With 100 years of experience removing contaminants, UOP provides proven wastewater treatment solutions that improve operating efficiency.
UOP’s XCeedTM bioreactor technology incorporates simple design principles and unique microbial growth support media for treating the most challenging industrial wastewater streams. This advanced technology provides robust and cost-effective operations while minimizing sludge production and energy consumption.
Technology Overview
High efficiency in a compact design
UOP’s XCeed bioreactor technology utilizes a packed bed, plug flow design that provides greater solids retention time while minimizing the hydraulic retention time. The increased solids retention time results in a high biomass to feed ratio that promotes biological oxygen demand (BOD) removal while minimizing sludge formation. High concentrations of immobilized bacteria provide natural resistance to and fast recovery from process upsets. The high rates of BOD reduction and flexible process configuration also
allows for asmall system footprint.
XCeed bioreactor technology key components：
- XCeed Bioreactor System: (Multi-chamber packed beds with adjustable aeration)
- Proprietary Mixed-Media:(High surface area for microbes to grow and mobilize, resulting in high rates of contaminant removal)
- Bio-catalyst: (Extended microbial life minimizes sludge generation)
Honeywell (HON) announced today that industrial wastewater technology from Honeywell UOP will help a Wyoming refinery remove contaminants from its wastewater to meet new environmental requirements.
HollyFrontier Cheyenne Refining LLC has selected Honeywell UOP’s XCeed bioreactor technology to remove selenium from wastewater at its 52,000 barrel-per-day refinery in Cheyenne, Wyo. The high-performance unit will process approximately 1 million gallons per day of wastewater when it goes online this year.
“Honeywell UOP’s XCeed bioreactor technology was selected above other technologies after a successful field demonstration for selenium removal,” said Jim Stump, senior vice president of refining for HollyFrontier. “Honeywell UOP has a long history as a supplier to HollyFrontier’s subsidiaries. Adding this new technology will help HollyFrontier continue to meet its environmental commitments by further polishing the refinery’s treated effluent water.”
Honeywell UOP’s XCeed bioreactor technology removes organic and inorganic contaminants to help industrial, manufacturing and groundwater remediation facilities meet contaminant removal specifications for wastewater discharge or reuse. Watch a video on how XCeed removes contaminants from wastewater.
“Honeywell UOP is working with HollyFrontier to deliver this project as a turnkey solution,” said Rebecca Liebert, vice president and general manager of Honeywell UOP’s Catalysts, Adsorbents and Specialties business. “With more than 50 successful installations, the XCeed bioreactor system is a reliable and cost-effective solution for food and beverage companies, chemical and textile manufacturers, refinery and petrochemical facilities, and for groundwater remediation, to meet increasingly strict wastewater regulations worldwide.”
This advanced biological technology is based on Honeywell UOP’s expertise in reactor design, applied microbiology and process control that enables long biomass retention time, resulting in efficient selenium removal with low sludge production, low energy consumption, low maintenance and minimal operator attention.
Other Honeywell UOP separations technologies have been commercially proven in many water applications, including the removal of radioactive contaminants from water at the Fukushima Daiichi nuclear plant in Japan.
HollyFrontier is an independent petroleum refiner, with operations throughout the Midwestern, Southwestern and Rocky Mountain regions. Subsidiaries of HollyFrontier produce and market gasoline, diesel, jet fuel, asphalt, heavy products and specialty lubricant products.
Case study
Customer Challenge
Garment finishing is a water intensive process that uses large volumes of water for the final laundering of finished garments, such as denim jeans. Many of these manufacturing plants are located in areas that have limited water availability. The recovery and reuse of water is essential to enable these manufacturing plants to operate at capacity. Advanced wastewater treatment processes are needed for removing contaminants that would otherwise impact the product quality when water is reused within these facilities.
A blue jeans manufacturer based in the Dominican Republic had historically high water consumption rates that were impacting the supply and pressure of the municipal water system it was connected to. This caused significant public dissatisfaction with the manufacturing facility, and local residents took to vandalizing the site.
Solution
The blue jeans manufacturer installed a wastewater treatment system that allowed for water reuse within the manufacturing facilities. The wastewater system is depicted in the flow scheme and incorporates UOP’s XCeedTM bioreactor technology for removing color and organics.
The operating parameters for the bioreactor are as follows:
- Mixed liquor suspended solids (equivalent) > 10,000 ppm;
- Biomass retention time > 60 days;
- Sludge yield: 0.07 – 0.12 kg biomass/kg BOD consumed;
- Biomass loading: 3.5 – 4.8 kg BOD/m3/day;
- Hydraulic retention time: 3 – 9 hours;
- Energy consumption: ~ 25 kw/hr.
The wastewater treatment and reuse system resulted in the following benefits:
Garment manufacturing facility recovered 80-90% of wastewater for reuse Product quality was maintained Production bottleneck issues associated with water supply were liminated Order backlog was reduced and orders could be filled on demand.
UOP XCeed bioreactor technology for contaminant removal from industrial waste streams
UOP’s XCeed bioreactor technology offers unique mixed-media support for immobilized microbes, providing outstanding removal rates for organic and inorganic contaminants from wastewater. It is effective on a wide range of difficult-to-treat contaminants and can be delivered as a modular system or as a retrofit to an existing basin.
UOP’s XCeed bioreactor technology:
- Reduces organic and inorganic contaminants by up to 90%;
- Produces up to 80% less sludge and consumes up to 60% less energy than alternative biological treatment systems;
- Meets water quality performance targets at industrial, manufacturing, and groundwater remediation facilities for regulatory compliance and enables water reuse;
- Manages varying contaminant loads and is resistant to process upset and shock;
- Improves overall resource efficiency for sustainable operations;
- Provides mechanical simplicity for ease of operation.
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