Actiflo+Steel+Plant+Paper.docx
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Actiflo+Steel+Plant+Paper.docx
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Actiflo+Steel+Plant+Paper
TREATMENTOFSTEELPLANTEFFLUENT
WITHHIGHSPEEDMICROSANDSETTLING
CharlesD.BlumenscheinandKashiBanerjee
USFilterCorporation
NorthAmericanTechnologyCenter
Pittsburgh,PA15108
INTRODUCTION
Totalsuspendedsolids(TSS)andoilandgrease(O&G)aretwomajorpollutantsthatarepresentinthewastewatergeneratedfromthesteelmakingoperations.Thereleaseofthesesubstancesintotheenvironmentmustbecontrolledtominimizeeffectsonaquaticlifeanddownstreamuses.IncreasinglystringentenvironmentalregulationspertainingtodischargescontainingTSSandO&Gnecessitatethedevelopmentoftechnicallyandeconomicallyfeasibleprocessesfortheremovalofthesepollutantsfromindustrialwastewaterpriortodischarge.
IronoralumcoagulationfollowedbyconventionalclarificationisacommonprocessforremovalofTSSandO&Gfromindustrialwastewater.Theoverflowrateofaconventionalclarificationsystemrangesbetween0.25and1.0gallonsperminutepersquarefoot(gpm/sf).Thisdesigncriterionoftenresultsinalargesystemfootprint.Additionally,conventionaltreatmentmethodscannothandlesuddenincreasesinhydraulicloadingthatmaybecausedbystormevents.Directdischargeofcontaminatedstormwatercanbeavoidedbybuildinglargestoragereservoirsatthefacilityandtreatingthewatergradually,orbytreatingthepeakflowcontinuously.Typically,installationofalargestoragetankiscostprohibitive.
VivendiWater/USFilterCorporationhasdevelopedacost-effectivesystem,knownasActiFlo,fortreatingwastewater.Theprocesshasanextremelysmallfootprint,typicallyrequiringlessthan10%ofthespaceneededforaconventionalsedimentationprocess.Evenatahighwastewaterflowrate,thisprocessiscapableofproducingexcellenttreatedwaterquality.Pilot-scaleoperationofthissystemwasconductedtoverifytheapplicabilityoftheActiFloprocessforefficientlyhandlingwastewaterfromasteelmakingfacility.TheprimaryobjectivesofthisstudyweretodemonstratetheeffectivenessofthisballastedcoagulationprocessfortheremovalofTSSandO&Ginacontinuous-flowsystemaswellastodeterminethedesiredoperatingconditionsoftheActiFlosystem.
PROCESSDESCRIPTION
ActiFloisacompact,conventional-typewaterclarificationsystemthatutilizesmicrosandasaseedforflocformation.Themicrosandprovidessurfaceareathatenhancesflocculationandactsasaballastorweight.Theresultingsand-ballastedflocdisplaysuniquesettlingcharacteristics,whichallowforclarifierdesignswithhighoverflowratesandshortdetentiontimes.Thesedesignsresultinsystemfootprintsthatarebetween5and20timessmallerthanconventionalclarificationsystemsofsimilarcapacity.Theuseofmicrosandalsopermitstheunittoperformwellunderdramaticallychangingflowrateswithoutimpactingfinaleffluentquality.Theoverflowratecanvaryfrom20gpm/sftoashighas60gpm/sfwithinshortperiodsoftime(lessthanone-halfhour)withoutsacrificingperformance.
RawwaterenterstheActiFlosysteminthefirstflashmixtank(coagulationtank).Here,chemicalcoagulant(alum,ferricion,etc.)isaddedtodestabilizesuspendedsolidsandcolloidalmatterintheinfluentstream.Typicalhydraulicdetentiontimeinthecoagulationtankisaroundtwominutes.Thecoagulatedwaterthenpassesintothesecondflashmixtank(injectiontank)wherepolymericflocculantandmicrosandareaddedtoinitiateflocformation.Theseserveas“seed”forflocformationanddevelopmentinthenextprocessstep.
ActiFlotreatmentcontinuesaswaterpassesthroughtheunderflowpassagefromtheinjectiontankintothematurationtank.Inthematurationtank,relativelygentlermixingprovidesidealconditionsfortheformationofpolymerbridgesbetweenthemicrosandandthedestabilizedsuspendedsolids.Thisprocessisfurtheraugmentedbythelargespecificsurfaceareaofthemicrosand,whichprovidesenhancedopportunityforpolymerbridgingandenmeshmentofmicrosandandflocalreadyinsuspension.
Thefullyformedballastedflocsleavethematurationtankandenterthesettlingtank.Here,laminarupflowthroughthelamellarsettlingzoneprovidesrapidandeffectiveremovalofthemicrosand/sludgeflocs.ClarifiedwaterexitstheActiFlosystemviaaseriesofcollectiontroughsorweirs.
Theballastedflocsand-sludgemixtureiscollectedatthebottomofthesettlingtankandwithdrawnusingarubber-linedcentrifugalslurrypump.Thesand-sludgemixtureisthenpumpedtothehydrocycloneforseparation.Energyfrompumpingiseffectivelyconvertedtocentrifugalforceswithinthebodyofthehydrocyclone,causingthesludgetobeseparatedfromthehigherdensitymicrosand.Onceseparated,themicrosandisconcentratedanddischargedfromthebottomofthehydrocyclone,andre-injected
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