© 2002 by CRC Press LLC AERATION: Principles and Practice VOLUME 11 WATER QUALITY MANAGEMENT LIBRARY LIBRARY EDITORS W. W. ECKENFELDER J. F. MALINA, JR. J. W. PATTERSON © 2002 by CRC Press LLC WATER QUALITY MANAGEMENT LIBRARY The immense environmental challenges facing the world now and in coming years can only be met through marshalling the talents of the best environmental engineers and scientists and through the use of innovative, cost-effective solutions. The Water Quality Management Library addresses these challenges and reflects the organized efforts of leading international experts. Collectively, the eleven volumes in this library are a pertinent and timely compendium of water pollution control and water quality management. They form a unique reference source of international expertise and practice in key aspects of modern water pollution science and technology. With such valuable communication of knowledge using these and other books, we can hope to overcome the critical environmental issues challenging us today. Volume 1 ACTIVATED SLUDGE PROCESS DESIGN AND CONTROL: Theory and Practice—Second Edition Volume 2 UPGRADING WASTEWATER TREATMENT PLANTS— Second Edition Volume 3 TOXICITY REDUCTION: Evaluation and Control— Second Edition Volume 4 MUNICIPAL SEWAGE SLUDGE MANAGEMENT: A Reference Text on Processing, Utilization and Disposal— Second Edition Volume 5 DESIGN AND RETROFIT OF WASTEWATER TREATMENT PLANTS FOR BIOLOGICAL NUTRIENT REMOVAL Volume 6 DYNAMICS AND CONTROL OF WASTEWATER SYSTEMS— Second Edition Volume 7 DESIGN OF ANAEROBIC PROCESSES FOR THE TREATMENT OF INDUSTRIAL AND MUNICIPAL WASTES Volume 8 GROUNDWATER REMEDIATION Volume 9 NONPOINT POLLUTION AND URBAN STORMWATER MANAGEMENT Volume 10 WASTEWATER RECLAMATION AND REUSE Volume 11 AERATION: Principles and Practice CRC PRESS Boca Raton London New York Washington, D.C. AERATION: Principles and Practice VOLUME 11 WATER QUALITY MANAGEMENT LIBRARY James A. Mueller, Ph.D., P.E. William C. Boyle, Ph.D., P.E. H. Johannes Pöpel, Dr Ing LIBRARY EDITORS W. W. ECKENFELDER J. F. MALINA, JR. J. W. PATTERSON with significant contributions from: Martin Wagner David E. Gibson Yeong-Kwan Kim This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the authors and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. 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Visit the CRC Press Web site at www.crcpress.com © 2002 by CRC Press LLC No claim to original U.S. Government works International Standard Book Number 1-56676-948-5 Library of Congress Card Number 2001052466 Printed in the United States of America 1 2 3 4 5 6 7 8 9 0 Printed on acid-free paper Library of Congress Cataloging-in-Publication Data Mueller, James A. Aeration : principles and practice / James A. Mueller, William C. Boyle, H. Johannes Pöpel ; with significant contributions from Martin Wagner, David E. Gibson, Yeong-Kwan Kim. p. cm. — (Water quality management library) Includes bibliographical references and index. ISBN 1-56676-948-5 (alk. paper) 1. Sewage—Purification—Aeration. I. Boyle, William C. (William Charles), 1936– II. Pöpel, H. Johannes. III. Title. IV. Series. TD758 .M84 2002 628.3 ′ 5—dc21 2001052466 CIP Dedication To our wives: MaryBeth, Nancy, and Ursula © 2002 by CRC Press LLC © 2002 by CRC Press LLC Preface The use of aeration in the wastewater treatment field has been in existence for over a century. Each of the authors has been involved with the theory and application of aeration systems for a little less than half a century. It was a daunting task to put together what we considered the important principles underlying the mechanisms involved in aeration and show how they are applied in practical applications. The objective was to not only provide the basic theory, but also the current practice and latest