Design Considerations

for BioMag Facilities

Thor Young | Principal Manager
 Introduction
Overview of BioMag Process
Conventional Activated Sludge Process Solids loading rate < clarifier capacity
MLSS, mg/L Capacity
3,000 Loading Rate

Influent Effluent
Mixed Liquor
Reactor Clarifier

Return Activated Sludge (RAS)

Biological Floc

Waste
Activated
Sludge
(WAS)

GHD @ WEFTEC 2014

To achieve better treatment increase MLSS clarifier at capacity
(BNR/ENR) MLSS, mg/L Capacity
4,000
3,000 Loading Rate

Influent Effluent
Mixed Liquor
Reactor Clarifier

Return Activated Sludge (RAS)

Waste
Activated
Sludge
(WAS)

GHD @ WEFTEC 2014

 Further increase MLSS clarifier overloaded
MLSS, mg/L Capacity
6,000
4,000 Loading Rate

Influent Effluent
Mixed Liquor
Reactor Clarifier

solids
in effluent
Return Activated Sludge (RAS)

Waste
Activated
Sludge
(WAS)

GHD @ WEFTEC 2014

 enhanced clarifier capacity
MLSS, mg/L
MLSS, mg/L Capacity
6,000
6,000 Loading Rate

Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier
Magnetite
improved settling high-
Mag quality effluent
Silo Magnetite Ballasted Return
Return
Activated
Activated
Sludge
Sludge
(B-RAS)
(RAS)
Feed
System
Virgin
Magnetite

Ballasted
Waste
Activated
Sludge
wasted magnetite?
(((B-WAS)
(WAS)
(B
B--WAS)
WAS)
(WAS)
WAS)

GHD @ WEFTEC 2014

 MLSS, mg/L Capacity
6,000 Loading Rate

Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier

Mag
Silo Ballasted Return Activated Sludge (B-RAS)

Virgin
Magnetite

Magnetite Recovery System Ballasted

Recovered Shear Mill Waste
Magnetite Activated
Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

 Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier

Mag
Silo Ballasted Return Activated Sludge (B-RAS)

Virgin
Magnetite Ballast
Mix Tank

Magnetite Recovery System Ballasted

Recovered Shear Mill Waste
Magnetite Activated
Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

 Overview Chemical
Addition
Biological Secondary
Processes Clarifiers
Preliminary
Treatment Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier
Aeration and
Mixing
Mag
Silo Ballasted Return Activated Sludge (B-RAS)

Pipes and
Virgin Open Channels Solids
Magnetite Ballast Wasting
Mix Tank
Magnetite
Feed Magnetite Ballasted
Recovered Recovery Shear Mill Waste
Solids Magnetite Activated
Treatment Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

Preliminary Treatment
2-mm Fine Screen (B-WAS)
Ballasted
Influent Effluent
Mixed Liquor
Reactor
Reactor Clarifier

Mag
Silo Ballasted Return
Ballasted Return Activated
Activated Sludge
Sludge (B
(B-RAS)
(B RAS)

Virgin
Magnetite Ballast Equipment needed
Mix Tank to protect magnetite
recovery equipment
from rags, debris, Ballasted
Recovered fibrous materials
Shear Mill Waste
Magnetite Activated
Sludge
Magnetic
Primary Clarifier 2-mm Fine Screen
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

Biological Processes

Ballasted
Influent Effluent
Mixed Liquor
Mixed Liquor
Reactor Clarifier
BioMag compatible with:
Conventional aeration
Mag Extended aeration
Silo4-Stage Bardenpho Ballasted Return Activated Sludge (B-RAS)
5-Stage Bardenpho
Modified
Virgin Ludzack-Ettinger (MLE)
Sequencing
Magnetite Batch Reactors
Ballast
Mix Tank
Typical MLSS concentrations:
Conventional: 2,000 4,000 mg/L Ballasted
BioMag: 5,000 8,000 mg/L (excl. magnetite)
Recovered Shear Mill Waste
Double or triple Magnetite
biological treatment capacity Activated
Sludge
within existing tank volume Magnetic
(B-WAS)
Recovery
"Charging"
Waste system(WAS)
Activated Sludge with magnetite
Drum takes weeks

