OXYGEN TRANSFER EFFICIENCY SURVEYS AT THE
JONES ISLAND TREATMENT PLANTS
1985 - 1988
bv
Read Warriner
Milwaukee Metropolitan Sewerage District
Milwaukee, Wisconsin 53204
Cooperative Agreement No. CR812167
Project Officer
Richard C. Brenner
Water and_Hazardous Waste Treatment Research Division
Risk Reduction Engineering Laboratory '.
Cincinnati, Ohio 45268
RISK REDUCTION ENGINEERING LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
Development of the information in this report has been
funded in part by the U.S. Environmental Protection Agency under
Cooperative Agreement No. CR812167 by the American Society of
Civil Engineers. The report has been subjected to Agency peer
and administrative review and approved for publication as an EPA
document. Mention of trade names or commercial products does not
constitute endorsement or recommendation for use.
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FOREWORD
Today's rapidly developing and changing technologies and
industrial products and practices frequently carry with them the
increased generation of materials that, if improperly dealt with,
can threaten both public health and the environment. The U.S.
Environmental Protection Agency (EPA) is charged by Congress with
protecting the Nation's land, air, and water resources. Under a
mandate of national environmental laws, the Agency strives to
formulate and implement actions leading to a compatible balance
between human activities and the ability of natural systems to
support and nurture life. These laws direct EPA to perform
research to define our environmental problems, measure the
impacts, and search for solutions.
The Risk Reduction Engineering Laboratory is responsible for
planning, implementing, and managing research, development, and
demonstration programs to provide an authoritative, defensible
engineering basis in support of the policies, programs,' and
regulations of EPA with respect to drinking water, wastewater,
pesticides, toxic substances, solid and hazardous wastes, and
Superfund-related activities. This publication is one of the
products of that research and provides a vital communication link
between the researcher and the user community.
As part of these activities, an EPA cooperative agreement
was awarded to the American Society of Civil Engineers ;(ASCE) in
1985 to evaluate the existing data base on fine pore diffused
aeration systems in both clean and process waters, conduct field
studies at a number of municipal wastewater treatment facilities
employing fine pore aeration, and prepare a comprehensive design
manual on the subject. This manual, entitled "Design Manual -
Fine Pore Aeration Systems," was completed in September 1989 and
is available through EPA's Center for Environmental Research
Information, Cincinnati, Ohio 45268 (EPA Report No. EPA/625-1-
89/023). The field studies, carried out as contracts under the
ASCE cooperative agreement, were designed to produce reliable
information on the performance and operational requirements of
fine pore devices under process conditions. These studies
resulted in 16 separate contractor reports and provided critical
input to the design manual. This report summarizes the results
of one of the 16 field studies.
E. Timothy Oppelt, Director :
Risk Reduction Engineering Laboratory
111
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PREFACE
In 1985, the U.S. Environmental Protection Agency funded
Cooperative Research Agreement CR812167 with the American Society
of Civil Engineers to evaluate the existing data base on fine
pore diffused aeration systems in both clean and process waters,
conduct field studies at a number of municipal wastewater
treatment facilities employing fine pore diffused aeration, and
prepare a comprehensive design manual on the subject. This
manual, entitled "Design Manual - Fine Pore Aeration Systems,"
was published in September 1989 (EPA Report No. EPA/725/1-89/023)
and is available from the EPA Center for Environmental Research
Information, Cincinnati, OH 45268.
As part of this project, contracts were awarded under the
cooperative research agreement to conduct 16 field studies to
provide technical input to the Design Manual. Each of these
field studies resulted in a contractor report. In addition to
quality assurance/quality control (QA/QC) data that may be
included in these reports, comprehensive QA/QC information is
contained in the Design Manual. A listing of these reports is
presented below. All of the reports are available from the
National Technical Information Service, 5285 Port Royal Road,
Springfield, VA 22161 (Telephone: 703-487-4650).
1. "Fine Pore Diffuser System Evaluation for the Green Bay
Metropolitan Sewerage District" (EPA/600/R-94/093) by J.J.
Marx
2. "Oxygen Transfer Efficiency Surveys at the Jones Island
Treatment Plants, 1985-1988" (EPA/600/R-94/094) by R.
Warriner
3. "Fine Pore Diffuser Fouling: The Los Angeles Studies"
(EPA/600/R-94/095) by M.K. Stenstrom and G. Masutani
4. "Oxygen Transfer Studies at the Madison Metropolitan
Sewerage District Facilities" (EPA/600/R-94/096) by W.C.
Boyle, A. Craven, W. Danley, and M. Rieth
5. "Long Term Performance Characteristics of Fine Pore Ceramic
Diffusers at Monroe, Wisconsin" (EPA/600/R-94/097) by D.T.
Redmon, L. Ewing, H. Melcer, and G.V. Ellefsoh ;
6. "Case History of Fine Pore Diffuser Retrofit at Ridgewood,
New Jersey" (EPA/600/R-94/098) by J.A. Mueller and P.O.
Saurer
iv ;
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7. "Oxygen Transfer Efficiency Surveys at the South Shore
Wastewater Treatment Plant, 1985-1987" (EPA/600/R-94/099) by
R. Warriner
8. "Fine Pore Diffuser Case History for Frankenmuth, Michigan"
(EPA/600/R-94/100) by T.A. Allbaugh and S.J. Kang
9. "Off-gas Analysis Results and Fine Pore Retrofit Information
for Glastonbury, Connecticut" (EPA/600/R-94/101) by R.G.
Gilbert and R.C. Sullivan
10. "Off-Gas Analysis Results and Fine Pore Retrofit Case
History for Hartford, Connecticut" (EPA/600/R-94/105) by
R.G. Gilbert and R.C. Sullivan
11. "The Measurement and Control of Fouling in Fine Pore
Diffuser Systems" (EPA/600/R-94/102) by E.L. Barnhart and M.
Collins •
12. "Fouling of Fine Pore Diffused Aerators: An Interplant
Comparison" (EPA/600/R-94/103) by C.R. Baillod and K.
Hopkins
13. "Case History Report on Milwaukee Ceramic Plate Aeration
Facilities" (EPA/600/R-94/106) by L.A. Ernest ;
14., "Survey and Evaluation of Porous Polyethylene Media Fine
Bubble Tube and Disk Aerators" (EPA/600/R-94/104) by D.H.
Houck
15. "Investigations into Biofouling Phenomena in Fine Pore
Aeration Devices" (EPA/600/R-94/107) by W. Jans en1, J.W.
Costerton, and H. Melcer
16. "Characterization of Clean and Fouled Perforated Membrane
Diffusers" (EPA/600/R-94/108) by Ewing Engineering Co.
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ABSTRACT
Ceramic plate diffusers were among the earliest forms of
fine pore diffusers used for oxygen transfer in activated sludge
treatment. They have been successfully used for over 60 years in
the Jones Island West Plant of the Milwaukee Metropolitan
Sewerage District and, since initial start-up, in the Jones
Islaind East Plant and the South Shore Plant. Surveys of
performance of these diffusers in all three plants were included
in the EPA/ASCE Fine Pore Aeration Project. This report presents
the results of off-gas sampling surveys carried our at|the
original Jones Island West Plant and in the newly rehabilitated
East Plant. The West Plant basins were scheduled for
rehabilitation in 1989-90.
Twenty-one (21) basin surveys were carried out in the West
Plant and 30 in the East Plant. For the West Plant basins, which
contained the original ceramic diffusers with 15 feet of
submergence, installed in 1923 and 1924, the median value of
standardized oxygen transfer efficiency, alphaF(SOTE), was 11.8%.
For the East Plant basins, which contained diffusers with 14 feet
of submergence, installed in 1983, the median value of
alphaF(SOTE) WAS 15.3%.
Cleaning history was noted for each basin at the time of
each off-gas survey. An effect of time-in-service since cleaning
on oxygen transfer efficiency was not documented by these
surveys; however, there was an indication that short-term
improvement occurred in the East Plant. Since alpha is unknown
and varies widely between surveys, and possibly during surveys,
it is difficult to separate alpha effects from fouling (F)
effects on oxygen.transfer efficiency. For the most part,
extended periods of basin operation have no measurable•effect on
performance.
This report was submitted in partial fulfillment of
Cooperative Agreement No. CR812167 by the American Society of
Civil Engineers under subcontract to the Milwaukee Metropolitan
Sewerage District under the partial sponsorship of the U.S.
Environmental Protection Agency. The work reported herein was
conducted over the period of 1985-1988.
