Innovative Cost-Effective Control Device For Wastewater … · Annual AWMA Fall Conference - Louisiana Section, Crowne Plaza Hotel, Baton Rouge. October 27-28, 2009. Innovative Cost-Effective

Annual AWMA Fall Conference - Louisiana Section, Crowne Plaza Hotel, Baton Rouge

October 27-28, 2009

Innovative Cost-Effective Control Device For Wastewater Benzene Emissions

(A Case Study)

Innovative Cost-Effective Control Device For Wastewater Benzene Emissions

(A Case Study)

Presenter/Senior Author:Dr. Carl E. Adams, Jr.

ENVIRON International Corporation

Contributing Authors:Dr. Lial F. TischlerTischler-Kocurek

Andrew Edwards, Matt HausmannENVIRON International Corporation

Elizabeth Olavesen, Wallace E. Dows, IIIRyan Cole, Ruth Cade,

Marathon Petroleum LLC

Presentation Outline

Section 1: Overview

Section 2: Current Benzene Control Devices & Impacts

Section 3: Proposed Alternative Control Device – ADVENT Integral System (AIS)

Section 4: Development and Confirmation of Proposed Alternative Control Device-AIS

Section 5: Conclusions

Section 1Overview

1-A. BWON (Benzene Waste Operations NESHAP): Wastewater Gaseous Emissions

Aqueous Wastewater Considerations– Influent wastewater benzene concentration must be <10 mg/L to avoid

required regulatory inventory accounting procedures– Wastewater treatment bioplant must qualify as an Enhanced

Biodegradation Treatment Unit (EBU)– Current approved control considers excellent benzene separation in

production processes and use of a NESHAPS Benzene Steam Striperon benzene-laden wastewaters

Wastewater Gaseous Emissions Considerations– Applies to gaseous emissions from wastewater treatment processes– Includes API separators, dissolved air and induced air flotation

processes, uncovered or fixed-cover tanks and includes sumps and wet wells emissions

– Must incorporate an approved Control Device to reduce benzene emissions from these sources by 98%

– Current EPA-approved controls are thermal oxidizers and vapor-phase activated carbon

The term, Enhanced Biodegradation Treatment Unit (EBU), as specified by EPA and described in 40 CFR 61.348 (b)(2)(ii)(B), applies to Conventional Activated Sludge Systems with both External and Integrated Clarifiers (AIS)

– Generates biomass– Recycles biomass– Periodically waste biomass– Typically operates

F/M in the range of 0.05 to 1 kg BOD per kg biomass per dayMixed liquor in the range of 1 to 8 kg SS per literResidence time in the range of 3 to 36 hours

These regulatory criteria have been applied to the MPC-Garyville Refinery Integrated Activated Sludge Process, The ADVENT Integral System (AIS).

The ADVENT Integral System (conventional activated sludge with integral clarifier) at MPC-Garyville qualifies as an Enhanced Biodegradation Treatment Unit (EBU).

1-B. Enhanced Biodegradation Unit

1-B. Enhanced Biodegradation UnitComparisons of EPA Requirements vs. MPC-Garyville AIS Full-Scale Operating Parameters

COMPARISON OF CONVENTION EXTERNAL AND INTEGRATED SECONDARY CLARIFIER DESIGN APPROACH

Parameter

EPA Criteria for Enhanced Biological

Treatment Unit

MPC-Garyville Refinery AIS

Operating Parameters

F/M, kgs BOD/kg MLVSS-day 0.05 to 1.0 0.15

MLVSS Concentration, mg/L 1,000 to 8,000 3,500

Hydraulic Retention Time (based on wastewater inlet flow), hours 3 to 36 12

Title 40: Protection of Environment: 40 CFR § 61.340 presents two basic Control Devices that are acceptable, pursuant to specific design constraints:

(i) An enclosed combustion device (e.g., vapor incinerator, boiler, or process heater)

(ii) A vapor recovery system (e.g., a carbon adsorption system or a condenser)

(iii)A flare

Title 40: Protection of Environment: 40 CFR § 61.340 also states “other”Control Devices can be used provided that certain conditions are met.

(iv) A control device other than those described in paragraphs (a)(2) (i) through (iii) of this section may be used provided that the following conditions are met:

1-B. BWON (Benzene Waste Operations NESHAP): Control Devices

1-B. BWON (Benzene Waste Operations NESHAP): Control Devices

(A) The device shall recover or control the organic emissions vented to it with an efficiency of 95 weight percent or greater, or shall recover or control the benzene emissions vented to it with an efficiency of 98 weight percent or greater.

