Development, Challenges, and
Validation of a High Efficiency
UV Unit
Wayne M. Emery, P.E.
Calgon Carbon Corp
Presentation Outline
Introduction
System Details
Delta Wings
Case Study
Title 22
System Sizing
Installations
Closing Remarks
Who is Calgon Carbon?
 We solve customer purification
and separation problems with
a variety of technologies
 World’s Largest Producer of
Granular Activated Carbon
 Diverse Product Portfolio
 900+ employees
 240 patents
 10 sales offices – 6 countries
 14 manufacturing facilities – 6
countries
 Revenues: > $500 M
 On New York Stock Exchange
(CCC)
 60 + Years of Experience in
Water Treatment
UV Technologies Division
 25 year track record in UV water
treatment
 UV products for treating
contaminated water, wastewater,
drinking water and ballast water
 Pioneered the use of UV
technology for the inactivation of
Cryptosporidium and Giardia in
drinking water
 > 500 installations
 Located and manufactured in the
Pittsburgh, PA area
Calgon Carbon’s UV Technologies
Drinking Water Disinfection – to inactivate
pathogenic bacteria, viruses, and protozoa
(Cryptosporidium and Giardia control)
Wastewater Disinfection – to reduce
chlorine discharge into the environment
Advanced Oxidation – to destroy toxic
chemical contaminants
Ballast Water Treatment – to remove or kill
invasive species transported by marine
vessels
Calgon Carbon’s UV History
Started in Advanced Oxidation (MP + Hydrogen
Peroxide): 1985, acquired by CCC in 1996
Progressed to Drinking Water with MP: 1997,
CCC innovation
Entered Wastewater Market with LP: 2004, CCC
acquisition 2004
Entered Ballast Water Market (MP UV and
filtration): 1995, acquired by CCC 2010
How Should You Want Your System
Designed?
 Use advanced science and technology to develop
products
 Bioassay validated products – true sizing and
performance verification, not just “manufacturer’s
claims”
 Make sure the system won’t have to be ‘upgraded’
due to performance or design issues
 Use high powered lamps for WW open channel –
basis for low O&M and smallest footprint
 Focus on real Cost of Ownership for lowest 20 year
Net Present Value
Typical System
Technical Details – Lamp Rack
 8 lamps per rack, max.
 Interchangeable design
 Individually isolated
 Designed to comply with
IP67 for intermittent
submergence
 Cleaning system is
electrically driven
minimizing number of
components
 Two cable assemblies
per rack each powering
4 lamps
Technical Details – Lamp




520 W low pressure high output pellet amalgam lamp
Up to 205 W of UVc output
Coated lamp for longer life, 12,000 hour guarantee
Pre-heat start configuration to reduce the effects of cycling due to
process conditions such as Sequential Batch Reactors
 Continuous heat configuration for power savings and extended lamp
life
Lamp
Data
Technical Details –
Cleaning System
Technical Details – UV Sensor
 UV sensor, factory
calibrated to DVGW
reference standard
 One sensor per UV
bank
 Value used in dose
calculation to allow
maximum turn-down
when Dose Pacing
enabled
 Maximize energy
savings
Technical Details – PDC
 Designed to comply
with NEMA 4X (IP 65)
ratings
 Each supplied with main
breaker and lockable
doors
 Operator Station on
front door allows
Operators to view PDC
status and control PDC
manually, if required
Technical Details – Ballast
 Each Ballast drive one lamp
 Variable output 60 to 100%
 Powered by single phase
220 - 277VAC, 60 Hz
 Interchangeable, addressed
via slot in card cage
 Individual lamp failure
indication reported locally via
LED and remotely at SCC
 System Power Factor > 0.98
at full power
 Complies with Current Total
Harmonics Distortion
guidelines specified in IEEE
519-1992 standards
UV System Control Center
 Allen Bradley
CompactLogix or
ControlLogix PLC
 Allen Bradley
PanelView Plus
600/1000/1500
 Standard Designs
Level Control
Weir
Motorized Weir Gate
Level Control Gate
Delta Wings
Background
Irradiance drops off exponentially with distance
from the lamps
100%
90%
Relative Irradiance
80%
65%T
70%
55%T
60%
50%
40%
30%
20%
10%
0%
0
0.5
1
1.5
Distance from Lamp, in
2
2.5
3
Relative Irradiance in Lamp Array
x
Relative Irradiance at Center Point
30%
25%
x
20%
65%T
55%T
15%
10%
Center point has
the lowest intensity
5%
0%
2
2.5
3
3.5
4
4.5
5
Spacing Between Lamps, in
Relative Irradiance at the center point between 4 lamps in a square lamp array vs.
lamp spacing between adjacent lamps in the array
The Challenge with Higher Power
Amalgam Lamps
 To maintain the same hydraulic efficiency, the flow per
lamp must be proportional to the Lamp Power
 Lamp spacing must be increased to limit the pressure
drop due to the increased flow per lamp (velocity)
 Increased lamp spacing results in poor dose distribution
and hence lower hydraulic efficiency
 We calculate a limit of approx. 300 Watts per lamp for 3
to 4 inch spacing at 55 and 65%T, respectively
HOW DO WE ACHIEVE ACCEPTABLE HYDRAULIC
EFFICIENCY WHEN WE HAVE CONFLICTING
REQUIREMENTS.
Design Requirements
Design an open channel UV disinfection
system with 500 to 600 Watt lamps that:
Complies with NWRI guidelines
Produces a high MS2 RED at relatively low
flows
Optimizes hydraulics efficiency due to larger
lamp spacing required for higher power
lamps
The Solution - Mixing
Mixing devices - Delta Wings
Create large scale counterrotating vortices.