VI
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CONTENTS
Foreword iii
Preface .......... ±v
Abstract vj_
l^res '.'.'.'.'.'.'.'.'.'.'. 'viii
Tables ....... ix
Acknowledgements '.'.'.'. x
Introduction . . . . . . 1
Survey Program .'.'.'.'.'. 1
Conclusions ' '.'"'' 3
East Plant . ........ 3
West Plant \ \ \ [ ' [ \ 4
Recommendations 5
Treatment Plant Descriptions .......... 6
East Plant . ......... 6
V7est Plant ] [ . . . . . 8
Conduct of the Surveys '.'.'. ] ...... 10
Off-Gas Survey Methods ........ 10
East Plant '.'.'.'. 10
West Plant . . . . 11
Aeration Basin Operation [ ] ] 11
East Plant ........... 11
West Plant '.'.'.'.'.'' 12
Treatment Plant Operation 12
Presentation of Survey Data . . 13
Survey Results ..... !!!!!!!!! 16
East Plant . . . . . 16
West Plant • ..\ 27
Diurnal Study . I . . 27
Collection Hood Orientation * * " 32
Discussion . . . 33
East Plant ........ 33
West Plant ......... 33
References .34
Appendices •-.......
A. Overall Plant Data Form, East Plant 35
B. Overall Plant Data Form, West Plant ........ 44
C. Additional West Plant Operation Data ....." 1 ."." 53
via.
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FIGURES
Number
1 Layout and Dimensions of the North and South Passes
of East Plant Tank Number 6 ......... ... 7
2 Layout and Dimensions of West Plant Tank Number 6 ... 9
3 Sample Report Format Used for East Plant Off Gas
Survey Data ... ....... ......... 14
4 Sample Report Format Used for West Plant Off Gas
Survey Data ......... .......... 15
5 Oxygen Transfer Efficiency and Dissolved Oxygen
Concentration in East Plant Basin No. 6, May 22,
1987. ....... ...... ......... 21
6 Oxygen Transfer Efficiency and Dissolved Oxygen
Concentration in East Plant Basin No. 6, May 28,
1987 ....... .... ......... ...... 22
7 Oxygen Transfer Efficiency and Dissolved Oxygen
Concentration in East Plant Basin No. 6, November
12, 1987 ..................... 24
8 Oxygen Transfer Efficiency and Dissolved Oxygen
Concentration in West Plant Tanks 6 and 16 . . . . 30
9 Diurnal Test Results for West Plant Tank 16 on
September 2 and 3, 1986 ..... ...... . . 31
viil
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TABLES
Number •
1 Summary of East Plant Oxygen Transfer Survey Data . . 17
2 Supplementary Air Flow Rate Data for East Plant
Oxygen Transfer Surveys . is
3 East Plant Secondary Treatment Nitrogen Data .... 19
4 Operating Conditions and Oxygen Transfer Efficiency
Survey Results for East Plant Basin 6 ...... 20
5 Oxygen Transfer Measurements at the Inlet, With a
Low Oxygen Uptake Rate, in East Plant Basin 6 . . 25
6 Oxygen Transfer Measurements at the Inlet, With a
High Oxygen Uptake Rate, in East Plant Basin 6 . . 25
7 Oxygen Transfer Measurements at the Outlet in East
Plant Basin 6 26
8 Summary of West Plant Oxygen Transfer Survey Data . . 28
9 Secondary Treatment Nitrogen Data for the Jones
Island Plant for the West Plant Survey Data ... 29
10 Averaged Results for the West Plant Hood Position Test 32
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ACKNOWLEDGEMENTS
The involvement of engineering co-op students from Marquette
University and the University of Wisconsin - Milwaukee was
indispensable for this project. They are (in chronological order
of participation): Robert Dumke, Michael Mitchell, Tom Raasch,
Rockne Elgin, Robert Harley, Robert Carroll and Mark Wang. Their
eagerness, excellent suggestions, and unflagging interest are
gratefully acknowledged.
Larry Ernest, who was at that time Manager of Central Laboratory
Services, was principal investigator at the inception;of this
project and a provider of encouragement and valuable advice
throughout its course. .
Operations and Maintenance staff of the Jones Island Wastewater
Treatment Plant provided valuable guidance and logistical support
from start to finish. Thanks are also in order to Lloyd Ewing
and Dave Redmon of Ewing Engineering Company for their continuing
support and guidance.
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INTRODUCTION
Ceramic plate diffusers were among the earliest forms of fine
pore diffusers used for oxygen transfer in activated sludge
treatment. They have been successfully used for over sixty years
in the Jones Island West Plant of the Milwaukee Metropolitan
Sewerage District (MMSD) and, since initial start-up/ in the
Jones Island East Plant and the South Shore Plant. Because of
this record, surveys of current performance of these diffusers in
all three activated sludge plants were included in the EPA/ASCE
Fine Pore Diffuser Project. This report presents the results of
off-gas sampling surveys carried out in the original Jones Island
West Plant and in the newly rehabilitated East Plant. The West
Plant basins are scheduled for rehabilitation in 1989-90.
The present Jones Island Plant treats a dry weather flow of
approximately 100 MGD with 70 MGD going to the East Plant and 30
MGD to the original West Plant. Aeration basins in both plants
are equipped with one foot square diffuser plates assembled in 9-
plate containers. However, the diffusers in the West Plant are
the original fused silica plates installed in 1923 and; 1924.
They are one and a half inches thick, and the containers are
placed across the' direction of basin flow in a ridge and furrow
configuration. In the East Plant the diffuser material is a
mixture of alumina and silica, and the diffusers are one-inch
thick with the containers arranged in a longitudinal, full floor
coverage pattern. These diffusers were installed when the plant
was rehabilitated in 1983. Diffuser submergence for the West
Plant was 15 feet, and for the rehabilitated East Plant it is 14
feet.
SURVEY PROGRAM .--.-,
Oxygen transfer efficiency surveys in the East Plant were made on
15 test days between August 30, 1985 and June 1, 1988. Both
north and south passes of the basin were surveyed on each test
date. Since the East Plant aeration basins were not included in
the original EPA/ASCE Fine Pore diffuser Project, a testing
program was not laid out in advance. Instead, surveys were
conducted in response to requests from Operations staff. In 1985
and 1986, surveys were conducted in four different basins.
However, Basin 6 was tested on 10 of the 15 survey days. Since
Basin 6 was cleaned only in June, 1985 and June, 1988, the survey
record provided an opportunity to monitor diffuser performance as
a function of time in service. In addition to full basin
surveys, special studies were carried out in Basin 6 on the
influence of air flow rate on zero-DO OTE under process
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conditions. This normalized value for basin efficiency is known
as alphaF(SOTE).
In the West Plant a program was planned to include twenty surveys
of West Plant basins. Originally, five basins were to be tested
four times each over a two-year period; however, due to a
cleaning program in progress when off-gas surveys were scheduled,
only five or six basins were normally available for testing.
Since different basins were available at different times, the
off-gas survey program had to be changed to include those basins
that could be tested at the times equipment and personnel were
available. None of the basins could be tested in all four of the
test periods.
Following the April, 1986 Contractors' meeting, two additional
surveys in the West Plant were added to the program. : The first
was a one-time investigation of the effects of collection hood
placement patterns on observed oxygen transfer efficiency. The
second was a 24-hour survey with hourly OTE observations for two
hood stations in basin No. 16. ;
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CONCLUSIONS
Overall average values of alphaF(SOTE) were higher in the East
Plant than in the West Plant. The difference was probably due in
part to the fact that all the West Plant basins tested were
equipped with the original diffuser plates that had been
installed in 1923-24. The East Plant diffusers were installed in
1983. Since the West Plant is scheduled for complete
rehabilitation with installation of new diffuser plates, much
maintenance has been deferred. The tank surface revealed
boiling, indicative of damaged or poorly maintained diffusers.
Another difference between the plants was in the layout of
diffusers, a ridge and furrow pattern in the West Plant and a
longitudinal pattern in the East Plant.
While many factors potentially contributed to differences in
oxygen transfer efficiency between the two plants, the mean
values for alphaF(SOTE) of 3.6% per meter of depth for the East
Plant and 2.7% per meter for the West Plant were both considered
representative of excellent fine pore diffuser performance for
highly loaded municipal activated sludge plants (1). It is
noteworthy that data obtained in 1964,. for East Plant basins
equipped with square diffusers in a similar longitudinal grid,
showed almost the same average zero DO efficiency of 3'. 4% per
meter of depth (2). Another conclusion applicable to both plants
was tht time-in-service since diffuser cleaning had no
discernible effect in alphaP(SOTE).
EAST PLANT ;
1. The flux weighted alphaF(SOTE) values obtained from 30 Jones
Island East Plant aeration basin surveys on 15 test days
ranged from 11.4% to 19.2% with a mean value of 15;. 4%. (The
mean for 20 surveys in Basin 6 was 15.6%.) I
2. The mean sludge age for the East Plant for the 15 test days
was 3.8 days with a range of 2.3 to 5.3 days. The mean F/M
ratio was 0.65 day L, with a range of 0.32 to 0.97 day ~^.