GHD @ WEFTEC 2014

Biological Processes

Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier
Microbial Kinetics
No negative impacts to nitrification/denitrification
Mag shown by McConnell et al. (2010)
SiloImproved simultaneous Ballasted Return Activated Sludge (B-RAS)
nitrification-denitrification
observed by Jimenez et al. (2013), possibly from
Biofilm formed on magnetite
Virgin
Magnetite
Magnetite facilitates electron transfer
Ballast
Further investigation
Mix Tankneeded on SND kinetics

Ballasted
Filamentous Growth Recovered Waste
Shear Mill
Magnetite weighs down filamentous
Magnetite floc and Activated
improves clarifier performanceMagnetic
Sludge
(B-WAS)
Additional
Waste Activatedmeasures requiredRecovery
Sludge (WAS) in severe cases
Drum

GHD @ WEFTEC 2014

Aeration &
& Mixing
Mixing

Ballasted
Influent Effluent
Mixed Liquor
Mixed Liquor
Reactor Clarifier
Aeration Considerations:
Increased MLSS and
Mag biomass will decrease
Siloalpha (oxygen transfer coefficient)
Ballasted Return Activated Sludge (B-RAS)
Aeration system will need to be evaluated
Magnetite does not increase alpha
Virgin
Magnetite testing
(independent by McKean et al., 2013)
@ 3,000 mg/L 0.8
Ballast
Mix Tank
BioMag has been testedwith: @ 8,000 mg/L 0.5
Coarse-bubble diffusers, Ballasted
Recovered Shear Mill Waste
Fine-bubble diffusers,Magnetite Activated
Jet aeration, and Magnetic
Sludge
(B-WAS)
Mixers
Waste withSludge
Activated air sparge
(WAS)
Recovery
Drum

2003 Krampe & Krauth. Oxygen transfer into activated sludge with high MLSS concentrations
GHD @ WEFTEC 2014
Aeration &
& Mixing
Mixing

Ballasted
Influent Effluent
Mixed Liquor
Mixed Liquor
Reactor Clarifier
Mixing Considerations:
Maintain ballasted
Mag solids in suspension
Silo Supplemental mixingBallasted Return tanks
for aerated Activated Sludge (B-RAS)
May need to upsize mixers in unaerated tanks
Watch out in corners and behind mixers
Virgin
Magnetite Ballast
Design GuidelinesMix Tank
HP per gallon varies based on tank geometry
Ballasted
Minimum velocity of 1.5 fps along tank floor
Recovered Waste
Shear Mill
Magnetite
CFD has been attempted with mixed results Activated
Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum
Moody et al. (2011). Beyond Desktop Evaluation: Key Design Criteria
for Mixing and Settling of Magnetite-Impregnated Mixed Liquor

GHD @ WEFTEC 2014

Aeration &
& Mixing
Mixing

Ballasted
Influent Effluent
Mixed Liquor
Mixed Liquor
Reactor Clarifier

Recommendations:
Mag Systems that allow for
Siloindependent mixing and Ballasted Return
aeration Activated Sludge (B-RAS)
preferred
(e.g. jet aeration systems, mixers with air sparge)
Involve mixer manufacturer early in design
Virgin
Consider
Magnetitea low-DO zone to promote SND
Ballast
Mix Tank

Ballasted
Recovered Shear Mill Waste
Magnetite Activated
Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

Chemical Addition Metal Salt Polymer
pH, Alkalinity

Ballasted
Influent Effluent
Mixed Liquor
Reactor
Reactor Clarifier
Clarifier
Magnetite does not
impact alkalinity or pH
Mag
Ballasted
SiloMetal salts required for Return
enhanced TPActivated
removalSludge (B-RAS)
Effluent TP < 0.2 mg/L without filtration
Compatible with alum, ferric, PACl
Virgin
Magnetite
Magnetite does not impact chemical stoichiometry
Ballast
Mix Tank
Polymer required upstream of secondary clarifier
Ballasted
Feed rate = 2 mg/L x (Plant + RAS flow)
Recovered Waste
Shear Mill
Magnetite
Size system to provide dose at peak flows Activated
Sludge
Avoid insufficient or excessive mixing
Magnetic
(B-WAS)
Recovery
Activated
Waste Dry feedSludge
more cost-effective
(WAS) for large facilities
Drum

GHD @ WEFTEC 2014

 Secondary Clarifiers

Ballasted
Influent Effluent
Effluent
Mixed Liquor
Mixed Liquor
Reactor Clarifier
100
100
Solids Loading Rate, lb/d/ft

