Contact Water Filtration Severn Trent

Contact Water Filtration
Presented to:
Steel Making Water Conference

CLEARWATER, FLORIDA
Prepared by:
Mr. Charles J. Guzelli

Industrial Sales Manager
13 September 2012
ChemTreats Steel Industry Water Conference 9-12 to 9-14-2012 , Clearwater Beach FL * Confidential * Do Not Duplicate without Permission
CHARLES J. GUZELLI Industrial Sales Manager

Career - With Dravo / Tetra / Severn Trent - 30 years
Dravo Corporation - Machine Shop Production Manager Blaw Knox Mill Machinery - Class A Estimator Wean United Engineering - Chief Estimator Dravo Corporation - Proposal Engineer Tetra Technologies - STS
1988 to 1993 - Chief Estimator 1993 to 1994 - Field Service Manager 1994 to 1997 - Senior Project Manager 1995 - Construction Manager g 1997 to 1999 - Proposal Manager 1999 to - Industrial Sales Manager
Education - RMC / Business: PITT / Mechanical Engr

METHODS OF TREATMENT
Various treatment processes in US Steel market - Once pass through systems with no treatment
- Sedimentation Basins and Dragout Conveyors - Mixed bed and multi-media Filtration Systems - Horizontal Clarifiers and Settling Basins - Ponds and Lagoons - 1959 DRAVO introduces Mono-media Filter to USA - 1962 DRAVO begins to install Filters in Refineries - 1965 DRAVO begins to install Filters in Steel Mills - 1968 Clean Cl AIR act t passed d by b US G Government t - 1972 Clean WATER act passed by US Government - Continuous Backwash Filters and EMF Filters - Future ?????
FILTRATION BENEFITS
Filters help Steel Producers achieve:
Higher Steel Production through more usable water - Improving Mill Efficiency through even cooling - Improving Impro ing Prod Product ct Q Quality alit - Reducing Maintenance
MORE WATER = MORE STEEL

- No strainer - spray nozzle plugging at Casting Machine - Fewer Roll turn downs at the Rolling Mill - Fewer Roll change outs at Mill Stands
These are all indirect benefits of having clean water return to the process
FILTRATION BENEFITS
Selection of Filters should achieve following:
- Full time operators should not be required - Low or no maintenance required q - Robust bulletproof reliability - Low energy consumption use - Low / no chemical usage - Low Backwash water - Filter Longevity
YOU MAKE STEEL - FILTERS MAKE WATER

These are the direct benefits of selecting a Filter System for an application
Steel Mill Recycle / Reuse Contact Water

DIRECT FROM SCALE PIT - No settling
Rolling Mill Contact Water
Reheat furnace
Mill Scale, Solids and O&G removal Scale S l Pit Gravity G it Filter Filt or Pressure Filter System
Dirty Backwash to De-watering
Cooling Tower
Hot Rolling Mill for shaping final Products
D Descale l Laminar
VOD - Degas Filtered Water Returns to Mill
Caster Spray Water Return

Casting Machine
LMF 90 ton l dl ladle
Mill Scale Scale, Solids and O&G removal Gravity Filter or Pressure Press re Filter System
Dirty Backwash to De-watering
Makes scrap into steel forms
Scale Pit
Filtered Water Returns to Caster

Cooling Tower
NO WATER from Filter System is discharged to the Environment

DISCUSSION OVERVIEW
Mill Water Contact Systems
FILTRATION Design Basics Applications INTERNALS Underdrain System Media BACKWASHING MAINTENANCE
DESIGN BASICS
Flow Rate - Average and Max
1. Determines # of Filters Required - Hydraulics is sized on gpm / sq ft - Based on Size of Particles 2. Pounds of Solids (type and size) Removed - Calculated on loadings g - surface area
Water Characteristics
1 TSS (Total Suspended Solids) - Average & Max 1. - Mill Scale - Particle Size Distribution 2. O&G (Oil and Grease) - Average & Max - Open or closed lube system - synthetic?
DESIGN BASICS
What is upstream of Filter System?
1. Scale Pit - Design D i and dT Type of f Pit Pit; Pit R Retention t ti Ti Time - Pit Maintenance; frequency and how is it cleaned 2. Oil and Grease Removal Systems - Skimmers, Ropes, Mops, Beaches
Where does effluent & dirty y backwash g go?

