AST PolyGeyser User Manual
108 Industrial Avenue
New Orleans, LA 70121
Phone (504) 837-5575
Fax (504) 837-5585
Info@astfilters.com
www.ASTfilters.com
Updated 08/10/16 V1-AST
1
Table of Contents
Introduction to the HPPG Series ................................................................................................................... 2
Operation ...................................................................................................................................................... 2
Backwash Operation Overview ..................................................................................................................... 0
HPPG Bead Filter Major Components ........................................................................................................... 3
Installation .................................................................................................................................................... 4
Pump Configuration .................................................................................................................................. 4
Airlift Configuration .................................................................................................................................. 6
Backwash Air Pump ....................................................................................................................................... 8
General Setup Directions ........................................................................................................................ 10
Adjusting your Backwash Frequency ...................................................................................................... 11
Sludge Drainage Assembly .......................................................................................................................... 14
Air Pump Requirements for Backwashing .............................................................................................. 15
Backwash Frequency ............................................................................................................................... 15
Troubleshooting (Filter Function) ............................................................................................................... 17
Trouble Shooting for Recirculating Aquaculture Applications ............................................................ 20
Sulfide Production ....................................................................................................................................... 21
Filter Acclimation ........................................................................................................................................ 22
Appendix A: The Science behind Bioclarification ........................................................................................ 27
Clarification ............................................................................................................................................. 27
Biofiltration ............................................................................................................................................. 29
Warranty. .................................................................................................................................................... 32
2
Introduc�on to the HPPG Series
The High Pressure PolyGeyser® (HPPG) blter series is the newest addon to Aquaculture Systems
Technologies’ line of bead lters. Patented ( U.S. Patent #9,227,863 Patent Pending , European
Patent #0977713B & Canadian Patent #2,287,191) fully exploits the biolm protecon provided by our
Enhanced Nitricaon (EN) Bead Media in a durable berglass hull. Designed as “bioclaris” capable
of performing both biological and mechanicalaon, PolyGeyser
biological loads 50% to 100% higher than our Bubble Bead o
standard bead media. Addionally, the PolyGeyser
®
Bead Filters are virtually immune to clogging and
r Propeller Bead Filters equipped with
caking, since they are backwashed pneumly at a high frequency. These High Pressure PolyGeyser
(HPPG) Bead Filters recycle their own backwash waters. The HPPG lters are the bioclari of choice
for commercial aquaculture and wastewater applicaons dealing with high organic loads.
Opera�on
The PolyGeyser® Bead Filter stands apart from AST’s other Bead Filter technologies primarily through its
automneuma backwash mechanism. Water is introduced below the bed of packed EN bea
media and travels upward through the ltraon chamber where mechanical and biologicalltraon
takes place. Simultaneously, air is slowly introduced into the air charge chamber at a constant,
predetermined rate to achieve the desired backwash frequency. Once the charge chamber has reached
capacity, the pneumac trigger res, releasing the entrained air from the charge chamber below the
media bed. The sudden release of air from the charge chamber causes the beads to mix, roll and “drop”
as the air agitates the beads.
®
Bead Filters are capable of handling
d
®
The circulaon pump/airli operates connually
immediately aer each backwash event. This causes the beads to oat upward and reform as a bed.
During the recharge cycle (a few hours), suspended solids in the trapped backwash waters sele into the
sludge storage chamber for later disposal via the sludge drain valve (usually every 3 days- 1 week). At
the same me, the claried backwash waters are passed slowly through the bead bed again eliminng
any backwash water losses.
The eliminaon of water loss associated with backwashing is a key element in this new techn
most applicaons, dozens of backwash sequences can be automly executed before sludge removal
is required. There is no water loss associated with the backwash process and the water loss associated
with sludge drainage is negligible. This strategy is paularly advantageous for marine systems, where
the loss of saltwater must be minimized.
, which ensures that ther chamber begins relling
ology. In
3
The pneuma�c strategy breaks the linkage between backwash frequency and water loss and allows the
nitrifica�on capacity of the unit to be fully utilized. Frequent backwash sequences have proven
advantageous for op�mizing the nitrifica�on capacity of the unit. Numerous gentle scrubbing cycles
promote high rates of nitrifica�on by maintaining a healthy thin biofilm on the bead surfaces. Typical
backwash cycles occur once every three to six hours. In recircula�ng bioclarifier applica�ons, where the
High Pressure PolyGeyser
®
Bead Filter operates concurrently as a clarifier and biofilter, total ammonia
nitrogen (TAN) levels below 0.3, 0.5 and 1.0 mg-N/l can be expected at feed loading rates of 0.5, 1.0 and
1.5 pounds feed per cubic foot of EN bead media (8, 16 and 24 kg-feed m
-3
day-1), respec�vely.
