FLUORIDE REDUCTION in COMMUNITY WATER SUPPLIES .Je: prepared for the •. . STATE OF SOUTH CAROLINA DEPARTMENT OF HEALTH & ENVIRONMENTAL CONTROL WATER SUPPLY DIVISION » JOINT VENTURE J.E.SIRRINE COMPANY & AWARE, INC. Summervilli, South Carolina Brentwood, TIMISSII volume ONE ------- FLUORIDE REDUCTION IN COMMUNITY WATER SUPPLIES Prepared For STATE OF SOUTH CAROLINA DEPARTMENT OF HEALTH AND ENVIRONMENTAL CONTROL WATER SUPPLY DIVISION A Joint Venture Of J. E. SIRRIME COMPANY and AWARE, INC. Summerville, S. C. Brentwood, TN VOLUME ONE ------- ABSTRACT Forty-three community water supplies located along the east coast of South Carolina contain fluoride concentrations which exceed the limit estab- lished by law. During the course of this study, each high fluoride sup- ply was evaluated in an effort to identify one or more viable alternatives that might be implemented to achieve compliance. The primary option proposed for the majority of systems was blending. By constructing shallow wells that tap a low-fluoride aquifer and mix- ing their yield with that of the existing deep wells, fluoride concen- trations can be attenuated to acceptable levels in the combined supplies. For blending to be successful, twenty—five coninunities would be required o drill 204 new wells. The total estimated capital cost of blending is $15,305,000. The remaining communities can achieve compliance by implementing one of four other alternatives. Those alternatives and their attendant capital costs are as follows: seven would replace existing wells with new ones at a cost of $385,000, eight would abandon existing supplies and purchase water from an adjacent utility at a cost of $200,000, two would employ activated alumina treatment to reduce fluoride at a cost of $10,472,000, nd the remaining one would construct a separate distribution system to .erve exempt users exclusively at a cost of $230,000. iiplementation of the primary alternative by all forty-three communities )uld require a state-wide capital expenditure of $26,592,000. 1 ------- ACKNOWLEDGEMENTS This report represents the combined efforts of a great many individuals. It would be impractical to express appreciation to every contributor; however, the authors wish to acknowledge the assistance of Bob Heater of Heater Well Company, Larry West of the S. C. Water Resources Commission, and Al Zack of U.S. Geological Survey in providing groundwater data. The authors also wish to express their gratitude to the various equip- ment vendors, especially Hydronautics Water Systems and UOP Fluid Sys- tems Division, for the invaluable information that they provided on water treatment processes . A special thanks is due the personnel that manage and/or operate the water systems included in this report for the information and advice that they offered. Two of those managers, Ron Bycroft of Mt. Pleasant and Robert Winfield of Conway, made significant contributions to this study by providing accommodations and facilities for the bench scale testing that was conducted. Another noteworthy con- tributor to the testing effort was Culligan Water Conditioning, Inc. who provided the equipment. Finally the authors thank Fred Soland of the South Carolina Department of Health and Environmental Control for his valuable guidance and suggestions. 11 ------- TABLE OF CONTENTS CHAPTER 1 Fluoride Reduction in South Carolina Introduction PAGE 1—1 1— 1 • . 2—1 • . 2—1 • . 2- 1 • . 2-4 • • 2-4 • . 2-6 • • 2-6 • . 2-7 • . 2-7 • . 2-7 • . 2-10 • . 2-13 2-1 3 Proposed Fluoride Reduction Methods 1-2 Blending 1-2 Abandonment 1-3 Treatment 1-5 Unique Solutions 1—6 Regional System 1-6 Fluoride Reduction Cost 1-9 Summary 1-10 a. 2 Treatment for Fluoride Reduction Incidental Fluoride Removal Lime Softening Activated Carbon Adsorption . Ion Exchange Using Synthetic Resins Ferric Salts Zeolite Fluoride Removal Using Bone-Related Medi Bone Bone Char Synthetic Bone Sorption Using Aluminum Compounds . . Aluminum Sulfate Ill ------- TABLE OF CONTENTS (cont.) CHAPTER PAGE 2 Activated Alumina 2-18 Demineralization by Reverse Osmosis . . 2-28 Configurations of Membranes 2-28 Prevention of Fouling and Pretreatment Requirements 2-31 Bench-Scale Testing 2-34 Installations Employing RO . . . 2-35 Summary 2-38 3 Activated Alumina Pilot Studies . . . 3-1 Experimental Procedures . . . 3-1 Experimental Results 3-3 Discussion of Results • • 3—8 4 Basis of Design and Treatment Costs for Activated Alumina 4-1 Basis of Design 4-1 Activated Alumina - Cost Estimates . 4-9 Process Design - Regional Water Treatment Facility . 4-12 iv ------- FIGURES FIGURE PAGE 2-1 Effect of Influent-Water Composition on Fluoride Exchange Capacity Utilizing Amberlite XE—75 2-5 2-2 Relation of Exchange Capacity and Fluoride Ion Concentration in Influent Utilizing Activated Alumina . . 2-21 2—3 Relation of Exchange Capacity and Alkalinity of Influent Utilizing Activated Alumina 2-22 2-4 Relation of Exchange Capacity and pH of Influent Utilizing Activated Alumina 2-23 2-5 RO Spiral Wound Module Configuration 2—30 2-6 RD Hollow Fine Fiber Module Configuration 2—32 3—1 Mt. Pleasant Pilot Plant Run 3-6 3—2 Conway Pilot Run 3-7 4-1 Activated Alumina System - Capital Cost 4-10 4—2 Activated Alumina System - Annual 0 & M Cost 4—11 4-3 Process Flow Schematic - Pee-Dee River Regional Facility 4-13 V ------- TABLES TABLE 1-1 Regional Water System Data 1-2 Summary of Fluoride Reduction Alternatives 2—1 Fluoride Reduction at Three Lime-Softening Plants 2-2 Bench-Scale Study of Aluminum Sulfate 2-3 Removal of Fluorides from Salts in Water p1 1 Values by ALUM FLOC 2—4 EPA Comparative Costs 3—1 Mt. Pleasant Fluoride Removal Pilot Test Summary 3—2 Mt. Pleasant Fluoride Removal Pilot Test Summary 3-3 Conway Fluoride Removal Pilot Test Run I 3-4 Conway Fluoride Removal Pilot Test Run 2 4—1 Process Design Summary (100 GPM System). 4-2 Process Design Summary (250 6PM System). 4-3 Process Design Summary (500 6PM System). Process Design Summary (1,000 GPM System) Basic Column Information Process Design Summary At Various Run I Data Run 2 Data Data Summary Data Summary PAGE 1-8 1—1 1 2—3 2-15 2—17 2-39 3-4 3-4 3-5 3-5 4-2 4-3 4-4 4-5 4-8 4-14 4-4 4-5 4-6 V . ’ ------- CHAPTER 1 FLUORIDE REDUCTION IN SOUTH CAROLINA INTRODUCTION As of the 24th of June, 1977, water supplies throughout the United States were required to comply with the Environmental Protection Agency (EPA) National Interim Primary Drinking Water Standards. Those standards es- tablished a maximum contaminant level (MCL) for fluoride and nine other inorganic chemicals. Enforcement responsibility for the standards was requested by, and subsequently granted to, the South Carolina Department of Health and Environmental Control (SC DHEC). As an initial step toward winging South Carolina water supplies into compliance with the law, the State authorized this study of fluoride reduction alternatives. During the course of the study, which was funded by EPA and conducted under the auspices of SC DHEC, forty-three community water supplies were evaluated and conceptual solutions for reducing fluoride concentrations were form- ulated for each of the affected systems. For systems where treatment of an existing or alternate water source was indicated, desk-top system de- signs were developed; where fluoride attenuation by blending the exist- ing supply with the yield from proposed shallow wells was indicated, designs were based upon estimates of water quality and quantity obtained from well drillers, the South Carolina Department of Water Resources, arid United States Geological Survey personnel. Planning-level cost esti- mates were prepared in 1980 dollars for all alternatives and served as a ‘sis for ranking the various solutions in their order of viability. 1— I ------- Individual reports documenting the results of the study, as applicable to a specific system, were prepared and transmitted to the respective purveyor responsible for each supply determined to be in non-compliance. Copies of those reports are contained in Volume Two of this document. PROPOSED FLUORIDE REDUCTION METHODS All high fluoride water utilized as a couniunity source of supply in South Carolina is drawn from wells. Reduction of the fluoride concentration in the yield from those wells can be achieved in one of three ways. The water can be treated to remove a portion of the fluoride, it can be blended with a low fluoride source, or the source can be abandoned in favor of a more acceptable supply. Depending upon a host of site-spe- cific conditions, variations of all three basic fluoride reduction methods can be implemented by the various purveyors to bring their respective systems into compliance. Bi ending Blending low fluoride water with existing supplies to achieve an accept- able mix was determined to be a viable option for twenty-seven systems. Of those, blending ranks • s the least expensive solution for twenty-five. Implementation of the primary alternative in all systems would require the construction of 204 new shallow blending wells having a combined capacity of 11,573 gallon per minute (GPM). The cost of designing and constructing the blending facilities was esti- mated at $15,305,000. The blended supply would be distributed to 29,465 consumers (approximately 100,00 people). 1—2 ------- Water Quantity . The scope of this study did not include the construc- tion of test wells; consequently, availability and capacity were estima- ted from existing information obtained from private contractors and governmental agencies. Some capacity variation will occur in all wells constructed in response to the information provided in this report. However, the projected yield should be attainable in most instances. Water Quality . Blending shallow well water with existing supplies will create iron-related aesthetic problems in most communities. The sever- ity of those problems will vary with the actual iron concentrations that are encountered and with the blending ratios required to reduce the fluoride content of the combined supply to acceptable levels. Lacking accurate quality data, the assumption was made that sequester- ing would provide a relatively inexpensive means of controlling red water in most systems. Iron removal was included in the blending scenario for three communities where the success of sequestering is doubtful. Those communities are the City of Conway, Bulls Bay Rural Community t later District, and North Myrtle Beach. Shallow wells are generally more susceptible to bacterial contamination than are deep wells. Consequently, gas chlorination equipment and con- tact tanks were included in the estimated cost of several specific blend- ing alternatives. Abandonment Abandonment of existing wells in favor of another source of supply was determined to be a viable option for twenty-five communities. Purchas- 1-3 ------- ing water from another utility and constructing new wells were the two variations of abandonment found to be feasible. Purchase . Buying water from an adjacent utility was presented as a pri- mary option for eight systems. Of those, five would be able to obtain a low-fluoride supply, the remaining three would tie to a larger system that is in noncompliance. The rationale behind connecting to a larger non-complying utility lies in the economy-of-scale that would be realized by the large purveyors in reducing fluoride as opposed to the small sys- tem operator. For example, Crystal Lakes Mobile Home Park would incur an annual per consumer cost increase of $540.00 by installing an acti- vated alumina treatment system on its existing supply. However, by pur- chasing water from the City of 4yrtle Beach, which would also employ activated alumina treatment, Crystal Lakes could reduce its annual per consumer cost increase to $133.11. Comparison of the two treatment alternatives in terms of cost per unit of installed capacity verifies the economy-of—scale to which the significant decrease in consumer cost is attributed. That comparison is as follows: Crystal Lakes Mobile Home Park • Installed A.A. system capacity 125 GPM • Annual cost increase $108,000 • Annual cost increase per GPM of installed capacity $864.00 City of Myrtle Beach • Installed A.A. treatment capacity 9460 GPM • Annual cost increase $2,222,800 • Annual cost increase per GPM of installed capacity $234.00 1-4 ------- Implementation of the primary alternative in all eight systems would re- sult in the abandonment of 1127 GPM of water supply capacity. The service to 1378 consumers, approximately 4,800 people, would shift to a larger municipal supply. Construction of New Wells was indicated as the primary option for seven communities. As was the case with blending wells, quality and quantity were estimated from existing information. Therefore, actual conditions encountered will vary somewhat from results predicted in this study utilizing assumed data. The new wells, if constructed, will replace 775 GPM of existing capacity which will be abandoned. The replacement facilities will serve 305 consumers, approximately 1,100 people. Treatment Initially, two methods of water treatment were identified as possible fluoride reduction alternatives. One was reverse-osmosis, the other was an ion-exchange process utilizing activated alumina as the exchange med- ium. Further efforts, which included a complete review of available fluoride treatment literature and two limited bench-scale tests that were conducted as part of this study, resulted in the selection of acti- vated alumina as the most viable process for fluoride reduction treat- ment. It was noted that both treatment processes have demonstrated technical feasibility in many instances. However, full scale fluoride reduction is a relatively new area of endeavor for municipal water purveyors. 