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KEE SERVICES OFFER PLANNED MAINTENANCE AND OPERATION OF WASTEWATER TREATMENT EQUIPMENT BY ANY MANUFACTURER

KEE Services Logo

The maintenance and operation of wastewater treatment equipment is a specialised task and KEE Services Limited recognises this.

With its extensive experience of on-site servicing of all types of wastewater treatment and pumping equipment, its technicians have the knowledge necessary to protect its customers’ investment and the environment.

KEE Services Limited offers planned maintenance programmes ranging from an annual visit to full plant operation. Its aim is to respond to all of your urgent servicing and maintenance needs. The KEE Services Team of fully trained Technicians operates on both a local and regional basis to ensure a prompt and reliable service.

  • Emergency Services
  • Planned Maintenance
  • Breakdowns
  • Equipment Refurbishment
  • Plant Operation
  • Spares
  • Ancillary Products
  • Plant Hire

Committed to maintaining your environment

  • KEE Service Ltd offers Preventative Maintenance, Process Operation and Breakdown Services for all types of treatment plant and pumping equipment, from all manufacturers.
  • KEE Services Ltd supports its UK customers during out-of-hours emergencies by offering a 24-hour manned call out service.
  • KEE Technicians are trained in long-term servicing and look after over 8,000 installations in the UK. They have sound mechanical and electrical experience, combined with application knowledge, and can identify problems early.
  • Working on a local basis, KEE technicians give a prompt service and have a good understanding of the conditions and legislations in each area.
  • Service and maintenance contracts include routine visits to keep equipment from both KEE Process and other manufacturers in top condition and prolong its lifespan.
  • There is a range of contracts available or a package can be designed specifically.
  • If refurbishment or upgrading is necessary, KEE Services can advise on the alternatives.
  • Site assessment can be made and installations planned for new and existing sites.

For full information on KEE Technologies and Services visit the:
KEE Services Planned Maintenance site.

KEE GROUP CAPABILITIES – OVER 350,000 WASTEWATER TREATMENT INSTALLATIONS WORLDWIDE

KEE seeks to identify and satisfy the needs of their customers by providing quality engineered solutions priced to offer value for money. KEE has over 60 years’ experience in wastewater treatment, process engineering, servicing and operation with over 350,000 installations worldwide. 

 The technologies and services offered by the KEE Group of companies are listed below:

Design, Installation and Operation of On-Site Plants

  • Anaerobic Reactors – The KEE Group offer design, installation and operation of on-site treatment plants. Their technologies include anaerobic digestion, aerobic processes including RBC and Submerged Aerated fixed film systems, extended aeration and SBR activated sludge processes, complemented with physical and physio-chemical processes. KEE also have a team of experienced process engineers and project engineers capable of delivering solutions to suit

Rotating Biological Contactor (RBC)

  • NuDisc© Single Piece Packaged RBC Treatment Plants
  • Modular Packaged RBC Treatment Systems
  • Large Diameter RBCs for site erection

Submerged Aerated Filters (NuSAF)

  • Single piece NuSAF© Systems,
  • Modular Packaged NuSAF© Treatment Systems
  • Large NuSAF© – in on-site constructed concrete tanks

Activated Sludge Systems

  • Extended Aeration, Sequencing Batch Reactors (SBR)
  • Oxidation Ditch

Fine Bubble Aeration & Mixing Systems

  • KEE Triton Aerator/Mixer

Attached Growth Airlift Reactor (AGAR®)

  • Moving Bed Biological Reactor (MBBR)
  • Integrated Fixed Film Activated Sludge (IFAS)

Dispersed Air Flotation (DAF)

  • pre-treatment of industrial and food processing wastewater
  • KEE Microfloat® – Dispersed Air Floatation Technology,  for pre-treatment of industrial and food processing wastewater to reduce FOG, BOD, COD & SS. The KEE Microfloat system achieves the same result as conventional DAF systems without the need to use a high-pressure pump and venturi. It incorporates a system to produces extremely fine bubbles 10 to 50 micron air bubbles into the water to float the light fractions

Primary and Final Settlement Tanks

  • GRP Hopper Bottom Settlement Tanks – A range of advanced design Hopper Bottom GRP Settlement Tanks for small wastewater treatment plants.

