RAUBIOXON PLUS Pipe Aerator

Transcription

1 RAUBIOXON PLUS Pipe Aerator Technical Information 316 TI-E Technical modifications reserved

2 Contents Page 1. Areas of application 1 2. RAUBIOXON PLUS pipe aerator Components Material property of silicone membrane Product range Pipe aerator Pipe aerator with non-return valve Pipe aerator with 1 1 /4" internal thread Marking 3 3. Advantages of RAUBIOXON PLUS pipe aerator 3 4. Accessories Stainless steel rod Adaptor for square air distribution pipes Adaptor for round air distribution pipes Air distribution pipe (air header) Square air distribution pipe Round air distribution pipe End cap Assembly adaptor Stainless steel clamp Pipe clamp distance 5 5. Delivery make-up 6 6. Design of aeration system General Diagrams Oxygen transfer tests 7 7. Assembly General Storage Inspection Preparation for assembly RAUBIOXON PLUS pipe aerator Positioning of pipe aerator Assembly of the pipe aerators Arrangement of pipe aerator 9 8. Commencement of operation Commissioning Oxygen transfer measurement Idle time, prior to continuous operation Operation General Air supply Maintenance/cleaning Warranty Project questionnaire 11

3 1. Areas of application The RAUBIOXON PLUS pipe aerator system was specially developed for fine bubble aeration of municipal 3 wastewater in biological treatment processes. It can be operated with an airflow rate of between 2-12m N /h*m a and is suitable for both continuous and intermittent operation. Refurbishment with RAUBIOXON pipe aerators at Wittenberg STP in 1998 Moreover, RAUBIOXON PLUS pipe aerators have also shown to produce excellent results in the following industrial applications: Food industry such as production of milk, chocolate, starch and meat Beverage industry Leather processing Paper production Textile cleaning Mineral oil processing Refurbishment with RAUBIOXON pipe aerators at Nestle Ltd in Spain in 1998 However, RAUBIOXON PLUS pipe aerators are not suitable for industries, which produce wastewater containing the following types of chemicals: 1. Organic solvents 2. Strong acids 3. Strong alkaline 1

4 2. RAUBIOXON PLUS pipe aerator RAUBIOXON PLUS is an enhanced version of RAUBIOXON pipe aerator. It comes with a new silicone rubber membrane, which has a higher tear strength and anti-microbial property. 2.1 Components RAUBIOXON PLUS pipe aerator comprises a support pipe made of RAU-PP (polypropylene), a membrane made of RAU-SIK (silicone rubber), which is fixed to the support pipe by two stainless steel clips and an EPDM seal. 2.2 Material property of silicone membrane RAUBIOXON PLUS silicone membrane does not contain plasticizer. It is permanently elastic and therefore does not harden or become brittle. It is resistant to high temperature. Moreover, it is also suitable for certain industrial wastewater treatment plants. The patented antimicrobial property of the silicone rubber membrane inhibits incrustation. As a result, there is substantial energy saving due to small increase of back pressure. Material Properties Standard Unit Value Shore hardness DIN Shore A 60 5 Density DIN g/cm Tensile strength DIN SII N/mm 2 9 Elongation at break DIN SII % 450 Tear strength ASTM-D624B N/mm Product range Pipe aerator C = 43mm, D = 63mm EPDM seal Article no. Overall length A (mm) Effective length B (mm) Weight (kg) Pipe aerator with non-return valve C = 43mm, D = 63mm Article no. Overall length A (mm) Effective length B (mm) Weight (kg)

5 2.3.3 Pipe aerator with 1 1 /4" internal thread D = 63mm Article no. Overall length A (mm) Effective length B (mm) Weight (kg) Marking REHAU RAUBIOXON PLUS Brand name 64 x 1.5 Diameter and wall thickness Date Date of production Number Production number 3 Advantages of RAUBIOXON PLUS pipe aerator The advantages of RAUBIOXON PLUS pipe aerator are as follows: Permanently elastic RAU-SIK membrane High temperature resistance No hardening/brittleness Low susceptibility to incrustation Suitable for industrial wastewater treatment plants Suitable for intermittent operation High oxygen utilisation Bubble size of 1.5 to 2mm at the membrane surface Low buoyancy aeration unit Self sealing when air supply is cut off Quick and robust installation Economical conversion of existing systems 4 Accessories 4.1 Stainless steel rod RAUBIOXON PLUS pipe aerator can be installed easily in pairs. One end of the pipe aerator has a threaded insert. Two pipe aerators can be connected using a M10 threaded stainless steel rod. Depending on the size of the air distribution pipe, the following rods are used. Article no. Threaded rod length (mm) For air distribution pipes x80x x100x x120x3 4.2 Adaptor for square air distribution pipes If the diameter of the opening in the square air distribution pipe is not 45mm, a PVC adaptor ring with EPDM seal is to be added onto the pipe aerator to ensure that the connection to the air distribution pipe is tight. Depending on the size of the opening, the following adaptors are used: 3