No relationship was found between process OTE values and
sludge age or F/M ratio.
3. During the second and third years following diffuser cleaning
in Basin 6, with no primary sedimentation to reduce the waste
load, the oxygen transfer capability, as measured by the off-
gas method, was unchanged.
4. In two side-by-side trials, tapering the air supply had
little effect on the overall rate of oxygen transfer.
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5. At the basin inlet, under conditions of high potential oxygen
uptake rate and very low dissolved oxygen, the oxygen
transfer efficiency was constant over a large range of'air
flow rate.
WEST PLANT
1. The flux weighted alphaF(SOTE) values obtained from 21 West
Plant aeration basin surveys ranged from 6.6% to 15.6% with a
mean value of 11.7% (The median was 11.8%.)
2. The mean and the median sludge age for the West Plant for the
21 test days in the_study period was 3.3 days. The mean F/M
ratio was 0.82 days -1. (The median was 0.63 days"71.)
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RECOMMENDATIONS
1. Since a prominent characteristic of the aeration basins in
both treatment plants is large diffuser areas and low air
flux rates, further attention should be directed to this
variable. The effect of diffuser surface area on performance
should be investigated and should be examined separately from
the effect of air flux rate.
2. Since the effects of wastewater characteristics (alpha) and
fouling (F) may have quite different effects on operating
costs, an attempt should be made to separate these two
phenomena. This could be done, for example, by comparing a
freshly acid cleaned basin and a long time-in-service basin
side-by-side, by comparing a week-end (low BOD loading)
survey with a mid-week survey, and by surveying a basin with
mixed liquor feed temporarily cut off.
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TREATMENT PLANT DESCRIPTIONS
Detailed information concerning the historical records, aeration
basin and process air supply designs, and the operation of both
plants are presented in a report by Ernest (3) on the operating
history of the Milwaukee Aeration Facilities as part of the same
ASCE/EPA project.
EAST PLANT
The East Plant provides activated sludge treatment for
approximately 75 MGD of screened municipal and industrial
wastewater with 5-day BOD of 300 mg/L. Forty aeration basins are
operated in pairs with the layout and dimensions shown in
Figure 1. Part of the plant was constructed in 1935 and the
remainder in 1952. Each pair of basins was operated as one
2-pass basin. Various fine bubble diffuser types and floor
coverages were employed, and, at times, severe problems with
aeration capacity were experienced. Extensive investigations in
the 1960s (2) led to the longitudinal, full floor coverage
patterns of diffusers still used today. In 1983, the basins were
rehabilitated with new diffuser plates and piping and :
improvements in the distribution of air to downcomers and the
tank drainage. The diffuser layout and the plate specifications
were essentially unchanged. In June, 1985, the basins were
converted to single pass operation.
The diffusers are square ceramic plates, mixtures of alumina and
silca 12 inches square and 1 inch thick. The permeabilities
range from 17 to 23. The plates are grouped by permeabilities in
ranges of 17-19, 20-21, and 22-23. Each downcomer is fitted with
plates of only one range. The plates are grouted into concrete
containers placed flush with the bottom of the tank. Each
container contains 9 plates and is connected at one end to a
1-inch diameter air pipe. The containers are placed end to end
in the direction of the tank length, 32 containers in a row and 5
rows across the width of the basin. There are 1450 plates in
each basin, 2900 plates in each pair.
As shown in Figure 1, air is supplied from downcomers to 3
separate zones in each basin. Air flow to each zone is set
manually by a butterfly valve, but within each zone there are no
orifices for control of air distribution. Each downcomer is
equipped with an orifice meter and the air flow corresponding to
the pressure drop is read from a portable flow indicator. A
permanently mounted orifice meter and flow indicator for each
pair of basins (6 zones) provides a check on the sum of the
readings taken at the separate zones. :
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tone I
Process Air
Oomccaer
113.5 a
2-7.
Zone 2
Zone 3
NOT TO SCALE
0
o
1 dm.
1 rlW
0 • o >i
' 1
j> : o x"
_/^ ! Pa
j
t
Mixed 1
Li(?JOr 2.4m
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Process Air
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Section A -
Figure 1. Layout and dimensions of the north and south passes
of East Plant Tank No. 6.
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WEST PLANT '
The Jones Island West Plant comprised two batteries of 12
aeration basins each. All surveys for the fine pore diffuser
project were carried out in. the South Battery. Recycle sludge
and screened sewage are combined to form the mixed liquor feeding
both north and south batteries. The aeration basins are two-
pass; each pass is 222 feet long and 22 feet wide. The water
depth is 15 feet to the surface of the plates.
Figure 2 shows plan and cross-section views of Basin Number 6
which was also the location of a four unit disk diffuser test
plenum that was installed and monitored during the course of
these surveys.
The air supply to each tank is metered through a single main that
divides into two downcomers, one feeding each pass as indicated
in Figure 2. The air supply pipe runs along the center near the
bottom of each pass with take-offs to diffuser containers on
either side and along the center line. Each container holds nine
plates. The containers are placed in the bottom of the tank in a
ridge and furrow configuration, so that they lie across the
direction of flow except for one row that runs longitudinally
along the center of the tank floor parallel to the air supply
line. All 12 aeration basins in the South Battery contain the
original Filtros silica plates, 12 inches square by 1-1/2 inches
thick with permeabilities of 9-10, that were installed in 1923
and 1924. The total number of plates in each two-pass tank is
2348.
The aeration basins in the South Pass of the West Plant are
scheduled to be completely rehabilitated with new plates and air
piping as well as conversion from two-pass to single pass
operation before 1990. Therefore, a significant amount of
maintenance has been deferred. During the 1985/86 testing
periods, all of the tanks had one or more large boils
representing damaged plates or piping. Furthermore, the operator
frequently experienced difficulty in getting sufficient air flow
to some of the tanks to keep a consistent positive dissolved
oxygen measurement at the three-quarter point where the Zullig DO
probe was located. In an effort to correct this apparent fouling
problem, several tanks were taken out of service for acid
cleaning in,1985 and 1986.
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Jones Island - test Plant
Tank 16
L
9
i— Process Air
/ Domcoaer
- Access Kalk
*
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Flw
13
Test Plenm
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Scale: I i = 10 ft.
Plan View
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CONDUCT OF THE SURVEYS
OFF-GAS SURVEY METHODS
The MMSD purchased an "Aerator-Rator, Mark IV" off-gas analyzer
from Ewing Engineering Company in June, 1985. This provided the
opportunity to use the off-gas method for measurement of oxygen
transfer efficiency as described by Redmon, et al. (4). The off-
gas monitoring unit was used with two gas collection hoods,
designed and built by Ewing Engineering Company. The hoods,
constructed of fiber glass and PVC pipe reinforcing, each had a
collection area of dimensions 2 feet by 16.5 feet or 33 square
feet. The volume under the hood was approximately 30 cubic feet
and depended on the hood position in the mixed liquor. The
connection between each hood and the Aerator-Rator was made with
50 feet of 1-1/4 inch vacuum cleaner hose.
Carbon dioxide content in the off-gas was measured using a Dwyer
CO, indicator. The Aerator-Rator came equipped with a drying
column, so humidity data were not collected for either off-gas or
reference air. At least two gas samples were collected for CO.,
determination for every collection hood position. Mixed liquor
dissolved oxygen concentration was also measured at every
collection hood station using YSI dissolved oxygen meters and
field probes. Readings were taken at depths of approximately
four feet and ten feet and averaged.. These two readings rarely
varied by more than 0.1 mg/1.
East Plant
Before an East Plant tank was surveyed, 12 test stations were
located at equal distances along the length. With a hood
collecting off-gas from 33 square feet at each station, the total
area sampled was 396 square feet or five percent of tank surface
area. For the East Plant surveys, north and south passes were
tested on the same day with one collecting hood in each pass and
the Aerator-Rator set up between the two passes. Stations were
sampled in sequence from the inlet to the outlet, alternating
between the north and south passes. At each station, ;the hood
was positioned lengthwise across the width of the tank,
approximately in the center, and secured with ropes. As soon as
a station was sampled, the hood was moved to the next location
while a measurement was completed for the adjacent tank.
The traverse from inlet to outlet for both passes usually
required 6 hours. The average time on a station was 15 minutes,
with the oxygen sensor millivolt output recorded for the latter
half of that period. After data for a station were recorded, the
hood was moved immediately to the next station where about' 20
10
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minutes elapsed before off-gas readings were started., These
readings were recorded at one-minute intervals, and the data were
accepted when 4 readings had been obtained within a range not
exceeding 4 millivolts.
