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CopaIndustrialEffluentTreatmentusingMembraneBioreactorsSteveChurchouseCIWEMandIChemESeminarBridgewater12thMay2005CopaCopaKubotaProcessDevelopment•Pilotplantandtestingfrom1989•FirstcommercialplantcommissionedAugust1991•Firstsludgetreatmentplants1994•Over1200plantsareoperationalorunderconstruction(Jan2005)-600industrialplantsCopaCopaTheKubotaProcessSchematicoperationCopaCopaMembraneBioreactorOperationCopaCopaTheKubotaProcessMembraneunitandpanelsCopaCopaMembraneSurfaceKingstonSeymourmembraneafter4yearscontinuousoperationCopaCopaKubotaMembraneUnitsMembranefiltrationtopsection(150panel)BasicProductRange•Includesaerationandfiltrationsections•StandardKubotaunits:7-200panels•DoubleDeckdesign:300and400panel-reducedplanarea•Customdesignstofitapplication•GravityorsuctionoperationDiffuseraerationlowersectionCopaCopaDoubleDeckMembraneUnitTopMembraneSectionLowerMembraneSectionandManifold3.5mIntermediateSectionDiffuserSectionCopaCopaMembranediffusersectionsFeb04DoubleDeckPlantCopaCopaDoubleDeckPlantDoubledeckmembraneunitscommissioningFeb04CopaCopaDoubleDeckPlantTanks1&2operationalJuly04CopaCopaExampleOperationalPlantsApplications•Sewage-Sludgetreatment-Sludgeliquortreatment•Pharmaceutical/Chemical•Maltingeffluent•Papereffluent•Milkprocessingplant•Sugarprocessing•DrinksandFoodprocessing•Tobaccowastewater•Leachatetreatment•Greywaterrecycling-Themepark-Officeblock-GardencentreCopaCopaExample:-PulpandPaperIndustryPilotPilotTrials•PulpingPlant,TissueandPaperManufacture(SA)•Tissueproduction(Medrim)•Mediumdensityfibreboard(Ireland)•PIRABiowisetrials(UK)-Papertoweltissueandbabywipes-NewspaperrecyclingCopaCopa10panelpilottrial–paperindustry10panelpilotplantCopaCopaPaperIndustryTrialsContainerisedPlant•Aimto:-Evaluatebiologicaltreatability-Establishsustainablefluxratesandkeydesigncriteria-Demonstratepotentialforwaterreuse•Tissueproductionwastewater•PlantincludesfinebubbleaerationdO2•75membranepanelunit(60m2)CopaCopaPulpandPaperIndustryTrialsBODremovalTimeindaysFeedBODmgO2/lPermeateBODmgO2/lFeedBOD(mgO2/l)PermeateBOD(mgO2/l)10020030040050060070080090010000501001502002503000CopaCopaPulpandPaperIndustryTrialsCODremoval020040060080010001200140016001800050100150200250300TimeindaysCODmgO2/lFeedCOD(mgO2/l)PermeateCOD(mgO2/l)CopaCopaPaperIndustryTrialsResultsfromtrial11.6(Overdoseofnutrient)0.1(+~15mgNaddition)NH30.01(99.9)71SS15(97%)450BOD81(93%)1188CODPermeateAverageFeed15/4–2/6/2004CopaCopaPaperRecyclingplantCasestudy•Whiteandbrownpaperrecycling•900m3/ddesignflow(actualFFT1100m3/d)-1-4,000kgCOD/d•Newriverdischargeconsents•10EK400doubledeckunits•Start-upApril04•CommissioningproblemsincludelimescaleformationCopaCopaFullScalePaperRecyclingMBRplantGeneralviewshowingbalanceandpreaerationtanksInstallinglowerdeckofmembraneunitCopaCopaCODRemovalfullscaleplant050010001500200025003000350040004500500003-Apr23-Apr13-May02-Jun22-Jun12-Jul01-Aug21-Aug10-Sep30-SepCOD(mg/lO2)RawWaterPermeatePlantshutdownCopaCopaPharmaceuticalApplication•Biologicallyandhydraulicallyoverloaded,insufficientbiomass•Pooranderraticsettlement•Failuretomeetdischargeconsents•Limitedlandavailability•Difficultwastewater-COD7-13000mgO2/l-3-9000mgCl/lTheproblem-existingplantCopaCopaPharmaceuticalApplicationUpgradedplantStream2PreaerationAAnoxiczoneSteam2AerationBAerationtankStream1MembraneAerationtank45m3100m3/d200m3/d4000kgCOD/dRawfeedFinaleffluentClarifierMembraneSludgerecycleCopaCopaPharmaceuticalApplication3x150panelmembraneunitsCopaCopaSugarBy-productWastewater•Biologicallyandhydraulicallyoverloaded,insufficientbiomass•Newdischargeconsents•Difficultwastewater-COD18000mgO2/l-HighorganicacidcontentpH2.7-4feed-Highlevelsofaceticandformicacids-ChemicalneutralisationprohibitivelyexpensiveTheproblem-existingplantCopaCopaSugarBy-productWastewaterpHcontrolcriticalSamplepHBiomassCultureViability7.080%6.080%5.575%5.05%5.0BiomassdeadCopaCopaSugarBy-productWastewater75panelpilotplanttrialincludingadditionalFBDACopaCopaSugarBy-productWastewaterConstructingthe4000m3FBDAandMembranetankCopaCopaSugarBy-productWastewaterInsidetheFBDAandMembranetankshowing12x400panelmembraneunitsCopaCopaSugarBy-productWastewaterCompletedtreatmentplantinoperationMay2005CopaCopaVinylproductionMiddleEastvinylprocessingwastewater(backgroundisthepetrochemicalplant)CopaCopaDrinksManufacture2x3000m3FBDAand10x200panelmembraneunitsCopaCopaFoodPreparation/ProcessingCombined150m3FBDAand200panelmembraneinstallationCopaCopaOperation&MaintenanceKeyMBRprocess•Daily-none(autoflushofaerators)•~Weeklyorwhensampling,visualcheckofaerationpattern-Remotemonitorcheckontrends•6monthly-in-situchemicalcleaning•Yearly-visualhealthcheckofmembraneunits•4-5yearlycheck.RefurbishorreplaceanyfailedmembranesandreusecleanedmembranesCopaCopaChemicalCleaningSewage/industrialapplications•In-situcleaningasabackwash-noremovingunitsorsludge•Organicfouling-6monthlycleaningwithtypically0.5%NaOCl•Inorganicfouling(Al,Fe)yearlycleaningwith1%CitricorOxalicacid.(CaCO3scaling),0.5-3%HClCopaCopaMembraneLife-ExamplePlantsPorlock(sewage)•13panelsreplacedouto