1-5 ------- Therefore, the reader is cautioned that any design of full scale treat- ment facilities should be preceded with adequate bench scale and pilot plant testing of each source of supply. Activated alumina treatment was determined to be a possible solution for twenty communities. Of those, only two, the City of Myrtle Beach and the Town of Edista Beach, exhibit existing situations that favor the selection of treatment as the primary fluoride reduction alternative. Unique Solutions Of the forty-three communities evaluated, only the Town of Kingstree pre- sented a situation requiring a unique solution. The primary alternative for the community proposes the construction of a separate distribution system which would serve exempt users exclusively. Five major consumers two schools, two industries, and a hospital are located in close proximity to the only municipal well that contains excessive concentra- tions of fluoride. By constructing a mini-system to serve the exempt users from the high fluoride well, Kingstree can achieve compliance with- out constructing treatment facilities or shallow blending wells. Regjonal System In addition to the individual alternatives that were presented for each community, a regional water system concept was developed for Horry and Georgetowr Counties. The source of supply for the system would be the Great Pee Dee River. A 35 MGO conventional surface water treatment facil- ity would be located on the northeast side of the river along U.S. High- way 701. 1-6 ------- Transmission mains varying in diameter from 14 to 60 inches would convey the water in a westerly direction as far as Conway, in a southerly direc- tiori as far as Pawley’s Island, and in a northerly direction as far as North Myrtle Beach. Management and operation of the proposed system would be effected under a joint agreement of all political subdivisions involved. Each community system served would purchase water on a bulk basis for re- sale to its consumers. The capital cost of the regional system has been estimated at $85,000,000. Assuming that the system operated during calendar 1980, annualized costs would total $11,695,000. The bulk water purchase rate for that period was calculated to be $2.95 per 1000 gallons. That computation was made as follows: • Debt Service at 12% for 30 Years $10,551,900 • Estimated Operating Cost 1,143,100 Annualized Cost $11,695,000 • Current Annual Demand (in thousands) (10,860)(365) = 3,963,900 • Cost Per 1000 Gallons S11,695,000 = $2.95 3,963,900 Design, securing permits and approvals, solicitation of proposals, con- tract negotiation and award, and construction of the proposed regional system can be accomplished within 60 months of completion of required referendums, rate structure studies, funding procurement, etc. 1—7 ------- TABLE 1-1 REGIONAL WATER SYSTEM DATA COMMUNITY North Myrtle Beach Briarci iffe Myrtle Beach Myrtle Beach Air Force Base Crystal Lakes MHP GSW&SA Socastee Area GSW&SA Garden City Area Forest Acres Trailer Park Platt Water Company Surfside Beach Garden City Pawley’s Island! Murrell’s Inlet Wagon Wheel Farms Inlet Oaks Trailer Park Conway & Conway Rural Mike Williamson MHP Oakey Swamp Trailer Park Bucksport Water Corn- pa fly CURRENT DEMAND (MGD) 1.571 0. 120 5.700 0.173 0.032 0.338 0.135 0.003 0.085 0.336 0.402 0.500 0.008 0.020 1.330 0.008 0.008 0.061 10. 860 1990 DEMAND (MGD) 5. 100 0.309 13. 330 0.311 0.058 3. 300 0.385 0.007 0.323 1 . 400 2.160 3.820 0.018 0.036 4.000 0.014 0.012 0.220 34.803 1-8 ------- A summary of the community data utilized in developing the regional water system concept is tabulated in Table 1-1. FLUORIDE REDUCTION COST The financial information presented in this report is based upon 1979 consumer levels and 1980 planning-level cost data. The annual costs pre- sented do not represent the total cost of any alternative . They do repre- sent the increase that would be incurred if the proposed facilities were constructed and became operational during calendar 1980. For example, blending alternatives include the estimated annualized capital cost and the estimated operating cost for all proposed facilities. They do not include similar costs for existing facilities which will remain in operation. Con- sequently, the annual cost data presented in this document represents the increase that will result from fluoride reduction, not the total operating cost that will be borne by the community. Another noteworthy item is that all capital expenses were assumed to be financed completely with long term loans repayable over a 30-year period at a 12% rate of interest. The assumption was made primarily to place the alternatives on an equal basis for comparison. Secondarily, evaluation of the fiscal position of each purveyor included in the study was not possible within the scope of this project. In actuality, the funding program selected by each community will have a significant impact on the per consumer cost increases listed throughout this writing. In most cases - grants, utiliza- tion of existing cash reserves, and lower interest rates will act singularly or in concert to reduce the stated incremental cost increases. For example, at an interest rate of 12% for 30 years, annual debt service on $1,000,000 1-9 ------- would be $124,140. By reducing the interest rate to 8% for 30 years, the annualized expense would be reduced to $80,590. Implementation of the primary alternative by all communities included in this study would result in a state-wide capital expenditure of $26,592,000. That translates to approximately $177 for each of the 150,000 people who would have the fluoride concentration of their water supply reduced as a result of the proposed changes. SUMMARY The results of this study are summarized in the following table. 1-10 ------- TABLE 1-2 SUMMARY OF FLUORIDE REDUCTION ALTERNATIVES FOR COMMUNITY WATER SYSTEMS IN SOUTH CAROLINA _____________ — ANNUAL COST INCREASE COMMUNITY L L CI) end I . . . ALTER NA TI VES b Lj ‘ - ‘._)‘__ American Heritage MHP 1 65 44 50 0.1 6.3 97.05 Construct shallow well and blend Aynor Construct shallow wells and blend Treat existing deep well supply with tivated alumina 1 2 325 150 150 90 340 0.8 27.0 11.2 42.2 36.92 212.95 Belmont S/D Purchase water from Summerville 1 32 N/A 35 1.6 4.4 187.50 Briarcliffe S/D Construct shallow wells and blend Purchase water from Myrtle Beach Treat existing deep well supply with activated alumina 1 2 3 417 300 N/A 300 110 35 397 1.2 70.3 38.5 13.7 4.3 49.3 35.63 178.91 210.51 Bucksport Water Company Construct shallow wells and blend Purchase water from Conway Tie to regional system Treat existing deep well supply with activated alumina Construct surface water treatment facility on Pee Dee River 1 2 3 4 5 303 355 N/A 150 175 175 180 100 453 70 500 0.5 40.7 6.0 46.7 77.9 22.3 12.4 56.2 58.3 62.1 75.39 175.43 205.00 346.53 462.05 1—11 ------- TABLE 1-2 SUMMARY OF FLUORIDE REDUCTION ALTERNATIVES FOR COMMUNITY WATER SYSTEMS IN SOUTH CAROLINA COMMUN/ T Y and 4LTERNA TI YES Bull Construct s Bay Water Di shallow wells strict with iron treatment facilities and blend Central MHP Construct new well and abandon isting supply Conway Construct shallow wells with iron treatment facilities and blend Treat existing deep well supply with activated alumina Tie to regional system Crystal Lakes MHP Purchase water from Myrtle Beach Treat existing deep well supply with activated alumina 1 2 1 2 200 N/A 125 30 355 22.9 63.9 3.7 44.1 133.11 540.00 Edisto Beach Treat existing deep well supply with activated alumina Treat abandoned brackish well yield with reverse-osmosis 750 360 360 1,077 1,100 71.3 185.4 133.7 136.5 273.33 429.33 Forest Acres MHP Purchase water from GSW&SA struct new wells and abandon existing supply 1 2 14 8 N/A 20 45 1.6 0.1 2.5 5.6 290.07 402.64 ANNUAL COST INCREASE 3,000 1 3,930 2 3,000 22.8 290.5 2,340 2,270 207.0 79.72 281.8 124.38 3 2,777 10,427 138.7 1,294.5 364.67 1—12 ------- TABLE 1-2 SUMMARY OF FLUORIDE REDUCTION ALTERNATIVES FOR COMMUNITY WATER SYSTEMS IN SOUTH CAROLINA ANNU4L COST C ) iNCREASE COMMUNITY — L and ‘ I) ALTERNA Ti VES L Lu 3Q Garden City Beach Construct shallow wells and blend Tie to regional system Treat existing deep well supply with activated alumina 1 2 3 — 1,319 1,580 1,500 1,580 1,000 3,134 2,890 4.0 41.7 216.2 124.2 389.0 357.5 97.16 326.54 434.97 GCbI&SA Pawley’ s/Murrel l’s i11 shallow wells and blend Tie to regional system Treat existing deep well supply with activated alumina 1 2 3 2,555 1,810 2,653 1,810 900 2,139 2,255 2.7 28.5 208.0 111.7 265.5 279.9 44.80 115.05 190.97 GSW&SA Garden City Area Construct shallow wells and blend Tie to regional system Treat existing deep well supply with activated_alumina — 1 2 3 800 400 267 400 310 1,058 840 1.5 14.1 62.0 38.5 131.3 104.3 49.90 181.70 207.85 GSW&SA Socastee Construct shallow wells and blend Treat existing deep well supply with activated alumina Tie to regional system 1 2 3 1,571 1,500 1,500 2,292 900 1,590 2,650 3.4 156.0 35.2 111.8 197.4 328.9 73.28 224.94 231.80 Henu i ngway Construct shallow wells and blend 1 532 785 205 0.3 25.5 48.30 -iat existing deep well supply with 2 500 435 52.0 54.0 199.25 ivated alumina 1-13 ------- TABLE 1-2 SUMMARY OF FLUORIDE REDUCTION ALTERNATIVES FOR COMMUNITY WATER SYSTEMS IN SOUTH CAROLINA 44’NUAL COST INCREASE COMMUNITY L - L and ALTER /VA TI VES c ) . j Q;: ZCr INLET OAKS MHP Construct shallow wells and blend Purchase water from GCW&SA 1 2 95 38 N/A 40 25 0.2 21.8 5.0 3.1 54.38 262.15 Isle of Palms Water Company Construct shallow wells and blend eat existing deep well supply with activated alumina 1 2 1,439 1,000 1,000 340 734 0 72.5 42.2 82.6 29.47 107.71 James town Install pump in existing shallow well and blend 1 90 180 28 0.1 3.5 39.22 Ki ngs tree Isolate well and construct mini- system to serve exempt consumers Construct shallow wells and blend 1 2 1,800 500 785 230 250 0 0.5 28.6 31.0 15.86 17.52 Lane onstruct shallow well and blend 1 135 145 60 0.1 7.5 55 .93 Little River 3nstruct shallow wells and blend irchase water from GSW&SA neat existing deep well supply with :tivated alumina 1 2 3 290 259 N/A 325 110 0 331 1.0 21.4 26.0 13.7 0 41.1 50.5 73.71 231.3 Loris )nnect selected existing wells and lend existing low fluoride wells to !move iron eat existing high fluoride we ith activated alumina 1 2 870 440 450 400 100 400 405 3.3 19.5 To 12.4 49.7 18.0f - 7 9 .4ç T 4 ------- TABLE 1-2 SUMMARY OF FLU RIDE REDUCTION ALTERNATIVES FOR COMMUNITY WATER COMMUN/ TV and AL TERNA TI VES Mike Williamson MHP o Construct new well • Purchase water from Conway construct shallow wells and blend • Treat existing deep well supply with activated alumina SYSTEMS IN SOUTH CAROLINA Myrtle Beach • Treat existing deep well supply with activated alumina • Tie to regional system 1 2 10,000 9,460 J,257 9,395 44,665 ,056.5 593.9 1,166.3 5,543.5 222.2 613.75 Myrtle Beach Air Force Base • Construct shallow wells and blend • Purchase water from Myrtle Beach 1 2 865 325 N/A 380 45 0.2 102.0 47.2 5.6 54.7 124.3 North Myrtle Beach • Construct shallow wells and blend • Treat existing deep well supply with activated alumina • Tie to regional system 1 2 3 4,70 4,400 4,400 3,542 5,100 4,915 12,535 32.0 461.0 166.7 633.2 610.2 1,556.1 141.5 227.9 366.5 North Tranquil Acres S/D • Purchase water from Summerville — 1 175 N/A 13 7.1 1.6 49.71 Oakey Swamp MI-IP urchase water from Conway 1 20 N/A 4 2.8 0.4 162.6( ANNUAL COST /NC/?EA SE 1 2 40 1 2 5,200 2,460 ,250 1,470 0 182.5 35. 