Table 5. High Pressure
PolyGeyser
®
Bead Filter Specifica�ons
Backwash Operation Overview
The PolyGeyser filter is a breakthrough in filter technology. It features an advanced auto-pneumatic
backwash mechanism. Water enters below the bed of enhanced nitrification media and travels upward
through the filtration chamber where mechanical and biological filtration take place. Simultaneously, air
is introduced into the charge chamber at a constant predetermined rate to achieve the desired
backwash frequency.
Once the charge chamber has reached capacity, the pneumatic trigger fires. This releases the entrained
air from the charge chamber below the bead bed. The sudden release of air from the charge chamber
causes the beads to mix as the air agitates the beads. As the beads drop, the bead bed expands
downward while water rushes downward through the expanded beads, sweeping the solids away and
into the air charge chamber.
In the chamber, the solids settle out from the backwash waters and are later removed from the filter.
Essentially, this type of filter recycles the backwash water while concentrating the waste products so
that you have extremely low water loss while maximizing the nitrification capacity.
Frequent backwashing has proven advantageous for optimizing the nitrification capacity of a
Polygeyser® filters. Numerous gentle scrubbing cycles promotes a higher rate of nitrification by
maintaining a healthy thin biofilm on the surface of the bead media. Typical backwash cycles occur every
3-6 hours.
1
2
-
3
HPPG Bead Filter Major Components
Descriptor
Function
Comment
A
Inlet
Directs flow into filter via the
diffuser
B
Screen
Passes water while retaining the
beads in the filter
C
Outlet
Directs the filtered water into the
return lines.
Multiple outlets are generally used for
airlift models to lower water velocity and
hydraulic friction
D
Bead Bed
Captures suspended solids while
providing surface area for biological
processes, such as nitrification, used
to restore water to a pristine
condition
The beads float to form tightly packed
granular bed ideal for physical and
biological filtration. Beads are typically 2-3
mm in diameter.
Table 6. Major Component List – Basic Configuration
4
E
Charge Chamber
The air tight cone defines the charge
chamber while forming a conduit for
water transmission into and out of
the charge chamber
In this design series, the charge chamber is
wrapped around the centralized conduit
which re-suspends and aerates sludge
during each backwash event
F
Air Inlet
Slowly fills the charge chamber with
air
Air is added at a slow rate so that it takes a
few hours to fill the charge chamber.
G
Trigger
Catastrophically releases air from
the charge chamber once it is filled
H
Diffuser
Redirects the incoming water
beneath the bead bed.
Hydraulically designed to minimize
turbulence that may erode the bed.
I
Sludge Basin
Provides for temporary sludge
storage.
The sludge that is released from the bead
bed during a backwash settles out of the
cone and charge chamber that can be
removed periodically as a thick sludge
through the sludge outlet.
J
Sludge Outlet
Facilitates the removal for thickened
sludge from the unit.
Sludge is typically concentrated to 10,00020,000 mg/L in the HPPG series.
Cap
Directs flow from the screen to the
Outlet pipe(s)
The cap assembly also includes gaskets that
seal the screen to the filter hull.
Installation
Installation will require that you hook up a water pump to circulate water through the filtration bed and
an air compressor to fill the charge chamber for the back wash sequence. Filters in the HPPG series are
most frequently paired with a low head centrifugal pump capable of delivering a high rate of flow at
relatively low pressures (5-10 psi). However, in commercial scale recirculating aquaculture
applications, the units can be paired with airlifts to minimize energy consumption. Use of airlifts,
however, generally requires lowering (burying) the unit so water can be filtered by gravity and then
airlifted back up. With total filtration head losses beneath 0.5 psi, use of airlifts can be attractive
whenever the physical configuration permits.
The backwashing air source must be matched with the circulation method you select. Simply stated the
air pressure must exceed the water pressure for air to flow into the unit.
Pump Configuration
A self-siphoning, above ground, centrifugal water pump can be used to circulate water through an
HPPG. The unit should have a water delivery capacity of 10-15 gallons per minute for each cubic foot of
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media at the operational pressure for the unit (typically in the range of 5-15 PSI). The shutoff pressure
off the pump should be less than 20 psi, or near 20 psi when a pressure relief is installed to avoid
damaging the HPPG hull.
HPPG Filter External Plumbing illustrates a typical plumbing arrangement. In most case the pump (9)
should be protected by a screen or an inline screen basket (10). Many pumps already have the inline
basket attached. A hard PVC couple (8) is placed immediately adjacent to the pump discharge to
facilitate pump replacement or servicing. A rubber or flexible couple should be avoided here, as they
are sensitive to pump vibration tend to work loose. This coupling is followed immediately by a
mandatory check valve (7) which prevents the backflow of beads into the pump during periods of
power interruption. If the pump’s flow capacity is significantly greater than the filters rating then a ball
valve (5) is then placed in line to allow the pump to be throttled to manage flow through the HPPG unit.