(B) The owner or operator shall develop test data and design information that documents the control will achieve an emission control efficiency of either 95 percent or greater for organic compounds or 98 percent or greater for benzene.

(C) The owner or operator shall identify:1) The critical operating parameters that affect the emission

control performance of the device;2) The range of values of these operating parameters that ensure

the emission control efficiency specified in paragraph (a)(2)(iv)(A) of this is maintained during operation of the device; and

3) How these operating parameters will be monitored to ensure the proper operation and maintenance of the device.

1-C. Marathon Petroleum Corporation (MPC) –Garyville, Louisiana

Marathon Petroleum’s Garyville Refinery – Last grass-roots refinery built in U.S. in 1976– Complies with the 6 MG/yr Treat-to-Target Option under BWON

(§342(e)(2)(i), which requires:All uncontrolled aqueous wastes be less than 6 MG/yr benzeneAll organic wastes be controlled

– MPC’s NSR Global Settlement also requires facility comply with End-of-Line Sampling Plan and be less than 4.8 MG/yr uncontrolled benzene.

– Installed innovative AIS-1(Integrates bioreactor and clarifier) in 2005 to supplement 3 older existing external clarifier activated sludge trains.

1-C. Marathon Petroleum Corporation (MPC) –Garyville, Louisiana

Garyville Major Expansion (GME) project in progress– Capacity increase from 185,000 bpd to 370,000 bpd– WWTP capacity increase from 2,100 gpm to 3,300 gpm– Addition of NEW parallel WWTP train, including new:

API (Oil/Water Separator)IGF (Induced Gas Floatation)Closed Circuit Cooling TowerInstalled new AIS-2 (second system) activated sludge system to handle entire expansion wastewater

First Stage: Anoxic Or Aerobic Zone (Involves Turning Aeration Header One

Valve)

Second Stage: Aerobic Zone

Second Stage: Aerobic Zone

1-C. MPC-Garyville Refinery BioReactor Schematic – ADVENT Integral System (AIS)

MarathonAshland REFINERYGaryville, LA

Closed Circuit Cooling Tower

UNICELL Induced Air Floatation (IGF)

1-C. MPC-Garyville Refinery BioReactor Construction - ADVENT Integral System (AIS)

Marathon Petroleum CorporationGaryville, Louisiana Refinery

1-C. MPC-Garyville Refinery AIS Process Flow Schematic as an EBU

19 – Influent20 – Anoxic to Aerobic21 – Anoxic Recycle (Aerobic to Anoxic)22 – Aerobic to Clarifiers23 – Recycle Sludge (Clarifiers to Anoxic)24 – Effluent25 – Waste Activated Sludge

A – Anoxic Zone B – Aerobic 2nd Stage Zone 1C – Aerobic 2nd Stage Zone 2D – Integral Secondary Clarifier

1-C. MPC-Garyville Refinery AIS Process Flow Schematic as an EBU

23

InletWastewater

TreatedEffluent

ANOXIC 1st STAGE(Completely and Thoroughly

Mixed with Turbine Mixer)

AEROBIC 2nd STAGE(Full floor coverage with Coarse bubble diffusers at 24 ft SWD)

AEROBIC 1st STAGE ZONE 2 OF INTENSE BACK

MIXING(THOROUGHLY MIXED

50% OF AEROBIC VOLUME)

AEROBIC 1st STAGE ZONE 1 OF LESS INTENSE BACK MIXING

(SERIES FLOW ZONE IS50% OF AEROBIC VOLUME)

Air Lift Pump

Recycled Activated Sludge

A

DC

B

1

20

22

2424

Integral Secondary Clarifier

No internal walls(Flow between Zones 1 & 2

is contiguous)

22Anoxic Recycle(Air Lift Pump)

25 Excess Sludge Wastage

1-C. MPC-GaryvilleCurrent Wastewater Facilities at MPC Simplified Current VOC Control Strategy

AIS Systems must be both:- Enhanced Biodegradation Unit (EBU)- Qualify as an Alternative Control Device for IGF Off-gas

Controlled API

RefineryUncontrolled Storm

Sewer System

Tank Water Draws(Benzene Containing

Products)

Crude DesalterWater

NESHAPS Stripper

GMETank Water Draws

(Benzene Containing Products)

GMECrude Desalter

Water

NESHAPS Stripper

ControlledEQ

Tank & Sumps/Wells

ControlledIGF

AIS-22009(EBU)

IGFLoading is Controlled

to Comply with BWON

Conventional Secondary WWTP

Discharge to River

Offgas

CarbonCanisters

Floating Roof

Conventional Control Device

Older Wastewater Plant

AIS-12005(EBU)

