Advanced cost optimization in drinking water treatment with activated filter media AFM by SVS Aqua
Drinking water treatment plants are essential for delivering safe and potable water. Traditionally, Ultrafiltration (UF) systems have been implemented for advanced treatment due to their high efficiency in producing superior water quality. However, the associated high capital and operational expenditures often challenge the economic viability of these systems. This innovation presents a comprehensive evaluation of Activated Filter Media (AFM) as a cost-effective replacement for UF systems. ( Except RO ). The study demonstrates how AFM achieves comparable water quality while delivering significant cost savings, making it an attractive solution for drinking water treatment facilities.
Treatment Process Comparison
Existing UF-Based Treatment Process:
- Pump
- Pre-chlorination
- Tube settler with coagulant and flocculant dosing
- Dual Media Filter (DMF) with sand
- Activated carbon filter
- 10-micron cartridge filter
- Softener
- Ultrafiltration (UF) system with CIP assembly
- Post chlorine dioxide dosing
Replaced with AFM-Based Treatment Process:
- Pump
- Pre-chlorination
- Tube settler with coagulant and flocculant dosing
- PSF with Activated Filter Media (AFM) replacing UF
- Activated carbon filter
- Softener
- Post chlorine dioxide dosing
Performance Evaluation
Key Performance Metrics
| Parameter | UF System | AFM System | Compliance Standards |
|---|---|---|---|
| Turbidity (NTU) | < 0.1 | < 0.2 | < 1.0 |
| Total Suspended Solids | < 5 mg/L | < 5 mg/L | < 10 mg/L |
| Oil and Grease | Negligible | Negligible | Negligible |
Cost and Operational Insights
Financial Comparison
For 110 m3/hr.
| Category | UF System | AFM System | Savings (%) |
|---|---|---|---|
| Capital Expenditure | 1.8 crore | 90 Lakh | >50% |
| Operational Expenditure | 50 Lakh/year | 10 Lakh/year | >80% |
| Chemical Consumption | High | Low | Significant |
| Power Consumption | High | Low | Significant |
| CIP Chemicals | Required | Not Required | 100% |
| Dechlorination Needs | Required | Not Required | 100% |
| Manpower (hours/year) | 1,200 | 400 | 66% |
Operational Benefits
-
- CAPEX Reduction: Simplified system design by eliminating UF modules
- OPEX Efficiency: Substantial savings through reduced energy and chemical usage.
- Maintenance Optimization: Eliminating complex cleaning-in-place (CIP) procedure.
- Enhanced Sustainability: Lower resource utilization aligns with environmental goals.
Technical Principle of AFM
Activated Filter Media (AFM), , is a high-performance filtration medium engineered from recycled glass. AFM provides:
- Fine Filtration: Removal of particles down to submicron levels.
- Biofouling Resistance: Inherent self-sterilizing properties reduce microbial growth.
- Hydraulic Efficiency: Consistently low head loss and superior flow rates.
- Extended Durability: Chemical and mechanical stability ensures long-term performance.
Detailed Advantages of AFM Over UF Systems
1. Economic Feasibility: AFM substantially reduces both capital and operating expenditures. With a simplified process flow and elimination of UF modules, the initial investment decreases by over 50%. Operational costs are also significantly reduced due to lower energy and chemical requirements, contributing to long-term savings.
2. Superior Filtration Performance: AFM delivers excellent water quality with turbidity levels of <0.2 NTU, well within drinking water standards. Its ability to remove submicron particles ensures comparable performance to UF systems while avoiding the operational complexities.
3. Biofouling Resistance: Unlike traditional sand or UF membranes, AFM resists biological fouling due to its self-sterilizing surface. This reduces the need for frequent cleaning, extending the operational life of the system and lowering maintenance costs.
4. Energy Efficiency: AFM operates at significantly lower pressure compared to UF systems, reducing energy consumption. This makes it an environmentally friendly option for facilities aiming to minimize their carbon footprint.
5. Chemical Reduction: By eliminating the need for dechlorination and reducing coagulant and flocculant dosages, AFM minimizes chemical consumption. This not only reduces OPEX but also aligns with sustainability goals by decreasing chemical waste.
6. Simplified Maintenance: AFM eliminates the need for complex cleaning-in-place (CIP) processes associated with UF systems. This simplifies plant operations and reduces downtime, allowing for more consistent water treatment.
7. Environmental Sustainability: AFM is made from recycled glass, contributing to waste reduction and promoting circular economy principles. Its long lifespan further reduces the frequency of replacement, making it an environmentally responsible choice.
8. Versatility in Applications: AFM is suitable for a wide range of water treatment applications, including municipal, industrial, and commercial settings. Its adaptability ensures consistent performance across varying operational conditions.
The integration of AFM in place of UF systems in the 115 m3/hr drinking water treatment plant resulted in substantial economic and operational benefits. With over 50% CAPEX savings and 80% OPEX savings, AFM is a robust and cost-effective alternative that does not compromise on water quality or operational reliability. These findings underscore the potential of AFM as a preferred choice for water treatment applications aiming for techno-commercial optimization.
Summary
This case study highlights the transformative potential of replacing UF systems with Activated Filter Media (AFM) in drinking water treatment plants. AFM offers:
- Comparable water quality with reduced turbidity and suspended solids.
- Over 50% savings in capital expenditure and 80% in operating costs.
- Simplified maintenance, biofouling resistance, and reduced chemical and power consumption.
The results demonstrate that AFM is not only a cost-effective solution but also an environmentally sustainable choice for wastewater treatment facilities. By embracing AFM technology, plants can achieve operational excellence while meeting stringent water quality standards.