1. Effluent - Returns to Mill for Reuse - discharged to surface 2. Dirty Backwash Water - Return to Scale Pit - De-watering Circuit - mudwell - thickener - filter press
APPLICATIONS
Casting Machines
1 Water that is pumped from scale pit through a 1. filter system and returned to spray nozzles
Contact Water
1. Water used to cool in steel in Rolling Process Can be on HM - Laminar, Descale, Degas
River Ri and d Well W ll Water W Make M k up Systems S Cooling Tower Side-stream Systems Non Contact - Not Suitable for Sand Filters
1. Machine Water and Mold Water 2 Process Water 2.
10
FILTRATION BASICS
TWO ( (2) ) OPERATING PHASES
1. Filtration - Removing Particles from a Water Source 2. Backwashing - Removing Captured Particles from Filter Media
TWO (2) TYPES of f FILTER OPERATION

1. Continuous -Traveling Traveling Bridge Bridge, Continuous Backwash Filters 2. Semi-Continuous y and Pressure Filter Systems y - Most Gravity
11
FILTRATION .. is a Physical Process

Captured Solids
Wastewater with Suspended Solids and Oils / Grease
Clear Filtrate
Filter Medium ( IN THIS CASE SAND) - but can be any medium that captures solids to release
12
FILTRATION SPECTRUM
13
DESIGN BASICS
Industrial Filters
Filter Bed Solids Loading g
Pressure Filters Range Between 4 and 8 lbs./ft2 Gravity Filters Range Between 1 and 4 lbs./ft2 Filter Bed Solids Loading Varies Based on: Type of Solid Being Filtered Size of Solid Being Filtered Available Head
When Does Backwash Occur

When Maximum Headloss is Reached Pressure System Designed for 15 psi P Effluent Quality Deteriorates
Backwash B k hF Frequency Calculated C l l t d Based B d on Loading L di

Need to Know TSS & Flow
14
DESIGN BASICS
HOW THE PROCESS WORKS
Forward Flow
Down-flow or Up-flow Filtration Filtration Filt ti R Rate t i in gpm/ft /ft2
Flow Control (Constant Rate vs. Variable Declining Rate)

Constant Rate Weir Levels (Gravity Filters) Influent / Effluent Flow Control (Gravity or Pressure)
Variable Declining Rate

Headloss in Each Filter Determines Flow Better Effluent Quality Less L W Working ki H Head d and dO Operating ti P Power R Required i d Longer Filter Runs
15
CONSTANT verses VDR

Constant
Requires Individual Flow on each filter Requires Individual dP on each filter Additional Instruments to calibrate Additional Instrument Wiring Additional I/O required
Variable Declining Rate

System S dP across i influent fl and d effluent ffl h header d No individual Flow measurement required Less instruments = less maintenance Longer run time between Backwash
16
Media Depth Definitions and Filt ti Parameters Filtration P t

HOW THE PROCESS WORKS
Media Depth and Solids Capture
Shallow Bed Filtration Media Depth: 24 - 36 inches DeepBed Filtration Media Depth: 48 - 72 inches
Media Size and Solids Capture
Too Large Media Finer Fi P Particles ti l P Pass Th Through hB Bed d Too Small Media Driving force must overcome media too much Hi h H High Head-loss dl can occur R Regularly l l *Capture Rate is defined by Hydraulics and size of particle
17
BACKWASHING METHODS
Backwash Method
High BW Rates Water Only
Backwash Water Rate (gpm/ft2)