West Plant
For a West Plant survey, 15 test stations were located at
approximately equal intervals along the length of the'tank. With
a hood collecting off-gas from 33 square feet at each station,
the total area sampled was 495 square feet or five percent of
tank surface area. The hoods were positioned lengthwise across
the width of the tank, except at the turning point (Station 8)
where the hood was halfway between the baffle and the endwall,
along the direction of flow. The West Plant tanks are laid out
in pairs with the second pass of one tank sharing a common wall
with the first pass of the other tank. Therefore, the off-gas
analyzer could be used from only one side of the tank. Hood
placements in the pass away from bhe operator had to be made by a
team member in a boat. Hooks that could be moved from position
to position had to be constructed so that ropes from the hoods
could be secured as required.
For the West Plant surveys, testing began in the morning at the
turning point. One hood was then moved along each pass. The
final readings were taken about six hours later at the furthest
upstream and furthest downstream positions in the tanks
(stations 1 and 15). I
AERATION BASIN OPERATION
East Plant
Screened wastewater is combined with return sludge and conveyed
in an aerated channel approximately 450 feet to the East Plant
basins. Each of the 20 pairs of basins has a common tieadworks.
The split in mixed liquor flow between the north pass .and the
south pass is partly controlled by weir elevations at the
discharge end and is intended to be exactly even. A dye test
carried out shortly after the start of single-pass operation in
1985 showed that the flow in the south pass of Basin 6 was about
10 percent higher than the flow in the north pass. The mixed
liquor in the feed channel travels about 1200 feet from Basin 1
to Basin 20. Measurements of dissolved oxygen and oxygen uptake
rate at intervals along the feed channel have shown that a
fraction of the waste load is removed in the channel, 'but the
extent of this treatment has not been measured.
11
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The inlet zone of each pass is about 25 percent larger than the
second or the third zone, but the density of diffuser plates is
the same. Usually, during off-gas OTE surveys air flows to the
zones were adjusted to provide the same air flow rate per
diffuser throughout the tank; however, in some cases air flow was
tapered (i.e., more air was added in the first zone). During a
survey, air flow to the basin was kept constant. Mixed liquor
flows varied only slightly (usually within plus or minus 10%).
West Plant
For West Plant tanks both air flow and mixed liquor flow were
manually controlled. Mixed liquor flow varied diurnally, but
variation did not exceed 25 percent of average flow during a
test. Air flows varied even less and were manually adjusted to
keep them within about 10 percent of the average for the test
period.
TREATMENT PLANT OPERATION
Measurements of screened sewage 5-day BOD and mixed liquor
suspended solids were obtained from plant monthly reports
providing analytical data from 24-hour composite samples and
operations data based on the same 24-hour periods. Nitrogen data
were all compiled from plant monthly reports and based on 24-hour
composite samples of screened sewage and final effluent.
I
Sludge is wasted at the Jones Island West Plant through separate
gravity thickeners which are fed mixed liquor from aeration tanks
isolated for this purpose. Sludge wasting from the East Plant is
accomplished by pumping return sludge across to the West Plant
return sludge line. This procedure probably did not affect the
West Plant OTE surveys because none of the aeration basins used
for sludge wasting was included in the study. However, the
calculation of sludge age estimates for West Plant was
complicated by the inflow of East Plant waste sludge which would
have to be subtracted from the total sludge wasting for the
entire Jones Island Plant. Since the former can vary widely over
24 hours, such a calculation is questionable. As an alternative,
sludge age values reported for the West Plant are those
calculated for the entire plant by plant operations staff for the
monthly data summary. The calculation is based on the total
solids inventory throughout the plant and the total solids
wasting rate. For the East Plant surveys, on the other hand, the
sludge ages reported are based on East Plant data including
estimates of the solids in the clarifiers and feed channels.
12
-------
PRESENTATION OF SURVEY DATA
Survey data were recorded on the "Off-Gas Field Data Sheet"
(5). The value of beta, the ratio of the saturation oxygen
concentration in process water to that in clean water, was
assumed to be 0.99 for all of the surveys. The clean water
saturation values selected were 10.5 mg/1 for the 14-foot deep
East Plant aeration basins and 10.6 mg/1 for the West Plant
basins where the submergence was 15 feet (6). An effective
saturation depth of 43% of submergence was assumed in obtaining
the pressure correction factor used to calculate the field
dissolved oxygen saturation value and the deficit or driving
force at each station.
A FORTRAN program was written to accept the data obtained from an
off-gas survey, complete the required calculations, and print a
report displaying the data and the calculated efficiencies for
each station as well as flux weighted values for the field
efficiency (FOTE) and the standard efficiency for a dissolved
oxygen concentration of zero, i.e., alphaF(SOTE). Figure 3 is an
illustration of a survey summary report for the East Plant and
Figure 4 is an illustration for the West Plant.
13
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SURVEY RESULTS
EAST PLANT
Fifteen pairs of surveys were completed for the Jones Island East
Plant. Table 1 is an overall summary of test dates, test
conditions and flux weighted average field and standard OTE
values. Also shown are tank cleaning information and sludge age
and loading estimates for the test dates. In addition to
maintaining a constant air flow to the basin pair during an OTE
survey, the survey team also monitored the air flows in the six
downcomers (three in each pass). These zone air flows; were also
recorded and are shown in Table 2. Table 3 contains nitrogen
related data taken from plant laboratory records for the 15 test
dates. Detailed information concerning treatment plant
facilities and operation is included in the East Plant Overall
Plant Data Sheet (Appendix A). •
Since 10 of 'the 15 surveys in the East Plant between August, 1985
and June, 1988, were conducted in Basin 6, Table 4 was prepared
to show the trends in performance of this basin. Basin 6 was
hosed and acid cleaned in June, 1985, the same month when the
East Plant aeration basins were converted from 2-pass to single
pass operation.
Tank 6 performance was evaluated in September, 1985, and
subsequently in 1986-88, as shown in Table 4. AlphaF(SOTE)
varied between 14 and 17 percent, but showed no decrease with the
two years in service. The tank was hosed and acid cleaned in
May, 1988. Values of alphaF(SOTE) of 19 and 17 percent were then
obtained for the north and south passes, respectively. While
these efficiencies were higher than average for the previous
three years, one cannot, on the basis of this one survey,
conclude the cleaning procedure produced significant improvement.
During May, 1987, two surveys were conducted in Basin 6 when the
air flow was set at a uniform rate to all three zones in one pass
but concentrated in the first zone in the other pass. For the
higher air flow test (Fig. 5), the north pass with air; flow at a
uniform rate of about 1.3 scfm/diffuser had a flux weighted
alphaF(SOTE) value of 17 percent. The south pass with! a tapered
air supply had a flux weighted alphaF(SOTE) value of 15
percent. However, the dissolved oxygen (DO) concentration in the
South Pass rose more rapidly in the first zone which may at times
be a desirable operating condition (e.g., as a possible means for
control of the growth of filamentous bacteria).
For the test with lower air flow (Fig. 6), the DO concentration
at the overflow from the basin with a uniform air supply was
16
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-------
TABLE 2. SUPPLEMENTARY AIR FLOW RATE DATA FOR EAST
PLANT OXYGEN TRANSFER SURVEYS
Air Rate (1)
Date
8/30/85
9/04/85
9/19/85
9/24/85
4/22/86
4/24/86
10/07/86
10/22/86
10/27/86
10/28/86
5/22/87
5/28/87
7/14/87
11/12/87
6/1/88
Tank
18
6
6
18
3
17
6
18
6
6
6M
6S
6N
63
6
6
6
Zone 1
1250
750
960
750
700
840
3400
700
615
500
740
1080
820
540
675
570
600
scftn
Zone 2
750
500
710
500
430
570
(North and
500
520
400
590
420
290
,430
550
470
490
Zone 3
500
500
540
500
280
390
South)
400
490
350
580
410
280
420
545
460
480
scfta/diffuser
Zone 1
2.24
1.34
1.72
1.34
1.25
1.51
1.17
1.25
1.10
0.90
1.33
1.94
1.47
0.97
1.21
1.02
1 .08
Zone 2 Zone 3
1.67
1.11
1.58
1.11
0.96
1.27
(North and
1.1,1
1 . 1:6
0.89
1.31
0.93
0.6'4
0.96
1.22
1.04
1.09
1.13
1.13
1.22
1.13
0.63
0.88
South)
0.91
1.11
0.79
1.31
0.93
0.63
0.95
1.23
1.04
1.09
(1) Unless otherwise indicated, zone air flows were the same for the North Pass "
and the South-Pass. Numbers of plates per zone are as follows: Zone 1 - 558
Zone 2 - 450, Zone 3-442. '
18
-------
TABLE 3. SECONDARY TREATMENT NITROGEN DATA FOR
EAST PLANT OXYGEN TRANSFER SURVEYS
Date
Screened Sewage
TKN
East Plant Effluent
TKN NO2 NO3
8/30/85
9/14/85
9/19/85
9/24/85
4/22/86
4/24/86
10/07/86
10/22/86
10/27/86
10/28/86
5/22/87
5/28/87
7/14/87
11/12/87
6/01/88
37
40
38
43
—
39
24
—
24
25
41
50
38
48
47
5
7
7
8
10
12
5
5
7
8
6
8
9
12
12
0.6
1.4
1.9
1.3
0.2
0.2
0.5
0.4
0.4
0.4
0.1
0.1
j
0.5
0.1
0.1
3.4
4.1
2.2
2.7
0.2
0.2
3.7
2.2
2.4
1.2
0.2
0.1
0.9
0.1
0.1
All
values in mg/1; (—) denotes missing value.
