C A S E S T U D Y FOR N E W

IN

JERSEY AMERICAN WATER

PURAFIL ESD RETROFITS EMERGENCY SCRUBBER
FOR JUMPING BROOK WATER TREATMENT PLANT

PURAFIL

FIRST CL E A N AIR

www.purafil.com

ABOUT THE PLANT

For more than a century, the American Water Works & Guarantee Company, which is headquartered in Voorhees, NJ, is the largest investor-owned water and wastewater utility company in the U.S. With more than 700 water treatment plants and 1,000 wells, 99 dams and 45 wastewater treatment facilities among other assets, American Water is undoubtedly intertwined within North Americas vast water system. New Jersey American Water is a subsidiary of the parent company, and it serves more than two million customers.
THE PROBLEM

As a part of its continued quality efforts, New Jersey American Water sought to replace its nearly 10-year-old wet, caustic scrubber with a dry scrubber located within its Jumping Brook Water Treatment Plant (WTP) At its maximum capacity, the plant uses chlorine to treat 30 mgd of water. Wet scrubber systems use a liquid caustic solution to remove chlorine gas (Cl2) in the event of an accidental release. The liquid caustic material in the wet scrubber system is usually comprised of NaOH and is highly hazardous. Wet scrubbers are maintenance-intensive and require yearly repairs to replace pumps, nozzles and valves. The hazardous liquid caustic is extremely corrosive and can deteriorate pumps and fiberglass. In addition, the liquid caustic reacts with CO2 to form Na2CO3 which can clog nozzles and valves. Replacement of the liquid caustic material is normally required at a minimum of every three years to maintain the correct level of potency and effectiveness for successful chlorine removal. Persons performing maintenance to liquid caustic scrubbers are required to have specialty training and to use specialty equipment. The training and equipment can be costly, which increases the overall maintenance expenses of a liquid caustic wet scrubber.
PURAFIL ESD PROVIDES THE SOLUTION

follow steps to remove the caustic solution, convert the scrubbers key internal elements and add Purafils improved, dry-scrubbing, Chlorosorb Ultra media. As a result of the transformation, the retrofit dry-chemical scrubber is hasslefree, hazard-free and maintenance-free. Purafil ESD professionals accessed Jumping Brook WTPs room that housed the wet scrubber and decided it was too confined to accommodate a one-ton aluminum EGS or an AOC1. As an alternative, they agreed to retrofit the existing unit. Purafil ESD also replaced the blower in the unit to achieve a higher airflow. The overall process was complete in approximately two weeks. The Purafil ESD retrofitted drychemical EGS is connected to the plants chlorine rooms by ducts. In the event of an accidental chlorine release, the EGS will discharge less than 25 ppb, whereas the previous wet scrubber would have discharged 1-4 ppm.
CUSTOMER SATISFACTION

Purafils Environmental Systems Division (ESD) developed the Retrofit Plan for Liquid Caustic Scrubbers, which serves as a cost-effective alternative to purchasing new equipment to replace existing, problematic, caustic scrubbers. Purafils Wet Scrubber Retrofit transforms a hazardous and problematic wet scrubber into a hazard-free and maintenance-free dry-chemical scrubber for a fraction of the cost. Chlorosorb Ultra media is at the heart of the dry Emergency Gas Scrubber (EGS) as it removes 15 pounds of the gas for every 100 pounds of accidentally released chlorine. Purafils Wet Scrubber Retrofit provides the necessary, easy-to-

Brian Weir, New Jersey American Water Company Operations Supervisor, explained how the plant documented its temporary and permanent changes to the facility, safety procedures and drawings as well as held personnel training on the new benefits of the EGS. It was also necessary to notify the State of New Jersey Department of Environmental Protection of the facilitys changes and the retrofitted unit. Once the retrofit was complete, the immediate savings on maintenance, disposal and labor totaled more than $25,000. Weir admits, I really appreciate the reduction in maintenance and the ease of the conversion.
ABOUT PURAFIL ESD

Purafil ESD is the premier single-source provider of clean air throughout North America and Europe. A division of Purafil, Inc., Purafil ESD manufactures a broad range of dry-chemical media and scrubbers that remove odors, prevent toxic gas releases, and prevent corrosion of electronics.

