Toray TMR140 Series Manual de usuario

AIRE-064-1-6

Submerged Membrane Module

for MBR

TORAY “MEMBRAY”

“TMR140 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

AIRE-064-1-6

Content

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

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

2. Outline of “TMR140 Series”................................................................................................... 2

II. FOR SAFE OPERATION OF “TMR140 SERIES”.................................................................. 5

1. Unpacking and Installation .................................................................................................... 5

2. Operation and Maintenance.................................................................................................. 6

3. Chemical Cleaning of Element.............................................................................................. 7

III. SPECIFICATIONS AND PERFORMANCE OF “TMR140 SERIES” ...................................... 9

1. Specifications of Element ...................................................................................................... 9

2. Specifications of Polyurethane Permeate Tube.................................................................... 9

3. Specifications and Performance of “TMR140 Series” Module............................................ 10

IV. MEMBRANE FILTRATION PROCESS DESIGN FOR “TMR140 SERIES”......................... 12

1. Standard Time Chart ........................................................................................................... 12

2. Flow Diagram of Membrane Filtration................................................................................. 13

3. Layout of “TMR140 Series” Modules in Membrane Submerged Tank ............................... 18

4. Piping................................................................................................................................... 21

V. INSTALLATION OF “TMR140 SERIES”............................................................................... 23

1. Preparatory Procedure ........................................................................................................ 23

2. Unloading/lifting Products.................................................................................................... 23

3. Checking Products .............................................................................................................. 24

4. Storage Products................................................................................................................. 24

5. Installation Products ............................................................................................................ 25

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 “TMR140 SERIES” .............................................................................. 40

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

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

3. Chemical Cleaning of Element............................................................................................ 43

4. Chemical Agents Available for Chemical Cleaning............................................................. 43

5. Handling of Chemical Agents.............................................................................................. 44

6. Chemical Cleaning Procedure............................................................................................. 47

7. Lifting Procedure ................................................................................................................. 52

AIRE-064-1-6

8. Storage Products after Use................................................................................................. 53

9. Disposing Procedure ........................................................................................................... 54

IX. REPLACEMENT PARTS LIST ............................................................................................. 55

X. TROUBLESHOOTING.......................................................................................................... 56

XI. APPENDIX ............................................................................................................................ 57

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

AIRE-064-1-6

I. INTRODUCTION

Toray "MEMBRAY" is the submerged membrane module suitable for the membrane

bioreactor (MBR) that has been developed based on the polymer science and the membrane

fabrication technologies accumulated for a long time in Toray Industries, Inc.

"TMR140 Series" is a standard model of "MEMBRAY". This manual explains MBR's features

and describes the specifications of "TMR140 Series" and its safe operations including

installation, operation, maintenance procedures and peripheral equipments. 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

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.

Sedimentation Tank

Waste

water

Aeration Tank

Discharge

Wastewater

Discharge or Reuse

Reuse

membrane

Submerged

embrane

Module

Membrane

Submerged

Tank

Fig. I-1 CAS Flow

Fig. I-2 MBR Flow

AIRE-064-1-6

2. Outline of “TMR140 Series”

“TMR140 Series” is the membrane module composed of the element block and the aeration

block. The element block contains a number of membrane elements stacked at equal

clearance, each of which has flat sheet membranes attached on both sides of ABS panel.

Each element is connected via polyurethane tube to the permeated water manifold. The

aeration block consists of coarse-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 “TMR140 Series”.

Fig. I-3 Appearance of “TMR140-100S”

Element

Coarse Air

diffuser

Tube

Permeated water Manifold

Element block

Aeration block

AIRE-064-1-6

(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, thanks to the long element design (1.6 m), a larger membrane area is achieved

per footprint, allowing effective use of diffused air.

Fig. I-4 Structure of Element

Fig. I-5 Filtration Principle of Activated Sludge

Supporting panel

Permeated Water

Nozzle

Membrane

1.6 m

0.5

Air

Element

Supporting

panel Membrane

Permeated

water

Activated sludge particle

Membrane

Air

AIRE-064-1-6

(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 an outstanding high treated water quality and an

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

Membrane

東レ

BF014

クボタ

Number of pore (10

12/m2)

Toray PVDF Membrane

3.0 micron 3.0 micron

Oth

er Membrane

AIRE-064-1-6

II. FOR SAFE OPERATION OF “TMR140 SERIES”

Before using “TMR140 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 “TMR140 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 "TMR140 Series" or its part.

Check the condition of each part before lifting and never use

damaged one. Never stand below the membrane module when

lifting. Be careful of the balance of the module when lifting.

When lifting TMR140-200D or 400DW, do not lift upper element

blocks and lower element blocks all together. Upper/lower element

block has to be lifted separately.

When installing “TMR140 Series” module, please set up a foothold

in advance. 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 "TMR140 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 "TMR140 Series" for hours in the place where

the temperature is higher than 40 degree C or in the place exposed

to direct sunlight. Especially ABS supporting panel may be

deteriorated with direct sunlight, ultraviolet ray.

Please take adequate measures to protect “TMR140 Series” from

sparks caused by welding, fusion cutting or grinding throughout the

entire process from installation work to operation startup.

Please protect “TMR140 Series” from freezing at any time.

Please don't pressurize the permeate side of "TMR140 Series”.

DANGER

CAUTION

DANGER

AIRE-064-1-6

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.

2. Operation and Maintenance

Don't use permeated 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 tank 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.

ABS supporting panel may get chemical cracks by some organic

solvent, such as alcohols and oils, and some synthetic detergents. So

don't make ABS panel contact such materials.

Please avoid abrupt changes of operating conditions, especially

pH, temperature and the suction pressure of the membrane even

within the range of the standard operating conditions (Table VII-1).

WARNING

CAUTION

AIRE-064-1-6

Please replace the renewal parts periodically or when the

deterioration is detected at the inspection.

Prevent “TMR140 Series” from freezing at any time.

Please take care not to dry the membranes when taking "TMR140

Series" out of the liquid for the inspection or the maintenance. If

the wet membrane is dried up again, the permeability of the

membrane might be decreased seriously.

Please stop the scouring air when the filtration operation stops

except for the following conditions:

1) In case of applying intermittent filtration, do not stop the

scouring air for each relaxation period.

2) In case that the plant operation stops for a while, aeration is

applicable for mixing or aeration demand, however, the flow rate

should be controlled minimal.

Please don’t re-use the old permeate tubes once disconnected

from the nozzles since the connection tightness of the tubes are

reduced.

3. Chemical Cleaning of Element

The chemical agents used for the chemical cleaning are harmful to

the health. When handling chemicals, please read their material

safety data sheet (MSDS) in advance and make sure to wear

necessary protectors such as protective goggles and protective

gloves.

If the chemical agents stick to your skin or clothes, immediately

wash it away with enough amount of running water.

If the chemical agents enter your eyes, immediately wash it away

with enough amount of running water and see the doctor.

If any abnormality is found in the equipment during chemical

cleaning, immediately stop operation and check it.

If chemical is injected forcibly directly with the chemical feed pump

or by any other means, the internal pressure of the elements will

increase and the elements will get damaged. Be sure to inject

chemical with the pressure of lower than 10 kPa (100 mbar).

WARNING

CAUTION

WARNING

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