22% Savings in energy consumption of the plant
Sustainable and reliable operation of cooling water supply to the plant.
Reliable water treatment operations support, assisting the reuse of wastewater.
Intelligent operations of existing plant assets to reduce the water footprint of energy resources.
Situation
The cycle times of Sequencing Batch Reactors (SBR) are programmed based upon influent conditions and adjusted periodically to insure complete treatment is accomplished. However, their operations are seldom optimized through automation on a cycle by cycle basis.
Task
To improvise the profile of the plant thereby increasing the daily throughput and energy efficiency.
Action
IntelliFlux was installed on a customer’s 15,000 m3/day capacity SBR as an automation retrofit to optimize the treatment performance and increase the throughput of the system. They utilized the system’s inline COD, TSS, Turbidity, NO3-N2, and Dissolved Oxygen (DO) sensors. The retrofit consisted of installing an industrial grade edge control device (ECD) adjacent to the PLC of the system. The installation was conducted while the plant was operational.
Following the installation and commissioning, the baseline mode of operation was monitored over several cycles to assess the reaction kinetics. Following this, IntelliFlux mode control and optimization was implemented on one of the SBR tanks, while a second SBR tank was operated side-by-side in the baseline mode. The IntelliFlux mode operation involved dynamic adjustment of several reactor settings, such as, fill level, aerobic and anoxic cycle times, DO settings, decant level, sludge wastage, as well as sludge settling time between limits specified by the plant engineers.
IntelliFlux provided a complete digitalization upgrade for the system, providing continuous remote monitoring of the reactor performance, machine learning and artificial intelligence guided control and optimization of the reaction conditions, including alarms for operators during influent quality excursions or when inline sensors required maintenance.
Result
The system was operated in four cycles per day as opposed to three,as well as lowered the aeration times and intensities in 60% of the cycles, giving up to 45% savings in energy per cycle and an increase in the daily plant throughput by 28% over baseline. The energy savings alone amounted to $2,450 per month.
IntelliFlux improved the digitalization profile of the plant by implementing a digital twin and AI based Decision Support and Automation layer, while improving the PLC/SCADA/IoT level system integration and performance. It was the least cost and quickest option toward digitalization for the plant.
