Toray TMR140 Series, TMR140-100S, TMR140-050S, TMR140-200D, TMR140-200W Instruction Manual

Submerged Membrane Module

for MBR

TORAY “MEMBRAY”

“TMR140 Series”

Instruction Manual

Toray Industries, Inc.

Water Treatment Division

8-1, Mihama 1-chome, Urayasu, Chiba 279-8555 Japan

Tel: +81-47-350-6223

Fax: +81-47-350-6066

URL: http:// www.toray.com

Published: February 2008

AIRE-064-1-4

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. MEMBRANEFILTRATION PROCESS DESIGN FOR “TMR140 SERIES”.................................. 12

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

2. Flow Diagram of Membrane Filtration........................................................................................ 12

3. Layout of “TMR140 Series” Modules in Membrane Submerged Tank......................................17

4. Piping ......................................................................................................................................... 20

V. Installation of “TMR140 Series” ........................................................................................................ 22

1. Preparatory Procedure............................................................................................................... 22

2. Unloading Products....................................................................................................................22

3. Checking Products..................................................................................................................... 22

4. Storage Products ....................................................................................................................... 23

5. Installation Products...................................................................................................................23

VI. Start of Operation.............................................................................................................................27

1. Clean Water Operation .............................................................................................................. 27

2. Seeding Sludge Injection ........................................................................................................... 28

3. Actual Filtration Operation..........................................................................................................28

VII. Operation Control.........................................................................................................................29

1. Standard Operating Conditions.................................................................................................. 29

2. Operating Parameters................................................................................................................31

3. Daily Inspection..........................................................................................................................32

VIII. Maintenance of “TMR140 Series”................................................................................................ 34

1. Maintenance Items and Maintenance Frequency......................................................................34

2. Air Diffuser Cleaning..................................................................................................................35

3. Chemical Cleaning of Element................................................................................................... 35

3. Chemical Cleaning of Element................................................................................................... 36

4. Chemical Agents Used for Chemical Cleaning.......................................................................... 36

5. Handling of Chemical Agents..................................................................................................... 37

6. Chemical Cleaning Procedure...................................................................................................40

7. Lifting Procedure........................................................................................................................ 43

IX. Replacement Parts List................................................................................................................ 44

IIX. Troubleshooting............................................................................................................................ 45

AIRE-064-1-4

Symbols used in this manual

DANGER

This symbol is used to indicate an imminent hazardous situation which, if not avoided, will result in serious injury or death.

WARNING

CAUTION

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.

AIRE-064-1-4

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 method (ASM) and MBR are shown in Fig.I-1 and Fig.I-2, respectively. Unlike ASM, which employs the sedimentation tank, MBR separates sludge with membranes. MBR provide the following advantages: (1) Small Footprint In the case of MBR, the biological treatment can be operated at higher MLSS, so the aeration tank is reduced. And MBR does not need a sedimentation tank. As a result, MBR provides smaller footprint of the plant. (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.

Waste water

Membrane

Submerged

Tank

Aeration Tank

Fig. I-1 ASM Flow

Submerged membrane

module

membrane

Sedimentation tank

Discharge

Discharge or Reuse

Reuse

Fig. I-2 MBR Flow

AIRE-064-1-4

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”.

Tube

Permeated water Manifold

Element

Element block

Aeration block

Coarse Air diffuser

Fig. I-3 Appearance of “TMR140-100S”

AIRE-064-1-4

(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.

Supporting panel

0.5 Permeated Water

zzl

Membrane

1.6 m

Fig. I-4 Structure of Element

Element

Permeated

water

Air

Membrane

Supporting

panel

Membrane

Activated sludge particle

Fig. I-5 Filtration Principle of Activated Sludge

AIRE-064-1-4

東

クボタ

東

クボタ

(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)

1.5

)

1.0

0.5

umber of pore (10

3.0 micron 3.0 micron

Other Membrane Toray PVDF Membrane

PVDF

TorayPVDF Membrane

Other Membrane

レ

BF014

0.2 0.4

Pore Size (micron)

Fig. I-7 Pore Size Distribution

0.6 0.8

AIRE-064-1-4

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

DANGER

When lifting “TMR140 Series” or its part, please attach chains or slings to it and raise it straight upward 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.

calmly to prevent it from

DANGER

CAUTION

When installing “TMR140 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 "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.

