Cyber-physical system for a water reclamation plant: Balancing aeration, energy, and water quality to maintain process resilience.

摘要

Aeration accounts for a large fraction of energy consumption in conventional water reclamation plants (WRPs). Although process operations at older WRPs can satisfy effluent permit requirements, they typically operate with excess aeration. More effective process controls at older WRPs can be challenging as operators work to balance higher energy costs and more stringent effluent limitations while managing fluctuating loads. Therefore, understandings of process resilience or ability to quickly return to original operation conditions at a WRP are important. A state-of-art WRP should maintain process resilience to deal with different kinds of perturbations even after optimization of energy demands. This work was to evaluate the applicability and feasibility of cyber-physical system (CPS) for improving operation at Metropolitan Water Reclamation District of Greater Chicago (MWRDGC) Calumet WRP. In this work, a process model was developed and used to better understand the conditions of current Calumet WRP, with additional valuable information from two dissolved oxygen field measurements. Meanwhile, a classification system was developed to reveal the pattern of historical influent scenario based on cluster analysis and cross-tabulation analysis. Based on the results from the classification, typical process control options were investigated. To ensure the feasibility of information acquisition, the reliability and flexibility of soft sensors were assessed to typical influent conditions. Finally, the process resilience was investigated to better balance influent perturbations, energy demands, and effluent quality for long-term operations. These investigations and evaluations show that although the energy demands change as the influent conditions and process controls. In general, aeration savings could be up to 50% from the level of current consumption; with a more complex process controls, the saving could be up to 70% in relatively steady-state conditions and at least 40% in relatively challenging transient conditions. The soft sensors can provide reliable and flexible performance on target predictions. The plant can still maintain at a similar level of process resilience after 50% aeration saving, even during long-term perturbations. Overall, this work shows that it is well feasible to provide more cost-effective operations at the Calumet WRP, and meanwhile influent perturbations, effluent quality, and process resilience are well in balance.