Kubota’s Online Operator Workshop

Basics
 TODAY’S AGENDA
• Basics
• Break
• Case Study
• Break
• Case Study
• Quiz
 Basics
• Terms, Definitions
• Submerged Membrane Unit Structure and
Function
• System Components
• Managing MBR System Performance
• Biofilm Management
• Controls
• Biological Nutrient Removal
•
Terms and Definitions
The rate of filtration per unit area of membrane material is called flux. Defined here in the U.S. as
gallons per square foot.
• Typical value 12 gfd at 10°C
• 14 at 15°C
• 17 at 20°C

• The water that is produced during filtration is called permeate

• The pressure difference across a membrane during filtration is called transmembrane pressure
(TMP)
• Typical TMP at design flux rates 0.5‐1.0 psig
• Maximum TMP 3.0 psig

• Air Scour
• Determined by number of membranes and flux rate

• The ratio of flux to TMP is referred to as permeability

• Permeability=Flux/TMP

• Biofilm is a complex dynamic matrix comprised of microorganisms, EPS/SMP, non‐biological solids,

substrates, metabolites, interior pores and channels

• The interdependency between biological process conditions and membrane hydraulic performance
through a biofilm is termed BioHydraulics
 Measuring TMP
Pumped
PS System
PG

PG = PS - PP - TMP TMP = Membrane & biofilm pressure losses

PP = Piping friction losses (fittings, piping, etc.)
TMP = PS - PP – PG
PG = Gauge reading during filtration
PS = Static pressure reading at zero filtration

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 Terms and Definitions
• Production Capacity: The net permeate flow rate over a given period of continuous operation
accounting for CIP procedures and relaxation.
– Average Daily Flow (ADF): The net daily flow requirement generally occurring during dry
weather conditions and lasting nine (9) months.
– Maximum Monthly Flow (MMF): The net daily flow requirement generally occurring
during wet weather conditions and lasting three (3) months.
– Peak Daily Flow (PDF): The net daily flow required during peak daily flow conditions and
lasting 24hr.
– Peak Hourly Flow (PHF): The net peak hourly flow requirement generally occurring
during wet weather flow conditions and lasting 4hr.
Submerged Membrane Unit (SMU)
Structure and Function

Tube
Cartridge Anatomy
‐ABS plate
Type 515
-1.64ft x 4.92ft
‐Chlorinated polyethylene
membrane
-15.61ft2 Area
‐Thermal weld process
Tube ‐Polyester plenum material
‐0.4 m mean pore size
‐<0.2 m effective pore size
Submerged Membrane Unit (SMU)
Structure and Function
Submerged Membrane Unit (SMU)
Structure and Function

MBR has 4X to 5X the bacteria concentration

 Submerged Membrane Unit (SMU)
Structure and Function
Tubes
Manifold

Membrane case

Diffuser case

Diffusers
Submerged Membrane Unit (SMU)
Structure and Function
• Flat Plate Geometry
Matters
– Fixed spacing between
cartridges (8 mm)
– Very little for “solids” to
hang up on
– Airlift pump action keeps
sludge moving between
cartridges
Submerged Membrane Unit (SMU)
Structure and Function
• Acts like an airlift pump
– Continuous coarse bubbles at
the bottom
– Fully enclosed
– Air scour in constant contact
with the membranes
– Continuous movement of
mixed liquor keeps tank
contents well mixed and in
suspension
 System Components
• Fine Screen
– Achilles heel of all
MBRs
– Ideal to have
duty/standby
– Ensure there is no
bypass
– Outdoor installations
may require heat
tracing
 System Components
• Permeate Pumps
– Ideal to have
dedicated pumps for
each MBR basin with
a common standby
– Make sure there
aren’t high points in
the suction piping
that can lead to air
binding
 System Components
• Blowers
– MBR tanks and pre‐
air basins should have
separate blowers
(though they can
share a common
standby)
– Make sure you have
spare parts such as
belts or filters on
hand at all times
 System Components
• Clean in Place
– Semi‐automatic
– Pumped or Mazzei
injector
– Become familiar with
isolation valves,
especially the vent
valve
 Managing MBR System
Performance
Biological Process
Solids Handling
Design

Integration
Pre‐Treatment &
Controls

MBR SYSTEM
Plant Hydraulics Equipment
Selection

Operation
Aeration Systems &
Maintenance
 Managing MBR System
Performance
• Think MBR system not membranes
Process Condition Impact on MBR