Mag
Silo Ballasted Return Activated Sludge (B-RAS)
(B RAS)
80 Peak solids loading
increased by 150%
60Virgin SLR does not include
Magnetite Ballast weight of magnetite
Mix Tank 40 Hydraulic loading rate
40 35
hasBallasted
not been a limiting
25
Recovered factor to date; limits
Waste
Shear Mill
20 Magnetite unknown
Activated
Sludge
Magnetic
Recovery (B-WAS)
0 Activated Sludge (WAS)
Waste Drum
Average Peak
GHD @ WEFTEC 2014
Secondary Clarifiers

Ballasted
Influent Effluent
Effluent
Mixed Liquor
Mixed Liquor
Reactor Clarifier
Design Guidelines
Conventional activated sludge SVI correlations may not
Mag
Mag be appropriate for
be appropriate for design/evaluation
design/evaluation
Silo
SiloDesigns should be
Designs should
Designs Ballasted
be based
based on Return Activated
on site-specific
Ballasted Return
site-specific Sludge
column
Activated
column (B-RAS)
(B
tests,
Sludge RAS)
(B-RAS)
tests,
pilots, or consultation
pilots, or consultation with
with system
system supplier
supplier
L Loading rates on
oading rates on previous
previous slide
slide may
may bebe used
used as
as guide
guide
Virgin
Virgin
No No impact on
impact
Magnetite on mechanisms
mechanisms (negligible
(negligible load
load increase)
increase)
Magnetite Ballast
Ballast
Mix
Mix Tank
Tank
Additional Considerations
Additional Considerations
Ballasted
BioMag
BioMag is is well-suited
well-suited
suited for sludge blanket
for sludge
Recovered
Recovered
blanket level
level detectors
detectors Waste
Shear Mill
Shear Mill
Tested on
Tested on circular
circular and
and rectangular
Magnetite
rectangular
Magnetite clarifiers
clarifiers Activated
Suction manifold
Suction manifold clarifiers
clarifiers headers
headers recommended Sludge
Magneticrecommended
Magnetic
Recovery (B-WAS)
Special
Special
Waste
Waste considerations
Activated
Activated (WAS)needed
Sludge (WAS)
considerations
Sludge needed for peripheral
for peripheral feed
Recovery feed
Drum
Drum
1995 Daigger. Development of Refined Clarifier Operating Diagrams Using an Updated Settling Characteristics Database

GHD @ WEFTEC 2014

Solids Wasting

Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier
Design Considerations
Don't include magnetite in SRT calculations
Mag Consider different options for wasting
Ballasted Return
(B-RAS)Return Activated
Silo Clarifier underflow Ballasted Activated Sludge
Sludge (B
(B-RAS)
(B-RAS)
(B RAS)

Virgin
Magnetite Ballast 12,000 16,000
Mix Tank mg/L TSS
Avoid progressive
cavity pumps Ballasted
Recovered Shear Mill
Shear Mill Waste
Magnetite Activated
Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

Solids Wasting

Ballasted
Influent Effluent
Mixed Liquor
Mixed Liquor
Reactor Clarifier
Design Considerations
Don't include magnetite in SRT calculations
Mag Consider different options for wasting
Ballasted Return
(B-RAS)Return Activated
Silo Clarifier underflow Ballasted Activated Sludge
Sludge (B
(B-RAS)
(B

Classifying selector (surface wasting)

Target foam-causing organisms
Virgin
IncreasedBallast
Magnetite flow to recovery equipment 12,0008,000
6,000 16,000
mg/L
Mix Tank mg/L TSS
TSS

Ballasted
Recovered Shear Mill
Shear Mill Waste
Magnetite Activated
Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

Solids Wasting

Ballasted
Influent Effluent
Mixed Liquor
Mixed Liquor
Reactor Clarifier
Design Considerations
Don't include magnetite in SRT calculations
Mag Consider different options for wasting
Ballasted Return
(B-RAS)Return Activated
Silo Clarifier underflow Ballasted Activated Sludge
Sludge (B
(B-RAS)
(B

Classifying selector (surface wasting)

Target foam-causing organisms
Virgin
IncreasedBallast
Magnetite flow to recovery equipment 6,000 8,000 mg/L
Thickener
Mix Tank to gravity thickener
Classifying selector TSS
Target foam-causing organisms Ballasted
Reduced flow to recovery equipment Shear
Recovered Shear Mill
Mill Waste
Magnetite
Storage capacity for operational flexibility Activated
Sludge 1-5% solids
Magnetic
HRT allows polymer to biodegrade
Recovery (B-WAS) Thickened
Waste Activated
Consider Sludge (WAS)
providing flexibility toDrum
use various means B-WAS

