Reliable Aeration Systems :4/22/2008 1 Reliable Aeration Systems Presented by:
Tom Frankel
Slide 2 :4/22/2008 2 STAMFORD SCIENTIFIC INTERNATIONAL, INC (SSI)
4 Tucker Drive
Poughkeepsie, NY 12602
U.S.A * SSI IS DEDICATED TO THE RAPID ADVANCEMENT
OF DIFFUSER TECHNOLOGY Stamford Scientific Intl. maintains production and supports facilities in various locations including U.S.A ( New York- Headquarters, Manufacturing, Engineering and Customer Service), Europe (Holland-Warehouse and Germany-Manufacturing), Asia ( Korea- Manufacturing and Engineering, China-Manufacturing & India- Engineering)
Slide 3 :EXPERIENCE:
BNR
SBR
MBR
UASB
CONVENTIONAL
EXTENDED AERATION
FIXED FILM TECHNOLOGY SKILL SET:
ACAD2007 2D + 3D
BIOWIN SIMULATION
INVENTOR 3D
MATHCAD 13
FLASH ANIMATION
PROPRIETARY SOFTWARE
JOBSITE EXPERIENCE
Slide 4 :REFERENCES:
TURNKEY SUPPLY
BLOWER ROOM DESIGN
PIPING LAYOUTS
MULTISTAGE BLOWERS
ROOTS TYPE BLOWERS CALCULATIONS:
SOTEHEADLOSS
BUYOANCY LOADINGBUBBLE ASCENT VELOCITY
HEAT TRANSFER
DO PROFILE ANALYSIS
MINIMUM MIXING
LIFE CYCLE COST
Slide 5 :4/22/2008 5 INSTALLATIONS INCLUDE:
Large Municipal Installations @ Bangkok BMA3 and BMA4, Makkah 1 South, Jeddah Airport, Kwangju Korea, Monterrey, Mexico, Baranquilla, Colombia, Al-Ansab WWTP, Muscat, Oman.
Pulp and paper: Kimberly Clark™, SCA Tissue™,
International Paper, Velio, Weyerhauser, Tembec
Textile: Several tanneries around the world
Food: Coca-Cola™, Pepsi-Cola™, Nestle™,Kraft™, Entenmanns, Sara Lee Dairy: Danon™, Yoplait, Agropur™, Schreiber, Fage
Petrochemical: Sunoco™,
Conoco Philips Petroleum™, Repsol, Exxon
OEM – Kubota, Aqua Aerobics, GE Zenon,
Parkson, ADI, EarthTech
Slide 6 :4/22/2008 6 What sets SSI apart?:
Proven Performance
Experienced Staff & Agents
PTFE & fEPDM membranes
QC saddles for disc and tube
Industry #1 Research & Development Program
Compression molded tube membranes
Low Headloss/High SOTE products
Proven solutions to difficult problems
Wide product range
Significant local inventory – USA, Korea, Rotterdam and Dubai
Slide 7 :4/22/2008 7 INNOVATIONS: SSI’s new Ultra Fine Bubble disc diffuser is a new
Breed of diffuser. Thin EPDM base material, fabric molded
Into center, and special surface coating together with
Needle perforation result in 0.2 to 0.5mm bubble sizes
Evenly dispersed across the surface of the diffuser.
Initial off-gas test results are 15% higher than standard
Membranes.
( Smaller bubbles result in more bubble surface area per unit
volume and greater OTE)
Slide 8 :4/22/2008 8 PTFE MEMBRANES – Failure Mode? Not Yet We observe that a biofilm layer does form on PTFE
Membranes, though it takes a long time to form, and when it
Does, even in aggressive environments, it can be removed
With a fingertip. The scale does not affect performance and
Does not enter the slits. See below…
Slide 9 :4/22/2008 9 Why PTFE??? – Don’t let this happen to you!
Slide 10 :4/22/2008 10 PTFE FINE BUBBLE DIFFUSER MEMBRANES SSI’s PTFE ( Polytetrafluoroetyhylene) layered EPDM disc
and tube diffuser membranes combine the reliability of EPDM with outstanding anti fouling resistance of PTFE.
Benefits of PTFE layer are:
Resistance to fouling and calcium scaling
Extended life
Reduces cleaning 6-10 times compared to EPDM
Outstanding chemical resistance
Outstanding resistance to fats, oils and greases
Outstanding resistance to hydrocarbons, fuels,
and solvents
“PTFE IS THE BEST THING TO HAPPEN TO
FINE BUBBLE AERATION SYSTEMS”
Dave Redmon, Eng.