6 Article no. size of opening (mm) Flat EPDM seal, art , is required to be used together with the adaptor, art while EPDM seal, art is to be used together with adaptor, art , and With the addition of such adaptor on each side of the air distribution pipe, the length of the threaded rod has to be increased by about 20mm. 4.3 Adaptor for round air distribution pipes To connect the pipe aerator to round air distribution pipe, a PP adaptor with EPDM seal is required. PVC adaptor ring Article no. Pipe DN Adaptor for round pipe As a result of using the adaptor, the length of the threaded rod has to be increased follows: Article no. Threaded rod length (mm) Pipe DN Air distribution pipe (air header) There are two types of air distribution pipes, namely square stainless steel pipe, grade 304 or higher and round upvc pipes. The air distribution pipes are usually mounted with its centre at a distance of approximately 200mm from the tank base Square air distribution pipe adaptor for square air distribution pipe Material: Dimensions: SS 304 (standard) 80x80x2, 100x100x3, 120x120x Round air distribution pipe adaptor for round air distribution pipe Material: Dimensions: upvc ø90x6.7, ø110x8.2 4

7 4.5 End cap Should there be a need to install pipe aerator on one side of the air distribution pipe only, end cap made of PP, art can be used to seal off the other end. 4.6 Assembly adaptor End cap For the assembly of pipe aerator, an assembly adaptor made of stainless steel, art is required. 4.7 Stainless steel clamp Assembly adaptor When upvc pipes are used as air distribution pipe, they have to be secured to the tank base using stainless steel clamps made of SS 304. Article no. upvc pipe DN Pipe clamp distance Stainless steel clamp The distance between pipe clamps varies according to the size and depth of wastewater as shown in the following 4 charts: Pipe clamp distance for tank with 3m water depth Pipe clamp distance for tank with 4m water depth Pipe clamp distance (mm) Pipe clamp distance (mm) upvc pipe PN 16 according to DIN 8061/62 (DN) Pipe clamp distance for tank with 5m water depth Pipe clamp distance (mm) Pipe clamp distance (mm) upvc pipe PN 16 according to DIN 8061/62 (DN) Pipe clamp distance for tank with 6m water depth upvc pipe PN 16 according to DIN 8061/62 (DN) upvc pipe PN 16 according to DIN 8061/62 (DN) 5

8 5. Delivery make-up Article no. Effective length (mm) Packing unit (pcs) Carton size (mm) /291716/ x 375 x /291726/ x 375 x / x 375 x Design of aeration system 6.1 General It is the purpose of each design to supply the required amount of oxygen into the wastewater under a given set of conditions in the most economical way, taking into consideration the investment and operating cost. The basis for the design are the aerator characteristic values in clean water, which are based on standard condition (1013 mbar or kpa, 20 0 C). See diagrams 3 and 4. Through calculation and factors obtained empirically the aerator characteristic values are adjusted to the actual available conditions. For example, the wastewater temperature and air pressure are taken into consideration as they influence the oxygen saturation concentration, increased content on dissolved salts and surface active substances (Tenside), flow, arrangement and size of the non-aerated zones. Please contact our technical application department with your specific problem and provide information by filling up the project questionnaire found in section 10. Diagram 1 shows the relationship between pressure loss of the pipe aerator and specific air flow rate. Diagram 2 shows the relationship between pressure loss of the pipe aerator with non-return valve and specific air flow rate. 6.2 Diagrams Pressure loss of RAUBIOXON pipe aerator, measured in air specific air flow rate (m N3 /h*m a ) Diagram 1 Pressure loss of RAUBIOXON pipe aerator with non-return valve, measured in air Pressure loss (mbar) Pressure loss (mbar) Diagram 2 specific air flow rate (m N3 /h*m a ) 6

