Toray TMR090 Series Manual de usuario

GIRE-097-2-2

Submerged Membrane Module

for MBR

TORAY “MEMBRAY”

"TMR090 Series"

Instruction Manual

Toray Industries, Inc.

Water Treatment Division

1-1, Nihonbashi-muromachi 2-chome, Chuo-ku, Tokyo 103-8666 Japan

Tel: +81-3-3245-4542

Fax: +81-3-3245-4913

URL: http://www.toraywater.com

Published: April 2013

GIRE-097-2-2

Content

I. INTRODUCTION ................................................................................................................................ 1

1. Features of MBR ................................................................................................................... 1

2. Outline of “TMR090 Series”................................................................................................... 2

II. FOR SAFE OPERATION OF “TMR090 Series”............................................................................ 6

1. Unpacking and Installation.................................................................................................... 6

2. Operation and Maintenance.................................................................................................. 7

3. Chemical Cleaning of Element .............................................................................................. 8

III. SPECIFICATIONS AND PERFORMANCE OF “TMR090 Series”............................................ 10

1. Specifications of Element.................................................................................................... 10

2. Specifications of Polyurethane Permeate Tube.................................................................. 10

3. Specifications and Performance of "TMR090 Series" Module............................................ 11

IV. MEMBRANE FILTRATION PROCESS DESIGN FOR “TMR090 SERIES”............................ 13

1. Standard Filtration Pattern .................................................................................................. 13

2. Flow Diagram of Membrane Filtration Process................................................................... 14

3. Layout of “TMR090 Series” Modules in Membrane Submerged Tank ............................... 19

4. Piping................................................................................................................................... 22

V. INSTALLATION OF “TMR090 SERIES”....................................................................................... 26

1. Preparatory Procedure ........................................................................................................ 26

2. Unloading/lifting Products.................................................................................................... 26

3. Checking Products .............................................................................................................. 27

4. Storage Products................................................................................................................. 27

5. Installation Products ............................................................................................................ 28

VI. START OF OPERATION ................................................................................................................ 30

1. Clean Water Operation........................................................................................................ 30

2. Seeding Sludge Injection..................................................................................................... 31

3. Actual Filtration Operation................................................................................................... 31

VII. OPERATION CONTROL .............................................................................................................. 33

1. Standard Operating Conditions........................................................................................... 33

2. Operating Parameters ......................................................................................................... 35

3. Basic Control Philosophy .................................................................................................... 36

4. Daily Inspection ................................................................................................................... 37

VIII. MAINTENANCE OF “TMR090 SERIES” ...................................................................................... 40

1. Maintenance Items and Maintenance Frequency............................................................... 40

2. Air Diffuser Cleaning............................................................................................................ 41

3. Chemical Cleaning of Element ............................................................................................ 42

4. Chemical Agents Used for Chemical Cleaning................................................................... 42

5. Handling of Chemical Agents.............................................................................................. 43

GIRE-097-2-2

6. Chemical Cleaning Procedure............................................................................................. 46

7. Lifting Procedure ................................................................................................................. 50

8. Replacement of Element Fixing Gaskets ............................................................................ 51

9. Element Replacement ......................................................................................................... 52

10. Air Diffuser Replacement................................................................................................. 54

11. Storage Products after Use ............................................................................................. 56

12. Disposing Procedure ....................................................................................................... 57

IX. REPLACEMENT PARTS LIST....................................................................................................... 58

X. TROUBLESHOOTING .................................................................................................................... 59

XI. APPENDIX ........................................................................................................................................ 60

Symbols used in this manual

This symbol is used to indicate an imminent hazardous situation

which, if not avoided, will result in serious injury or death.

This symbol is used to indicate a potentially hazardous situation

which, if not avoided, can result in serious injury or death.

This symbol is used to indicate a potentially hazardous situation

which, if not avoided, may result in injury or property damage.

