane surface, reducing
the sieving ability of the membranes.
The results of total coliform, fecal coliform and total coliphage analyses conducted on the
Kubota MBR system are presented in Figure 5-20. As indicated, samples were analyzed from
both the upper and lower membrane cassettes. Total and fecal coliform rejections (5-7 log) were
obtained with most permeate levels at or below the detection limit (2.2 MPN/100 ml). In
addition, significant rejections (3-5) of total coliphage virus were also obtained by the Kubota
MBR system.
5.4.3.5 Other Water Quality Parameters
The results of the US Filter MBR system analyzed by the Point Loma Satellite and Alvarado
Water Treatment Facility Laboratories during Part 1 and Part 2 testing are presented in
Tables 5-3 and 5-4, respectively. Laboratory results for the Kubota MBR system are presented
in Tables 5-5 and 5-6, respectively.
5.4.4 RO Pilot Unit
5.4.4.1 Inorganic Nitrogen and Ortho-Phosphate Removal
The Saehan 4040 BL RO feed and permeate inorganic nitrogen species are shown in Figure 5-21.
The RO permeate NH
3
-N values were all below 0.3 mg/L with many values below detection; the
NO
3
-N values were between 0.1 and 1.9 mg/L; and the NO
2
-N values ranged from 0.006 to
0.021 mg/L with many values below detection. Ortho-phosphate measured in the Saehan RO
36
feed and permeate is shown in Figure 5-22. All PO
4
measurements in the RO permeate were
below 0.03 mg-P/L with majority below the detection limit of 0.02 mg-P/L.
The Hydranautics LFC3 RO feed and permeate inorganic nitrogen species are shown in
Figure 5-23. The RO permeate NH
3
-N values were all below 0.3 mg/L with many values
below detection; the NO
3
-N values were between 0.1 and 0.8 mg/L; and the NO
2
-N values
ranged from 0.005-0.019 mg/L with many values below detection. Ortho-phosphate
measurements in the LFC3 RO permeate are shown in Figure 5-24. All PO
4
measurements in
the RO permeate were below 0.04 mg-P/L with majority below the detection limit of 0.02 mg-
P/L.
5.4.4.2 TOC Removal
All TOC measurements in the effluent of the Saehan 4040 BL and Hydranautics LFC3 RO
membranes were below detection of 0.5 mg/L.
5.4.4.3 Salt Rejection
The conductivity measured in the feed and Saehan RO permeate is provided in Figure 5-25. The
Saehan RO membranes achieved greater than 96 percent reduction in conductivity throughout
the testing.
The conductivity measured in the feed and Hydranautics LFC-3 RO permeate is provided in
Figure 5-26. The LFC-3 RO membranes achieved greater than 98 percent reduction in
conductivity throughout the testing.
5.4.4.4 Other Water Quality Parameters
The results of the Kubota Saehan RO samples analyzed by the Point Loma Satellite and
Alvarado Water Treatment Facility Laboratories are presented in Table 5-7. Laboratory results
for the Kubota Hydranautics RO pilot unit can be found in Table 5-8.
37
6. Results and Discussion- Phase II:
Optimization of MBR Systems
6.1 MBR Operating Conditions
Upon completion of Phase I testing, the Kubota and US Filter MBR systems were
decommissioned and removed from the pilot site. Next, the site was completely cleared and
prepared to accommodate the Zenon and Mitsubishi MBR pilot systems. Representatives from
each manufacturer came to the site to commission their MBR systems and assist the project team
in preparing hydraulic and electrical connections. Past research by the project team
demonstrated that the Zenon and Mitsubishi MBR systems could operate successfully on raw
municipal wastewater (Adham et al., 2000). Therefore, during Phase II testing, both systems
were connected to receive advanced primary effluent to assess the affect of polymer and
coagulant addition on their performance. Furthermore, the project team worked closely with
Zenon, the current market leader in MBR technology, to test their system under extreme
operating conditions. Both systems were seeded using activated sludge from the nearby South
Bay Water Reclamation Plant (SBWRP). During start up, the systems were operated without
wasting to allow the MLSS to increase to target values of 10-12 g/L, the operation goal. At this
time, a daily wasting routine was implemented to maintain the MLSS concentration in the
aeration tanks.
Zenon. The Zenon MBR system was operated with an aerobic tank and ZenoGem tank having a
combined HRT of 2 hours at a flux of 22 gfd (37.3 L/hr-m2). The ZW 500 d membrane was
operated with a 10 minutesfiltration cycle, followed by a 30 s relaxation period. Maintenance
cleans were performed three times per week (2/week, 250 mg/L-NaOCl, 1/week, citric acid-2
percent). A mixed liquor wasting routine was implemented to give an SRT 7-d of 18-21 days
and MLSS concentration of 1012 g/L.
HRT and SRT 7-d data are presented in Figure 6-1. The Zenon MBR concentrations of MLSS
and MLVSS are presented in Figure 6-2. As indicated, after 2,300 hours of operation the MLSS
concentration decreased from 10.7 to 3.3 g/L. This occurred due to failure of the wasting valve
on the pilot system. The valve was repaired and the system was re-seeded with a fresh batch of
MLSS of approximately 5.0 g/L from the SBWRP. As shown, the MLSS reached the target
10-12 g/L shortly thereafter. As presented in Figure 6-2, the normal sludge-wasting rate required
to maintain the target solids concentration was 2-3 kg VSS/day. The course bubble aeration in
the ZenoGem tank was operated at 21 scfm (0.6 m3/min) intermittently (10 s on, 10 s off). The
aerobic tank air flow rate was constant at 56 scfm (1.6 m3/min). The DO measured in the
aerobic tank is presented in Figure 6-3. As shown during stable operation the DO was between
0.5 to 1.5 mg/L.
38
Mitsubishi. The Mitsubishi MBR system was initially operated with an aerobic tank having a
HRT of 3.5 hours at a flux of 11.8 gfd (20 L/hr-m2). Later, the flux was increased to 14.7 gfd
(24.9), which reduced the HRT to 2.8 h. The Mitsubishi Sterapore HF membrane was operated
with a 12 minutes filtration cycle, followed by a 2-minute relaxation period; air stayed on during
relax. Mixed liquor was wasted daily to give an SRT 7-d of 25-37 days and MLSS concentration
of 1115 g/L. HRT and SRT 7-d data are presented in Figure 6-4. The Mitsubishi MBR
concentrations of MLSS and MLVSS are presented in Figure 6-5.
As shown, the MLSS was allowed to increase from 3.6 to 12.9 g/L during start up. After
2,352 hours of operation, the MLSS were severely diluted resulting in a decrease in
concentration from 10.3 to 2.2 g/L. The MLSS dilution occurred during an attempt to control
foam using a spray nozzle attached near the overflow of the aeration tank. Lastly at 2,568 hours
of operation the blower on the system failed and the system was shut off. During the down time,
the solids in the aeration tank received no air and therefore went anoxic. A new blower was
installed and the system was re-seeded and brought back online at 3,000 hours of operation.
The total and fine air flow rate provided to the aerobic tank is provided in Figure 6-6. Initially,
the system was only operated with coarse air bubble aeration at a rate of 45 scfm (1.3 m
3
/min).
However, as the flux was increased, the DO in the aerobic tank dropped below values conducive
for nitrification. Several modifications were made to the aeration system to combat the low DO
levels. First, at 489 hours of operation an in-line check valve was removed from the blower
which increased the air flow to 52 scfm (1.5 m
3
/min). Second, after 650 hours of operation, the
blower was modified which further increased the air flow to 67 scfm (1.9 m
3
/min). Lastly, after
1,447 hours of operation fine bubble diffusers were added to the aeration tank. The fine bubble
air flow rate was set between 10-16 scfm (0.28-0.45 m
3
/min) for the remainder of the testing.
The DO measured in the aerobic tank is provided in Figure 6-7. During steady periods of
operation the DO was maintained around 0.5 mg/L (with coarse air only) and 1-2 mg/L (with
coarse and fine air).
6.2 Membrane Performance
6.2.1 MBR Pilot Plants
Zenon. The membrane performance data from the Zenon MBR system is presented in
Figure 6-8. As indicated at 674 hours of operation, the variable frequency drive (VFD)
controlling the influent feed pump failed. Over the next 150 hours of operation the overall
vacuum pressure increased from 1.0 (0.069 bar) to 3.3 psi (0.23 bar). This sharp increase in
vacuum pressure resulted from the system being operated with no input of feed water. As
filtration continued, the operating HRT decreased with the level in the aerobic tank. Eventually,
the DO in the aerobic tank became insufficient for biological oxidation of organic material to
occur which caused membrane fouling. At 800 hours (33 days) of operation, the membranes
were cleaned using acid and chlorine. The cleaning reduced the overall vacuum pressure from
3.3 to 1.9 psi
(0.23 to 0.13 bar). During the next operational period the VFD continued to fail; resulting in
unstable operation and continued membrane fouling. It should be noted that during this time
period the on-site engineer worked with a representative from Zenon to change the settings on
the VFD in hopes of correcting the problem. It was finally decided to remove the VFD from the
39
system and operate using a constant feed pump, controlled by level sensors placed in the aerobic
tank. At this time, a representative from Zenon came to the site to make appropriate changes to
the system to allow such operation.
A membrane cleaning was performed again at 1,350 hours (56 days) of operation which reduced
the overall vacuum pressure from 7.5 to 2.3 psi (0.52 to 0.16 bar). The system was then placed
in operation at a flux of 22 gfd (37.3 L/hr-m2) and HRT of 2 hours. As shown, the overall
vacuum pressure remained near 2.5 psi (0.17 bar) for nearly 550 hours (23 days) of operation.
However, at 1,850 hours of operation nitrification was partially lost; which caused the overall
vacuum pressure to quickly increase from 2.5 to 9.5 psi (0.17 to 0.66 bar). Based on discussions
with Zenon, it was determined that the decrease in nitrification and subsequent membrane
fouling may have resulted from a low, operating food to microorganism ratio (F/M ratio). The
manufacturer recommended increasing the MLSS in the aeration to approximately 11 g/L to
maintain F/M ratio < 0.4 day -1. The system was cleaned again at time of operation 1,950 hours
and placed back into operation. As previously explained the mixed liquor was diluted at 2,350
hours of operation. The system was cleaned again after 2,450 hours of operation which reduced
the overall vacuum pressure to 1.8 psi (0.12 bar). Post cleaning, the system was brought back on
line at flux of 17 gfd
(28.8 L/hr-m2). At 2,639 hours of operation the flux was increased to 22 gfd (37.3 L/hr-m2) and
HRT of 2 h. The 500 d membrane was operated for over 1,800 hours (75 days) at these
conditions during which time the overall vacuum pressure only increased from 1.3 (0.09 bar) to
3.0 psi (0.21 bar).
Mitsubishi. The membrane performance of the Mitsubishi MBR system is shown in Figure 6-9.
As indicated the flux was increased to 11.8 gfd (20 L/hr-m2) after 128 hours (5.3 days) of
operation. The system was operated for over 1,500 hours (62 days) during which time the
overall vacuum pressure increased from 0.71 (0.05 bar) psi to 2.0 psi (0.14 bar). As part of
optimizing the Mitsubishi MBR system, the flux was increased to 14.8 gfd (25.1 L/hr-m2) after
1,700 hours (70.8 days) of operation. Over the next 150 hours (6.3 days) of operation the overall
vacuum pressure was stable at 2.5 psi and the DO in the system remained above 0.5 mg/L. As
indicated, the membranes were cleaned after 1,850 hours (77 days) of operation. The cleaning
reduced the vacuum pressure from 2.6 (0.18 bar) to 1.3 psi (0.09 bar). Post cleaning, the system
was brought back on-line at the target flux of 14.8 gfd (25.1 L/hr-m2). However, as shown in the
upper graph, after 1,990 hours of operation it was necessary to decrease the operating flux
because of excessive foaming in the aerobic tank. The foaming is believed to have resulted from
the membrane cleaning because chlorine was brought into direct contact with the MLSS. As
shown during the next 724 hours (30 days) of operation foaming continued and resulted in
unstable operation of the MBR system. During this time period, several tactics were employed
to mitigate foaming and resume stable operation. For example, a sprayer system was constructed
and installed on the pilot system. The sprayer system consisted of inch tubing which
surrounds the perimeter and passes across the center of the aeration tank. Spray nozzles which
produce a fine mist were placed every 6 inches along the tubing. The sprayer system was
operated using a timer which can be set to turn on/off up to 6 times per day.
The Mitsubishi MBR system was shut down after 2,568 hours (107 days) operation when the
blower failed. A new blower was immediately ordered and installed within 2 weeks of the
40
occurrence. The aerobic tank was drained, flushed with potable water and reseeded prior to start
up because the MLSS was without aeration for several weeks. The system was brought back on
line after 3,000 hours of operation at a flux of 11.8 gfd (20 L/hr-m2) and the MLSS was allowed
to reach
14 g/L. At this time the flux was increased to 14.8 gfd (25.1 L/hr-m2) and the Mitsubishi
Sterapore HF membrane was operated for over 800 hours (30 days) during which time vacuum
pressure increased from 2.13 to 3.27 psi.
6.3 Water Quality
6.3.1 Advanced Primary Effluent
The results of advanced primary effluent wastewater grab sample analyses conducted by the
Point Loma Satellite and Alvarado Water Treatment Facility Laboratories are presented in Table
6-1.
6.3.2 MBR Pilot Systems
6.3.2.1 Turbidity
The Zenon MBR effluent on-line turbidity data is provided in Figure 6-10. As shown, the
advanced primary effluent turbidity measured during Phase II testing ranged from 23-63 NTU.
During the entire testing period, the Zenon MBR effluent turbidity ranged from 0.03 to 0.1 NTU
with average value of 0.06 NTU. As shown, at 2700 hours of operation the MBR effluent
turbidity decreased from 0.06 to 0.04 NTU after the turbidimeter was cleaned.
The Mitsubishi MBR effluent on-line turbidity data is provided in Figure 6-11. During the entire
testing period, the Mitsubishi MBR effluent turbidity ranged from 0.04 to 0.10 NTU with
average value of 0.07 NTU. As shown, the turbidimeter cleaning performed at 3,772 hours of
operation reduced the turbidity from 0.08 NTU to 0.05 NTU.
6.3.2.2 BOD
5
, COD and TOC
The BOD
5
, COD and TOC values for advanced primary effluent and the Zenon MBR effluent
are shown in Figure 6-12. The median value of BOD
5
, COD and TOC measured in the advanced
primary effluent during Phase II testing was 112 mg/L, 237 mg/L and 44 mg/L, respectively.
The BOD
5
in the Zenon MBR effluent was below the detection limit of 2 mg/L in all samples.
Zenon MBR effluent TOC samples were all < 9 mg/L and all COD samples < 28 mg/L.
The BOD
5
, COD and TOC values for the advanced primary effluent and the Mitsubishi MBR
effluent are shown in Figure 6-13. The BOD
5
in the Mitsubishi MBR effluent samples were all
< 2 mg/L. All Mitsubishi MBR effluent TOC samples were < 10 mg/L and the COD ranged
from 18-31 mg/L with median value of 21 mg/L.
6.3.2.3 Biological Nutrient Removal
The inorganic nitrogen results including ammonia, nitrate/nitrite and nitrite from the Zenon
MBR effluent are shown in Figure 6-14. All of the Zenon MBR samples measured for NH
3
-N
were < 2 mg/L except the sample taken at 1,872 hours of operation which measured 5.0 mg/L.
At this time, the MBR system was being operated with F/M > 0.4 day-1 which is above the
41
manufacturers recommendation. Following this event, the F/M was decreased by increasing the
MLSS concentration and nitrification was resumed. As shown in the middle graph, the
(NO
3
/NO
2
)-N of MBR effluent was consistently above 18 mg/L indicating complete nitrification.
Figure 6-15 shows PO
4
-P results for analyses conducted on the advanced primary effluent and
Zenon MBR effluent. As shown, the PO
4
content of the advanced primary effluent was between
0.035- 1.23 mg/L and Zenon MBR effluent ranged from 0.3 to 1.24 mg/L. BPR will not occur in
MBR systems operating with only an aerobic tank.
The inorganic nitrogen results for the Mitsubishi MBR system are shown in Figure 6-16. The
high levels of ammonia (>5 mg/L) present in the Mitsubishi permeate during the initial
600 hours of operation indicate the system was not achieving complete nitrification. Such data is
expected as the seed sludge was growing during this time period and the nitrifying bacteria are
relatively slow growers. However, after 850 hours of operation all ammonia samples from the
Mitsubishi permeate were below 1.0 mg/L as N. The achievement of nitrification can also be
seen in the plot of nitrite/nitrate which shows a trend of increasing NO
2
/NO
3
concentration in the
Mitsubishi permeate with an increase in time of operation. Figure 6-17 shows PO
4
-P results for
analyses conducted on the advanced primary effluent and Mitsubishi effluent.
6.3.2.4 Total Coliform, Fecal Coliform, Total Coliphage
The results of total coliform, fecal coliform and total coliphage analyses conducted on the feed
wastewater and Zenon MBR effluent are presented in Figure 6-18. As shown, the Zenon system
achieved total and fecal coliform rejections ranging from 3-7 log. The total coliform measured
in the Zenon permeate were quite high ranging from 14 to 5,000 MPN/100 mL while the fecal
coliform were consistently below the detection limit of 2.2 MPN/100 mL. Also shown, the
Zenon MBR system achieved total coliphage rejections (4.0-5.5 log) with all values in the
permeate at or below the detection limit of 1.0 plaque forming units (PFU)/100 mL.