Offgas

Offgas

CarbonCanisters

1-C. MPC-GaryvilleCurrent Wastewater Facilities at MPC Simplified Current VOC Control Strategy

AIS Systems must be both:- Enhanced Biodegradation Unit (EBU)- Qualify as an Alternative Control Device for IGF Off-gas

Controlled API

RefineryUncontrolled Storm

Sewer System

Tank Water Draws(Benzene Containing

Products)

Crude DesalterWater

NESHAPS Stripper

GMETank Water Draws

(Benzene Containing Products)

GMECrude Desalter

Water

NESHAPS Stripper

ControlledEQ

Tank & Sumps/Wells

ControlledIGF

AIS-22009(EBU)

IGFLoading is Controlled

to Comply with BWON

Conventional Secondary WWTP

Discharge to River

Offgas

Alternative Control Device-AIS

CarbonCanisters

Floating Roof

Conventional Control Device

Older Wastewater Plant

AIS-12005(EBU)

Offgas

Offgas

Offgas

Offgas

x

1-D. Objectives of Investigation

Evaluate feasibility of Innovative ADVENT Integral System (AIS) as a BWON Control Device for biodegradation of injected gaseous benzene.– Project maximum operating conditions– Select an appropriate model and conduct Preliminary Modeling with

assumed rates and operating parameters– Development of site-specific benzene biodegradation rate– Confirm full-scale application and performance

Follow EPA guidelines to demonstrate full-scale, site-specific benzene removal by the proposed Benzene Alternative Control Device.Demonstrate acceptable gaseous benzene removal with the AIS at maximum anticipated design and operating conditions.Confirm all assumptions and modeling with full-scale performance data: not required, but prudent.

Section 2Current Benzene Control Devices & Impact

2-A. Current Control Devices

Fugitive off-gas sources include:– Dissolved or Induced Air Flotation processes– API separators

Off-Gas must be controlled to 98% removal of benzene or 95% removal of organics by an approved Control Device.Most common Control Devices are:– Thermal Oxidation processes (gas fired to incinerate benzene)– Granular Activated Carbon adsorption (adsorbs benzene from

gas stream and regenerated thermally)These technologies are:– Capital and operationally expensive– Consume considerable energy– Generate Green House emissions

MPC wishes to demonstrate the AIS as an Alternative Control Device.

2-B. Environmental Impacts for Major VOC Control Devices at MPC-Garyville Refinery

Process TechnologyAnnual Impact

Energy Consumption, Million BTUs per year

CO2 Emissions, tons CO2 per year

Thermal Oxidizer (calculated) 868 49

Granular Activated Carbon (in operation) 192 10

Biological (AIS) Minimal Minimal

2-B. Environmental Impacts for Major VOC Control Devices at MPC-Garyville Refinery

Process Technology

Cost-Effective Impact

Capital cost ($) Annual Operating Cost ($)

Thermal Oxidizer $1,200,000 $300,000

Granular Activated Carbon (6 carbon canisters on each of two API separators,22 change-outs/yr per API))

$240,000 $240,000

Biological (AIS) $25,000 Minimal

Section 3Proposed Alternative Control Device

ADVENT Integral System (AIS)

3-A. Proposed Innovative Benzene Control Device: ADVENT Integral System (AIS)

The AIS, as installed in MPC-Garyville Refinery, is a candidate for acceptance as a Control Device

Have found that AIS offers excellent conditions for treatment of biodegradable VOCs– Minimal surface area– Deep anoxic and aerobic bioreactors, using diffused aeration– Ease of aeration control in several zones

Concept has been previously tested at a Formaldehyde Resin production to biologically treat off-gases from production processes from 1,000 - 3,000 mg/L to 99% degradation – Formaldehyde– Methanol– Phenol

3-C. Mass Balance of Benzene at MPC GaryvilleSpecify Design Input Information

Influent Wastewater Conditions (Design Maximum)Influent to AIS-1 = 1,100 gpm (250 m3/hr)Benzene in water to API = 0.35 mg/LBenzene in water from IGF to BioReactor = 0.142 mg/L

Off-Gas Conditions (Design Maximum)API Off-Gas Flow = 65 scfm (111 m3/hr)

maximum 24 hr avgAPI Off-Gas Benzene Concentration = 0.10 ppmv (0.32 µg/L)IGF Off-Gas Flow = 3.8 scfm (6.5 m3/hr)

maximum 24 hr avgIGF Off-Gas Benzene Concentration = 10 ppmv (32 µg/L)