12 - 25
Backwash Air Rate (cfm/ft2)
Comments
High Rates for Fluidization 25 - 50% Bed Expansion Commonly Used with Fine Media and Mixed Beds
High BW Rates Air Scour Only Water Only Low BW Rates L R t Air/Water Scour is concurrently run
12 - 25
25
High Rates for Fluidization 25 - 50% Bed Expansion Commonly Used with Fine Media and Mixed Beds No Fluidization N Fl idi ti < 5% Bed Expansion Can only be used with Coarse Mono-Media Beds
4-6
3-6
Uses Less Backwash Water Than Other Designs

18
PUMPED verses STANDPIPE

Pumped p Backwash
Requires Additional Set of Pumps Backwash Water Flow Control Loop Additional Manual and Check Valves Additional Power and Instrument Wiring May Require Holding Tank for Backwash Water
Stand-Pipe Backwash
Backwash Water Taken Directly from Effluent Pipe No Pumps Required - Uses Height of Stand-Pipe for Backpressure Valve Design g Allows Correct Amount of Backwash Water into Filter
19
BACHWASHING FLOW SHEET

Dirty BW Water Influent P 1 Wastewater From Mill Scale Pit DeepBed Gravity or Pressure Filter Effluent
Filtration Circuit w BW Pumps

Clean Backwash Tank P 2
Cooling Tower
Filtered Water To Mill
Clean BW Water
P 3
Dirty BW Water Influent P 1 Wastewater From Mill Scale Pit To Mill
DeepBed Pressure Filter
Filtration Circuit with Standpipe

Effluent
Cooling Tower
Filtered Water
NOTE: Clean BW Water Each Mill might have a preference on Pumped verses standpipe backwash design. Many circuits draw clean water by placing a ChemTreats Steel Industry Water Conference 9-12 to 9-14-2012 , Clearwater Beach FL BW pump in the Cooling Tower cold-well.
* Confidential * Do Not Duplicate without Permission
20
Underdrain System
Nozzle-Bottom Filter
N Nozzles/Strainers l /S i
FLOOR NOZZLES FALSE-BOTTOM
21
Underdrain System y
Typical Nozzles/Strainers Used in False-Bottom Underdrains
22
Underdrain System y
N Nozzle l Type T Filter Fil
Dead Space
23
Underdrain System
N Nozzle-Bottom l B tt Filt Filter
Coal
Nozzles
Sand
Gravel Air scour pipe
Air Distribution Holes
Concrete Piers
24
TETRA U Underdrain de d a Construction Co st uct o

Effluent Sump
25
TETRA Underdrain Construction

Sump Cover Plates
26
Underdrain System y
Backwash Air System BW Air Injection Location
Under Main Floor Directly Above Main Floor In Between Gravel and Media Inject Air and Water to Same Area and Use Floor Orifices to Distribute Both Backwash Air has its own Separate Piping
System for Distribution Across the Filter Area Before f C Combining with Backwash Water
Distribution Process
27
TETRA Underdrain Construction Air Laterals
28
BW WATER AND AIR DISTRIBUTION SYSTEM

304 SS Box Header Wall W ll Thi Thickness k i is 3/16 Air Laterals - Schedule 40 304 SS and Other Alloys Air Laterals Protected from Gravel and Media Located Under T Block Arch
29
Underdrain System
Underdrain Distribution Block
None Clay Tile Block Plastic Nozzles Wedge-wire Screens Metal Fabricated Underdrain Snap-T; T-Block and M Block
30
TETRA Underdrain Construction Concrete M Blocks
31
TETRA U Underdrain de d a Construction Co st uct o

Concrete M Blocks
32
TETRA Underdrain Construction

Plastic T and Snap-T Blocks Purpose
1. 2 2. 3. 4. 5. Support structure for gravel & media P Prevents t gravel l from f penetrating t ti underdrain d d i Minimizes damage to filter internals from hydraulic shock Allows filtered water to pass through to the effluent Starts backwash air & water distribution across filter area
33
TETRA DeepBed Filter Operation
34
GRAVEL - Tetra Configuration