CAUTION

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

Please install the screen with openings of 3.0 mm or under before "TMR140 Series” or the membranes might be polluted and clogged severely with foreign substances brought with the raw water.

AIRE-064-1-4

2. Operation and Maintenance

WARNING

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.

WARNING

CAUTION

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.

CAUTION

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).

Please replace the renewal parts periodically or when the deterioration is detected at the inspection.

AIRE-064-1-4

CAUTION

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.

CAUTION

Please stop the scouring air when the filtration operation stops. In the case of applying the relaxation operation for the filtration, it is not required to stop the scouring air for each relaxation period.

3. Chemical Cleaning of Element

WARNING

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.

WARNING

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.

Don't inject the chemical agents directly from the chemical feed pump to the elements at the chemical cleaning, or the internal pressure of the elements may increase and, the elements may be damaged. Be sure to inject the chemical agents by gravity with less than 10kPa.

AIRE-064-1-4

WARNING

When injecting the chemical agents at the chemical cleaning, please confirm beforehand that the modules are completely submerged in the liquid and the liquid level of the membrane submerged tank is higher by more than 500 mm than the top of the module.

WARNING

CAUTION

Please store the chemical agents in a dark cold place free from direct sunlight.

Please use the appropriate tank or the container, for storing the chemical agent, made of the material having enough corrosion resistance to each chemical agent.

Don't mix sodium hypochlorite with heavy metals or acids. In particular, toxic chlorine gas is generated when mixing sodium hypochlorite and acids.

Don't mix sodium hypochlorite with oxalic acid or citric acid, or toxic chlorine gas is generated.

Please stop the scouring air during the chemical cleaning, or the membrane elements might be damaged.

AIRE-064-1-4

III. SPECIFICATIONS AND PERFORMANCE OF “TMR140 SERIES”

1. Specifications of Element

TableIII-1 and Fig.III-1 shows the specifications and the appearance of the element for TMR140 Series, respectively.

Table III-1 Specifications of Element (TSP-50150)

Model name TSP-50150 Membrane configuration Flat sheet Application Filtration of activated sludge

Filtration method Suction filtration Nominal pore diameter (µm) Effective membrane area (m2) 1.4

Dimensions (mm)

Weight (kg)

Main material

Total width 515 Total height 1,608 Thickness 13.5 Dry 4.8

Wet (Reference) 8.0 Membrane PVDF and PET non-woven fiber Supporting panel ABS resin

0.08

515 mm Permeated water nozzle

50 mm

1608 mm

Fig.III-1 Appearance of Element

2. Specifications of Polyurethane Permeate Tube

Table III-2 shows the specifications of Tube.

Table III-2 Specifications of Polyurethane Permeate Tube

Material TPU-ARET*1

Inside diameter / outside diameter / total length (mm) 8/11/380

*Allowable temperature limit: 60 degree C *1 The material name due to the ISO-18064.

AIRE-064-1-4

3. Specifications and Performance of “TMR140 Series” Module

Table III-3 shows the specifications of “TMR140 Series” modules.

Table III-3 Specifications of Module

Model name TMR140-050S TMR140-100S TMR140-200W TMR140-200D Number of membrane elements 50 100 200 200

Element block structure

Dimensions

Weight（kg）

Material

Connection

flange

Operating Range

*1 The total dimensions excluding the connection tube *2 The weight assumed in the case of sludge clogging between elements. *3 The flange dimensions are described in the drawings attached to this manual. *4 Except when the chemical cleaning with the designated chemical agents.. *5 The air supply equipments such as blower shall be designed b ased on the standard operating conditions