Assume the Off-Gas flows are combined with the aeration flow of 3,200 scfm (aeration flow that goes to aerobic zones) in the Inlet to the blowers

3-C. Mass Balance of Benzene at MPC-Garyville

3-D. Flexibility of Benzene Gaseous Injection into AIS System



Section 4Development and Confirmation of Proposed

Control Device-AIS

4-A. Data Collection & Model Selection

Major Variables– Air Flow– Biomass Concentrations– Benzene Biodegradation Rate– Potential Benzene Injection

Locations into AIS– Benzene Loadings

Other Significant Variables– Air Distribution in Zones– Depth of BioReactor– Aeration Tank Surface Area– Temperature– Hydraulic Flow & COD Loading

4-A. Data Collection & Model Selection Basis for Site-Specific Modeling: Significant Components

Water9 vs. Toxichem+Toxchem+ model used because it allows introduction of target constituents in gas streams as well as in wastewater.Toxichem+ is approved in 40 CFR Part 63 Appendix C for emissions modelingToxichem+ assumes non-equilibrium conditions for vapor phase-liquid phase transfer

4-B. Develop Site-Specific Biodegradation Model

Refinery Test Type Date Runs

Average for multiple

runs

Value selected for Model

evaluationA BOX Oct-02 2 48.9 --A 304A Oct-02 1 120.1 84.5B BOX Sep-93 1 79.1 79.1C BOX Sep-93 2 78.4 78.4D EKR Jun-92 4 17.3 17.3E BOX Aug-90 5 122 --E BOX Oct-90 2 31 --E BOX Nov-90 6 199 --E BOX Mar-91 5 199 --E BOX Mar-91 7 172 --E BOX May-91 4 206 185.5F BOX Jun-91 3 4.4 4.4G BOX Feb-96 3 64 64

Median 78.4

EPA Water 9 Rate (default rate) 1.6

Rate developed by ENVIRON for another Refinery 3.5

K1 (L/g VSS-hr)

(From API comments on Residual Risk Rule)

This rate used as the default for conservatism until site-specific rate is Developed)

Develop Preliminary Benzene Biodegradation ModelAssume conservative biodegradation rate

96.0

96.5

97.0

97.5

98.0

98.5

99.0

99.5

100.0

2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000

MLSS (mg/L)

Perc

ent B

enze

ne R

emov

al (%

)

Kb = 3.5 L/g-hr @ 3,200 scfm

Kb = 6.5 L/g-hr @ 3,200 scfm

Kb = 10.0 L/g-hr @ 3,200 scfm

Kb = 3.5 L/g-hr @ 2,800 scfm Minimum MLSS to achieve

5,150 mg/L

Kb =5.0 L/g-hr @ 3,200 scfm

3,850 mg/L3,200scfm 5.0 L/g-hr

2,800 scfm 3.5 L/g-hr

4-B. Develop Site-Specific Biodegradation Model Modeling Results Using Assumed Benzene Biodegradation Rates

4-B. Develop Site-Specific Biodegradation ModelSummarize Preliminary Modeling for Limitations

Must achieve 98% benzene removal from gaseous streams

Requires a benzene biodegradation rate of > 6 L benzene biodegraded/gm VSS-hr

If rate is < 6 L/gm-hr, system will require lower air flow rate and/or higher MLVSS concentrations

Neither option is desirable for operational protocol at site

Develop Site-Specific Bio-Rate Using Biological Oxidation Test (BOX Test) Procedures For Site-specific Parameters

Referred to as the BOX Test

4-C. Develop Site-specific Biodegradation Rate (BOX Test) and Rerun Calibrated Model

1. BOX Test Apparatus as recommended and designed by ENVIRON (Procedure 40, 40 CFR 63, Appendix C)

2. Use continuous on-line GC to monitor real time off-gas benzene concentration

4-C. BOX Test Apparatus as recommended and designed by ENVIRON and approved by EPA and the State of Louisiana

RECIRCULATION PUMP (IF NEEDED)

SOURCE OF AIR OR OXYGEN OR NITROGEN GAS (ANOXIC)

FINE PERFORATED GAS DIFFUSER PLATE

CLEAR PVC BIOREACTOR

TYGON OR SS GAS LINE

ATMOSPHERIC VENT FOR MONITORING OR VENTING OFF-GAS

BASE

6" dia

4ft 8

"