Transports the water:
 farthest from the lamps in
towards the lamps
 close to the lamp moved away
from the lamps
Permits lamps of 500 Watts
and greater to be employed
Research & Development
Development of mixing
device to increase the
hydraulic efficiency of the
UV reactor
Use patent # 6,015,229,
dated Jan. 18, 2000,
issued to Calgon Carbon
as basis of design
How does a Delta Wing work?
Flow across a delta
wing inclined to the
flow of water
produces two
counter-rotating
vortices
CFD Analysis
CFD analysis of UV reactor without mixing
High fluence rate
around lamp,
lower fluence
between lamps
Velocity vectors showing
Vortices generated by Delta Wings
CFD Modeling of Delta Wings
MS2 Concentration as the fluid exits the UV Bank Array
No Mixing
1 set of Delta Wings
3 sets of Delta Wings
C3500D Research & Development
Performance of mixing devices
24
MS2 RED mJ/cm2
22
20
18
16
14
12
10
0
1
2
3
Number of Delta Wings
4
Pilot Tests
Pilot system tested with and without
Delta Wings
Worked with the University of Toronto and
GAP Enviro Microbial Services to test the
various combinations
Secondary effluent with MS2 & T1 phage
added as surrogate organisms
UV Transmission ranged from 50 – 70%
using SuperHume™
C3500D Piloting
PDC
MS2 & T1 Dosing
UV Bank
Valve
Pump
Flow Meter
Pilot Tests with & without Delta
Wings
140
120
50%T w/o Delta
60%T w/o Delta
67%T w/o Delta
50%T w Delta
60%T w Delta
67%T w Delta
MS2 RED
100
80
60
40
20
0
20
40
60
Flow
80
100
Product Finalization
Product Finalization
NWRI Validation
Pilot test site at Stockton
WWTP, CA
Carollo Engineers as 3rd
Party Engineer
Low dose (T1) and
NWRI (MS2) testing
simultaneously
UVT range: 35 – 74%
Flow range: 0.7 - 4.3
MGD
Case Study:
City of Stockton, CA
Case Study – Design Parameters
•
•
•
•
•
•
•
Peak Flow: 55 MGD
Average Flow: 38 MGD
UV Dose: 110 mJ/cm2, 70 mJ/cm2,
50 mJ/cm2
UVT: 65%
Total Coliform Permit Limit: 2.2 CFU/100
mL, based on a 7 day median
Power Cost: $0.12/kWh
Labor Cost: $50/hour
Detailed Cost
Analysis
Equipment & Footprint Decreases
with Increased Efficiency
Type of UV
# Channel/Trains
# Reactors/Trains
Total # Lamps
Footprint
110 mJ/cm2
MP
15
2
540
104' x 90'
LPHO A
4
2
4032
120' x 110'
LPHO B
4
4
3072
160' x 50'
C3 500TMD
4
4
1792
140' x 60'
70 mJ/cm2
MP
9
2
324
104' x 55'
LPHO A
3
2
2592
120' x 75'
LPHO B
3
4
1920
150' x 45'
C3 500TMD
3
3
1152
150' x 40'
50 mJ/cm2
MP
12
1
216
63' x 99'
LPHO A
3
2
1728
90' x 60'
LPHO B
3
3
1296
36' x 150'
C3 500TMD
3
2
768
40' x 130'
Efficient C3500D System Allows
for Most Cost Effective O&M
$2,000,000
$1,800,000
$1,600,000
$1,200,000
$1,000,000
MP
MP
$0
110
70
50
-2
Dose, mJ cm
C 3 500
LPHO B
MP
LPHO A
3
C 500
LPHO B
$200,000
LPHO A
3
$400,000
C 500
$600,000
LPHO B
$800,000
LPHO A
Annual O&M Cost, $
$1,400,000
Efficient C3500D System Allows
for Most Cost Effective Life Cycle
$50,000,000
$45,000,000
$40,000,000
$0
110
70
50
-2
Dose, mJ cm
3
C 500
LPHO B
LPHO A
$5,000,000
MP
3
C 500
LPHO B
MP
LPHO A
$10,000,000
3
$15,000,000
C 500
$20,000,000
LPHO B
$25,000,000
LPHO A
$30,000,000
MP
Life Cycle Cost, $
$35,000,000
Summary
C3500D Validation Illustrates
High Level of Disinfection &
Germicidal Efficiency
 High LPHO UV lamp output
 Optimized lamp spacing overcomes substantial
head loss
 Fewer lamps than other LPHO systems
Decreased equipment costs
Decreased installation/construction costs
Decreased O&M costs
Title 22
Calgon Carbon receives Conditional
Acceptance for the C3500D from CDPH –
December, 2011
Check-point Bioassay –
Field Challenges
 Channel dimensions
 Channel hydraulics
 Channel flow distribution
 Level Control
 Fouling and EOLL design factors
These items are easy to confirm via measurement and
velocity profiling, prior to commencement of check-point
bioassay.
Installations
Typical Open Channel Installation
Baker Heights, WV
Baker Heights, WV
Eastman, GA
Eastman, GA
Closing Remarks
C3500D UV SYSTEM
 Conditional Acceptance from CDPH
 Smallest footprint. Less Lamps to buy, install, and
maintain, leading to lower Capital and O&M costs.
 Delta configuration puts the flow where you want it, next
to the lamp.
 Proven mechanical only cleaning. No chemicals to buy,
store or leak.
 Ballasts are located in the Power Distribution Center as
opposed to the head of the rack. When the channel
floods, the ballasts are kept out of harms way.
 This bioassay validated system will meet specified
permit limit – guaranteed.
Thank You