The fact that the Zenon permeate showed high total coliform counts, despite low counts of fecal
coliform and total coliphage suggested the presence of contamination on the permeate side of the
membrane. Accordingly, the entire permeate piping system was disinfected after 2,900 hours of
operation. As shown, all post disinfection total and fecal coliform measurements in the Zenon
MBR permeate were 2.2 MPN/100 ml.
Figure 6-19 presents the total and fecal coliform and total coliphage in the influent and effluent
of the Mitsubishi measured during Phase II testing. As shown, the Mitsubishi system achieved
excellent rejections (5.5-7.0 log) of total and fecal coliform with permeate levels consistently
below the detection limit of 2.2 MPN/100 mL. Such data indicates the Mitsubishi MBR is an
excellent barrier to bacteria present in the feed wastewater.
Also shown, the Mitsubishi system achieved between 3-5 log rejection of total coliphage with
many measurements in the permeate below the detection level of 1.0 PFU/100 mL. The data
collected during the first 1,100 hours of operation, clearly shows a trend of decreased permeate
coliphage with increasing time of operation. This would be expected for two reasons. First, the
amount of total coliphage absorbed to the MLSS increases with increased solids concentration.
Secondly, as the membranes become clogged the pore size is decreased which results in removal
of virus and other particles which could normally pass through the membrane. It should be noted
new membranes were installed on the pilot system before beginning the study.
42
6.3.2.5 Other Water Quality Parameters
The results of water quality analysis conducted on Zenon MBR effluent by the Point Loma
Satellite and Alvarado Water Treatment Facility Laboratories is presented in Tables 6-2.
Likewise, laboratory results for the Mitsubishi MBR system from Phase II testing are presented
in Table 6-3.
43
7. Title 22 Approval of MBR Systems
7.1 Zenon and Mitsubishi
In March 2000, the project team met with the CDHS to develop a specific testing protocol for the
approving MBR systems as an acceptable filtration technology for compliance with the State of
Californias Water Recycling Criteria (Title 22). It was decided approval would be based on the
systems ability to meet the following criteria:
- Turbidity performance (not to exceed 0.2 NTU more than 5 percent of the time within
24-hour period; and 0.5 NTU anytime)
- Long Term Operational Data (approval to be based on flux and vacuum pressure range)
- Approval to be membrane specific
- Demonstrate ability of the system to achieve 1-log virus reduction at the 50th percentile
Shortly after these criteria were established, the project team performed long term testing on the
Zenon and Mitsubishi MBR systems under grant funding from the Reclamation (Adham et al.,
2000). Following this testing, the project team conducted virus challenge studies on these
systems through funding provided by the National Water Research Institute. Based on the
results from these two research projects, both the Zenon and Mitsubishi MBR systems received
Title 22 approval in April 2001 (Adham et al., 2001 a and b).
7.2 Kubota and US Filter
At the end of Phase I pilot testing of the current study, representatives from Enviroquip
Inc./Kubota Corporation expressed interest in obtaining regulatory approval for the use of the
Kubota MBR to meet California's Title 22 Water Recycling Criteria. Accordingly, the project
team conducted additional testing on the Kubota MBR system at PLWTP to meet the
requirements established by the CDHS. The project team prepared a report summarizing the
results of the virus challenge experiments and operational performance data collected from the
evaluation of the Kubota MBR system pilot system at PLWTP. This report was submitted to the
CDHS in February 2003 (Adham and DeCarolis, 2003). In March 2003, the CDHS sent an
approval letter to Kubota stating their acceptance of the Kubota Type 510 flat sheet membrane to
meet Title 22 water recycling criteria. A copy of the approval letter is presented in Appendix E.
Also during the current study, representatives from the US Filter Corporation/Jet Tech Products
Group contacted the project team and the CDHS regarding Title 22 approval requirements for
MBR systems. After reviewing MBR operational data collected from Point Loma, the CDHS
44
accepted the MemJet B10 R membrane to meet the Title 22 water recycling criteria. The virus
rejection data of the MemJet B10 R membrane was collected during CDHS approval testing of
the membrane for drinking water applications conducted at the Aqua 2000 research center.
(Adham and Gramith, 2001).
45
8. MBR Performance Comparison
8.1 MBR Operating Experience
The four MBR pilot systems were all completely automated, however; a varying degree of
operator attention was required for each pilot system. The following summarizes operational
experiences with each system.
8.1.1 US Filter MBR System
On numerous occasions during operation on raw wastewater several components of the US filter
MBR pilot were clogged with debris and hair which ultimately caused the system to enter into
alarm mode and shut down. In particular, clogging occurred in the following areas: pre-
screen, piping from the aerobic tank to the membrane tank and the rotameter located before the
membrane tank. Another operational problem experienced with the US Filter MBR system was
the level control system equipped in the aerobic tank. On several occasions during testing the
tank overflowed causing the MLSS to be severely diluted. This made it difficult to maintain a
steady SRT. It was later discovered that the wiring for the high/low level switched was reversed.
As a result, when the aerobic tank level reached a high level the feed pump would continue as if
the level was low. These reoccurring incidences throughout the testing made it necessary to
provide a significant amount of operator attention to keep the US Filter MBR operating at steady
state.
8.1.2 Kubota MBR System
On two occasions during testing, the stainless steal camlock fitting on the discharge side of the
submersible transfer pump located in anoxic zone deteriorated and became detached. The
transfer pump is used to transfer wastewater from the anoxic tank to the aerobic tank where
membrane filtration occurs. Once the camlock became detached, the membrane tank received no
further input of feed wastewater and therefore the level dropped as filtration continued. Because
the transfer pump was submerged, it was necessary to use a fork lift to remove the pump from
the system in order to replace the camlock fitting. Also, as mentioned in Section 5.3, the pilot
system was originally equipped with permeate piping lines. This appears to have caused an
increase in pressure loss associated with piping loss. As a result, the system was taken offline.
During this time it was necessary to remove the membrane cassettes using a crane and replace
perm piping with 2 line. Once these modifications were made, the Kubota MBR pilot operated
smoothly with little operator attention.
8.1.3 Zenon MBR System
During the initial period of Phase II testing, the VFD controlling the feed water flow rate to the
aerobic tank failed. The VFD was removed from the system and replaced with level control
switches. From this point forward the Zenon MBR required minimal operator attention.
46
8.1.4 Mitsubishi MBR System
Upon increasing the flux rate it was necessary to modify the blower system equipped on the
Mitsubishi pilot to provide adequate DO for biological oxidation. Also, after the first membrane
cleaning event the biological system was unstable causing a significant amount of foam to form
in the aerobic tank. During periods of foaming the Mitsubishi MBR system required a lot of
operator attention to prevent MLSS from spilling over the top of the aeration tank. This included
building and installing a sprayer system to help control foaming.
8.2 Operating Conditions
8.2.1 Flux, HRT, SRT and MLSS
The US Filter and Kubota MBR systems were operated with flux and HRT values typical of full
scale MBR processes. These include flux of 15 gfd and HRT ranging from 4-8 h. However, the
Zenon and Mitsubishi systems were operated under more extreme operating conditions in effort
to optimize the MBR process for water reclamation. For example, the flux of the Zenon and
Mitsubishi MBRs systems was increased and sustained at 22 gfd and 15 gfd, respectively. Such
flux values exceed the manufacturers recommended membrane flux. The HRT of the Zenon and
Mitsubishi systems were ultimately reduced to 2 hours and 2.8 h, respectfully. All four systems
were operated with typical SRT (11-20 days) and MLSS concentrations (9-14 g/L) used in full
scale MBR processes.
8.2.2 Frequent Relaxation/Backpulsing
The Kubota, Mitsubishi and Zenon MBR systems relaxed during operation to prevent membrane
fouling while the US Filter system used backwashing. The frequency and duration of relaxations
ranged from 9-12 minutes and 0.5 2 minutes, respectively. The backwash frequency and
duration of the US Filter MBR was 12 minutes and 1 minute, respectively. The use of
relaxation, as opposed to backpulsing, eliminates the need for additional permeate storage tanks
and/or valves and piping. In addition, total coliform results collected from the US filter MBR
system also suggest that backpulsing can introduce contamination into the permeate piping due
to algae growth in the permeate tank. Lastly, as reported by Adham et al., 1998, membrane
integrity is another factor to consider in systems that use backpulsing. The authors explained
that during filtration the applied vacuum pressure typically causes the solids to clog broken
fibers. However, on systems that backpulse these seals can become broken over time which
makes it necessary to replace the compromised fiber(s).
8.2.3 Air Usage (Membrane Scour and Biological Requirements)
Each MBR system used coarse bubble aeration to reduce membrane fouling. Membrane airflow
rates per membrane area (scfm/ft
2
) for the US Filter, Kubota, Zenon and Mitsubishi MBR
systems were 0.023, 0.033, 0.030, and 0.028, respectively. The Zenon MBR system was the
only system operated with intermittent coarse air, which reduced the total air usage by
50 percent. Each system also used fine bubble aeration to provide sufficient DO to the activated
sludge. The fine air to the Kubota MBR was applied intermittently as necessary to maintain 2
mg/L DO in the aerobic tank. All other MBR systems tested were operated with constant fine
bubble aeration.
47
8.2.4 Membrane Cleaning
The cleaning procedures for all four MBR systems used chlorine (2-3 g/L) followed by citric or
oxalic acid (2 percent). However, the Zenon and US Filter membranes were cleaned in place
(CIP) while the Mitsubishi and Kubota membranes were cleaned in-line (CIL). During a CIP,
the membranes were isolated from the MLSS and chemicals were recirculated through the
membranes prior to soaking. During a CIL, the membranes were not isolated from the MLSS
and chemical was allowed to slowly flow by gravity from the inside to the outside of the
membranes. This procedure introduces chemicals into direct contact with activated sludge.
Such contact caused a significant amount of foaming to occur in the Kubota and Mitsubishi
MBR systems during post cleaning operation. For the Kubota MBR system, which transferred
MLSS from anoxic to aerobic zone foaming was mitigated within 1 or 2 days following a
cleaning event with no added foam control. However in the case of Mitsubishi, which was only
operated with an aerobic tank, foaming persisted for several weeks after cleaning. As a result, it
was necessary to install a sprayer system for foam control. Other than foaming issues, both
methods of cleaning were effective at reducing vacuum pressure. Furthermore, acid was the
most effective cleaning chemical for all four systems.
8.3 Membrane Performance
All four MBR systems demonstrated good membrane performance throughout the testing.
The Kubota and US filter membranes required minimal cleaning during operation on both raw
wastewater (Part 1) and advanced primary effluent (Part 2). In Part 1 testing, the Kubota MBR
was only cleaned once after 788 hours (33 days). Post cleaning the membrane was operated for
over 2,000 hours (83 days) at 15 gfd without cleaning. During Part 2, no cleanings were
performed and the membrane operated for over 1,800 hours (75 days) at 15 gfd on advanced
primary effluent with no fouling. During Part 1 testing, the US Filter was cleaned with chlorine
after
2,954 hours (123 days) at 11.5 gfd. Shortly after, the system was cleaned using acid which
further reduced the TMP. Following this cleaning the membrane operated for nearly 1,000 hours
(42 days) at 14.5 gfd during which time little fouling occurred. The system was cleaned again
after 4,201 hours of operation to begin testing at increased flux rates ranging from 19-24 gfd. In
Part 2 testing no cleanings were performed and the US Filter membrane was operated for 1,000
hours (42 days) at 14.5 gfd during which time little membrane fouling was observed.
The Zenon membrane was cleaned after 800 hours (33 days) and 1,350 (56 days) of operation
due to problems associated with the feed pump which caused membrane fouling. After this
problem was fixed the membrane was operated for 600 hours (25 days) at 22 gfd before another
cleaning was performed. A final cleaning was necessary at time of 2,500 hours (104 days) due
to dilution of the solids. The system was then operated for 1,800 hours (75 days) at 22 gfd
without cleaning and with minimal fouling. Throughout testing, maintenance cleans were
performed three times per week on the Zenon membrane to mitigate fouling. The Mitsubishi
MBR system was cleaned after 1,850 hours (77 days) while operating at 11.8 gfd. Following
this cleaning the system was operated at low flux due to excessive problems with foaming. The
system was brought back online at 3,000 hours of operation and operated for 800 hours (30 days)
at a flux of 15 gfd without cleaning. During this time minimal membrane fouling occurred.
48
Each MBR system demonstrated the ability to operate for a run time of 1800 hours (75 days)
between membrane cleanings with minimal to moderate increases in vacuum pressure. The
increased amount of cleaning necessary on the Zenon system was largely due to the reduced
HRT and increased flux under which the system was operated.
8.4 MBR Effluent Water Quality (Phase I, Part 1: Kubota and US
Filter)
8.4.1 Particulate Removal
The US Filter and Kubota MF membranes produced turbidity values 0.06 NTU and
0.10 NTU, respectively, in 90 percent of the samples as shown in Figure 8-1. The slightly
lower turbidity values measured in the US Filter MBR effluent as compared to Kubota MBR
effluent may be due to differences in the on-line turbidity instrumentation equipped on each
MBR system. As presented in Appendix C, the US Filter was equipped with a GLI Accu4
turbidimeter while the Kubota MBR system was equipped with Hach 1720D turbidimeter. This
was confirmed by analyzing a series of grab samples from each membrane using a desktop
turbidimeter. Results showed the average turbidity of the US filter and Kubota membranes to be
0.06 NTU and 0.07 NTU, respectively.
8.4.2 Organics Removal
Both MBR systems produced excellent removal of organic constituents while operating on raw
wastewater. For instance, as shown in Figure 8-2, the BOD
5
measured in the MBR effluent was
below the detection limit of 2 mg/L in 92 percent of the US filter samples and 100 percent of the
Kubota samples. Figure 8-3 shows a probability plot of TOC measured in the raw wastewater
and effluent from both MBR systems. As shown, both the US filter and Kubota MBR systems
produced TOC 9 mg/L in 90 percent of all sample measurements.
8.4.3 Biological Nutrient Removal
During Part 1 testing the US Filter and Kubota MBR systems produced effluent with
NH
3
< 2 mg-N/L in 90 percent of all samples measured as shown in Figure 8-4. Such results
indicate that the both MBR systems successfully achieved nitrification during operation on raw
wastewater. Also, shown the total inorganic nitrogen in the US filter system was < 27 mg-N/L in
80 percent of samples while the Kubota MBR effluent was <2 mg/L in 100 percent of the
samples. Such results indicate that Kubota system successfully achieved complete denitrification
throughout Part 1 testing. As expected denitrification was not observed in he US filter MBR
because the anoxic tank was bypassed and the system was only operated with an aerobic zone.
Both MBR systems showed removal of Ortho-phosphate during Part 1 testing as shown in
Figure 8-5. The MBR PO
4
measured < 0.5 mg-P/L and < 0.1 mg/L in 90 percent samples of the
US filter and Kubota MBR systems respectively. The higher removal of Ortho-phosphate
removal by the Kubota system was attributed to the presence of the anoxic zone which provides
a conducive environment for BPR occur once.
49
8.4.4 Total Coliform, Fecal Coliform, Total Coliphage Removal
Both MBR systems removed total and fecal coliform throughout Part 1 Testing as shown in
Figures 8-6 and 8-7, respectively. Total coliform analysis showed the US Filter MBR effluent
contained 1,000 MPN/100 mL in 90 percent of all samples and Kubota MBR effluent was
2 MPN/100 mL in 100 percent of the samples measured.
Fecal coliforms in the US filter MBR effluent were 100 MPN/100 mL in 90 percent of samples
and Kubota MBR effluent 2 MPN/100 mL in 100 percent of the samples measured.
Figure 8-8 shows the US Filter MBR total coliphage was 30 PFU/100 mL in 80 percent of
samples and Kubota MBR total coliphage effluent was <10 PFU/100 mL in 80 percent of the
samples.
8.5 MBR Effluent Water Quality (Phase II: Zenon and Mitsubishi)
8.5.1 Particulate Removal
The Zenon UF and Mitsubishi MF membranes produced turbidity values < 0.10 NTU,
respectively, in 90 percent of the samples as shown in Figure 8-9.
8.5.2 Organic Removal
Both MBR systems produced excellent removal of organic constituents during Phase II testing.
As shown in Figure 8-10, the BOD
5
measured in the MBR effluent was below the detection limit
of 2 mg/L in 100 percent of the samples measured in the Zenon and Mitsubishi MBR effluent
samples. Figure 8-11 shows a probability plot of TOC measured in the primary effluent and
effluent from both MBR systems. As shown both the Zenon and Mitsubishi MBR systems
produced TOC 9 mg/L in 90 percent of all sample measurements.
8.5.3 Biological Nutrient Removal
During Phase II testing the Zenon and Mitsubishi MBR systems produced effluent with
NH
3
< 1 mg-N/L in 90 percent and 70 percent, respectively, as shown in Figure 8-12. The
samples of Mitsubishi effluent that were >1 mg/L-N were measured during the start up period,
prior to the establishment of the nitrifying bacteria in the MLSS. Such results indicate that both
MBR systems successfully achieved nitrification during operation on primary effluent. As
shown in Figure 8-13 PO
4
was measured to be 0.65 mg-P/L and 0.75 mg/L in 70 percent of
the samples from Zenon and Mitsubishi MBR systems, respectively. Accordingly, the primary
effluent contained 0.9 mg-P/L in 70 percent of the samples. Such data indicates that Ortho-
phosphate removal was not significant during Phase II testing.