Grease Management System – Biological Solution to Fat, Oil and Grease (FOG)

  • KEE Bio-GuardThe grease digester that’s the biological solution for the removal of Fat, Oil and Grease.

 

KEE Services Logo

For full information on KEE Technologies and Services visit the KEE Group website
or call 01296 634500

KEE Services Ltd – A BRITISH COMPANY OFFERING A COMPLETE NATIONWIDE WASTEWATER TREATMENT OPERATION AND MAINTENANCE SERVICE ON A LOCAL BASIS

KEE Facilities Show Leaflet.indd

  • Process Review and Assessment
  • Sewage and Wastewater Management and Operation
  • Planned Preventative Maintenance
  • 24hr Emergency Call-Out
  • Tankering and Jetting Operation
  • UKAS Accredited Laboratory Effluent Testing
  • Sewage and Drainage Asset Management
  • Plant and Equipment Repair and Refurbishment
  • Installation and Commissioning
  • Forecourt Services
  • Spares and Replacement Parts
  • Commercial and Domestic Sewage Systems
  • Grease Management
  • Plant Hire and Rental

KEE Services recognises that the maintenance and operation of wastewater treatment equipment is a specialised task. With its extensive on-site servicing of all types of wastewater treatment and pumping equipment, its engineers have the knowledge necessary to protect customers’ investment and the environment.

KEE Services offers planned maintenance programmes, ranging from an annual visit to full plant operation. Its aim is to respond to all of your servicing and maintenance needs.

The KEE nationally-based Services Team of over 30 fully trained and certified British Water accredited engineers operates on both a local and regional basis to ensure a prompt and reliable service.

Management and Operation . . . a long-term commitment to you
All mechanical and electrical systems require regular maintenance to ensure a long, trouble-free and cost-effective operational life. Regular servicing can prevent the occurrence of costly problems.

  • KEE Services Ltd offers maintenance, operation and breakdown services for all types of treatment plant and pumping equipment, from all manufacturers.
  • KEE technicians are trained in long-term servicing and are currently maintaining over 8,000 installations within the UK.
  • Sound mechanical and electrical experience, combined with application knowledge, means they can identify problems early on and recommend the best solutions.

24hr Emergency Call-Out . . . a national company with local knowledge
KEE’s nationwide team of technicians operates on a local basis, so that wherever you are in the country, you can be assured of prompt service. Because they work in specific regions, KEE’s technicians have a good understanding of the conditions and legislations in your particular area.

A central call centre is staffed by people who are trained to understand the common problems you may experience and give you advice. From here, the nearest available technician can be contacted, thereby making the most of the extensive resources to solve your problems quickly.

Preventative Maintenance . . . a tailored approach
Focusing on your particular issues, KEE can help prevent potential problems, before they become costly or hazardous situations. From installation of the most appropriate equipment to routine inspections and maintenance, different clients have different needs. However, the aim is always the same – to provide you with competent support for the long-term management of wastewater.

Service, Maintenance and Operations
The KEE service package comprises a complete range of options, from servicing and repairs through to regular maintenance and full plant operation.

Site Assessment
KEE technicians can assess your site if it is not linked to mains drainage and can recommend the most appropriate and effective systems to suit the local ground conditions.

When considering the purchase of a new house, office or industrial unit, KEE can assess the local ground and offer options for the discharge of the wastewater.

Installations and Commissioning
KEE technicians can supervise the installation of your equipment, to make sure it is completed effectively. Correct installation will help avoid problems and unforeseen future costs.

Forecourt Services
From installation and commission of oil level and fuel tank alarms to servicing and routine operation checks, KEE has SPA trained technicians who can provide you with a complete service. They can also carry out routine checks on coalescer and closure devices on Class 1 and 2 separators.

Service and Maintenance Contracts
Routine visits will help keep your equipment in the best order and KEE has a range of contracts to choose from. As well as servicing its own systems, its technicians are trained to maintain those of other manufacturers, giving you a comprehensive service.

Refurbishment and Upgrades
As your needs change, KEE is on hand to offer advice on how to refurbish or upgrade existing equipment to meet those needs, from minor improvements to enhance the functioning of a plant, the addition of extra units, catering for expansion or to provide a higher quality of effluent.

Sludge Tankering and Jetting services
Residential or commercial, customers can save time and money by having KEE Services de-sludge and service your treatment plant.