Layer No. 1 No. 2 No. 3 No. 4 No. 5 Depth (inches) 4 2 4 4 4 Size (inches) 1-1/2 x 3/4 3/4 x 1/2 1/2 x 1/4 1/4 x 1/8 1/2 x 1/4
Rule of Thumb: Each Upper Layer is ~50% of the Size Below it it.
35
Filt Media Filter M di Configurations C fi ti

Configuration
Dual Media Multi-Media
Media Type
Anthracite (Top) Sand (Bottom) Anthracite (Top) Sand Garnet (Bottom) Sand or Anthracite Sand TETRA #7 or #8 Sand TETRA #5
Media Size (mm)

1 - 1.5 0.5 - 1 1 - 1.5 0.5 - 1 0.4 - 0.6 0 5 - 2.0 0.5 20
Normal Depth (inches)

12 - 24 12 - 24 12 - 24 12 - 24 3-6 36 - 72 48 - 72 48 - 72
Mono-Media Mono Media
36
TETRA TAMPA TESTING LAB AND WAREHOUSE
37
MEDIA CHARACTERISTICS
SHAPE
Sphericity of > 0.8 (Perfect Sphere is 1.0) Advantage: Rounded R d d grains i t tend d to t rotate t t during d i BW Uniform void spaces - Tetra Media has a 40% void space which leads to greater capture and bed penetration Non-Round Media Sharp p angular g g grains interlock and increase headloss for filtration and BW. Angular grains stick together on large flat surfaces preventing total bed cleaning
38
MEDIA CHARACTERISTICS
HARDNESS
MOH Scale S l (1 is i t talc l and d 10 is i di diamond) d) Sand (Quartz = 7 or Silica = 8) A th it 3.5 Anthracite 35
Hard media minimizes attrition (wearing of media) during backwashing Attrition leads to reduced media size (smaller Effective Size), , higher g head losses and shorter filter runs therefore, Tetra Municipal filters longevity is 20 to 35 years before filter needs rebuilt and media needs replaced Tetra Industrial filters have operated 5 to 30 years before filter needs rebuilt and media needs replaced
39
TETRA DeepBed Filter Silica Media

MEDIA SPECIFICATION
Effective Size 1.7 to 3.0
High Uniformity Coefficient <1.40 High Sphericity >0.80 6 to 7 on MOH Scale Acid Solubility < 5%
Is coarse mono-media that allows greater solids capture and deeper bed penetration Leading to longer run times Carefully screened, washed and dried to the mill specific application and product mix
40
BACKWASHING
Typical Mono-Media BW Sequence
Take a e filter te o off line e Scour Media with aironly y Scrub media with air and water Rinse Put filter back on line
2 minutes 15 - 20 minutes 5 minutes

41
BACKWASH MODE
DeepBed Gravity Filters Air/Water Scour
42
BACKWASHING
Dirty Backwash Water
What To Do With Dirty Backwash Water
Transferred Directly to Upstream Scale Pit Must Have Ample Retention in Pit to Allow for Increased Flow to Not Stir Up Settled Solids Must Keep Pit Cleaned of Solids to Allow Room for Solids Settling Transferred to Collection Tank for Transfer to
Solids Handling System

Mudwell, Thickener, Dewatering Equipment
43
SAND FILTRATION
CHEMICAL ADDITION
Influent Filter Aid
May be Required to Remove Colloidal Particles Add Chemical Coagulants to Produce Pinflocs Inorganic Coagulants are Not Recommended Must be Careful Not to Overdose
Dirty Backwash Water for Improving Solids Settling

May be Especially Important if Dirty BW Flows to Scale Pit Upstream of Filter System
44
FILTER OPERATION - Data Collection