19
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EAST PLANT TANK 6 NORTH
TESTED ON MAY 22,1987
O-JJ
0-10-
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ZONE1
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I
-------
EAST PLANT TAN'K 6 NORTH
TESTED ON MAY 28,1987
OJI
ZONE 3
5
S
o.io-
0.0*-
0.00
10 20 30 40 60 60 70 80 90 100 110
Tank Length (meters)
0-J«
0-JO
EAST PLANT TANK 6 SOUTH
TESTED ON MAY 28, 1987
ZONE 1 ZONE 2 ZONE 3
o.o*
0.00
0 10 20 30 40 60 eb 70 80 90 100 no"
Tank Length (meters)
Figure 6'. Oxygen transfer efficiency and dissolved oxygen
concentration in Basin No. 6, May 28, 1987.
Note:
Air flow to each pass was 1390 scfm, added uniformly in
the south pass at 0.96 scfm per diffuser and at 1.47, 0.64
and 0.63 scfm per diffuser in the first, second and third
zones of the north pass, respectively.
22
-------
about 3 mg/L. For the basin with a tapered air supply it was
close to zero. Several months later, when the same average air
flow rate of about one scfm per diffuser was applied uniformly in
both passes during a survey, the OTE and DO profiles were almost
identical for both passes as shown in Figure 7.
Boyle (7) cited reports indicating decreased SOTE with increase
in air flow per diffuser for various types of fine bubble
diffusers. This effect was investigated for this diffuser system
by measuring alphaF(SOTE) for a range of air flows at a location
4_meters from the basin inlet (where oxygen uptake rate would not
limit oxygen transfer rate) and at a location 6 meters from the
basin outlet (where oxygen uptake rate would probably;limit
oxygen transfer rate). The results of two tests at the basin
inlet are shown in Tables 5 and 6. In both test series
alphaF(SOTE) was constant as air flow per diffuser increased.
There are several possible explanations for this finding. SOTE
may have decreased at the same time as alpha increased. A more
likely condition, given the absence of air flow control orifices
to the individual containers, is that SOTE decreased for diffuser
plates in service, but previously inactive diffuser plates were
brought into service as air flow to the zone increased. This
could produce the overall result that alphaF(SOTE) stayed
constant.
At the basin outlet alphaP(SOTE) appeared to be constant for the
range of air flows shown in Table 7. Field oxygen transfer rate
and dissolved oxygen concentration also increased. While it is
possible that oxygen uptake rate increased even with DO
concentrations in the range of 3 to 6 mg/L, additional test runs
will be needed to establish that test conditions were at steady
state during the measurements.
23
-------
0.2*
0.20
0.10-
0.0*-
EAST PLANT TANK 6 NORTH
TESTED ON NOVEMBER 12. 1987
ZONE1
ZONE 3
A A——A. A, _aj A .£•
•I
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hi
o
0 10 20 30 40 60 60 70 80 90 100 110
o Q
Tank Length (meters)
OJO
5
&
0.10
0.0* -
EAST PLANT TANK 6 SOUTH
TESTED ON NOVEMBER 12,1987
ZONES
10 20 30 40 60 60 70 80 90 100
Tank Length (meters)
Figure 7. Oxygen transfer efficiency and dissolved oxygen
concentration in Basin No. 6, November 12, 1987.
Note: Air flow to each pass was 1.09 scfm per diffuser to all
three zones.
24
-------
TABLE 5. OXYGEN TRANSFER MEASUREMENTS AT THE INLET,
WITH A LOW OXYGEN UPTAKE RATE (1) ,
IN EAST PLANT BASIN 6
Air Flow
scfm/ft3
0.34
0.68
1.02
FOTR(2)
g/m3-hr
7
15
22
AlphaF(SOTE)
%
8
8
10
Dissolved Oxygen
mg/1
0.2
0.3
2.0
(1) Wastewater 5-day BOD was 300 mg/1; mixed liquor volatile
suspended solids concentration was 900 mg/1.
(2) FOTR = field oxygen transfer rate.
TABLE 6. OXYGEN TRANSFER MEASUREMENTS AT THE
INLET, WITH A HIGH OXYGEN UPTAKE RATE (1),
IN EAST PLANT BASIN 6
Air Flow
scfm/ft3
0.38
0.76
1.11
1.43
1.76
FOTR(2)
g/m3-hr
10
22
33
37
42
AlphaF(SOTE)
%
10
• 11
11
10
9
Dissolved Oxygen
rag/1
0.1
"'•' 0.1
0.1
0.1
; 0.2
(1) Wastewater 5-day BOD was 290 mg/1; mixed liquor volatile
suspended solids concentration was 1700 mg/1.
(2) FOTR = field oxygen transfer rate.
2.5
-------
TABLE 7: OXYGEN TRANSFER MEASUREMENTS AT THE OUTLET (1)
IN EAST PLANT BASIN 6
Air Flow
scfm/ft3
0.42
0.68
1.02
FOTR(2)
g/m~-hr
12
17
19
AlphaF(SOTE)
%
14
. 16
15
Dissolved Oxygen
mg/1
3.3:
4.7;
5.8
(1) Mixed liquor volatile suspended solids concentration was 1200
rag/1. ;
(2) FOTR = field oxygen transfer rate.
26
-------
WEST PLANT
Twenty-one surveys were completed for the Jones Island West
Plant. Table 8 is an overall summary of test dates, test
conditions, and flux weighted average field and standard OTE
values. Also shown are tank cleaning information and kludge age
and loading estimates for the test dates. Table 9 contains
nitrogen related data taken from plant laboratory records for the
21 test dates. Detailed information concerning treatment plant
facilities and operation are included in the Overall plant Data
Sheet (Appendix B) and in the monthly averages of analytical data
for Jones Island screened sewage and of operating data for the
West Plant activated sludge basins. These latter data were
compiled in connection with the EPA/ASCE Interplant Fouling Study
(Appendix C). :
Figure 8 shows two of the profiles obtained, one in August, 1985,
and one in August, 1986. The first showed a DO concentration of
one to three mg/L throughout most of the basin, while in the
second the DO concentration never exceeded one mg/L. The flux-
weighted standardized OTE values were nearly identical (11.9 and
11.8%). The form of the DO profile for the 1985 survey was quite
unexpected for a tank designed for plug flow. In fact, many of
the DO profiles observed were difficult to explain. Conditions
that contributed to these results in many of the surveys included
one or more of the following:
1. The survey schedule that sampled the middle of the basin
early in the day and then moved both upstream and
downstream as the load increased. :
2. Operator determined changes in air flows and mixed liquor
flows while surveys were in progress.
3. Severe boils or gushers where plates or pipes were
damaged, starving the immediate vicinity for air and
causing low OTE for the air escaping at the boil.
Diurnal Study
The results of a diurnal test at stations 2 and 14 are shown in
Figure 9. The test ran from noon, September 2, to noon,
September 3, 1986. The air flow to the basin was maintained at
3000 scfm. The dissolved oxygen profile was nearly flat at less
than 0.2 mg/L throughout the 24 hours at station 2, while it
varied between 1.0 and 2.5 mg/L, probably in response to plant
loading, at station 14.
Since the collection hoods were kept at fixed locations, changes
in alphaF(SOTE) were presumably the result of changes in mixed
27
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TABLE 9. SUPPLEMENTARY SECONDARY TREATMENT NITROGEN
DATA FOR JONES ISLAND PLANT FOR THE
WEST PLANT SURVEY DATES
Date
Screened Sewage
TKN
TKN
Final Effluent
NH-
NO.
NO-
7/31/85
8/12/85
8/14/85
8/20/85
8/23/85
8/27/85
10/14/85
11/04/85
11/05/85
11/07/85
11/14/85
5/02/86
5/08/86
5/13/86
6/23/86
6/25/86
8/11/86
8/12/86
8/13/86
8/19/86
8/20/86
34
24
41
39
38
42
35
29
34
37
30
38
34
35
24
32
27
27
29
26
10
5
8
5
6
6
7
12
12
7
12
11
14
4
5
3
5
6
3
5
0.4
0.6
1
3
1
3
3
1.1
0.5
0.8
0.5
0.6
6.0
1.5
6.5
3.8
3.2
4
8
6
4
8
6
8
2
2
1
2
3
2
2
0.9
0.9
1.1
0.5
0.5
0.6
0.4
0.9
0.4
0.4
0.5
0.4
2.8
3.6
1.8
0.5
0.6
0.1 : 0.3
0.2 0.2
0.2. 0.1
8.8
1.5
4.6
0.9
0.9
1.7
1.3
All values in mg/L; {-) denotes missing value; during the study
period, no samples were collected for West-Plant'alone:. Data in
this table apply to the entire Jones Island Plant.
