24 Feature

Filtration+Separation January/February 2009

Saving energy:
Using fine
bubble diffusers
ine bubble diffusers have largely replaced coarse bubble
F diffusers and mechanical aerators when it comes to treating
sewage and wastewater. But what role does energy efficiency
play? Adrian Ovezea explains how efficient use of this
technology can save energy in treatment plants and looks
at the different options available.

The need for technology with the liquor in the reactor, followed by (usually 2mg/l). This criterion is easy to
mechanical stirring. More recently, the air understand on one hand, but also subject to
Fine bubble diffusers are all about satisfying diffusing concept developed, enabling us to many other factors. We will return to these
the needs of the wastewater and sewage distinguish between coarse bubbling systems aspects elsewhere in this article.
treatment industry, in order to achieve an (with a bubble size of 5-10mm diameter) and
efficient mass transfer of oxygen to the water, 2. The other aspect to consider is
fine bubble diffusing (FBD) systems. The
particularly that with a suspension of active maintenance costs. It looks easy to clean
industry evolved to reach the point where we
sludge in a biological reactor. The oxygen a diffuser membrane as long it operates in
can now speak about ultra fine bubbles.
allows bacteria in a fermentation process to an accessible medium, but is very difficult
digest the food source (the sewage). These performing such operations in reactors
OPEX and CAPEX aspects
processes break down the waste and reduce it, with hundreds of thousands of cubic
so that it can settle in clarifiers or get filtered 1. The main way of evaluating the operational meters of sewage, without interrupting
by membranes in a last stage of treatment, expenses (OPEX) of the technology is by the process, and without causing higher
before being returned as final effluent into the using the aeration efficiency (AE). This related additional costs. Never argue the
environment. figure is a ratio between how many kilos importance of minimal capital expenses
Originally the method was mechanical and of O2 can be transferred into wastewater (CAPEX) during initial plant design, or
worked well for decades. Atmospheric air by using 1 kWh of electrical energy, at the during refurbishment, as costs incurred later
or even pure oxygen was injected or mixed required desired dissolved oxygen levels could make this a false economy.

Figure 1: Blower station and aerial view of covered aeration reactors at WwTP Linz Austria. This plant uses biogas digestion and compensates power balance with the national
grid. It uses the latest FBD technology from Aquaconsult Anlagenbau GmbH, Austria
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Filtration+Separation January/February 2009

TCO and WLC aspects

Total cost of ownership (TCO) and whole
life costs (WLC) are the concepts that prevail
today. Environmental aspects must also be
considered, which may contradict the usual
TCO and WLC workings.
s A technology entirely dedicated to
environmental protection, such as
wastewater treatment, may be impacting on
the carbon footprint of a treatment plant.
s The environmental impact of bypassing all
biological stages because of an incident in
the aeration system in a large treatment
plant must be considered.
s Typically 80% of the energy consumption
of a treatment plant goes to the blower
station in the process of air-feeding the
aeration reactors.
s Energy also goes into inefficient
mechanical aeration devices, usually
installed only for the sake of reduced
CAPEX some years ago.
Figure 2: Feldbach-Rabau, Austria. AEROSTRIP diffusers in conjunction with a mixer propeller in a racetrack reactor.
Bubbles, bubbles, bubbles….
WwTP goes straight into the aeration plant. many treatment plants are currently running
Usually the air bubbles are generated in
The second stage of the WwTP process is on old technologies, and how many more are
diffusers mounted on grids on tank floors,
“biological treatment” which requires oxygen. being planned, intended to be environmental
and they rise slowly to the water surface. The
friendly with current engineering techniques
finer the bubbles, the better, say the scientists, Let’s look at some figures. We speak often about incorporated into their design?
when it comes to the bubble size and oxygen flows of thousands of normal cubic meters
transfer through interfacial surface of the (Nm³) of air, and in large WwTP we may Designing a FBD system
water wall of the bubble. speak of airflow rates of 30-50000 Nm³/h to
They are many types and shapes of fine bubble assure amounts of 3500-4000 kgO2/h in clean When considering the energy question, the
diffusers. They have evolved according to the water (the criterion here is SOTE – standard design of any new fine bubble diffuser system
market’s needs and include: oxygen transfer rate in clear water, standard must focus on the following aspects:
conditions) at differential pressures as high as
s Ceramic diffusers. Made of ceramic porous s Use strip shaped diffusers, with a turndown
750mbar, all varying in time as requirement
material, with a dome structure. Air is ratio of 20:1, in order to get the smallest
from the reactors. The blower stations for
blown to a bottom mounted grid, diffused bubble size possible in any situation, and
such schemes are huge energy devourers – for
through the ceramic pores into water. lowest dynamic resistance against water
example, 8-10 units delivering on a common
flow (when using propellers).
Although they have high resistance to manifold, each using a 315 kW motor, running
corrosion, they are very prone to clogging. mostly in schemes of 24/7/12, with duty/assist s Lay out the design in order to maximise the
configurations, would use approximately 3 MW life of the bubble on its way to the surface,
s Floor covering panels with flexible poly-
installed power. using the whole water depth as immersion
urethane or silicone membranes. Very high
depth, by mounting diffusers directly on to
efficiency and long life, but heavy in weight Optimising energy use and saving energy is the tank floors – no grids, no condensate
and difficult to manipulate and replace. very important at this scale. Consider how removal, no deposits underneath diffusers.
s Flexible EPDM membranes of any shape,
from disc to flat surface and tubes. Very low
CAPEX, but short membrane life. Table 1: Comparison of aeration methods

