Challenge

The Inegol Industrial Site in Inegol, Turkey, consisted of a combined wastewater stream – municipal and industrial textile waste – about evenly split at 50%. The system had difficulty meeting peak flow conditions, but an expansion was in the works.

Among goals of the expansion were to increase plant capacity by 80,000 cubic meters per day (m³/day) to135,000 m³/day, reduce power usage by conversion to a high efficient aeration system, improve effluent parameters, and reduce solids production. Limited site-usage of existing tankage was critical. And savings were anticipated in power costs as well as reduced solids production.

Solution

Siemens Water Technologies proposed a system consisting of a conversion of the existing low-speed vertical turbine aeration to the high efficiency VertiCel® system. Ideal for wastewater treatment process flows above 2 million gallons per day (MGD), design is based on the aerated anoxic system, under which at least 50% of the  total process volume operates under 0 mg/L dissolved oxygen (DO), followed by an aerobic tank. Some benefits are as follows:

• Prevents short circuiting.
• Improves effluent levels.
• Achieves a higher kinetic reaction rate so basin volume can be reduced.
• Can maintain different environments in each reactor for nitrogen and phosphorus removal.
• The deep tank design reduces the footprint, thus cutting construction and maintenance costs.

The patented Siemens Cannibal® Solids Reduction system was implemented, and the existing scraper type clarifiers were converted to the Tow Bro® clarifier with a FEDWA-designed stilling well.

The only tankage added to the system was related to the Cannibal system. All other process tanks were utilized and the additional capacity, improved performance levels were achieved.

Results

The biological process optimization program employed with the Inegol project is a total solution-based idea. Siemens Water Technologies analyzes an existing system to evaluate how it can be improved to meet a variety of new and updated effluent parameters.

In this case, benefits provided to the customer – in addition to the capacity boost – included a reduction in civic works by 70% at a value of €1,600,000, 35% less energy consumption in biological processes (800 kWh) at a value of €700,000/year, and 50% less sludge production for:

• Disposal cost savings of €900,000/year.
• Investment cost savings for sludge drying plant of 50%.
• Operation cost savings of sludge drying plant (natural gas) of 50%.

Download Full Case Study