Debris Accumulation → Reduced Scour→ Localized Dewatering

Screenings Bypass
Membrane Damage → High Turbidity

Insufficient Aeration Fouling → CIP frequency

Air leaks / Air Lock in Permeate Pipe False ‘High’ TMP → Reduced Capacity

Unrecognized Flow/Loading Changes Poor Sludge Quality → Increased Fouling

Flow Splitting MLSS Imbalance → High MBR Solids → Increased Fouling

Poor Air/Permeate Control
Non-ideal Biofilm Thickness → Increased Fouling, Increased CIP
Improper Relaxation
Frequency

Lower Than Design Temperature Increased TMP → Decreased Capacity

Poor Sludge Quality

Unmanaged SRT/MLSS Low MBR Solids → Increased Fouling
High MBR Solids → Increased Fouling
 Managing MBR System
Performance
• The Basics:
– TMP/Permeability
– Air Scour Rate
– Permeate flow rate
– Air scour bubble pattern/Diffuser clean cycles
– MLSS
– Filterability
 Biofilm Management
• All submerged membranes have them,
managing them is key
• Biofilm, what is it?
– A complex dynamic matrices comprised of microorganisms, EPS/SMP,
non‐biological solids, substrates, metabolites, interior pores and
channels.
– Create a dense secondary membrane that can allow for enhanced
nutrient removal and degradation of refractory organics
– As soon as filtration starts and biological solids are brought to the
membrane surface, biofilm formation occurs.
– Biofilm serves as the secondary dynamic filter and represents a
changing resistance to filtrate flow.
 Biofilm Management
• Membrane Air Scour
• Relaxation
• Sludge Quality Control
– SRT/MLSS
• Maintenance Cleaning
 Biofilm Management
Total Flow Resistance Through Membranes:
RT = (RM + RF) + RC
 RM = Membrane Resistance
 RF = Membrane Pore Clogging RM + RF
& Adsorption
 RC = Cake Resistance (Biofilm) RC

DirectlyCan
Biofilm Impacts Hydraulics
Represent 90% of
Total Resistance Across
and Cleaning Membrane
(TMP)
 Biofilm Management
• Good
 Biofilm Management
• BAD
 Biofilm Management
Ideal Non‐Uniform
Thick

Stable
Variable
High TMP
Increased TMP
TMP
TMP
 Biofilm Management
Relaxation
Air Scouring
• The rise velocity of bubbles • Permeate
impacts shear force and suspended while
biofilm thickness aeration continues
• Intensity requirement is a • Increases biofilm
function of deposition rate porosity
(flux) and fluid viscosity • Decreases biofilm
• Defined air flow pathways thickness
promote even distribution • Can increase overall
• Turbulent velocity (slug flow) sustainable flux
maximizes effect
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 Biofilm Management
Normal Filtration Relax
 Biofilm Management

Improving Sludge Quality

 12 days < SRT < 54 days

 8,000 mg/l < MLSS < 18,000

mg/l
 MPE50
TM for upsets &

operations outside design

conditions

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 Biofilm Management
Maintenance Cleaning Recovery Cleaning
• Intended to remove surface • Intended to “dislodge
particles from membrane
(biofilm or cake) fouling.1
microstructure.”1
• Does not involve taking • May take from >4‐24hrs.
tanks out of service for
• Requires that membranes
extended periods of time be soaked in concentrated
(~1‐4hr) chemical solution.
• Routine procedure • Generally a non‐routine
• Can return to MBR filtration procedure for flat plate
mode in ~15 minutes systems

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 Biofilm Management

Pressure
Chemical Eductor Flow Meter
Regulator

Stock Chemical
Supply
Control Valve
The Operator’s Toolbox
 Biofilm Management
Suspected Recommended Alternate Cleaning Solution Cleaning
Fouling Cleaning Chemical Cleaning Weight Percent Duration
Material Chemical

Organic Sodium Hypochlorite Hydrogen 0.5% or 1/3*MLSSd 1.0 - 2.0 hrs

(Bleach) Peroxide

Aluminum Oxalic Acidc Citric Acid 0.5% to 1.0% 0.5 - 1.0 hrs
Oxidea

Ferric Oxidea Oxalic Acidc Citric Acid 0.5% to 1.0% 0.5 - 1.0 hrs

Calcium Hydrochloric Acid Citric Acid 2% 0.5 - 1.0 hrs

Carbonateb
 Biofilm Management
Calculate the amount of cleaning solution (VCS) required to clean one bank
of membranes (uppers or lowers in one MBR basin):

# Cartridges 1.35gal
VCS # SMU 
SMU Cartridge
# of SMUs = 3

# of Cartridges = 200
 Biofilm Management
Calculate the approximate concentration of the cleaning solution (CCS) that should
be used at the given MLSS concentration