4 ft

SAMPLE INJECTION/COLLECTION PORT

6" FERNCO COUPLING

CLAMPS TO ENSURE GAS-TIGHT SEAL

IMPERMEABLERUBBER SEPTUM

Ability to Disassemble

Reactor

DISSOLVED OXYGEN &TEMPERATURE PROBE

DISSOLVED OXYGEN &TEMPERATURE MONITOR

SAMPLE OR FILL PORT, IF

REQUIRED

STAINLESS STEEL TUBING

GAS FLOW ROTAMETER

GAS FLOW ROTAMETER

TO CONTINUOUS ON-LINE ANALYZER WITH CARRIER GAS

Water volume = 22.2 L(5.9 gals)

4-C. Specifics of the on-line Photovac Voyager GC

Size– 15.4“ (39 cm) long, 10.6“

(27 cm) wide, 5.9“ (15 cm) high

Display– 128 x 64 element graphical

LCD with backlighting

Serial Output– RS-232, for connection to

Windows™ based PC and communication to Site Chart software

Detectors– Photoionization detector

with quick-change electrodeless discharge

– UV lamp, 10.6 eV (standard); Electron Capture Detector (optional)

Alarm Output– Internal audio - 85 decibels– Alarm LED

Operating Temperature Range– 41°F to 105°F (5°C to 40°C)

Operating Humidity– 0-100% Relative Humidity (non-condensing)

4-C. BOX Test Apparatus Setup

BOX Test Column (without aeration)

Air Supply Tank(Supplies BOX Test

Column & GC)

Sample Syringes

Fine-Bubble Air Diffuser

(Off)

Voyager Photovac On-

Line Photo-ionization GC

4-C. BOX Test Data Correlation Filtered Effluent Stripping Evaluation Data (Henry’s Law Confirmation)

BENZENE EMISSIONS IN FILTERED EFFLUENT

0

50

100

150

200

250

0 50 100 150 200 250 300 350 400 450

TIME (min)

BEN

ZEN

E IN

OFF

-GA

S EM

ISSI

ON

S (p

pmv)…

...

0

0.5

1

1.5

2

2.5

BEN

ZEN

E IN

WAT

ER

(mg/

L)

Aqueous benzene concentration

Off-Gas in Head SpaceWITHOUT BIOMASS~2 mg/L Benzene added to filtered effluentpH = 7.8Dissolved Oxygen = 10.6 mg/LTemperature = 21.0 oC

4-C. BOX Test Data Correlation Benzene Emissions With Biomass Present

BENZENE IN OFF-GAS EMISSIONS

0

20

40

60

80

100

120

140

160

180

200

0 10 20 30 40 50 60

TIME (min)

BEN

ZEN

E IN

OFF

-GA

S EM

ISSI

ON

S (p

pmv)

Off-Gas in Head SpaceWITH BIOMASS~2 mg/L Benzene added to biomassMLVSS concentration of 800 mg/LAir flow through diffuser = 1 L/min pH = 7.3Dissolved Oxygen = 7.5 mg/LTemperature = 26.0 oC

4-C. BOX Test Data Correlation Comparative Results of Benzene Stripping with and without Biomass

0

50

100

150

200

250

0 50 100 150 200 250 300 350 400 450

TIME (min)

BENZ

ENE

IN O

FF-G

AS E

MIS

SIO

NS (p

pmv)

Off-Gas in Head SpaceWITHOUT BIOMASS ~2 mg/L Benzene added to filtered effluentpH = 7.8Dissolved Oxygen = 10.6 mg/LTemperature = 21.0 oC

Off-Gas in Head SpaceWITH BIOMASS ~2 mg/L Benzene added to biomassMLVSS concentration of 800 mg/LAir flow through diffuser = 1 L/min pH = 7.3Dissolved Oxygen = 7.5 mg/LTemperature = 26.0 oC

4-C. BOX Test Data Correlation Calibration of Site-specific Biodegradation Rate from Curve Fit of BOX Test Data

4-C. BOX Test Data Correlation Rerun Calibrated Model With Site-specific Biodegradation Rate

The K1 rate (site-specific benzene biodegradation rate) was determined to be:– 29.3 L / g VSS-hr at 25.8 oC– This rate must be corrected to 20 oC for input into the model

The site-specific biodegradation rate, corrected to 20 oC, is:– 22.6 L / g VSS-hr @ 20 oC

During modeling, the Toxichem+ model will adjust this rate to the selected temperature for full-scale operating conditions.