DANGER

WARNING

CAUTION

GIRE-097-2-2

I. INTRODUCTION

“MEMBRAY” is a submerged membrane module suitable for the membrane bioreactor

system (MBR) that has been developed in Toray Industries, Inc based on the years of

experience of polymer science and the membrane technologies.

"TMR090 Series" is a lineup of "MEMBRAY", which is more compact compared to the other

"TMR140 Series", thus, suitable for the application where only a limited space is available,

such as for containerized package plants, domestic wastewater treatment, reclamation in

buildings or on marine boats application.

"TMR090 Series" is equipped with fine-bubble air diffusers, which significantly reduces the

daily cleaning operation of air diffusers and increases the oxygen dissolution efficiency.

This manual describes the specifications of "TMR090 Series", necessary peripheral

equipments and the safe and proper handling method of the module during installation,

operation and maintenance works.

Designer and operators should thoroughly read this manual to ensure stable operation.

1. Features of MBR

The process flow of the conventional activated sludge system (CAS) and MBR are shown in

Fig.I-1 and Fig.I-2, respectively.

MBR provides the following advantages:

(1) Small Footprint

Unlike CAS, MBR separates sludge within aeration tank using membranes, thus eliminate

Sedimentation Tank

Waste

water

Aeration Tank

Discharge

Waste

water

Discharge or Reuse

Reuse

membrane

Submerged Membrane

Module

Membrane

Submerged

Tank

Fig. I-1 CAS Flow

Fig. I-2 MBR Flow

GIRE-097-2-2

the space for preparing sedimentation tank. Also with membrane, MBR can hold higher

concentration of activated sludge in the aeration tank, so its volume can be reduced. As a

result, MBR provides smaller footprint compared to CAS.

(2) High quality of treated water

MBR removes suspended solid (SS) from the sludge liquid with membrane much more

certainly than conventional sedimentation process. MBR also rejects microorganisms such

as Escherichia coli and Cryptosporidium efficiently.

2. Outline of “TMR090 Series”

“TMR090 Series” is the membrane module composed of the element block and the aeration

block. The element block contains a number of membrane elements set at equal clearance,

each of which has flat sheet membranes fixed on both sides of ABS panel. Each element is

connected via polyurethane tube to the permeated water manifold. The aeration block

consists of fine-bubble air diffusers to supply scouring air (see Fig.I-3). This module is used

submerged in sludge liquid. The following shows the features of “TMR090 Series”.

Aeration Block

Element Block

Permeated Water Manifold

Tube

Fine-bubble

ir Diffuser

Element

Element Fixing

Bracket

Fig. I-3 Appearance of "TMR090-050S"

GIRE-097-2-2

(1) Shape of Element

The membrane element is a flat sheet type as shown in Fig.I-4. At the normal filtration

operation, the sludge accumulated on the membrane surface is cleaned up effectively with

upward water stream generated with the scouring air supplied from the air diffusers installed

at the bottom side (Fig.I-5). This mechanism ensures stable filtration, since the membrane

does not easily admit of sludge adherence to its surface.In addition, shorter element (1059

mm) compared to "TMR140 Series" allows the use in the space with height limitation.

Fig. I-4 Structure of Element

Fig. I-5 Filtration Principle of Activated Sludge

Supporting panel

Permeated Water

Nozzle

Membrane

1059 mm

515 mm

Air Diffuser

Element

Supporting

panel

Membrane

Permeated

Water

Membrane

Air

Sludge

flock

GIRE-097-2-2

3.0 micron

(2) Membrane Structure

The flat sheet membrane consists of PVDF (Polyvinylidene Fluoride) functional layer and the

base layer of PET (polyester) non-woven fabric. This structure gives the membrane superior

physical strength and high chemical resistance.