applications, so the book would be useful to today’s professional engineers as well as to future engineers now studying the field. The task was conceived in the early 1990s by Wes Eckenfelder, who recognized a gap in the field. After a number of false starts, and with Bill and I soliciting the assistance of Johannes at the WEF convention in Chicago in 1997, it was begun in earnest in 1998—taking several years to complete. Johannes supplied an in-depth theoretical background as well as the European experience, especially in deep tank aeration. Bill supplied his experience in the diffused aeration area, and his desire to continually find the state of the art and how it is—and should be—practiced today. I enjoyed tying the theory and practice together to attain a good understanding of the most recent applications. We received much assistance from our colleagues in the field. Especially noted on the title page are those who spent a great deal of time and effort providing critical input. They provided a needed jolt for each author to finish the endeavor by their knowledge of the field, review of concepts, and critical editing when required. I would especially like to mention the assistance of a number of former students at Manhattan College. Richard Carbonaro scanned critical pictures while Rosanne Schirtzer, Clayton Conklin, Kevin Clarke and Sue Hildreth dug into the economics data from various agencies, a daunting task in itself. John Gormley, Engineering Librarian at Manhattan, continually obtained needed references and ran critical interference allowing me to ignore due dates. The assistance of large municipal agencies in supplying critical information is acknowledged. The New York City Department of Environmental Protection, NYCDEP (especially Robert Adamski, John Leonforte, James G. Mueller (son), Hilary Einsohn, and Siobahn Rohan), coordinated efforts to obtain cost information on the New York City plants. The Metropolitan Water Reclamation District of Greater Chicago, MWRDGC (especially Hugh McMillan), provided the latest developments on the Chicago side channel aeration systems. The Middlesex County Utilities Authority, MCUA (especially Victor Santamarina), supplied insights into their high purity oxygen system upgrade. Most of all I would like to thank God for giving us the energy and insights to complete this book. I look forward to it continuing to shed light on the profession and leading to the design and development of better aeration systems. © 2002 by CRC Press LLC The poem that follows was composed by Jim McKeown, a member of our original oxygen transfer standards committee, who died of cancer in the winter of 1990–1991. It gives a bit of the history of the standards work, supported by the USEPA and ASCE, that Bill and I were involved with since 1976. It is a reminder that our work should never get the best of us—not above our relationships with each other, and with our God. James A. Mueller © 2002 by CRC Press LLC To the Study of the Drop and the Bubble James J. McKeown This is a poor story about the dirty water band who took to the field when standardization was at hand. After all, wasn’t it clear, although the data wasn’t “purty,” what was named the clean water test was really very dirty. The next step was upon us it took only a spark of inspiration for our band to begin the search for the transfer of mass during respiration. So we left the mainstream, unfortunately, to no one’s real sorrow to pursue our fair dream in a breach where Whittier did Narrow. The first results were so startling, every possible relationship linear, we had to move east—to avoid the critique— our findings were true, but only in Califor-ni-a. Where we could test to avoid bias oracle; where wastewater was by all standards, categorical. Who could