Subsequent modeling runs evaluating potential points of gaseous injection are summarized in the following two slides:

4-C. Rerun Calibrated Model AIS Process Flow Schematic Showing Potential Benzene Injection Locations



4-C. Rerun Calibrated Model Potential Benzene Injection Locations into AIS

There are several potential injection locations for the gaseous benzene. Comprehensive modeling revealed the following anticipated benzene removal efficiencies: 1. BEST: Inject directly into existing aeration blower inlet for grids in

both Aerobic Bioreactor Zones B & C2. INTERMEDIATE: Inject into Anoxic Bioreactor (Zone A) as a

separate gas stream, using down flow mixer3. LEAST EFFECTIVE: Inject in either or both Anoxic and Aerobic

Bioreactor zones as a separate gas stream

4-C. Rerun Calibrated Model Rerun Calibrated Model With Site-specific Biodegradation Rate

Final modeling at the BEST injection location (inlet to aeration blowers) and at the temperature-corrected (20 oC) benzene biodegradation rate, has confidently predicted 99+% removal for the IGF + API off-gas, without modifications to the aeration system, i.e., aeration rate, biomass concentration, F/M, etc.

IGF & API benzene off-gases are assumed to be injected into the inlet of the aeration blowers at 3,200 scfm total air flow to bioreactor

The removals as a function of MLVSS and air flow rate (scfm) at 30 oC (annual average at MPC-Garyville) are shown in the following page.

The final modeling is presented by the blue curve at the top of the graph.

4-C. Rerun Calibrated Model Benzene Removal with Preliminarily Assumed Rates vs. Actual Site-Specific Rate (Corrected to 20 oC)

96.0

96.5

97.0

97.5

98.0

98.5

99.0

99.5

100.0

2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000

MLSS (mg/L)

Perc

ent B

enze

ne R

emov

al (%

)

Kb = 3.5 L/g-hr @ 3,200 scfm

Kb = 6.5 L/g-hr @ 3,200 scfm

Kb = 10.0 L/g-hr @ 3,200 scfm

Kb = 3.5 L/g-hr @ 2,800 scfm Minimum MLSS to achieve

3,850 mg/L 5,150 mg/L

Kb =5.0 L/g-hr @ 3,200 scfm

3,200scfm 5.0 L/g-hr

2,800 scfm 3.5 L/g-hr

Kb = 22.6 L/g-hr @ 3,200 scfm @ 30 oC

Assumed biodegradation rates, Kb, for preliminary modeling

Actual site-specific biodegradation rate, Kb, determined by BOX Testing. Benzene gases injected into aeration blower inlet.

4-D. Full-Scale Confirmation

4-D. Full-Scale ConfirmationOptions Available

Flux Chamber: Monitors off-gas emissions directly from the surface of the bioreactor using a surface floating plastic ½ sphere– Pro: Direct measurement of full-scale performance– Con: No control of parameters to insure design (maximum stress)

conditions during performance testingOR

External Core Column representing a “core sample” of the actual full-scale bioreactor, operating in parallel to the full-scale bioreactor. Column is same operating depth as full-scale bioreactor– Pro: Can control all operating parameters to examine performance

under maximum stress conditions– ENVIRON developed this method and received approval to evaluate

from both EPA and the State of Louisiana

The External Core Column method was selected with EPA/State approval

4-D. Full-Scale ConfirmationFlux Chamber

4-D. Full-Scale ConfirmationCore Column Simulation

Prepared for: Prepared by:

SCHEMATIC OF COLUMN FULL-SCALE SYSTEM

20-22249A 18-May-09

Marathon PetroleumGaryville, Louisiana

BENZENECALIBRATION

GAS

OPEN TO ATM

SAMPLELOCATION

AERATION TANK

TOTE OFWASTEWATER

MASTERFLEXPUMPS

ROTOMETER

COMPRESSOR

12" Ф PVC PIPE

SAMPLE LOCATION

VENT TO ATM

ELEV. 24 ft

VENT TO ATM

ELEV. 27 ft

ELEV. 4 ft

ELEV. 0' ELEV. 0'

M

EMPTY

Aeration TankWater Level

BIOMASS

ELEV. 24 ft

M

M

ROTOMETER

CENTRIFUGAL PUMP

BIOMASS RECYCLE LINE

AERATION + BENZENE INPUT

SAMPLE PORT

INFLUENTWASTEWATER

DRAIN

SUPPORT PIPE

(EMPTY)

GRAVITY OVERFLOWLINE BACK TO FULL-SCALE

AEROBIC ZONE

OFF-GAS VENT

SAMPLE GAS LINETO ON-LINE GC

RECYCLE BIOMASSPORT


BLOWER(AERATION +

BENZENE INPUT)