29
-------
OJO-
o.w
0.10-
0.08-
0.00-
JONES ISLAND WEST PLANT TANK 6
TESTED ON AUGUST 12,1985
[STANDARD EFHaENCYl
RELDEFHaENCrl |P«SSOtyg) OXYt^N
A-
0 10 20 ao 40 60 60 70 ao M 100 110 120 130'
(mtt»r»)
-4
-a
2 '
-1
-0(
0.20
JONES ISLAND WEST PLANT TANK 16
TESTED ON AUGUST 19,1986
o 16 20 ao 40 eo ao TO ao ab I»B io
0.00
Tfenk Length (meters)
iao
Figure 8. Oxygen transfer efficiency and dissolved oxygen
concentration in West Plant Tanks 6 and 16.
30
-------
O.M-1
0.10
O.M-
O.M-
0.04-
o.os
0.00
—I—
4
JONES ISLAND WEST PLANT
DRJRNAL STUDY
TANK 16 STATION 2
Legend
D 8TAMDAHD EPRqENCV
o
A DI8$OtVEO OXY604
NA-A-A-A-A-
T
T
10 a u
Run Time (Houra)
i
18
—1—
20
—I—
22
rl
-OJ,
-0
24
Noon
O.M-1
ISLAhD WEST PLANT
DRJRNAL STUDY
TANK 16 SWTON14
0.00'
0
Neo*
10 tt M
Run Tims (Houra)
1*
20
24
Neo*
Figure 9. Diurnal test results for West Plant Tank 16 on
September 2 and 3, 1986.
31
-------
liquor characteristics, that is, alpha, in response to changes in
plant organic loading. Although the swing was not dramatic,
there was an increase in alphaF(SOTE) beginning about 6:00 a.m.
at station 2 and 10:00 a.m. at station 14, a change that was
consistent with the hydraulic residence time of about 4 hours
during the survey. !
Collection Hood Orientation
On July 3, 1986, the effect of the pattern used for the hood
locations was tested in a separate set of OTE measurements in the
downstream pass of Tank 20. The two hoods were moved in tandem
in a "T" formation. The lead hood was positioned across the
direction of mixed liquor flow (the pattern presently used) and
the trailing hood was positioned in the center of the i tank along
the direction of flow. One hood was slightly ahead of, and the
other slightly behind, the usual test locations for Tank 20 in
the downstream pass. '
Seven tank locations were tested in this manner. There was no
significant difference (P<0.05) for OTE values, but the mean flux
rate for the cross-tank position was nearly double the mean flux
rate; for the along-the-tank position. The results are shown in
Table 10. The applied air rate was approximately 0.12 scfm/sq
ft. The most likely explanation for the high flux rates measured
in the cross-tank orientation was the presence of severe boils at
two stations.
TABLE 10. HOOD POSITION TEST AVERAGE RESULTS FOR
THE WEST PLANT
Hood Position AlphaF(SOTE) Flux Rate
% scfm/sq -ft. (1)
Across Tank 10.5 0.207
Along Tank 10.5 0.124
(1) The applied air flow rate was 0.122 scfm/sq ft
32
-------
DISCUSSION
The standardization of oxygen transfer efficiency under process
conditions, alphaF(SOTE), has been proposed by the ASCE Oxygen
Transfer Committee for characterizing performance of aeration
basins equipped with fine pore diffusers (1). SOTE refers to clean'
water performance which is unknown in this case. Alpha is the
ratio of oxygen transfer rate under process conditions to the rate
in clean water. With time, diffusers operating underiprocess
conditions may suffer fouling and loss of efficiency.: This effect
is incorporated in the modified transfer efficiency term,
alphaF(SOTE). :
EAST PLANT '
The average value of alphaF(SOTE) for all 30 East Plant surveys was
15.4% with a range of 11.4 to 19.2%. For the East Plant tanks the
average efficiency per meter of depth was 3.6%, a very high value
in comparison with the values in the interim data base presented by
Brenner and Boyle (1).
Among the operating variables presented in Table 1, sludge age
varied from 2.3 days to 5.8 days, air flow from 1250 scfm (0.86
scfm/diffuser) to 2500 scfm (1.72 scfm/dif fuser), and !time in
service since previous cleaning from one month to two and a half
years. The influence of these variables on efficiency was examined
by applying stepwise multiple regression. With a 5% level of
significance, no statistical relationship was found between any of •
these 'variables and alphaF(SOTE). ',
WEST PLANT .
The average value of alphaF(SOTE) for 21 West Plant surveys was
11.7% with a range of 6.6 to 15.6%. For the West Plant tanks the
average efficiency per meter of depth was 2.7% which, ,for a sludge
age of 3.3 days, was quite a good value in comparison with the
values in the interim data base presented by Brenner and Boyle.
This performance is especially remarkable in view of the age of the
diffusers of over 60 years.
Among the operating variables presented in Table 8, sludge age
varied from 2.7 days to 12 days, air flow from 1300 scfm (0.55
scfm/diffuser) and 3300 scfra (1.41 scfm/diffuser), and time in
service since previous cleaning from 6 months to nearly 5 years. !
The influence of these variables on alphaF(SOTE) was examined by
applying stepwise multiple regression. With a 5% leveil of
significance, no statistical relationship was found between any of
these variables and alphaF(SOTE). ;
33
-------
REFERENCES
Brenner, R.C., and Boyle, W.C., "Status of Fine Pore Aeration
in the United States," In: Proceedings of the lith United
States/Japan Conference on Sewage Treatment Technology, EPA
600/9-88/010, NTIS No. PB88-214986, U.S. E.P.A. Cincinnati,
Ohio, 1988. !
Leary, R.D., Ernest., L.A. and Katz, W.J., "Full Scale Oxygen
Transfer Studies of Seven Diffuser Systems," Journal WPCF, 41-
459-473, 1969.
Ernest, L.A. Case History Report on Milwaukee Ceramic Plate
Aeration Facilities. Study conducted under Cooperative
Agreement CR812167, Risk Reduction Engineering Laboratory, U.S.
E.P.A., Cincinnati, Ohio (to be published).
Redmon, D.T., Boyle, W.C. and.Ewing L., "Oxygen Transfer
Efficiency Measurements in Mixed Liquor Using Off-Gass
Techniques," Journal WPCF, 5_5:1338-1347, 1983. :
Cooperative Agreement CR812167, Risk Reduction Laboratory, U.S.
E.P.A., Cincinnati, Ohio, Manual of Methods for Fine Bubble
Diffused Aeration Field Studies, Appendix A, July 1985.
Personal communication from David T. Redmon, Ewing' Engineering
Co., Milwaukee, WI September 27, 1985. '•
Boyle, W.C. (Ed.) Summary Report: Fine Pore (Fine Bubble)
Aeration Systems, EPA/625/8/85/010. Prepared by the American
Society of Civil Engineers (ASCE), Committee on Oxygen
Transfer, New York, 1985.
34
-------
APPENDIX A
Section No. Al.O
Ear is ion. No. 0
Data 7/23/25
Faga 7 of 13
EXHIBIT A.I: OVERALL PLANT DATA SHEET
BASED ON PREVIOUS TEAR OF RECORD
IS1nd
Plant Name. . . 1™??. .I.S.1An.d. .E.3.^ . H ???. Locat ioa. . ."!!*§ .4?^. W.Uco.n^iQ . . .
82 145
Flow Througli Secondary Treataeat: Average MGD Max.Day. iiGD
WASTEWAEER CHARACTERISTICS- BASED ON HONIHLI AVERAGES
17.7 15 3 19 3
Temperature, deg. C: Average ' ""
5 day BOD
COD ^opt)
TSS
TDS
TEN
Total P
pH (aot ag/1)
Alialiaity*
Hardness*
Nitrate-N
RAW ]
Ave
293
212
772
31
4.9
7.3
—
[nflueat ngy
Mia
216
163
642
23
2.9
6.9
—
'1
Max
372
"304
928
36.9
7.0
7.6
—
Sao. Effl. ag/1
Are Mia Max
19.3 9.5 ; 17.2
..A3*? ..Pv.6. .:..!?, §.
752 628 ; 923.