GHD @ WEFTEC 2014

 Solids Wasting

Assuming 95% magnetite capture efficiency

Ballasted
Influent and 25% Effluent
Mixedbiological
Liquor solids return rate
Reactor Clarifier
Further Considerations
Not all B-WAS is wasted (biological floc attached to recovered magnetite)
Mag
Keep in mind when sizing B-WAS pumps and magnetite recovery system
Silo Ballasted Return Activated Sludge (B-RAS)
WAS Recovered Magnetite B-WAS

19,950 gal/day 50 gal/day 20,000 gal/day

750Virgin
lb/day MLSS 250 lb/day MLSS 1,000 lb/day MLSS
Magnetite Ballast
50 lb/day magnetite 950 lb/day magnetite 1,000 lb/day magnetite
Mix
Mix Tank
Tank

Ballasted
Ballasted
Recovered Shear Mill Waste
Magnetite Activated
Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

Magnetite Recovery

Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier

Mag
Silo Ballasted Return Activated Sludge (B-RAS)

Virgin
Magnetite
Magnetite Ballast
Mix Tank

Ballasted
Recovered Shear Mill Waste
Magnetite Activated
Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge
Sludge (WAS)
(WAS) Drum

GHD @ WEFTEC 2014

Magnetite Recovery

Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier
Shear Mills
Improves magnetite recovery efficiency,
Mag particularly at
particularly at high
high flow
flow and
and load
load conditions
conditions
SiloHigh
High
High electrical load Ballasted Return Activated Sludge (B
electrical load (B-RAS)
Operators have to weigh cost of energy use
with
with cost
cost of
of reduced
reduced magnetite
magnetite recovery
recovery
Virgin
Yearly
Yearly blade replacement,
blade
Magnetite replacement, depending
depending onon use
use
Ballast
Variable
Variable speed
speedMixdrives
Tankto
drives to run
run at
at constant
constant torque
torque
Should
Should bebe near
near Magnetic
Magnetic Recovery
Recovery Drums
Drums
Ballasted
Loud!
Loud! Consider
Consider siting
siting in
in basement
basement
Recovered Waste
Shear Mill
Shear Mill
Magnetite Activated
Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

Magnetite Recovery

Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier
Magnetic Recovery Drums
Retrieves magnetite from B- B-WAS
B -WAS
Mag Permanent
Permanent magnet
magnetnot not an electro
electro-magnet
magnet
Ballasted Return Activated Sludge (B
(B-RAS)
SiloFlow
Flow
F low meters
Flow meters and
and valves
valves to
to evenly
evenly distribute
distribute flow
flow
Hydraulic and solids loading rates
Provided
Provided by
Virgin by manufacturer
manufacturer
Magnetite
Consider
Consider all
all sludge
Ballast wasting
sludge wasting options
options
Consider Mix Tank solids
Consider biological
biological solids capture
capture rate
rate
Variable speed drives to adjust rotation speed Ballasted
Continuous
Continuous operation recommended
Recovered
operation recommended Shear Mill Waste
Wet environment Magnetite
Magnetite Activated
Sludge
Magnetic
Recovery
FM
(B-WAS)
Waste Activated Sludge
Sludge (WAS)
(WAS) Drum
M

GHD @ WEFTEC 2014

Magnetite Recovery

Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier
Ballast Mix Tank
Blends magnetite into mixed liquor
Mag Pump or gravity flow to reactor distribution box
Ballasted Return
Ballasted Return Activated
Activated Sludge
Sludge (B
(B-RAS)
(B RAS)
SiloArrangements for multiple drums

Virgin
Magnetite
Magnetite Ballast
Mix Tank

Ballasted
Recovered
Recovered Shear Mill Waste
Magnetite Activated
B-RAS (100-200 gpm) Sludge
Magnetic
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

 Magnetite Feed

Ballasted
Influent Effluent
Mixed Liquor
MagnetiteReactor
Magnetite Feed
Feed System
System Clarifier

Storage: magnetite silo (30-day

(30 day storage)
Mag Small installations may use skid hopper
Silo Ballasted Return Activated Sludge (B
Conveyance:
Conveyance: pneumatic system
pneumatic (B-RAS)
system
Air compressor, dryer, and conveyor
Virgin
Virgin Storage silo should be near ballast mix tank
Magnetite
Magnetite For long distances:
Ballast
CONVEYOR Mix Tank Water eductor and carrier fluid may be required