INFLUENTWASTEWATER

PUMP

RECYCLEBIOMASS

PUMP


4-D. Full-Scale ConfirmationBrief Outline of Approach

Define parametric conditions for full-scale and apply to column

Conduct full-scale tests

Determine % benzene removal

4-D. Full-Scale ConfirmationParametric Test Conditions

PARAMETER UNITS FULL-SCALE PILOT

Side Water Depth ft 24 24

Aeration Volume gal 758,400 141

Flow 1: Wastewater Flow gpm 1,100 0.20

Flow 2: Clarifier Underflow gpm 1,900 0.35

Flow 3: Internal Anoxic Recycle gpm 6,000 1.1

Flow 4: Total Hydraulic Flow through Aeration Volume gpm 9,000 1.67

Air Flow to Bioreactor scfm 3,200 0.60

Pressure psig 10 10

Pressure Drop on Orifice psig 0.68 0.53

Orifice Diameter in 3/8 7/64

Benzene Concentration in Gas to Aeration Basin ppmv 0.014 0.014

Ratio of Influent Flow to Aerobic Volume m3/m3-day 2.1 2.1

Ratio of Air Flow to Aerobic Volume m3/m3-day 45 45

Hydraulic Retention Time with Flow 1 hrs 11 11

Hydraulic Retention Time with Flows 1 & 2 hrs 4 4

Hydraulic Retention Time with Flows 1, 2 & 3 hrs 1.4 1.4

4-D. Full-Scale Confirmation Operational Conditions Comparison : Pilot vs. Full-ScalePARAMETER UNITS RUN 1 RUN 2 RUN 3 RUN 4 RUN 5 FULL-SCALE

A B A B A B (a)

Inlet Benzene Gas Concentration ppbv 21 Overheated 121 153 156 482 182 226 -

Outlet Off-Gas Benzene Concentration ppbv 0.0 - 0.0 0.0 0.0 13.3 0.0 0.0 -

Influent Aqueous Benzene µg/L 109 113 129 129 137 - 245 245 -

Effluent Aqueous Benzene µg/L < 1 < 1 < 1 < 1 < 1 - < 1 < 1 -

Inlet Raw Wastewater Flow gpm 0.21 0.21 0.21 0.21 0.21 0.21 0.35 0.35 761

Biomass Recycle from Clarifier gpm 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 2,239

Internal Anoxic Recycle gpm 0 0 0 0 1.1 1.1 1.1 1.1 6,000

F/MCOD/VSS lbs/lb-day - 0.52 0.48 0.48 0.75 - - - 0.35

MLSS mg/L 3,347 2,810 3,580 3,580 2,670 - 3,240 3,240 5,283

MLVSS mg/L 3,000 2,500 3,170 3,170 2,380 - 2,880 2,880 3,694

Influent pH s.u. - 7.1 7.0 7.0 7.4 - 7.1 7.1 6.9

Effluent pH s.u. 6.4 6.3 6.4 6.4 6.3 - 6.4 6.4 6.6

D.O. mg/L 4.5 6.2 5.4 5.4 5.5 - 4.3 4.3 5.0

Temperature °C 36.0 38.5 36.1 36.1 38.5 - 36.0 36.0 37.3

Conductivity µS 3,637 - - - - - - - 5,644

OUR mg/L/hr 6.7 9.6 9.6 9.6 10.8 9.6 16.8 16.8 8.2

Influent COD mg/L - 615 722 722 851 - - - 888

Effluent COD mg/L - 224 730 730 406 - - - -

Influent Phenol mg/L - 8 8 8 8 - 4 4 6

Effluent Phenol mg/L - 0 0 0 0 - 0 0 -

Influent NH4-N mg/L - 15 15 15 15 - 15 15 17

Effluent NH4-N mg/L - 0 0 0 0 - 0 0 0

Influent Turbidity NTU - 74 18 18 97 - 26 26 35

Effluent Turbidity NTU - 17 17 17 20 - 8 8 3

Note: (a) Average of all operational data during test period of June 22-25

4-D. Full-Scale ConfirmationBenzene Analytical Results of Full-Scale Confirmation

PARAMETER UNITS RUN 1 RUN 3 RUN 4 RUN 5

A B A B A B

Inlet Benzene Gas Concentration ppbv 21 121 153 156 482 182 226

Outlet Off-Gas Benzene Concentration ppbv < 2 < 2 < 2 < 2 13.3 < 2 < 2

Percent Benzene Removal % NA > 98.35 > 98.69 > 98.72 97.24 > 98.90 > 99.11

Influent Aqueous Benzene µg/L 109 129 129 137 137 245 245

Effluent Aqueous Benzene µg/L < 1 < 1 < 1 < 1 < 1 < 1 < 1

Percent Benzene Removal % > 99.09 > 99.22 > 99.22 > 99.27 > 99.27 > 99.59 > 99.59