Slide 11 :4/22/2008 11 NEW fEPDM & WEBBED SILICONE – PROMISING NEW TECHNOLOGIES SSI’s over-active R & D team has developed two new technolgies to solve age-old industry problems. Together with the ultra fine bubble EPDM membrane, both of these new technologies are under test, but show particularly in the case of fEPDM have shown very promising results.
Slide 12 :4/22/2008 12 SSI COMPRESSION MOLDS MOST MEMBRANES SSI’s EPDM compound is specially formulated for wastewater
applications providing:
Even specific gravity, thickness, and tear resistance
Greater resistance to elongation and tearing
(multidirectional tear resistance)
Resistant to material property changes.
High modulus for elasticity.
Proper taper to reduce unit stress.
High oxygen transfer efficiency.
Extended service life
:4/22/2008 13 Same slit pattern, different compounds =
different bubble size & distribution COMPOUND DEVELOPMENT
DISC MANUFACTURE :4/22/2008 14 DISC MANUFACTURE DIFFUSER ASSEMBLY MEASURING BREAKPRESSURE FINE BUBBLES
AFD350 TESTING MEMBRANESTRENGTH
Slide 15 :4/22/2008 15 PATENTED QUICK CONNECT SADDLE MOUNTING
SYSTEM FOR 9” AND 12” DISCS
DISC CONNECTIONS :4/22/2008 16 DISC CONNECTIONS
TUBE MANUFACTURE :4/22/2008 17 TUBE MANUFACTURE MILLING HOLES GLUEING PIPE TO SUPER SADDLE DRYING PREPARING THE CRATE
Slide 18 :4/22/2008 18 SNAPPY SADDLE™ Each diffuser has a single seal on top of the headers and can be installed by 1 person rapidly
Quick connection – low headloss – high SOTE – compression molded tube membranes
COARSE BUBBLE DIFFUSERS :4/22/2008 19 COARSE BUBBLE DIFFUSERS The plastic Airflex Cap and Stainless Wide Band types are the most common coarse bubble diffusers. These are often used in digesters, sludge holding tanks, and equalization basins. Airflex™ Cap Airflex™ Band
Slide 20 :4/22/2008 20 SSI PLASTIC PIPE FABRICATION
(Poughkeepsie, NY)
Slide 21 :4/22/2008 21 SSI SS PIPE FABRICATION
(Cincinnati, OH)
Slide 22 :4/22/2008 22 WEB (.NET)+ LOCAL CALCULATION SOFTWARE
Slide 23 :4/22/2008 23 WEB (.NET) BASED DRAFTING SOFTWARE
Slide 24 :4/22/2008 24 WEB (.NET) BASED DRAFTING SOFTWARE
Typical Results
Slide 25 :4/22/2008 25 BIOWIN SIMULATION CAPABILITY
INDEPENDENT NON-STEADY STATE TESTINGDetermination of SOTE of SSI Airflex Diffusers per ASCEATC, SA Barcelona SpainRedmon Engineering, Milwaukee, USA :4/22/2008 26 INDEPENDENT NON-STEADY STATE TESTINGDetermination of SOTE of SSI Airflex Diffusers per ASCEATC, SA Barcelona SpainRedmon Engineering, Milwaukee, USA
Slide 27 :4/22/2008 27 INDEPENDENT NON-STEADY STATE TESTING
Slide 28 :4/22/2008 28 COMPETITIVE RESULTS
Slide 29 :4/22/2008 29 INDEPENDENT STEADY STATE TESTINGDetermination of in a Virginia, USA BNR
Redmon Engineering, Milwaukee, USA
Slide 30 :4/22/2008 30 NEW VS. OLD SSI MEMBRANE PERFORMANCE
Slide 31 :4/22/2008 31 SSI PLASTIC PARTS SUPPLIER QC MONITORING & PROTOCOL
Slide 32 :4/22/2008 32 SSI MEMBRANE SUPPLIER QC MONITORING & PROTOCOL
Slide 33 :4/22/2008 33 LARGE PROJECT – MIL 105E TEST PROTOCOL
Slide 34 :4/22/2008 34 IN-HOUSE TESTING & REPORTS
Slide 35 :4/22/2008 35 IN-HOUSE TESTING & REPORTS
Slide 36 :4/22/2008 36 IN-HOUSE TESTING & REPORTS
SUPPORTSABS and Stainless Steel :4/22/2008 37 SUPPORTSABS and Stainless Steel
EXPANSION JOINTS :4/22/2008 38 EXPANSION JOINTS
REPLACEMENT MEMBRANES :4/22/2008 39 REPLACEMENT MEMBRANES EPDM
EPDM w/VITON layer
EPDM w/PTFE layer
Plat. Cured Silicone
Neoprene (CR)
Polyurethane Replacements made for
Many US and European
Disc and tube manufacturers
9”&12” discs, 50mm to 117mm
Dia. tubes
SYSTEMS :4/22/2008 40 SYSTEMS “We are extremely pleased with our latest purchase from you. Our wasted biomass is now kept fresh and free from release of NH3 and Ortho-P during storage. We will be looking at replacing all membranes in the Ford Road Aeration Basins in 2007. I would like to get a price from you soon. Have a happy holidays! Jason Tincu, Xenia WWTP Supervisor”
Slide 41 :4/22/2008 41 SYSTEMS “After evaluation, EA decided to proceed with
SSI's 12-inch diameter fine bubble diffusers. Due to the size and efficiencies of the SSI diffuser,
the number of diffusers required for the project is significantly less than the other Manufacturers. We highly recommend SSI and we would like to work with them again on our next project.”
