SPX Cooling Technologies MCR3100 User's Manual
Contents
1. Marley MARPAK Modular Biomedia SP COOLING TECHNOLOGIES The Marley MARPAK Difference SPX Cooling Technologies is a world leader in the design manufacturing and construction of cooling products The design and production of modular corrugated PVC media used in Marley cooling products is the same technology and expertise utilized in the develooment of the MARPAK product line of modular PVC media for biological wastewater treatment Since the origin of Marley in 1922 we have maintained a commitment to total quality in engineering in customer service and in the close teamwork of our employees and representatives around the world This long term dedication is what makes the Marley MARPAK Difference Influent amp Intermediate Pumping Secondary Treatment Sludge Treatment Building Heating amp Cooling 1 2 3 4 E 6 8 10ft Total Head 30ft Total Head 100ft Total Head m En T A nm i a vena eI DRT Se ae reatmen ce ar Eir Activated ee ke Ta a le e A Extended Aeration a ee Incineration i Aerobic Digestion Thicken amp rea Pn z AFE e r Haul to Landfill _ ENE Yan Drying Beds Kz ba a a Baxda z u Chlorination a N Northern US Southern U S n For over 100 years the fixed film reactor trickling filter has been used in wastewater treatment to reduce the biochemical oxygen demand BOD an2. produced for over 30 years and the advantage of taller fill heights has been recognized This has resulted in the development of larger thermoformers to product fill media up to 6 ft tall There are several advantages of taller media primarily due to the presence of fewer interfaces between modules e Less deflection under load because the edge to edge interface between modules deforms more than the internal structure of the media e Less clogging by biosolids because module interfaces produce a blockage location due to exposed media edges e Less air blockage pressure drop for better air distribution e Less installation time Just as with a cooling tower water and air distribution efficiency is critical to the performance of a trickling filter For that reason SPX advocates minimizing the number of module interfaces by using taller modules in any media installation whether for a cooling tower or for a trickling filter MARPAK Advantages Taller heights of 4 ft MXF 4800 and MXF 3000 and 6 ft MCR 3100 Taller MARPAK modules mean e Stability Less settling over you filter s life e Efficiency Less clogging by biomass at module interfaces e Performance Less air blockage due to interfaces e Quicker Installation Fewer modules to handle In third party test of MXF 3000 media two 2 ft tall modules deflected nearly 70 more than two 4 ft tall modules For example if filter media with 2 ft tall
3. arification Fig 8 1 can reduce BOD and suspended solids to above 90 Reactor Trickling Filter ps Solids Contact TF SC The TF SC process utilizes the trickling filter followed by short term aeration Fig 8 2 The recirculation of sludge to the aerated contact basin enhances the agglomeration of fine particles and Pri i rima improves settling characteristics At the Clarifier same time the aeration continues to N remove soluble organics The aerated contact basin combined with a center well final clarifier can readily achieve a 95 plus percentage reduction in BOD and total Wate MARPAK Suspended solids Sludge Reactor Seconda m gt Clarifier TF SC Process Seconda Clarifier Aerated Contact Basili eg Roughing or Pretreatment 8 2 ee MARPAK MXF and MCR Series fixed film biological reactors Fig 8 3 are an effective method of pretreating difficult wastes and reducing the organic load on subsequent biological treatment steps fi Marpak Plus Activated Sludge Prima Clarifier Seconda Clarifier MARPAK Ka GULL Reactor Basil ji Applications BOD lt 15 Nitrification SS lt 15 NH Nc1 Nitrification Effluent from In the nitrification process Fig 9 1 MARPAK Secondary MXF Series fixed film reactor provides an Treatment 1N MARPAK effective means of oxidizing ammonia nitrogen of Nitrification secondary treated wastewater Reactor Nitrifying trickling filters req
4. ater treatment including complete secondary treatment Figs 8 1 and 8 2 nitrification Fig 9 1 denitrification industrial roughing filters and anaerobic treatment Flow Configuration of MARPAK MXF Series Media Retention Time Versus Flow At A Media Depth Of 10ft Faster Installation Flow m m2 h Extensive testing has proven that taller mod ules produce the same water distribution as alternating 1 O modules This means 4 ft 6 ft or even 8 ft modules can be used to reduce installation time and minimize the number of clog prone module interfaces Retention Time Versus Flow At A Media Depth Of 10ft Flow m m2 h 1 2 2 4 3 6 Retention Time In Minutes 0 4 0 8 1 2 1 6 2 0 2 4 Flow GPM ft2 4 2 Source Plastic Packed Trickling Filters by E Sarner Retention Time In Minutes o 05 10 T 5 Flow GPM ft Source Evaluation of Plastic Media In Trickling Filters by T Richards and D Reinhart MARPAK MXF Series Advantages of MARPAK ji De MARPAK MXF Series incorporates the well established 60 MXF Series 60 flow media cross corrugated cross flow design Fig 4 1 This geometry gt 1 Superior oxygen transfer has proven to be the most efficient for reducing BOD biochemical oxygen demand and for nitrification Typical The MXF Series geometry allows applications are shown in Figure 5 1 MXF Series media is for the continuous and uniform available in modules 2 ft wide 2