Purafil, Inc. 2654 Weaver Way, Doraville, Georgia, 30340, U.S.A. www.purafil.com tel: (770) 662-8545 (800) 222-6367
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C A S E S T U DY F O R
THE CITY OF RICHLANDS COLUMBIA R I V E R W AT E R T R E AT M E N T P L A N T
PURAFIL PERFORMS SUCCESSFUL RETROFIT FOR THE CITY OF RICHLANDS W AT E R T R E AT M E N T P L A N T

IN

PURAFIL

FIRST CL E A N AIR

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A B O U T T H E C I T Y O F R I C H L A N D WAT E R T R E AT M E N T P L A N T The City of Richlands Columbia River Water Treatment Plant (WTP) was built and put into operation in the fall of 1963, supplementing a system of wells that were constructed by the Federal government in the 1940s. Richlands WTP is a direct filtration surface water treatment plant designed to treat a maximum flow of 30 million gallons a day. The plant is one of three water treatment sites operated and maintained by Richland Water. The system presently serves a population of approximately 50,000. The WTP handles surface water in a series of treatment processes, including coagulation, chlorination, and filtration. Chlorine disinfection may occur both before and after filtration depending on the surface water conditions. Chlorine usage during the summer months can exceed 500 pounds per day.
THE PROBLEM

In 1996, the WTP went through a plant expansion that doubled the rated capacity from 15 mgd to 30 mgd. The renovation included construction of a chlorine handling facility and the installation of a wet chlorine scrubber with a designated emergency generator. The emergency scrubber developed leakage problems and ended up being drained and shipped out for repairs twice in a four-year period. Caustic wet scrubbers use large amounts of chemicals to operate and also require much more maintenance than dry scrubbers; and because they use harsh chemicals, they are also subject to very strict guidelines. The plant operators also noticed caustic freezing issues that would render the scrubber inoperable during very cold periods of the winter months.

(UVDF). This facility was designed to use chlorine for contact time and residual detection to ensure maximum disinfection. Since the disinfection facility was storing large amounts of chlorine, they decided to invest in a more efficient emergency standby equipment to prevent accidental chemical releases. Based on their previous experience with wet scrubbers, Richland Water incorporated a Purafil dry Emergency Gas Scrubber (EGS) to the UVDF. Seeing the benefits of using Purafils EGS, Richland Water decided to replace the failing wet scrubber at the WTP with a dry scrubber.
PURAFIL PROVIDES THE SOLUTION

At first, the city considered switching the wet scrubber to a brand new Purafil dry 1-ton capacity scrubber. When the plant operators local Purafils contacted Treatment representative, Equipment Company, they learned about the capability to retrofit existing wet chlorine scrubbers to dry scrubbers using Chlorosorb Ultra Media. Chlorosorb Ultra Media Purafil Water-Wastewater Market Manager, Colin Christie, provided a competitive quote to complete the retrofit. Due to the significant cost savings and the capabilities of Richland Waters staff to perform the work in-house, the plant managers decided to turn their existing installation into an efficient, low maintenance dry scrubbing system. Purafil project engineers worked closely with the WTP staff to make the retrofit a success.

Crystallized caustic found in the wet scrubber during the retrofit

In 2006, Richland Water completed construction of a new multiple phase Ultraviolet Disinfection Facility

Purafil, Inc. 2654 Weaver Way, Doraville, Georgia, 30340, U.S.A. www.purafil.com tel: (770) 662-8545 (800) 222-6367
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C U S TO M E R S AT I S FAC T I O N

Richland Waters staff was able to perform all the required labor. With the guidance of Purafils project engineers, all questions and issues regarding the project were dealt with in a timely manner. Thanks to the support and efforts of Purafil and its representatives, the project was completed on time and under budget. Based on the approved budgeted amount for the project, Richland Water saved approximately $70,000 by retrofitting its existing installation using Purafils expertise. Richland WTPs Water Manager, John Finch, told Purafil, Having owned and operated two different types of scrubbers, I know for a fact that the Purafil dry scrubber is much easier to operate and maintain.

Thanks to its successful retrofit, Richland water treatment plants are currently only using dry scrubbers.
D RY S C R U B B E R S V E R S U S W E T S C R U B B E R S

Dry scrubbers have several advantages over conventional wet scrubbers. For instance, dry scrubbers require significantly less maintenance than wet scrubbers. They have just one moving parta blower. No need to hassle with pumps, spray nozzles, or pH controls! Dry scrubbers are much safer, too. Instead of using toxic caustic liquid, they neutralize gases with non-toxic dryscrubbing pellets. These pellets are called media, and they permanently transform gases into harmless solids. Unlike caustic liquid scrubbers which require staff to Purafil Emergency Gas Scrubber regurlarly measure the total amount of gas that can be fed in the scrubber, the media inside dry scrubbers are immediately available for instantaneous reaction, regardless of the gas load rate. Purafils dry emergency gas scrubber discharges less than 25 parts per billion, whereas wet scrubbers discharge 1-4 parts per million.

Retrofitted scrubber at the water treatment plant

P U R A F I L S PAT E N T E D R E T R O F I T P L A N F O R WET TO DRY CONVERSION IS AS EASY AS 1, 2, 3!

STEP 1: STEP 2:

Remove Caustic Material

Remove the three-panel lid. Drain and dispose of liquid caustic from reservoir and reaction chamber. Remove recirculation pump and pipe. Remove and dispose of tower packing material. Cut out internal fiberglass walls and barrier between reaction chamber and liquid reservoir. Install aluminum posts and secure to external fiberglass walls. Install perforated, aluminum media screens and secure to posts. Install Purafil ESD Chlorosorb Ultra dry chemical media between media screens. Replace three-panel lid and plug holes.

Modify Existing Scrubber

STEP 3: Install Purafil Chlorosorb

Ultra Media

Purafil, Inc. 2654 Weaver Way, Doraville, Georgia, 30340, U.S.A. www.purafil.com tel: (770) 662-8545 (800) 222-6367
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C A S E S T U DY FOR

IN

M O C C A S I N B E N D W A S T E W AT E R T R E AT M E N T P L A N T

PURAFIL

FIRST CL E A N AIR

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P U R A F I L E G S P R E V E N T S TOX I C CHLORINE GAS RELEASE

F O R T H E C I T Y O F C H AT TA N O O G A

M O C C A S I N B E N D W W T P C U S TO M E R S AT I S FAC T I O N

We installed a Purafil [emergency chlorine] gas scrubber in 2000 [to comply with] our risk management plan, explains Jerry Stewart, City Director of Waste Resources for the City of Chattanooga which oversees Moccasin Bend Wastewater Treatment Plant (WWTP). Its been nine years and we never had to use it. The day finally came and it performed as advertised. As a plant operator attempted to switch the chlorine cylinders, a potentially catastrophic chlorine leak occurred. Although the plant operator escaped the chlorine leak and did not sustain injury, the WWTP implemented its emergency response plan; the Chattanooga Fire Department hazardous waste unit responded to the site; an Incident Command Structure was established; and the plant site and surrounding areas were secured; and the local chlorine suppliers emergency response team was called to access and shut off the leaking one-ton chlorine cylinder Fortunately, the risk was minimal; and Stewart reported, the plants emergency gas scrubber neutralized all of the chlorine that leaked out of the one-ton cylinder.
THE PROBLEM

Wastewater treatment plants combine four primary steps to process sewage: liquid handling, solid handling, pump stations and plant maintenance. During the liquid handling process, chlorine (Cl2) is used to treat the cleaned wastewater. Facilities storing large quantities of chlorine, typically in one or more one-ton cylinders, must invest in emergency standby equipment to prevent accidental chemical releases. The U.S. Environmental Protection Agencys (EPA) Risk Management Program for Chemical Accident Release Prevention requires regulated facilities to develop and implement appropriate risk management programs to minimize the frequency and severity of chemical plant accidents. In addition, a performancebased approach towards compliance with the risk management program rule is required. If a toxic gas release from a one-ton cylinder were to occur, the thermodynamic properties of chlorine suggest that approximately 400 lbs of liquid chlorine would flash into vapor and the remaining contents of the cylinder would spill out as a liquid at its boiling point. According to the American Water Works Association (AWWA) Risk Management Program (RMP) Guidance, the outer limit of the impact area, in a chlorine release, is drawn at a fivemile radius in all directions from the point of impact.
PURAFIL PROVIDES THE SOLUTION

EGS is designed to neutralize an initial 400 lbs in the first minute and any additional chlorine at a rate of 80 lbs/min thereafter, which exceeds the requirements of the Uniform Fire Code. Instead of using toxic, liquid caustic to neutralize gases, the EGS uses non-toxic, dry-scrubbing medium. This mediums chemisorptive process removes chlorine by means of adsorption, absorption and chemical reaction. Chlorine gas is trapped within the medium pellet where an irreversible chemical reaction changes the chlorine gas into a harmless solid. During the chlorine leak at Moccasin Bend, Purafil ESDs EGS immediately began to disinfect the chlorine gas, minimizing the risk to the worker and the community. Gary Williams, Occupational Safety Specialist admits, Its an emotional thing when you think that someone could have died. This unit and site are prime examples of the benefits of

In 2000, Moccasin Bend officials purchased a Purafil ESD FOC-1, fiberglass EGS with Chlorosorb dry-scrubbing medium and installed it adjacent to the chlorination room. Purafil ESDs dry-chemical EGS is designed to contain the entire contents of a fully loaded 1-ton chlorine cylinder in a worst-case release scenario. The

P U R A F I L E S D F I B E R G L A S S O N E - TO N ( F O C - 1 ) EMERGENCY GAS SCRUBBER (EGS)

PURAFIL ESD CHLOROSORB ULTRA DRYSCRUBBING MEDIA

Purafil, Inc. 2654 Weaver Way, Doraville, Georgia, 30340, U.S.A. www.purafil.com tel: (770) 662-8545 (800) 222-6367
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an EGS with dry-scrubbing media. The dry-scrubbing

medium within the unit is non-toxic, n o n - h a z a r d o u s, maintenance-free, UL Classified, and most importantly, it can effectively help to save the priceless elements of a community. Stewart contends, The biggest thing [the TANKS EGS] did for us was CHLORINE ROOM WITHIN MOCCASIN BEND WWTPS CHLORINE turn a [potentially] major chlorine incident into a minor one. We were able to shut the gas off without it escaping to surrounding areas.
For years, Moccasin Bend WWTPs officials have underscored safety. The chlorine rooms sensors were installed to measure a leak of 1 part per million (ppm), which will activate an alarm and seal the building to contain the gas. These preventative measures are vital to guard against a worst-case scenario leak. In 2004, Moccasin Bend professionals also conducted the largest regional chlorine drill with the Chattanooga Fire Department to enact proper procedures during a simulated leak. Purafil is proud to have played an integral role in protecting the Moccasin Bend community. The EGS filled with the original Chlorosorb medium remained unchallenged for nearly 10 years. When the leak occurred, it performed as specified without any evidence of medium degradation due to age or environmental conditions. When the all clear signal was given and the Chlorosorb in the EGS was removed, all indications were that the unit performed properly and it successfully withstood the toxic exposure. Moccasin Bend WWTP recently ordered 23,000 pounds of new Chlorosorb Ultra media, which has a minimum removal capacity of 15% by weight and the capacity to remove up to 3450 pounds of chlorine.
ABOUT THE SITE

National Historic Landmark and a Native American Burial Ground. According to The Friends of Moccasin Bend National Park, a nonprofit organization, the area represents the historical Native essence of Chattanooga. Its place in history, which predates the Common Era, has been chronicled with life and its necessity for potable water. Subsequently, the wastewater treatment plant was built in the 1960s and bears the same name. Moccasin WWTP serves 250,000 people, treats 140 million gallons of water per day (MGD) and has a maximum hydraulic capacity of 220 MGD.
ABOUT PURAFIL ESD

Purafil ESDs EGSs are more advantageous than toxic, liquid wet scrubbers. Purafil introduced an easy Retrofit Plan for Liquid Caustic Scrubbers transform wet scrubbers and protect wastewater facilities and their communities from potential risk. Purafil ESD is the premier single-source manufacturer of clean air products throughout North America and Europe. A division of Purafil, Inc., Purafil ESD manufactures a broad range of dry-chemical media and scrubbers that remove odors, prevent toxic gas releases, and corrosion of electronics. Call Purafil ESD at 1-800-222-6367 for assistance with your air quality concerns or visit our Web site at www.purafil.com. L I F E A N A LY S I S A F T E R R E L E A S E MEDIA

The Tennessee River and Cumberland Escarpment intersect to form the historical Moccasin Bend in Chattanooga. The 925-acre areas significant PURAFIL ENGINEERS DESIGN SYSTEMS TO HANDLE MORE THAN A ONE-TON CHLORINE RELEASE. development and relevance for its original Native FIELD ANALYSIS SHOWS THAT AFTER THE RELEASE IT STILL HAS OVER 10% LIFE REMAINING. American inhabitants span more than 10,000 years. LIFE ANALYSIS (MLA) SHOWN ABOVE DEPICTS In fact, residents and historians, alike, have lobbied THE MEDIARELEASE WITHIN THE FOC-1 UNIT LOCATED AT THE PURAFIL CHLOROSORB MEDIA AFTER THE THE MOCCASIN BEND WWTP, WHICH to preserve Moccasin Bend for more than 20 years. GENERATES 5,000 CFM. In turn, the plush grounds nestled within the Chickamauga and Chattanooga National Military parks have also been deemed an Archaeological District among the National Register of Historic Places, a

Purafil, Inc. 2654 Weaver Way, Doraville, Georgia, 30340, U.S.A. www.purafil.com tel: (770) 662-8545 (800) 222-6367
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