9 Specific Oxygen Absorption of RAUBIOXON Pipe Aerator at 3.6m immersion depth SOA (go 2 /m N 3 m) Aerator density 10% Aerator density 20% Aerator density 30% Air flow rate (m N3 /h*m a ) Diagram 3 Specific Oxygen Absorption (SOA) of RAUBIOXON pipe aerator Aerator density 30% airflow rate 8/10m N3 /h*m Aerator density 20% airflow rate 8m N3 /h*m Aerator density 20% airflow rate 10m N3 /h*m 23 Aerator density 10% airflow rate 8m N3 /h*m SOA (go 2 /m N 3 m) Aerator density 10% airflow rate 10m N3 /h*m Immersion depth of pipe aerator (m) Diagram 4 The diagrams for specific oxygen absorption apply to measurements in tank with clean water under standard conditions with constant area aeration with a tolerance of +/- 10%. 6.3 Oxygen transfer tests Oxygen transfer ability and yield can often be proven by corresponding tests. The oxygen transfer measurements are in most cases carried out in clean water according to the absorption method. Chemicals are added to the water in order to remove all oxygen present in it. Through the aeration system, oxygen is introduced; the concentration increases from zero up to maximum saturation. Out of the resulting concentration curve, the oxygen transfer capacity is calculated. By using the output of the compressor as a reference, the specific energy consumption of the so-called oxygen efficiency is calculated. The conduct of transfer measurement in Germany is regulated by the working paper M209 of the Wastewater Technical Association (ATV). It is, however, necessary for the project owner and supplier 7

10 The conduct of transfer measurement in Germany is regulated by the working paper M209 of the Wastewater Technical Association (ATV). It is, however, necessary for the project owner and supplier to agree explicitly on certain parameter such as, for example, the permissible tolerance. Specific Oxygen Utilization rate RAUBIOXON pipe aerator Source : Gutachten TH Darmstadt to agree explicitly on certain parameter such as, for example, the permissible tolerance. 7. Assembly 7.1 General Storage The aerators are to be stored in their original packaging, in a dry, ventilated room, in compliance with DIN Inspection Every pipe aerator, especially the aerator tube, must be checked for damage and tight fixing of the clips Preparation for assembly After the air supply pipe work has been assembled and the air distribution pipes connected to it, the pipe work should be cleared of other foreign bodies by blowing pressurized air through it for about 10 minutes. When this has been carried out, the pipe aerator can be assembled to the air distribution pipes. Object such as stones, pieces of wood etc. are to be removed from the treatment tank. 7.2 RAUBIOXON PLUS pipe aerator Positioning of pipe aerator Ribbon aeration Zonal aeration Separate mixing Sheet aeration (foils) The values apply to universal aeration with an utilisation density of 29.7% at an immersion depth of 3.60m. Square distribution pipe Holes with ø 45mm (-0/+1mm) are to be made on both sides of the square air distribution pipe so that the pipe aerators can be fitted. Round upvc pipe Holes with ø 30mm (-0/+0.5mm) and ø 5.0 (-0/+0.5mm) are to be made along the axis on both sides of the upvc pipe as shown below: These holes must lie on the same axis (maximum deviation 0.5mm)! The air distribution pipes have to be adjusted in relation to one another, both horizontally and vertically. Proper function of the pipe aerator depends on precise positional adjustment. 8

11 7.2.2 Assembly of the pipe aerators A special adaptor is used for the assembly of the RAUBIOXON PLUS pipe aerators. It is to be used together with a torque wrench with 1 / 2 " square bit. A screwdriver with a shaft diameter of between 5 to 6mm can be placed in the slot in the opposite pipe aerator so that it does not rotate during tightening of the pipe aerators. Assembly adaptor A pair of RAUBIOXON PLUS pipe aerators can be assembled as follows: The M10 threaded rod is screwed into the female threaded insert of the pipe aerator until is hand tight (about 1 cm deep). Lubricants should not be applied onto the sealing surfaces! The two pipe aerators are assembled together using a torque wrench with the assembly adaptor on one end and the screwdriver inserted in the slots of the pipe aerator at the other end. Note: The tightening of the pipe aerator cannot be carried out by holding onto the pipe aerator tube as the pipe aerator tube will be twisted. This is not permitted! The pipe aerator is fixed in position by using a screwdriver. The screwdriver should be held in an upright position. Threaded rod screwed into the pipe aerator Assemble with torque wrench The other pipe aerator is to be tightened using a torque wrench with a torque of 35 Nm. Thereafter, the RAUBIOXON PLUS pipe aerator is to be further tightened until one of the aerator tube groove appears at the top. The pipe aerator is allowed to be further tightened by at most half a turn. Align with screwdriver Note: An imaginary line between the two aerator-tube grooves may deviate from the vertical by 10 o C. If the EPDM seal is not compressed evenly, the tightening process has to be repeated Arrangement of pipe aerator If RAUBIOXON PLUS pipe aerators 1000mm are used in tanks of certain geometry, sometimes, as a result of overflowing water, the pipe aerator can start to oscillate. This can result in negative effects on the entire pipe aerator unit. Therefore, when designing a layout of RAUBIOXON PLUS pipe aerators 1000mm, the direction of the overflow should be +/-45 o to the long axis of the pipe aerator. This is essential for pipe aerators 1000mm only but not 500mm and 750mm. Positioning of pipe aerator Layout of RAUBIOXON PLUS pipe aerator 1000mm 9