5. d for nitrification As the wastewater passes down through the trickling filter microorganisms on the surface of the media convert the dissolved organic wastes and ammonia nitrogen into stable by products carbon dioxide nitrates nitrites and biosolids which are removed by clarification The advantage of the trickling filter process over other methods of treating wastewater include 1 Lower energy consumption Fig 3 1 2 More resistant to hydraulic and organic shock loads 3 Simple operational procedures 4 Fewer personnel required to operate 5 Reduces sludge bulking problems With the advent of the highly efficient modular 60 cross flow media MARPAK MXF Series the trickling filter is a viable alternative for complete secondary treatment Figs 8 1 and 8 2 and nitrification Fig 9 1 of municipal wastewater As energy and labor costs continue to increase the trickling filter process will become even more cost effective in wastewater treatment Modular Biological Treatment Media MARPAK is a modular PVC corrugated media specifically designed for biological treatment applications MARPAK media is manufactured from rigid PVC sheets that are UV protected and resistant to rot fungi bacteria acids and alkalies commonly found in wastewater MARPAK modules are manufactured in various sheet thicknesses to meet specific structural requirements MARPAK includes a full range of modular PVC media geometries for wastew
6. eactor Adequate protection and precaution should be taken to insure that no damage is done to the placed media and that no debris from the cutting process Is allowed to lodge in the placed media Warranty The media supplier shall certify to the general contractor and the engineer in writing that the media to be supplied will meet or exceed the specifications Limited warranty shall be provided by the manufacturer for a period of one year after installation against defects in material and workmanship For a more detailed specification for your specific application please contact SPX Cooling Technologies at 800 462 7539 and ask for MARPAK SP COOLING TECHNOLOGIES 7401 WEST 129 STREET OVERLAND PARK KANSAS 66213 UNITED STATES 913 664 7400 spxcooling ct spx com spxcooling com In the interest of technological progress all products are subject to design and or material change without notice 2008 SPX Cooling Technologies Inc Printed in USA Marpak 08
7. ft or 4 ft high and 4 ft or horizontal redistribution of air and 6 ft long water Fig 4 1 maximizing oxygen uptake 2 High Efficiencies at shallow depths The MXF Series 60 cross erd Specific TEER corrugated geometry maximizes eee Surface Area atio Application hydraulic retention time compared Identification 12 443 to other media types Fig 4 2 amp 4 3 MXF Series media can provide MXF 3000 30 95 EE aia effective treatment at media depths as low as 3 ft MXF Series media Anaerobic can be used as a direct replacement Treatment for rock media to increase both Secondary capacity and efficiency of existing MISE Treatment trickling filters Fig 7 1 Mila ai 3 Wide hydraulic range MXF 7400 eskere MXF Series is effective in reducing pal BOD and nitrification at hydraulic Nitrification wetting rates of below 0 2 gom ft to over 2 5 gpm ft MCR3100 High Strength Wastewater Anaerobic Treatment MARPAK MCR Series MARPAK MCR Series is a vertically corrugated clog resistant media designed to minimize the potential for excessive solids buildup The geometry is ideally suited for treating high strength wastewater Typical applications are shown in Figure 5 1 MCR Series media is available in modules 2 ft wide 2 ft 4 ft 6 ft or 8 ft high and 4 ft long a r Ii J a Hi gn Fi jiJ j d onm A unua g F E Ts Fp AA Y KAX o ae el E d kama MI Ew iu T e k j WW A L_l e s Numerous emp