s Flexible polyurethane or silicone Surface mechanical devices

membranes, on extremely flat stripes, as
floor covering. Higher CAPEX, but low Brush aerators / Mammoth rotors 1.5-1.8 kgO2/kWh
OPEX. Long membrane life.
Vertical shaft aerator 1.5-2.0 kgO2/kWh
It may be that the approach focussed on the
diffusers themselves and not on the whole
Submersible air-blowing diffusers
assembly, being the blower station, pipework,
headers, manifolds, diffusers and process AEROSTRIP™ 3.0-5.9 kgO2/kWh
automation.
Ceramic aerators 1.8-2.2 kgO2/kWh
The energy usage Hose EPDM shaped aerators 2.0-2.5 kgO2/kWh

Approximately 70-80% of the energy Disc EPDM shaped aerators 3.0-4.5 kgO2/kWh
consumption of a biological reactor in a
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Filtration+Separation January/February 2009

s Implement preventive maintenance s Some is lost into transformers, inverters, Facts about AEROSTRIP™:
on diffusers into plant logic controllers MCCs, cables, motors.
s Oxygen transfer efficiency of up to 60%.
(flexing and blow down cycles).
s The remainder is converted into
s Competitive performance through optimal
s Reduce over-aerating in the tanks, by mechanical energy at the blower shaft.
aeration efficiency value – aeration
implementing a fuzzy dissolved oxygen
s Blowers take air and feed the pipe work. efficiency of up to 5-6 kg O2/kWh
(DO) control, ensuring this is plant and
They lose energy at the intake filter
process specific. s Diffusers are extremely flat and are strip
and inside engine, depending on their
shaped, allowing installation mostly on
s Use positive displacement blowers on concept. Part of the absorbed energy will
the bottom of the tank, at full immersion.
VSD (variable speed drive) on common be delivered as compressed air with a given
This will gain water depth and more
manifolds and adaptive flow control, in pressure and airflow rate. Some is lost into
travelling time for the bubble on their
order to avoid unwanted waste of energy. heat generation, machine losses, friction on
way to the surface.
pipework, pressure drops, waves, noise, etc.
s Use control logic to adapt the operating
s The diffusers do not use EPDM membranes
range of the blowers and diffusers to match s Part of the energy is needed to beat the
but another type that is perforated without
their highest efficiency peak. static pressure of the immersion depth.
material dislocation, and opens pores
s Implement bursts in aeration and avoid s Part of the energy is lost through valves, gradually as the specific load increases.
continuous mixing, as a requirement of controlled orifices, etc.
s The membranes have a lifespan of 15 years,
minimum airflow for mixing.
s Another part is used in the aeration device. depending on plant design and operating
The results in terms of energy savings are up conditions.
s Bubbles with potential energy will be
to 6.0 kgO2/kWh. Is this high or low? The s 20:1 turndown ratio in continuous
released into water. Kinetic energy is used
comparison in Table 1 shows the difference operation (100 Nm³/hm² / 5 Nm³/hm²).
for suspended solids mixing. Approx 3W/
between aeration methods in terms of ranges
m³ of liquor is needed for mixing.
of SAE (Standard Aeration Efficiency) s Intermittent operation possible (0-100%
in normalised conditions. These results s The thermal energy of the air is transferred control of airflow range).
have been recorded in different plants and to water. s Coverage. A disc shape generates a
facilities worldwide, and speak mostly about
s Bubbles tend to accelerate to the surface. theoretical limit of 78% but feasibly can be
the principle of aeration and not about
The lower this speed, the better for oxygen just a maximum of 39%. AEROSTRIP™
manufacturers.
transfer efficiency. has theoretical coverage of 98% and a
The point of the comparison in Table 1 is not feasible coverage of maximum 70%.
how efficient the AEROSTRIP™ diffusers s Any remaining energy is returned to the
