A closed loop reactor system is a recirculating process that is designed specifically for efficiency, reducing effluent variability, and optimizing reactions. This type of system is becoming an industry standard due to tightening discharge regulations and the need for energy-efficient treatment facilities. We are going to take a look at the end-to-end implementation of a closed loop reactor system for organizations that want to switch to a more efficient and sustainable option. With this step-by-step guide you and your team will understand the ins and outs of implementing a closed loop reactor system, how to prepare, and what options are available to your facility.
Step 1: Feasibility and Development
The first step is the development phase, which involves determining whether this type of system is feasible for your particular facility. You’ll look into what the treatment objectives would be for the system, including whether it will be used for nitrification, anaerobic digestion, oxidation, or biological nutrient removal. It’s important to look at wastewater flow patterns, nutrient composition, toxic compounds, and inflow considerations. Look into the financial commitment and its relationship to tanks, pumps, mixers, and SCADA upgrades. Lastly, it’s crucial to review permits, local discharge limits, biosolids-handling standards, and odor-control regulations to ensure this system meets regulatory requirements.
Step 2: Design and System Specification
This step focuses on engineering the system to produce a buildable system. You’ll want to start with a wastewater-specific PFD that includes screening, treatment interfaces, sludge return lines, decanters, and aeration systems. P&IDs (piping and instrumentation diagrams) are essential for understanding how the system will work together. Consider oxygen sensors, sludge blanket detectors, gas flow meters, and flow control valves. Choose a corrosion-resistant material suitable for wastewater environments, as well as equipment that will handle solids, grit, and pH variation. Consider how the implementation will look for SCADA and advanced process control loops for recirculation, aeration, and nutrient monitoring.
Step 3: Safety, Environmental and Risk Considerations
There are multiple safety, risk, and environmental considerations that might affect the system and its setup. Ensure you assess risks such as gas buildup, sludge bulking, clogging, and contamination of effluent pathways. It’s also essential to consider safety management integration, such as emergency bypass activation, odor control, and chemical handling protocols. Environmental impact is a huge factor that organizations are considering in almost every aspect they are implementing, including closed loop systems. Consider the environmental impact, including potential reductions in greenhouse gas emissions, improvements in effluent quality, and overall ecological footprint.
Step 4: Fabrication and Quality Control
Select vendors at this stage with experience in the wastewater industry, and be sure to evaluate their warranties, compatibility, and availability before choosing. Consider fabrication needs and factory acceptance testing, including the accuracy of analyzers and the performance of their variable-frequency drives.
Step 5: Integration and Installation
In this phase, you will prepare your site and coordinate your layout to address any space constraints or structural upgrades needed. Look into mechanical and electrical integration, including aeration blowers, RAS systems, and backup power systems. You will also have to complete site acceptance testing during this stage to validate system functionality in a low-risk environment.
Step 6: Start Up Wastewater Operations
You’ll start this phase by conditioning the reactor with initial seeding of biomass and stabilizing DO and pH. You’ll also conduct flow testing, leak checks, recirculation verification, and sensor performance testing to ensure everything is ready to go and working properly. It’s critical to ensure your staff is properly trained on the new system, including SOPs for cleaning, monitoring, and maintenance.
Step 7: Long-Term Performance Management
Once your system is up and running efficiently, it’s important to ensure that your long-term performance is efficient and stable. Look into your system’s KPIs, including nitrate removal efficiency, DO energy consumption, phosphorus levels, oxygen transfer efficiency, and sludge age. To optimize your system long-term, you’ll want to use real-time monitoring and predictive analysis to reduce energy consumption. It’s essential to stay on top of your performance management to ensure your systems are as efficient as possible and free of setbacks.
Lakeside Equipment’s Closed Loop Reactor Systems
At Lakeside Equipment, we offer a closed loop reactor system process that offers support from the initial concept to the full execution of the system. Our process prioritizes low life-cycle costs, energy-saving designs, multiple operational modes, an adaptable configuration, and nitrogen and phosphorus removal capabilities. Our process is conventional and made specifically for organizations that are in need of a reliable and energy-efficient CLR system that can keep up with their needs, but provide a range of flexible features for your wastewater treatment facility. At Lakeside Equipment, our CLR systems also come in a variety of shapes, which is convenient when determining how much construction and cost you’d like to incorporate into building this system.
Implementing a Close Reactor Loop
As a wastewater treatment facility, it’s crucial to ensure that you have the best options for all of your systems, including a closed reactor system. These systems can take many shapes, sizes, and configurations, ensuring you have options to create an efficient system for your needs, budget, and space. This step-by-step guide walks you through every aspect of integrating this system and can help prepare you and your team for what to expect during the process. Closed loop reactors are essential to your system, but knowing how to implement them and what it takes will make all the difference when choosing a system and getting your property prepared for it. Contact us at Lakeside Equipment if you feel that a closed loop reactor system is the best choice for your wastewater treatment facility, and we will gladly walk you through our options to find the best fit for your facility.