Inlet Raw Wastewater Flow gpm 0.21 0.21 0.21 0.21 0.21 0.35 0.35

Biomass Recycle from Clarifier gpm 0.35 0.35 0.35 0.35 0.35 0.35 0.35

Internal Anoxic Recycle gpm 0 0 0 1.1 1.1 1.1 1.1

Note: All percent removals used the detection limit as the effluent concentration when GC indicated < detection limitRun 2 was deemed inadequate due to overheating of Voyager GC

4-D. Full-Scale ConfirmationCompliance with 40 CFR § 61.340

The information provided herein summarizes the BOX Test and Full-Scale Confirmation testing objectives and achievement of benzene removal goals under maximum stress conditions at the MAP-Garyville site.

The methodology and apparatus developed and employed by ENVIRON have been approved by the state and federal agencies.

The following information confirms compliance with 40 CFR §61.340.

4-D. Full-Scale ConfirmationCompliance with 40 CFR § 61.340

Investigative responses to 40 CFR § 61.340 are given in BLUE

Title 40: Protection of Environment: 40 CFR § 61.340 also states “other” Control Devices can be used provided that certain conditions are met.

The ADVENT Integral System (AIS) is offered as an effective Control Device to achieve BWON compliance with benzene in off-gas emissions at wastewater plants.

(iv) A control device other than those described in paragraphs (a)(2) (i) through (iii) of this section may be used provided that the following conditions are met:

4-D. Full-Scale ConfirmationCompliance with 40 CFR § 61.340 (Cont’d)

(A) The device shall recover or control the organic emissions vented to it with an efficiency of 95 weight percent or greater, or shall recover or control the benzene emissions vented to it with an efficiency of 98 weight percent or greater:

Direct injection of the off-gases into the inlet to the aeration blowers, which discharged into the longitudinal sections of the aerobic zone, demonstrated >98% biodegradation of benzene on the full-scale confirmation evaluation. The test was conducted at up to 15 timesthe anticipated benzene gaseous loading to the bioreactor. The COD loading to the system was twice the normal and expected organic loading. These conditions insured very conservative performance of the biosystem.


(B) The owner or operator shall develop test data and design information that documents the control will achieve an emission control efficiency of either 95 percent or greater for organic compounds or 98 percent or greater for benzene.

Using a BOX Test apparatus, developed by ENVIRON, site-specific benzene biodegradation rates were developed (22.6 L benzene biodegraded / gm VSS-hr) and applied to Toxichem+ modeling techniques to project >99.7% benzene biodegradation under maximum site operating conditions.

Using a full-scale BWON Column, designed and proposed by ENVIRON, it was confirmed that >99+% benzene in injected gases can be successfully biodegraded up to at least 15 times anticipated benzene gas loadings.


(C) The owner or operator shall identify:1) The critical operating parameters that affect the emission control

performance of the device:2) The range of values of these operating parameters that ensure the

emission control efficiency specified in paragraph (a)(2)(iv)(A) of this is maintained during operation of the device:

Critical operating parameters:

MLVSS >3,000,

F/MCOD <0.50,

temperature >18 oC,

Aeration air flow to aerobic zone <3,200 scfm


3) How these operating parameter will be monitored to ensure the proper operation and maintenance of the device.

– The operating parameters and percentage benzene removal will be monitored quarterly by implementing the BWON Column and monitoring benzene gaseous inlet to and outlet from the column to confirm removal efficiency.

– Maintenance procedures will comprise insuring that all piping of the benzene-containing gases to the aeration blowers is tight and not leaking.

Section 5Conclusions

Conclusions

The AIS qualifies as an Enhanced Biodegradation UnitAll EPA-approved BOX Test requirements were met and the developed site-specific bio-rate is representative of the full-scale system– The site-specific benzene biodegradation rate is 29.3 L / g VSS-hr @

26 oC (22.6 L/gm-hr, corrected to 20 oC)

The AIS provides excellent configuration and flexibility to achieve benzene removals >99+% even under benzene loadings >15 times projected operating maximum conditionsThe AIS is an appropriate cost-effective Control Device for benzene VOC emissions from WWTP sources, e.g., API, IGF/DAF, sludge storage tanks, etc.The AIS is an environmental-friendly Control Device– Negligible additional energy usage– Minimal carbon footprint

Innovative Cost-Effective Control Device For Wastewater … · Annual AWMA Fall Conference - Louisiana Section, Crowne Plaza Hotel, Baton Rouge. October 27-28, 2009. Innovative Cost-Effective

Documents