atmosphere. s Layout design with flexible lengths and
are, but how energy can be saved using the
adaptive densities – tapered designs for plug
proper technology combined with the best We took each of these aspects and adapted flow schemes always possible.
engineering, and treating the system as a our devices to get the most efficiency from
whole unit. them, in order to develop AEROSTRIP™. s Condensate removal systems needed
We also realised that modern inverters allow for other systems – not needed for
Where does energy usually go? us to drive blower motors and their shafts at AEROSTRIP™ manifolds.
their optimal speeds, as modern controllers s Lowest dynamic resistance against water
s Energy comes from the power station may control blowers’ speeds operating on a flow (when using propellers).
through distribution lines to the MCC common manifold as an adaptive source of air,
(motor control centre) units. always at peak efficiency. And the costs?
What are the expenses and savings the client
will assess when computing TCO or WLC?
1. CAPEX and OPEX shall be reported up to a
life cycle of minimum 10-15 years.
2. Membrane renewal expenses are normal.
The frequency of the renewal depends on
the manufacturer and method used. There
are manufacturers offering systems with a
15 year lifespan, while others offer 2-3 years
lifespan (EPDM mostly).
3. Energy expenditures tend to be increasing –
therefore there is a need for high efficiency
FBD systems.
4. Efficient systems demand less airflow,
smaller pipe work sizes and smaller
blower units.
5. Maintenance costs get higher when
preventive maintenance is ignored and
action taken after damage occurs.
6. Initial basic engineering and concept
development should be performed by
specialists. The tender documents should
Figure 3: An installation using AEROSTRIPs, at Brescia wastewater treatment plant, Italy. specify the requirements in clear water for
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Filtration+Separation January/February 2009

the oxygen demands, and allow impact

of the aeration design onto pipework,
blower, and I&C (instrumentation and
control) subpackages.
It is a common practice to focus on the diffusers
themselves and not on the whole assembly.
This shall gradually change, and total costs
shall be the future target to minimise.

Conclusion
From the manufacturers’ and researchers’
point of view, the following approaches are
recommended, which increase the SAE to
realistic limits for the industry:
s Reduce over-aerating in the tanks, by
implementing a fuzzy dissolved oxygen (DO)
control, always plant and process specific.
s Use positive displacement blowers on
VSD (variable speed drive) on common
manifolds and adaptive flow control,
Figure 4: Graph showing the typical curves of SOTE for different immersion depths for strip shaped diffusers
in order to avoid unwanted waste of energy. AEROSTRIP™

s Use control logic to adapt operating range tried – some energy was still wasted, but costs The above applies on active sludge
of the blowers and diffusers to match their were lowered due to recycling. However, there wastewater treatment. The multitude
highest efficiency peak. remained a high carbon footprint. of reactors types, shapes, processes and
technologies vary from land to land, from
We are positive that process engineers will
s Implementing bursts in aeration and avoid
continuous mixing, as a requirement of
pay more and more attention in saving energy
continent to continent. s
in the future, contributing to the slowing of Contact:
minimum airflow for mixing.
global warming, minimising carbon footprints Adrian Ovezea
Readers may think the wasted energy could be and minimising energy use by considering the AQUACONSULT Anlagenbau GmbH
recompensated by the production of electricity latest generation of diffusers as best response Email: [email protected]
from biogas in plants with digesters. This was to this challenge. www.aquaconsult.at