APPLICATION OF DIRECT FILTRATION UTILIZING FLOATING BEAD FILTERS AND FLOCCULATION AIDS FOR FINE SUSPENDED SOLIDS AND PHOSPHORUS REMOVAL

• Sponsoring Institution: National Institute of Food and Agriculture
• Project Status: COMPLETE
• Funding Source: SMALL BUSINESS GRANT
• Reporting Frequency: Annual
• Accession No.: 1000518
• Grant No.: 2013-33610-21077
• Cumulative Award Amt.: $373,000.00
• Proposal No.: 2013-02669
• Project Start Date: Sep 1, 2013
• Project End Date: Aug 31, 2018
• Grant Year: 2013
• Program Code: [8.7]- Aquaculture

Recipient Organization
AQUACULTURE SYSTEMS TECHNOLOGIES, LLC
108 INDUSTRIAL AVENUE P.O. BOX 15827
JEFFERSON,LA 70121

Performing Department
(N/A)

Non Technical Summary
As aquaculture, particularly marine aquaculture continues to expand worldwide environmental regulations pertaining to waste discharge from fish farms are also becoming more stringent having an environmentally sound waste management, recovery and disposal plan are thus becoming increasingly more important, particularly in marine aquaculture. Two of the primary concerns for extending water reuse and recovery are the suspended solids and phosphorous in the effluent. The direct filtration process provides aquaculturist with a tool to allow both freshwater and marine recirculating aquaculture systems (RAS) (including zoos and aquaria) to recover and extend the use of water in their facilities resulting in a significant cost savings through the reduction of the volume of waste water being discharged and the cost of make-up water, especially on marine systems which rely on expensive artificial sea salt mixtures or transport of saltwater from offshore sites. The direct filtration process is a simplified strategy for implementing a coagulation/flocculation process. Coagulation and flocculation aids have long been used in the drinking water and wastewater treatment industries. Traditional water treatment utilizes the process of dosing chemical coagulation and flocculation aids for the removal of turbidity-causing fine solids in a progressive, 4-step process. To improve upon the traditional coagulation/flocculation approach to water treatment, the direct filtration process combines the individual unit processes with the particle capture benefits of a floating bead filter (FBF) to create an efficient, integrated, and streamlined package. The integration of electro-flocculation, a promising new technology which does not require the dosing of chemical coagulation and flocculation aids, may reduce the amount of residue from the coagulation/flocculation process and simplify the direct filtration process. Electro-flocculation is the application of electrical current to a pair of electrodes to improve and facilitate the flocculation of fine solids. While highly effective at the removal of fine suspended and colloidal particles, the direct filtration process may potentially be tuned to have the secondary benefit of effective phosphorus removal. As a result of the Phase I research, the application of the direct filtration process with a FBF was shown to be incredibly successful in the removal of turbidity-causing fine suspended solids. Likewise, the effect of orthophosphate sequestration and removal with an appropriate coagulant makes the direct filtration FBF even more desirable. Combining the removal of turbidity-causing fine suspended solids with the removal of orthophosphate in a space-saving, innovative package will serve as an excellent addition to the existing line of highly successful FBFs which AST has successfully marketed for over 17 years. The key to successful aquatic animal production systems is the availability of reliable and cost effective production technologies. AST has successfully commercialized a family of FBFs, or bioclarifiers, which can accomplish both solids capture and nitrification in a single unit economically and efficiently. AST believes that this "next generation" of FBF optimized for direct filtration will provide an efficient and cost effective solution which directly addresses the regulations imposed on the aquaculture, zoo and large aquarium industries.

Animal Health Component

0%

Research Effort Categories

Basic

0%

Applied

0%

Developmental

100%

Classification

Knowledge Area (KA)	Subject of Investigation (SOI)	Field of Science (FOS)	Percent
403	3799	2020	100%

Knowledge Area
403 - Waste Disposal, Recycling, and Reuse;

Subject Of Investigation
3799 - Cultured aquatic animals, general/other;

Field Of Science
2020 - Engineering;

Keywords

bead filters

coagulant

direct filtration

effluent

flocculant

Goals / Objectives
1) Evaluate the suitability of electro-coagulation as an alternative to coagulant chemical dosing for commercial use in a FBF direct filtration application. Using the design principles and testing apparatus developed in the Phase I research, implementation of electro-coagulation will be evaluated. Tests will focus on both the effectiveness and the energy consumption for both fresh and marine RAS production systems. 2) Automate the direct filtration process with AST's process controller platform using water quality sensors, controls and feedback loops. A principle component analysis (PCA) will be conducted to determine the appropriate use of sensors for water quality parameters such as turbidity, zeta-potential, and/or regulation of voltage (or coagulant feed pumps). The PCA will be used to reduce the cost of treatment and optimize the direct filtration treatment process. The final control system design will use feedback loops with the sensors and a custom-designed fuzzy logic controller to automate the treatment process. 3) Finalize the ICAP design based on the results from Objectives 1 and 2. The finalized design will include either chemical coagulant dosing or electro-coagulation as the primary means for flocculation. The automation system will utilize the components selected in Objective 2. 4) Conduct "in-house" trials using the AST research systems. Based on system data from collaborating partners, the systems to be tested will be representative of the freshwater and marine RAS targeted in the commercialization plan. 5) Conduct beta-tests on site with one or more partner organizations which provided system data for the in-house trials. The Phase II final report will then be generated as a result of the beta test results.

Project Methods
Tasks to accomplish Objective 1 (Week 3-10): Task 1: Evaluate the suitability of electro-coagulation as an alternative to coagulant chemical dosing for commercial use in a FBF application. Standard jar tests are used to rapidly determine the necessary coagulant dosage for a sample of water. The industry standard guidelines for standard jar tests will be followed with modifications for electro-coagulation (ASTM, 1995). Task 2: Characterize the removal efficiency of electro-coagulation for the chosen electrode metal type over a range of current densities through a series of standard jar tests with representative samples of both fresh and marine production water from the AST research RAS. Task 3: Integrate electro-coagulation for direct filtration using the FBF testing apparatus from the Phase I research. The electro-coagulation electrodes will be installed; replacing the chemical coagulant dosing setup previously used in the Phase I research. Tasks to accomplish Objective 2 (Week 11-26): Task 1: Automate the direct filtration process with AST's process control platform using our proprietary turbidity sensor couple with a fuzzy logic controller. A principle component analysis (PCA) will be conducted to determine the optimal number of sensors to control the water quality parameters such as turbidity, conductivity and/or regulation of voltage (or coagulant feed pumps). A principle component analysis (PCA) will be conducted to determine the optimal number of sensors to control the water quality parameters such as turbidity, conductivity and/or regulation of voltage (or coagulant feed pumps) to reduce the cost of treatment while optimizing the direct filtration treatment process. Task 2: Configure the process controller platform to monitor and control the direct filtration process using our proprietary turbidity sensor couple with a fuzzy logic controller. The direct filtration process is directly influenced by specific water quality parameters, thus dynamic monitoring and regulation/control can be used to optimize the process. Turbidity sensors will be installed to monitor influent, effluent, and in-situ turbidities. Task 3: Test the automated controller with the integrated electro-coagulation apparatus (or coagulant dosing pump) on the direct filtration research FBF. Once the automated controller is programmed and sensors are in place as the result of completing Task #4, testing of the automated controller will begin. The controller will be used to regulate the direct filtration process in real-time using the research FBF with the integrated electro-coagulation assembly (or dosing pump). All measurements and control actions will be logged and recorded for the purpose of controller modification and improvement. Data from the testing phase of the controller will be used to perform the principal component analysis in order to streamline the full controller design using only the most pertinent and necessary sensors and controllers Task 4: Perform a principal component analysis using the results from the tests in the previous task(s) to streamline the controller design. The PCA will be used to select the most appropriate tools required for the final, optimized automated direct filtration controller. PCA is a mathematical method for evaluating a set of input variables or parameters to generate a linear set of "principal components". The number of principal components may be the same or less than the number of independent variables or parameters. To maintain the assumed linearity of the input data, PCA will be performed only around selected operating points for each variable, thus controlling errors associated with the non-linear real world. The selection of the principal components is the essence of optimizing the automated filter controller and will be used as the final justification for or against using various controllers and/or sensors. Tasks to accomplish Objective 3 (Week 27-32): Task 1: Finalize the ICAP design by integrating the electro-coagulation apparatus (or coagulant dosing pump), monitoring sensors and controls for the automated controller. Using the results from the previous tasks, a final set of design criteria may be generated for the automated ICAP filter. Task 2: Create a finalized 3-dimensional drawing of the ICAP complete with sensors, controllers, and electro-coagulation components (or coagulant dosing pump) integrated into the design. This design will serve as the basis for the filter to be fabricated and used in the in-house testing phase of the automated ICAP system. Task 3: Create a finalized design blueprint detailing the automated filter control system complete with wiring diagram and controller housing. Tasks to accomplish Objective 4 (Week 32-52): Task 1: Conduct "in-house" trials on-site at AST. Testing of the finalized automated ICAP filter system design will first need to be conducted on-site using the AST research RASs. To ensure success for field trials during the beta-testing phase, testing sites will be selected at this time so water quality conditions in the research RASs may be adjusted and the systems operated similarly. The final portion of this objective includes a final design revision for both the ICAP filter and the automation system prior to moving into the beta-testing phase in the next objective. Task 2: Adjust/Configure AST research recirculating systems so that they have water quality conditions similar to the beta test sites and evaluate the performance of the revised automated ICAP system. The in-house tests will be used to both tune the automated ICAP filter design as well as evaluate the performance of the automation system. The AST research RASs will be adjusted to mimic the water quality conditions of the systems selected for beta testing. Task 3: Make final adjustments to the automated control system and ICAP filter design. Any changes that will be required for the automated ICAP system design will be made prior to rolling out the system to the off-site locations for beta testing. Tasks to accomplish Objective 5 (Week 53-104): Task 1: Conduct beta-tests on site with one or more partner organizations. Off-site testing will begin using the beta sites identified in the previous objective. Task 2: Install the automated ICAP filter on-site at two or more locations within the industry The finalized automated ICAP system will be delivered and installed at two or more beta test sites by AST technicians and/or engineers. Training and system start-up will be provided on-site at the beta test sites for the operators. Task 3: Prepare of ICAP System Operations and Maintenance Manual. Following beta testing a final Operations and Maintenance Manual for the ICAP System will be prepared. Task 4: Prepare and submit the Phase II final report.

Progress 09/01/13 to 08/31/18

Outputs
Target Audience:Primarily, the focus will be on transitioning the aging propeller-wash bead filter technology to the High Profile Polygeyser® (HPPG) technology and equipment into commercial operation as quickly as possible. This will include conducting field beta tests at several tertiary lagoons for effluent polishing. The HPPG and Recirculating Polygeyser® (RCPG) units are likely to become a major tool in the treatment of industrial and small agricultural operations. As always with AST's filter product lines, the major emphasis is aquaculture, agriculture, and aquaria applications as these are the main industry sales currently supporting the company capital and operating expenses. Changes/Problems:The unexpected death of the previous owner in 2014 resulted in several company and project changes. New ownership of the company was established in 2015 by Rick Malone, his son, Michael Malone, and his brother, Ron Malone. Rick Malone serves as the company CEO, Dr. Ron Malone is the Chief Technical Officer, and Michael Malone is a system designer and head sales representative for the Wastewater Unit. Dr. James Ebeling resigned from the company and project in 2013 and Dr. Tim Pfeiffer assumed the role of Project Manager in September 2014. With the loss of the original company owner, the relationship and contacts for utilizing an EC unit from the arranged commercial collaborating partner was also lost as the commercial EC collaborator had requested increased funds for use of their equipment that was above the project budget. Original project researchers for developing a direct filtration Electrocoagulation (EC) unit had also moved on to other ventures and the project collaborator for developing the filter controller was bought out. As a result, the new AST company and staff had to reinitiate trials of an experimental laboratory top EC units to move the project forward in developing a suitable filter product(s). What opportunities for training and professional development has the project provided?The company has made a conscience effort to include all staff, including sales, shop, and office personnel in professional development by extending offers to attend local, regional, and national aquaculture and wastewater conferences. Most of the staff has attended the World Aquaculture Society's Aquaculture America (WAS AA) 2017 conference in San Antonio as well as the Water and Environment Federation Trade Exhibition Conference (WEFTEC) in 2016 and 2018. Key personnel (CTO, CEO, sales and research personnel) have attended the WAS AA conferences in Las Vegas (2016 and 2018). Students and technicians are given the opportunity to attend seminars on the LSU campus presented either through the Civil and Environmental Engineering Department or the Fisheries Department. Occasionally, as available, staff attends workshops related to projects that are involved in, i.e., shrimp production or Recirculating Aquaculture Systems (RAS) technology workshops. How have the results been disseminated to communities of interest?Results to communities of interest continue to be reached by presenting our filter technology via presentations and tradeshow exhibition at aquaculture and aquaria conferences namely the WAS AA where AST is usually a Silver sponsor as well as a corporate sponsor for the Aquacultural Engineering Society (AES). AST also had a booth and presentations at the (WEFTEC) the last 3 years to exhibit their filter technology. WEFTEC is the largest wasterwater trade show in the continental U.S. AST also maintains an active website (www.astfilters.com) that includes filter use for a range of applications including marine and freshwater aquaculture, zoo, and aquaria displays, aquaponics, and wastewater. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? The use of electrocoagulation with aluminum electrodes was effective at removing targeted solids but, when employed with the floating bead filter, a whitish fine solids effluent with a turbidity above 10 NTU was consistently produced. It was concluded that the floc formed by electrocoagulation was very fragile and was sheared by the turbulence within the bead bed. This fragile sheared floc material was reintroduced into the water and was difficult to recapture thus causing an increase in turbidity. At the end of year, the objectives were redirected towards the use of an internally recirculating filtration format and development of a theoretical model, which focused on strategies that could overcome the residual turbidity issues. Despite the shortfall in meeting the above initial grant objectives, the theoretical study and modeling efforts stimulated the production of two new filters, the High Profile Polygeyser® (HPPG), and the Recirculating Polygeyser® (RCPG).

Publications

• Type: Conference Papers and Presentations Status: Published Year Published: 2016 Citation: Malone, R. F. (2016) Pneumatic Sludge Handling in Low Profile PolyGeyser Floating Bead Filters, Presented at the 11th International Conference on Recirculating Aquaculture, Roanoke VA, August 19-21st
• Type: Theses/Dissertations Status: Under Review Year Published: 2019 Citation: Louque, Matthew. Low-Density Static Granular Media Filter Bed Turbidity Removal Model. M.S. Thesis, Louisiana State University, Baton Rouge, LA, 2018.
• Type: Conference Papers and Presentations Status: Published Year Published: 2018 Citation: Louque, Matthew. 2018. Combined Use of Foam Fractionation and Bead Filtration to Achieve Visibly Clear Water. Presented at Aquaculture America 2018, February 19-22, 2018 Paris Las Vegas, Las Vegas, Nevada USA. Abstract.
• Type: Conference Papers and Presentations Status: Published Year Published: 2018 Citation: Rhine Perrin, Ron Malone and Tim Pffeifer. Feed Based Sizing of a Floating Bead Bioclarifier. 2017. Abstract. Presented at Aquaculture America 2017, February 20-22, 2017 San Antonio Marriott Rivercenter, San Antonio, Texas USA.
• Type: Conference Papers and Presentations Status: Published Year Published: 2018 Citation: Rhine Perrin and Ron Malone. 2018. Treatment of Aquaculture Waste Lagoon Effluent using Recirculating PolyGeyser Technology. Presented at Aquaculture America 2018, February 19-22, 2018 Paris Las Vegas, Las Vegas, Nevada USA. Abstract
• Type: Conference Papers and Presentations Status: Other Year Published: 2018 Citation: Rhine Perrin and Ron Malone. 2018. Facultative Lagoon Polishing using Recirculating PolyGeyser Technology. Presented at MSWEA 2018 Conference, Vicksburg, MS.
• Type: Conference Papers and Presentations Status: Published Year Published: 2018 Citation: Rhine Perrin, Ron Malone, and Bryson Agnew. Facultative Lagoon Polishing using Recirculating PolyGeyser Technology. 91st Annual Water and Environment Federation Technical Exhibition & Conference, September 29-October 3, 2018, New Orleans Morial Convention Center, New Orleans, LA.
• Type: Conference Papers and Presentations Status: Other Year Published: 2018 Citation: Rhine Perrin and Ron Malone. 2018. Nutrient Removal using Recirculating PolyGeyser Technology. WEF Webinar, 2018.
• Type: Conference Papers and Presentations Status: Published Year Published: 2017 Citation: Malone, R. F. and R. Perrin, (2017) Application of Recirculating PolyGeysers� to Wastewater Treatment 2017 Specialty Conference, Arkansas Water and Environment Association, Little Rock, November 14th
• Type: Conference Papers and Presentations Status: Published Year Published: 2017 Citation: 2. Malone R. F. (2017) Application of PolyGeyser� Fixed Film Bioclarifiers to Industrial and Domestic Wastes, 60st Annual Meeting and Technical Conference. Mississippi Water Environment Association, Vicksburg, June 6th
• Type: Conference Papers and Presentations Status: Published Year Published: 20107 Citation: Malone, R. F., R. Perrin, and T. J. Pfeiffer (2017) Application of Recirculating PolyGeysers to Aquacultural Effluent Flows. 4th NordicRAS Workshop on Recirculating Aquaculture Systems, Aalborg, Denmark, October 12-13.
• Type: Conference Papers and Presentations Status: Published Year Published: 2017 Citation: Malone, R.F. (2017) Improved Pneumatic Sludge Handling In PolyGeyser Floating Bead Filters, presented at Aquaculture America 2017, San Antonio, TX, August February 19-22nd