Width (mm) 810 810 840 810 Length (mm) 950 1,620 3,260 1,620 Height (mm) 2,100 2,100 2,100 4,160 Module (dry) 400 695 1,430 1,365 Aeration block (dry) 40 65 150 65 Element block (dry) 360 630 1,280 1,300 Element block

(sludge clogging) Diffuser, Flame, Permeated

water manifold

Manifold ANSI 1 1/2inch ANSI 2inch ANSI 3inch ANSI 2inch Air diffuser ANSI 1 1/4inch ANSI 1 1/2inch ANSI 2inch ANSI 1 1/2inch

Temperature (degree C) 5-40 pH*4 of liquid 5-10

MLSS (mg/L) Not higher than 18,000 Trans-membrane pressure

(kPa ) Cleaning chemicals feed

pressure (kPa )

Cleaning chemicals and chemicals concentration

Scouring Air Flow rate *5 (NL/min/Module)

shown in Table VII-1.

1 EBL 1 EBL 2 EBL jointed

690 1,240 2,480 2,500

304 stainless steel

(316SS or 316LSS is available as option)

Not higher than 20

Not higher than 10

Sodium hypochlorite (effective chlorine concentration) ： 2,000-6,000 mg/L(pH is around 12) Oxalic acid ： 0.5-1.0wt％ Citric acid ： 1.0-3.0wt％

500 - 1,000 1,000 - 2,000 2,000 - 4,000 1,300 - 2,000

Double Deck

with 2 EBL

AIRE-064-1-4

Table III-4 shows the performance of ”TMR140 Series” modules.

Table III-4 “TMR140 Series” Module Performance

Model name TMR140-050S TMR140-100S TMR140-200W TMR140-200D

Permeate water quality

Filtration capacity

TSS (mg/L)

Turbidity (NTU) ＜Reference＞

Quantity of water treated

/d)

*1 This value can be attained when operated under the standard operating conditions as specified in this

Instruction Manual during a period specified separately by Toray.

*2 Measuring method of TSS is complied with Standard Method of Exami nation of Water and Wastewater

Edition (1998), Section 2540D, Total Suspended Solids Dried at 103-105 degree C or ISO 11923.

*3 Measuring method of NTU is complied with Standard Meth od of Examination of Water a nd Wastewater

Edition (1998), Section 2130, Turbidity or ISO 7027.

*4 Reference value, not guaranteed, in the case of the treatment of sewage at higher than 15 degree C of

the temperature.

Not higher than 3.0

Not higher than 1.0

53 105 210 210

AIRE-064-1-4

IV. MEMBRANE FILTRATION PROCESS DESIGN FOR “TMR140 Series”

The standard filtration pattern time chart, the schematic flow diagram of the membrane filtration, the layout of “TMR140 Series” modules in the membrane submerged tank, and the piping procedures are described in this section. These would help you design the membrane filtration process with “TMR140 Series”.

1. Standard Time Chart

Two kinds of the filtration patterns are available with "TMR140 Series". One is the simple continuous filtration. And the other is the filtration with relaxation, that is the intermittent filtration. In the case of the intermittent filtration, the filtration is suspended for a short period at certain intervals while the scouring air continues, as shown in Fig.IV-1. While the filtration is suspended, the membrane surface is cleaned up more effectively with the scouring air due to the absence of suction. Although the automatic system control for periodical start and stop of the filtration is required, the intermittent filtration would be recommended if you need higher filtration flux. The recommended time cycle for the intermittent filtration is 9-minute filtration and 1-minute suspension

Cycle of 10 minutes

Filtration

Suspension

9 min.

1 min.

Air diffusion

Contenuous

Fig.IV-1 Recommended Time Chart for Intermittent Filtration

2. Flow Diagram of Membrane Filtration

Two schematic flow diagrams of the membrane filtration process are shown below. One is for the filtration with natural water head and the other is with suction pump. And some explanation is added for the devices used in the membrane filtration process in the latter part

AIRE-064-1-4

+ 34 hidden pages

Toray TMR140 Series, TMR140-100S, TMR140-050S, TMR140-200D, TMR140-200W Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual