MARINETTE, WI
Inclined Plate Settler Clarification Regional Developments
Spring Regional Meetings April 17 - Ann Arbor & April 18 - Kalamazoo April 24 - Mt. Pleasant & April 25 - Gaylord
Thomas P. Grubb Meurer Research 6270 Joyce Drive Golden, CO 80403
Plate Settler System Components EFFLUENT TROUGHS SLUDGE COLLECTOR DRIVE
LEVELING WEIR
STAINLESS STEEL SUPPORT BEAM
FLOW CONTROL DECKS
HISTORY OF PLATE SETTLERS
1886 - English Patent 1904 - Hazen’s Theory of Sedimentation
1936 - Plate Settlers Used in Mining Industry 1946 - Camp’s Shallow Depth Sedimentation Theory 1993 - MRI Top Tube Plate Settler Design
Theory behind High Rate Clarification Multi-Sectional Settling Tanks developed to minimize short circuiting and maximize flow distribution
Camp’s Shallow Depth Sedimentation Theory
Tube Settlers Flow Distribution
3 ft Tubes: Louisville, CO Square btm trough, submerged orifices
3 ft Tube Settlers: Bloomington, IN Inlet baffle directing flow under tubes Circular thickener sludge collection
2 ft Tubes: Ft. Thomas WTP, KY V-notch troughs 3’ above tubes
MIXERS / FLOCCULATORS
Flocculation
Proper floc formation is key to settling • Vertical impeller mixers: rapid or flash mix for pH adjustment, oxidant and coagulant addition using high particle collisions
• Paddle wheels: medium mixing energy for floc formation, maturation/growth and contaminant adsorption
• Hydraulic mixing: reduce hydraulic energy & distribute flow across basin width
Vertical turbine mixers Paddle wheel mixers
Flocculation
Tapered Flocculation for Optimum Contaminant Removal Flash Mix
Stage One
Stage Two
Stage Three
Stage Four: Hydraulic Mixer
Vertical Turbine Flocculators
Horizontal Paddle Wheel Flocculators
Inlet Diffuser
Flocculation
Progressively Lower G-Values form a settlable floc 1000’s 100’s 80 Rapid Mix
Vertical Turbine
Paddle Wheel
Hydraulic
60
40
20
10
0
Flocculation
Configuration - Flow Control to Minimize Short Circuiting •Over Under Baffling
•Serpentine Flow
•Ported Baffle Walls
•Full Width Distribution
WYOMING, MI INLET DIFUSERS REDIRECT FLOW ACROSS BASIN WIDTH and REDUCE FLOC SHEAR
PLATE SETTLERS
Advantages of Plate Settlers T-304 stainless steel lasts indefinitely No power is required
No pumps, valves or blowers No moving parts Very low maintenance Small Footprint Clarification Process
Advantages of Plate Settlers 12MGD Footprint Comparison
Conventional Sedimentation 0.5 gpm/ft2 SOR 80’ x 208’
Plate Settler 0.3 gpm/ft2 40’ x 50’ Lower cost of land, construction & building. Less space to maintain & smaller building size.
HOW PLATE SETTLERS WORK
How Plate Settlers Work Falling particle sees the “projected area” of each Plate
Flow Distribution Stable Laminar Flow Low Reynolds # & High Froudes #
Projected plate area overlap
Results – plate settler basin is 1/10th that of conventional basin
How Plate Settlers Work The settling distance is reduced by 98%, 3.5” compared to 15’ in a conventional basin Particles migrate to the plate surface along the resultant vector of the two forces – fluid drag (Fd) and gravity (Fg)
3.5"
Fg
Plate settlers provide a “perfect environment” low velocities and no currents (Laminar flow)
10’ plate length / 0.022 fps (¼”/sec) = 7.57 minutes residence time in plate Particle must fall 3.5” vertically in 7.57 minutes = 0.46 in/min plate settling rate 15’ deep basin with 2 hr HRT, 180”/120 minutes = 1.5”/min conventional sedimentation basin settling rate 0.5”/min in plate basin compared to 1.5”/min for the conventional basin
How Plate Settlers Work EFFLUENT COLLECTION ORIFICES
TOP TUBE
SETTLING ZONE
INLET PORTS SLUDGE ZONE, 10%
How Plate Settlers Work Flow Path Through Plate Settlers 1. Flow enters basin high up & travels through inlet channel
3. Top tube contains orifices which distribute flow evenly across the plate
2. Flow enters plate settlers through inlet ports and moves up the plate
Feed Channels
Plate Cartridge
Flow Control Decks
Cable-Vac Sludge Collection Stainless Steel Support Beam
How Plate Settlers Work The Search for Perfect Flow Distribution The “Pinch Zone”, a Full-Width Plate Orifice
0.1000
Orifice width @ 4.5’L & 0.3 gpm/sf
