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Upflow Calcite Contactor Study

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Upflow Calcite Contactor Study Upflow Calcite Contactor Study Final Report by Wen Yi Shih, Ph.D. Justin Sutherland, Ph.D., P.E. Bradley Sessions Erin Mackey, Ph.D., P.E. W. Shane Walker, Ph.D. Texas Water Development Board P.O. Box 13231, Capitol Station Austin, Texas 78711-3231 April 2012 This page is intentionally blank. Texas Water Development Board Contract #1004831105 Upflow Calcite Contactor Study by Wen Yi Shih, Ph.D. Justin Sutherland, Ph.D., P.E. Bradley Sessions Erin Mackey, Ph.D., P.E. Carollo Engineers, Inc. W. Shane Walker, Ph.D. University of Texas at El Paso April 2012 This page is intentionally blank. ii Table of Contents 1 Executive summary .................................................................................................................... 1 1.1 Results and conclusions .................................................................................................. 4 2 Introduction ................................................................................................................................ 6 2.1 Post-treatment water quality objectives .......................................................................... 8 2.2 Options for water remineralization ............................................................................... 11 3 Literature review ...................................................................................................................... 15 3.1 Calcite contactor process .............................................................................................. 15 3.2 Parameters in calcite contactor design .......................................................................... 17 3.3 Types of calcite contactors ............................................................................................ 24 3.4 Examples of facilities with upflow contactors .............................................................. 30 3.5 Calcite selection criteria ................................................................................................ 31 3.6 Calcite manufacturers in United States ......................................................................... 33 3.7 General calcite contactor design guidelines .................................................................. 40 3.8 Summary of data gaps ................................................................................................... 40 4 Project implementation ............................................................................................................. 42 4.1 Influent water quality and finished water quality goals ................................................ 42 4.2 Pilot plant system and design criteria ........................................................................... 43 4.3 Experimental approach ................................................................................................. 46 4.4 Corrosivity modeling .................................................................................................... 46 5 Results and discussion .............................................................................................................. 47 5.1 Phase 1 – Impact of calcite purity ................................................................................. 48 5.2 Phase 2 – Impact of influent loading rate ..................................................................... 54 5.3 Phase 3 – Impact of calcite particle sizing .................................................................... 62 5.4 Phase 4 – Optimizing treatment conditions .................................................................. 68 6 Cost analysis ............................................................................................................................. 73 7 Conclusions and recommendations .......................................................................................... 73 7.1 Impact of calcite purity on effluent water quality ......................................................... 74 7.2 Impact of influent flow rate on effluent water quality .................................................. 78 7.3 Impact of particle sizes on effluent water quality ......................................................... 78 7.4 Optimized treatment conditions .................................................................................... 78 8 References ................................................................................................................................ 79 List of Figures Figure 2-1. Schematic of calcite contactors as RO post-treatment in a desalter. .................... 14 Figure 2-2. Proportion of H2CO3 available as a function of pH in the water. ......................... 15 Figure 3-1. Schematic of a calcite contactor. .......................................................................... 16 Figure 3-2. Relationship between superficial velocity (meters per hour) and turbidity .......... 19 Figure 3-3. Head loss of the upflow calcite bed for particle sizes between 2.0 and 2.5 mm .. 21 Figure 3-4. Example of relationship between particle diameter and calcite bed height .......... 21 Figure 3-5. Variation of specific conductivity with contact time with calcite samples L1 to L5................................................................................................................. 23 Figure 3-6. Empirical relationship between empty bed contact time required to reach pH 8.2 and temperature for permeate water with a dose of 23 mg/L CO2 ........... 24 i Figure 3-7. Simplified configuration of a Center for Science and Industrial Research type fixed bed limestone contactor ....................................................................... 27 Figure 3-8. Schematic of a fluidized calcite contactor ............................................................ 28 Figure 3-9. Cross-section of DrinTecTM calcite contactor ....................................................... 29 Figure 3-10. Imerys calcium carbonate samples. ...................................................................... 34 Figure 3-11. Mississippi Lime CalCarb® R1 and R2 samples. ................................................ 35 Figure 3-12. Columbia River Carbonates Puri-CalTM C and Puri-CalTM samples. ................... 36 Figure 3-13. Specialty Chemicals, Inc. VICAL samples........................................................... 37 Figure 3-14. Lhoist W16X120 and W16X calcium carbonate samples. ................................... 38 Figure 3-15. Calcite pellets from the intermediate pellet softening process. ............................ 39 Figure 4-1. Process flow diagram. ........................................................................................... 44 Figure 5.1. Box-whisker plot of calcite particle size changes in Phase 1. .............................. 49 Figure 5.2. Phase 1: Alkalinity for 3.8 gpm/ft2 calcite dissolution at various calcite purities. Finished water quality goals are represented by the area between the two horizontal lines........................................................................... 52 Figure 5.3. Phase 1: Calcium concentration for 3.8 gpm/ft2 calcite dissolution at various calcite purities. Finished water quality goals are represented b y the area between the two horizontal lines. ......................................................... 52 Figure 5.4. Phase 1: pH for 3.8 gpm/ft2 calcite dissolution at various calcite purities. Finished water quality goals are represented by the area between the two horizontal lines. .............................................................................................. 53 Figure 5.5. Phase 1: Turbidity for 3.8 gpm/ft2 calcite dissolution at various calcite purities. ...................................................................................................... 53 Figure 5.6. Phase 1: EBCT for 3.8 gpm/ft2 calcite dissolution at various calcite purities. ...................................................................................................... 54 Figure 5.7. Box-whisker plot of calcite particle size changes in Phase 2. .............................. 56 Figure 5.8. Influent permeate conductivity changes of Kay Bailey Hutchison Desalination Plant in Phase 2. ............................................................................... 56 Figure 5.9. Phase 2: Alkalinity for 1-mm calcite dissolution at various influent flow rates. Finished water quality goals are represented by the area between the two horizontal lines. The gray bar in the figures indicates the depletion of CO2 gas supply............................................................................ 58 Figure 5.10. Phase 2: Calcium concentration for 1-mm calcite dissolution at various influent flow rates. Finished water quality goals are represented by the area between the two horizontal lines. The gray bar in the figures indicates the depletion of CO2 gas supply............................................................................ 58 Figure 5.11. Phase 2: pH for 1-mm calcite dissolution at various influent flow rates. Finished water quality goals are represented by the area between the two horizontal lines. The gray bar in the figures indicates the depletion of CO2 gas supply.............................................................................................................. 59 Figure 5.12. Phase 2: Turbidity for 1-mm calcite dissolution at various influent flow rates. The gray bar in the figures indicates the depletion of CO2 gas supply. ..... 59 Figure
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