AST PolyGeyser User Manual

Bead filter

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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

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Page 1 108 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...
Page 2: Table Of Contents
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 ........................
Page 3: Introduction To The Hppg Series
Bead Filters are virtually immune to clogging and ® caking, since they are backwashed pneuma�cally at a high frequency. These High Pressure PolyGeyser (HPPG) Bead Filters recycle their own backwash waters. The HPPG ﬁlters are the bioclariﬁer of choice for commercial aquaculture and wastewater applica�ons dealing with high organic loads.
Page 4 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...
Page 5: Backwash Operation Overview
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.
Page 8: Hppg Bead Filter Major Components
HPPG Bead Filter Major Components Table 6. Major Component List – Basic Configuration Descriptor Function Comment Inlet Directs flow into filter via the diffuser Passes water while retaining the Screen beads in the filter Outlet Directs the filtered water into the Multiple outlets are generally used for return lines.
Page 9: Installation
Charge Chamber The air tight cone defines the charge In this design series, the charge chamber is chamber while forming a conduit for wrapped around the centralized conduit water transmission into and out of which re-suspends and aerates sludge the charge chamber during each backwash event Air Inlet Slowly fills the charge chamber with...
Page 10 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.
Page 11: Airlift Configuration
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.
Page 12 Air Flowrate Calculations for Airlift Con guration Table 8. Air Flowrate Calcula ons Model Flowrate Outlet Flow Screen Air Li Air Flowrate Level Requirement Injec on Delivery , scfm) Pipe Size (in) Velocity gpm) (in) (in) Depth (in) Pressure ( /s) (in) ) (D ) (V...
Page 13: Backwash Air Pump
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.
Page 14 10 psi range. These units are typically the air supply of choice for ® facilities containing multiple High Pressure PolyGeyser filters. The common oil-less shop compressors can be used to backwash a HPPG unit. Commonly capable of producing pressures in excess of 100 psi, these units are capable of overcoming any pressure produced by a water pump.
Page 15: General Setup Directions
General Setup Directions 1. Prepare your filter’s location. The High Pressure Polygeyser® must be installed on a level surface to backwash properly. The unit is designed to tolerate only about ½ inch of vertical displacement edge to edge across its width in any direction.
Page 16: Adjusting Your Backwash Frequency
Adjusting your Backwash Frequency ® Your PolyGeyser filter employs a static bed of beads to capture suspended solids and/or provide substrate for development of a biofilm to remove targeted dissolved pollutants (organics, ammonia).
Page 17 and the flow passed through the unit declines. Each application has its optimum interval for backwashing. In some cases, an extended backwash interval produces optimum performance and in others, and extremely short backwash interval is best. In broad terms, short backwash intervals (<6 hours) are associated with heavy loads.
Page 18 (MCRT) protozoa that will be found in the filter. ® In recirculating aquaculture applications, PolyGeyser are widely used as bioclarifiers simultaneously removing suspended solids, dissolved organics, total ammonia nitrogen (TAN) and nitrite nitrogen. Here the limiting process step is usually TAN conversion since the TAN must diffuse into the biofilm prior to conversion.
Page 19: Sludge Drainage Assembly
Sludge Drainage Assembly, recommended Plumbing: PVC pipe, 90° elbow, Tee. Ball Valve is included. Pipe clamp recommended. Connect drain line to the installed bottom valve for sludge drainage. AST recommends that the sludge pipe connect to a 90° elbow, pointing up. The vertical pipe should come to a tee positioned on the midline of the inlet to prevent bead loss when draining the sludge.
Page 20: Air Pump Requirements For Backwashing
The ﬂow rate can then be regulated by installing an air ﬂow meter, with a built-in regula�ng valve. AST oﬀers an air ﬂow meter kits which includes an Acrylic Air Flowmeter, a Labcock Valve, a Pressure Gauge, a Nylon Spacer and Fasteners, Barb Fi�ngs and other PVC Fi�ngs. This is strongly recommended for air pumps that do not have built-in air adjustment on them.
Page 21 Figure A : Air input rate required to obtain a targeted backwash interval for the HPPG series can be estimated from this graph. Flowrates are given at operating pressure as would be shown on an attached rotameter. The optimum frequency of backwash intervals varies with feed loading. Figure B below presents recommended backwash regimes and associated air flowrates for targeted feed rates.
Page 22: Troubleshooting (Filter Function)
This troubleshooting guide is based upon the feedback received from actual PolyGeyser® users. The most common solution to the issue is listed first. The PolyGeyser® line is generally a very trouble free unit. If you are having trouble, call your supplier for help. Other than beads, there are no moving parts in a HPPG unit.
Page 23 turn the pump back on and set your backwash frequency higher. i. Put a pressure relief valve on the intake side of the filter and set it below the shutoff pressure of your air pump. ii. Buy an air compressor with a shut off pressure higher than your water pump.
Page 24 1. The trigger is clogged. This condition occurs most often when a unit is just set up or subject to heavy organic loading. Basically a clump of beads has jammed in the trigger preventing air release. a. Try tapping the trigger on the inlet end (the low end) with a rubber mallet. This will normally vibrate the clump free.