8.5.4 Total Coliform, Fecal Coliform, Total Coliphage Removal
Both MBR systems removed total and fecal coliforms throughout Phase II testing as shown in
Figures 8-14 and 8-15 respectively. The Zenon MBR produced 1,100 MPN/100 mL in
80 percent of all effluent samples and Mitsubishi MBR effluent was 10 MPN/100 mL in
80 percent of the samples measured. Higher counts of total coliform measured in the Zenon
permeate was shown to be a result of contamination on the permeate side of the membrane.
50
Fecal coliforms in the Zenon MBR effluent were 2 MPN/100 mL in 80 percent of samples and
2 MPN/100 mL in 100 percent of the samples measured from the Mitsubishi MBR.
Figure 8-16 shows the Zenon UF membrane total coliphage were 1 PFU/100 mL in
100 percent of samples and Mitsubishi MF membrane produced total coliphage effluent
20 PFU/100 mL in 80 percent of the samples.
51
9. Cost Analysis
9.1 Costing Approach
A cost analysis was performed to determine capital and operational costs of full-scale MBR
water reclamation systems for treatment capacities ranging from 0.2-10 MGD
(800-40,000 m
3
/day). The specific approach used to perform the costs analysis is outlined in
Figure 9-1. As shown, the project team began by first organizing a workshop with all
participating MBR manufacturers including: US Filter Corporation/Jet Tech Products Group,
Zenon Environmental, Inc., Ionics/ Mitsubishi Rayon Corporation, Enviroquip Inc./Kubota
Corporation. During this workshop members of the project team met with representatives from
each manufacturer to discuss the major factors affecting the cost and operation of full-scale MBR
systems. Based on information gathered during this workshop, the project team developed a
specific list of operational and design criteria to be used in preparing the cost estimates. Key
parameters included flux, HRT, SRT, and MLSS. In addition, items such as cleaning interval,
membrane replacement period and warranty information was established based on discussions
with the manufacturers.
Following the workshop, the project team developed and sent a memo to each manufacturer
requesting budgetary cost estimates of capital and O&M costs for the membrane portion of MBR
systems for the capacities being considered. A modified version of this memo which contains
information specific to the current study is provided in Appendix F. As described, the
manufacturers were requested to provide membrane costs based on specific operating parameters
such as flux, TMP, loss of active membrane area and redundancy. At the same time, the MWH
design team completed cost estimates for complete MBR water reclamation systems (excluding
membrane costs) including headworks, process basins, mechanical equipment, blower and pump
building, chlorination system and effluent storage. Initial cost estimates were based on the
operation of raw wastewater. These costs were further refined for 1 and 5 MGD installations to
determine the cost savings associated with operation on advanced primary effluent.
52
9.2 Operation on Raw Wastewater
9.2.1 Design Criteria
Cost analyses were performed for 0.2, 0.5, 1.0, 5 and 10 MGD (800, 2,000, 4,000, 20,000, and
40,000 m
3
/day) installations. All systems were assumed to be sewer mining or scalping facilities
built on a clean plot of land and designed to operate on raw municipal wastewater. Such
facilities differ from end-of-pipe systems as raw wastewater is acquired directly from a sewer
pipe and all residuals (screenings, grit and waste-activated sludge [WAS]) are returned to the
same pipe which eliminates the need for sludge handling and disposal. The following wastewater
characteristics, typical of raw municipal wastewater, were used to model the MBR systems:
BOD
5
290 mg/L
COD 700 mg/L
TSS (total suspended solids) 320 mg/L
VSS 260 mg/L
NH
3
-N 30 mg/L
TKN (total Kjeldahl nitrogen) 60 mg/L
TP (total phosphorus) 2 mg/L
TDS 1,200 mg/L
Alkalinity 245 mg/L
Temperature 20 C
The MBR systems were designed using the following criteria:
Flux 15 gfd @ 15 C
MLSS 8,000 mg/L
F/M 0.13 day-1
HRT 6 h
SRT 10 days
Furthermore, all installations were designed to meet the following effluent water conditions:
Complete nitrification (i.e. NH
4
+-N<1.0 mg/L)
Denitrification (i.e. NO
3
-N<10 mg/L)
Biochemical Oxygen Demand (BOD
5
) < 2.0 mg/L
Biological Phosphorus Removal (i.e. Total Phosphorus-P <0.2 mg/L)
A schematic of the MBR reclaimed water system is provided in Figure 9-2. As shown, the
system included a biological reactor with three distinct zones (anoxic, anaerobic and oxic),
membrane bays and a chlorine contact chamber. The system was designed to allow screened and
degritted wastewater to enter the anoxic zone. Next, the wastewater would pass through the
anaerobic and oxic zone before entering the membrane bays. As shown, solids would then be re-
circulated from the membrane bay to the oxic zone. This would provide a crossflow velocity on
the membrane surface, which would help mitigate fouling and allow excess DO to be consumed.
As shown, MLSS was also re-circulated from the oxic zone to the anoxic zone. This allows
nitrates produced from the nitrification process to be brought into the anoxic environment, which
53
is conducive for denitrification. Lastly, re-circulation from the anoxic zone to the aerobic zone
promotes enhanced biological phosphorous removal (EBPR).
9.2.2 Capital Costs
Table 9-1 provides the capital costs for each capacity designed to operate on raw wastewater.
The table includes total capital costs ($K) and amortized capital costs ($K/year) assuming a
5 percent interest rate over a 30 year period. As shown, the total capital cost estimate for the
1.0-MGD installation ranged from $7,710 $9,280, while the amortized cost ($/yr) ranged from
$502-$604. The range in capital costs directly reflects the range of membrane costs acquired
from the four participating MBR manufacturers.
The headworks for all installations consisted of bar screening (6 mm), vortex grit removal, lift
pumps and odor control. All capital costs associated with headworks were taken from standard
budgetary costs used by the MWH.
Basin costs include concrete and ancillary costs associated with the aerobic/membrane, anoxic
and anaerobic components of the MBR system. In addition, the costs include basin excavation,
structural fill, back fill and waste dirt to haul off site. Lastly, for the 1, 5 and 10 MGD
installations the basin costs includes a 5-ton bridge crane; for smaller capacities it was assumed
the bridge crane would be rented as needed and therefore was included in the O&M costs
(See Section 9.2.3).
Mechanical costs shown include fine screening, mixers, aeration equipment, and recirculation
pumps and piping. Fine screening costs were provided by Waste Tech Inc (Libertyville, IL).
The costs were based on Roto-Sieve (RS) perforated drum screens and includes costs of both
duty and stand screens as recommended by the manufacturer. A factor of 25 percent was
included in the mechanical cost to account for equipment installation.
Membrane system costs including membranes, pumps, blowers and miscellaneous equipment
were developed from budgetary cost proposals provided by the participating manufactures. Each
manufacturer was requested to provide membrane costs to include a 5-year non-prorated
warranty.
Blower and pump building costs shown are based on two-story building and include all capital
costs associated with process blowers, blower piping and valving and blower instrumentation. A
factor of 25 percent was added the cost to account for equipment installation.
9.2.3 Operation and Maintenance Costs
Table 9-2 provides the annual O&M costs and the total estimated O&M costs (5 percent interest
rate over a 30-year period) for all MBR installations considered. Membrane replacement costs
were provided by the participating manufacturers and are based on an 8-yr membrane life. The
MWH design team provided all other annual costs. Unit cost assumptions for these annual costs
are provided in Appendix F. The table shows the annually O&M cost ($K/yr) for the
1-MGD installation ranges from $158-$212.
54
9.2.4 Total Costs
Table 9-3 provides a summary of the capital and O&M costs for all capacities operating on raw
wastewater. The total capital costs and estimated O&M costs were summed to provide present
worth values of each installation. The present worth values shown are based on a 5 percent
interest rate over a 30-year period. As shown, the present worth ($K) for the 1-MGD was
estimated between $10,139-$12,539. Table 9-4 provides total costs ($/1000 gallon) for each
capacity. These costs were derived from the amortized capital cost and the annual O&M cost
associated with each capacity. The table shows the total cost ($/1000 gallon) for the 1-MGD
capacity ranged from $1.81-$2.24.
Figure 9-3 illustrates the range of total costs ($/1000 gallon) based on the various membrane
suppliers for 0.2-10 MGD installations operating on raw wastewater. The shaded area on the
graph shows the difference between the high and low end of the range. As shown, the range is
greatest for 0.2-MGD facilities and decreases with capacity.
9.3 Consideration of Advanced Primary Treatment
The above cost estimates were tailored for municipalities which, like the City of San Diego, are
considering using the MBR process to reclaim wastewater at an existing advanced primary
wastewater treatment facility. The major factors considered when performing the cost estimates
for such facilities were:
- Access to advanced primary effluent
- Ability to use the existing headworks
Reclaimed water generated at an existing facility, such as PLWTP, can be used to meet industrial
and irrigation demands on-site reducing the use of imported potable water.
9.3.1 Design Criteria
To accommodate for on-site demand and the potential for increased demand from adjacent areas,
costing was performed for 1 and 5-MGD (4,000 and 20,000 m
3
/day) MBR facilities. All
facilities were assumed to be scalping facilities built on a clean plot of land and designed to
operate on advanced primary effluent. The following wastewater characteristics, typical of
advanced primary treated municipal wastewater, were used to perform the process design of the
MBR systems:
BOD
5
130 mg/L
COD 280 mg/L
TSS 65 mg/L
VSS 50 mg/L
NH
3
-N 30 mg/L
TKN 40 mg/L
55
TP 2 mg/L
TDS 1,200 mg/L
Alkalinity 230 mg/L
Temperature 20 C
Comparing the above water quality to the raw wastewater quality (Section 9.2.1) it is evident
there is a significant reduction of organic (BOD/COD) and particulate (TSS/VSS) contaminates
by the advanced primary treatment process.
All installations on advanced primary effluent were based on following criteria:
Flux 15 gfd @ 15 C
MLSS 8,000 mg/L
F/M 0.13 day-1
HRT 3 h
SRT 10 days
It should be noted the HRT was reduced by 50 percent (i.e. 6 hours to 3 h) as compared to MBR
installations designed to operate on raw wastewater. This reduction is attributed to the lower
organic and solid loading rate to the MBR system during operation on advanced primary
effluent.
9.3.2 Capital Costs
Table 9-5 provides capital costs for MBR installations designed to operate on advanced primary
effluent. The table shows the total capital cost ($K) and the amortized cost ($K/yr) assuming
5 percent interest rate over a 30-yr period for each capacity. As shown, the total capital cost for
the 1.0-MGD installations range from $6,150 $7,730, while the amortized costs ($K/yr) range
from $400-$503. A comparison of these costs to the capital cost estimates for the 1.0 MGD
installations operating on raw wastewater, indicates a savings between 17 percent-20 percent is
realized by designing MBRs to operate on advanced primary effluent when no headworks costs
are considered.
The specific capital cost items reduced for MBR plants operating on advanced primary effluent
include basin costs, mechanical equipment costs and blower and pump building costs. All of the
costs listed above are related to the solid and organic loading rate to the MBR system, which is
reduced during operation on advanced primary effluent. In addition, the capital cost is reduced
due to the exclusion of a headworks system, which would be necessary if the facility was not
being built at an existing plant.
9.3.3 Operation and Maintenance Costs
Table 9-6 provides the annual O&M costs for MBR facilities designed to operate on advanced
primary effluent. As shown, the O&M costs are provided for both the first year and total
estimated costs, assuming a 5 percent interest rate over 30-yr period. Membrane replacement
costs were provided by the participating manufacturers and are based on 8-yr membrane life. All
other annual costs were provided by MWH. Specific unit costs and assumptions regarding
annual costs are provided in Appendix F. As shown in Table 9-6, the annual O&M costs ($K/yr)
56
for the 1-MGD installations range from $139-$194. A comparison of these costs to the annual
O&M cost estimates for the 1.0 MGD installations operating on raw wastewater, indicates
savings of 8 percent-12 percent is realized by designing MBRs to operate on advanced primary
effluent when no headworks costs are included.
O&M cost reduction for systems operating on primary effluent is attributed to lower electrical
requirements for the biological process, reduced equipment repair and reduced diffuser
replacement.
9.3.4 Total Costs
Table 9-7 provides a summary of the capital and O&M costs for 1.0 and 5.0 MGD capacities
designed to operating on primary effluent. The total capital costs and estimated O&M costs
were summed to provide present worth values of each installation. The present worth values
shown are based on a 5 percent interest rate over a 30-year period. As shown, the present worth
($K) for the 1-MGD was estimated between $8,287-$10,712. Table 9-8 provides total costs
($/1000 gallon) for each capacity. These costs were derived from the amortized capital cost and
the annual O&M cost associated with each capacity. The table shows the total cost ($/1000
gallon) for the 1-MGD capacity ranged from $1.48-$1.91.
Figure 9-4 shows the total costs ($/1000 gallon) for 1.0 and 5.0 MGD installations operating on
raw wastewater and advanced primary effluent. The costs in this graph are based on median
total cost values presented in Section 9.2.4 and 9.3.4. As shown, the total cost is reduced for
both capacities based on design using advanced primary effluent (excluding headwork costs) and
the reduction increases with capacity.
9.4 Economy of Scale Analysis
Figure 9-5 presents total costs ($K/MGD) for 1.) complete MBR systems and 2.) membranes
only. Costs shown are for systems designed to operate on raw wastewater and are based on
median values determined in Sections 9.2.4. The plot shows both costs decrease with increasing
capacity indicating an economy of scale; however, the scale is more profound for the complete
MBR system costs.
57
Reference List
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of Reclamation, November, 1998.
Adham, S., Mirlo R. and Gagliardo, P., Membrane Bioreactors for Water Reclamation - Phase II,
Desalination Research and Development Program Report No. 60; Project No. 98-FC-81-0031,
Bureau of Reclamation, November, 2000.
Adham, S., Trussell, S., Membrane Bioreactors: Feasibility and Use in Water Reclamation, Final
Report Project #98-CTS-5, Water Environment Research Foundation, 2001.
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Zenogem Membrane Bioreactor to Meet Existing Water Reuse Criteria, Final Report, National
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Lozier, J., Fernandez, A., Hines, B., and Carns, K., Using a Membrane Bioreactor/Reverse
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van der Roest, H.F., Lawrence, D.P., van Bentem, A.G.N Membrane Bioreactors for Municipal
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www.werf.org/products/membranetool/home, 2003.
APPENDIX A
Tables and Figures
This Appendix contains the tables and figures referred to in the main report.
