BiZen

Client Case Studies

BI-ZEN provides bespoke IoT-enabled dashboard solutions that simplify complex processes into actionable process and business intelligence.

Carbonaceous ASP with N. BAF (PE: 165,000)

Problem statement

Technical Evaluation to enable CAPEX avoidance for a growth scheme

The 165,000 PE works incorporating carbonaceous ASP, nitrifying BAF, as well as a strategic anaerobic digestion sludge treatment centre is at full capacity. Further process capacity concerns are linked to local development plans for project growth.

A notional solution to install additional N.BAFF cells to compliment an AMP5 scheme has been considered and are costly (ex. £3 million). The client required an appraisal to determine other technical options, as well as quantification of actual performance of the works treatment load and asset performance.

What we did

Strategic evaluation of design capacity validated with digital live data

Two Optimiser units were deployed in early March just before the national Covid-19 lock down. The units were retained on site for the duration of 3 to 4 months benefiting the client with a rich data set of a large city, pre- and post-lock down. The duration offered the potential for operators to monitor process performance from their homes, as well as giving the opportunity to determine the sensor reliability when left in situ for a sustained period.

With both the Optimiser, as well as key SCADA data being surfaced to the cloud, effective integration of the data set could be readily achieved. This enabled an assessment of periods when assets were operating close to their design capacity.

In collaboration with the client’s operational team, informed interventions to optimise the works assets were conducted. The provided tools enabled rapid evaluations to take place and efficient quantification of the results to be communicated to all stakeholders.

Carbonaceous ASP with N. BAF (PE: 165,000)

Key Benefits

To sustain any interventions, you need to understand what is right for your plant, people and infrastructure. Our optimiser solution gets you on the right track.

  • Unmatched site-specific process insights
  • One version of the truth, reducing process risk
  • Strategically valuable toolkit to meet AMP7 challenges
  • Rapid results with the right focus to implement change and immediately monitor the benefits.

SBR with N. Filters (PE: 20,000)

Problem statement

Improve asset operation to decommission an adjacent old works

The 20,000 PE works incorporates carbonaceous Sequencing Batch Reactors (SBR’s) followed by Nitrifying tower filters (N. Filters) to meet a tight Ammonia permit. The SBR includes a large proportion of aerated fill, with an associated long sludge age, contributing to filamentous bacteria issues and inconsistent loading onto the N. Filter. With poor solids settlement, and unreliable nitrification, over pumping to the adjacent old works was required to complete treatment of the effluent. The client required detailed insights, to inform on the operational and design needs that would support interventions to facilitate the decommissioning of the old works. As well as ensure robust operational control was secured from the existing asset base.

What we did

Strategic evaluation of design capacity validated with digital live data

Within two weeks of first contact, two Optimisers were deployed in early February 2021, one on the feed to the SBR, and one on the outlet. By surfacing flow data, on top of the IoT enabled sensors from the Optimiser, a high level ‘Digital Twin’ was developed within days of mobilising onsite. The clear-cut cloud-based dashboards enabled the client to understand the current plant operation, and its process limitations quickly and efficiently. The insights from the dashboards measured the loading into the works, and quantified actual performance of the SBR, and the inconsistent loading onto the downstream nitrifying filters.

By the third day, clear trends where identified, evidencing defined periods when the SBR was completely nitrifying, but more surprisingly fill cycles when the SBR decanter was letting-by. A quick win, within hours of receiving the data, was linking the decanter issues with rag blockages on non-return valves.

The Optimiser dashboards efficiently evidenced inconsistent ammonia loading, periods of high solids, and organic load break through, onto the downstream N. filters. This would have been missed during a conventional flow & load survey.

SBR with N. Filters (PE: 20,000)

Key Benefits

To sustain any interventions, you need to understand what is right for your plant, people and infrastructure. Our optimiser solution gets you on the right track.

  • Rapid and clear digital twin tools, informing on operational and design limits.
  • Tools to quantify the causation of issues, enabling clients to regain headroom from the installed asset base.
  • Unmatched granular insights that would be missed during a conventional flow & load survey.
  • More cost effective and quicker than conventional approaches.

Filter works with new storm permit (PE: 22,500)

Problem statement

Quantification of Storm Loads and Capex avoidance

The 22,500 PE works incorporates primary settlement, biological filters, humus settlement tanks (HST’s), nitrifying tower filters (N. filters) with tertiary filtration.

The works is subject to a new full flow to treatment permit, requiring the construction of a side stream storm treatment process. In addition, there was concern over the performance of the HST for solids capture.

Conventional sampling programmes had failed to capture storm events, to inform on the design of the new side stream process, as well as quantify interstage asset performance.

What we did

Captured un-matched storm data & proved a zero build opportunity

Two Optimisers were deployed, one on the inlet and the other on the HST outlet, to capture COD, NH4-N, NO3-N, Turbidity, Redox, pH and temperature. The data was fed, with surfaced clients flow data, into a site-specific dashboard. To report on asset process and hydraulic loading rates, under varying conditions, including storm events.

With data obtained every minute, and packaged into 15min increments, the client was able to capture periods, great and small, when the works was going to storm. Generating a rich data set informing on first flush conditions, through to prolonged storm events, enabling the client to de-risk the design of the future plant upgrades.

Outputs also included quantification of the HST solids capture, under varying hydraulic loading conditions, efficiently proving that the solids capture was maintained, even when the technical standards were exceeded. With the data presented in easy to assimilate dashboards, operational acceptance that additional HST capacity could be avoided, was effectively communicated to the business. A conventional sampling programme would not have provided the equivalent repeatable evidence, to support such a robust challenge of the technical standards, leading to unnecessary capital spend and potential operational difficulties within the future operation of the plant

Filter works with new storm permit (PE: 22,500)

Key Benefits

To sustain any interventions, you need to understand what is right for your plant, people and infrastructure. Our optimiser solution gets you on the right track.

  • The tools to measure key storm events, both large and small.
  • Dashboards that incorporate asset data, to efficiently evaluate actual performance, against the installed capacity.
  • Cloud-based tools that facilitate easy interpretation of process performance and identify opportunities to de-risk and optimise design decisions.
  • Data to challenge conservative design standards, leading to CAPEX avoidance.

PST & Bio-P Optimisation (PE: 325,000)

Problem statement

Optimum PST and Bio-P process

The 325,000 PE works incorporates 6 no. primary settlement tanks (PST’s), enhanced biological removal (Bio-P) in the anaerobic, anoxic, aerobic configuration, followed 4 no. final settlement tanks. The site is also a strategic sludge reception facility, with THP digestion, as well as a Sharon return liquor plant.

The Bio P process is influenced by the availability of VFA (soluble carbon source) with some load generated from a trader, and any shortfall in VFA supplemented by retainment of a high sludge blanket in the PST’s, as well as the addition of Glycol dosing as required.

Despite extensive conventional sampling programmes, the client had not been able to quantify the performance of the PST’s organic matter removal rates, as well as any associated phosphorus release and VFA generation potential.

What we did

Cost to serve data in real time & sustained optimisation at zero cost

Two Optimisers were deployed, one on the inlet to the works, downstream of the return liquors, the other on the outlet of one PST. A battery operated, IoT linked, sludge blanket detector was also installed on the PST.

In collaboration with the site operational team, sludge blanket levels were adjusted during the trial. Data captured from the Optimisers and sludge blanket monitor was pushed to the cloud, including key SCADA data. By incorporating flow to treatment, return liquor pump operation, process monitoring data, in addition to asset capacity and technical design standards, a comprehensive dashboard was established.

The dashboard was designed to derive the financial impact on treatment performance, at varying sludge levels. Equating the increased energy for treatment, when linked to reduced PST organic removals, as well as the value of the VFA release, from the sludge that benefits the Bio-P process. With such a rich data set, presented within an easy to interpret dashboard, the team were able to derive an optimum sludge blanket level. Noting the tipping point between optimum VFA production, and prevention of re-solubilisation of bound up Phosphorus from the sludge blanket. The final benefits are still being processed, but conversative estimates are over £150k/pa, with no change to the assets and operator resourcing.

Without the Optimiser a full understanding of PST operation could not be achieved, which is an industry challenge not unique to our client.

PST & Bio-P Optimisation (PE: 325,000)

Key Benefits

To sustain any interventions, you need to understand what is right for your plant, people and infrastructure. Our optimiser solution gets you on the right track.

  • The mobile Optimiser rigs, including sludge blanket monitoring, can be rapidly deployed to support any R&D / process handover scheme.
  • Data sets are un-matched, filling the void in current process monitoring, and a route to greater process insights and innovation.
  • Evidencing and then equating simple metrics, like PST sludge blankets to financials, empowers operators to make informed changes to the operation.