7.7 . 3.7 . 11.7
.41 .23 ' .83
7.2 6.8 ; 7.6
2.3 .3 ; 4.7
•as caleiua caxbo&ate aq-oivalent 35
-------
APPENDIX A
Section AI.O
Revision No. 0
Date 7/23/85
Page 8 of 13
PROCESS FLOW DIAGRAM INCLUDING TANK SIZES AND RETURN FLOWS FROM SLUDGE PSOC.
90,000
Primary Sod. Area, sq ft Final Clar. Area, sq ft
** • 1R
Aeration Tank Vol. cu ft.. Aeration. Tank Water .Depth ft....
** During 1935/86, the number of West Plant aeration basins in service
varied from 10 to 20, depending on total plant loading and the fraction
taken by the East Plant. '.
8AM
SEWERAGE COMMISSION
or im errr or tajmtxa
JONES SLAW WASTE WkTER TREATMENT (VAMT
CXjDFttNATCW
LAKE MICHIGAN
MAJOR INDUSTRIAL WASTES- Averages
Brewing
5.9
.Flow JfGD
2.8
.Flow J{GD
Vt ' 2-9
.Flow
HGD
Machinery (including plating)
Food
Tan?j.n?. Flow..2.'.0...HGD
PaPf .r. ir.e.91cAe.d) Flow. . /A . . JJGD
1655
BOD ..... . ..ag/1
42
BOD ..... i...mg/l
BOD...7.5.°...ag/l
36
-------
APPENDIX A
Section No. Al.O
Revision No. 0
Date 7/23/85
Page 9 of 13
RETURN FLOWS FBDM SLUDGE PROCESSING- Averages
Source Flow MOD BOD ng/1 TSS aj/l TEN ng/1 pfl
Vacuum
Filter .Filtrate 2.6 220 450 -- . 3.5-4.5
Sc'rubbVrVateV * "'"
° 1200 - 6.8
Notes: Overflow from gravity thickeners is discharged with plant 'effluent.
SCREENED SEWAGE
P8&te8»;£3F*l,gEHT CHARACTERISTICS- AVERAGE INCLUDING RETURN FLOWS
Flow..5.7.;6... MOD BOD..2.7.7 «g/l TSS.. 2.25...ag/l TEN...,.3.0... .ag/1 '
TDS...-.-,; ng/1 Oil and Grease :r....Bg/l
PEOCESS PARAMETERS- Based on Averaga Conditions +/- percent variability
max. nonti to nia. nonth
Min. Max.
Prinarr Overflow Rate, gpd/sf " V. .."
Aeration Detention Tiaa, V/Q. 5;? 4/.3. 7"2
MLSS Concentration mg/1.... ,24?.0... 2.°.°.0 ..3300
Ratio. 1ILVSS/MLSS. .'7? -.6.6. •77
HLSS Inventory Ib*
Solids Wasting Rate, ib HLSS/da7..cAaiQt.&§.c?Jp.u.lated for We§t.P.lAa1;.4lone.
Sludge Volume Inde*... A°.6. 5.9.......... 2°3
Recycle Ratio. R/Q ;5? ;32 -48
37
-------
APPENDIX A
Section No. Al.O
Revision No. 0
Data 7/23/85
Page 10 of 13
Sludge Age, Days*.Uottcs. Jones. J;;.lA[lct.P.Uat).3,5 2.7(mij\.X--»!4.6(n3ax.}
F/M Ratio, per d»y«W?s.t.Plan;t}_4 0^51 0-37(m.VU).--Qt68(rnax.)
(based on MLVSS)
*estimated clarifier holdup included in solids inventory
AIE DIFFUSION SYSTEM: For Each Tank Studied. Tank Designation.S.oMIl .R35S .tanks in
the West Plant
Dif fiLsers, Type and Number, P?IW.lp. AUto .(£1 ItTPSJ. ". A-JA :
permeability, 2343 per basin. ;
Recommended Air Rates for this Diffaser, SCFM Min.. 0SS Max.J..9S
Typical Wet Resistance for this Diffuser over the Rec. Air Rate Rang,e
at Min Rate at Max Rate
Orifice Resistance, inches water 0ri.t!9?.!Jf?..1s 1-5 ^".9/165.
Clean Diffuser, inches water.
These data unavailable for West. Plant.
Dirty Diffuser, inches water-
(if available)
Year InstalledA.9Zi/.24 , Submergence, ft. .15 Water Depth, ft.3.5...
Cleaning Practice and History:
Please see the plant history report by :
Larry Ernest. :
Sketch of Diffuser Arrangement in Tank. Give Essential Dimensions for
Diffuser Spacing and Air Distribution Piping. Indicate Tapering.
Begin with Downcomer.
Please see the plant history report by Larry Ernest.
38
-------
APPENDIX A
BLOTERS AND All SBPPLT PIPING
Blower Type, Braad, Model
Namber
Section Al.O
Revision. No. 0
Date 7/23/85
P»|e 11 of 13
4
5
Allis-Chalmers, VA904
leaz
I
1972
* * • • •
1972
Allis-Chalmers, VA904 1972
***•••««•*•••«*•**•»•• **•••
A1rs'VA90 72
HP
.5.5.QQ
5500
• • • • •
5500
» • • • *
5500
8PM
4,882
4,882
* • • « •
4,882
SOFM
Op. Tiae
Hr/Iear
ll.O^.O.O.O
110,000
..46.,
5126
110,000
••••••
110,000
^2682
*••*•<
939
?? nnn
Total Installed Blower HP "...". SC?K
lac lade the Eat lag Carre for Each Blover if Available
SEE ATTACHED
Describe t&e Air Filtratioa System:
Air flow first goes through a media type roll filter then goes through a
agglomerator followed by a bag and cartridge system before reaching compressor
1 i i I " U •
SttpplKaeatal laformatioa oa Blower Drives
Drive
No*b"
2
3
4
5
6
Drive Type. Braad. Model
Synchronous Motor
Tear
Desija
1PM
HP at Desija 8PM
Allis-Chalmers
.I?7.2. .1.'2.°.°.
.1972. l.,200.
1972 1
.5500
550°
5500
5500
39
-------
APPENDIX A
13 -
12 -
0
55 -11 -
0.
in 10 -
(X
3
5°
0°
•
''^-MODULATION VANEl
SETTING ANGLE (TYP)
I
-i\J ' * -
CURVES BASED ON:
BAROMETER = 14.4 PS1A ; ;
c OOQ • INLET PRESSURE = 14.25 PSIA ;
5 000 •
4 000-
0.
ffi
3 000-
2,000-
1 ,000 -
'
NLET TEMPERATURE
GAS = AIR @ 45% R
SPEED = 4,880 RPM
1
i
I
f
^N
\
= 90° F
.H.
-^
\
-20°
j ^*—*-*
^,
\ '
-10°!
I
I
I
|
\
^0°
+5°
\
•
6° 70 80 90 100 110 120 13
INLET VOLUME - ACFMxIO-'
Note: Curves based on' shop test dam.
40
FIGURE 1
ALL1S-CHALMERS
PAC CURVES
-------
APPENDIX A
Section No. Al.O
Revision No. 0
Date 7/23/85
Page 12 of 13
Typical Blowers Used at Average Operating Conditions:
Blower Numbers Total Horsepower
Measured Pressure at Blower Discharge, psi ^'A..'.
Measured Dynamic »et Pressure at Diffuser. psi
Nominal SCFK per Diffuser
Typical Blowers Used at Maxian Operating Conditions: '
Blower Numbers 1..... Total Horsepower... .5.180 ,
Measured Pressure at Blower Discharge, psi.. £.'A..
Nominal SCFM per Diffuser
Describe Blover Turndown Capability...
66520 scfm minimum output per blower
Describe Strategy Osed to Manage Blowers.
Proride a Sketch Stowing tne Arrangement of Blowers and Transmission Piping.
If P««>*1«. Stow Sufficient Detail so that Friction Loss Calculation, Could
v », - P* Slze*' Lengths. Control Valres and Nuaber of Bends fro.
the Blowers to the Aeration Tank*.
SEE ATTACHED
41
-------
APPENDIX A
Section No. Al.O
Revision No. 0
Date 7/23/85
Ptge 13 of 13 '
Describe the Data Base for Aeration Tank Dissolved Oxygen:
Frequency of Measurement .„. JWO. AT. .th.r.ee .tV5e$. P§C. $bj f Jt
Number of Locations. .8 Wig. Pf. ?&W\A .B4« .13.§] t?rP?f P. &!»&..
Length of Record
Typical Aeration Tank D.O. Values
Maiimum Minimum
First Quarter
Second Quarter A.... <<>>p
Third Quarter .... .... 1......
Fourth Quarter .5 ....!..
RESULTS OF PREVIOUS OXYGEN TRANSFER TESTS AT THIS PLANT
ADDITIONAL COMMENTS
42
-------
Section No. Al.O
Revision. No. 0
Date 7/23/85
Page 13 of 13
Describe the Data Base for Aeration Tank Dissolved Oxygen:
Frequency of Measurement. . . JS». Pf. .three .times . per. Shift.. .....