A-i
LIST OF TABLES
TABLE 4-1: SPECIFICATIONS FOR THE MBR MEMBRANES .........................................................................................A-2
TABLE 4-2: SPECIFICATIONS FOR THE ROMEMBRANES.............................................................................................A-2
TABLE 4-3: SPECIFICATIONS FOR THE AQUIONICS UVPILOT.....................................................................................A-2
TABLE 4-4: ANALYTICAL METHODS / DETECTION LIMITS FOR MEASURED WATER QUALITY PARAMETERS..............A-3
TABLE 5-1: RAWWASTEWATER QUALITY DATA DURING PHASE I (PART 1)..............................................................A-4
TABLE 5-2: ADVANCED PRIMARY EFFLUENT WASTEWATER QUALITY DATA DURING PHASE I (PART 2) ..................A-4
TABLE 5-3: US FILTER MBR PERMEATE WATER QUALITY DATA DURING PHASE I (PART 1)....................................A-5
TABLE 5-4: US FILTER MBR PERMEATE WATER QUALITY DATA DURING PHASE I (PART 2)....................................A-5
TABLE 5-5: KUBOTA MBRPERMEATE WATER QUALITY DATA DURING PHASE I (PART 1) .......................................A-6
TABLE 5-6: KUBOTA MBRPERMEATE WATER QUALITY DATA DURING PHASE I (PART 2) .......................................A-6
TABLE 5-7: SAEHAN ROPERMEATE WATER QUALITY DATA DURING PHASE I..........................................................A-7
TABLE 5-8: HYDRANAUTICS ROPERMEATE WATER QUALITY DATA DURING PHASE I .............................................A-7
TABLE 6-1: ADVANCED PRIMARY EFFLUENT WASTEWATER QUALITY DATA DURING PHASE II................................A-8
TABLE 6-2: ZENON MBRPERMEATE WATER QUALITY DATA DURING PHASE II .......................................................A-8
TABLE 6-3: MITSUBISHI MBR PERMEATE WATER QUALITY DATA DURING PHASE II ...............................................A-9
TABLE 9-1: CAPITAL COSTS FOR VARIOUS CAPACITY MBR SYSTEMS OPERATING ON RAWWASTEWATER...........A-10
TABLE 9-2: O&MCOSTS FOR MBRSYSTEMS OPERATING ON RAW WASTEWATER ................................................A-11
TABLE 9-3: SUMMARY OF CAPITAL AND O&MCOSTS OPERATING ON RAWWASTEWATER ...................................A-12
TABLE 9-4: SUMMARY OF COSTS, $/KGAL OPERATING ON RAWWASTEWATER ......................................................A-12
TABLE 9-5: CAPITAL COSTS 1&5 MGDMBROPERATING ON ADVANCED PRIMARY EFFLUENT.............................A-13
TABLE 9-6: O&MCOSTS FOR MBRS OPERATING ON ADVANCED PRIMARY EFFLUENT ..........................................A-14
TABLE 9-7: SUMMARY OF CAPITAL AND O&MCOSTS OPERATION ON ADVANCED PRIMARY EFFLUENT................A-14
TABLE 9-8: SUMMARY OF COSTS, $/KGAL OPERATION ON ADVANCED PRIMARY EFFLUENT...................................A-14
A-ii
LIST OF FIGURES
FIGURE 4-1: SCHEMATIC DIAGRAM OF THE POINT LOMA ADVANCED WASTEWATER TREATMENT PLANT..............A-15
FIGURE 4-2: SCHEMATIC DIAGRAM OF PILOT TREATMENT TRAIN DURING PHASE I (PART 1 &PART 2)..................A-16
FIGURE 4-3: SCHEMATIC DIAGRAM OF PILOT TREATMENT TRAIN DURING PHASE II ...............................................A-17
FIGURE 4-4: KUBOTA MBR: SIDE VIEW (TOP); PLAN VIEW (BOTTOM) ...................................................................A-18
FIGURE 4-5: US FILTER MBR: SIDE VIEW (TOP); PLAN VIEW (BOTTOM)................................................................A-19
FIGURE 4-6: ZENON MBR: SIDE VIEW (TOP); PLAN VIEW (BOTTOM)......................................................................A-20
FIGURE 4-7: MITSUBISHI MBR: SIDE VIEW (TOP); PLAN VIEW (BOTTOM) ..............................................................A-21
FIGURE 5-1: HRT AND SRT
7-D
FOR THE US FILTER MBR........................................................................................A-22
FIGURE 5-2: MIXED LIQUOR SOLIDS FOR THE US FILTER MBR...............................................................................A-23
FIGURE 5-3: DOCONCENTRATION IN THE US FILTER MBR ....................................................................................A-24
FIGURE 5-4: HRT AND SRT
7-D
FOR THE KUBOTA MBR...........................................................................................A-25
FIGURE 5-5: DOCONCENTRATION IN THE KUBOTA MBR........................................................................................A-26
FIGURE 5-6: MIXED LIQUOR SOLIDS FOR THE KUBOTA MBR..................................................................................A-27
FIGURE 5-7: MEMBRANE PERFORMANCE OF THE US FILTER MBR..........................................................................A-28
FIGURE 5-8: MEMBRANE PERFORMANCE OF THE KUBOTA MBR .............................................................................A-29
FIGURE 5-9: SAEHAN 4040 BL ROMEMBRANE PERFORMANCE ..............................................................................A-30
FIGURE 5-10: HYDRANAUTICS LFC3 ROMEMBRANE PERFORMANCE.....................................................................A-31
FIGURE 5-11: TURBIDITY REMOVAL BY THE US FILTER MBR.................................................................................A-32
FIGURE 5-12: TURBIDITY REMOVAL BY THE KUBOTA MBR....................................................................................A-32
FIGURE 5-13: ORGANIC REMOVAL BY THE US FILTER MBR ...................................................................................A-33
FIGURE 5-14: ORGANIC REMOVAL BY THE KUBOTA MBR.......................................................................................A-34
FIGURE 5-15: INORGANIC NITROGEN REMOVAL BY THE US FILTER MBR...............................................................A-35
FIGURE 5-16: INORGANIC NITROGEN REMOVAL BY THE KUBOTA MBR..................................................................A-36
FIGURE 5-17: ORTHO-PHOSPHATE REMOVAL BY THE US FILTER MBR...................................................................A-37
FIGURE 5-18: ORTHO-PHOSPHATE REMOVAL BY THE KUBOTA MBR......................................................................A-37
FIGURE 5-19: COLIFORM AND COLIPHAGE REMOVAL BY THE US FILTER MBR ......................................................A-38
FIGURE 5-20: COLIFORM AND COLIPHAGE REMOVAL BY THE KUBOTA MBR..........................................................A-39
FIGURE 5-21: INORGANIC NITROGEN REMOVAL BY THE SAEHAN 4040 BL ROMEMBRANE ...................................A-40
FIGURE 5-22: ORTHO-PHOSPHATE REMOVAL BY THE SAEHAN 4040 BL ROMEMBRANE .......................................A-41
FIGURE 5-23: INORGANIC NITROGEN REMOVAL BY THE HYDRANAUTICS LFC3 ROMEMBRANE............................A-42
FIGURE 5-24: ORTHO-PHOSPHATE REMOVAL BY THE HYDRANAUTICS LFC3 ROMEMBRANE................................A-43
FIGURE 5-25: CONDUCTIVITY PROFILE ACROSS THE SAEHAN 4040 BL ROMEMBRANE..........................................A-44
FIGURE 5-26: CONDUCTIVITY PROFILE ACROSS THE HYDRANAUTICS LFC3 ROMEMBRANE .................................A-44
FIGURE 6-1: HRT AND SRT7-D FOR THE ZENON MBR............................................................................................A-45
FIGURE 6-2: MIXED LIQUOR SOLIDS CONCENTRATION FOR THE ZENON MBR ........................................................A-46
FIGURE 6-3: DOCONCENTRATIONS IN THE ZENON MBR ........................................................................................A-47
A-iii
FIGURE 6-4: HRT AND SRT7-D FOR THE MITSUBISHI MBR.....................................................................................A-48
FIGURE 6-5: MIXED LIQUOR SOLIDS CONCENTRATION FOR THE MITSUBISHI MBR.................................................A-49
FIGURE 6-6: AIR FLOW TO THE MITSUBISHI MBR....................................................................................................A-50
FIGURE 6-7: DOCONCENTRATIONS IN THE MITSUBISHI MBR.................................................................................A-50
FIGURE 6-8: MEMBRANE PERFORMANCE OF THE ZENON MBR................................................................................A-51
FIGURE 6-9: MEMBRANE PERFORMANCE OF THE MITSUBISHI MBR........................................................................A-52
FIGURE 6-10: TURBIDITY REMOVAL BY THE ZENON MBR.......................................................................................A-53
FIGURE 6-11: TURBIDITY REMOVAL BY THE MITSUBISHI MBR...............................................................................A-53
FIGURE 6-12: ORGANICS REMOVAL BY THE ZENON MBR .......................................................................................A-54
FIGURE 6-13: ORGANICS REMOVAL BY THE MITSUBISHI MBR................................................................................A-55
FIGURE 6-14: INORGANIC NITROGEN SPECIES IN THE ZENON MBR.........................................................................A-56
FIGURE 6-15: ORTHO-PHOSPHATE REMOVAL BY THE ZENON MBR.........................................................................A-57
FIGURE 6-16: INORGANIC NITROGEN SPECIES IN MITSUBISHI MBR ........................................................................A-58
FIGURE 6-17: ORTHO-PHOSPHATE REMOVAL BY THE MITSUBISHI MBR.................................................................A-59
FIGURE 6-18: COLIFORM AND COLIPHAGE REMOVAL BY THE ZENON MBR ............................................................A-60
FIGURE 6-19: COLIFORM AND COLIPHAGE REMOVAL BY THE MITSUBISHI MBR.....................................................A-61
FIGURE 8-1: PROBABILITY PLOT OF TURBIDITY REMOVAL BY MBRSYSTEMS DURING PHASE I (PART 1)...............A-62
FIGURE 8-2 PROBABILITY PLOT OF BOD
5
REMOVAL BY MBRSYSTEMS DURING PHASE I (PART 1)........................A-63
FIGURE 8-3 PROBABILITY PLOT OF TOCREMOVAL BY MBR SYSTEMS DURING PHASE I (PART 1) .........................A-64
FIGURE 8-4 PROBABILITY PLOT OF AMMONIA REMOVAL BY MBRSYSTEMS DURING PHASE I (PART 1).................A-65
FIGURE 8-5 PROBABILITY PLOT OF PHOSPHATE REMOVAL BY MBRSYSTEMS DURING PHASE I (PART 1) ..............A-66
FIGURE 8-6 PROBABILITY PLOT OF TOTAL COLIFORM REMOVAL BY MBRS DURING PHASE I (PART 1) ..................A-67
FIGURE 8-7 PROBABILITY PLOT OF FECAL COLIFORM REMOVAL BY MBRS DURING PHASE I (PART 1)...................A-68
FIGURE 8-8 PROBABILITY PLOT OF THE TOTAL COLIPHAGE REMOVAL BY MBRS DURING PHASE I (PART 1)..........A-69
FIGURE 8-9 PROBABILITY PLOT OF THE TURBIDITY REMOVAL BY MBRS DURING PHASE II ....................................A-70
FIGURE 8-10 PROBABILITY PLOT OF BOD
5
REMOVAL BY MBRSYSTEMS DURING PHASE II ...................................A-71
FIGURE 8-11 PROBABILITY PLOT OF TOCREMOVAL BY MBRPILOT SYSTEMS DURING PHASE II...........................A-72
FIGURE 8-12 PROBABILITY PLOT OF AMMONIA REMOVAL BY MBRSYSTEMS DURING PHASE II ............................A-73
FIGURE 8-13 PROBABILITY PLOT OF ORTHO-PHOSPHATE REMOVAL BY MBRSYSTEMS DURING PHASE II .............A-74
FIGURE 8-14 PROBABILITY PLOT OF TOTAL COLIFORM REMOVAL BY MBR SYSTEMS DURING PHASE II ................A-75
FIGURE 8-15 PROBABILITY PLOT OF FECAL COLIFORM REMOVAL BY MBR SYSTEMS DURING PHASE II ................A-76
FIGURE 8-16 PROBABILITY PLOT OF TOTAL COLIPHAGE REMOVAL BY MBR SYSTEMS DURING PHASE II ..............A-77
FIGURE 9-1 OUTLINE OF COSTING APPROACH..........................................................................................................A-78
FIGURE 9-2 MBRRECLAIMED WATER SCHEMATIC: FORWARD FLOW (TOP); RECYCLED FLOW (BOTTOM) ............A-79
FIGURE 9-3: TOTAL COSTS OF VARIOUS CAPACITY MBR SYSTEMS OPERATING ON RAW WASTEWATER................A-80
FIGURE 9-4: TOTAL COSTS OF 1&5 MGDMBRSYSTEMS (RAWWASTEWATER / PRIMARY EFFLUENT) ................A-80
FIGURE 9-5: ECONOMY OF SCALE ANALYSIS FOR MBR SYSTEMS OPERATING ON RAW WASTEWATER..................A-81
A-2
Table 4-1: Specifications for the MBR Membranes
1
Flow capacity based on recommend design flux and active membrane area supplied with the pilot unit.
Table 4-2: Specifications for the RO Membranes
Table 4-3: Specifications for the Aquionics UV Pilot
Units Value
Characteristics
Lamp Type NA Low pressure
Lamp Power watts 150
Design Flow Rate gpm 30
Operating Conditions
Flow Rate gpm 14.4
Feed Water UV Transmittance % 70
Estimated UV Dose mJ/cm
2
~42
Units Saehan Hydranautics
Commercial Designation --- RE 4040-BL LFC3-4040
Active Membrane Area ft
2
(m
2
) 85 (7.9) 85 (7.9)
Membrane Material --- Polyamide (thin film composite) Polyamide (thin film composite)
Operating pH Range --- 3-10 3-10
Maximum Feedwater Turbidity NTU <1 <1
Maximum Feedwater SDI (15 minute) --- <5 <5
Maximum Operating Temperature
o
F (
o
C) 113 (45) 113 (45)
Free Chlorine Resistance mg/L <0.1 <0.1
Specific Flux @ 25 deg C gfd/psi 0.20 0.10
Maximum Operating Pressure psi (bar) 600 (40) 600 (40)
Units Kubota US Filter Zenon Mitsubishi
Commercial Designation ---- Type 510 MemJet B10 R ZW 500 D Sterapore HF
Membrane Classification ---- MF MF UF MF
Membrane Configuration Vertical Vertical Vertical Horizontal
Approx. Size of Element (LxWxH) mm 490X6X1000 1850x100 1930X711X229 886X606X1483
Number of Sheets per membrane cassette --- 100 ------ ------ ------
Number of Fibers per membrane cassette ----- ----- ~2000 ~2700 ~1820
Inside Diameter of Fiber mm ----- 0.65 0.75 0.35
Outside Diameter of Fiber mm ----- 1 1.9 0.54
Length of Fiber m ----- 1.5 1.7 3.24
Active Membrane Area (MBR Pilot) ft
2
(m
2
) 1721 (160) 398 (37) 720 (67) 1076 (100)
1
Flow Capacity (MBR Pilot) gpm 17.6 4.0 7.5 9.2
Flow Direction --- outside - in outside - in outside - in outside - in
Nominal Membrane Pore Size micron 0.4 0.08 0.04 0.4
Absolute Membrane Pore Size micron ----- 0.2 0.1 0.5
Membrane Material/Construction ---
chlorinated
polyethylene;
flat sheet
PVDF/
hollow fiber
proprietary/
hollow fiber
polyethylene/
hollow fiber
Recommended Design Flux gfd (L/h-m
2
) 14.7 (24.9) 14.4 (24.4) 15 (25.4) 12.3 (20.8)
Standard Testing pH range --- 5.8 - 8.6 2-11 5-9.5 2-12
Vacuum Pressure for System psi (bar) <3 (<0.2) <7.3 (<0.5) <11.9 (<0.8) <5.8(<0.4)
A-3
Table 4-4: Analytical Methods / Detection Limits for measured Water Quality Parameters
Parameter Units Method Number and
Type
Detection Limit
Total/Volatile
Suspended Solids
mg/L SM 2540D&E 1.6
Ammonia-N mg/L SM 4500 B&E 0.2
BOD5 mg/L SM 5210B 2
COD mg/L SM5220D/EPA 410.4 22/5
Nitrate/Nitrite-N mg/L HACH 8171 0.1
Nitrite-N mg/L HACH 8507 0.005
Ortho-Phosphate-P mg/L HACH 8048 0.02
Total Hardness mg/L as CaCO3 EPA 130.1/130.2 0.3
Alkalinity mg/L as CaCO3 SM 2320 B 1.5
TKN mg/L EPA 351.3 0.5
TOC mg/L EPA 415.1 0.5
Total Coliform MPN/100 mL SM 9221E <2 MPN/100 mL
Fecal Coliform MPN/100 mL SM 9221B <2 MPN/100 mL
Coliphage pfu/100 mL
1
SM 9224F <1PFU /100mL
HPC CFU/mL SM 9215B 1 CFU/mL
1
20th Edition Addendum.
A-4
Table 5-1: Raw Wastewater Quality Data during Phase I (Part 1)
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 22 mg/L 27.3 30.2 22.4
Nitrate/Nitrite -N 24 mg/L 0.56 2.4 0.36
Nitrite -N 24 mg/L 0.005 0.05 0.001
TKN 14 mg/L 42.9 69.0 33.9
Ortho-Phosphate-P 24 mg/L 0.61 1.53 0.054
BOD
5
20 mg/L 213 274 88.3
COD 23 mg/L 463 783 211
TOC 16 mg/L 40 56 15
Total Hardness 9 mg/L 533 578 15
Calcium Hardness 9 mg/L 245 270 160
Magnesium Hardness 9 mg/L 285 315 192
Alkalinity 20 mg/L 264 286 233
Table 5-2: Advanced Primary Effluent Wastewater Quality Data during Phase I (Part 2)
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 7 mg/L 26.6 29.4 24.1
Nitrate/Nitrite -N 5 mg/L 0.79 1.5 0.06
Nitrite -N 5 mg/L 0.026 0.16 0
TKN 1 mg/L 44.8 44.8 44.8
Ortho-Phosphate-P 5 mg/L 0.46 2.24 0.421
BOD
5
8 mg/L 97 110 57.8
COD 6 mg/L 216 245 147
TOC 1 mg/L 44 44 44
Total Hardness 6 mg/L 393 437 377
Calcium Hardness 6 mg/L 186 202 181
Magnesium Hardness 6 mg/L 208 235 193
Alkalinity 7 mg/L 247 257 238
A-5
Table 5-3: US Filter MBR Permeate Water Quality Data during Phase I (Part 1)
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 14 mg/L 0.3 0.2 0
Nitrate/Nitrite -N 25 mg/L 22 39.9 5.34
Nitrite -N 23 mg/L 0.02 9 0
TKN 8 mg/L 8.45 13.2 2.62
TKN (CEL) 2 mg/L 0.7 0.7 0.7
Ortho-Phosphate-P 24 mg/L 0.357 0.635 0.119
BOD
5
21 mg/L ND 6.27 ND
COD 23 mg/L 43 66 ND
TOC 16 mg/L 6.1 7.6 3.3
Total Hardness 9 mg/L 439 489 378
Calcium Hardness 9 mg/L 210 223 185
Magnesium Hardness 9 mg/L 222 266 193
Alkalinity 21 mg/L 64.3 108 30.1
Table 5-4: US Filter MBR Permeate Water Quality Data during Phase I (Part 2)
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 3 mg/L ND ND ND
Nitrate/Nitrite -N 3 mg/L 26.9 41.8 23.9
Nitrite -N 3 mg/L 0.045 0.077 0.042
TKN 2 mg/L 1.2 1.3 1.1
Ortho-Phosphate-P 3 mg/L 0.771 1.37 0.654
BOD
5
3 mg/L ND ND ND
COD 3 mg/L 31 47 26
COD (CEL) 2 mg/L 10.05 15 5.1
TOC 2 mg/L 6.35 6.6 6.1
Total Hardness 1 mg/L 344 344 344
Calcium Hardness 1 mg/L 164 164 164
Magnesium Hardness 1 mg/L 180 180 180
Alkalinity 3 mg/L 65.1 83.4 48.4
A-6
Table 5-5: Kubota MBR Permeate Water Quality Data during Phase I (Part 1)
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 22 mg/L 0.3 7.6 ND
Nitrate/Nitrite -N 18 mg/L 2.25 2.7 0.30
Nitrite -N 18 mg/L 0.012 0.19 0.005
TKN 8 mg/L 7.06 14.80 2.53
Ortho-Phosphate-P 18 mg/L 0.07 0.15 0.025
BOD
5
16 mg/L ND ND ND
COD 18 mg/L 52 80 29
TOC 13 mg/L 7 8 3.5
Total Hardness 8 mg/L 449 495 410
Calcium Hardness 8 mg/L 216 241 196
Magnesium Hardness 8 mg/L 233 270 215
Alkalinity 16 mg/L 147 182 140
Table 5-6: Kubota MBR Permeate Water Quality Data during Phase I (Part 2)
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 8 mg/L 0.2 1.4 ND
Nitrate/Nitrite -N 9 mg/L 4.11 6.9 2.42
Nitrite -N 24 mg/L 0.165 2.71 0.006
TKN (CEL) 3 mg/L 0.2 0.8 0.12
Ortho-Phosphate-P 24 mg/L 3.80 7.46 0.045
BOD
5
21 mg/L ND 2 ND
COD 5 mg/L 52 59 29
COD (CEL) 4 mg/L 16.5 23 5.1
TOC 5 mg/L 7 9 6.2
Total Hardness 8 mg/L 6 15 2.53
Calcium Hardness 9 mg/L 52 80 29
Magnesium Hardness 9 mg/L 0 0 0.009
Alkalinity 20 mg/L 280 495 14.2
A-7
Table 5-7: Saehan RO Permeate Water Quality Data during Phase I
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 18 mg/L 0.2 0.3 0.2
Nitrate/Nitrite N 18 mg/L 0.45 1.9 0.10
Nitrite N 19 mg/L ND 0.05 ND
TKN (PL LAB) 7 mg/L 2.6 15.1 ND
TKN (CEL) 4 mg/L ND 0.7 ND
Ortho-Phosphate-P 18 mg/L 0.02 0.04 0.02
COD 18 mg/L ND 29 ND
COD (CEL) 4 mg/L 6.35 8 ND
TOC 12 mg/L ND ND ND
Total Hardness 5 mg/L 12 18 7.68
Calcium Hardness 5 mg/L 10 11 6.8
Magnesium Hardness 5 mg/L 2 7 0.874
Alkalinity 17 mg/L 7 8.8 4.5
Table 5-8: Hydranautics RO Permeate Water Quality Data during Phase I
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 17 mg/L 0.2 0.3 0.2
Nitrate/Nitrite -N 17 mg/L 0.31 0.8 0.10
Nitrite -N 18 mg/L ND 1.90 ND
TKN (PL LAB) 7 mg/L ND 8.0 ND
TKN (CEL) 3 mg/L ND ND ND
Ortho-Phosphate-P 18 mg/L ND 0.04 ND
COD 18 mg/L 41.2 66.3 ND
COD (CEL) 3 mg/L 5.1 21 ND
TOC 0 mg/L ND ND ND
Total Hardness 5 mg/L 0 0 0.056
Calcium Hardness 5 mg/L 22 22 22
Magnesium Hardness 5 mg/L 0 0 0.005
Alkalinity 17 mg/L 5 17.9 0.049
A-8
Table 6-1: Advanced Primary Effluent Wastewater Quality Data during Phase II
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 16 mg/L 25.5 28 23
Nitrate/Nitrite -N 16 mg/L 1.06 1.5 0.41
Nitrite -N 16 mg/L 0.01 0.02 0.005
TKN 8 mg/L 29 35.0 1.4
Ortho-Phosphate-P 16 mg/L 0.76 1.23 0.035
BOD
5
14 mg/L 112 165 83.8
COD 26 mg/L 237 285 149
COD (CEL) 7 mg/L 200 230 150
TOC 7 mg/L 44 50 37
1
Total Hardness 6 mg/L 437 456 407
Alkalinity 16 mg/L 252 266 30
1
Total hardness is presented as CaCO
3.