12 8. Commencement of operation 8.1 Commissioning A trial of the system should be carried out as soon as possible after fitting, with the tank filled with clean water. The system should be checked for air tightness, section by section, with a maximum depth of 20 cm of water above the pipe aerators. Leaks are revealed when, after a brief period, the air supply is cut off. Air bubbles then rise where the seal is poor (depending on system pressure). Work that can cause damage to the aerators (such as painting, welding, concrete sealing etc.) must not be carried out in the area of the treatment tank. 8.2 Oxygen transfer measurement Prior to taking oxygen transfer readings, the aerating process is to be continued for a period of at least 48 hours at a specific air flow rate of at least 8m N3 /hm a in order to ensure that the aerators function properly. Otherwise, the latest version of the wastewater purification regulations, ATV M209, apply. 8.3 Idle time, prior to continuous operation If the aerators are not put into operation immediately following the trial, then the depth of water above the aerators is to be increased to 1m. This depth of water must be maintained until the equipment is finally put into operation. Keep an eye on water evaporation. If the aerators heat up due to exposure to sunshine, the starting torque is to be checked once more prior to putting into operation. If there is frost, the depth of water above the aerators must be at least 10% of the minus temperature (in metres). Example: at C, water depth above aerators = 2m 9. Operation 9.1 General Water temperature must be between 5 and 30ºC. Higher temperatures are possible. However, it is necessary to consult the manufacturer beforehand. 9.2 Air supply The air supply system has to be free of oil, dust and solvent and must include a filtration system. The air supply system must comply with local Health and Safety legislation. Dust filters for ambient dust are to be designed to achieve 90% filtration in conformity with EN 779, filter class G4. Air temperature at inlets may not exceed 80 o C. Higher temperatures may be permitted in consultation with the manufacturer. The pipe aerator can be operated with an air supply of between 2-12m N3 /h*m a. 9.3 Maintenance/cleaning If the treatment tank is drained or the aerator system is pulled up, care is to be taken that the deposits on the aerator tubes do not dry out, i.e. the aerators are to be immediately cleaned. Dried deposits will impair aerator performance. Occasionally, there might be process-related deposits, which can be removed in their initial stages. It is therefore necessary to check for such deposits regularly, right from the start, and to determine an appropriate cleaning cycle. Mechanical cleaning can be carried out using high pressure water jet on the pipe aerator, which are covered by about 10cm of water. Also, an air flow rate of 4 to 5m 3 /hm should be applied when cleaning is carried out. N a 9.4. Warranty Warranty is given according to our current warranty declaration. 10

13 10. Project Questionnaire Design data for new plant*/refurbishment* (*Please delete accordingly) Customer Name: First name: Company: Address: Telephone/Fax: Wastewater treatment plant Project name: Owner: Address : Telephone/Fax : Contact person: Design basis : people Tank shape Radius (R): m Internal diameter (Di): m Width (B): m Length (L): m No. of tanks: Oxygen demand: min: max: kg/h in clean water min: max: kg/h in wastewater Input of industrial Yes, which type? waste No Required compressor Type of compressor: Max. air flow intake: Max. operating pressure: Type: Quantity: Remarks: Rotary piston Turbo Rotary slide valve m 3 /min mbar Round tank Rectangular tank Circulation tank Combination tank Depth of water (wt) : m Outer diamater (Da): m 11

14 316 TI-E UNI V09.04

15 Notes :