1,650 167.2 204.8 7l.5 1—15 ------- TABLE 1-2 SUMMARY OF FLUORJDE REDUCTION ALTERNATIVES FOR COMMUNITY WATER SYSTEMS IN SOUTH CAROLINA COMMUN/ r Y and AL TERNA TI VES ANNUAL COST INCREA SE p.’ H L c.) L —4 L c. ‘- - —‘ ‘4 i L (r 22 Pine Ridge MHP urchase water from regional water ystem. Note: regional system is n planning stage. Cost and iniple- entation schedule not available at Ms time. shallow well and blend Plantersville Water System instruct shallow wells and blend rchase water from Brown’s Ferry stern 1 2 N/A 33 29 0.1 1 2 240 164.77 3.6 150 N/A 55 0 0.3 8.0 6.8 0 29.70 33.22 Platt Water Company truct shallow wells and blend at existing deep well supply with :ivated alumina to regional system 1 2 3 450 270 200 224 160 350 666 0.7 29.6 8.9 20.0 43.5 82.7 45.56 162.22 203.39 Red Hill Water System 1 2 40 28 N/A 35 45 0.1 1.3 4.3 5.6 111.13 172.93 struct new well chase water from Brown’s Ferry tern Rock Bluff S/D :ruct new well 1 21 8 45 0.1 5.5 268.24 Rose Hill Water System ;truct new well hase water from Brown’s Ferry I 2 32 N/A 42 35 42 0. 1 1.5 4. 3 5.2 106.07 158.95 1-16 ------- TABLE 1-2 SUMMARY OF FLUORIDE REDUCTION ALTERNATIVES FOR COMMUNITY WATER SYSTEMS IN SOUTH CAROLINA COMMUNITY 0/70’ AL TERNA TI VES ANNUAL COST iNCREASE cr H L (, J L (- ‘ -. J — LI (r Sangaree Sf0 Purchase water from CCPW 1 2 N/A 96 27.5 11.5 47.85 South Tranquil Acres S/D 1 100 N/A 2.0 2.9 0.3 31.00 Purchase water from Surnmerville Town of Stuckey 1 86 200 -135 0 16.7 194.31 Lonstruct new well Sull-ivans Island Constructidditiona] shallow wells and blend Construct new deep well and treat with activated alumina 1 2 790 500 500 18 865 0 50.7 2.2 107.4 2.83 200.00 Surfside Beach Construct shallow wells and blend Treat existing deep well supply with activated alumina Tie to regional system 1 2 3 1,485 1,167 1,170 972 700 1,115 2,632 3.4 102.8 35.0 86.9 138.4 326.8 60.78 162.40 243.63 Sycamore Acres S/D Transfer water from adjacent system nd blend 1 91 175 50 0 6.2 68.22 Wagon Jhee1 Farms onStruct new well ‘urchase water from GCW&SA 40 1 2 19 45 0 5.6 140.23 N/A 4 5.4 0.5 147.93 1—17 ------- CHAPTER 2 TREATMENT FOR FLUORIDE REDUCTION Previous experiences with the removal of fluoride were reviewed in order to evaluate methods which have been used to remove fluoride from drinking water. The purpose of this review was to define the process capabilities and limitations of demonstrated systems, and to establish the most appro- priate technologies for the systems being evaluated on this project. INCIDENTAL FLUORIDE REMOVAL There are a number of processes employed in water treatment systems which may incidentally remove fluoride. The following technologies fall into this category and are briefly discussed with respect to their defluor- idation capabilities: • Removal of fluoride utilizing the lime softening process. • Removal of fluoride using carbon adsorption. • Removal of fluoride utilizing ion exchange resins. • Precipitation of fluoride using ferric salts. • Fluoride removal utilizing zeolites. Lime Softening Lime is best considered a viable defluoridation alternative for harder waters having moderately low fluoride levels, between 3.0 and 4.0 mg/i. 1 2-1 ------- Laboratory Experiments . In 1934 Boruff 2 discovered that the addition of lime to fluoride spiked waters resulted in partial fluoride removal, reducing 5.0 mg F71 to 3.0 mg F/l. Co-precipitation of the fluoride was found to occur when the carbonate and magnesium hardness precipitated arid the phenolphthalein alkalinity was greater than or equal to the total alkalinity. A detailed analysis of the mechanism of fluoride reduction during lime softening was made by Scott. 3 Scott observed that fluoride was adsorbed on the gelatinous magnesium hydroxide precipitate formed in the lime/magnesium reaction. Scott also found a mathematical relation between magnesium and fluoride removal which holds that the fluoride reduction is approximately equal to 7 percent of the initial fluoride multiplied by the square root of the magnesium removed. Consequently, only a high degree of magnesium removal will result in significant reductions of fluoride. Strict control of pH and caustic alkalinity must be maintained to secure proper magnesium precipitation. Installations Employing Lime Softening for Defluoridation . Early reports of fluoride reduction by three small lime softening plants 3 showed modest removal capabilities, as shown in Table 2-1. Culp and Stoltenberg 4 ran experiments on a local water to determine the increase in fluoride reduc- tion when adding sufficient magnesium in a lime softening process. Their magnesium dosages, according to Scott’s formula, resulted in good fluoride removals (from 3.2 mg F/l influent to less than 1 mg F/l effluent). However, scale-up calculations indicated that the additional magnesium requirement was excessive. Several plants in states with hard water wells, such as Ohio, Indiana and Illinois were able to achieve modest fluoride 2- 2 ------- TABLE 2-1 FLOURIDE REDUCTION AT THREE LIME-SOFTENING PLANTS (Scott, et al ) Plant 1 Plant 2 Plant 3 Raw Eff Raw Eff Raw Eff Fluoride 1.5 0.7 2.1 1.6 1.7 0.95 Magnesium 46 14 23 9 42.7 16 Total Hardness 523 121 234 65 449 99 Alkalinity 337 42 270 101 373 88 pH 7.8 10.3 7.7 10.0 7.1 10.0 2-3 ------- levels economically 5 because these waters contained adequate amounts of magnesium. The operating costs of these softening plants were much lower than any of the more specialized processes, but the initial capital required to build such a plant was high. Activated Carbon Adsorption Few studies have been done on the potential of carbon adsorption because of the high costs associated with lowering (and subsequently raising) the pH of the water. 6 In 1934, McKee and Johnston experimented with four differ- ent types of carbon. One carbon type was successful in removing fluoride, an acid-treated carbon discarded from a soda pulp industry. The carbon removal efficiency was excellent on those waters having a pH of 3.0 or less. During this study fluoride levels were reduced from 8.0 mg F71 to less than 1 mg F71. Tests on water at pH values above 3 showed no fluoride reduction. Ion Exchange Using Synthetic Resins The Rohm & Haas Amberlite IR-4B was first thought to be promising for the removal of fluorides. However, later studies showed that its capacity was entirely due to the precipitated aluminum oxide which had formed in the bed during alum regeneration. The floc caused severe flow restriction through the column and the process had to be abandoned. 8 Thompson and McGarvey 9 discovered that the strong basic Amberlite XE-75 (also made by Rohm & Haas) was quite effective for removing fluorides. The efficiency of the column was observed to be a function of the ratio of fluorides to the amount of total anions in the raw water as seen in Figure 2-1. Maier 8 calculated that 2- 4 ------- 400 350 0 U 300 ‘I i p250 >. I- C.) 4 A. 4 C.) U I C, z 4 150 x U. ’ UI 0 1 U. 50 0 0.16 0.20 RATIO OF FLUORIDE TO TOTAL ANIONS FIG. 2 -1 . EFFECT OF 1NFLUENT-WATER COMPOSITION ON FLUORIDE EXCHANGE CAPACITY UTILIZING AMBERLITE XE-75 0 0.04 0.08 0.12 2-5 ------- if the water being treated at Bartlett, Texas (with a fluoride-total anion ratio of 0.0147) were treated with this resin, the salt regeneration alone would cost about $200/mil gal (1953 dollars). He also pointed out that most high-fluoride waters have very low fluoride—total anion ratios, exemplified by the 0.0083 ratio for Britton, South Dakota water which contained an average of 6.7 mg F/l. Due to practically obtainable capa- cities ranging from 100-400 grains F1cu ft, 9 resinous ion exchange is not economically competitive with the more fluoride-specific removal processes. 1 Ferric Salts Experiments by Boruff 2 were performed to determine removal of fluoride by complexing using ferric salts. The floc produced is a ferric fluoride complex which is slightly ionized. Applications of 34 to 85 mg/l of ferric salts on waters containing from 1.8 to 5.0 mg F7l at pH 7.2 achieved minimal fluoride removal. When this treatment was accompanied by 170 to 340 mg/l lime, waters containing 1.8 to 5.0 mg F7l were reduced to 1.6 and 4.7 mg F/l, respectively. Ferric salts were found to be largely ineffec- tive for practical fluoride removal. Zeolite Boruff 2 determined that natural zeolite (the particular type was not spec- ified) has a small removal capacity for fluoride, based on laboratory experiments with a 5.0 mg Ff1 water. Using a miniature contact bed, Boruff found that fluoride residuals of 0.6 mg F71 were obtainable after passage of 6 liters of the stock water. After the first regeneration with 2- 6 ------- a saline solution, the minimum effluent fluoride concentration was 0.9 mg F7l in the 4- to 6-liter fraction and 4.0 mg F71 in the 44- to 47-liter fraction. Subsequent saline regenerations showed rapidly deteriorating capacity. Such a limited removal capability precludes zeolite from con- sideration as a viable treatment alternative. FLUORIDE REMOVAL USING BONE-RELATED MEDIA Bone and its related materials have demonstrated fluoride removal capabil- ity. Fluoride removal efficiencies are found to be much greater than those found with the more general treatment methods already discussed. Bone The use of bone as a substrate for defluoridating water was the earliest reported methodology shown to be effective, but it imparted an unwelcome flavor to the water. Bone is essentially a calcium phosphate, Ca 3 (P0 4 ) 8 CaCO 3 , in which the carbonates are replaced by fluoride when fluoride- bearing waters are contacted with the media. The resulting fluorapatite compound is later flushed with a caustic solution to remove the attached fluoride, leaving behind a hydroxy apatite compound available f or further fluoride sorption. Matters of economy led to the obsolescence of bone as a defluoridation media, as the use of charred bone and synthetic tricalcium phosphate/hydroxyapatite mixtures became widespread.’ Bone Char Bone char is more economical and asthetically pleasing than bone. Conse- quently, it replaced bone as a media in contact filters. The concept of 2— 7 ------- using bone char was borrowed from the sugar industry, where it had been employed in the decolorization of syrups. Charred bone, which is an apatite and carbon mixture,’ has proved its viability in many years of use as the media in the Britton, South Dakota plant and five California plants. Laboratory Experiments . Burwell, et al ’° ran field tests on 30-40 mesh virgin bone black and obtained excellent fluoride removals on waters con- taining 5.0 mg F/l. At an average flow rate of 20 gal/hr. 700 gal of the water could be passed through a 10 lb bed before effluent fluoride levels reached 1 mg F71. The authors found in a separate test that fluoride removal efficiencies quadrupled when 900 mg/i bicarbonate was reduced (by the addition of hydrochloric acid) to 100 mg/i bicarbonate. Trisodium phosphate regenerant was used instead of the cormion, but difficult to handle, caustic soda solution for easier handling in a small plant applica- tion. This method was compared to the caustic/hydrochloric acid method. It was found that although trisodium phosphate and sodium acid phosphate were more expensive, their superior performance and ease of handling jus- tified these costs. However, other reports 8 reported that this pair of regenerant compounds reduced bed capacities by 12 percent after the ini- tial regeneration. Regardless of the choice of regenerant, other studies have shown that bone char is not very durable and periodic media replace- ment is required.” Installations Employing Bone Char . Bone char has been found to be a successful defluoridation media in several small installations in California. 12 The Camp Irwin plant serves a 200-family housing unit and a 50-space trailer court, treating a natural water with fluoride levels 2-8 ------- between 9 and 12 mg F7l. The plant has two separate contact units. Each unit is capable of treating 15,000 gal/cycle at an average flow of 10 gpm. Automatic controls enable the second unit to cut on when the first unit becomes exhausted. Tests taken during the first 30 days’ operation showed that the fluoride content of the treated water was reduced to 0.6 to 0.8 mg F/l. Sodium hydroxide and phosphoric acid are employed as regen— erant chemicals. 13 Regeneration costs were high ($1.20/1,000 gal in 1955). Media loss of 2 to 4 in. annually has been a problem, along with decreasing cycle times with each regeneration. The Camp Irwin plant changed to an activated alumina media in July of 1959, but returned to bone char in December of 1960.12 The oldest continously operated defluoridation plant in the United States ran from 1948 to 1971 at Britton, South Dakota; this plant began operation with bone char in 1953.14 The supply consisted of three wells containing 6.7 mg/l F which were pumped to an enclosed steel tank at rates varying from 38 to 206 gpm. The contact tank contained 300 cu ft of 28-48 mesh bone char, resting on 12 in. of gravel. Regeneration was found to be necessary about every 450,000 gal. The media would first be backwashed with treated water (370 gpm for approximately 18 mm) to remove the accumu- lated sand followed by 5,000 gal of a 1 percent caustic solution. The caustic was then removed by rinsing with raw water (7,000 gal at 150 gpm) and applying a weak carbon dioxide solution to the bed. When the p 1 - i of the effluent approached that of the raw water, the end of the cycle was reached. 5 After it was demonstrated through laboratory investigations that lowering the p 11 of the raw water could optimize the use of bone char, the Britton plant included such a modification in its process. An existing 2-9 ------- sulfuric acid dilution system was altered to feed acid continuously to the raw water. However, due to the solubility of bone char in acids, the pH was maintained at levels of 8.4 to 7.1 which are above the range in which optimal removal is accomplished. 14 Synthetic Bone Tricalcium phosphate and hydroxyapatite can be formed by reacting phos- phoric acid and lime. The use of this material as a fluoride removal media stermied from the need for a cheaper alternative to natural bone or bone char. In powder form, this synthetic bone can be added to raw fluoride- bearing water to precipitate the insoluble apatites. The material can also be made in the form of coarse granules for use as a contact medium in a f liter. 1 Laboratory Experiments . Investigations conducted by Adler et al ’ 5 on tricalcium phosphate showed promise for its defluoridation capabilities. In column tests on a 30 mg F71 water, the synthetic bone lowered the fluoride concentration to 0.3 mg F71 in the first 3-liter fraction. Adler et al found that neither influent fluoride levels nor raw water pH have any significant effect on the fluoride removal capacity of tricalcium phosphate. Influent water hardness was found to have a slight effect (lower amounts being optimal). Comparative tests indicated that, pound for pound, tricalcium phosphate had roughly twice the capacity of activa- ted alumina. Testing of several regenerants indicated that sodium hydrox- ide followed by hydrochloric acid was most cost effective. However, this method resulted in a loss of 2.5 to 3 percent of the tricalcium phosphate per regeneration. 2-10 ------- Citing this loss of media, Behrman and Gustafson 16 conducted tests to study regenerant effects on the tricalcium phosphate. A fluoride-bearing water (5 or 10 tug F/l) was passed downward through a 10-in, depth of 20 to 40 mesh tricalcium phosphate granules, at the rate of 1 gal/sq ft/mm. Regeneration was accomplished by passing 1 liter of sodium hydroxide solu- tion successively through the unit at 0.61 gal/sq ft/mm. Behrman and Gustafson found that the fluoride removal efficiency of the bed became unacceptable in 25—35 cycles. Loss of efficiency occurred even though the 2 percent media loss per regeneration was being replaced at regular inter- vals. The actual overall loss per cycle was far greater than the 2 percent visible shrinkage observed by Adler at al . Careful examination of the tricalcium phosphate showed that the bulk density had increased from the original value of 35 lb/cu ft to about 68 lb/cu ft, and that the original porosity of 72 percent had decreased to about 45 percent. Furthermore, the average particle size of the spent material was appreciably greater than that of the original. Upon examination of the spent regenerating solu- tions, Behrman and Gustafson hypothesized that the hydrochloric acid had dissolved certain constituents from the upper part of the bed. These materials were being partly redeposited in the lower portion of the bed, with a consequent increase in density and particle size and a corresponding decrease in porosity. A modified method of tricalciurn phosphate regenera- tion was proposed, which neutralized with carbon dioxide instead of with hydrochloric acid. More tests were done with the same bed, increasing the water wash to 2 liters, and substituting the hydrochloric acid with 3 liters of an aqueous solution of carbon dioxide containing 1.5 g C0 2 /l. The rate of flow during the application of the carbon dioxide solution was 2—11 ------- increased to 1.8 gal/sq ft/m m. At the end of one hundred thirty cycles, the following conditions were observed: • The original volume of tricalcium phosphate had not decreased. $ The fluoride-removal capacity had remained the same. • There was no apparent change in the density, porosity, or parti- cle size of the granules. • The fluoride concentration was reduced from 10 mg F7l to 0.1 mg/l after 2,377 LV. The city water in which these tests were conducted had a pH of 7.8 to 8.1 and an alkalinity of 110 to 115 mg/i. Studies were also made by Goodwin and Litton, 1 7 who ran pilot plant experi- ments on natural waters containing 5.2 mg F7l fluoride. The pilot plant consisted of a 1.3 c i i ft bed of a tricalcium phosphate/hydroxyapatite mixture, through which the raw water was passed at the rate of 1.5 gpm. Goodwin and Litton achieved an effluent fluoride level of 0.42 mg F71, averaged over 50 runs. It was found that approximately 1 lb of caustic was required for each cubic foot of phosphate, and the authors estimated that a phosphate replacement of 5 percent might be necessary for every three hundred cycles of operation. Installations Employing Synthetic Bone . Synthetic bone had its first full-scale application in 1937 at the Climax, Colorado water plant. Scooba, Mississippi followed in 1940. Both plants were abandoned in 1949.1 The Climax plant, which treated a 14 rug F71 water, consisted of four tanks, each charged with 45 in. of tricalcium phosphate. The combined capacity of the four units was a net of 300,000 gal of treated water in 24 2-12 ------- hours. One or two of the units were regenerated each day, using sodium hydroxide and carbonic acid (carbon dioxide in solution). Loss of media from the filter was reported to be negligible. 18 The previously described plant at Britton, South Dakota, began its opera- tions in 1948 using Fluorex, a synthetic hydroxyapatite, as its media. The existing water supply system at Britton consisted of three 1,000-ft deep wells, drawing water with an exceptionally high mineral content, and a fluoride concentration of 6.7 mg F/l) 4 Regeneration was performed every third day with a caustic solution followed by neutralization with carbonic acid. 19 The Fluorex media, although efficient for fluoride removal, was subject to high losses through regeneration. These losses through attri- tion reached 52 percent per year. Subsequently, the plant was forced to change to a bone char media in 1953.14 SORPTION USING ALUMINUM COMPOUNDS A variety of compounds containing aluminum have been proposed for removing fluorides from water, including bauxite, sodium aluminate, aluminum sul- fate, and activated alumina. Early research indicated bauxite and sodium aluminate had minimal removal capacity. 2 Aluminum Sulfate and activated alumina will be discussed with respect to their potential as viable full- scale defluoridation media. Aluminum Sulfate Aluminum sulfate has a high fluoride absorption capacity, but would be considered an effective treatment methodology only for certain waters. Coagulant aids such as clays and activated silicas may increase aluminum 2-13 ------- sulfate capacity.’ Certain cations also reduce capacity. In many cases, the reduction in capacity renders this method economically impractical. Laboratory Studies . Regardless of potential cation interference, several laboratory experiments have demonstrated the effectiveness of aluminum sulfate in defluoridation. Kempf et al 20 added anhydrous alum, Al 2 (SO 4 ) 3 , to a city water containing 7.5 mg 171. The pH of the raw water had been adjusted from 8.4 to 7.15. The vessel was stirred for 30 mm and allowed to stand, samples being removed at intervals. Fluoride levels were found to be 0.85 mg 171 after two hours, and 0.40 mg F7l one day later. Tests were made on a separate city water with a fluoride concentration of 8.5 mg 171 to determine the effect of pH on defluoridation. The results of varying alum doses at two pH levels are shown in Table 2-2. Fluoride levels were measured 2.5 hr after mixing. Boruff 2 found that a dose of 170 mg/i aluminum sulfate was necessary to reduce fluoride concentrations from 5.0 mg F/l to 1.0 mg F/l in a stock water. The alum was added to a vessel, mixed for 30 mm and allowed to stand. The optimum pH range for the renioval of fluorides with aluminum sulfate was found to lie between 6.25 and 7.0. Boruff observed that the chemical composition of the water was not of great importance in fluoride removal efficiencies. Boruff found that even chloride and sulfate levels as high as 1,000 mg/l had no effect on defluoridation. Treatment of waters containing 256 mg/l sodium silicate was found to decrease the removal capa- bilities of aluminum sulfate. Kempf et al 2 ’ published a report two years after their original study describing successful fluoride removal in a pilot plant using aluminum 2-14 ------- TABLE 2-2 BENCH-SCALE STUDY OF ALUMINUM SULFATE (Kempf, et al ) Aluminum Sulfate (mg/i) pH =_788 (mg F /1) pH (mg = 6.95 F /1) 110 6.5 5.85 220 3.75 3.25 440 1.13 0.45 2-15 ------- sulfate. The plant, attached to the mains in a school, consisted of three mixing tanks, a settling basin, and sand filters. Fluoride levels, which originally ranged from 7 to 10 mg F7l, were reduced to between 1.5 and 2 mg F71 with alum doses of approximately 340 mg/l. Scott et al 3 treated stock waters of various fluoride concentrations with aluminum sulfate, thoroughly mixing each flask and allowing it to settle. The results of this work indicated that required alum doses exceeded those found adequate by Boruff. 2 Scott et al lowered initial fluoride levels of 1.7, 3.0 and 6.0 mg F/l to 1.0 mg F/l by the addition of 200, 340, and 890 mg/l alum, respectively. Later work by Boruff et a1 22 investigated a discrepancy noted between fluoride removal in natural waters and the removal earlier demonstrated with his laboratory—made sodium fluoride solutions, the natural waters showing a decrease in removal efficiencies. Tap water samples were pre- pared with 4 mg/i calcium fluoride, magnesium, fluoride, aluminum fluo- ride, sodium fluoride, and sodium fluorosilicate, respectively. All sam- ples were treated with 9.72 grains of Al(S0 4 ) 3 18 1 120 per gal (167 mg/l), mechanically stirred, and allowed to settle. This study indicated that the cation associated with the fluoride ion in water greatly affected the degree of its removal by alum floc. The magnesium and aluminum fluoride salts exhibited a modest removal rate; sodium fluoride salt demonstrated a higher degree of defluoridation. The study results are summarized in Table 2-3. 2-16 ------- TABLE 2-3 REMOVAL OF FLUORIDES FROM SALTS IN WATER AT VARIOUS pH VALUES BY ALUM FLOC Salt — pH 7 • 4 a 54 a 6 a pH I F I F I F I F NaF 4.0 1.7 4.0 1.8 4.0 1.6 4.0 1.0 CaF 2 3.7 1.7 -— -- 4.0 3.0 4.0 2.3 MgF 2 3.9 1.5 3.9 2.2 4.0 3.5 4.0 3.3 A1F 3 3.6 1.6 3.6 2.8 4.0 3.4 4.0 2.6 Na 2 SiF 6 4.0 1.9 4.0 2.2 4.0 3.1 4.0 1.2 acoagulant added over a period of 2-3 mm. bCoaguiant added over a period of 30 mm. C 1 initial fluoride concentration in mg/i concentration in mg/i; F = final fluoride 2—17 ------- Activated Alumina Known chemically as garuna aluminum oxide (y.A1203), activated alumina is manufactured both in gram quantities as an analytical reagent and in large quantities as a desiccant. It becomes “activated” when neutral alumina is treated with acid, cormionly sulfuric or hydrochloric. The crystal struc- ture of activated alumina is known to contain gaps in its cation lattice which result in local sites of negative charge. However, the availability of positively-charged sites is also indicated by the electroneutrality of the substance. Said sites acconinodate anion “adsorption”. Ionic adsorp- tion of cations and anions may take place simultaneously but one path of exchange usually dominates. Experimental data presented in 1947 indicated that activated alumina was preferential to particular anions over others. In this hierarchy fluoride ranks third, after hydroxide and phosphite. Fluoride was followed by sulfite, ferrocyanate, chromate, sulfate, ferro- cyanite, dichromate, nitrite, bromide, chloride, nitrate, et al , respec- tively. in treatment processes, the preferred ions can be used to displace (or regenerate) lesser-preferred ions. Activated aluminas’ high prefer- ence for fluoride is a direct reversal of fluorides’ low selectivity with most synthetic anion exchange resins. Since many ions are usually present to compete for adsorption sites, activated alumina is more efficient for fluoride uptake than any other anion-exchange media. 23 In all applications of activated alumina this preferred—ion substitution principal holds true. If, for example, the media was manufactured with hydrochloric acid activation, the initial exchange upon water application would be fluoride taking the place of chloride, as long as the most- 2-18 ------- preferred hydroxides are absent. Addition of hydroxide, which is more preferred than fluoride, is necessary to regenerate the fluoride-contain- ing adsorbent. The hydroxide added at this point must be in dilute solu- tion because strong caustic solution has been found to dissolve the alumina. Finally, applying dilute acid restores the fluoride removal capacity and readys the acidic alumina for another adsorption cycle. 23 This procedure is suriinarized as follows: • Alumina-HC1 + NaF Alumina — HF + NaC1 • Alumina-HF + NaOH Alumina - NaOH + NaF + H 2 0 • Alumina-NaOH + 2 HC1 Alumina - HC1 + NaC1 + 1120 (23) Maler’ states that activated alumina can be reused indefinitely, but mini- mal replacement, 3 percent annually, of the media has been found to be required. Bench Scale Testing . Various laboratory experiments substantiated chem- ists’ early claims of activated alumina’s affinity for fluoride. In 1934, Boruff 2 reduced the fluoride concentration of 30 liters of water from 5.0 to 1.6 mg F/l by passing the liquid through 300 g of activated alumina in a contact filter. Results of the 2 1/2-hour run indicated a bed capacity of 119 gr F/cu ft. A total of nine such runs were made, during which regenerants and application rates were varied. Boruff also conducted tests on the effectiveness of adding powdered activated alumina to a stirred reactor containing water with 5 mg F/l. The addition of as much as 50 mg/i powdered alumina failed to reduce the fluoride concentration below 2 mg F/l. 2-19 ------- Two years later, Fink and Lindsay 24 achieved a fluoride removal capacity of 334 gr/cu ft in a slightly larger contact apparatus. In their experiment, 250 gal of 5 mg F7l water was passed through the unit before the effluent reached 1 mg F7l. Fink and Lindsay tried different regener- ant solutions, but found that only 8 percent NaOH accomplished complete renewal of the activated alumina. Swope and Hess 25 reduced a 6.4 mg F71 water to 1.1 mg F/l using the same apparatus as that described by Fink and Lindsay. Interestingly, they achieved their highest bed capacities at their most rapid application rate (12 gal/hr), after the bed had been regenerated with 5 percent caustic. In addition, Swope and Hess attributed a significant reduction in water hard- ness to contact with the activated alumina. In their laboratory studies on activated alumina, Savinelli and Black 26 used aluminum sulfate as a regenerant. Figures 2—2, 2—3, and 2—4 show relationships found for exchange capacity and influent fluoride concentra- tion, influent alkalinity, and influent pH. Increasing regenerant dosages up to 12 lb alum/cu ft resulted in rapidly increasing fluoride removal efficiencies, approaching 2,000 gr/cu ft. Likewise, increasing regenera- tion time from 1 hr to 5 hr increased bed capacity from 600 to 1,750 gr/cu ft with the same regenerant dose. Concentration of the alu m regenerant was found to have no effect on fluoride exchange capacity. No relationship was found for influent sulfate or chloride ion concentration and fluoride removal efficiency. Savinelli and Black determined that the most critical parameter affecting bed capacity was the influent alkalinity. Their data indicates that a fluoride removal efficiency of 3,400 gr/cu ft is achieva- ble when the p H of the influent water is lowered to 5.6. 2-20 ------- 2,000 I I I 0 U 4 : 1,500 — --S <2 (.)0 w - )(..1 LuL l- 500 — 3 9 12 FLUORIDE ION IN INFLUENT — mg/I FIG. 2-2 RELATION OF EXCHANGE CAPACITY AND FLUORIDE ION CONCENTRATION IN INFLUENT UTILIZING ACTIVATED ALUMINA 0 I I I 6 ------- 2,000 0 1,500 1,000 x-j wu- 500 0 ALKALINITY OF INFLUENT WATER —mg I CaCO 3 FIG. 2-3 . RELATION OF EXCHANGE CAPACITY AND ALKALINITY OF INFLUENT UTILIZING ACTIVATED ALUMINA 50 100 150 ------- 4,000 It r 3,200 0 L u a g 2,400 1,600 4 (3 ‘ U C, 2 4 x CI , ‘C ‘ U 0 10 pH OF INFLUENT FIG. 24 .RE IATION OF EXCHANGE CAPACITY AND pH OF INFLLJENT UTILIZING ACTIVATED ALUMINA 5 6 7 6 9 ------- The small bench column used by Bishop and Sansoucy 27 achieved a capacity of 1,424 gr/cu ft when reducing an influerit 10 mg F71 to 0.5 mg F71. The capacity was 600 gr/cu ft when treating a 5 mg F71 influent to the same level. This finding illustrated the increasing difficulty in removing smaller quantities of fluoride. Their studies also confirm the feasibil- ity of a fluidized activated alumina reactor. The increased surface area of the alumina granules provides greater exchange capacity than column applications while allowing high flow rates. Wu 28 , also experimenting with a fluidized system, added activated alumina to stirred 2-liter reac- tors containing fluoride solutions. Wu found that the ratio of fluoride concentration to activated alumina dose was an important factor in removal efficiency. He also determined that removals increase with lower fluoride to activated alumina ratios. Fluoride uptake was also found to be most efficient at a pH of 5 in this type of system. Installations Employing Activated Alumina . Few full-scale fluoride removal plants exist. Those which have incorporated activated alumina technology have shown great improvement over the years in optimizing bed capacities. Three decades ago, bed capacities of 4001 and 50029 gr/cu ft were considered acceptable. Recently, capacities of over 3,000 gr/cu ft 28 ’ 30 have been reported. Activated alumina filtration was employed at the Bartlett, Texas plant from the time the plant opened in 1952 until its shutdown in 1977.11 The plant was designed to reduce the fluoride concentration from 8.0 mg F71 to an average of 1.0 mg F71 and was capable of treating 400 gpm well water. 8 The 500 cu ft of activated alumina would require regeneration after approx- imately 450,000 gal of the fluoride-bearing water had been treated. A 2-24 ------- 1 percent sodium hydroxide solution was applied countercurrently to the bed at the rate of 235 gpm, and discarded to the sewer. After a rinse of 28,000 gal raw water, dilute sulfuric acid was passed through the media until the effluent alkalinity was the same as the influent. The total amount of water used per regeneration amounted to approximately 68,500 gal. In 1960, a new well was drilled at Bartlett that contained 3.0 mg F/l fluoride; this extended the average cycle length to 1.5 mu gal. However, the overall bed capacity was reduced from 700 gr F /cu ft to 400 yr F7cu ft. 5 The Army plant at Camp Irwin, California (normally employing bone char) temporarily used activated alumina as its filter media, but with little success. 12 It reportedly achieved an initial bed capacity of 500 gr E/cu ft, but this dropped sharply after several regenerations. Large amounts of rinse water were mandatory to maintain acceptable efflu- ent fluoride levels. The effective capacity was reduced to approximately 100 gr/cu ft after 30 to 35 cycles. Lee and Haras state that the plant study was similar to laboratory tests projecting a capacity loss rate of about 30 gr F7cu ft per cycle for activated alumina.” Although reports of capacity loss are unconunon, consideration should be given to frequent citations of bed cementing and blinding. Several authors 11 ’ 12, 27 have noted a tendency of activated alumina beds to become clogged, thus creating shorter cycle times and highly inefficient removal. Harmon and Kalichman 12 cite the Elsinore, California plant as suffering from this “cementing ’ from an early point in its operation. Plant engi- 2-25 ------- neers found it necessary to remove, dry, and crush all the media in the unit, as filter fines had aggregated to form a wet, grey plastic material. The problem at Elisnore was remedied by increasing caustic and acid doses. Rubel and Woosley 3 ° dismiss these failures of activated alumina to ignor- ance and/or shortcutting by plant operators. They recently studied three fluoride removal plants with widely different raw water characteristics and outlined a program by which activated alumina’s routine removal capa- bility could be rnaiitained above 2,000 gr/cu ft. Rubel and Woosley’s recommendations for maximizing removal efficiency are reported to involve installation and operating costs compatible with limited public budgets and funding programs. Their optimization plan focuses mainly on six aspects of operation: • Treatment Mode . Rubel arid Woosley have determined that a pH of 5.5 is the optimum pH for activated alumina to attract fluoride ions, and advise that raw water pH be carefully held to this value. This recommendation is paramount to process optimization. If raw water pH goes above 6.0 or below 5.0, experiments have shown activated alumina bed capacity to decrease to 500 gr/cu ft. Earlier breakthrough also occurs when pH is not held at the optimum, serving as further incen- tive for careful pH control. • Backwash Mode . The authors recommend backwashing with raw water prior to regeneration for two reasons: 1. to remove those suspended solids which tend to blind the filter 2. expand the bed to break up any channeling or wall effects. They cite an adequate backwash rate of 5 to 6 nini/s, which will expand the bed approximately 50 percent. • Regeneration Mode . The most complete regeneration should proceed as follows: 1. Upflow the regenerant while the bed is still expanded from back— washi ng. 2. Follow regeneration with an upflow rinse, draining to the top of the media bed 3. Downf low the regenerant and immediately follow with neutraliza- t i on 2-26 ------- Regeneration, say Rubel and Woosley, employs 1 percent sodium hydrox- ide solution flowing at 1.7 m Is, and assuming a standard bed depth of 1.5 m, each step takes 35 m m. Chemical requirements in each regener- ation step are 27 liters of 50 percent NaOH per cubic meter of media (0.2 gal/cu ft). The intermediate upflow rinse flows at a rate of 3.4 mm/s for 30 mm. The regenerate solution is usually an in-line di lutipn of 50 percent NaOFI with raw water. • Neutralization Mode . As soon as the downf low regeneration is com- pleted, raw water with ph adjusted to 2.5 is fed downflow at the normal treatment flow rate. As the effluent pH neutralizes down to 9.0 to 9.5, the raw water p 1 - I is adjusted up to 4.0. When the treated water p h reaches 7.5, the final adjustment of the influent is made to 5.5 and carefully maintained. • Initial Start-up Mode . Proper start-up procedures are critical when the activated alumina is first put on line. Rubel and Woosley strongly recommend that the contact vessel be half-filled with water before any bed material is placed into it. The presence of the water serves several important purposes. First, it can prevent cementing of the bed because it helps to dissipate the heat generated when the alumina becomes wet. Fines present in the bed material re separated out by the water from the more granular component, initiating strati- fication. Also, the water will protect the underdrain assembly from impact by the filling of the bed with media. An initial backwashing is also recommended to flush out all of the alumina fines. The backwashing should be carried out for an extended period of time. • Blending . A large portion of the run time shows an effluent fluoride concentration far below the required level; likewise, there is a gradual increase to beyond maximum limits of concentration as break- through occurs. As a very cost effective method of increasing cycle time and cutting operating expenses, blending fluoride—bearing waters to ot*a n 1 n average acceptable concentration is not a new con- cept. ‘ ‘ For the three plants they studied, Rubel and Woosley found that the treated water can still be allowed to flow to storage or distribution until its fluoride concentration reaches one and one— half to two times the maximum allowable level. In systems without a large reservoir in which the major volume of a treatment run can be stored, blending can still be accomplished by staggered regenerations in plants that have two or more treatment units. Other recommendations for the optimization of activated alumina technology include the hiring of fully qualified operators, proper selection of con- struction materials, and the disposal of wastewaters in accordance with local discharge standards. 3 ° 9_9 1 ------- DEMINERALIZATION BY REVERSE OSMOSIS The reverse osmosis process was reported to be employed in more than five hundred plants having capacities greater than 25,000 gpd in 1977.31 The principle underlying desalination by reverse osmosis CR0) is that fresh water will diffuse out of a brine solution across a membrane when the pressure applied to the brine side is greater than the osmotic pres- sure. 32 ’ The applied pressure, the ambient water temperature, and the permeability of the membrane are the major factors determining the quality and quantity of the product water. As an indication of fresh water flux across the membrane, approximately 1,000 mg/l of total dissolved solids (lOS) is equivalent to 10 psig osmotic pressure; the volume of desalinated effluent will be directly proportional to the difference between the externally applied pressure and this osmotic head. 31 Configurations of Membranes In terms of its effect on overall process performance, the membrane is the most critical cost-determining item in an RU installation. 33 ’ Several different membrane configurations are in common use at reverse osmosis facilities: spiral wound, tubular, hollow fiber, and plate and frame. Whatever the physical arrangement, the membrane must be extremely well supported in order to withstand the high pressure drop across it. 32 There are also a large number of available membrane materials, although not all are readily convertible to any desired configuration of the menibrane. 33 Comercially available membranes are commonly categorized as either cellu- losic or non-cellulosic, with the most popular cellulose acetate being responsible for the recent strides in making RO an economically competi- tive technology. 36 ’ 37 Reinforcing material or backing is compulsory for 2-28 ------- adequate mechanical support of the film as the semipermeable cellulose 0 acetate is often made in sheets only 1,000 A thick. This backing material 0 must consequently have pores less than 1,000 A in diameter. Certain noncellulosic materials like DuPonUs polyamidic nylon can be formed into hollow fibers that do not require any external support to withstand 1,000 psi or more. 33 Applicability of the different membrane materials also depends on certain influent water quality parameters, with the cellu- losic membrane systems being much more constrained by their limited pH tolerance (approximately 3.5 to 7.5) than the non—cellulose forms (tolera- ting 3 to 11). However, these latter forms which include mostly polya— mides, are unable to withstand free chlorine. 36 Often employing cellulosic materials, the spiral wound RO element is com- posed of two reinforced membrane sheets sandwiching a product water col- lection tube, rolled up as illustrated in Figure 2—5. These spiral RO elements are assembled in series to produce the required flow. This particular configuration is known to have fairly good resistance to foul- ing, fair im munity to plugging, good production per unit volume, and high flux and rejection ranges. A broad span of operating pressures is attain- able with spiral wound elements, and their costs/gal are relatively low. 36 The tubular configuration utilizes its tube wall as a pressure vessel and the tube surface as its membrane support structure, thus combining two functions. The membrane is usually placed on the inside of the tube, and product water passes through to the outside. 34 Tubular systems have the widest range of operating pressures for reverse osmosis, from 400 to 1,000 psig. They are also the easiest of all configurations to clean and 2-29 ------- RoH to assemble Product-water-side backing material with membrane on each side, glued around edges and to center tube (after passage throug \ ‘ - membrane) Product- water side back ng M Brine- side FIG. 2-5. RO SPIRAL VVOUND MODULE CONFIGURATION Br In —side Product wate- , -Brine flow Product-water f \ 2-30 ------- have a high resistance to plugging and fouling. These qualities make the tubular system the best choice for waters which contain very high levels of suspended solids. Compared to the spiral wound, however, production per unit volume is poor and they have a high capital cost/gal of water pro— duced. 36 When membranes are cast in the form of hollow fibers, product water is collected in the inside, where it flows out axially to a collection mani- fold. This structural form may range from the size of a human hair (the polyamide hollow fiber) to four tinies larger (cellulose acetate hollow fibers). 34 ’ 36 Sometimes referred to as “permeators ”, the hollow fiber configuration manifests high salt rejection, fair resistance to fouling, and very good tolerance toward chemical cleaning agents. Their low flux is compensated for by the extremely large surface area, which makes the gross production per unit very high. Costs/gal of water produced are relatively low for hollow fiber membranes. 36 The hollow fiber configuration is pre- sented in Figure 2-6. In plate and frame construction, membranes are mounted on both sides of solid plates into which product water channels have been cut. These plates alternate with brine feeding frames with the entire array housed in a pressurized vessel. 34 This configuration, which resembles a filter press, is not as widely employed as the other forms. Prevention of Fouling and Pretreatment Requirements There are two major causes of membrane fouling: 2-31 ------- Feed wafer , 0 Product Brine water Brackish feed water Product wafer collec ted in hollow fibers Product water removed Brine removed Typical - OD:ID - 44 . 6 i: 24 .9p FIG. 2-6. RO HOLLOVV FINE FIRER MODULE CONFIGURATION 0 Hollow Fibers ED ED ED ED 2—32 ------- • The presence of colloidal material and/or certain dissolved salts in the untreated water. 38 ’ 39 (However, these materials can be dealt with through pretreatment, which will be discussed later.) • The lack of maintenance of a minimum brine flow rate, a param- eter which is coninonly reduced with the intention of increasing product water f low. 3 1 ’ 40 (This practice, however, robs the brine membrane surface of the turbulence necessary to prevent precipi- tation (scaling) and solids buildup, thereby causing what is known as concentration polarization.) Polarization encourages dissolved ion breakthrough and deteriorating pro- duct water quality. However, as pointed out previously, certain membrane configurations are more inherently prone to this problem than other forms. 4 ° Precipitates that are most apt to foul RO membranes include calcium carbon- ate, calcium sulfate, and various iron and manganese oxides. 4 ° Silica, humic acids, bacteria, and fine clay particles are also potential foul- ants. 38 ’ 3 The expediency of pretreatment for RO is dependent upon the case and effectiveness of periodic membrane flushing or cleaning, the frequency of such cleaning, and the membrane’s resistance to cleaning agents. The need for pretreatment is indicated when the frequency of cleaning is unacceptable to the customer, or if the raw water contaminants cause irreversible fouling. Typical pretreatment consists of micron fil- tration for suspended solids removal, pH adjustment or softening, and some times activated carbon for organic removal. 38 Controlling pH to 5.0 to 6.0 2-33 ------- will minimize the calcium carbonate scale. Calcium sulfate solubility can be increased by sequestering the calcium with the addition of sodium hexa- rnetaphosphate at temperatures below 96°F. Manganese levels to 1.5 mg/i and iron levels of 4.0 mg/i can be economically controlled with very small quantities of coninercially available chelants, dispersants and sequester- ing agents. 4 ° Bench—Scale Testing Pilot plant data has yielded much encouraging information concerning the efficacy and economy of reverse osmosis plants. Cruver and Sleigh 41 con- ducted studies at a 1,000 gpd sea water pilot plant at Sea World in’ San Diego, California to compare single-stage and two—stage reverse osmosis schemes. The authors admit that a single-stage system initially appeared more cost effective, since 20 percent less equipment was required. Their data, •however, showed that the capital cost savings would be completely offset by the higher membrane costs. They found that their single-stage system required a membrane with 10 times the salt rejection capability’of a two-stage system to achieve the same product water quality, one that would reject 99 percent of the salt. Such a membrane is certainly available, but the price is prohibitively high. The decision by Cruver and Sleigh’ to choose a double-pass system was also made on the basis of the increased reliability margin with such a system. Schmitt and Hurley 42 report that the U.S. Army is testing portable RO units on surfacewaters to develop a transportable packaged system suitable for emergency use. Being employed in the studies are cellulose acetate tubular modules, rated at 10,000 gpd with 90 percent salt rejection. In tests on 2-34 ------- Potomac River water, excellent results were found with these units, except for three instances of stoppage due to damaged parts. Separate experiments on spiral wound units showed a greater tendency toward fouling by suspended material. The authors admit that further study is needed before a recom- mendation can be made on a unit suitable for field army use. Installations Employing RO Reverse osmosis systems have been installed to provide suitable water supply for both domestic and industrial use. It is currently employed at the Manassas, Virginia IBM semiconductor plant. The modules are used for demineralization of raw water prior to being fed to a mixed bed demineral- izer. The influent water is drawn from a municipal surface water reser- voir, having between 95 and 180 mg/i lOS. Pretreatment for the polyamide RO units includes acidification, cationic polymer coagulation, sand filtra tion, and carbon adsorption. The reverse osmosis system has been operating at the semiconductor facility since 1972 without any major problems. 43 Crabbe 44 described the success of a double-stage RO system for the produc- tion of water for pharmaceutical use. He cites the major reason for selecting the double—pass system as added protection from biological con- tamination. The 25 gpm installation includes softening, activated carbon, and a 10 micron filter as pretreatment. The influent water characteristics include 207 mg/i bicarbonates and 330 mg/i TDS, which are reduced to 4.9 and 7.3 mg/i, respectively. A reverse osmosis system at a utility company is used as an effective pretreatment for the cation-anion deniineralizer train f or condensate water makeup. Wadiington 45 reports that the installation of the three-stage RO 2—35 ------- unit (and its own pretreatment units) has resulted in substantial savings for the utility in regenerant chemicals. The number of pressure vessels in the three stages is staggered 7-4-3 (70 membrane modules) in the sumner and altered 8-6-3 (185 membrane modules) in the winter to reduce increased system pressure. Membranes were replaced at this facility after two years of operation when water quality began to deteriorate. A similar experience is noted by Hollier 46 in his observations on an RO demineralizer for boiler feedwater at a Louisiana power station. Product water flux and quality had been seen to deteriorate, with the original output of 250 gpm dropping in 2½ years to 200 gpm, and conductivities from both stages increasing approx- imately 75 percent over that time period. The problem was found to be caused by iron oxides which were causing the membranes to foul. This was remedied later by acid pretreatment of the weliwater and installation of a different media in the prefilter. Wastewater is being reclaimed with the aid of reverse osmosis in the Fountain Valley, California “Water Factory 21” plant. The final effluent from this 15 mgd facility is injected into wells, to be withdrawn later for irrigation, domestic, and industrial use. One-third of the flow passes through the RO unit, which utilizes large spiral wound cellulose acetate modules in a three-stage process. Six parallel pressure vessel assemblies each contain 35 vessels arranged in a 20-10-5 array, enabling the plant to attain 85 percent water recovery. Sodium, sulfate, chloride, electrical conductivity and COD are all reduced approximately 95 percent. 47 Responsible for desalinating Red Sea water, the 3.2 mgd RO plant at Jeddab, Saudia Arabia is reported by Al-Gholaikah et a1 48 to be performing well. 2-36 ------- Spiral wound polyamide membrane modules are employed in a two-stage proc .- ess, the first-stage units running at a 30 percent recovery and the second stage at 85 percent recovery. Pretreatment equipment for the reverse osmosis system includes acid storage and injection pumps, hexametaphos- phate injection pumps, and cartridge filters. Waste brine from the first stage is discharged back into the Red Sea; reject from the second stage, being cleaner than the raw influent, is recycled to the front of the plant. The Yuma, Arizona desalting plant is designed to operate on a 3,200 mg/i TDS feedwater. It will use reverse osmosis to produce a low lOS product water that can be blended with raw water to achieve the allowed effluent solids limits. 1 to 5 mgd will be treated by membrane desalination, with product water salinity approximately 386 mg/i lOS. The reject brine flow will be passed through an energy-recovery turbine and then routed to the Santa Clara Slough in Mexico. 49 2-37 ------- SUMMARY The review of demonstrated treatment technologies for the removal of fluoride indicate that there are three processes which have the capability to provide required water quality: • Activated alumina. • Bone char. • Reverse osmosis. The relative costs for the three processes have been prepared by the EPA 5 ° and The State of Arizona 51 . The EPA comparative costs for each of the three processes utilizing a 500 gpm system are presented in Table 2-4. The Arizona Report indicates a total cost of 35 /1,OOO gal utilizing acti- vated alumina, 95 /1,0OO gal utilizing bone char, and 90 /1,OOO gal utilizing reverse osmosis for a 500 gpm system. Based on the outlined costs, and operational considerations, activated alumina has been chosen as the most viable technology for fluoride removal. 2-38 ------- TABLE 2-4 EPA COMPARATIVE COSTS Process Construction Costs ($) O&M Costs ($lyr) Activated Alumina 100,000 19,000 Bone Char 130,000 20,000 Reverse Osmosis 450,000 100,000 2—39 ------- CHAPTER 3 ACTIVATED ALUMINA PILOT STUDIES The findings of the literature survey, conversations with operators and engineers of existing fluoride removal facilities, and general cost sur- veys indicated that the activated alumina process is the most viable proc- ess for fluoride removal. Significant quantities of information are available on the use of activated alumina for fluoride removal. In order to confirm the application of activated alumina for fluoride removal, pilot studies were conducted at two sites in South Carolina. The purpose of these pilot studies was to establish the fluoride removal capacities for a high and low fluoride water. The two pilot studies were conducted at the communities of Mt. Pleasant and Conway. Both sites were selected based on the fluoride content of the raw water. Mt. Pleasant’s water supply contains a relatively high fluoride level, 4.3 mg F/l. Conway’s wells yield a relatively low fluoride level, 2.2 mg F/l. The methods utilized, experimental results, and conditions are presented below. EXPERIMENTAL PROCEDURES Identical columns were employed for both tests. Each column had a diameter of 4.5 in. and was charged with sufficient activated alumina to provide a bed depth of 2 ft. The total bed volume for each column was 0.8836 Cu ft. 3- 1 ------- Each column was prepared by partially filling the vessel with water and adding a predetermined quantity of activated alumina. The virgin column contents were neutralized by downf lowing water with a pH of 4-5 units in the Culligan laboratory. The pFI was controlled by the addition of muriatic acid. When the pH of the column effluent reached the level of 8.0, the columns were transported to the test site. The time required to reach an effluent pH of 8.0 was 45-90 mm equivalent to 87-175 Bed Volumes (BV) at a flow of 1.72 gpm. The column was operated on-site at a pH of 5.5 for a period of 30 mm at the test flow. At this time, the initial column operating conditions were established. Each column, which had a detention time of 5 mm, was opera- ted until fluoride breakthrough occurred. Throughout the run flow, influ- ent fluoride, effluent fluoride and pH data was collected. Analytical procedures utilized through the course of study conformed to Standard Methods for the Examination of Water and Wastewater , 14th Edition, 1975. After column exhaustion, the unit was transported to the Culligan labora- tory for regeneration and neutralization. The column was first backwashed in the upf low mode for a period of 30 mm at a flow of 10 gpm, equivalent to approximately 23 gpm/sq ft. The backwash rate forced the media out of the column into a device which allowed collection and continued backwash of the media. The column was recharged with the backwashed media and regenerated with approximately 1 percent caustic. Caustic regeneration was conducted for a period of 30 mm at a flow of 1.72 gpm. This flow is equivalent to a loading rate of 3.9 gpm/sq ft. 3- 2 ------- The column was again backwashed (rinsed) for a period of 30 mm after regeneration. The backwash flow was 5 gpm, equivalent to a loading rate of 11.3 gpm/sq ft. Following backwash the column was neutralized in the downf low mode utilizing raw water with a pH of 4-5 units using the same procedure as outlined previously. EXPERIMENTAL RESULTS Experimental operating data is sun iiarized in Tables 3—1 through 3—4 for each of the four experimental pilot runs. These data have been plotted to determine capacities for the two waters (see Figures 3—1 and 3—2). The test results indicate that approximately 10,000 gal of Mt. Pleasant raw water was treated without exceeding the MCI for fluoride utilizing 1 cu ft of media. The fluoride exchange capacity at Mt. Pleasant was approximately 0.424 lb F/cu ft of activated alumina. The Conway data indicates that 8,500 gal of raw water was treated success- fully with 1 cu ft of media. The fluoride exchange capacity at Conway was 0.18 lb F7 cu ft of activated alumina. 3- 3 ------- TABLE 3-1 MT. PLEASANT FLUORIDE REMOVAL PILOT TEST RUN 1 DATA SUMMARY Cumulative Flow (gal) (BV) Fluoride Concentration inital final mg/i mg/i initial pH final 0 4.4 0.82 5.5 9.1 1,740 263 4.2 0.15 7.0 7.5 2,250 340 4.3 0.12 6.5 7.0 3,620 548 4.3 0.43 4.5 4.8 4,220 638 4.2 3.8 5.0 4.9 TABLE 3-2 MT. PLEASANT FLUORIDE REMOVAL PILOT RUN 2 DATA SUMMARY TEST Cumulative Fluoride Concentration Flow inital final pH (gal) (By) mg/i mg/i initial final 0 0 4.3 0.95 5.5 9.5 570 86 4.4 0.24 5.7 5.4 1,920 290 4.3 0.23 5.5 5.3 2,340 354 4.3 0.23 5.7 5.3 3,840 581 4.3 0.25 5.9 5.8 4,490 679 4.2 0.28 5.5 5.2 5,700 862 4.2 0.28 5.8 5.6 6,230 943 4.3 0.35 5.9 5.8 7,660 1,159 4.2 0.32 6.5 6.4 8,070 1,221 4.2 0.48 5.7 5.8 9,070 1,372 4.3 2.4 5.8 5.7 3- 4 ------- TABLE 3-3 CONWAY FLUORIDE REMOVAL PILOT TEST RUN 1 DATA SUMMARY Cumulative Flow (gal) (BV) Fluoride inital mg/i Concentration final mg/i pH initial final 0 0 2.6 0.85 5.5 9.3 1,540 233 2.2 0.15 6.0 7.9 1,670 253 2.3 0.10 4.9 6.5 3,680 557 2.0 0.11 5.5 6.0 5,380 814 2.2 0.10 6.0 5.8 5,540 838 2.1 0.20 5.5 5.7 7,260 1,098 2.3 0.91 5.5 5.6 7,420 1,123 2.3 1.40 5.5 5.7 TABLE 3-4 CONWAY FLUORIDE REMOVAL PILOT TEST RUN 2 DATA SUMMARY Cumulative Flow (gal) (BV) Fluoride inital mg/i Concentration final mg/I pH initial final 0 0 2.3 0.43 5.5 8.3 1,390 210 2.2 0.24 5.5 5.2 1,630 247 2.0 0.25 5.5 5.1 3,450 522 2.1 0.17 5.4 5.8 3,620 548 2.2 0.24 5.6 5.7 5,290 800 2.2 0.91 7.3 7.1 5,650 855 2.2 0.60 5.6 5.8 6,920 1,047 2.2 1.80 5.7 5.7 3— 5 ------- 7 0 151 302 453 604 755 906 1057 1208 1359 CUMULATIVE FLOW. BV 1000 gal 3.0 2.0 U. 1.0 0 I a. I- z w U 1 U. 2 5 1510 FIG. 3-1 . MT. PLEASANT PILOT PLANT RUN ------- 3.0 7 1.0 0 0 151 302 453 604 755 906 1057 1208 1359 CUMULATIVE FLOW, BV 1000 gal E 2.0 U- 0. I- 2 -J U. 2 5 1510 FIG. 3-2 .CONWAY PILOT RUN ------- DISCUSSION OF RESULTS The data indicate that influent pH control is of primary importance in the operation of the alumina column. AWARE had difficulty controlling pH during the initial runs at both Mt. Pleasant and Conway. The systems were equipped with a pulse type acid feed pump. During the initial runs pH was monitored utilizing grab samples. The pH was adjusted based on the grab sample analysis. Due to the pulsing of acid, this mode of operation was discontinued during the second run. During run 2 pH was monitored on a small composite sample. As a result of this modification, the run time was significantly greater at the Mt. Pleasant site during the second run. The Conway experimental data is somewhat erroneous. During the second run, acid feed was discontinued for a period of less than 24 hr. It is felt that this loss of acid feed was responsible for not obtaining the antici- pated throughput of 10,000 gal/cu ft. 3- 8 ------- CHAPTER 4 BASIS OF DESIGN AND TREATMENT COSTS FOR ACTIVATED ALUMINA Activated alumina fluoride removal systems were designed for systems in which this technology might be feasible. The process design summaries for a 100, 250, 500, and 1,000 gpm system are presented in Tables 4-1, 4—2, 4—3, and 4-4, respectively. The basis for design and associated capital and O&M costs for each system are described below. BASIS OF DESIGN Activated alumina column beds were designed based on maintenance of a 5 mm bed detention time, 12 BV/hr. The detention time selected was based on the experience of operating activated alumina fluoride removal facilities and pilot studies conducted as part of this project. The column surface area was based on a hydraulic loading rate of 9 gpm/sq ft utilizing the design flowrate. The hydraulic loading rate of 9 gpm/sq ft was selected based on the flow required to expand the media bed during backwash. The column length was designed based on a 60 percent bed expansion volume. Acid feed equipment would be required to adjust the column feed p11 and adjust the alkaline byproducts generated during the regeneration and neu- tralization operating modes. No information on acid requirements was available during the investigation period. Experience of other facilities indicated that sulfuric acid usage was equivalent to 1 tank truck load (approximately 3,400 gal) per year for a 100 gpm plant operated 16 hr/day. 4-1 ------- TABLE 4-2 PROCESS DESIGN SUMMARY 250 gpm System Bed Depth in Single Column, ft 6.0 Length of Single Column, ft 9.6 Column Surface Area, sq ft 28.27 