Table 6-2: Zenon MBR Permeate Water Quality Data during Phase II
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 12 mg/L 0.6 5 ND
Nitrate/Nitrite -N 15 mg/L 23.1 5 ND
Nitrite -N 15 mg/L 0.013 0.103 0.006
TKN 8 mg/L 0.98 1.7 0.7
Ortho-Phosphate-P 15 mg/L 0.49 1.24 0.309
BOD
5
14 mg/L ND ND ND
COD 24 mg/L 41 67 ND
COD (CEL) 6 mg/L 18 28 8
TOC 7 mg/L 6.4 8.6 6.1
1
Total Hardness 6 mg/L 400 434 380
Alkalinity 16 mg/L 66 111 7.35
1
Total hardness is presented as CaCO
3.
A-9
Table 6-3: Mitsubishi MBR Permeate Water Quality Data during Phase II
No. of
Analyses Units Median Maximum Minimum
Ammonia-N 12 mg/L 0.3 16 0.3
Nitrate/Nitrite -N 13 mg/L 17.90 29.5 0.20
Nitrite N 13 mg/L 0.057 5.19 0.006
TKN 6 mg/L 4.2 33.0 ND
Ortho-Phosphate-P 13 mg/L 0.59 1.47 0.185
BOD
5
12 mg/L ND ND ND
COD 21 mg/L 44 61 ND
COD (CEL) 6 mg/L 21 31 18
TOC 7 mg/L 6.6 8.7 5.6
Conductivity 66 micromho 2,475 3,270 1,300
1
Total Hardness 7 mg/L 8 31 0.3
1
Total hardness is presented as CaCO
3.
A-10
Table 9-1: Capital Costs for Various Capacity MBR Systems Operating on Raw Wastewater
Headworks $250 $300 $450 $1,800 $3,100
Basins $101 $222 $484 $2,101 $4,154
MBR System $512-$1,375 $991-$1,688 $1,579-$2,347 $5,975-$6,614 $9,600-$12,200
Mechanical $96 $176 $420 $2,438 $5,779
Blower and Pump building $78 $152 $247 $861 $1,661
Chlorine Dosing System $62 $123 $217 $1,083 $2,167
Subtotal $1,099-$1,962 $1,964-$2,660 $3,397-$4,165 $14,258-$14,897 $26,461-$29,061
Electrical, 15% $165-$294 $295-$399 $510-$625 $2,139-$2,235 $3,969-$4,359
Mechanical/ Plumbing/HVAC, 13% $143-$255 $255-$346 $442-$541 $1,854-$1,937 $3,440-$3,778
Sitework, 9% $99-$177 $177-$239 $306-$375 $1,283-$1,341 $2,381-$2,615
Subtotal $1,506-$2,688 $2,691-$3,644 $4,654-$5,706 $19,533-$20,409 $36,252-$39,814
Contractor Overhead and Profit, 15% $226-$403 $404-$547 $698-$856 $3,061-$2,930 $5,438-$5,972
Subtotal-Construction Cost $1,731-$3,091 $3,094-$4,191 $5,352-$6,562 $22,463-$23,470 $41,689-$45,786
Land $250 $500 $750 $1,750 $2,500
Contingency, 15% $260-$464 $464-$629 $803-$984 $3,370-$3,521 $6,253-$6,868
Engineering/Legal/Administration, 15% $260-$464 $464-$629 $803-$984 $3,370-$3,521 $6,253-$6,868
$2,500-$4,270 $4,520-$5,950 $7,710-$9,280 $30,950-$32,260 $56,700-$62,020
Interest Rate 5% 5% 5% 5% 5%
Number of Years 30 30 30 30 30
P/A Factor
15.37 15.37 15.37 15.37 15.37
$294-$387 $502-$604 $2,013-$2,099 $3,688-$4,034 Amortized Capital Cost, $/yr
Total Capital Cost, $
$163-$278
Item
Capital Costs, $K
0.2 MGD 0.5 MGD 1.0 MGD 5.0 MGD 10.0 MGD
A-11
Table 9-2: O&M Costs for MBR Systems Operating on Raw Wastewater
1
Crane cost for 1, 5, and 10 MGD included in capital costs.
2
Membrane replacement costs based on 8-yr life; annual cost shown would be used to fund account
annually.
Electrical Power for Process/Miscellaneous $14 $35 $70 $350 $701
Equipment Repairs/Lubricants/Replacement $6-$11 $10-$14 $16-$21 $70-$70 $144-$149
1
Crane $2.0 $3.0 -------- -------- ---------
Chemical Cleaning $1.6 $4.0 $8.0 $40.0 $80.0
Chemical Cost for Disinfection $0.9 $2.3 $4.6 $22.8 $45.7
Diffuser Replacement $0.5 $1.2 $2.4 $11.8 $23.5
2
Membrane Replacement $5-$15 $10-$40 $20-$80 $87-$400 $171-$800
Labor $18 $25 $31 $88 $229
$54-$58 $94-$120 $158-$212 $671-$983 $1,394-$2,028
Interest Rate 5% 5% 5% 5% 5%
Number of Years 30 30 30 30 30
P/A Factor
15.37 15.37 15.37 15.37 15.37
Total Estimated O&M Costs, $K
Total O&M Costs in First Year, $K
$830-$892 $1,445-$1,845
Item
$2,429-$3,259 $10,315-$15,111 $21,429-$31,175
O & M Costs, $K/yr
0.2 MGD 0.5 MGD 1.0 MGD 5.0 MGD 10.0 MGD
A-12
Table 9-3: Summary of Capital and O&M Costs MBR Operating on Raw Wastewater
Table 9-4: Summary of Costs, $/kgal MBR Operating on Raw Wastewater
$2,500-$4,270 $830-$892 $3,330-$5,162
$4,520-$5,950 $1,445-$1,845 $5,965-$7,795
$7,710-$9,280 $2,429-$3,259 $10,139-$12,539
$30,950-$32,260 $10,315-$15,111 $41,265-$47,371
$56,700-$62,020 $21,429-$31,175 $78,129-$93,195
1
5
10
0.2
0.5
Capacity (MGD)
Raw Wastewater
Capital Costs, $K Total O&M Costs, $K Present Worth Value, $K
$163-$278 $54-$58 $217-$336 $2.97-$4.60
$294-$387 $94-$120 $388-$507 $2.13-$2.78
$502-$604 $158-$212 $660-$816 $1.81-$2.24
$2,013-$2,099 $671-$983 $2,684-$3,082 $1.47-$1.69
$3,688-$4,034 $1,394-$2,028 $5,082-$6,062 $1.39-$1.66
Capacity (MGD)
10
O&M Costs, $K/yr Total Cost $/1000 gal
0.2
1
0.5
5
Raw Wastewater
Amortized Capital Costs,
$K/yr
Total Cost $K/yr
A-13
Table 9-5: Capital Costs 1&5 MGD MBR Operating on Advanced Primary Effluent
1
Excluded headworks cost assume facilities are built at existing advanced primary treatment plant.
1
Headworks
$0 $0
Basins $281 $1,099
MBR System $1,579-$2,347 $5,975-$6,614
Mechanical $395 $2,518
Blower and Pump Building $166 $497
Chlorine Dosing System $217 $1,083
Subtotal $2,638-$3,406 $11,812-$11,173
Electrical, 15% $396-$511 $1,676-$1,772
Mechanical/Plumbing/HVAC, 13% $343-$443 $1,452-$1,536
Sitework, 9% $237-$307 $1,006-$1,063
Subtotal $3,614-$4,667 $15,307-$16,183
Contractor Overhead and Profit, 15% $542-$700 $2,296-$2,427
Subtotal-Construction Cost $4,156-$5,367 $17,603-$18,610
Land $750 $1,750
Contingency, 15% $623-$805 $2,640-$2,792
Engineering/Legal/Administration, 15% $623-$805 $2,640-$2,792
$6,150-$7,730 $24,630-$25,940
Interest rate
5% 5%
Number of Years
30 30
P/A Factor
15.37 15.37
$400-$503 $1,602-$1,687
Item
Capital Costs, $K
1.0 MGD 5.0 MGD
Amortized Capital Cost, $/yr
Total Capital Cost, $
A-14
Table 9-6: O&M Costs for MBR Operating on Advanced Primary Effluent
1
Membrane replacement costs based on 8-yr life; annual cost shown would be used to fund account annually.
Table 9-7: Summary of Capital and O&M Costs Operation on Advanced Primary Effluent
Table 9-8: Summary of Costs, $/kgal Operation on Advanced Primary Effluent
Electrical Power for Process/Miscellaneous $56 $280
Equipment Repairs/Lubricants/Replacement $13-$18 $65-$65
Chemical Cleaning $8 $40
Chemical Cost for Disinfection $4.6 $22.8
Diffuser Replacement $1.3 $6.4
1
Membrane Replacement $20-$80 $87-$400
Labor $31 $88
$139-$194 $590-$903
Interest rate 5% 5%
Number of Years 30 30
P/A Factor 15.37 15.37
Total Estimated O&M Costs, $
Yearly O&M Costs, $/yr
Item
$2,137-$2,982 $9,070-$13,881
O&M Costs, $/yr
1.0 MGD 5.0 MGD
$6,150-$7,730 $2,137-$2,982 $8,287-$10,712
$24,630-$25,940 $9,070-$13,881 $33,700-$39,821
1
5
Advanced Primary Effluent
Capacity (MGD)
Capital Costs, $K Total O&M Costs, $K Present Worth Value, $K
$400-$503 $139-$194 $572-$729 $1.48-$1.91
$1,602-$1,687 $590-$903 $2,241-$2,614 $1.20-$1.42
Advanced Primary Effluent
Amortized Capital
Costs, $K/yr
Total Cost $K/yr
1
5
Capacity (MGD)
O&M Costs,
$K/yr
Total Cost
$/1000 gal
A-15
Figure 4-1: Schematic Diagram of the Point Loma Advanced Wastewater Treatment Plant
Grit
Chamber
Sedimentation
Basin
Primary
Sludge
Grit Screenings
Ferric
Chloride
Flow Baffling
(Solids flocculation)
Effluent Screening
Ocean Discharge
Coagulation
Process
Anionic
Polymer
Raw Wastewater
(MBR Feed)
Primary Effluent
(MBR Feed)
A-16
Feed
Holding
Tank
Kubota MBR
RO
Effluent
Permeate
Tank
Kubota MBR RO Skid
Brine
WAS
Process Tank
US Filter
Permeate
Aerobic Tank
US Filter MBR
Permeate
Tank
WAS
Equalization
Tank
Raw Wastewater
(Part 1)
Drum
Screen
Advanced
Primary Effluent
(Part 2)
Rotary
Brush
Screen
.
