Document GzrY0e6b3d35ep0vB5aB5kLGv

E. I. DU PONT DE NEMOURS & COMPANY 256 VANDERPOOL STREET NEWARK, NEW JERSEY Soria! No./fy'-71-15 Copy No. 18 RETURN TO JACKSON LABORATORY FILE ROOM \ It NEWARK PLANT PIGMENT COLOR RESEARCH REPORT OPTIMIZATION OP ANNUAL PII/TER AID COST Period Covered APRIL - MAY 1971 FILE: DATE: 114 6/29/71 N42416 NJ 14071 m 71-15 Copy No* Is 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Numerical Pile Research Office Pile - 114 Newark Library Pile - 114 M.Hunt, Pigments# Wilmington W.S .Struve/J. Jackson/A. R.Hanke R.H.Wetzel, Newport (Circ. and file) E.E.Jaffe/E.F.Kl enke/B. H. Perkins/Library P.J.Monahan, Newark (Vital Records) N.G.Fisher, Central Research Dept., Wilmington Newark Library - for Central Report Index Newark Library - for Central Report Index R.H.Akins/W.J.McClure R.B .Morton/R.Gedd S.L.Ritchey Extra Extra Extra . Extra Extra NEWARK PLANT PIGMENT COLOR RESEARCH REPORT TITLE: OPTIMIZATION OP ANNUAL FILTER AID COST PERIOD COVERED: SUBMITTED BY: Date Submitted: 6/21/71 APPROVED BY: Date Released: 6/29/71 ABSTRACT: Seme grade of filter aid will be required in the operation of the Newark liquid waste treatment plant. A laboratory stucty was made of fifteen candidates to determine which offered the lowest operating cost. "Celite 545," the filter aid used in the evaluation of the "MATE" filter, was included. The lowest cost filter aid of those tested was Grefco, Inc. "Perlite" product# "CP-150," Assuming the liquid waste samples used in this study represented what will ultimately be processed, 'use of "CP-150" will result in a filter aid materials cost of about $126,000 per year, a saving of about $62,000 per year over "Celite 545." RETURN TO JACKSON LABORATORY FILE ROOM DUP050082782 TABLE OP CONTENTS INTRODUCTION. ................................................................................... SUMMARY AND CONCLUSIONS............ . ... PATENT STATUS. .............................................. DISCUSSION Objectx^e. Description of Experiment......................................... Data Collection and Treatment......................... RESULTS AND CONCLUSIONS.........*.................... APPENDIX Exhxbxt A............... . > Exhibit B ............................................................ Page 1 1 2 2 4 4 7 S 12 DUP050082783 1-- -- INTRODUCTION A liquid waste treatment facility is being built at the Newark plant which will employ four "MATZ" micro solids separators. These units can operate with various grades of commercial filter aids. Johns-Manville "Celite 545" diatomacious earth was employed exclusively in a four month test program using a full sized separat or. This study was undertaken to evaluate fifteen grades of filter aids to determine which has the lowest operating cost, or value in use. Throughout the study, consistent operating conditions were used to make the results comparable. These conditions were similar to the optimum conditions determined in the evaluation of the full sized separator. SUMMARY AND CONCLUSIONS From this investigation, the following conclusions can be drawn. 1. Of the fifteen filter aid products tested Grefco's "Perlite" product, "CP-150" offers the lowest annual operating cost. Use of "CP-150" will incur a filter aid materials cost of $126,000 per year- "CP-150" should be thoroughly plant tested for operating feasibility, because of the potential cost savings of $61,800/year over "Celite 545." However, "Celite 545" should be used in plant start-up, as it has been proven adequate in previous plant tests. 2. The Grefco products, "CP-150," "CP-175" and "Speedplus" should be evaluated to determine if the optimum operat ing conditions for each are the same as for "Celite 545." 3. Georgia-Kaolin Company product "Eydrite MP," and the grade of bituminous coal BX 28 will not act as acceptable filter aids. 4. Widely varying data using "Celite 503" were inconclus ive, and an operating cost was not calculated. DUP050082784 -2 - PATENT STATUS No patent action will be taken as a result of this study. DISCUSSION Objective A liquid waste treatment facility is being built at the Newark plant to reduce the solids' concentration and heavy metal concentration in the plant effluent* A battery of four "MATZ" 350 gallon per minute filters will be used to separate sewage solids. Three of these will be operational, with one an installed spare. The filters {"MATZ" micro solids separators) operate by coating the filter screens with a filter aid on a specified cycle, then pumping sewage through the coated screens. The sewage is filtered until a differential pressure of 50-60 psig exists across the screens. At this point the filter cycle is terminated, and the screens are shaken for a specified time. The filter aid coating (precoat) cycle is then begun again. To aid filtration, filter aid as body feed is added to the sewage continuously on a ratio to solids before the sewage / encounters the filter screens. A full size filter was tested for four months. Using a Johns-Manvilie diatomacious earth filter aid, "Celite 545," an average filter cycle time of 20 minutes was observed. This result came from using plant sewage of widely varying solids concentrat ions, the average concentration being about 1500 ppm. A total of seven minutes per cycle was required to complete the precoating and shaking operations. Other filter aid products are available which will adequately filter the plant sewage. Each has a unique value in use, e.g., cost per cycle vs. cycle length. The purpose of the laboratory work DUP050082785 3 covered in this report was to evaluate fifteen filter aid products, including "Celite 545," to determine which would give the lowest operating cost, or value in use, The filter aids tested were? Johns-Manville diatomacious earth products "Celite 545" "Celite 560" "Celite 501" "Hyflo Supercel" "Standard Supercel" "Celite 503" Qrefco diatomacious earth product "Speedplus" Eagle-Picher Industries diatomacious earth products MFW-50" "FW-60" Grefco "Perlite" products "CP-175" "CP-150" "4156" "BW-40" cellulose fiber product Georgia-Kaolin product "Hydrite MP" BX 28 grade of bituminous coal DUP050082786 4Description of Experiment A Johns-Manvilie pressure filter was used in the laboratory to simulate the micro solids separator. The laboratory filter consisted of a circular, vertical filter plate, 1.0 ft2 in area. The filter plate was housed in a transparent pressure cell. Flow rate and differential pressure could be read directly from a rotameter and gauge on the filter cell body. Two agitated tanks were provided for precoat solution and sewage solution. A three-way valve setup allowed easy switching from One tank to the other. The effluent, except for periodic samples, was ditched. Sewage collected from the plant was analyzed for solids concentration, then adjusted to 1500 ppm for each run. Body feed was added to the feed tank at 0.2 pounds of filter aid per pound of solids, prior to filtration of the sewage* A precoat slurry was made up at an arbitrary concentration to deposit 0.1 pound filter aid per square foot of filter area on the filter screen. This was accomplished by recirculating the precoat slurry until all the filter aid was deposited on the screen. Once the filter was properly precoated, filtration was begun. Pressure and time were recorded at one minute intervals. These data form the results shown in Exhibit A. All runs were made at a feed rate of one gallon per minute. After each run the screen was thoroughly washed, so the initial pressure drop across the filter was due only to that of the screen and precoat cake. Data collection and Treatment During collection of the data characterizing each type of filter aid it became apparent that not all results would be directly DUP050082787 -5 comparable due to differences in the sewage. As can be seen in Exhibit A, the pressure-time relationship for the same filter aid using different sewage samples is markedly different. To compensate for this, "Celite 545" was used with each sewage sample as a control. Effluent solids concentration was not correlated with filter aid type or filter cycle time. One constraint of the sewage plant operation is the required effluent concentration of 400 ppm or below. All runs made in this investigation were far enough below this level that no effort was made to characterize filter aid types with this variable, No effort was made to evaluate different levels of precoat quantity or body feed concentration for a given filter aid type. A few runs (Exhibit A) were made with "Celite 545" to substantiate optimum operating conditions resulting from the tests with the full-sized separator. A precoat quantity of 0.1 pound filter aid per square foot of filter surface and body feed concentration of 0.2 pound filter aid per pound feed solids concentration were picked as generally optimum conditions. However, these are the best conditions for using "Celite 545." This may or may not be true for other filter aid types. If not, of course, the relative operating costs for the different filter aid types could be altered. This question should be investigated with the three filter aids which have the lowest operating costs based on this investigation. One limitation of the test apparatus was the inability to reach a differential pressure of 50 psig across the filter screen and cake. To compensate for this, the data from each run were plotted as logarithm of differential pressure (psig) vs. logarithm of the filter cycle time (minutes). This assumes a relationship ofs DUP050082788 -6g Filter Time ** A (Differential Pressure) A, B, constants* This is consistent with theory for this type of filtration.* The data frail each run. plotted in this manner, gave a linear relation ship, which was extrapolated to 50 psig differential pressure. The filter cycle time at 50 psig is the data which appears in Exhibit A. The calculation of operating cost of each filter aid was based on the experience gained in the tests of the full-size separator. Three separators were assumed to operate on a 27 minute cycle (20 minutes filtering, seven minutes in other operations) treating a feed of 1500 ppm solids at 350 gallons per minute (per separator) using "Celite 545" as a filter aid. Each separator has 344 square feet of filter surface which requires a precoat of 0-1 pound of filter aid per square foot of filter area. Body feed is added to the feed at 0.2 pound of filter aid per pound of solids in the feed. The data of Exhibit A indicate the per cent increase or decrease in filter cycle to be expected from each filter aid type relative to "Celite 545." From this the filtering time per operat ing hour and number of precoat cycles per operating hour were calculated for each filter aid. It was assumed that the filters would operate continuously throughout the year. A price list including freight costs for- each filter aid appears in Exhibit B. Using these and the annual filter aid volume per year calculated as described above, the operating costs per year were determined. These results appear below in order of increasing cost. Tiller, Frank M., "Filtration Theory Today," Chemical Engineering June 20. 1966, DUP050082789 -7 ANNUAL FILTER AID COST Filter aid Annual Cost ($M/Yr) "CP-150" "Speedplus" "CP-175" "4156" "FW-50" "Celite 501" "FW-60" "Standard Supercel "Hyflo Supercel "Celite 545" "Celite 560" "BW-40" 126.0 131.9 134.0 148.5 150.0 152.2 154.0 154.2 162.0 187 .8 275 .4 525.2 "Celite 503" "Hydrite MP" BX 28 Bata inconclusive Not feasible for use Not feasible for use RESULTS AND CONCLUSIONS Prom this investigation, the following conclusions can be drawn? 1, Of the fifteen filter aid products tested, Grefco "Perlite" product, "CP-150*" offers the lowest annual operating cost. Use of "CP-150" will incur a filter aid materials cost of about $12jS,Q00/yr. "CP-150" should be thoroughly plant tested for operating feasibility because of the potential cost savings of about $61,80Q/yr. over "Celite 545." However, 'Celite 545" should be used in plant start-up, as it has been proven adequate in previous plant tests. 2. The Grefco products - "CP-150," "CP-175" and "Speedplus" should be evaluated to determine if the optimum operating conditions for each are the same as for "celite 545." DUP050082790 8~ 3. Georgia--Kaolin product "Hydrite MP" and the grade of bituminous coal BX 28 will not act as acceptable filter aids. 4. Widely varying data using "Celite 503" were inconclusive/ and an operating cost was not calculated. 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EXHIBIT B FILTER AID PRICES Manufacturer Filter Aid Price(S/Ton) Grefco, Inc. Speedplus 68.00 Freight* ($/Ton) 33.20 CP-150 66.00 12.60 CP-175 71.00 12.60 4156 80.00 12.60 BW-40 315.00 12.60 JohnsManville Celite 545 84.00 33.20 Celite 560 100.00 33.20 Celite 501 73.00 33.20 Standard Supercel 63.00 33.20 Hyflo Supercel 68.00 33.20 Eagle-Picher FW-60 84.00 33.20 FW-50 82.00 33.20 Total (5/Ton), 101.20 78.60 83-60 92.60 327.60 117.20 133.20 106.20 96.20 101.20 117.20 115.20 *601# carload lots DUP050082795 N ew Jersey Office Supply Co. F iling Specialists 401 Frelinghuysen Ave., Newark, N . J. DUP050082796