Chuck Place, P.G., EA Engineering Inc.
SYSTEMS :4/22/2008 42 SYSTEMS “SSI designs complete aeration systems including calculations of SOTE, temperature, with drawings and all complimentary information for aerobic reactors. Their technical help is the best in the business. “
Marcelo Mascheroni Lay, Sanitary Engineer, Ecoplan Uruguay (former SanitaireTM
Slide 43 :4/22/2008 43 SYSTEMS “In 2003 our company El Concorde purchased 6000 sets AFT1000 diffuser from SSI to be used on a wastewater treatment project in Iraq under the Program Oil for Food with the UN. I evaluated a number of American and European companies and finally selected SSI due to a robust product and good communication.”
Ghassan Ayyubi – El Concorde Ltd, Jordan
SYSTEMS :4/22/2008 44 SYSTEMS
SYSTEMS :4/22/2008 45 SYSTEMS “We have had the Stamford disc diffusers installed in
our two 450,000 gallon sludge holding basins for nearly
five years and we have never had a problem with them.
We also see adequate mixing and desired performance.
The basins are inspected periodically and we have not
had to replace any of the modules to date.”
Jerry Basham - Chief Operator North WWTP,
Henderson Water Utility, Henderson, KY
SYSTEMS :4/22/2008 46 SYSTEMS “I called Pierre Filion today. He is just back from vacation. He said that he checked his aeration system this morning and everything seems OK. The bubbles are still nice, so he does not expect problems for sometimes. The Teflon membranes were installed Dec. 04. One month earlier, he had installed (other brand) EPDM membranes in the other reactor (Nov. 1) and the bubble size is not so good and he is expecting problems soon.”
Gaetan Desjardins, Premier Tech Environment – QC, Canada
SYSTEMS :4/22/2008 47 SYSTEMS “We came across the SSI diffusers and first tried them in the summer of 2005. It was probably the best decision we have made in our wastewater treatment plant since it started processing water. Not only can we afford to replace the old diffusers, the new SSI seem to be more durable than the old ones and don't require as much maintenance. We also see that they do not plug up or scale up as bad as the old diffusers. Our current blowers could not be happier as well as myself. We have been thoroughly satisfied with the SSI diffusers from DGJ Gongol and Associates and would recommend these diffusers to everyone. Thank you for such a good and reliable product. You have definitely made life easier for all of us
here at SCA Tissue. “, Paul Johnson – SCA Tissue, Menasha, WI
SYSTEMS :4/22/2008 48 SYSTEMS “We hereby confirm that TEFLON membranes have been working since beginning of February without clogging problems. Before we had to clean the (NoponTM) EPDM membranes every 3-4 weeks!”
Ringkøbing Renseanlæg, Denmark
Gunnar Larsen
SYSTEMS :SYSTEMS 4/22/2008 49 “The diffusers AFD-350 are working very well in Podolsk. At present we are installation some diffusers in Protvino and Redkino. We have received ≈ 2 thousand pieces in Solnechnogorsk. “
Robert Agronanonik, BIFAR, Russia
Slide 50 :4/22/2008 50 SYSTEMS “Pumpteknik have delivered 800 pcs of SSI membranes to Flygt SanitaireTM 9” discs. Today we see a much better oxygen transfer as before surely caused by the better materiel and perforation. We can warmly recommend this product!”
- Nilks Bak Andersen, Teknisk Chef, A/S Saeby Fiske-Industri
Denmark
SYSTEMS :SYSTEMS 4/22/2008 51 “We’ve have had very good luck with the membranes we purchased from your company last year.”