Alternately a “tee” can be placed at this location with two ball valves allowing for flow to bypass the unit
to a parallel use. You will find a 0-30 psi pressure gauge (3) will greatly facilitate the management of
the filter. High pressures are an indication to increase the backwash frequency. Finally, in situations
where either the water pump or the backwashing air pump have high shutoff pressures (>20 psi) then
a pressure relief valve must be placed immediately adjacent to the filter input to assure protection of
the hull. The pressure relief valve can be set to pop at 20 psi. All HPPG filters are pressure tested at a
higher pressure to ensure quality prior to shipping, but the operational pressures should not exceed 20
psi.
6
Airlift Configuration
The HPPG series is equipped with an oversized screen and inlet/outlet plumbing to facilitate airlift
operation. Typically, the filter must be positioned next to the tank so that the screen is 12-15” below
the water level in the tank. The siphoning outlet pipes are then directed toward the ground to develop
pressure for the airlift operation. The discharge pipes are then curve back to the vertical draft tube. Air
is injected near the bottom of the draft tube to create a low density air/water mixture that is pushed
upward by the dense water in the siphon line. The elevated air and water mixture is then moved
horizontally to the tank.
Water Flow in an Airlifted HPPG: Water exits from the top of the filter, into the U pipe. Air injected into
the far draft tube pushes the water up and out of the pipe, back into the tank.
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Air Flowrate Calculations for Airlift Con guration
Model
Flowrate
Outlet
Flow
Screen
Air Li
Air
Air
Air Flowrate
(D
)
(D
)
(Vin)
(Vli)
(H)
(L)
(S)
(L+S)
HPPG-10
150 4 6
3.84
1.69
83
12
48
60
41
HPPG-25
300 68
3.37
1.94
80
12
48
60
83
HPPG-50
750 8 12
4.86
2.17
111
12
48e
60
206
Table 8. Air Flowrate Calculaons
(Qf, gpm)
Pipe Size (in)
down
li
Velocity
( /s)
Level
(in)
Requirement
(in)
Injecon
Depth (in)
Delivery
Pressure
(in)
(Qair, scfm)
8
Backwash Air Pump
Backwash air pumps are required to operate an HPPG filter. If you have not purchased a backwash
pump with your HPPG filter, you require a low volume continuous duty pumps that is sized to sustain
the appropriate backwash frequency for your filter model. The pump must also be compatible with the
pressure range that is appropriate to the filter. Noise will be generated by the pump, so placement
should be carefully considered. If the pump is placed outside or in a wet room, it should be properly
insulated from water and condensation.
The operational pressure for air injection into the charge chamber of a water pump driven HPPG filter
with a free discharge out of the outlet pipe should be in in the range of 4-6 psi if the backwash
frequency is set properly. At design flow rates about half of this pressure is attributed to the physical
depth of the air injection, the balance is attributed to baseline friction loss through the bead bed or
fittings. If the backflush frequency is set too low, the pressure loss across the bead bed will increase. In
the extreme, the hull pressure will be defined by the shutoff pressure of the pump. The air pump should
be sized to overcome this pump shutoff pressure. Ideally, the air pump and water pumped should be
matched with the air pump having a shut off pressure higher than the pump.
Injection pressures for HPPG airlift applications are controlled by the distance from the tank water
surface to the centerline of the horizontal pipe in the unit’s external trigger (typically a maximum of
about 100 inches or 4 psi). The air injection pressure in an airlifted HPPG does not vary much. An
operational pressure of 5 psi is sufficient.
A medium sized linear air pump is a good choice for airlift applications where backpressures on the
HPPG unit are minimized. These units operate by oscillating a rubber diaphragm that moves air through
a series of valves. These pumps are readily available in weather resistant configurations used for pond
and home packed wastewater treatment units. The flow rates delivered by these blowers are generally
in excess of the backwashing needs, so the unit should be selected based upon its maximum operational
pressure. The larger liner pumps have shutoff pressures in the range of 10 psi which is suitable for most
HPPGs where the unit is not back pressured by downstream devices. Linear air pumps contain a
replaceable rubber diaphragm that will ultimately fail (every 2-3 years depending on the model and
pressure).
A small oil free continuous duty piston pump with an operational pressure rating of about 20 psi is most
ideally suited for delivering air for a wide variety of HPPG applications. These units have small pistons
that are driven directly by a small electric motor. Producing only moderate amount of air, these unit are
recognized for sustained operation at the moderate pressures demanded by HPPG applications.
Capable of delivering a continuous supply of air at the HPPG maximum hull pressure of 20 psi, these
units also display relatively high shutoff pressures that are compatible with a wide variety of pumps.
The air volume produced by this unit is reduced and thus the air delivery capacity should be matched to
the HPPG. These units are most often sized to serve the air demands of a single HPPG unit.
Rotary vane compressors operate in a pressure range (0-15 PSI) well above the more widely recognized
rotary vane blower (0-3 psi). A rotary vane compressor consists of a motor that spins a set of inclined
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