Figure 4-2: Schematic Diagram of Pilot Treatment Train during Phase I (Part 1 & Part 2)
A-17
Primary Effluent
Break Tank
Aerobic Tank
Mitsubishi MBR
Permeate
Tank
WAS
Aerobic Tank
ZenoGem Tank
Zenon MBR
Permeate
Tank
WAS
Drum Screen
(0.75 mm screen)
Advanced
Primary Effluent
from PLWTP
Over Flow to
Grit Chamber
MBR Effluent
MBR Effluent
Figure 4-3: Schematic Diagram of Pilot Treatment Train during Phase II
A-18
Figure 4-4: Kubota MBR: Side View (Top); Plan View (Bottom)
Permeate
Raw
Wastewater
Pre-
nitrification
Zone
Denitrification
Zone
Feed
Holding
Tank
Screen
638 gal 1,695 gal
Nitrification Zone
Upper membrane bank
WAS
7
2,664 gal
8
500 gal
Process Tank
15
7
Upper / Lower Membrane Cassettes
Coarse
Bubble
Diffuser
Submerged
Transfer
Pump
Platform with
Guard rail
Nitrification Zone Denitrification Zone
Mixer
A-19
Figure 4-5: US Filter MBR: Side View (Top); Plan View (Bottom)
B
WAS
Wastewater
7.8
7.5
Air
Fine Air Diffusers
1.0 mm wedge
wire screen
Mixed Liquor
3.5
Equalization
Tank
Aerobic Tank
Membrane Tank
Permeate
Storage Tank
7.5
1.6
1.2
1500 gal
90 gal
Wastewater
1 mm Screen
Equalization
Tank
A-20
Figure 4-6: Zenon MBR: Side View (Top); Plan View (Bottom)
B
WAS
MBR
Permeate
Advanced
Primary
Effluent
3.5
7.8
7.8
Coarse Air
Diffusers
Fine Air Diffusers
Aerobic Tank
ZenoGem Tank
Permeate
7.5
2.8
1.6
1300 gal
185 gal
Advanced
Primary
Effluent
0.75 mm
Screen
A-21
Permeate
Advanced
Primary
Effluent
WAS
7.2
1.1
5.3
Coarse air
0.75 mm screen
WAS
Permeate
Advanced
Primary
Effluent
8.7
4.6
1601 gal
Figure 4-7: Mitsubishi MBR: Side View (Top); Plan View (Bottom)
A-22
0
4
8
12
16
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
H
R
T
,
h
Part 1 Part 2
0
50
100
150
200
250
300
350
400
450
500
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
W
a
s
t
i
n
g
R
a
t
e
,
g
a
l
/
d
0
5
10
15
20
25
30
35
40
45
S
R
T
7
-
d
,
d
Wasting Rate, gal/d SRT-7d
Figure 5-1: HRT and SRT
7-d
for the US Filter MBR
A-23
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
TSS VSS
Solids
Dilluted
Part 1 Part 2
0
2
4
6
8
10
12
14
16
18
20
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
V
S
S
W
a
s
t
i
n
g
R
a
t
e
,
k
g
V
S
S
/
d
Figure 5-2: Mixed Liquor Solids for the US Filter MBR
A-24
0
2
4
6
8
10
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
D
O
,
m
g
/
L
Aerobic Tank
Increased Flux
Part 1 Part 2
0
10
20
30
40
50
60
70
80
90
100
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
A
i
r
F
l
o
w
,
s
c
f
m
Total Air Flow Aerobic Tank Membrane Tank
Modif ied
Blower
Figure 5-3: DO Concentration in the US Filter MBR
A-25
0
2
4
6
8
10
12
14
16
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
H
R
T
,
h
Part 1 Part 2
0
200
400
600
800
1000
1200
1400
1600
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
W
a
s
t
i
n
g
R
a
t
e
,
g
a
l
/
d
0
5
10
15
20
25
30
35
40
45
50
S
R
T
7
-
d
,
d
Wasting Rate SRT 7-d
Figure 5-4: HRT and SRT
7-d
for the Kubota MBR
A-26
0
1
2
3
4
5
6
7
8
9
10
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
D
O
,
m
g
/
L
Aerobic Tank
Part 1 Part 2
Figure 5-5: DO Concentration in the Kubota MBR
A-27
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
20,000
22,000
24,000
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Aerobic Tank TSS Aerobic Tank VSS
Pilot Modif ications
Part 1 Part 2
0
10
20
30
40
50
60
70
80
90
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
V
S
S
W
a
s
t
i
n
g
R
a
t
e
,
k
g
V
S
S
/
d
Figure 5-6: Mixed Liquor Solids for the Kubota MBR
A-28
0
2
4
6
8
10
12
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
T
M
P
,
p
s
i
0
5
10
15
20
25
30
35
40
T
e
m
p
e
r
a
t
u
r
e
,
d
e
g
C
TMP Membrane Tank Temperature
cl
2
Backwash
Chemical Clean (cl
2
+acid)
Chemical Clean (cl
2
)
cl
2
Backwash
Part 1 Part 2
0
5
10
15
20
25
30
35
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, hr
F
l
u
x
@
2
0
C
,
g
f
d
0
5
10
15
20
25
30
35
S
p
e
c
i
f
i
c
F
l
u
x
@
2
0
C
,
g
f
d
/
p
s
i
Flux @ 20C Specif ic Flux @ 20C
14.5 gf d
Target Flux =
11.5 gf d 11.5 gf d 14.5 gf d 19-24 gf d 14.5 gf d
Figure 5-7: Membrane Performance of the US Filter MBR
A-29
0
2
4
6
8
10
12
14
16
18
20
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, hr
A
v
e
r
a
g
e
T
M
P
,
p
s
i
0
5
10
15
20
25
30
35
A
e
r
o
b
i
c
T
a
n
k
T
e
m
p
e
r
a
t
u
r
e
,
d
e
g
C
Average TMP Aerobic Tank Temperature
Start up
Chemical Cleaning
Bottom membrane
cassette of f line
Part 1 Part 2
0
2
4
6
8
10
12
14
16
18
20
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
F
l
u
x
@
2
0
C
,
g
f
d
0
5
10
15
20
25
30
35
40
S
p
e
c
i
f
i
c
F
l
u
x
@
2
0
d
e
g
C
,
g
f
d
/
p
s
i
Flux @ 20C Specif ic Flux @ 20C
Target Flux=15 gf d
Figure 5-8: Membrane Performance of the Kubota MBR
A-30
0
25
50
75
100
125
150
175
200
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
N
e
t
O
p
e
r
a
t
i
n
g
P
r
e
s
s
u
r
e
,
p
s
i
0
5
10
15
20
25
30
35
40
T
e
m
p
e
r
a
t
u
r
e
,
C
Net Operating Pressure Temperature
Began chloramine
addition
Membrane Cleaning
Part 1 Part 2
0
5
10
15
20
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
F
l
u
x
@
2
5
C
,
g
f
d
0.0
0.2
0.4
0.6
0.8
S
p
e
c
i
f
i
c
F
l
u
x
@
2
5
C
,
g
f
d
/
p
s
i
Flux @ 25C Specif ic Flux @ 25C
Target Flux = 10 gf d
Figure 5-9: Saehan 4040 BL RO Membrane Performance
A-31
0
25
50
75
100
125
150
175
200
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
N
e
t
O
p
e
r
a
t
i
n
g
P
r
e
s
s
u
r
e
,
p
s
i
0
5
10
15
20
25
30
35
40
T
e
m
p
e
r
a
t
u
r
e
,
d
e
g
C
Net Operating Pressure Temperature
Began chloramine
addition
Membrane Cleaning
Part 1 Part 2
0
5
10
15
20
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
F
l
u
x
@
2
5
d
e
g
C
,
g
f
d
0.0
0.1
0.2
0.3
0.4
S
p
e
c
i
f
i
c
F
l
u
x
@
2
5
d
e
g
C
,
g
f
d
/
p
s
i
Flux @ 25C Specif ic Flux @ 25C
Target Flux = 10 gf d
Figure 5-10: Hydranautics LFC3 RO Membrane Performance
0.01
0.10
1.00
10.00
100.00
1000.00
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
T
u
r
b
i
d
i
t
y
,
N
T
U
Feed Wastewater Turbidity MBR Permeate Turbidity
Part 1 Part 2
Figure 5-11: Turbidity Removal by the US Filter MBR
0.01
0.10
1.00
10.00
100.00
1000.00
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
T
u
r
b
i
d
i
t
y
,
N
T
U
Feed Wastewater Turbidity MBR Permeate Turbidity
Part 1 Part 2
Figure 5-12: Turbidity Removal by the Kubota MBR
A-33
1
10
100
1000
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater BOD5 MBR Permeate BOD5
open symbols denote below detection limit
Part 1 Part 2
1
10
100
1000
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater COD MBR Permeate COD (City Lab) MBR Permeate COD (Commercial Lab)
Part 1 Part 2
1
10
100
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater TOC MBR Permeate TOC
Part 1 Part 2
Figure 5-13: Organic Removal by the US Filter MBR
A-34
1
10
100
1000
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater BOD5 MBR Permeate BOD5
open symbols denote below detection limit
Part 1 Part 2
1
10
100
1000
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater COD MBR Permeate COD (City Lab) MBR Permeate COD (Commercial Lab)
Part 1 Part 2
1
10
100
1000
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater TOC MBR Permeate TOC
Part 1 Part 2
Figure 5-14: Organic Removal by the Kubota MBR
A-35
0
10
20
30
40
50
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Watsewater NH3-N MBR Permeate NH3-N
open symbols denote below detection limit
Part 1 Part 2
0
10
20
30
40
50
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater NO3-N MBR Permeate NO3-N
Part 1 Part 2
0
10
20
30
40
50
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater NO2-N MBR Permeate NO2-N
Part 1 Part 2
Figure 5-15: Inorganic Nitrogen Removal by the US Filter MBR
A-36
0
10
20
30
40
50
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater NH3-N MBR Permeate NH3-N
open symbols denote below detection limit
Part 1 Part 2
0
10
20
30
40
50
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater NO3/NO2-N MBR Permeate NO3/NO2-N
Part 1 Part 2
0
10
20
30
40
50
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Feed Wastewater NO2-N MBR Permeate NO2-N
Part 1 Part 2
Figure 5-16: Inorganic Nitrogen Removal by the Kubota MBR
A-37
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
P
/
L
Feed Wastewater PO4-P MBR Permeate PO4-P
Part 1 Part 2
Figure 5-17: Ortho-Phosphate Removal by the US Filter MBR
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
P
/
L
Feed Wastewater PO4-P MBR Permeate PO4-P
Part 1 Part 2
Figure 5-18: Ortho-Phosphate Removal by the Kubota MBR
A-38
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
s
,
M
P
N
/
1
0
0
m
L
Feed Wastewater Total Coliforms MBR Permeate Total Colif orms
Permeate Line Disinf ected
Part 1 Part 2
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
M
P
N
/
1
0
0
m
L
Feed Wastewater Fecal Coliforms MBR Permeate Fecal Coliforms
open symbols denote below detection limit
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
M
P
N
/
1
0
0
m
L
Feed Wastewater Total Coliphage MBR Permeate Total Coliphage
open symbols denote below detection limit
Figure 5-19: Coliform and Coliphage Removal by the US Filter MBR
A-39
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
M
P
N
/
1
0
0
m
L
Feed Wastewater Total Coliforms Lower Permeate Total Coliforms Upper Permeate Total Colif orms
open symbols denote below detection
Part 1 Part 2
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
M
P
N
/
1
0
0
m
L
Feed Wastewater Fecal Coliforms Lower Permeate Fecal Colif orms Upper Permeate Fecal Colif orms
open symbols denote below detection limit
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
p
f
u
/
1
0
0
m
L
Feed Wastewater Total Coliphage Lower Permeate Total Coliphage Upper Permeate Total Coliphage
open symbols denote below detection limit
Figure 5-20: Coliform and Coliphage Removal by the Kubota MBR
A-40
0.001
0.010
0.100
1.000
10.000
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
Feed NH3-N RO Permeate NH3-N
open symbols denote below detection limit
0.001
0.010
0.100
1.000
10.000
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
Feed NO3/N02 RO Permeate NO3/NO2-N
open symbols denote below detection limit
0.001
0.010
0.100
1.000
10.000
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
Feed NO2-N RO Permeate NO2-N
open symbols denote below detection limit
Figure 5-21: Inorganic Nitrogen Removal by the Saehan 4040 BL RO Membrane
A-41
0.01
0.10
1.00
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
P
/
L
Feed PO4-P RO Permeate PO4-P
open symbols denote below detection limit
Figure 5-22: Ortho-Phosphate Removal by the Saehan 4040 BL RO Membrane
A-42
0.001
0.010
0.100
1.000
10.000
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
Feed NH3-N RO Permeate NH3-N
open symbols denote below detection limit
0.001
0.010
0.100
1.000
10.000
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
Feed NO3/NO2-N RO Permeate NO3/NO2-N
open symbols denote below detection limit
0.001
0.010
0.100
1.000
10.000
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
Feed NO2-N RO Permeate NO2-N
open symbols denote below detection limit
Figure 5-23: Inorganic Nitrogen Removal by the Hydranautics LFC3 RO Membrane
A-43
0.01
0.10
1.00
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
P
/
L
Feed PO4-P RO Permeate PO4-P
open symbols denote below detection limit
Figure 5-24: Ortho-Phosphate Removal by the Hydranautics LFC3 RO Membrane
A-44
1
10
100
1000
10000
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
d
u
c
t
i
v
i
t
y
,
m
i
c
r
o
m
h
o
s
Permeate Conductivity Feed Conductivity
Figure 5-25: Conductivity Profile across the Saehan 4040 BL RO Membrane
1
10
100
1000
10000
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
d
u
c
t
i
v
i
t
y
,
m
i
c
r
o
m
h
o
Feed Conductivity Permeate Conductivity
Figure 5-26: Conductivity Profile Across the Hydranautics LFC3 RO Membrane
A-45
0
2
4
6
8
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
H
R
T
,
h
0
50
100
150
200
250
300
350
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
S
o
l
i
d
s
W
a
s
t
i
n
g
R
a
t
e
,
g
a
l
/
d
0
5
10
15
20
25
30
35
40
S
R
T
7
-
d
,
d
Wasting Rate SRT 7-d
Figure 6-1: HRT and SRT7-d for the Zenon MBR
A-46
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
20,000
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
S
o
l
i
d
s
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
TSS VSS
Mixed Liquor Diluted
Start Up
0
2
4
6
8
10
12
14
16
18
20
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
V
S
S
W
a
s
t
i
n
g
R
a
t
e
(
k
g
V
S
S
/
d
a
y
)
Figure 6-2: Mixed Liquor Solids Concentration for the Zenon MBR
A-47
0
1
2
3
4
5
6
7
8
9
10
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
D
O
,
m
g
/
L
Aerobic Tank
Figure 6-3: DO Concentrations in the Zenon MBR
A-48
0
2
4
6
8
10
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
H
R
T
,
h
0
50
100
150
200
250
300
350
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
S
o
l
i
d
s
W
a
s
t
i
n
g
R
a
t
e
,
g
a
l
/
d
0
5
10
15
20
25
30
35
40
45
50
S
R
T
7
-
d
,
d
Wasting Rate SRT 7-d
System shut down
Figure 6-4: HRT and SRT7-d for the Mitsubishi MBR
A-49
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
20,000
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
S
o
l
i
d
s
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
TSS VSS
Solids Diluted/ re-seeded
Start Up
System re-seeded/on line
Shut down to replace blower
0
2
4
6
8
10
12
14
16
18
20
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
V
S
S
W
a
s
t
i
n
g
R
a
t
e
,
k
g
V
S
S
/
d
a
y
Figure 6-5: Mixed Liquor Solids Concentration for the Mitsubishi MBR
A-50
0
10
20
30
40
50
60
70
80
90
100
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
A
i
r
F
l
o
w
,
s
c
f
m
Total Air Flow Fine Air Flow
Replaced Blower Shives
Removed Check Valve
Added Fine Bubble Dif f users
Figure 6-6: Air Flow to the Mitsubishi MBR
0
1
2
3
4
5
6
7
8
9
10
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
D
O
,
m
g
/
L
Aerobic Tank
Figure 6-7: DO Concentrations in the Mitsubishi MBR
A-51
0
1
2
3
4
5
6
7
8
9
10
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
V
a
c
u
u
m
P
r
e
s
s
u
r
e
,
p
s
i
0
4
8
12
16
20
24
28
32
36
40
T
e
m
p
e
r
a
t
u
r
e
,
C
Vacuum Pressure Maintenance Clean Zenogem Tank Temperature
VFD
Failure
VFD
Failure
Chemical
Clean
nitrif cation
lost
Flux
Increased
MLSS
Diluted
0
5
10
15
20
25
30
35
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
F
l
u
x
@
2
0
C
,
g
f
d
0
5
10
15
20
25
30
35
S
p
e
c
i
f
i
c
F
l
u
x
@
2
0
C
,
g
f
d
/
p
s
i
Flux @ 20C Specif ic Flux @ 20C
Target Flux = 22 gfd
Figure 6-8: Membrane Performance of the Zenon MBR
A-52
0
1
2
3
4
5
6
7
8
9
10
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
V
a
c
u
u
m
P
r
e
s
s
u
r
e
,
p
s
i
0
4
8
12
16
20
24
28
32
36
40
T
e
m
p
e
r
a
t
u
r
e
,
C
Overall Vacuum Pressure Aerobic Tank Temperature
Foaming
Blower Failed
Chemical Cleaning
System on line
0
5
10
15
20
25
30
35
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation (hours)
F
l
u
x
@
2
0
C
,
g
f
d
0
5
10
15
20
25
30
35
S
p
e
c
i
f
i
c
F
l
u
x
@
2
0
C
,
g
f
d
/
p
s
i
Flux @ 20C Specif ic Flux @ 20C
Target Flux = 11.8 gf d 14.8 gf d
Figure 6-9: Membrane Performance of the Mitsubishi MBR
A-53
0.01
0.10
1.00
10.00
100.00
1000.00
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
T
u
r
b
i
d
i
t
y
(
N
T
U
)
Primary Ef f luent Turbidity MBR Permeate Turbidity
Turbidimeter cleaned time of operation = 2,742 h
Figure 6-10: Turbidity Removal by the Zenon MBR
0.01
0.10
1.00
10.00
100.00
1000.00
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time of Operation, h
T
u
r
b
i
d
i
t
y
(
N
T
U
)
Primary Ef f luent Turbidity MBR Permeate Turbidity
Figure 6-11: Turbidity Removal by the Mitsubishi MBR
A-54
1
10
100
1000
0 500 1000 1500 2000 2500 3000 3500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
(
m
g
/
L
)
Primary Ef fluent BOD5 MBR Permeate BOD5
open symbols denote below
1
10
100
1000
0 500 1000 1500 2000 2500 3000 3500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
(
m
g
/
L
)
Primary Ef f luent COD MBR Permeate COD
0.10
1.00
10.00
100.00
1000.00
0 500 1000 1500 2000 2500 3000 3500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
(
m
g
/
L
)
MBR Permeate TOC
Figure 6-12: Organics Removal by the Zenon MBR
A-55
1
10
100
1000
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
(
m
g
/
L
)
Primary Eff luent BOD5 MBR Permeate BOD5
open symbols denote below detection
1
10
100
1000
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
(
m
g
/
L
)
Primary Ef f luent COD MBR Permeate COD
0.10
1.00
10.00
100.00
1000.00
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
MBR Permeate TOC
Figure 6-13: Organics Removal by the Mitsubishi MBR
A-56
0
5
10
15
20
25
30
35
0 500 1000 1500 2000 2500 3000 3500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
m
g
-
N
/
L
MBR Permeate NH3-N
0
5
10
15
20
25
30
35
0 500 1000 1500 2000 2500 3000 3500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
MBR Permeate NO2/NO3-N