HOW WELL IS THE SYSTEM OPERATING?
It Is Important to Monitor the Water Quality of the System Collect Influent and Effluent Samples Periodically Measure TSS and O&G TSS versus Turbidity C ll t samples Collect l and d measure both b th TSS and d Turbidity. T bidit Once a correlation is found, the turbidity can be used to monitor the operation. Periodically, collect Dirty BW Water Samples at Beginning and End of BW and measure TSS to check the efficiency of BW. BW
45
FILTER OPERATIONS
WHY DOES THE EFFLUENT QUALITY DETERORATE?
1 Overloading Filters 1. Check Influent TSS and Flow - Have They Increased? Is Scale Pit Being Cleaned on a Timely Basis? Check Backwash Frequency 2. Solids Are Colloidal (1-5 micron) in Nature Check All Waters Entering the System Have There Been Any Changes? Make-up Water? Has Product Mix Changed? Are Colloids Due to Oils? 3. System Failures Hydraulic Fluid Release from Mill Occurred Backwash System or Valve Failure Media Fouled
46
FILTER OPERATION
Maintenance Check C
1. Check Media for Loss by Measuring from Top of Media to a Common Reference Point 2. Check Media for Abnormal Appearance 3. Check for Proper BW Air pattern 4 Check for Proper BW Water Rise Rate 4. Normal Design - 9.6 inches/minute
47
FILTER OPERATION
Equipment Maintenance
Control valves
Check for Smooth Operation Keep Limits Adjusted Properly Ensure Clean Air Supply Check Grease & Oil Monthly Change Oil Every 6 Months ** Grease Motor Bearings Once Per Year Change Air Filter Every 6 Months ** Check Belt Tension & Sheave Alignment Every 6 Months
Backwash Air Blowers
48
Contact Water Filtration Q Questions? ti ?
49

Contact Water Filtration Severn Trent

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Contact Water Filtration

Steel Making Water Conference

Mr. Charles J. Guzelli

CHARLES J. GUZELLI Industrial Sales Manager

Education - RMC / Business: PITT / Mechanical Engr

MORE WATER = MORE STEEL

YOU MAKE STEEL - FILTERS MAKE WATER

Steel Mill Recycle / Reuse Contact Water

Hot Rolling Mill for shaping final Products

VOD - Degas Filtered Water Returns to Mill

Caster Spray Water Return

Makes scrap into steel forms

Filtered Water Returns to Caster

NO WATER from Filter System is discharged to the Environment

Where does effluent & dirty y backwash g go?

TWO (2) TYPES of f FILTER OPERATION

FILTRATION .. is a Physical Process

Wastewater with Suspended Solids and Oils / Grease

When Does Backwash Occur

Backwash B k hF Frequency Calculated C l l t d Based B d on Loading L di

Flow Control (Constant Rate vs. Variable Declining Rate)

Variable Declining Rate

CONSTANT verses VDR

Variable Declining Rate

Media Depth Definitions and Filt ti Parameters Filtration P t

Media Size and Solids Capture

Backwash Water Rate (gpm/ft2)

Backwash Air Rate (cfm/ft2)

Uses Less Backwash Water Than Other Designs

PUMPED verses STANDPIPE

BACHWASHING FLOW SHEET

Filtration Circuit w BW Pumps

Filtered Water To Mill

Dirty BW Water Influent P 1 Wastewater From Mill Scale Pit To Mill

DeepBed Pressure Filter

Filtration Circuit with Standpipe

Typical Nozzles/Strainers Used in False-Bottom Underdrains

N Nozzle l Type T Filter Fil

Gravel Air scour pipe

Air Distribution Holes

TETRA U Underdrain de d a Construction Co st uct o

TETRA Underdrain Construction

TETRA Underdrain Construction Air Laterals

BW WATER AND AIR DISTRIBUTION SYSTEM

TETRA Underdrain Construction Concrete M Blocks

TETRA U Underdrain de d a Construction Co st uct o

TETRA Underdrain Construction

TETRA DeepBed Filter Operation

GRAVEL - Tetra Configuration

Filt Media Filter M di Configurations C fi ti

Media Size (mm)

Normal Depth (inches)

Mono-Media Mono Media

TETRA TAMPA TESTING LAB AND WAREHOUSE

TETRA DeepBed Filter Silica Media

2 minutes 15 - 20 minutes 5 minutes

Solids Handling System

Dirty Backwash Water for Improving Solids Settling

FILTER OPERATION - Data Collection

Backwash Air Blowers

Contact Water Filtration Q Questions? ti ?

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