Page 25: Trouble Shooting For Recirculating Aquaculture Applications
5. The trigger may be set to low (is this a new filter?). Try raising the unit on the trigger side and test firing. Call AST; highly unlikely, as all units are test fired before shipping. The Beads Seem to Be Fluidizing ®...
Page 26: Sulfide Production
1. You may have air bubbles in your recirculating flow. These bubbles are moving up through the bed dislodging fine solids. Check the suction side of the pump for air leaks. 2. Try decreasing your backflush frequency. This will increase your internal settling time between backwash events and improve the fine solids capture of the bead bed.
Page 27: Filter Acclimation
(safe). There are no documented cases of sulfides from a PolyGeyser® causing a fish kill. However, when an operational PolyGeyser® loses power so both the water circulation and the backwashing is disrupted, then the bacteria in the sludge and the biofilm in the bed will rapidly deplete all the oxygen in the filter.
Page 28 (from the filter, or tank substrate) from an established, cycled and healthy fish tank. The cycled media will aid the transfer of desirable bacteria into the system to colonize the filter. One way to acclimate a recirculating system with a biofilter is to add a few hardy fish, turtles, or mollusks to the system.
Page 29 PolyGeyser During acclimation, the backwash frequency of your ® filter should be 1-2 backwashes per day. This will keep the bead mixed and promote homogenous growth of nitrifying bacteria throughout the bead bed. Figure 4 illustrates the classical pattern of TAN (total ammonia nitrogen) and nitrite concentrations observed during filter acclimation with animals.
Page 30 Table 3. Things You can do to Accelerate the Initial Acclimation of a Bead Filter Procedure How does it help? Add sodium nitrite at a concentration of 1 mg-N/I Allows growth of Nitrobacter to start on the first day. immediately. Introduces species/strains of bacteria that Add beads or tank substrate from an established are well suited for the bead filter’s...
Page 31 C is less than half of than at 30 C. During acclimation a few bacteria with the right characteristics for your system must first attach to the media then reproduce through perhaps a hundred generations to reach acclimation. So if you wish to acclimate in a hurry then heat your water to 30 C until the systems then lower the temperature to the desired level for the fish.
Page 32: Appendix A: The Science Behind Bioclarification
Accelerates reproduction of nitrifying Adjust pH and alkalinity to optimum range. bacteria. Artificially increase the TAN loading prior to the increase by Promotes growth of the critical nitrifying dosing of ammonia chloride (NH 4 CI) and sodium nitrite bacteria, enriching their density in the (NaNO 2 ) to a level of 1 mg-N/I.
Page 33 1/8" Std. Bead Media Removal Efficiency 5-10 10-20 20-30 30-40 40-50 50-100 Particle Size [mm] Figure 1. All particles above 50 microns are removed in the first pass through the filter and the remainders are removed with multiple passes. The flowrate delivered to a bead filter is the principle management factor influencing suspended solids removal.
Page 34: Biofiltration
Biofiltration In the biofiltration mode, bead filters are classified as fixed film reactors. Each bead (Figure 2) becomes coated with a thin film of bacteria that extracts nourishment from the wastewater as it passes through the bed. There are two general classifications of bacteria, heterotrophic and nitrifying, that are of particular interest (Table 2).
Page 35 Table 2. In the Biofiltration Mode, Bead Filters Cultivate Two Types of Bacteria which Perform the Critical Biofiltration Function. Heterotrophic Bacteria Nitrifying Remove dissolved organics (BOD) from Convert toxic Function the water column; breakdown and ammonia and nitrite decay organic sludges. to nitrate.
Page 36 hydrogen ions (H ) in the water to form the ammonium ion (NH ) and the combination (NH ) it referred to as Total Ammonia Nitrogen or TAN. Although only the free ammonia is toxic to fish, it is the TAN concentration that controls the bacterial conversion rates.
Page 37: Warranty
The limited warranty (expressed or implied) during the warranty period shall consist of the repair or replacement of the items of manufacture, at the discretion of AST, and said warranty applies only to the original purchaser. This warranty is void if the items are damaged by negligence or accident after purchase;...
Page 38 3” Fipt Sludge Drain Valve 1.25” Fipt Estimated Sludge Water Loss 10-30 gallons Max Opera�ng Pressure 20 PSI Shipping Weight 750 Lbs AST Aquaculture Systems Technologies, LLC info@as�ilters.com 108 Industrial Avenue Phone: 504.837.5575 New Orleans, LA 70121 Toll-Free:800.939.3659 www.as�ilters.com Fax: 504.837.5585...
Page 39 4” Fipt Sludge Drain Valve 1.25” Fipt Estimated Sludge Water Loss 20-40 gallons Max Operating Pressure 20 PSI Shipping Weight 1200 Lbs AST Aquaculture Systems Technologies, LLC info@as�ilters.com 108 Industrial Avenue Phone: 504.837.5575 New Orleans, LA 70121 Toll-Free:800.939.3659 www.as�ilters.com Fax: 504.837.5585...
Page 40 3” Fipt Sludge Drain Valve 1.5” Fipt Estimated Sludge Water Loss 30-60 gallons 20 PSI Filter Weight/Shipping Weight ~1508 Lbs / 1700 Lbs AST Aquaculture Systems Technologies, LLC 108 Industrial Avenue Phone: 504.837.5575 New Orleans, LA 70121 Toll-Free:800.939.3659 Fax: 504.837.5585...
Page 41 1.5” Fip 5.75” Inlet Valve 6” Fipt Sludge Drain Valve 6” Fipt Es�mated Sludge Water Loss 50-150 gallons 20 PSI Shipping Weight 3250 Lbs AST Aquaculture Systems Technologies, LLC 108 Industrial Avenue Phone: 504.837.5575 New Orleans, LA 70121 Toll-Free:800.939.3659 Fax: 504.837.5585...
Page 42 Drawing is NOT 84” Sludge Drain Valve 3” Fip drawn to scale. 112” Inlet Valve 12” Fipt ~5” 20 PSI Shipping Weight ~6100 Lbs AST Aquaculture Systems Technologies, LLC 108 Industrial Avenue Phone: 504.837.5575 New Orleans, LA 70121 Toll-Free:800.939.3659 Fax: 504.837.5585...