Ballasted
Air Dryer Recovered Waste
Shear Mill
Magnetite Activated
Sludge
Air Air Magnetic
Recovery (B-WAS)
Compressor Compressor
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

Redundancy and Emergency Operations

Ballasted
Influent Effluent
Mixed Liquor
Magnetite recovery equipmentReactor not required to Clarifier
meet treatment requirements
Mag Shear Mills
Silo Not critical, may beBallasted
bypassedReturn Activated Sludge (B-RAS)
May be shut off during low flows
Magnetic Recovery Drums
Virgin
Magnetite
RedundancyBallast
recommended but not required
Many small Mixfacilities
Tank only have one unit
Ballast Mix Tank
Ballasted
Mixer should beRecovered
running at all times Waste
Shear Mill
Provide a spareMagnetite
mixer or gearbox/motor Activated
Sludge
Magnetite Feed System Magnetic
(B-WAS)
Recovery
Waste Activated
May be taken
Sludgeout
(WAS)of serviceDrum
for a few days
Standby air compressor & dryer optional
GHD @ WEFTEC 2014
Pipes and Open Channels

Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier
Design considerations:
Velocities for pipes and open channels:
Mag 1.5 feet per second
Silo 2 fps for re-suspensionBallasted Return Activated Sludge (B-RAS)
of settled magnetite
Consider startup and diurnal low flows
Avoid
Virginlow points in gravity pipes
Provide fillets and
Magnetite sloped floors for channels
Ballast
Run pumps at high Mix Tank
speed to flush pipes
Automatic program Ballasted
Particularly recommended
Recovered for RAS pumps Shear Mill Waste
Magnetite boxes
Provide mixers for distribution Activated
Sludge
Magnetic
VFDs to allow for speed/power optimization
Recovery (B-WAS)
Waste Activated Sludge (WAS) Drum

GHD @ WEFTEC 2014

Solids Handling and Treatment

Ballasted
Influent Effluent
Mixed Liquor
Reactor Clarifier
Design considerations for solids treatment and handling processes
Expect a amount of magnetite in solids process
Mag No impact on treatment and stabilization processes
Ballasted Return Activated Sludge (B-RAS)
Silo No issues anticipated with obtaining Class A biosolids
Residual magnetite may improve gravity thickener performance
Virgin
Magnetite Ballast
Mix Tank

Ballasted
Recovered Shear Mill Waste
Magnetite Activated
Sludge
Magnetic
Recovery (B WAS)
(B-WAS)
Waste Activated Sludge
Sludge (WAS)
(WAS) Drum

GHD @ WEFTEC 2014

 Installations

Startup YearBallastedPilot History

Average Flow,
Facility Name Location
Influent mgd Effluent
Long Trail Brewing Company VT 2008
Mixed LiquorNo pilot 0.013
Reactor Clarifier
Allenstown WWTF NH 2011 No pilot 1.3
Sturbridge WWTF MA 2012 2007 1.3
Upper
Mag Gwynedd WWTP PA 2014 2009 3.0
Silo
Smithsburg WWTP Ballasted
MD Return 2014
Activated
(est.) Sludge (B-RAS)
2013 0.3
Easterly WWTP MA 2014 (est.) No pilot 5.5
Mystic WPCF CT 2014 (est.) 2009 1.4
Virgin
Marlay-Taylor WWTP MD 2014 (est.) No pilot 6.0
Magnetite Ballast
Phillipsburg WWTP NJ 2015 (est.) No pilot 5.4
Mix Tank
Front Royal WWTP VA 2016 (est.) No pilot 5.3
Taneytown WWTP MD In design 2010 Ballasted 5.0
Opequon/Hedgesville WWTFRecovered
WV In design Shear Mill 2011 Waste 1.6
Kemptville WPCP Magnetite
Ontario In design 2013 Activated 3.1
Sludge
Winebrenner WWTP MD Magnetic In design 2009 2.2
Recovery (B-WAS)
Notes: Partial installation and pilot list provided by Evoqua Water Technologies, July 2014. Startup year for facilities currently under
Waste Activated Sludge (WAS)
construction are estimated based on construction schedule.Drum

GHD @ WEFTEC 2014

Thank you