Number of Locations ........ 9PP. Pg.r. .b.a.S.i.Q .(IJQCt!) . P??S. ppjyj ____ .........
Length of Record ........... 5 JJC.
Typical Aeration Tank D.O. Values
Maximum Mininum
.- m/1
First Quarter ..... 3 ..... 0
Second Quarter ..... 6 ..... 0
Tiird Quarter ..... ? ..... ..... }
Fourti Quarter ..... ? ..... ..... 3
RESULTS OF PREVIOUS OXIGEN TRANSFER TESTS AT THIS PLANT
ADDITIONAL COMMENTS
43
-------
81
§i
C i Q
3 »• 3 2
-------
APPENDIX B
Saotioa No. Al.O
Revision No. 0
Data 7/23/85
7 of 13
EXHIBIT A.I: OVERALL PLANT DATA SHEET
BASED ON PREVIOUS TEAR OF RECORD
Milwaukee, Wisconsin
_, „ Jones Island West Plant T<«»*i Hax.Day. . JP7. . . .USD
WASTEWATES CHAEACTEEISnCS- BASED ON MONTHLY AVEHA6ES
T corporators.
dai. C:
E
la* Influent fflg/1
Ara Uin Hax
5 day BOD
ODD (opt)
TSS
***
TDS
TSM
Total P
pH (not aj/i;
Alialinity*
Hardness*
Nitrata-N
293
212
772
31
4.9
7.3
• • •*"• •
216 372
.
16.3 . 304
642 928
23 36.9
2.9 7.0
6.9 7.6
• • * «"•"*• •• •»•••••
15.3
Sac.
Ava
18.2
22.3
828
•*•••*
8.8 -
.48
7.2
..24.Q..
1.8
. Hax....1?.-.3..,..
Em. ag/i
Hia . Hai
11 32.3
..ii*4. ..3A-.7..
..§«. ; ...wm
,.4.^. - ...1^.7.
.31. .87
6.8 j 7.6
• ***%** * • • * T 4 * a> • *
.2 ; 4.6
•as calettes carbonate
*** for the dates of January 1979 to November 1981
45
-------
Section Al.O
ROT is ion No. 0
Date 7/23/85 ',
Page 8 of 13
PBOCESS FLOW DIAGRAM INCLUDING TANK SIZES AND RETUBN FLOWS FEDM SLUDGE PEOC.
111,000
Primary Sad. Axes, sq ft Fiaml Clax. Are*, sq ft
5,000,000 ;1d
Ajirttioa Tank Vol. ou ft Aeration Tank Water Depth ft..1.....
SEWERAGE COMMISSION
CKLCRINATION
riEFflUENT
"II1
//////
SCREEN
r~
k
*'•••• j
SLU
X;
c
MtUDft
GflIT
REMCMU.
FILTRATE
/— -\
*U
.RLTERS
-K
^OR*SRS
ANITE
or i
JONES ISLAND
V
\J
AERATION- <
BASINS
RETURN SLUDGE
WEST PLANT
WASTE
SLUDGE
EAST PLANT
RETURN SLUOGE
AERATION ^
* BASINS *
xe CITY or
WAS ft KWIt
k
*- LIQUOR
STORAGE
LAKE MICHIGAN
MAJOR INDUSTRIAL WASTES- Averages
Brewing
Machinery (including plating)
Food
Tanning
Paper (recycled)
.Flow. ...'... 3HSD
2 8
.Flaw.,.. '...mo
.Flow.
2 9
.4
mo
.Flow. ,..'... HGD
BOD,
BOD,
BOD,
1655
42
880
.ag/1
.aS/1
BOD..7.5.0...ag/1
BOD. .1.8.6.°.i. ag/1
46
-------
Section No. AI.O
SOT is ion No. 0
Data 7/23/85
Page 9 o£ 13
EETIIEN FLOWS FEQH SLUDGE PEOCESSING- Average* None
Source Flov MGD BOD mg/1 TSS ag/1 TEN mg/1 pfl
• • *
Notes:
SCREENED SEWAGE
BXIMA^>EES:XXIS^ CHARACTERISTICS- AVERAGE INCLUDING EETOEN FLOWS
Flow...8.2....J«H> 27 24 30
TDS.... V.... ag/1 Oil and Greaa* ---- "I".... ag/1
PEOCESS RiEAiEBrEES- Based 25 -51
47
-------
Section No. Al.O
Revision No. 0
Date 7/23/85
Page 10 of 13
Sludge Age, Days*. . . . P«£. ....... ...................
F/M Ratio, per day-...
(based on MLVSS)
•estimated elarifier holdup included in solids inventory yes
AIS DIFFUSION SYSTEM: For Eacli Tank Studied. Tank Designation Jto.. Q .(Uorttl. or South)
Diffusers. Type and Number. .U5Q-rSgyar& Aejr.ajTjig;p]afe$j. J.2. A .U A;.l .O.JOCb thick.
Reconsseaded Air Sates for this Diffuser. SCFM Mia.. 0.7 ...... Max. .2. 5 .......
Typical 7et Resistance for this Diffuser over the Rec. Air Rate Range
at Mia Rate at Max Rate
Orifice Resistance, inches water .QCiflCe. J5. 1 .0 incA .
-------
Section Ai.O
Revision No. 0
Date 7/Z3/85
Page 11 of 13
BLOTTERS AND AIR SOPPLT PIPING
Blove
Ntzabe
1
2
3
4
5
6
Total
r Type, Brand, 3
1 Four stage
AIUs.-Qha.lmers..,
Allis-Chalmers,
Allis-Chalmers,
Allis-Chalmers,
Installed Blower
Kodel
axial var
VA904
VA904
VA904
VA904
BP ,
lear
ie
1972
• • • * •
1972
1972
1972
22,000
HP RPM SCFM
.5.5.QQ ^i§82 ljLO.,000
5500 4,882 110,000
5500 4,882 110,000
5500 4,882 110,000
SCFM...
Op. Tiae
Br/Zear
46
5126
1 2682. 25
' 939.25
•
Include: the RAtiag Curr« for Each Blower if Available
SEE ATTACHED
Describe the Air Filtration System:
Air flow first goes through a media type roll filter then goes through a
agglomerator followed by a bag and cartridge system before reaching compressor
inlet,, . • i
Scppl«siautal lafoaaation oa Blover Drives \
Drire Drive Type, Brand. Model Tear Design HP at Design EPIC
Nt*b*r Synchronous Motor KPM
Allis-Chalmers 1973 1,200 5500
Allis-Chafmers *''''
3 e .1972. 1..200 5500
4 ..™™ . .'..,. ....5.5.°.9
5
€ „
49
-------
c;
wi
o.
Ul
a:
D
U.I
a:
a,
U.I
Cl.
b
Cfli
14
13
12
11
10
a.
5
4
6.000
5.000
4,000
3,000
2.000
1.000
i
SURGE
LIMIT
'
/
/
_^
\
\
' N
! «''
< \
\
\
-20°
,
^
'-'"
-------
Section No. Al.O
SLOT is ion No. 0
Date 7/13/85
Page 12 of 13
Typical Blowers Csad at Arerage Operating Coaditioas:
Blower Numbers Total Horsepower
Measured Pressure at Blower Discharge, psi 7.\4.
Measured Dyaaaic Wet Pressure at Diffnser, pai
Noaiaal SCFK p«r Diffuses
TypAoal Blowers Used at Maxiaim Operating Coaditioas:
Blower Numbers }... Total Eorsepower....5.18Q
Measured Pressure at Blower Discharge, psi..P.-A
Nominal SCFM per Diffuser
Describe Blower Taradown Capability...
66520 scfm minimum output per blower
Describe Strategy Used to Hanage Blowers.
Proride a Sketch Sfcowiag the Arraagexeat of Blowers aad Traasmissioa Pipiat
If possible. Show Sufficient Detail so that Frictioa Loss Calcnlatioas Could
be Miide. Show Pipe Sizes. Lengths. Control ValTes aad Nuaber of Beads fro«
the Blowers to' the Aeration Taaka.
SEE ATTACHED
51
-------
f i!, i -t -t -y 1
f *•*??! «BKJ- «i JII *•/ J- ** *=
"SB
g s
c 2 5
I
-------
X
Q
Zl
UJ
CL.
Q.
w
(3
s
s
w
w <
a Q
O X
en j
B
§ 1
M S
CO
H
8
1
«
1
(
1
9
1
i
f^x
M 0
^
*<
itf O
E-i 8
*•*
W ft
W CJrH
a i cr
< £
^ ^^ ^J
1 O
n e-i
2 W
— w S
2 cs 3:
J O W
E 03 W
*^
1 fSJ
>4 W D
XO
M M
M
e^
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