CCS  MLSS  1
3
CCS  15,000mg / l  1  5,000mg / l  0.5%
3
Calculate the dilution factor (fD) given the concentration of the stock chemical and
the cleaning solution weight percent calculated above

wt % StockChemical 12.5%
fD  fD   25
wt %CleaningSolution 0.5%
 Biofilm Management
Calculate the amount of stock chemical (VSC) required to perform the
Maintenance Cleaning

VCS 
800 gal
 32 gal
VSC  VSC
25
fD

Therefore, only 32 gallons of 12.5% bleach are required to makeup the cleaning solution
 Controls
• Control System
Architecture
–PC and PLC networked via
Ethernet
–Remote access gained
through dial‐up modem or
VPN
 Controls
• The Plant’s Brain
 Controls
• The Brain is Dead
 Controls
• Manual Operation (becoming the brain)
• Think logically about how flow comes into the
plant
• Concentrate on the absolute basics
– Screens
– Recycle
– Air scour
– Permeate flow
– Achieve a good balance
 Biological Nutrient Removal
• Nitrogen
– Raw Wastewater contains nitrogen in the form of:
1. Organic nitrogen
2. Ammonia‐N (NH3‐N)
3. Nitrite (N02‐N)
4. Nitrate (NO3‐N)
 TKN = 1 + 2
 TIN = 2 + 3 + 4
 TN = 1 + 2 + 3 + 4
Inert nitrogen = 2% of TN
 Biological Nutrient Removal
• Autotrophic Bacteria
– Known as Aerobes or Producers
– Use carbon dioxide as their sole source of carbon
– Perform Nitrification
• Nitrosomonas convert ammonia to nitrite
• Nitrobacter convert the nitrite to nitrate
• Together they break down ammonia into nitrates
– Use dissolved oxygen to oxidize ammonia
– Thrive in the aeration basin and can survive in
anoxic
– Very sensitive to pH changes and toxins
 Biological Nutrient Removal
• Nitrification
– Presence of oxygen
– Occurs in Pre‐Air and MBR basins
– Autotrophic bacteria are slow growing. Longer SRT
– Nitrification consumes alkalinity @ 7.14 g alkalinity/g NH3‐N
• Nitrification ( NH3 to NO3) 4.57 gO2/gNH3
– Nitrosomonas
• NH3 to NO2 3.43 gO2/gNH3
– Nitrobacter
• NO2 to NO3 1.14 gO2/gNO2
– Electron Acceptor: Oxygen
 Biological Nutrient Removal
• Denitrification
– Absence of free oxygen
– Occurs in Anoxic basin
– Heterotrophic bacteria
– Denitrification recovers 50% alkalinity lost in nitrification @ 3.57g
alkalinity/g NO3‐N
• Denitrification ( NO3 to N2 gas)
– Alcaligens, Pseudomonas
• NO3 to N2 2.86 gO2/gNO3
– Oxygen Equivalent of NO3
– Electron Acceptor: Nitrate
– BOD:TN ratio greater than or equal to 4
 Biological Nutrient Removal
Heterotrophs also known as Anaerobes or Consumers
• They use BOD as their principle source of carbon
• 80‐90% of the overall population
• In the right environment, they perform Denitrification
• They are facultative
• They can use dissolved oxygen to oxidize BOD
• Or they can use oxygen from Nitrates to oxidize BOD
• Thrive in the aeration basin and thrive in the anoxic basin
• Compared to autotrophs, they are less sensitive to pH
changes and toxins
Biological Nutrient Removal
Characteristics or Traits A H
Perform Nitrification
Perform Denitrification
Require a long SRT
Require a short SRT
More sensitive to pH
Less sensitive to pH
Make up 10‐20% of the MLSS population
Make up 80‐90% of the MLSS population
Thrive in the aeration basin
Thrive in the anoxic basin
Use free oxygen when metabolizing
Use oxygen found in nitrate when
metabolizing
 Biological Nutrient Removal
• 100:1
For every 100 Pounds of BOD coming into the plant: a minimum of 1 Pound of
Phosphorous is needed to promote cell growth
• 20:1
For every 20 Pounds of BOD coming into the plant: a minimum of 1 Pound of Nitrogen
is needed to promote cell growth
• 7:1
For Every 1 Pound of Ammonia that is oxidized in the process: 7.14 Pounds of
Alkalinity (as CaCO3) is consumed
• 4.6:1
For every 1 Pound of Ammonia Nitrogen that is oxidized to Nitrate: 4.57 Pounds of
Oxygen is utilized.
• 4:1
For every 1 Pound of Nitrate to be reduced: 4 Pounds of BOD must be available
• 3.5:1
For every 1 Pound of Nitrate that is reduced in the system: 3.57 Pounds of Alkalinity
(as CaCO3) is recovered
 Biological Nutrient Removal
• Phosphorus
– Raw wastewater contains phosphorus in the form
of:
1. Orthophosphate
2. Polyphosphate
 Biological Nutrient Removal
• Phosphorus Accumulating Organisms (PAOs)
– Store carbon as an energy source in anaerobic
environments
– Burn polyphosphorus during this process and
release orthophosphate
– Convert carbon to energy and uptake phosphorus
in aerobic environments for cell growth, known us
luxury uptake
 Conclusions
• Flux is critical to proper operation of your Kubota
membranes
• Kubota SMUs are designed specifically for
wastewater treatment
• MBRs are a system of components including the
membrane
• Biofilm management is key to preventing premature
fouling
• Plants can be operated manually in emergencies
• Autotrophs, heterotrophs and PAOs allow us to
remove nutrients biologically
MBR System Upgrade and Replacement

Brian Codianne
Regional Manager, Kubota MBR Systems
[email protected]
425-898-3888
1
 The Focus

 Operators
• Sticking with our customers
• Reconnect with those who have slipped away
 Process
• Ensuring plants are consistent with current standards
• Improving plants that are below standards
 Equipment
• Membrane Units
• Pumps and blowers
• Instrumentation
 Controls
• Proactive Tools

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 Operators

 You are our greatest asset

 Process Improvements
 Equipment, instrumentation, control philosophy
 Validation
• You will let us know what works and what doesn’t
 TRAINING
 Determine their comfort level
 Provide refresher training as our product evolves
 Identify new operators requiring training. The outgoing guy probably
didn’t do a good job.
 Annual operator’s workshop
 Schedule periodic regional training sessions
 Operator conferences
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 Evaluating MBR Subsystems

Biological Process
Solids Handling
Design

Integration
Pre-Treatment &
Controls

MBR System
Plant Hydraulics Equipment
Selection

Operation
Aeration Systems &
Maintenance

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4
 To Ensure Proper Performance

• TMP / Permeability
• Air scour rate
• Permeate flow rate
• Process aeration requirements
• MLSS
• Filterability
• CSS testing

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 Process

• Improving plant performance through analysis and optimization

• Determine the most efficient points for MLSS, aeration rates, flux
rates, etc.
• Plant configurations
• Add zone bypass options to assist with process adjustments
• Hydraulic improvements
• System turndown conversion
• Chemical dosing
• Polymers for emergencies
• Nutrient removal ( carbon source, phosphorus)
• Energy Optimization
• Continue development of tools to determine most energy efficient
design

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 Equipment Improvements

• New fine screens

• Poor performance leading cause of problems
• New Pumps and Blowers
• 15-30% less energy than older equipment
• Added Benefits
• Integrated instrumentation
• Much quieter
• Smaller footprint
• Reduced O&M
Method of Air Flow Delivery and Control is Critical

• Carefully choose the type of blower

• Positive displacement
• Hybrid
• Turbo
• Connection method
• Independent, direct coupled blower to each service
• Common header approach with multiple flow control
valves
• Avoid varying water levels in aerated zones
 Equipment Upgrades

• Upgrade to our current standards for reliability or to reduce

nuisance alarms
• Electrical actuators
• Flow meters
• Additional instrumentation for additional protection and
operator aid
• MLSS probes
• NH3/NO3 analyzers
• Spare parts for critical items
• Electrical actuators
• Level transmitters
• Pressure transmitters
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 Membrane Unit Upgrade/Replacement

Larger Cartridge
Original Cartridge
15.61 Ft2/Cart
8.61 Ft2/Cart ʻLego Blockʼ
Module
108 Ft2/Mo

510 Cartridge 515 Cartridge SP Series

(10-400 cartridges / unit) (150-400 cartridges / unit) (20-80 modules / unit)

・Different models are available with various types of Membrane Cartridge and Module.
・ES-EK, with original 510 Membrane Cartridge is the long standing workhorse.
・RM-RW, with larger 515 Membrane Cartridge, same footprint, more capacity.
©2018 Kubota Corporation All Rights Reserved. 10
・SP, with ʻLego Blockʼ Membrane module, more compact, energy efficient, diffuser options.
 When to Replace Your Membranes
• Damaged
– Identify root cause
• Age
– Forensic testing can determine strength and flow capacity
• Plant expansion
• Desire more efficient operation
• System turndown
– Handling more flow with fewer membranes leads to energy efficiency
• Other types of membranes not working as advertised
 Controls

 Bring all plants up to our current standards

• We now provide more information, trends, etc.
allowing operators to be more proactive
• Eliminate known glitches
• Analyze alarm settings to eliminate nuisance alarms
and spurious callouts
• Equipment / instrument overrides
• Increase remote access capability

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Improving the Performance and Increasing the Capacity of
Existing and Older MBR Systems
 Small Plant
• 80,000 GPD MBR facility installed in 2011
• History of operational issues (2011 to 2015)
– Failure to meet hydraulic capacity
– Sludging
– Over flow events
– Short circuiting
• All of the above blamed on the membranes
• Owner wanted to fix operational issues and expand to a
capacity of 100,000 GPD
• Engineer wanted to replace with another type of membrane
 Issues Form Perceptions
• Inability to meet hydraulic demand
• Sludging
• Over flows
• Short Circuiting
• “It’s the membranes”
 Fundamental Issues
• Fine Screening
– Existing 2‐mm bar screen is inadequate
– Replace with a 2‐mm internally‐fed drum
• Hydraulics
– Uneven RAS returns
– Reconfigure the plant
• Permeate Pumps
– Issues with cavitation and air lock
– Replace pumps and reconfigure piping
• Control System
– Existing system uses unsupported, proprietary architecture
– Replace the control system
 Construction
• Construction tasks
– Install new equipment including fine screens, permeate
pumps, and SMUs
– Reconfigure the plant hydraulics
– Change the control system
• And do all this while keeping the plant online
Existing Tank Layout

MBR 1 PA 1 PA 2 MBR 2

AX 1 AX 2 AX 3 EQ 1 EQ 2

AX EQ
 Retrofit plan Proposed by KMU

• Retrofit ES to RM
• Split the plant MBR 1 PA 1 PA 2 MBR 2

AX1 AX2 EQ

Screen
 Medium Sized Plant
• 2 MGD MBR facility installed in 2004
• History of operational issues
– Poor screening
– Sludging
– Frequent foaming events
– Limited instrumentation and control
– Permeate pumps cross connected across two tanks (upper
and lowers on separate pumps)
• Owner wanted to fix operational issues and prepare for future
expansion
 SMU Upgrade

New Units
Old Units
SP-600
EK-400
6,459 ft2
3,444 ft2
surface area
surface area
88% more in
same footprint
 Construction
• Construction tasks
– Install new fine screens and SMUs
– Reconfigure the plant hydraulics
• Changed permeate piping to one pump aligned to one tank
arrangement. More flexibility
– Change the control system
• Added air scour control and monitoring
• Added ability to rotate membrane basins as needed
• And do all this while keeping the plant online
 Replacing Other Membrane Types

• 0.6 MGD MBR facility installed in 2016 with Microdyn Membranes

• History of operational issues
– Not capable of meeting flux and MLSS design points
• Very sensitive to low temperatures
• Plant had to be de‐rated
• Heavy requirements for additional chemicals for flux and TP removal
– Sheets sticking together
• Reduced surface area
• Faster fouling, more chemical cleans
• Sludging
• Replaced Microdyn with Kubota SP450 summer 2021
– Work limited to in‐basin
– Connect to existing air and permeate headers
SP450 Installation
Kubota Advantages

• Microfiltration membrane.
• Allows for higher sustained flux and mixed liquor concentrations.
• Virus removal testing has shown Kubota microfiltration membranes can achieve the log
removal rates at ultrafiltration membranes.
• Ease of use. Simple cleaning procedures.
• Weak chemical solutions injected inside the membranes via the permeate piping under
atmospheric pressure, so no pressurized back pulsing is required.
• Membranes and MLSS stay in the tank.
• Kubota membranes are rigid plates with fixed spacing.
• This provides an open flow path between membranes to minimize the accumulation of debris
or mixed liquor.
• Prevents membrane material that is adjacent to each other from sticking together, which is
common with hollow fiber and flexible sheets. The sticking together of membrane material
reduces the available surface area, which in turn reduces hydraulic capacity and requires more
frequent and intensive chemical cleaning procedures.
• Superior strength and durability with the use of chlorinated polyethylene as compared to PVDF.
• Membrane zones can be used as an active part of the biological process, and membrane air scour can
contribute to the process oxygen demand.
• This results in an overall smaller plant footprint and greater process flexibility.
 And in Conclusion!

 Our Goals for Plant Improvements

• Keep operators engaged
• Open conduits for information sharing
• Identify problems and resolutions
• Maintain and/or upgrade plants as our systems
continue to evolve and improve
• Ensure each plant is a great resource for all involved

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 Thank you

Brian Codianne
Regional Manager, Kubota MBR Systems
[email protected]
425-898-3888