(3) Membrane Pore Size

Numerous small-size pores are distributed evenly over the membrane surface with a sharp

pore-size distribution. This structure gives outstanding high treated water quality and

excellent water permeability, making the membrane highly resistant to clogging (see Fig.I-6

and Fig.I-7) compared to other membranes. The average pore size is 0.08 micron meter.

Fig. I-6 Membrane Surface (photo)

Fig. I-7 Pore Size Distribution

Other

Membrane

Toray PVDF

Membrane

Pore Size (micron)

東レ

BF014

クボタ

0.5

1.0

1.5

0.2

0.4

0.6

0.8

PVDF

東レ

BF014

クボタ

Number of pore (10

)

Toray PVDF Membrane

Other Membrane

GIRE-097-2-2

(4) Element replacement

Each element can be taken out from the modules separately for the inspection or the

replacement. In the case of the membrane damage, the filtration operation can be recovered

in a short time by replacing relevant elements one by one with spare ones.

(5) Fine-bubble Air Diffusers

"TMR090 Series" is equipped with fine-bubble air diffusers, which significantly reduces the

daily cleaning operation of air diffusers and additionally increase the oxygen dissolution

efficiency to 1.3-2.0 times as high as the coarse-bubble diffusers.

GIRE-097-2-2

II. FOR SAFE OPERATION OF “TMR090 Series”

Before using “TMR090 Series”, please thoroughly read this Instruction Manual and follow the

instructions described in this manual, especially the safety precautions shown below. The

details of each precaution are described in the relevant chapter.

1. Unpacking and Installation

When lifting “TMR090 Series” or its part, please attach chains or

slings to it and raise it straight upward calmly to prevent it from

shaking. Please never allow any person under lifted article.

Please use chains or slings compatible with lifting weight when

lifting "TMR090 Series" or its part.

When installing “TMR090 Series” module, please set up a foothold

in advance. Please never climb the module. Please use protective

equipment to ensure the safety of workers.

At transportation, storage and installation, please take appropriate

measures to protect "TMR090 Series" or its part from damage.

Please don't put any heavy objects on the module. Please take

care to protect the module from collision with other objects.

Please do not leave "TMR090 Series" for hours in the place where

the temperature is higher than 40 °C or in the place exposed to

direct sunlight.

Please take adequate measures to protect “TMR090 Series” from

sparks caused by welding, fusion cutting or grinding throughout the

entire process from installation work to operation startup.

Please protect “TMR090 Series” from freezing at any time.

Please don't pressurize the permeate side of "TMR090 Series".

Please install the screen with openings of 3.0 mm or under before

the membrane submerged tank. It is recommended to use the

mesh type screen. Overflow or waste carryover must be avoided at

any time.

DANGER

CAUTION

GIRE-097-2-2

2. Operation and Maintenance

Don't use the treated water for drinking.

Before discharging the treated water to the environment or reusing

it, make sure to analyze its quality and confirm that the water

quality meets the intended purpose.

Don't burn the membranes without appropriate facilities since

harmful Hydrogen fluoride (HF) gas is generated at burning.

When dispose membranes, please apply a service of a qualified

waste disposing company.

When the clean water operation, charging clean water to the

membrane submerged basin with the air discharge valve open to

release air from the elements. After charging water, close the air

discharge valve.

Don’t use the ground water, which contains considerable amount

of iron, manganese, calcium or silica, for the clean water operation

as it may cause the clogging of the membrane.

Don't continue the clean water operation unnecessarily. A

long-time filtration of clean water tends to cause the clogging.

Once the membrane gets wet, keep it wet. If the wet membrane is

dried up again, the permeability of the membrane might be

decreased seriously.

When feeding the seeding sludge, be sure to remove foreign

substances from it with the screen with openings of 5mm or under.

Don't do the filtration operation without supplying the scouring air in

a right way, or the membrane will be clogged severely.

Don't put in the activated sludge liquid chemicals, toxic agents, oils

or other substances that may adversely affect activated sludge.

WARNING

CAUTION

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