0.0900 0.0800
+1/32" = 1" HL 0.0700 0.0600
-1/32" = 3" HL 0.0500 0.0400 0.0300 0.0200
4.5' W Plate Space = 0.0340" to Achieve 2.0" Design Head Loss
0.0100
Plate Spacing Orifice
0.0000 0.25
0.5
1
1.5
2
2.5
HEADLOSS (Inches)
3
3.5
4
4.5
How Plate Settlers Work Orifices Insure Even Distribution Across Entire Plate & Basin
PLATE SETTLER CALCULATIONS
Plate Settler Calculations Sizing Calculation Example Calculation for 10 MGD (6,944 GPM): Choose the specific loading rate. For example a standard loading rate is 0.3 gpm/ft2 of effective plate area at 90% efficiency. Divide the projected area by the efficiency to get effective projected settling area
Divide the effective projected settling area by the area of each plate to get # of plates
• •
Divide the flow in gpm by the loading rate Flow = 6,944, Loading Rate = 0.3 gpm/ft²
6,944 gpm/0.3 gpm/ft² =23,147 ft² projected area
•
• • •
Efficiency = 90%, Projected Area = 23,147 ft² 23,147/0.9 = 25,719 ft² effective projected area
4.5’W x 10’L plate @ 55o(cos55) x 0.9 = 23.23 ft² Effective Projected Area Required = 23,147 ft² 25,719 / 23.23 = 1,107 plates
FABRICATION & INSTALLATION
PLATE SETTLER FABRICATION
Manufacture frames and supports
PLATE SETTLER FABRICATION
Inclined Plates installed into frames @ 550
PLATE SETTLER INSTALLATION
Load onto flatbed trucks for shipping
PLATE SETTLER INSTALLATION
Install Beams & Crane Plate Cartridges into Position
PLATE SETTLER INSTALLATION
Plate Cartridges are Secured to the Beams
PLATE SETTLER INSTALLATION
Troughs are Lowered into Position
PLATE SETTLER INSTALLATION
Weirs are Leveled and Installation is Complete
PLATE CLARIFICATION SYSTEM Rapid Mix, Flocculation, Hydraulic Baffling, Plate Clarification and Sludge Removal
Frederick MD
INCLINED PLATE SETTLER INSTALLATIONS BENTON HARBOR, MI MUSKEGON, MI SOUTH HAVEN, MI WYOMING, MI MARINETTE, WI
BENTON HARBOR, MI
BENTON HARBOR, MI 2010 2 Basins 12 MGD 40’L x 30’W x 15’D 0.3 gpm/sf @90%
BENTON HARBOR, MI 15’L x 30’W x 15’WD 40 min@ 6 MGD 1st : 3 HP 2nd: 2 HP 3rd : 1 HP
Horizontal Reels Ported Floc Baffle
BENTON HARBOR, MI G-Values, sec-1 1st : 70 2nd : 45 3rd : 20 4th : Hydraulic
Inlet Flow Diffusers
BENTON HARBOR, MI 4 Rows, 6 MGD
150 Plates/Row 600 Plates/Basin 5 Orifice/plate
MUSKEGON, MI Two (2) Basins
86’L x 50’W x 17.3’D 20 MGD/Basin Design 6 MGD/Basin Average 0.24 gpm/sf Loading 2-50 NTU Raw Water
MUSKEGON, MI 2006 393 Plates/Row 2,358 Plates/Basin 9.55’L x 4.5’W Plates 6 Orifice/plate
MUSKEGON, MI 3 Troughs/Basin 45’L x 24”W x 28” D 4,650 gpm Capacity each
MUSKEGON, MI
MUSKEGON, MI
MUSKEGON, MI
MUSKEGON, MI
SOUTH HAVEN, MI 2009 2 Basins 29’L x 28’W 7 MGD, 9.7MGD Peak 0.3 gpm/sf @ 100%
SOUTH HAVEN, MI G-Values, sec-1 1st : 60 2nd : 40 3rd : 30 4th : 15
3rd Stage
1st Stage
13.5’ L x 13.5’W 14.5’ WD 32 min@ 3.5 MGD 1st & 2nd: 2 HP 3rd & 4th: 1 HP
4th Stage
SOUTH HAVEN, MI 78 Plates/Cartridge
4 Cartridges/Basin 312 Plates, 4.5’ x 10’
SOUTH HAVEN, MI 2 Troughs/Basin 18”W x 18”D 2,000 gpm/trough 6 Orifice/plate
SOUTH HAVEN, MI Hoseless Cable-Vac™ Sludge Collector ¼ HP Reel-to-Reel Cable Drive
WYOMING, MI
Serpentine Flow Horizontal Reel Flocculators
WYOMING, MI 2010
3 Basins 86’L x 64’W x 16’D 30 MGD/Basin 0.30 gpm/sf @ 80%
WYOMING, MI
2009 - 2010 8 Rows of 4 Cartridges/Row 98 Plates/Cartridge = 3,136 Plates/Basin
8 Troughs/Basin, 22”W x 19”D x 85’L each 2,600 gpm capacity/trough
WYOMING, MI
MARINETTE, WI 2010
2 Basins 37’L x 22’W x 16’D 3.25 MGD/Basin Expandable to 4.1 MGD 0.30 gpm/sf 8-100 NTU Raw Water
MARINETTE, WI 1st Stage
2nd Stage
3rd Stage
70 sec-1 G, 1.5 HP
45 sec-1 G, 0.75 HP
20 sec-1 G, 0.5 HP
29 min. HRT @ 3.25 MGD
Coagulant: Sumalchlor 50 or AquaHawk 607, Chlorine @ 0.5 ppm average, 3-6 max
MARINETTE, WI Sludge Collector Cable Drive Future Plate Capacity
MARINETTE, WI Plate Support Beam
Hoseless Cable Driven Sludge Collector
Miramar WTP, San Diego, CA Four 55 MGD Basins 220 MGD
Largest Stainless Steel Inclined Plate Settler Installation in USA
Inclined Plate Settler Clarification Regional Developments
THANK YOU QUESTIONS?
Thomas P. Grubb Meurer Research 6270 Joyce Drive Golden, CO 80403