-Richard Rader, Sara Lee Bakery, Traverse, MI USA
Slide 52 :4/22/2008 52 SYSTEMS
Slide 53 :4/22/2008 53 SYSTEMS “Al Salam Alaikum,
Reference to your letter dated 13/1/1426 H. requesting our opinion about the Air diffusers supplied by SSI to our projects.
We would like to advise you that these diffusers have been approved based on their quality product and we did not notice any technical problems.”
-Yazeed Yehya Al Ayed, Ministry of Water, KSA
Slide 54 :4/22/2008 54 SYSTEMS “SSI has been a pleasure to work with before, during and after the sale and installation.
They hopped through hoops to meet tight delivery schedules and they stayed in touch to
insure the installed-system integrity was as promised and expected. Its nice to know
that there are firms out there that deliver quality product, in a timely manner and
recognize that there is more to a successful project than just the bottom line... their
service was exemplary.”
Don Mathsen, Grand Forks ND WWTP
Slide 55 :4/22/2008 55 SYSTEMS “Thank you for your excellent support at such short notice for the successful completion of the above project using Airflex Disc Diffuser System. I am pleased to inform you that
the client is very happy especially now that their power consumption has been greatly reduced and is now consuming about 30% of its original cost.The plant is now meeting all the necessary standards as required by the department of
Environment. “
-Debbie Chee, Tekno Suling SDN Bhd (former NoponTM customer)
Slide 56 :4/22/2008 56 SYSTEMS “I have also been in contact with the Supervising Engineer for the owner of our Activated Sludge WWTP in the Dominican Republic. He confirms that the aeration system continues to perform admirably - a claim he admits he cannot make for many of the other water purification systems. These reports confirm my confidence in the design, engineering and product support which I have come to rely on from SSI. The professional abilities of you and your staff help to relieve of the technical concerns I find to be so typical today with many of our systems suppliers.”
David Burgess, Dir. Of Engineering, Krofta Technologies, Inc.
Slide 57 :4/22/2008 57 SYSTEMS “We certify that we have bought along the last five (now 10) years, fine bubble disc diffusers and tubular diffusers from SSI, which have been installed in more than 30 of our Wastewater treatment plants projects we have manufactured within this time in different countries.
In most of these projects we have received not only the sales assistance but also technical support in the designing when it was required. All the projects we have installed the 9", 12" and tubular SSI diffusers operate successfully complying the parameters they were designed for, will no operational and
quality problems in diffusers and membranes”
Andres Silva, Proton USA Corp., Miami, FL USA
SSI vs Nopon TM :SSI vs Nopon TM 4/22/2008 58
Slide 59 :4/22/2008 59 Dear Tom.
The plant has 3 parallel tanks with first 2,100 pcs Nopon TM 215 then later 2,100 Nopon TM on top of them. The costumer has had problems with leak between the old and new one. Nopon TM have changed the system several times so the plant decided to use AFD 350 with saddl for pipe ø90. They are very surprised the SSI’s disc is as efficient as seen on the Graph from 06-11-2004. Visual you can see by photos
921 that Nopon TM in one place have pop up and photo 923 at sidewall you see no bubbles. On photo 924 you have a beautiful view of AFD 350’s efficiency and on photo 922 you can see the overwhelming amount of bubbles.
After having installed 700 pcs AFD 350, we shall deliver 700 more this year and 700 next year.
Dan Christensen
Pumpteknik ApS
Hans Rostgårdsvej 4
DK-3050 Humlebæk
Tlf.: 0045 49 16 16 76 - Fax: 49 16 16 96
Slide 60 :4/22/2008 60 The following graph depicts the performance of two tanks in Denmark. Tank 1 has Nopon TM 300 size diffusers. In Tank 2, SSI replaced the Nopon TM membranes with SSI 12” retrofit membranes. The two tanks ran side by side. Notice how the valve to the air supply in the SSI tank is mostly closed, and the valve to the air supply in the Nopon TM tank is mostly open, yet the DO is higher in the SSI tank, in spite of receiving much less air.
Slide 61 :4/22/2008 61 Hi Tom.
Here the first result of changing from Nopon TM 215 to AFD 350/PTFE. Saving ca 16%. But we have to adjust the plant concerning the pressure, so I’ll be back. I would like to end about 25%.
Med venlig hilsen/With best regards Pumpteknik ApS/SSI North Europe
Dan Christensen www.pumpteknik.dk Tlf.: ++45 49161676, Fax.: ++45 49161696
Mobil: ++45 31655158 - e-mail mobil: nokia@pumpteknik.dk Skype member: Pumpteknik Ad1)
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Slide 65 :4/22/2008 65 ARS TANK
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Slide 68 :4/22/2008 68 THANK YOU.
WE LOOK FORWARD
TO WORKING WITH YOU.