AIR-SPARGED HYDROCYCLONE (ASH) FOR TREATING WASTEWATER

Revision Date: 1/04
Process Code: Navy/Marines: SER-016-99; Air Force: FA09; Army: N/A
Usage List: Navy: High; Marines: High; Army: Medium; Air Force: High
Alternative For: Pump and treat systems, controlled release to industrial/municipal wastewater treatment plants, and other wastewater treatment strategies
Compliance Impact: Medium
Applicable EPCRA Targeted Constituents and CAS Numbers: N/A

Overview: The Air-Sparged Hydrocyclone (ASH) unit utilizes both air sparging and hydro-cyclone technologies to help improve the separation of oily particles and Aqueous Film-Forming Foam (AFFF), fire-fighting foam commonly used by the military. The ASH technology provides a cost-effective and versatile.

The wastewater treatment process begins by pumping contaminated wastewater from either a facility-supplied equalization tank or the ASH-supplied storage tank into three separate mixing tanks where coagulant (polymer) and flocculent (FeCl) are added. The coagulant helps to bind smaller suspended particles together and the flocculent helps to float these particles to the top of a liquid solids separator. The chemically treated wastewater is tangentially introduced into the ASH cylinder (see diagram) generating a cyclonic flow.

High-pressure air is introduced through the porous exterior wall of the cylinder. This high-pressure air forms air bubbles that migrate toward the center of the ASH cylinder. The rotation of the water around the cylinder creates a strong centrifugal force, which increases the probability of fine contaminants attaching to the air bubbles. The bubble/contaminant aggregates move to the center of the cylinder and form a froth. This froth travels through the center of the cyclone and is directed toward a separator via an over flow pipe. Once in the separator, the contaminant froth is removed from the surface by a skimmer and temporarily stored in a sludge holding tank. The sludge is then pumped into appropriate containers for proper disposal.

Currently the ASH is deployed on a mobile trailer and as such the ASH unit�s mobility affords it the flexibility of use in multiple scenarios. In its mobile configuration, it can be placed as needed in the treatment cycles for Collection Holding and Transfer (CHT), oily wastewater, and bilge water in both shore-based and shipboard applications. Determining factors for using the ASH unit include the volume of wastewater to be treated, the contaminant type, how early the contaminant is identified, and the location of the contamination source. The unit can be manufactured in a permanent configuration if it is desired to be part of a permanent pre-treatment facility.


Compliance Benefit: The use of an ASH treatment system can help facilities meet pretreatment standards for discharges of wastewater to a publicly owned wastewater treatment plant (40 CFR 403) or to meet the effluent limits of a National Pollutant Discharge Elimination System (NPDES) permit (40 CFR 122, 401). The technology may help certain facilities that directly discharge wastewaters from oily operations to meet the requirements of the new Metal Products and Machinery rule (40 CFR 438). In addition, this treatment process may help facilities meet the requirements of waste reduction under RCRA (40 CFR 262) and Executive Order 13148. It may also help facilities reduce the number of regulations required for compliance with the management of hazardous waste (i.e., recordkeeping, reporting, inspections, transportation, and accumulation) under RCRA (40 CFR 262).

The compliance benefits listed here are only meant to be used as general guidelines and are not meant to be strictly interpreted. Actual compliance benefits will vary depending on the factors involved, e.g., the amount of workload involved.


Materials Compatibility: Chemicals used with the ASH include a weak acid (ferric chloride) and a polymer. These materials pose an extremely small risk of incompatibility with the wastewater targeted for treatment with this technology.


Safety and Health: Due to the possible corrosive properties and inherently toxic nature of wastewater and the targeted contaminants, care should be taken when handling wastewater. Proper personal protection equipment is highly recommended. Additionally care should be taken when handling of the bulk chemicals used for chemical addition. Common splash gear and protective gloves should be used when handling the ferric chloride.

Consult your local industrial health specialist, your local health and safety personnel, and the appropriate MSDS prior to implementing this technology.


Benefits:
  • The technology can remove approximately 90 percent of the oily particles and AFFF.
  • The mobile ASH unit provides a timely response to spills and has the potential to reduce the cost of tank rental and final disposal.
  • The technology has the ability to handle a large range of volumes with a lower retention time and high contaminant removal rate than typical gravity-based separation technologies.
  • The rugged design allows for handling of multiple types of waste streams.


Disadvantages:
  • The ASH system requires trained personnel to maximize contaminant removal and to ensure that the system is operating within proper parameters.
  • The polymer used has a shelf life of approximately 6 months, necessitating rotation of stock.
  • The unit as currently used requires utilities (electricity, water, and sewer discharge) to be provided.
  • The ASH unit is a pre-treatment technology (i.e., further water treatment may be needed), not a turnkey treatment system.


Economic Analysis: On behalf of the Naval Station Mayport, Florida, and under the Navy Environmental Leadership Program (NELP) Demonstration Project, the National Defense Center for Environmental Excellence (NDCEE), compiled Navy-wide costs for the collection, treatment, and disposal of petroleum-contaminated bilge water. The NDCEE, operated by Concurrent Technologies Corporation, also investigated innovative methods for treating this waste stream to reduce treatment costs. The cost to pre-treat 10,000 gallons of AFFF-laden wastewater by way of the on-site ASH unit is approximately equal to the cost for offsite treatment and disposal of 1000 gallons.

Capital cost estimates range from $173,000 at 50 gpm to $275,000 at 150 gpm. Utility and chemical costs would range from approximately $0.17 per 1,000 gallons for AFFF removal only (i.e., no chemical treatment) to $2.54 per 1,000 gallons for extremely high oil and grease concentrations. In addition, repair and replacement costs for the alternative, more inefficient, oil/water separators are avoided. One estimate conducted by the U.S. Army Environmental Center stated that these repair and replacement costs of existing separators are on the order of $100 million.The payback would vary from 2-7 years, depending on the volume of the waste stream to be periodically treated, the concentration of the contaminants, and the cost of current treatment or disposal methods. Similar findings are reported in a 2003 ESTCP Cost and Performance Report in which the ASH technology was evaluated during 1-day field tests at nine Navy, Marines, and Air Force sites.


NSN/MSDS:
Product NSN Unit Size Cost MSDS*
Ferric Chloride F1060 N/A 500 grams  $90.15 Click me

*There are multiple MSDSs for most NSNs. The MSDS (if shown above) is only meant to serve as an example. To return from the MSDS, click the Back Arrow on the Tool Bar.


Approving Authority: Appropriate authority for making process changes should always be sought prior to procuring or implementing any of the technologies identified herein.


Points of Contact: For more information

Vendors: This is not meant to be a complete list, as there may be other suppliers of this type of equipment.

Kemco Systems
11500 47th Street North
Clearwater, FL 33702
Phone: (800) 633-7055


Related Links: Oil/Water Emulsion and Aqueous Film Forming Foam Treatment Using Air-Sparged Hydrocyclone Technology, Environmental Security Technology Certification Program (ESTCP)


Sources: Concurrent Technologies Corporation. Summary Report of Separation of Aqueous Film Forming Foam (AFFF) from Water (Task 1). Navy Environmental Leadership Program Demonstration Project, National Defense Center for Environmental Excellence (NDCEE).
Oil/Water Emulsion and Aqueous Film Forming Foam (AFFF) Treatment Using Air-Sparged Hydrocyclone Technology, Environmental Security Technology Certification Program, 2003, http://www.estcp.org/projects/compliance/200005v.cfm, accessed October 2003.


Supplemental: Overview or Illustration of Flow Process