Plant Hire and Rental
KEE offers one of the largest ranges of Process Equipment, Plant and Technologies for hire in the industry, available to the domestic, industrial and civil engineering markets

Grease Management

  • KEE Class 1 and Class 2 grease separator for physical solids and grease removal.
  • KEE Bio-Guard – for Biological Solution to Fat, Oil and Grease.

Total Management
KEE can offer a bespoke service package, tailored to individual requirements. Its total support means that you can expect peace of mind, knowing that it is working to protect your equipment and your environment.   Whether a single or multi-site operation anywhere in the UK, KEE can design a package to best suit your requirements, including routine inspections, maintenance, operation, emergency call-out services and supply of spares.

For full details of KEE Services visit their website.

KEE AERATION SYSTEM – UPGRADE FOR THE LARGEST CHEESE MANUFACTURER IN THE UK

KEE Tritons® Dual mode Processor (Aerator/Mixer)

Creamery

Dairy Crest Davidstow Creamery in Camelford is the largest cheddar cheese manufacturer in the UK. The process of collecting and processing milk is a 24/7 operation and therefore in a cheese-making facility like Davidstow effluent is generated round the clock on a daily basis and needs to be treated and disposed of continuously. Effluent from the cheese-making process contains high fat content and BOD/COD concentration.

The Creamery upgraded the effluent treatment plant during 2002/2003 and currently has DAF, a balancing tank, two aerobic reactors and a final clarifier. One of the aerobic reactors is MBR and the second reactor is an extended aeration system.

The original design was based on the MBR treating 60% of the total load and the extended aeration system expected to treat the balance. Due to various operational matters and high power consumption, the site was operating with the extended aeration system, consisting of a 5,000 m3 reactor, treating approximately 60% of the flow. The extended aeration system used helixor aerators for providing oxygen to the mixed liquor and the air was provided by Roots blowers at approximately 0.7bar pressure.

Approximately two-thirds of the helixors were still operational and this meant that one-third of the reactor was not being aerated and consequently was not effective in providing any treatment. The reactor was lacking in adequate mixing and due to the reduced operational volume of the reactor it was necessary to maintain high MLSS at around 7,000mg/l.

A further complication was introduced with high-pressure air at high temperatures increasing the bulk liquid temperature to 23ºC. The combination of high MLSS concentration, high bulk liquid temperature, lack of adequate mixing and the need to operate the reactor at a DO of 3.0-3.5mg/l meant that the blowers were consuming around 150kW of power. It was necessary to replace the disfunctional helixor aerators, as gradually more helixors were beginning to fail and the process was at risk of becoming unstable.

In order to replace helixor aerators, it would be necessary to de-commission the 5,000m3 extended aeration reactor, re-install the aerators and then re-commission the plant.

Whilst this refurbishment was being carried out, the Creamery would have had to make arrangements to dispose of 5,000m3 of mixed liquor and dispose of 850m3/d of high strength effluent for the duration of the refurbishment. Disposal of effluent would need to be continued after the plant had been re-commissioned and until the process was fully established and the effluent discharged from the plant was within consent. In addition to these logistical issues and the high cost of mixed liquor and effluent disposal, the Creamery also had concerns with the ageing Roots blowers, which were consuming approximately 3,600kWh of electrical power, associated maintenance and extremely high levels of noise. It would also be necessary to install 60kW of mixing power to optimise plant performance thereby increasing the power consumption to 5,040kWh/d.

To optimise the process it would also be advisable to introduce lateral mixing in the reactor and again this would have added to the power costs and additional electro-mechanical equipment to be maintained.

Tritons® Dual mode Processor (Aerator/Mixer)

KEE Process has been working with the Davidstow Creamery and their Consultant, Mr. D. Sharpe of Lanson Microbe, for some time to evaluate installation of KEE’s dual-mode Triton® processor which provides efficient mixing and fine bubble aeration for mixed liquors in any activated sludge system configuration. The Tritons® can be installed without de-commissioning the reactor and whilst the existing treatment process is ongoing thereby eliminating the logistics of emptying the reactor contents and finding a temporary solution for disposal of the effluent.

