Pilot Plant System Research Articles

Antimony Removal from Water by Adsorption to Iron-Based Sorption Materials

The paper presents the results of antimony removal from the Dubrava water resource using a pilot plant system capable of taking samples from different heights of adsorption materials. The adsorbents GEH, CFH12, CFH18, and Bayoxide E33 and two experimental stainless columns with bleeder valves located at heights of 20, 45, and 70 cm of the adsorption media and 91 cm (GEH), 94 cm (CFH18), 87 cm (CFH12), and 87 cm (Bayoxide E33) filter media high were used. The results of the experiments show that the most suitable material for removing antimony from water is GEH. For an antimony concentration of 78.4–108.0 μg/L in raw water and a filtration rate of 5.6–5.9 m/h, the limit concentration of 5 μg/L at the outlet of the 70-cm high adsorption media was reached at the bed volume 1788. In a case when the media height was 91 cm, the antimony concentration in the treated water would reach the limit value of 5 μg/L after a 672-h operation of the stainless column at the bed volume 4256. Under these conditions, the adsorption capacity was calculated at 184 μg/g. The adsorption capacities and bed volumes of the other adsorbents were lower in comparison to GEH.

Prediction of Chlorine Concentration in Various Hydraulic Conditions for a Pilot Scale Water Distribution System

Chlorine compounds are widely used in water distribution systems to prevent waterborne diseases. Maintaining a sustainable level of residual chlorine in domestic tap water is important to ensure the quality of drinking water. In this study, we designed and fabricated a pilot-scale water distribution system to explore the relationship between the hydraulic conditions and the temporal variation in chlorine concentration. Various hydraulic conditions were introduced during operation, and temporal variations in chlorine concentration were recorded. The existing chlorine models that are used for water distribution systems can be categorized into three distinct groups. A genetic algorithm was used to calibrate the parameters of the various models and hydraulics. Regression analysis under turbulent conditions indicated that the fitted parameters from several chlorine models significantly were correlated with Reynolds numbers. The parameter space of several chlorine decay models was configured in conjunction with the hydraulic condition, and parameters were modeled under various flow conditions. Validation of the chlorine decay models under turbulent flow condition (Reynolds numbers of 15,000-40,000) showed good agreement (R2 > 0.8) with the experimental observations obtained from the pilot plant system.

Simulation of the multicomponent distillation of spearmint essential oil by a predictive Soave-Redlich-Kwong equation of state and comparison with experiments

In this study, enrichment in major component of spearmint oil has been studied by continuous multicomponent distillation. A mathematical model was evaluated to predict the enrichment by multicomponent distillation of spearmint oil. The aim of the work was to obtain simulation data to compare with experimental data of spearmint oil enriching. The simulation model is based on bubble point method ,the Wang-Henke algorithm and predictive Soave-Redlich-Kwong (PSRK) equation. In this method, MESH equations are solved and a diagonal matrix method for solving equations is used. The model was validated by experimental data obtained from a pilot-plant system, where a continuous distillation column with trays of one to five numbers has been used. The simulation was able to predict satisfactory the experimental data. The results of simulation and experiments show that the major component of spearmint essential oil is enriched from 31% to 62.04% by the distillation column with five trays. The results show that the addition of a tray to the distillation column with a low number of trays, have more effective relative to add a tray to the distillation column with higher trays. The results indicate that increasing of reflux ratio from 2 to 3 increases separation of the major component from 62.04% to 67.04%.

The effect of aeration and effluent recycling on domestic wastewater treatment in a pilot-plant system of duckweed ponds

Three pilot-scale duckweed pond (DP) wastewater treatment systems were designed and operated to examine the effect of aeration and effluent recycling on treatment efficiency. Each system consisted of two DPs in series fed by pre-settled domestic sewage. The first system (duckweed+ conventional treatment) was 'natural' and included only duckweed plants. The second system (duckweed aeration) included aeration in the second pond. The third system (duckweed+ aeration+ circulation) included aeration in the second pond and effluent recycling from the second to the first pond. All three systems demonstrated similarly efficient removal of organic matter and nutrients. Supplemental aeration had no effect on either dissolved oxygen levels or on pollutant removal efficiencies. Although recycling had almost no influence on nutrient removal efficiencies, it had a positive impact on chemical oxygen demand and total suspended solids removals due to equalization of load and pH, which suppressed algae growth. Recycling also improved the appearance and growth rate of the duckweed plants, especially during heavy wastewater loads.