argue with respiration, although lazy extracted from sewage undergoing renovation in New Jersey? Convinced by such rationale supported by those seeking to prove that if things aren’t quite right once then they are always right when dual. We joined the band within site of sometime energetic Indian Point where sometime aeration interfered with our living in an otherwise elegant joint. © 2002 by CRC Press LLC Although we did proudly stand, our bloom soon lost its peak when K L a escaped us through an insidious leak. Suitably humbled, we moved on to further learn that the non-steady test couldn’t be rushed when for nearly 20 minutes all in Ridgewood town, everyone, refused to flush. Let’s not forget good can come from bad for here in course bubbly, we examined off-gas. And also, it can now be reported to superman’s value, we corralled fair krypton here by switching from plastic to glass. Undaunted we moved on to finale grand all planned to succeed where Miller had fallen now was the time to again make our stand. We would continue to search to stoop to lower ourselves to the depths where oxygen did lurk barely dissolved in such dirty water that we even enlisted one we called daughter—uh clerk. But success was to come from more than mere traces. Rather, from working together with methods as different as different as the looks on our faces. Now, you think we were done, but an epilogue beckons. Because this band, as a group learned of martinis Cajun and riverboat soup, not to mention, the proper way to eat grapefruit. But most important, to leave some work undone so we could meet once more to march to the cadence and the lure in search of a sponsor to help us continue to work toward making dirty water—pure. March 23, 1984 ASCE Oxygen Transfer Standards Committee Coronado, California © 2002 by CRC Press LLC Table of Contents Chapter 1 Introduction 1.1 Purpose 1.2 Intended Audience 1.3 Bibliography Chapter 2 Principles 2.1 Mass Transfer Principles 2.2 Application to Oxygen Transfer 2.3 Design Equations 2.4 Nomenclature 2.5 Bibliography Chapter 3 Diffused Aeration 3.1 Introduction 3.2 Description of Diffused Aeration Systems 3.3 Diffused Air System Layouts 3.4 Performance of Diffused Air Systems 3.5 Diffused Air System Design 3.6 Nomenclature 3.7 Bibliography Chapter 4 Deep Tank Aeration with Blower and Compressor Considerations 4.1 Introduction 4.2 Oxygen Transfer in Deep Tanks 4.3 Aeration Efficiency in Deep Tanks 4.4 Nomenclature 4.5 Bibliography Chapter 5 Surface and Mechanical Aeration 5.1 Introduction 5.2 Low-Speed Surface Aerators 5.3 High-Speed or Motor Speed Aerators 5.4 Horizontal Rotors 5.5 Submerged Turbine Aerators 5.6 Aspirating Aerators [...]... •4 stage HPO 95.5 •turbine (1 97 4) •surface +8.9 (1 99 5) Diffused, 95 fine tubes (1 99 5) with propellers •racetrack 4.43 (1 99 8) 4.05 (1 99 9) 7 .12 (1 99 8) 7.43 (1 99 9) 2.49 (1 99 8) 2.29 (1 99 9) 7 .15 (2 00 0) 25 24 17 19 .3 19 .3 16 .4 (1 99 7) 10 0 15 .2 Upgrade (1 99 9) 15 3.4 (1 99 7) 19 .5 before 13 after upgrade 11 . 4 (Poepel, 20 01; Wacker, 19 9 8) * Including air scrubbers the North River plant in New York City This plant,... 650 fine pore (1 99 0) 20 North River Manhattan, NY 7.5 (1 7 0) Diffused, 968 fine pore (1 98 6) 5.57 Red Hook Brooklyn, NY 2.6 (6 0) Diffused 232 (1 98 8) 16 .8 Owls Head West Point Brooklyn, NY Seattle, WA 5.3 (1 2 0) 5.8 (1 3 3) Diffused 380 (1 99 5) 229 (1 99 5) 27 MCUA Sayreville, NJ 6.5 (1 4 7) Darmstadt Central Germany 0.46 (1 0) High purity O2 •surface •4 stage HPO 95.5 •turbine (1 97 4) •surface +8.9 (1 99 5) Diffused,... (MGD) System Yearly Operating Costs Total Plant % Due Total Plant to 10 6 $/yr % Due to 10 6 $ (year) Aeration (year) Aeration Reference 20 .1 25.5* 20.3–25.2* (Conklin, 200 1) 15 .7 16 .8 (Conklin, 20 01; Leonforte, 19 9 8) (Conklin, 20 01; Leonforte, 19 9 8) (Clarke, 200 1) (Hildreth, 19 99; Hildreth, et al 19 9 7) (Schirtzer, 200 0) Plant Name Location Coney Island Brooklyn, NY 4.4 (1 0 0) Diffused, 650 fine pore (1 99 0). .. dumping Figures 1. 1 and 1. 2* illustrate the * Figures 1. 1 and 1. 2 also appear in the color insert following page 84 © 2002 by CRC Press LLC C D FIGURE 1. 1 (continued) differences in equipment requirements of the MCUA plant before and after upgrade to surface aeration (Schirtzer, 200 0) Costs due to aeration at the relatively simple racetrack system used in Darmstadt, Germany are only 11 . 4 percent of... secondary clarifiers and a scrubber system to capture and treat air emissions before discharge © 2002 by CRC Press LLC A B FIGURE 1. 1 Original submerged turbine system for MCUA plant showing aeration tank turbine drives (A), gear reducer (B), high purity oxygen delivery piping (C) and compressor room (D) (Photos courtesy of Middlesex County Utilities Authority, Sayreville, New Jersey .) Operation costs... required However, along with the principles, © 2002 by CRC Press LLC A B FIGURE 1. 2 (A) New surface aeration system for MCUA plant showing (B) compact surface aeration drives, (C) with elimination of most overhead piping, and (D) elimination of most equipment from compressor room (Photos courtesy of Middlesex County Utilities Authority, Sayreville, New Jersey .) the actual practice in the different applications... 617 –628 Leonforte, J P (1 99 8) Letter on NYC Wastewater Plant capital costs—4 Nov., 19 98 Chief, Division of Intergovernmental Coordination, Bureau of Environmental Engineering, NYCDEP Pöpel, H J (2 00 1) Personal communication breaking down costs of Darmstadt plant Emails, 3–5 Feb., 20 01 Schirtzer, R (2 00 0) “Submerged Turbine Aeration Conversion to Surface Aeration—Middlesex County Utility Authority (MCUA)... Three NYC Water Pollution Control Plants—Coney Island, North River and Red Hook.” Masters Degree Thesis, Department of Environmental Engineering, Manhattan College, NY Hildreth, S B (1 99 9) “Aeration Capital Costs for West Point, Seattle WWTP.” Personal communication, 13 Jan., 19 99 Hildreth, S B., Finger, R E., Hammond, R R., and Daigger, G T., (1 99 7) “Full Scale High Purity Oxygen Activated Sludge... Full-Scale Instream Aeration Systems Nomenclature Bibliography Chapter 9 9 .1 9.2 9.3 9.4 9.5 9.6 9.7 Testing and Measurement Introduction Aeration Tank Mass Balance Clean Water Performance Testing In-Process Oxygen Transfer Testing Quality Assurance for Fine-Pore Diffusers Characteristics of Diffused Air Materials Nomenclature Bibliography Chapter 8 8 .1 8.2 High-Purity Oxygen Aeration Operation and. .. developed to allow application to practice Various examples applying the principles to design will be useful to both groups 1. 3 BIBLIOGRAPHY Clarke, K (2 00 1) “Treatment Plant Costs for Owls Head NYC Water Pollution Control Facility.” Masters Degree Special Project, Department of Environmental Engineering, Manhattan College, NY Conklin, C (2 00 1) “Development of Capital and Operating Costs for Three NYC . pore 968 (1 98 6) 5.57 7 .12 (1 99 8) 7.43 (1 99 9) 15 .7 16 .8 (Conklin, 20 01; Leonforte, 19 9 8) Red Hook Brooklyn, NY 2.6 (6 0) Diffused 232 (1 98 8) 16 .8 2.49 (1 99 8) 2.29 (1 99 9) 25 24 (Conklin, 20 01; Leonforte,. (Hildreth, 19 99; Hildreth, et al. 19 9 7) MCUA Sayreville, NJ 6.5 (1 4 7) HPO •turbine •surface 95.5 (1 97 4) +8.9 (1 99 5) 19 .3 10 0 Upgrade 16 .4 (1 99 7) 15 .2 (1 99 9) 19 .5 before 13 after upgrade (Schirtzer, 200 0) Darmstadt Central Germany. 20 01; Leonforte, 19 9 8) Owls Head Brooklyn, NY 5.3 (1 2 0) Diffused 380 (1 99 5) 27 7 .15 (2 00 0) 17 (Clarke, 200 1) West Point Seattle, WA 5.8 (1 3 3) High purity O 2 •surface •4 stage 229 (1 99 5) 19 .3 (Hildreth, 19 99; Hildreth,