The Tritons® are surface-mounted fine bubble aerators and the aerator operates under water surface, thereby eliminating the atomisation and aerosol effect of the air-water mixture. The blower supplying low-pressure air is a high-efficiency regenerative unit and is quiet in operation. The Triton® injects a plume of fine bubble air and water mixture into the water and this action ensures that air reaches deep into the tank bottom up to a depth of 10m. The air-water mixture forms a cone-shaped plume which increases in its zone of influence with depth and this ensures that all the tank contents are completely mixed. As the Triton® uses low-pressure air, the mixed liquor temperature is not elevated and thus the energy required for process is minimised.

The blower can be controlled using a DO probe and PLC to facilitate effective dissolved oxygen in the mixed liquor as required. During the low-load conditions the blower would switch off but the Triton® would continue to provide efficient mixing to the reactor contents. The benefits of a well-mixed activated sludge reactor are that all the installed volume of the reactor is actively participating in the treatment process, the DO concentration throughout the reactor is homogenised and is always available throughout the tank and all the other tank contents, i.e. activated sludge and the substrate are uniformly distributed and this enables the reactor to operate as a completely stirred tank reactor. The system can therefore be operated at the desired DO set point of between 1.5mg/l and 2mg/l instead of 3.5mg/l previously.

KEE Process provided the necessary process engineering input to the creamery and re-evaluated the reactor design for treating 850m3/d of creamery effluent with influent COD load of 1,682kg/d (2,000mg/l) at a design MLSS concentration of 4,000mg/l, F:M ratio of 0.053, and mixed liquor temperature of 20ºC. The consent for final effluent for the Creamery is BOD < 13mg/l, SS <20mg/l, NH4-N < 5mg/l and PO4-P < 1mg/l/.

KEE concluded that the process required between two and three 48.5kW Tritons® for oxygen requirements but two would suffice for mixing. It was decided to install two 48.5kW Tritons® and these would provide the necessary mixing of the mixed liquor and almost 85% of the oxygen demand. The balance of the oxygen would be provided by the retained existing helixor aeration system as and when necessary. In effect, the Tritons® took over as the primary aeration system and provided the critical mixing vital to any activated sludge process. The Creamery could have installed three Tritons®, in which case the reactor would have been able to handle 30% more load than at present and this option still remains available to the Creamery. In fact the reactor is capable of treating a lot more load with 4 No. Tritons® but beyond that the process becomes limited by the solids handling capacity of the final clarifier.

The Tritons® were installed and commissioned and the existing aeration system was kept switched on to supplement any necessary deficiency in oxygen demand. The Creamery and Mr D. Sharpe monitored the existing variable speed Roots blower operation and concluded that they only need to operate at their lowest speed. They also monitored the D.O. concentration in the reactor and this was found to be consistently uniform compared to before the installation of the Tritons®. They also commented that the Tritons® were extremely quiet in operation.

Power Saving

Since commissioning the Triton® Dual Mode Processors, the power consumption is 2,580kWh/day and this represents a 28.3% drop in energy consumption compared with the previous aeration system. The annual power saving is 372,300kWh. More importantly, the contents of the reactor are now completely mixed thereby providing a true CSTR with uniform distribution of substrate and D.O. With mixing taken into account the annual power saving would be 897,900kWh. In addition to the power saving the noise from the Roots type blower is eliminated.

Conclusion

  • Tritons® can be installed in new plant, or in existing plants for supplemental aeration and/or mixing or for refurbishment.
  • Tritons® can be installed without de-commissioning the aeration reactor.
  • Tritons® are surface-mounted dual-mode processors and provide complete mixing and fine bubble aeration of the reactor whilst operating under water surface.
  • With complete mixing of the reactor contents, the process is completely optimised for performance and energy consumption with lower operational MLSS concentration.
  • The upgraded aeration system enables operation of the reactor at under 2mg/l DO and, apart from saving energy, it also enables control of DO in the anoxic selector tank.
  • Use of Tritons® enables lower MLSS concentration in operation and this will reduce solids loading on the final clarifier which, in turn, improves final clarifier effectiveness in removing solids or enables operation of the reactor at higher SSVI.
  • The use of high-pressure blowers leads to increased temperature of reactor contents thereby increasing energy consumption.
  • It is possible to treat more flow and load in the same reactor by adding further Tritons® to improve mixing or provide additional D.O. or both.