Enrichment of Soybean Meal with Microelements during the Process of Biosorption in a Fixed-Bed Column

The aim of the present investigation was to enrich the mineral content of soybean meal with essential chromium and copper metal ions by a biosorption technique in a fixed-bed column. The values of column parameters were determined at various process conditions: pH, temperature, flow rate, and concentration of the feed solution; mass and size of the particles of the bed to determine the breakthrough curves. Biosorption efficiency at optimal conditions (pH 5.0, temperature = 20 °C, Cr(3+) concentration = 200 mg/L, flow rate = 10 mL/min, and sorbent mass = 40 g) was 71.4%. Maximum uptake for Cr(III) and Cu(II) obtained in column was around 15.3 and 12.3 mg/g, respectively. The model constants obtained in this study can be used for design pilot plant systems. Soybean enriched with microelements by biosorption can be considered as biological carrier of microelements and therefore used as the component of livestock feed.

Hydrocracking of Vacuum Gas Oil: Conversion, Product Yields, and Product Quality over an Industrial Hydrocracking Catalyst System

Pilot plant experiments were conducted over an industrial hydrotreating/hydrocracking catalyst system using vacuum gas oil fraction obtained from a refinery crude distillation unit. Extensive pilot plant data were generated on the performance of industrial hydrocracking catalyst system with respect to conversion, product yields, and product quality at various operating conditions. The pilot plant experiments were carried out in a dual-reactor hydrotreating pilot plant system with downflow mode of operation. The temperature varied from 360 to 400°C and liquid hourly space velocity varied from 0.8 to 2.4 hr−1, keeping a constant pressure of 170 kg/cm2 and H2/HC feed ratio of 845 L/L. The hydrocracked total liquid product was distilled in a true boiling point distillation unit to obtain yields and qualities of different fractions such as naphtha, kerosene, diesel, and unconverted oil. The effect of operating conditions on the performance of the hydrocracking catalyst system was discussed in detail. The kinetics of hydrocracking reaction was studied using a simple first-order reaction and a complex four-lump reaction system and the kinetic parameters were reported.

Performance evaluation of a granular activated carbon-sequencing batch biofilm reactor pilot plant system used in treating real wastewater from recycled paper industry

A pilot scale granular activated carbon-sequencing batch biofilm reactor with a capacity of 2.2 m3 was operated for over three months to evaluate its performance treating real recycled paper industry wastewater under different operational conditions. In this study, dissolved air floatation (DAF) and clarifier effluents were used as influent sources of the pilot plant. During the course of the study, the reactor was able to biodegrade the contaminants in the incoming recycled paper mill wastewater in terms of chemical oxygen demand (COD), adsorbable organic halides (AOX; specifically 2,4-dichlorophenol (2,4-DCP)) and ammoniacal nitrogen (NH3-N) removal efficiencies at varying hydraulic retention times (HRTs) of 1–3 days, aeration rates (ARs) of 2.1–3.4 m3/min and influent feed concentration of 40–950 mg COD/l. Percentages of COD, 2,4-DCP and NH3-N removals increased with increasing HRT, resulting in more than 90% COD, 2,4-DCP and NH3-N removals at HRT values above two days. Degradation of COD, 2,4-DCP and NH3-N were seriously affected by variation of ARs, which resulted in significant decrease of COD, 2,4-DCP and NH3-N removals by decreasing ARs from 3.4 m3/min to 2.1 m3/min, varying in the ranges of 24–80%, 6–96% and 5–42%, respectively. In comparison to the clarifier effluent, the treatment performance of DAF effluent, containing high COD concentration, resulted in a higher COD removal of 82%. The use of diluted DAF effluent did not improve significantly the COD removal. Higher NH3-N removal efficiency of almost 100% was observed during operation after maintenance shutdown compared to normal operation, even at the same HRT of one day due to the higher dissolved oxygen concentrations (1–7 mg/l), while no significant difference in COD removal efficiency was observed.