0
5
10
15
20
25
30
35
0 500 1000 1500 2000 2500 3000 3500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
MBR Permeate NO2-N
Figure 6-14: Inorganic Nitrogen Species in the Zenon MBR
A-57
0
0.5
1
1.5
2
0 500 1000 1500 2000 2500 3000 3500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
P
/
L
Primary Ef fluent PO4-P MBR Permeate P04-P
Figure 6-15: Ortho-Phosphate Removal by the Zenon MBR
A-58
0
5
10
15
20
25
30
35
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
MBR Permeate NH3-N
0
5
10
15
20
25
30
35
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
MBR Permeate NO2/NO3-N
0
5
10
15
20
25
30
35
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
MBR Permeate NO2-N
Figure 6-16: Inorganic Nitrogen Species in Mitsubishi MBR
A-59
0
0.5
1
1.5
2
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
P
/
L
Primary Eff luent PO4-P MBR Permeate P04-P
Figure 6-17: Ortho-Phosphate Removal by the Mitsubishi MBR
A-60
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000 3500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
M
P
N
/
1
0
0
m
L
Primary Ef fluent Total Coliforms MBR Permeate Total Coliforms
After Disinfection
open symbols denote below detection
li i
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000 3500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
(
M
P
N
/
1
0
0
m
L
)
Primary Eff luent Fecal Colif orms MBR Permeate Fecal Colif orms
open symbols denote below detection
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000 3500
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
P
F
U
/
1
0
0
m
L
Primary Ef fluent Total Coliphage MBR Permeate Total Coliphage
open symbols denote below detection
Figure 6-18: Coliform and Coliphage Removal by the Zenon MBR
A-61
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
M
P
N
/
1
0
0
m
L
Primary Ef fluent Total Colif orms MBR Permeate Total Colif orms
open symbols denote below detection
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
M
P
N
/
1
0
0
m
L
Primary Eff luent Fecal Coliforms MBR Permeate Fecal Colif orms
open symbols denote below detection
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
0 500 1000 1500 2000 2500 3000
Time of Operation, h
C
o
n
c
e
n
t
r
a
t
i
o
n
,
P
F
U
/
1
0
0
m
L
Primary Eff luent Total Coliphage MBR Permeate Total Coliphage
open symbols denote below detection
Figure 6-19: Coliform and Coliphage Removal by the Mitsubishi MBR
A-62
0.01
0.1
1
10
100
1000
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Raw Wastewater Turbidity
Kubota MBR Permeate Turbidity
US Filter MBR Permeate Turbidity
T
u
r
b
i
d
i
t
y
,
N
T
U
Percent
Figure 8-1: Probability Plot of Turbidity Removal by MBR Systems during Phase I (Part 1)
A-63
1
10
100
1000
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Raw Wastewater BOD5
Kubota MBR Permeate BOD5
US Filter MBR Permeate BOD5
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Percent
Figure 8-2 Probability Plot of BOD
5
Removal by MBR Systems during Phase I (Part 1)
A-64
.01 .1 1 5 10 20 30 50 70 80 90 95 99 99.9 99.99
Raw Wastewater TOC
Kubota MBR TOC
US Filter MBR Permeate TOC
0
6
12
18
24
30
36
42
48
54
60
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Percent
Figure 8-3 Probability Plot of TOC Removal by MBR Systems during Phase I (Part 1)
A-65
0
10
20
30
40
50
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Raw Wastewater Ammonia-N
Kubota MBR Permeate Total Inorganic Nitrogen
US Filter MBR Permeate Total Inorganic Nitrogen
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
N
/
L
Percent
Figure 8-4 Probability Plot of Ammonia Removal by MBR Systems during Phase I (Part 1)
A-66
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Raw Wastewater PO4-P
Kubota MBR Permeate PO4-P
US Filter MBR Permeate PO4-P
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
P
/
L
Percent
Figure 8-5 Probability Plot of Phosphate Removal by MBR Systems during Phase I (Part 1)
A-67
Figure 8-6 Probability Plot of Total Coliform Removal by MBRs during Phase I (Part 1)
10
0
10
1
10
2
10
3
10
4
10
5
10
6
10
7
10
8
.01 .1 1 5 10 20 30 50 70 80 90 95 99 99.9 99.99
Raw Wastewater Total Coliforms
Kubota MBR Permeate Total Coliforms
US Filter MBR Permeate Total Coliforms
Percent
A-68
10
0
10
1
10
2
10
3
10
4
10
5
10
6
10
7
10
8
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Raw Wastewater Fecal Coliforms
Kubota MBR Permeate Fecal Coliforms
US Filter MBR Permeate Fecal Coliforms
C
o
n
c
e
n
t
r
a
t
i
o
n
,
M
P
N
/
1
0
0
m
L
Percent
Figure 8-7 Probability Plot of Fecal Coliform Removal by MBRs during Phase I (Part 1)
A-69
10
0
10
1
10
2
10
3
10
4
10
5
10
6
.01 .1 1 5 10 20 30 50 70 80 90 95 99 99.9 99.99
Raw Wastewater Total Coliphage
Kubota MBR Permeate Total Coliphage
US Filter MBR Permeate Total Coliphage
C
o
n
c
e
n
t
r
a
t
i
o
n
,
P
F
U
/
1
0
0
m
L
Percent
Figure 8-8 Probability Plot of the Total Coliphage Removal by MBRs during Phase I (Part 1)
A-70
0.01
0.1
1
10
100
1000
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Primary Effluent Turbidity
Zenon MBR Permeate Turbidity
Mitsubishi MBR Permeate Turbidity
T
u
r
b
i
d
i
t
y
,
N
T
U
Percent
Figure 8-9 Probability Plot of the Turbidity Removal by MBRs during Phase II
A-71
1
10
100
1000
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Primary Effluent BOD5
Zenon MBR Permeate BOD5
Mitsubishi Permeate BOD5
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Percent
Figure 8-10 Probability Plot of BOD
5
Removal by MBR Systems during Phase II
A-72
0
12
24
36
48
60
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Primary Effleunt TOC
Zenon MBR TOC
Mitsubishi MBR Permeate TOC
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
/
L
Percent
Figure 8-11 Probability Plot of TOC Removal by MBR Pilot Systems during Phase II
A-73
0
5
10
15
20
25
30
35
40
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Primary Effluent Ammonia-N
Zenon MBR Permeate Ammonia-N
Mitsubishi Permeate Ammonia-N
C
o
n
c
e
n
t
r
a
t
i
o
n
m
g
-
N
/
L
Percent
Figure 8-12 Probability Plot of Ammonia Removal by MBR Systems during Phase II
A-74
0
0.5
1
1.5
2
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Primary Effluent PO4-P
Zenon MBR Permeate PO4-P
Mitsubishi Permeate PO4-P
C
o
n
c
e
n
t
r
a
t
i
o
n
,
m
g
-
P
/
L
Percent
Figure 8-13 Probability Plot of Ortho-Phosphate Removal by MBR Systems during Phase II
A-75
Figure 8-14 Probability Plot of Total Coliform Removal by MBR Systems during Phase II
10
0
10
2
10
4
10
6
10
8
10
10
.01 .1 1 5 10 2030 50 7080 90 95 99 99.9 99.99
Primary Effluent Total Coliforms
Zenon MBR Permeate Total Coliforms
Mitsubishi Permeate Total Coliforms
Percent
A-76
10
0
10
1
10
2
10
3
10
4
10
5
10
6
10
7
10
8
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Primary Effluent Fecal Coliforms
Zenon MBR Permeate Fecal Coliforms
Mitsubishi Permeate Fecal Coliforms
C
o
n
c
e
n
t
r
a
t
i
o
n
,
M
P
N
/
1
0
0
m
L
Percent
Figure 8-15 Probability Plot of Fecal Coliform Removal by MBR Systems during Phase II
A-77
10
0
10
1
10
2
10
3
10
4
10
5
10
6
.01 .1 1 5 10 20 30 50 7080 90 95 99 99.9 99.99
Primary Effluent Total Coliphage
Zenon MBR Permeate Total Coliphage
Mitsubishi Permeate Total Coliphage
C
o
n
c
e
n
t
r
a
t
i
o
n
,
P
F
U
/
1
0
0
m
L
Percent
Figure 8-16 Probability Plot of Total Coliphage Removal by MBR Systems during Phase II
A-78
Conducted MBR Costing Workshop
Developed Specific MBR Design Criteria
Requested Membrane Costs
from 4 MBR Suppliers
Performed Preliminary Process Design of
Complete MBR Reclamation Facilities
Compiled Costs MBR and Process Costs to
develop Total Cost Estimates for 0.2-10 mgd
MBR Reclamation facilities
Tailored Costs to Consider Operation on
Advanced Primary Effluent
+
Figure 9-1 Outline of Costing Approach
A-79
Figure 9-2 MBR Reclaimed Water Schematic: Forward Flow (Top); Recycled Flow (Bottom)
Perm. Pumps Perm. Pumps
Chlorine Contact Chlorine Contact
Finished Water Finished Water Forebay Forebay
Selectors Selectors Nitrification Nitrification Membranes Membranes
Anoxic Anoxic
Zones Zones
Anaerobic Anaerobic
Zones Zones
Oxic Oxic Zones Zones
Screened Screened
&& Degritted Degritted
Wastewater Wastewater
Membrane Membrane
Bays Bays
Reclaimed Reclaimed
Water Water
Finished Water Pumps Finished Water Pumps
Selectors Selectors Nitrification Nitrification Membranes Membranes
Anoxic Anoxic
Zones Zones
Anaerobic Anaerobic
Zones Zones
Oxic Oxic Zones Zones
Screened Screened
&& Degritted Degritted
Wastewater Wastewater
Membrane Membrane
Bays Bays
Solids Recirculation System Solids Recirculation System
MLSS Recycle System MLSS Recycle System
A-80
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
0.2 0.5 1 5 10
Capacity, mgd
T
o
t
a
l
C
o
s
t
(
$
/
1
0
0
0
g
a
l
)
Figure 9-3: Total Costs of Various Capacity MBR Systems Operating on Raw wastewater
1
5
Primary Effluent
Raw Wastewater
0.00
0.50
1.00
1.50
2.00
2.50
Total Cost
($/1000 gal)
Capacity, mgd
Figure 9-4: Total Costs of 1& 5 MGD MBR Systems (Raw Wastewater / Primary Effluent)
A-81
0
4,000
8,000
12,000
16,000
20,000
24,000
0.2 0.5 1 5 10
Capacity, mgd
T
o
t
a
l
C
o
s
t
(
$
K
/
m
g
d
)
MBR System Costs Membrane Costs
Figure 9-5: Economy of Scale Analysis for MBR Systems Operating on Raw Wastewater
APPENDIX B
Membrane Cleaning Protocols
B-1
MEMBRANE CHEMICAL CLEANING PROTOCOLS
Mitsubishi MBR In-Line Chemical Cleaning Protocol
In-Line Chlorine/Acid Cleaning
NaOCl: effective concentration of 3,000 mg/L (0.3%)
Citric Acid: effective concentration of 2,000 mg/L (0.2%)
1. Mix together water with cleaning compound to achieve desired solution in the chemical
cleaning tank (40 gallons).
2. Close ball valve that is before the suction pump.
3. Open the two swagelok ball valves so the center chemical injection point is open to each side
of the membrane fibers.
4. Connect the ball valve on the chemical tank to the union on the injection port.
5. Allow the chemical tank to rest on the edge of the MBR tank.
6. Open the ball valve on the chemical tank and allow the chemical solution to back flow
through the membrane for 2 hours.
7. After 2 hours, close the valve on the chemical tank and allow the chemical solution to soak in
the membrane fibers for an additional 2 hours.
8. Repeat for the other membrane side.
9. Once complete, close the swage valves and open the ball valve near the suction side of the
pump.
10. Resume normal operation.
B-2
Zenon Clean-in-Place (CIP) Protocol
Chemical Reagent: Sodium Hypochlorite (effective chlorine concentration: 2,000 mg/L) or Citric
Acid (effective pH = 2.0-3.0, approximately 2,000-3,000 mg/L)
1. Isolate the ZenoGem tank.
2. Drain the ZenoGem tank by pumping mixed liquor into the aeration basin.
3. Hose down ZenoGem until water appears clear.
4. Prepare chemical reagent in CIP tank.
5. Backpulse the cleaning solution through the membrane until tank is empty.
6. Recirculate the dilute solution through membranes; measure flux, then allow to soak.
7. Repeat Step 6 until flux is equal in two consecutive readings. Allow to soak overnight, if
necessary.
8. Drain tank and hose down until there is no chlorine present.
9. Put back into service.
Zenon Maintenance Cleaning Protocol
Chemical Reagent: Sodium Hypochlorite (concentration = 250 mg/L in BW Tank) or Citric Acid
(concentration = 2,000 mg/L in BW Tank)
1. Shut down pilot unit.
2. Let the system relax for 5 minutes.
3. Fill the CIP (clean in place) tank with the cleaning solution.
4. Put the system in Backpulse mode.
5. Backpulse the system for 15 seconds at a flow rate of 16.7 gpm.
6. Relax for 30 seconds.
7. Backpulse the system for 10 seconds.
8. Relax for 30 seconds.
9. Repeat steps 7 and 8, two times.
10. Put system back into service.
B-3
Kubota Chlorine Cleaning Protocol
1. Prepare 160 gallons of 0.5 % (w/w) of sodium hypochlorite.
2. Stop the feed to system.
3. Stop filtration.
4. Stop MBR blower.
5. Stop recycle pump
6. Open caps on the 2 permeate lines (upper and lower membrane banks) at the top of the
nitrification tank.
7. Insert the chemical feed pump discharge into the upper permeate line.
8. Pump 80 gallons of the sodium hypochlorite solution prepared in Step 1.
9. Insert the chemical feed pump discharge into the lower permeate line.
10. Pump 80 gallons of the sodium hypochlorite solution prepared in Step 1.
11. Close caps on the permeate lines.
12. Soak membranes for 2 hours.
13. Turn all equipment back on and put the system in auto.
Kubota Oxalic Acid Cleaning Protocol
1. Prepare 160 gallons of 1% (w/w) Oxalic Acid.
2. Stop the feed to system.
3. Stop filtration.
4. Stop MBR blower.
5. Stop recycle pump
6. Open caps on the 2 permeate lines (upper and lower membrane banks) at the top of the
nitrification tank.
7. Insert the chemical feed pump discharge into the upper permeate line.
8. Pump 80 gallons of the sodium hypochlorite solution prepared in Step 1.
9. Insert the chemical feed pump discharge into the lower permeate line.
10. Pump 80 gallons of the sodium hypochlorite solution prepared in Step 1.
11. Close caps on the permeate lines.
12. Soak membranes for 1 hour.
13. Turn all equipment back on and put the system in auto.
B-4
US Filter Chemical Cleaning Protocol
Chemical Reagent: Sodium Hypochlorite (chlorine concentration = 100 mg/L) or Citric Acid
(acid concentration = 2,000 mg/L)
1. Isolate the aeration tank.
2. Pump the mixed liquor from the aeration tank.
3. Fill the aeration tank with rinse water (from the filtrate tank).
4. Aerate membranes and reticulate rinse water through mixed liquor manifold for 10 minutes.
5. Drain the rinse water.
6. Fill the aeration tank with chlorinated CIP water.
7. Recirculate chemical through lumens.
8. Recirculate chemical though mixed liquor manifolds.
9. Recirculate chemical through in-tank air manifold.
10. Soak for up to 4 minutes.
11. Drain tank and hose down until there is no chlorine present.
12. Return to normal operation.
B-5
Cleaning Protocol for Saehan RE4040 BL and Hydranautics LFC Reverse
Osmosis Membranes
Chemical Reagent: 0.1 gallons for sodium hydroxide, 0.025 gallons of sodium lauryl dodecyl
sulfate, pH 11 12, Temperature 30C, Volume of Chemical Reagent: 0.81 L/ft
2
of membrane
area.
1. Flush pressure vessels at 5 gpm with RO permeate for several minutes.
2. Circulate the cleaning solution at 5 gpm for 30 minutes. If the cleaning solution colors
becomes turbid, restart with freshly prepared cleaning solution.
3. Check pH of cleaning solution while in circulation. If pH increase by more than 0.5 pH
units, add acid (HCL).
4. Turn recirculation pump off and allow the membranes to soak for 1 hour.
5. Circulate the cleaning solution again at 10 gpm for 30 - 60 minutes.
6. Drain and flush cleaning tank.
7. Rinse pressure vessels with RO permeate whose pH has been adjusted to 4.5 - 5.5 using
hydrochloric acid (HCL) for several minutes. The minimum temperature of the rinse
water should be 68 F (20 C). Have both permeate and concentrate valves open during
flushing. Flushing should be once-through step.
8. Operate the system as normal.
APPENDIX C
QA/QC Memorandum
C-1
M E M O R A N D U M
To: Samer Adham, Ph.D. Date: 10-09-03
From: James DeCarolis / Jude Grounds
Reference:
Subject: Optimization of Various MBR
Systems for Water Reclamation:
QA/QC Protocol
Pilot testing for the Bureau of Reclamation project entitled Optimization of Various MBR
Systems for Water Reclamation, was begun in April of 2002 at the Point Loma Waste Water
Treatment Plant (PLWWTP) in San Diego, California. To ensure the accuracy and integrity of
the data collected, a number of quality assurance and quality control procedures were followed
throughout the experiment. This Technical Memorandum (TM) summarizes these procedures
for the on-site instrument verification and water quality analysis performed by the project team,
including:
On-line Turbidimeters
On-line Conductivity Meter
On-line Dissolved Oxygen (DO) Meters
Membrane System Thermometers
Membrane System Pressure Gauges
Membrane System Rotameters
Membrane System Level Sensors
Membrane/UV System Run Hour Clock
Chemical Feed Pumping Rate
Portable DO/Temperature Meter
Desktop pH Meter
Desktop Turbidimeter
Desktop Ultraviolet (UV) Spectrophotometer
Desktop Silt Density Index (SDI) Analyzer
The sampling protocol for off-site water quality analysis is also described herein. All off-site
water quality analysis were analyzed at one of the following locations: onsite, Point Loma
laboratory (PL Lab) the City of San Diego Water Quality Laboratory @ Alvarado and
Calscience Environmental Laboratories (CEL Lab). All labs have the State of California
Department of Health Services (DHS) Environmental Laboratory Accredited Programs (ELAP),
and follow the associated QA/QC requirements.
C-2
Lastly, this TM provides the QA/QC procedures followed to ensure accurate data management
and data analyses of all water quality and operational data collected during this study.
ON-LINE TURBIDIMETERS
Two types of on line turbidimeters systems were used during testing to acquire MBR permeate
turbidities. Permeate turbidities of the Kubota, Zenon and Mitsubishi MBR systems were
measured using Hach 1720D turbidimeters while the US Filter permeate turbidity was measured
using a GLI Accu4 turbidimeter system. The GLI system contained a Model T53 analyzer an
8320 sensor. Both the 1720 D and Accu4 systems are designed to accurately measure low range
turbidity. Turbidity values were manually collected from each MBR on a daily basis. The
following procedures were followed to ensure the integrity and accuracy of this data:
- A primary calibration of the on-line turbidimeters was performed at the beginning of the
test period and as needed during testing.
- On-line turbidities were compared to desktop turbidities to verify accurate calibration.
- The manufacturers specified acceptable discharge flow range for the Hach 1720 D is 250
to 750 mL/min and the GLI Accu4 is 190 to 1500 mL/min. On-line turbidimeter flows
were verified daily with a graduated cylinder and stopwatch, and adjusted as necessary.
- The turbidmeters were periodically cleaned using a 50 ppm free chlorine solution to
remove build of ferric hydroxide precipitate and/or algae.
ON-LINE CONDUCTIVITY METER
Three dedicated Fisher Scientific digital conductivity meters were used to check the conductivity
of the RO feedwater (i.e. Kubota MBR permeate) and each of the RO permeates. These meters
were calibrated at the beginning, and end of the test period using standard solutions; daily
comparisons are performed between the on-line conductivity readings and on-site lab results.
The first meter was used to measure the feed water to the RO system and was calibrated using a
conductivity standard of 2764 mhos @ 25 C. The remaining conductivity meters were used
for RO permeate and were calibrated using a 23 mhos @ 25 C standard.
ON-LINE DISSOLVED OXYGEN (DO) METER
DO meters equipped on the Kubota and US Filter MBR systems were calibrated using the
manufacturers protocol at the beginning of the study. To ensure accuracy, values were compared
throughout the study to those measured by the hand held DO meter.
MEMBRANE SYSTEM THERMOMETERS
At the beginning of the study, all thermometers that were verified at a normal operating
temperature (25-30C) using an NIST thermometer. Monthly verification of system
thermometers was performed. The thermometers used to monitor the temperature of the MBRs
were all within 5% error. The thermometers used to measure the RO influent water were also
verified and within 5% error.
C-3
MEMBRANE SYSTEM PRESSURE GAUGES
Pressure and vacuum gauges supplied with the membrane systems tested were verified against
recently purchased grade 3A certified pressure and vacuum gauges. The certified pressure and
vacuum gauges were manufactured by Ashcroft and have an accuracy of 0.25% over their range
(0-30 psi pressure, 0-30 in Hg vacuum). Where possible, system gauges were removed and tested
over the expected range of operating pressures against the verification gauge, using a portable
hand pump. The vacuum gauge for the Mitsubishi MBR is a pressure transmitter that has been
factory calibrated to an accuracy of 1%. The calibration report from the manufacturer is on file
at the PLWTP pilot site. The vacuum gauge for the Zenon system had an average error less than
5 % over the range of normal operating pressures. The pressure gauges for the RO skids were
also within 5% error.
MEMBRANE SYSTEM ROTAMETERS
Membrane system liquid flow rates were verified volumetrically by bucket tests using calibrated
containers or graduated cylinders and a stopwatch. The measured flow rate was compared with
flows indicated on the rotameters. Measured and indicated flow rates agreed to within 5% for
both the Zenon MBR permeate and the Mitsubishi MBR permeate. The combined flow rates,
concentrate and permeate, of the RO skid were checked volumetrically and were both within 5%
error.
Membrane system air flow rotameters were factory calibrated prior to the study. [Please note:
there exists no practical method of volumetrically verifying the air flow rates during the pilot
study.]
C-4
MEMBRANE SYSTEM LEVEL SENSORS
Three Endress+Hauser level sensors were included as part of the Zenon MBR skid. All sensors
were factory calibrated prior to installation; the accuracy of the sensors were verified over the
range of values using a standard measuring tape.
MEMBRANE/UV SYSTEM RUN HOUR CLOCK
All system run hour clocks used during this study are periodically checked for accuracy using a
stop watch.
CHEMICAL FEED PUMPING RATE
The LMI pumps used for chemical injection were continually checked for accuracy. Upon start-
up, the pumps were checked on a daily basis; this frequency was decreased to once per week
after pumping consistency was demonstrated. The accuracy is verified using a graduated
cylinder and stopwatch.
PORTABLE DISSOLVED OXYGEN/TEMPERATURE METER
A hand-held YSI Model 55 dissolved oxygen meter was used to measure DO in the aerobic tank
of the MBR systems. The DO meter was factory calibrated prior to the study, and was re-
calibrated before every use according to manufacturers directions. Periodic comparisons
between the hand-held meter, and the PL Lab DO sensor were also performed to ensure
continued accuracy. The meter membrane and electrolyte solution are replaced as needed.
DESKTOP pH METER
A Fisher Scientific Accumet Model AR 15 desktop pH meter1 was used throughout the study to
determine pH of the raw wastewater, primary effluent, MBR Effluent and MLSS. The meter was
calibrated daily using a 3 point calibration with buffers 4, 7, and 10. The calibration was
confirmed daily using a Laboratory check standard.
DESKTOP TURBIDIMETER
A Hach 2100N desktop turbidimeter was used to perform onsite turbidity analyses of feed and
permeate samples. Readings were recorded in non-ratio operating mode. The following quality
assurance and quality control procedures were followed to ensure the integrity and accuracy of
onsite laboratory turbidity data:
Weekly primary calibration of turbidimeter according to manufacturers specification.
Daily secondary standard calibration verification. Two secondary standards (approx.
0.05 NTU, and 19.1 NTU) were recorded after primary calibration and on the remaining
working days until the next primary calibration.
1
Fisher Scientific International Inc. Accumet Research AR15, Hampton NH
C-5
DESKTOP UV SPECTROPHOTOMETER
Samples collected for TOC analysis were analyzed for UV-254 absorbency using a Hach
DR/4000 UV spectrophoteter. This instrument was returned to the factory for calibration prior to
the study; the instrument was zeroed prior to each measurement.
DESKTOP SDI ANALYZER
A Chemetek, model FPA-2000 was used to measure SDI values on Kubota and US filter
permeate. This equipment was calibrated by the manufacturer prior to the pilot study.
Electronic results from the SDI tests were periodically forwarded to the manufacturer to ensure
continued accuracy.
The filters used for the SDI analysis were GelmanSciences 0.45 um, Sterile Acrodisc, HT
Tuffryn membrane (low protein binding, non-pyrogenic, product number 4184). MWH has used
these filters for SDI analysis in previous reclamation studies. Samples of these filters were also
forwarded to Chemetek for independent analysis.
WATER QUALITY SAMPLING PROTOCOL
All sample lines are properly sterilized (for microbial samples) and flushed for a minimum of
one minute prior to sampling. Sample containers are obtained from the labs performing the
analyses and all preservation chemicals are added to the bottles by the lab prior to sampling,
when required. Filtering or any other required preparatory steps are also be performed by the
respective lab performing the analysis. A courier from the MWWD or CEL Labs transports all
samples that will be analyzed off site. Standard shipping and packing procedures are followed,
including isolating samples and storage of samples in a cooler packed with plastic bubble wrap
to prevent breaking of glass sample bottles. Ice packs are added to the coolers containing
samples requiring storage at 4 degrees C. The samples will be delivered and analyzed within the
allotted holding time for each measured parameter.
A chain of custody is filled out on-site by the person performing the sampling and given to the
courier when the samples are picked up for delivery. Upon receipt, a representative from the lab
will sign the Chain of Custody and the samples will be released to their custody. A copy of the
signed Chain of Custody will then be sent back to the sampler and will be kept on file at the pilot
site.
DATA MANAGEMENT/ANALYSES
All water quality data collected on-site was merged with data obtained from offsite laboratories
throughout the study. Operational data was recorded on raw data sheets and routinely inputted
into a database. The water quality and operational databases were combined to create a
comprehensive database which was used for data analysis, retrieval, reporting and graphics. All
data inputted to the database was checked and verified by the onsite engineer. Lastly, data files
were periodically sent to TAC members during the study for analysis.
APPENDIX D
Photographs of Pilot Equipment
D-1
Kubota MBR Pilot Unit
D-2
Kubota: Upper Membrane Cassette (top); Lower Membrane Cassette (bottom)
D-3
Kubota Type 510 Membrane (single sheet)
D-4
Kubota Type 510 Membrane (after 2 months operation)
D-5
US Filter MBR Pilot Unit
D-6
US Filter MBR Pilot Membrane Tank
D-7
US Filter MemJet B10 R Membranes
D-8
US Filter MemJetB10 R Membranes
D-9
Zenon MBR Pilot Unit
D-10
Zenon 500d Membrane Cassette
D-11
Zenon MBR Aeration Tank with Fine Bubble Diffusers (Plan View)
D-12
Mitsubishi MBR Pilot Unit (Plan view)
Mitsubishi MBR Pilot Unit (front view)
D-13
Mitsubishi Sterapore HF Microfiltration Membranes
D-14
RO Pilot Skid
RO Pre Filters: New (bottom); After 1 month Operation (top)
D-15
Aquionics UV Pilot System Control Panel (Top); UV Reactor (Bottom)
D-16
Pre-Screen (Roto-Sieve Model 6013-11)
APPENDIX E
Kubota Title 22 Approval Letter
APPENDIX F
Additional Costing Information
F-1
M E M O R A N D U M
To: Membrane Manufacturer
From: Samer Adham, Ph.D./Steve Lacy, P.E.
Prepared by: James DeCarolis/Jude Grounds
Subject: MWH/MBR Vendor Workshop
MWH would like to thank you for your recent participation in the MBR Costing
Workshop. The workshop generated a lot of discussion and information regarding full-
scale design and costing issues related to the Bureau of Reclamations (USBR) project
entitled Optimization of Various MBR Systems for Water Reclamation. To meet the
costing requirements of the project, we would like to request additional capital and
operation/maintenance information associated with the membrane and ancillary systems.
The following memo outlines these additional requirements.
MWH will perform the biological portion of the design based on decisions made during
the workshop. The following design criteria will be used for preliminary design and
costing of the biological system:
1. Feed Water Costs will be generated for operation on both raw wastewater and
advanced primary effluent, assuming the following influent wastewater
characteristics:.
Parameter Raw Wastewater Primary Effluent
BOD
5
(mg/L) 290 130
COD (mg/L) 700 280
TSS (mg/L) 320 65
VSS (mg/L) 260 50
NH
3
-N (mg/L) 30 30
TKN (mg/L) 60 40
TDS (mg/L) 1,200 1,200
Alkalinity (mg/L) 245 230
Temperature (
o
C) 20 20
F-2
2. SRT The design SRT will between 10-15 days.
3. MLSS MLSS will range from 8,000 10,000 mg/L.
4. MBR Effluent The biological portion of the MBR system will be designed to
meet the following effluent water conditions:
- Complete nitrification (i.e. NH
4
+
-N<1.0 mg/L),
- Denitrification (i.e. NO
3
-N<10 mg/L)
- Biological Oxygen Demand (BOD) < 2.0 mg/L
Below are the key membrane system design criteria developed from discussions during
the workshop. Please use these as guidelines when developing costs for the membrane
system:
Capacity Costs will be generated for 0.2, 0.5, 1.0, 5.0 and 10 MGD MBR systems.
System will be for a sewer mining (scalping) plant. Residuals controlled through wasting
to a downstream treatment facility.
Peaking MBR systems will be designed with 1.0 Q.
Operating Flux Membrane costs will be based on net operating flux of 15 gfd @ 15
deg C.
Operating TMP - Costs will be based on operating TMP of 2 psi, with a range of 1 4
psi.
Screening Costs will include 0.8 mm perforated center feed rotary drum screens
required for both feed water sources. Screen capacity will be based on peak flow; during
periods of low flow, mixed liquor will be recycled/re-screened.
Cleaning Interval A minimum of 2 CIPs will be required per year; the frequency of
maintenance cleaning will be per the manufacturers recommendation.
Redundancy The MBR systems will be designed at average conditions to operate with
one filter unit out of service (OOS) for a routine relaxing and an additional membrane
filter unit OOS for chemical cleaning. System must be designed to accommodate
increased flow to remaining filter units due to OOS unit.
Warranty Costing will include a 5-year, non-prorated warranty. Warranty to cover
manufacturing defects, normal wear and include the cost for providing replacement
membranes to the plant site.
Please provide the following capital and operation/maintenance cost information as
described below. For your convenience, we have attached a spreadsheet to be used for
reporting cost estimates.
CAPITAL COSTS
Please provide the following capital costs for 0.2, 0.5, 1.0, 5.0 and 10 MGD capacities
(for both feed waters, if different):
1. Membrane Costs - Please provide membrane costs for the capacities listed above.
Include the membrane model number and values for total surface area and total
F-3
number of membrane filter units. The membrane cost shall be based on the following
conditions:
- Net operating flux of 15 GFD @ 15C
- Average operating TMP of 2.0 psi (This constitutes a average operating specific
flux of 7.5 gfd/psi @ 15 C)
- Net operating flux does not include loss of MBR permeate due to downtime and
the use of MBR permeate for membrane cleaning (including relaxation or
backwashing, CIPs and maintenance cleans, if applicable)
- Assume that 15% of the active membrane area will be lost over a 5 year period
due to irreversible fouling
- The number of membrane units used for costing must meet the redundancy
criteria listed above
2. Chemical Cleaning Equipment Please provide itemized list of cost for any
equipment necessary to perform CIPs and maintenance cleans including: pumps,
tanks, valves and ancillary equipment/instrumentation.
3. Membrane Chamber Please provide the sizing requirements for the membrane
chamber(s) to accommodate the various MBR system capacities. Include in the costs
for the membranes any internal components to the membrane chamber such as
membrane support systems, internal beams and ancillary equipment. The membrane
chamber must be sized with four feet of free-board for foam control.
4. Valves, piping and system controls Please provide itemized list of costs for all
valves piping and system controls necessary in the membrane chamber. Include any
costs for standard PLC associated with the membrane tank.
5. Membrane Aeration System Please provide the membrane aeration system design
and costs for the various components of the membrane aeration system. The design
should include items such as: air flow control valves, isolation valves, flow meters
and rotameters. The design should be based on the necessary airflow requirement for
membrane scouring. Please include membrane aeration system design and costs for
0.2, 0.5, 1.0, 5.0 and 10 MGD facilities. Equipment to provide air for the biological
treatment will be provided by others.
6. Permeate Collection System - Please provide costs for pumps, flow control valves,
and isolation valves related to the permeate collection system. In addition, please
provide cost of turbidimeters, flow meters, and TMP measuring equipment and
associated transmitters.
7. Warranty- Please provide a description and cost for a 5-year non-prorated warranty
for the various plant capacities.
F-4
OPERATION AND MAINTENANCE COSTS (O&M)
Please provide the following O&M costs for 0.2, 0.5, 1.0, 5.0 and 10 MGD capacities (for
both feed waters, if different):
1. Personnel Please estimate the number of hours per day for operation and
maintenance.
2. Chemical Requirements Please provide the amount of chemical required (lbs/year)
to perform CIPs and maintenance cleans. This quantity should be adequate to
perform a minimum of 2 CIPs per year and the manufacturers recommended number
of maintenance cleans per year. It should be noted the system should be operated to
meet the TMP requirement listed above.
3. Membrane replacement Please provide estimated membrane replacement cost over
a twenty year period. Assume membrane replacement every 8 years.
4. Electrical Permeate and backwash pump and blower demands (kWh) based on a
normal operating TMP of 2 psi. Additionally, electrical demands for all ancillary
systems should also be included in the estimate.
5. Spare parts Please identify and estimate the cost of spare parts typically incurred on
yearly basis.
To meet the project schedules, we would appreciate if you could provide these costs no
later than July 25th, 2003. If you would like to discuss any of the information requested
above, please contact James DeCarolis (619 221-8325).
F-5
Unit Cost Assumptions used to estimate MBR O&M Costs
Annual Cost Units Unit Cost Assumptions
Electrical power for process/miscellaneous kwh $0.08 Power usage = 100 kwh/day-mgd.
Equipment repairs/lubricants/replacement Is/yr 2%
Percentage of Capital Equipment inc. Headworks, MBR system,
Mechanical and Blower and pump building.
Crane per rental $1,000.00
Crane rental needed 2/yr for 0.2 mgd; 3/yr for 0.5 mgd. Crane to
be purchased for 1, 5 and 10 mgd systems included in capital
costs.
Sodium Hypochlorite gallons $0.50
Citric Acid kg $2.40
Sodium Hydroxide (neutralization) kg $0.31
Sodium Bisulfite (neutralization) kg $0.77
Sodium Hypochlorite gallons $0.50 Annual cost based on 3 mg/L dose @12% sol.
Diffuser Replacement per diffuser $25 8-year replacement life; 9" fine bubble diffusers.
Membrane Replacement Is/yr NA 8-year replacement life;provided by mfgs.
Labor per hour $50
(0.2 mgd) = 1 hr/day, 5 days/week + 1 hr /day, 2 days /week (0.5
mgd) = 1.5 hr/day, 5 days/week + 1 hr /day, 2 days /week (1
mgd) = 2 hr/day, 5 days/week + 1 hr /day, 2 days /week (5 mgd)
= 6 hr/day, 5 days/week + 2 hr /day, 2 days /week (10 mgd) = 16
hr/day, 5 days/week + 4 hr /day, 2 days /week.
Total Costs based on 2 cleanings per year. Quantity of each
chemical required derived from estimates provided by Zenon
Environmental.
Chemical Cleaning (Membranes)
Chemical Cost for Disinfection