KEE, a BSI Certified Company (IMS, QMS, OHS & EMS) offers domestic and industrial wastewater treatment solutions including lifetime operation and maintenance using RBC, SAF, SBR and Extended Aeration. With 60 years’ experience and over 350,000 installations, KEE have the expertise in design, build and operation of all wastewater treatment plants.

For full information on KEE Technologies and Services call 01296 634500 or visit: The KEE Group Website

KEE SERVICES LIMITED – REFURBISHMENT OF EXISTING TREATMENT SYSTEMS FOR IMPROVED PROCESS PERFORMANCE AND REDUCED LIFETIME COSTS

KEE Refurbishment of Packaged Treatment Plants

The Anglian Water Systems (AWS) Team undertook such an exercise over a range of small to medium sized treatment plants adapted by the plc from a local council. Instead of abandoning the existing works, KEE Services Ltd with support from their process partners, KEE Process Ltd, were commissioned to survey 11 sites and report the findings. The report was required to include inventory register, feasibility of refurbishment, process implications and improvements with the associated costs of refurbishment. The survey was undertaken and completed over four weeks and a complete report, with a costed refurbishment program for all the sites was submitted to the AWS Team.

The 11 plants varied from 40PE up to 500PE in size and included systems required to reduce BOD and, in some instances, provide fully nitrified discharge with less than 5mg/l ammoniacal nitrogen. All the plants surveyed were of packaged plant construction, single piece or modular, and included primary settlement stage with combined sludge storage, RBC type biological stage and final settlement tank. The report concluded that it was feasible to refurbish all the plants and included a program for refurbishing the plants to a standard where the operators would have the confidence that the plants would provide a reliable and useful life for a further 20 years. Depending on the extent of refurbishment work necessary, the costs associated with the refurbishment varied substantially, but in every case it was much cheaper than replacement. The cost of refurbishment included for supply and installation of new equipment.

KEE Refurb Sequence-01 KEE Refurb Sequence-02 KEE Refurb Sequence-03KEE Refurb Sequence-04 KEE Refurb Sequence-05 KEE Refurb Sequence-06 KEE Refurb Sequence-07 KEE Refurb Sequence-08

This relates to a cluster of small population equivalent installations where all the plants upgraded were over 20 years old and would now have in excess of a further 20 years life and an improved process performance. With all the sites, the outer GRP structure housing the plant was retained and, with the exception of one or two sites, the internal components including the RBC were replaced by brand new factory built units incorporating the latest concepts in mechanical, structural and process engineering.

All the above plants include sectional GRP covers and were replaced to provide the equivalent of a new plant without the high cost and resource required to build one.

Refurbishing Large Wastewater Treatment Works

The KEE refurbishment concept can also be applied to plants serving larger populations which can be electro-mechanically upgraded to show similar benefits and add 20 years or more useful life to the plant. Scottish Water undertook a similar exercise where an existing 4,750PE activated sludge plant needed to be refurbished to bring the plant back to its full performance requirement without necessarily having to re-build the works.

For more information on Wastewater Treatment Plant refurbishment call KEE Services on: 01296 634500 or visit the KEE Services website.

KEE TRITON AERATOR/MIXER OVERCOMES PREVIOUS LIMITATIONS OF OXIDATION DITCH TECHNOLOGY

KEE FINE BUBBLE AERATION WITH BUILT IN MIXER

Triton-Graphic-(2)

KEE Process Triton

The KEE Triton Aerator/Mixer overcomes the previous limitations of oxidation ditch technology and can be used to revitalise existing oxidation ditches and extended aeration plant or systems based on activated sludge process.

Using the dual mode processor capabilities of Triton Aerator, aeration basins up to depths of 10m can be completely aerated and mixed. Existing Oxidation Ditches (OD) can be retro-fitted and new OD plants benefit with much smaller footprint. Nitrification and denitrification can all take place in a single reactor. With two propellers and a regenerative blower, Triton is able to operate either as an anoxic mixer with the blower turned off, or an efficient aerator/mixer with the blower on.

Multiple Triton units can be arranged to provide extended contact time between air bubbles and water stream, with greater oxygen transfer efficiency. Improved biological treatment results in Biochemical Oxygen Demand (BOD) removal rates as high as 99% in highly contaminated wastewater.

The KEE Triton is the most versatile fine bubble aeration/mixing device for activated sludge treatment systems available with dual functions – aeration and mixing.