Initial Activated Alumina Inventory cu ft 169.62 lb 9,329.10 Time Between Regenerations, days 7.07 Operating Mode Downf low Flow Rate, By/mm 0.197 gpm 250 gpm/sq ft 8.84 Backwash Mode Upflow Backwash Rate, BV/min 0.197 gpm 250 gpm/sq ft 8.84 Backwash Duration, mm 10 Backwash Volume, gal 2,500 Regeneration Mode Upf low Regeneration Rate, BV/min 0.06675 gpm 84.7 gpm/sq ft 3.0 Regeneration Duration, mm 35 Regeneration Volume, gal 2,541 Rinse Mode Upf low Rinse Rate, BV/min 0.1335 gpm 169.4 gpm/sq ft 6.0 Rinse Duration, mm 5.0 Rinse Volume, gal 847 Neutralization Mode Downf low Neutralization Rate, BV/min 0.197 gpm 250 gpni/sq ft 8.84 Neutralization Duration 240 Neutralization Volume 60,000 4-3 ------- TABLE 4-3 PROCESS DESIGN SUMMARY 500 gpm System Bed Depth in Single Column, ft 6.0 Length of Single Column, ft 9.6 Column Surface Area, sq ft 56.75 Initial Activated Alumina Inventory cu ft 340.5 lb 18,727.5 Time Between Regenerations, days 7.09 Operating Mode Downflow Flow Rate, BV/min 0.196 gpm 500 gpmlsq ft 8.81 Backwash Mode Upflow Backwash Rate, BV/min 0.196 gpm 500 gpm/sq ft 8.81 Backwash Duration, mm 10 Backwash Volume, gal 5,000 Regeneration Mode Upf low Regeneration Rate, By/mm 0.06675 gpni 170 gpm/sq ft 3.0 Regeneration Duration, mm 35 Regeneration Volume, gal 5,950 Rinse Mode Upf low Rinse Rate, BV/min 0.1335 gpm 340 gpm/sq ft 6.0 Rinse Duration, mm 5.0 Rinse Volume, gal 1,700 Neutralization Mode Downflow Neutralization Rate, BV/min 0.196 gpm 500 gpm/sq ft 8.81 NeutraFizatjon Duration 240 Neutralization Volume 120,000 4-4 ------- TABLE 4-4 PROCESS DESIGN SUMMARY 1,000gpm System Bed Depth in Single Column, ft 6.0 Length of Single Column, ft 9.6 Column Surface Area, sq ft 113.5 Initial Activated Alumina Inventory ,cuft 681 lb 37,455 Time Between Regenerations, days 7.09 Operating Mode Downf low Flow Rate, BV/min 0.196 gpm 1,000 gpm/sq ft 8.81 Backwash Mode Upf low Backwash Rate, BV/min 0.196 gpm 1,000 gpm/sq ft 8.81 Backwash Duration, mi i i 10 Backwash Volume, gal 10,000 Regeneration Mode Upf low Regeneration Rate, BV/min 0.06675 gpm 340 gpm/sq ft 3.0 Regeneration Duration, mm 35 Regeneration Volume, gal 11,900 Rinse Mode Upflow Rinse Rate, BV/mun 0.1335 gpm 680 gpm/sq ft 6.0 Rinse Duration, mm 5.0 Rinse Volume, gal 3,400 Neutralization Mode Downf low Neutralization Rate, BV/min 0.196 gpm 1,000 gpm/sq ft 8.81 Neutralization Duration 240 Neutralization Volume 240,000 4—5 ------- The reviewed facilities did not require acid neutralization of spent regenerant. The acid holding tanks were sized based on the volume occupied by 40,000 lb of 92 to 96 percent H 2 S0 4 (approximately 3,500 gal). Caustic storage was based on the use of 50 percent NaOH shipped in drums for the 100 gpm and 250 gpm systems. The vessels were sized based on the feed dilution of 1 percent caustic with sufficient volume for one regener- ation cycle. The caustic storage tanks for the 500 gpm and 1,000 gpm systems were based on bulk delivery of 50 percent caustic. Caustic would be added in-line for dilution to 1 percent. The size of the caustic storage tank was based on the volume of 1 tank truck of 50 percent caustic, i.e., 4,000 gal. The volume is sufficient for 26 wk of 500 gpm system operation and 13 wk of 1,000 gpm system operation. Raw water storage will be required for those systems which do not have sufficient storage to maintain pressure during bed regeneration. A survey of the systems which do not have sufficient storage indicated that the maximum system flow was 300 gpm. A raw water storage tank was sized and costs were estimated based on a 250 gpm system. The storage tank volume is 70,000 gal. The developed costs are included in the total treatment costs for those systems without storage. A brine storage tank may be required at each site. The storage tank has three basic functions: • Batch neutralization of the alkaline regenerant. • Equalization for sewered systems. • Holding vessel for contract disposal. Costs were developed with and without brine storage. Brine storage may not be required in some of the larger sewered coimiunities. 4- 6 ------- The brine storage tank volume was based on the anticipated quantity of regenerant, 52 By. Pump capacities were sized based on the required flows to backwash, regen- erate, rinse and neutralize the bed. Those facilities with adequate water storage will utilize the well water pump to operate, backwash, regenerate, rinse, and neutralize the bed. This mode will require the use of a control valve and recycle loop to control flow. Those systems which do not have adequate raw water storage will be supplied with a groundwater storage tank equipped with a variable speed pump to backwash, regenerate, rinse and neutralize the bed. Operation of the facility requires strict pH control. Acid addition for maintenance of a feedwater pH of 5.5 will require pH controlled acid addition. Acid addition will be required to neutralize the bed. The neutralization acid feed system will be isolated to allow the continued raw water treatment in the second column. Acid addition will also be required for regenerant pH adjustment prior to disposal. The regenerant neutrali- zation system will utilize the bed neutralization acid feed system on a batch basis. The 100 and 250 gpm systems will not require in-line dilution for caustic regeneration. Caustic feed pumps have been based on a flow of 0.67 BV/min. The 500 gpm system and 1,000 gpm system will utilize 50 percent caustic diluted in—line to 1 percent followed by a static mixer. The caustic feed pump sizes are based on flows required for dilution of 50 percent caustic to 1 percent. A summary of the basic equipment sizes and flowrates are presented in Table 4-5. 4- 7 ------- TABLE 4-5 BASIC COLUMN INFORMATION System 100 250 500 1,000 Media Volume, cu ft Column Surface Area, sq ft 71.76 11.04 169.62 28.27 340.5 56.75 681 113.5 Media Depth, ft 6.5 6.0 6.0 6.0 Column Height, ft Backwash Flow, gpm Regeneration Flow, gpm Rinse Flaw, gpm Neutralization Flow, gpm Brine Volume, Gal 10.4 100 40 72 100 28,000 9.6 250 85 170 250 66,000 9.6 500 170 340 500 133,000 9.6 1,000 340 680 1,000 265,000 Backwash Feed Tank, Gal NA 70,000 NA NA Acid Storage Tank, Gal Caustic Storage Tank, Gal 5,000 1,500 5,000 3,000 5,000 4,000 5,000 4,000 ------- ACTIVATED ALUMINA - COST ESTIMATES Cost estimates were developed for 100, 250, 500, and 1,000 gpm activated alumina fluoride removal system models. Three systems were designed for each system capacity. The first system is a basic column design. The second system includes a brine storage or raw water storage vessel. The third system includes both raw water and brine storage facilities. The cost curves developed for the model systems are presented in Figure 4-1. Capital costs were developed for each individual system based on the required system to achieve a 1.6 mg F71 blended water supply. Annual capi- tal costs are based on a 30 year amortization at an interest rate of 12 percent. Operating costs are based on labor and chemical costs. Additional energy costs were assumed to be minimal. The anticipated labor requirements were based on the following: • 100 gpm System 3 M-H per day • 250 gpm System 5 M—H per day • 500 gpm System 6 M-H per day • 600 gpm System 8 M-H per day Labor costs were assumed to be $10/M-H. Chemical costs were based on the anticipated caustic and acid requirements FOB, Columbia, South Carolina. Annual maintenance costs were based on 3 percent of the total capital cost. The developed annual 0&M cost curve is presented in Figure 4-2. 4- 9 ------- 9 8 7 6 5 C C o4 0 0 ‘ft 1- ‘3 -J I .- C., 2 1 FLOW (gpm) • ACTIVATED ALUMINA SYSTEM • SYSTEM WITH BRINE OR RAW WATER STORAGE £ SYSTEM WITH BRINE AND RAW WATER STORAGE 10 50 100 200 300 400 500 1000 FIG. 4-1 ACTIVATED ALUMINA SYSTEM — CAPITAL COST ------- 0 0 0 0 0, 10 9 8 7 6 4 3 2 1 100 200 300 400 500 FLOW (gpm) FIG. 4-2. ACTIVATED ALUMINA SYSTEM — ANNUAL 0 & M COST 1000 ------- PROCESS DESIGN - REGIONAL WATER TREATMENT FACILITY A conventional surface water treatment facility was designed in order to develop capital and O&M costs. A process flow schematic is presented in Figure 4—3. The facility consisted of flash mixing, flocculation, sedi- mentation and filtration. Ancillary facilities consisted of gravity thickening and filter presses for sludge dewatering. A settling pond is also provided for sand filter backwash. A process design sumary is presented in Table 4—6. The estimated total capital cost for the treatment plant is $26,250,000. The estimated plant operating cost is $509,000 per year. These costs include energy, chemical, and labor costs. The estimated maintenance cost for the facility is $675,000 per year. 4-12 ------- ALUM GE FLASH MIX (Two Chambers) FLOCCULATOR SEDIMENTATI ON BASINS (13) THICKENERS 12) TANKS (3) DISTR1 BUTION SYSTEM FiLTER CAKE FILTER PRESSES (2) FIG. 4-3 . PROCESS FLOW SCHEMATIC — PEE—DEE RiVER REGIONAL FACILITY ------- TABLE 4-6 PROCESS DESIGN SUMMARY Flash Mix Basins Detention Time, sec 20 Number of Basins 3 2 Basin Volume, gal x 10 Basin 1 54 Basin 2 54 Basin Dimensions, ea. Length, ft 8.5 Width, ft 8.5 Depth, ft 10 SWD, ft 12 Power Requirement, ea Basin 1, HP on line 40 Basin 2, HP on line 40 Flocculation Basins Number of Basins 4 Detention Time Total, in 40 Basin Volume, gal x 10 Compartment 1 224 Compartment 2 224 Compartment 3 224 Basin Dimensions, ea Length ioo Width 30 Depth io SWO 12 Power Requirement, ea Compartment 1, HP on line 11 Compartment 2, HP on line 7 Compartment 3, HP on line 1 Paddle Area, sq ft 500 4-14 ------- TABLE 4-6 (Cont.) PROCESS DESIGN SUMMARY Paddle Velocity Compartment 1, fps 2.54 Compartment 2, fps 1.72 Compartment 3, fps 0.93 Revolutions per minute Paddle Compartment 1 6 Paddle Compartment 2 4 Paddle Compartment 3 2.25 Alum Dosage Supply Alum, ppm 3 40-100 Alum Dose, lb/day x 10 , maximum 37.5 Alum Supply, days 3 30 30-day supply, gal x 10 208.5 Alum Storage Tanks 3 2 Volume, ea, gal x 10 108 Tank Dimensions height, ft 15 diameter, ft 35 Sedimentation Basins Surface Overflow Rate, gpm/sq ft 0.25 Detention Time, hr 3 5 Basin Volume Total, gal x 10 9.724 Number of Basins 13 Basin Dimensions Length, ft 200 Width, ft 50 Depth, ft 10 SWD, ft 12 Flow per basin, gpm 2,400 Flow Velocity, fpm 0.6 Weir Overflow Rate, gpm/ft 8 Weir Length Total, ft 3,900 Weir Length, per Basin, ft 300 Thickener Mass Dry Solids, lbs/mg 490 Volume Underf low Sludge, g 1/mg 2,930 Thickener Surface Area, ft 4,400 Number of Thickeners - 2 Detention Time, days 3.9 4-15 ------- TABLE 4-6 (Cont.) PROCESS DESIGN SUMMARY Thickener Dimensions Height, ft 15 Diameter, ft 3 Sludge Removal Rate, gal x 10 75 Sludge Mass Removed, lb/day x 10 21.9 Filter Beds Filter Bed Components Coarse material Anthracite Fine material 2 3 Sand Filter Bed Area Total, ft x 10 12.6 Number of Filter Beds 2 6 Surface Area, ft 2,100 Filter Run Time Accepted Contemporary Maximum, hrs 60 Anticipated, Firs 48 Solids Accumulation Rate, lb/hr 6.6 Backwash Flow Rate, g rn 31,500 Backwash Flow, gpm/ft 1 5 Backwash Time,_min - 5—10 Backwash Holding Tank , Volume, ea, gal x 10” 423 Volume, Total, gal x 10 1,269 Number of Tanks 3 Tank Dimensions height, ft 20 diameter, ft 60 Settling Pond Number of Ponds 3 1 Volume for Settling, gal x 10 1,683 Pond Dimensions Length, ft 300 Width, ft 75 Depth, ft 10 Detention Time, days 1.8 4-16 ------- TABLE 4-6 (Cont.) PROCESS DESIGN SUMMARY Filter Press Condition Solids, lb Lime/lb sludge solids 0.15 Coagulant Condition, lb/ton dry SS 5 Cake Solids, % 3 25 Cake Density, lb/ft 70 Cake Thickness, in. 1.2 Filter Chamber Volume, ft 1.88 Cycle Time, hr 2 Filter Pressure, psig 225 Dry Weight Solids, 3 1b x 10 /day 25.2 Cake Solids, ib/lO /da 100.75 Filter Cake Volume, ft 1,450 Number of Chambers/day 775 Cycles per Day 8 No. of Presses 2 No. of Chambers, ea press 50 Chlorination Chlorine Dose, ppm 3 Contact Basin 3 Volume, gal x 10 945 Detention Time, mm 30 4-17 ------- REFERENCES 1. Maier, F. J. Fluoridation . CRC Press, Cleveland, Ohio (1972). 2. Boruff, C. S., “Removal of Fluorides from Drinking Waters.” md. Eng. Chem. , 26, 1, 69 (1934). 3. Scott, R. 0., et al., “Fluoride in Ohio Water Supplies.” Journal AWWA , 29, 17 1937). 4. Cuip, R. L., and Stoltenberg, H. A., “Fluoride Reduction at La Crosse, Kansas.” Journal AWWA , 50, 3, 427 (1958). 5. 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