KINETIC EVALUATION AND PROCESS PERFORMANCE OF A PILOT GAC-SBBR SYSTEM TREATING RECYCLED PAPER INDUSTRY WASTEWATER

Recycled paper industry wastewater generates potentially persistent and toxic pollutants which can affect the ecological balance and cause aesthetic concerns. In this study, the biodegradability of recycled paper mill wastewater by a granular activated carbonsequencing batch biofilm reactor (GAC-SBBR) pilot plant system during a period of 53 days was evaluated while on-line monitoring was used to observe the influence of parameter changes during the treatment process. The effect of nitrogen (N) and phosphorus (P) addition on removal of chemical oxygen demand (COD) in four phases was investigated. The COD:N:P ratio in the nutrient medium was considered as an independent variable at a fixed value hydraulic retention time (HRT) of 24 hours. The study demonstrated that the process was unstable during the initial phase and started to stabilise during the last phase when a COD:N:P ratio of about 100:5:1 was achieved. Degradation of COD was seriously affected by variation of COD:N:P ratios, resulting in the highest removal efficiency of COD at COD:N:P ratio of 100:5:1 (80.1 %) and a minimum degradation at COD:N:P ratio of 1000:7:0.2 (33.8 %). Using the Monod model, the kinetic parameters (μm, Ks, Y and Kd) were determined as 0.1007 mg MLSS/mg COD.day, 65.917 mg COD/L, 0.5199 mg MLSS/mg COD and 0.0048 mg MLSS/mg COD.day, respectively. These findings can be used to improve the performance of the pilot GAC-SBBR system.

Treatment of Adsorbable Organic Halides from Recycled Paper Industry Wastewater using a GAC-SBBR Pilot Plant System

Treatment of Adsorbable Organic Halides from Recycled Paper Industry Wastewater using a GAC-SBBR Pilot Plant System

Multiple use of an industrial‐distributed control system in control engineering education

AbstractThe paper demonstrates how a four‐tank laboratory process equipped with a modern distributed control system (DCS) is used in different control engineering laboratories for the undergraduate and graduate levels. This includes the utilization of commercial tools for DCS engineering as well as the design and commissioning of traditional and advanced control solutions. Using the same pilot plant and control system in different modules lowers the costs, allows the reutilization of results and enables an efficient laboratory organization. It also supports the process of learning the inner context of different process control related subjects. © 2011 Wiley Periodicals, Inc. Comput Appl Eng Educ 21: 313–321, 2013

Large scale chiral chromatography for the separation of an enantiomer to accelerate drug development

There are several approaches to produce enantiomerically pure drug substances, such as recrystallization, catalytic process (ligand and enzyme), indirect chromatographic resolution, and direct chromatographic resolution. However, the use of preparative chromatography with chiral stationary phases seems to be most effective for early phase projects, where the time and resources on the developments need to be minimized to get the drug candidates into the clinical studies. We showed that by following a well-defined process, chiral chromatography can be easily scaled up from an analytical system to a pilot plant system. We also used the results from a multicolumn continuous chromatography (MCC) study to conclude that MCC can be a cost-effective production method for chiral manufacturing.

A pilot-scale high-rate biohydrogen production system with mixed microflora

A pilot-scale high-rate dark fermentative hydrogen production plant has been established in the campus of Feng Chia University to develop biohydrogen production pilot-plant technology. This pilot-plant system is composed of two feedstock storage tanks (0.75 m 3 each), a nutrient storage tank (0.75 m 3), a mixing tank (0.6 m 3), an agitated granular sludge bed fermentor (working volume 0.4 m 3), a gas–liquid–solid separator (0.4 m 3) and a control panel. The seed mixed microflora was obtained from a lab-scale agitated granular sludge bed bioreactor. This pilot-scale fermentor was operated for 67 days at 35 °C, an organic loading rate (OLR) of 40–240 kg COD/m 3/d, and the influent sucrose concentration of 20 and 40 kg COD/m 3. Both biogas and hydrogen production rates increased with increasing OLR. However, the biomass concentration (volatile suspended solids, VSS) only increased with an increasing OLR at an OLR range of 40–120 kg COD/m 3/d, whereas it decreased when OLR was too high (i.e., 240 kg COD/m 3/d). The biogas consisted mainly of H 2 and CO 2 with a H 2 content range of 23.2–37.8%. At an OLR of 240 kg COD/m 3/d, the hydrogen content in biogas reached its maximum value of 37% with a hydrogen production rate (HPR) of 15.59 m 3/m 3/d and a hydrogen yield of 1.04 mol H 2/mol sucrose. This HPR value is much higher than 5.26 m 3/m 3/d (fermented molasses substrate) and 1.56 m 3/m 3/d (glucose substrate) reported by other pilot-scale systems. Moreover, HPR was also greatly affected by pH. At an optimal pH of 5.5, the bacterial community became simple, while the efficient hydrogen producer Clostridium pasteurianum was dominant. The factors of energy output compared with the energy input ( E f) ranged from 13.65 to 28.68 on biohydrogen, which is higher than the E f value on corn ethanol, biodiesel and sugarcane ethanol but in the similar range of cellulosic ethanol.

High-rate deposition of amorphous and nanocomposite Ti–Si–C multifunctional coatings

Abstract Amorphous (a) and nanocomposite Ti–Si–C coatings were deposited at rates up to 16 μm/h by direct current magnetron sputtering from a Ti 3 SiC 2 compound target, using an industrial pilot-plant system, onto high-speed steel, Si, and SiO 2 substrates as well as Ni-plated Cu cylinders, kept at a temperature of 200 or 270 °C. Electron microscopy, X-ray photoelectron spectroscopy, and X-ray diffraction analyses showed that TiC/a-C/a-SiC nanocomposites were formed consisting of textured TiC nanocrystallites (nc) embedded in a matrix of a-C and a-SiC. Elastic recoil detection analysis showed that coatings deposited at a target-to-substrate distance of 2 cm and an Ar pressure of 10 mTorr have a composition close to that of the Ti 3 SiC 2 compound target, as explained by ballistic transport of the species. Increased target-to-substrate distance from 2 cm to 8 cm resulted in a higher carbon-to-titanium ratio in the coatings than for the Ti 3 SiC 2 compound target, due to different gas-phase scattering properties between the sputtered species. The coating microstructure could be modified from nanocrystalline to predominantly amorphous by changing the pressure and target-to-substrate conditions to 4 mTorr and 2 cm, respectively. A decreased pressure from 10 mTorr to 4 or 2 mTorr at a target-to-substrate distance of 2 cm decreased the deposition rate up to a factor of ~ 7 as explained by resputtering and an increase in the plasma sheath thickness. The coatings exhibited electrical resistivity in the range 160–800 μΩ cm, contact resistance down to 0.8 mΩ at a contact force of 40 N, and nanoindentation hardness in the range of 6–38 GPa.

Investigation of the Colloidal Interactions at Play in Combined Acidification and Rennet of Different Heat-Treated Milks

The properties of gels obtained by combined acidification and rennet were investigated for milks heated at different temperature-time regimes using a high temperature short time (HTST) pilot plant system. Increasing amounts of heat-induced whey protein complexes were found in the soluble phase as a function of heating time/temperature, and only in the most extensively heated milk (i.e., 85 degrees C/300 s), these complexes were in quantities comparable to those reported in previous studies. Two levels of rennet were studied, and at the gelation pH, the amount of CMP released was 11 +/- 1% and 26 +/- 5% in the low and high rennet experiments, respectively. These two levels of rennet caused profound changes in the gelation behavior and in the structure development of the network. When a small amount of rennet was used, different heating temperature-time regimes did not affect the first stage of renneting. Increasing the extent of milk heat treatment and/or the level of rennet increased the pH of gelation and the stiffness of the gels. This work is the first to compare the effect of heating (using a pilot plant setup) and amount of rennet on the destabilization and interaction of casein micelles during aggregation by combined rennet and acidification.

Catalytic degradation of Orange II in a ferrioxalate-assisted photo-Fenton process using a combined UV-A/C–solar pilot-plant system

The catalytic degradation of Orange II in a ferrioxalate-assisted photo-Fenton process with combined solar and artificial ultraviolet light sources and continuous addition of H2O2 was investigated. The reaction was carried out in a pilot plant consisting of a compound parabolic collector (CPC) solar reactor in series with a UV-A/C reactor. An optimization study was done using a multivariate experimental design including the following variables: pH, H2O2 flow rate, UV-lamp exposure time, average temperature, average solar power and initial concentrations of Fe(II) and oxalic acid. The photocatalytic degradation efficiency was determined by the analysis of color and total organic carbon (TOC) removal. Under the optimum conditions, TOC removal increased to 99% in only 45min, and this system permitted the use of a low ferrous concentration of only 2mgL−1. In addition, oxalic acid was used for pH adjustment. Thus, the operating costs of Fe removal, chemicals and electric power were reduced. Artificial UV-A/C light can be used either to increase the efficiency of the single-solar process or as an alternative to solar CPC on cloudy days. The overall rate constant was split into three components: direct oxidation by hydrogen peroxide, photolytic breakdown of dye–oxalate complexes chromophore group and oxidation by hydroxyl radicals. The influence of the Fe catalyst on the molecular and/or radical reactions was studied by conducting the reaction in the presence and absence of tert-butyl alcohol; the radical mechanism's contribution to the overall degradation increased with increasing iron levels.

Plasma-Arc Technology for the Thermal Treatment of Chemical Wastes

Plasma-arc technology was developed to dispose of chemical wastes from a chemical plant by the Institute of Mechanics, Chinese Academy of Sciences (CAS-IMECH). A pilot plant system with this technology was constructed to destroy two types of chemical wastes. The system included shredding, mixing, and feeding subsystems, a plasma-arc reactor of 150 kW, an off-gas burning subsystem, and a scrubbing subsystem. The additives (CaO, SiO2, and Fe) were added into the reactor to form vitrified slag and capture the hazardous elements. The molten slag was quickly quenched to form an amorphous glassy structure. A direct current (DC) experimental facility of 30kW with plasma-arc technology was also set up to study the pyrolysis process in the laboratory, and the experimental results showed the cooling speed is the most important factor for good vitrified structure of the slag. According to previous tests, the destruction and removal efficiency (DRE) for these chemical wastes was more than 99.999%, and the polychlorinated biphenyls (PCBs) concentration in the solid residues was in the range of 1.28 to 12.9mg/kg, which is far below the Chinese national emission limit for the hazardous wastes. A simplified electromagneto model for numerical simulation was developed to predict the temperature and velocity fields. This model can make satisfactory maximum temperature and velocity distributions in the arc region, as well as the results by the magneto hydrodynamic approach.

Inactivation of Alicyclobacillus acidoterrestris in Orange Juice by High Electric Field Alternating Current

Alicyclobacillus acidoterrestris spores inoculated in orange juice were inactivated by applying a high electric field alternating current (HEF-AC) to food for a short duration. This new method is effective for inactivating all microorganisms in liquid foods. HEF-AC was compared with a conventional heating method using two oil baths and a tubular heat exchanger for the inactivation of A. acidoterrestris spores in orange juice. Using an HEF-AC pilot plant system at a flow rate of 100L/h, A. acidoterrestris spores in orange juice were exposed to an electric field of 2.5 - 2.7 kV/cm at 20 kHz for 13.8 ms in an electrode unit, as the temperature of orange juice was increased from 35°C to above 110°C upon leaving the electrode. Holding times between the electrode and cooling unit varied from 0.3 - 0.9 s. Increasing the holding time of HEF-AC enhanced microbial inactivation, while changing the holding time after the electrode unit was replaced with a tubular heat exchanger had no effect. Comparative studies revealed that the HEF-AC inactivated A. acidoterrestris spores 30 times faster than conventional heating using two oil baths during the holding time.

Radio frequency electric fields inactivation of Escherichia coli in apple cider

A nonthermal process using radio frequency electric fields (RFEF) was developed to pasteurize apple cider. An 80 kW RFEF pilot plant system was used to process cider at flow rates of 1.5 and 1.9 l/min. Escherichia coli K12 in apple cider was exposed to electric field strengths of 20–30 kV/cm at frequencies of 21, 30, and 41 kHz. Treatment times varied from 140 to 420 μs. Electrical energy costs were calculated using the measured voltages and currents. Energy balances were performed using the inlet and outlet temperatures. RFEF processing at an outlet temperature of 60 °C reduced the population of E. coli by 4.8 log, whereas thermal processing at the same conditions had no effect. Varying the frequency between 21 and 41 kHz had no effect on the level of microbial inactivation; however, increasing the treatment time, field strength and outlet temperature enhanced inactivation. The inactivation data at 20 kV/cm and 60 °C follow first order kinetics with a calculated D values of 74 μs. The inactivation data are represented well by the electric field strength model; the calculated critical electric field strength, E c, for 60 °C was 4.0 kV/cm. The electrical energy for RFEF pasteurization was 260 J/ml. The electrical cost was $0.0050/l of apple cider. Processing temperature had the greatest influence on energy efficiency. A RFEF nonthermal process has been developed to pasteurize apple cider. The effect of varying processing conditions on energy efficiency was investigated and at the optimum condition, the electrical cost appears to be minor. In addition, the RFEF process can be correlated using first order kinetic models.

A combined solar photocatalytic-biological field system for the mineralization of an industrial pollutant at pilot scale

A coupled solar photocatalytic-biological pilot plant system has been employed to enhance the biodegradability and complete mineralization of a biorecalcitrant industrial compound, α-methylphenylglycine, dissolved in distilled water and simulated seawater at 500 mg L −1. The pollutant was completely degraded by a solar photo-Fenton treatment in a 75-L pilot plant made up of four compound parabolic collector (CPC) units. The catalyst concentration employed was 2 and 20 mg L −1 of Fe 2+ and the H 2O 2 concentration was kept in the range of 200–500 mg L −1. A Zahn–Wellens (Z–W) test applied to photo-treated samples demonstrated that intermediates produced within a short time of starting the photo-Fenton process were biodegradable. Consequently, the photocatalytic and biological processes were combined. Biodegradable compounds generated during the preliminary oxidative process were biologically mineralized in a 170-L aerobic immobilised biomass reactor (IBR), filled with 90–95 L propylene Pall ® Ring supports colonized by activated sludge. Almost total mineralization (90% overall total organic carbon removed) was attained in the combined treatment system (for both distilled and seawater experiments). Moreover, nitrification and denitrification phenomena were also observed.

Ozone treatment and the depletion of detectable pharmaceuticals and atrazine herbicide in drinking water sourced from the upper Detroit River, Ontario, Canada

The depletion and degradation of pharmacologically active compounds (PhACs) and pesticides as a function of ozonation in drinking water treatment processes is not well studied. The A.H. Weeks drinking water treatment plant (DWTP) serves the City of Windsor, Ontario Canada, and incorporates ozone treatment into the production of drinking water. This DWTP also operates a real-time, scaled down pilot plant, which has two parallel streams, conventional and ozone plus conventional treatments. In this study water samples were collected from key points in the two streams of the pilot plant system to determine the depletion and influence of seasonal changes in water processing parameters on eighteen major PhACs (and metabolites) and seven s-triazines herbicides. However, only carbamazepine (antiepileptic), caffeine (stimulant), cotinine (metabolite of nicotine) and atrazine were consistently detectable in the raw water intake (low to sub-ng/L level). Regardless of the seasonality, the flocculation-coagulation and dual media filtration steps without ozone treatment resulted in no decrease in analyte concentrations, while decreases of 66–100% (undetectable, method detection limits 0.05–1 ng/L) of the analyte concentrations were observed when ozone treatment was part of the water processing. These findings demonstrate that ozone treatment is highly effective in depleting carbamazepine, caffeine, cotinine, and atrazine, and thus is highly influential in the fate of these compounds in drinking water treatment regardless of the seasonal time frame. Currently very few Canadian DWTPs incorporate ozonation into conventional treatment, which suggests that human exposure to these compounds via drinking water consumption may be an issue in affected communities.