KEE fixed price operation and maintenance contracts are available.

For full information on KEE Technologies and Services visit: KEE Fine Bubble Aeration
or call KEE on: 01296 634500

KEE SERVICES LIMITED MAINTAIN WASTEWATER AND SEWAGE TREATMENT EQUIPMENT MADE BY ANY MANFACTURER

Engineer-02

The maintenance and operation of any wastewater treatment equipment is a specialised task and KEE Services Limited recognises this.

KEE, with its extensive experience of on-site servicing of all types of wastewater treatment and pumping equipment, its technicians have the knowledge necessary to protect its customers’ investment and the environment.

KEE Services offers planned maintenance programmes ranging from an annual visit to full plant operation. Its aim is to respond to all of your urgent servicing and maintenance needs. The KEE Services Team of fully trained Technicians operates on both a local and regional basis to ensure a prompt and reliable service.

  • Emergency Services
  • Planned Maintenance
  • Breakdowns
  • Equipment Refurbishment
  • Plant Operation
  • Spares
  • Ancillary Products

Committed to maintaining your environment

KEE Services Ltd offers Preventative Maintenance, Process Operation and Breakdown Services for all types of treatment plant and pumping equipment, from all manufacturers. KEE Services Ltd supports its UK customers during out-of-hours emergencies by offering a 24-hour manned call out service.

KEE Technicians are trained in long-term servicing and look after over 8,000 installations in the UK. They have sound mechanical and electrical experience, combined with application knowledge, and can identify problems early.

Working on a local basis, KEE technicians give a prompt service and have a good understanding of the conditions and legislations in each area.

Service and maintenance contracts include routine visits to keep equipment from both KEE Process and other manufacturers in top condition and prolong its lifespan.

There is a range of contracts available or a package can be designed specifically. If refurbishment or upgrading is necessary, KEE Services can advise on the alternatives. Site assessment can be made and installations planned for new and existing sites.

For full information visit the KEE Services website or call 01296 634500 to arrange a visit.

 

KEE PROCESS LIMITED HAVE DEVELOPED A NEW SINGLE-PIECE FACTORY BUILT WASTEWATER TREATMENT PLANT TO ADD TO THEIR RANGE

Developed by KEE the NuDisc© 5000 HD RBC Sewage Plant and Treatment Centre – a new single-piece factory-built plant to add to their range to meet Severn Trent Water’s extremely stringent requirements.

a

Situated in the heart of the Peak District, the village of Hassop in north Derbyshire lies approximately 11 miles east of Chesterfield and 2 miles to the north of Bakewell, and is within the Severn Trent Water’s catchment. The properties subject to the Section 101a application were served by a village drain. This received flows from septic tank high level overflows and discharged to a local un-named watercourse. Local ground conditions were unsuitable for soakaways. Hassop Estate applied, under Section 101a of the Water Industry Act 1991 in December 2007, for a public sewerage system to be provided.

In 2010 STW accepted the need to lay new sewers and treatment system. The new wastewater treatment works was required to treat flow from a population equivalent of 210, and the consent to discharge for this site required that the BOD < 20mg/l, SS < 30mg/l and NH4-N < 5mg/l.

Project background and cost considerations
The construction of the Hassop WwTW involved the laying of approximately 1600m of foul sewer, an intermediate pumping station and a new RBC Unit to serve the Village. The work was undertaken by NMCNomenca as the Tier 1 Framework Partner and as part of S101A Scheme for Severn Trent Water Ltd.

NMCNomenca’s scope of works was for the detailed design, construction and supervision of the whole project from start to finish. NMCNomenca were also in control of the site until handed back to Severn Trent Water Ltd after commissioning and testing.

The project for capital delivery had to take into account CAPEX and OPEX costs to determine lifetime costs for the project over 20 years. This included the capital cost of delivering the project; design, manufacture, delivery and commissioning of the process plant and all site-related costs including provisions for on-site health & safety, environment and personal welfare for site operatives. The second part of the costs related to operational costs and included cost of energy, consumables, spares, labour and process-related costs such as desludging. The overall objective for the consortium is to minimise lifetime costs without compromising any aspects of the project delivery including site work.