8. irical equations have been developed in an attempt to mathematically describe the reaction taking place in the trickling filter The most common and generally accepted empirical equation in use today for predicting trickling filter performance in secondary treatment applications is the modified Velz equation MARPAK MXF Series media performance for secondary treatment Figs 8 1 and 8 2 can be evaluated using the modified Velz equation For information regarding the application of MARPAK MXF Series media for nitrification of municipal wastewater please reference Figs 9 1 and 9 2 trial Wastew MARPAK MXF and MCR Series media can be used to treat a variety of industrial waste streams Due to the wide variation in treat ability of industrial wastes trickling filter performance is best determined from data from trickling filter installations treating similar wastewater general design curves for various categories of industrial wastewater or pilot studies In addition to clarification pretreatment including pH adjustment and nutrient addition may be required The wastewater entering the trickling filter should have a pH between 6 0 and 8 5 and a nutrient balance among BOD ammonia nitrogen and phosphorous of 100 5 1 Applications Upgrading Existing Rock Trickling Filters MARPAK MXF 4800 with its 60 cross fluted geometry and high surface and void ratio is ideal for upgrading the performance of existing rock trickling fi
9. lters With a surface area and void ratio more than three times greater than rock upgrading with MARPAK MXF 4800 can more than double the organic capacity and improve effluent quality of an existing trickling filter A significant amount of nitrification can also be achieved depending on the organic loading Unlike rock or random plastic media MARPAK MXF 4800 provides continuous and uniform horizontal redistribution of air and water with no short circuiting In addition MARPAK MXF 4800 has no horizontal surfaces thus minimizing the potential for excessive solids buildup and plugging MARPAK MXF 4800 modules can be placed directly on rows of supports Fig 7 1 Removal of the existing clay tile along with the rock media is recommended Modifications to the existing trickling filter structure are generally not required MARPAK MXF 4800 a N r i a DRETS 000s yer 8 a a ook Boe eee poet ze ne pace Roc Media ce en oe ae age oe p 2 E test seo rt HENA Heii caps ta bait oe v a N WA N V HIN W Remove Existing Rock Media MarPier Supports and Underdrain Alternate Support Material Clay Tile Concrete Block Precast Concrete Beams Applications C lete S dary Treatment Complete Secondary e ery cen Treatment Primary MARPAK MXF Series fixed film 7 Clarifier n SS 20 biological reactors used in conjunction with primary and secondary cl
10. modules settle by 4 in during its lifetime 4 ft tall modules in the same filter will settle less than 2 in Based on percentage of height General Specification and Installation Information Media MARPAK is a Modular PVC media specifically designed for fixed film biological treatment applications MARPAK is available in both the highly efficient 60 cross flow design MXF Series for complete secondary treatment and nitrification and the vertical flow design MCR Series for treating high strength industrial wastewater MARPAK media is available in specific surface areas from 30 to 74 square feet per cubic foot with a 95 void to volume ratio The MARPAK modules are manufactured in various PVC sheet thicknesses to meet specific structural requirements Material MARPAK polyvinyl chloride PVC sheets are resistant to rot fungi bacteria growth and other forms of microorganisms and are chemically resistant to normal concentrations of sewage acids alkalis organic solvents and organic compounds The PVC compound is UV resistant and specifically formulated to resist long term fatigue cracking under continuous loading Installation MARPAK is installed so that the sheets of all modules in a particular layer are parallel Special care should be taken during installation of the media to protect the modules from damage Where necessary cutting and trimming of the modules may be performed within the fixed film r
11. uire less mechanical equipment less operating power and less attention than the activated sludge process ae Fig 9 3 Nitrifying trickling filters are less On effected by cold temperature than the activated sludge process Fig 9 4 E MARPAK nitrification fixed film reactor Surface 6000 when preceded by clarified secondary Area effluent with the BOD below 35 mg l will Required 4000 continue to reduce suspended solids and sq ft lb of BOD to a level below 20 mg l NHt N Oxidized T A performance curve for nitrification is Per Day shown in Fig 9 2 10 20 30 40 50 60 Effluent Ammonia N mg L Source Process Design Manual For Nitrogen Control U S EPA Cost Comparison Activated Nitrifying Cost Sludge Trickling Filter Project 8 497 000 4 870 000 Energy 10 year 3 450 000 1 175 000 Project present worth 7 423 000 4 250 000 Energy present worth 2 847 000 971 000 Total present worth 10 270 000 5 221 000 Source Water Engineering and Management Effect of Temperature 100 hing Filter nitrifying Tricking 80 a Nitrification Rate g0 soe as of rate N aww at 20 C 40 porn 20 8 0 10 12 14 16 18 20 Temperature C Source Water Engineering and Management EZI The MARPAK Advantage Fixed film media has traditionally been made in 2 ft height increments due to production limitations sizes of thermoformers and molds to create the media sheets Marley cooling tower fill has been
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