Consent standards
The site at Hassop required to treat wastewater from a population equivalent of 210 with design DWF of 32m3/d, FFT of 173m3/d, BOD load of 12.6kg/d, SS of 15.75kg/d and NH4-N of 1.68kg/d. The consent to discharge for this site required that the BOD< 20mg/l, SS < 30mg/l and NH4-N < 5mg/l.

Such consent standards from the Environment Agency are common for wastewater discharge to a watercourse, although for a small works with such a large variation in design flows during dry and wet weather, this does present a challenge to the designers to ensure that the plant performs to requirements under all these conditions throughout the year.

Process plant selection
KEE Process has, over the last 60 years, developed a range of plants to treat wastewater from municipal and industrial sources to similar and more stringent standards where the BOD values could be less than 5mg/l, SS less than 10mg/l, ammoniacal nitrogen less than 1mg/l, phosphorus less than 1mg/l and total nitrogen less than 15mg/l. The range from KEE includes small packaged systems for small flows, modular packaged units for larger flows and in situ constructed plants for populations larger than 5,000 PE.

For the site at Hassop, the largest single-piece factory-built plant available at the time in KEE’s range was not adequate to deal with the flows, so KEE developed a new single-piece factory-built plant to add to their range. The single-piece plant would be factory built and would take into account all the requirements laid out by Severn Trent Water in its specification and the plant would be delivered to site ready to be placed on a pre-prepared concrete slab and backfilled.

The plant would include installation of the remote desludging facilities and internal electrical wiring during the plant construction in the factory. This would, in effect, be a true ‘plug and play’ system with the objective of reducing site-related construction time and costs.

Building a plant in a factory provides a controlled environment and conducive conditions for maintaining quality standards, which are often difficult when the build is undertaken at a construction site under the prevailing conditions, which may include rain, snow, low temperatures and hazardous operating environment.

In addition, a factory-built plant would enable the duration of construction on site to be substantially reduced, as the factory-built plant can be backfilled within a day or two of being delivered. This means that the excavation is not left open for long periods and, in turn, this reduces any health and safety risks associated with working on site with deep excavations and in confined spaces. However, this may have a major impact on the project costs when plants are factory built compared to building on site.

NuDisc®
KEE NuDisc® 5000 includes the primary sedimentation stage with sludge storage, RBC for biological treatment and a hopper final clarifier, all housed in a single structural GRP housing and covered with lightweight GRP covers.

The RBC is driven by a 0.75kW geared motor at a slow speed of 1rpm and is designed to comply with all the structural and mechanical requirements stipulated by Severn Trent Water Ltd.

The FST includes a fully automated descumming and desludging system, for removal of scum and sludge at regular hourly intervals back to the primary clarifier.

The primary clarifier includes remote desludging facility and this is carried out at regular intervals of 90 days when 18.9m3 (5000 gls) of sludge is tankered away.

KEE packaged plants also include flow attenuation within the primary settlement chamber, in order to provide process stability with the large fluctuations in design flows.

The manner in which the attenuation system is organised also enables evening out peaks and troughs in organic load and this attenuation is achieved in the first stage of the biological process.

Designed and built at KEE’s factory, the KEE NuDisc® 5000 was delivered on time on a cold snowy day and was placed in an excavation ready to be backfilled all on the same day.

The plant was fully commissioned to receive flows only seven weeks from delivery – a big achievement for all the parties involved including KEE Process, NMCNomenca and the client, Severn Trent Water. All other site related matter including landscaping, electrical control gear, remote telemetry system and landscaping were completed within timescales.

Operational and maintenance requirements
The operational and maintenance requirements are desludging every 90 days, lubrication of bearings required every six months. With a daily energy consumption estimated at 21kWh/d. The OPEX costs for the site are therefore minimised.

Summary
Although KEE Process does not have comparative lifetime costs for this specific project, the costs for similar projects with other water companies have shown 30% reduction in capital costs compared to other technologies with substantial amount of site related construction and equally a large proportion of savings in operating costs resulting from savings in energy consumption and operational labour requirement.

KEE, a BSI Certified Company (IMS, QMS, OHS & EMS) offers domestic and industrial wastewater treatment solutions including lifetime operation and maintenance using RBC, SAF, SBR and Extended Aeration. With 60 years’ experience and over 350,000 installations, KEE have the expertise in design, build and operation of all wastewater treatment plants.

For full information on KEE Technologies and Services visit the KEE Group website: