The F.B. Leopold Company, Inc.

W H I T E P A P E R
JUST ADD WATER

The Leopold Clari-DAFSystem for Potable Water

Clarification
James E. Farmerie, Product Manager
The F. B. Leopold Co., Inc.
227 South Division Street
Zelienople, Pennsylvania 16063

Potable water treatment plants process raw water from ground and surface sources to
produce a product that meets all of the regulatory requirements for consumption. Surface
water treatment plants are required to have at least filtration, and usually will first remove
solids in order to optimize filter performance. The conventional design of surface water
treatment plants include rapid mix, flocculators, clarification, filtration, clearwell, and
contact tank. In the treatment process, there are a number of chemicals used to produce
quality water. The clarification process affects the type and quantity of chemicals required.

Where systems remove solids prior to filtration, the goals of the clarification unit are to:

1. Remove suspended and colloidal solids

2. Remove algae
3. Provide contact time for taste and odor control strategies
4. Remove naturally occurring organic matter
5. Remove Cryptosporidium and Giardia
6. Remove precipitated dissolved solids (e.g., Fe, Mn, As, hardness)
7. Remove contaminants that demand disinfectant or oxidant
8. Produce and collect solids that are easily processed downstream
9. Provide consistent water quality to filters to maximize filter run time
10. Minimize the footprint for the unit processobtain a high loading rate in gpm/ft

The clarification equipment has a major impact on downstream processes. The effluent
water quality affects the filters run time and will affect cost with respect to backwash water,
media breakdown, energy cost, filter-to-waste quantity, and elimination or reduction of filter
aids. The solids leaving the process affects the volume of sludge to handle and the time
required to dewater the sludge, which then affects the cost associated with energy,
chemicals, cake solids, and disposal.

In many cases, a LeopoldClari-DAF(Dissolved Air Flotation) system is an excellent

choice for potable water clarification. In the Clari-DAF system process, raw water particles
are flocculated and separated out of the water by floating them to the surface, rather than
settling them to the bottom of a basin. The process introduces micro-sized air bubbles
through diffusers at the bottom of the contactor where it mixes with coagulated solids and
floats the floc. The air bubbles are produced by recycling a portion of the effluent through a
tank where air is introduced, the water saturated, and then reduced to ambient pressure,
thus creating the pressurized flow. The floated sludge is removed from the top of the basin
by mechanical or hydraulic means, while the clarified water is removed by laterals from the
bottom of the basin.
The Clari-DAF system is particularly effective in removing low-density solids such as
turbidity, color, algae, Cryptospordium/Giardia, and precipitated organic material and
metals. These are all contaminants that do not settle well, but tend to float or hover in the
water column. The Clari-DAF system can effectively remove some taste and odor
compounds that can be readily stripped by the dissolved air in the water. It can also handle
rapid changes in temperature and water quality provided that the coagulation chemistry is
optimized. With the advent of the Environment Protection Agency (EPA) Backwash Water
Treatment Rule, the Clari-DAF system can be an effective process for separating solids
from filter backwash so that the effluent can be recycled to the head of the plant or
discharged to a stream and the solids processed through the plant solids handling scheme.

The Clari-DAF system is less costly than conventional sedimentation basins because the
flocculation section is one-half to one-quarter in size. Depending on how the calculations
are done, the surface loading of the solids separation part of a conventional DAF process
can be up to 10 gpm/ft2, while high-rate systems can be up to 20 gpm/ft. Some
manufacturers calculate surface area by including the entire length of the flotation cell,
while others calculate the rate using the clarified water collection area.

Since particle removal is by flotation, rather than sedimentation, both the flocculation and
clarification detention times are less than conventional treatment. The particle size for
removal in flotation can be tens of microns rather than the hundreds of microns required for
sedimentation, and the Clari-DAF system will produce a more consistent effluent quality for
filter loading, thus maximizing filter run times between backwashes. It will also produce
sludge solids in the float of 2% to 5%, which reduces the sludge volume to handle and the
cost of further processing whether by dewatering or hauling away the sludge solids.

REMOVING MANGANESE AND ALGAE

An excellent example of a system that installed a Clari-DAF system to remove manganese

and algae is a water treatment plant in Pennsylvania where the raw water source for the
plant influent is a 2.2-billion-gallon lake that feeds another 1.3-billion-gallon reservoir.
Soluble manganese had always been a problem, and increased agricultural run-off and a
reduction in the surrounding forestry were causing progressively higher algae blooms
during the summer months. These conditions were creating severe taste and odor
problems and shortened filter run times, and causing discoloration and staining in the
distribution system due to the manganese.

The 12-MGD-designed plant had a conventional treatment scheme with rapid mix, upflow
clarifiers, filters, clearwell, and a contact tank, as well as vacuum drying beds for sludge
dewatering. The recommended solution to the problem of increased manganese and algae
was to install a Leopold Clari-DAF system and to replace 5 filters.

The flow through the plant averages 9 MGD, with peaks of 13 MGD. The influent turbidity
averages 3 NTU, with influent soluble manganese levels averaging 0.1 mg/L, but peaking
at 0.172 mg/L. Previously, potassium permanganate (KMnO4) was regularly fed at the
intake for taste and odor control as well as manganese oxidation. The plant also fed
inorganic flocculant and polymer for clarification, fluoride, caustic for corrosion control,

The F.B. Leopold Company, Inc.

W H I T E P A P E R
2
chlorine for disinfection, and ammonia to form chloramines to carry the residual throughout
the large distribution system.

In the summer of 1999, a Leopold Clari-DAF system mobile pilot plant was brought in to
determine process effectiveness and to develop design criteria. The six-week pilot study
optimized the inorganic coagulant doses at 15 to 20 mg/L, and was able to achieve an
operating loading rate of 7 gpm/ft with an efficient recycle flow of 7.8%. The Clari-DAF
system pilot study indicated that it could efficiently remove algae and manganese, provide
low turbidity effluent, and produce high sludge solids for dewatering. In addition, with the
smaller footprint, it allowed the water utility to handle a proposed 36% increase in ultimate
plant capacity to 15 MGD.

Before system start-up, the utility added aeration in the reservoir to help oxidize the
manganese so that it precipitates and is easily removed by the Clari-DAF system. Aeration
has reduced the KMnO4 feed from 9 months per year to only a couple of weeks per year
during the summer. Operators have reduced the inorganic flocculant chemical feed to 8 to
15 mg/L. Some of the reduction is due to the fact that the Clari-DAF system is more
efficient in removing smaller-diameter particles by flotation than by clarifiers attempting to
settle them.

The Clari-DAF system effluent turbidity is consistently below 0.2 NTU and has increased
filter runs to the Pennsylvania-state-regulatory-recommended maximum of 72 hours.
Previously, with the upflow clarifier, the filter runs were 24 hours between backwashes.
The taste and odor problems have been resolved, soluble manganese in the finished water
is now below 0.02 mg/L, and the process removes a minimum of 85% of the incoming
algae.

One of the bonus benefits of the Clari-DAF system installed in at the water treatment plant
is the high solids content of the floated sludge. As it comes off the top of the unit, it is
actually diluted to 2% for pumping purposes, and then sent to a belt press that has
replaced the vacuum drying beds. The belt press, using anionic polymer as a sludge
conditioner, produces sludge cake ranging from 16% to 22% solids. This out-performed the
drying beds that produced 5% cake solids and required sawdust filler to be added to
handle it for hauling to the landfill. The belt press processes a one-week accumulation of
sludge in 10 to 14 man-hours rather than the 48 to 60 man-hours previously required using
the drying bed. This has reduced the overall operating costs of solids handling and
disposal by greater than 60%.

Performance data before and after installation of the Clari-DAF system is listed in Table 1.

Today, the effluent water quality and subsequent filter run times of the installed Clari-DAF
system are exceeding expectations. Also, the maintenance and operations requirements of
the Clari-DAF system units are less than anticipated, allowing treatment plant operators
extra time to accomplish more tasks during their regular shift.

The F.B. Leopold Company, Inc.

W H I T E P A P E R
3
Table 1
Performance of Clari-DAF System vs. Upflow Unit Clarification
at a 12 MGD Pennsylvania Water Treatment Plant
Parameter Upflow Unit Clari-DAF System

Raw Water Turbidity 2.0 - 5.0 NTU 2.0 - 5.0 NTU

Raw Water Manganese 0.1 - 0.17 mg/L 0.1 - 0.17 mg/L

Effluent Turbidity 1.0 NTU 0.2 NTU

Effluent Manganese 0.05 mg/L 0.02 mg/L

Filter Run Length 24 hours 72 hours

Filter Effluent Turbidity 0.1 NTU 0.04 NTU

Filter Effluent Manganese 0.05 mg/L 0.02 mg/L

MORE SUCCESS REDUCING TASTE- AND ODOR-CAUSING ALGAE, COLOR,

AND TOTAL ORGANIC CARBON

The City of Waco, Texas has consistently had a problem with taste- and odor-causing
compounds in its raw water supply from Lake Waco. These problems were strongly
associated with the presence of high concentrations of algae species such as Oscillatoria,
Mycrocystis, and Anabaena. The existing treatment plant scheme uses a variable height
intake pump to draw water into the main pumping station, and a two-stage sedimentation
process followed by filtration to control the problem, but without much success during
period of algal bloom.

The Lake Waco source water is low in iron, manganese, and turbidity, but has high
apparent color and high concentrations of various species of algae. The F.B. Leopold
Company was invited by the City of Waco to conduct a Clari-DAF system pilot study to
evaluate its effectiveness as a treatment process.

Two pilot plant studies were conducted: one in May/June 2000, the other in
November/December 2000. Both studies confirmed that the Leopold Clari-DAF system
proved reliable and effective for reducing algae (as well as related taste and odor), color,
and total organic carbon (TOC) while producing consistently low-turbidity effluent to
achieve maximum filter run times as well as producing high levels of floated sludge solids
to minimize dewatering and disposal cost. The pilot test achieved over 2.5-log removal of
algae cells while producing clarified effluent turbidities below 0.5 NTU, filtered water
effluent below 0.1 NTU, a drop in TOC of 36% over the Clari-DAF system unit, and sludge
consistently over 2% dry solids.

The F.B. Leopold Company, Inc.

W H I T E P A P E R
4
REMOVING CRYPTOSPORIDIUM AND GIARDIA

Leopold was invited back to Waco, Texas in June 2002 to conduct a third study to confirm
the performance of the first two pilot studies with the additional objective of collecting data
on removing the pathogens Cryptosporidium and Giardia from the raw water supply. The
watershed for Lake Waco is an area that is farmed with dairy cattle and therefore has an
elevated risk of Cryptosporidium contamination.

The Clari-DAF system-and-filter was optimized prior to the oocysts and cysts spiking study.
Alum was the coagulant used in the trials at an optimum dosage of 40 mg/L with no pH
adjustment chemical correction. G values were set at 60 s-1 for the first stage and 30 s-1for
the second stage with a 20-minute total retention time. The recycle rate was fixed at 10%
of the influent flow and the loading across the Clari-DAF system basin was fixed at 6
gpm/ft2.

In order to evaluate the recovery figures for the laboratory analytical techniques, a matrix
spike was conducted. Ten liters of pilot plant filtrate was sent to the laboratory,
Environmental Associates LTD. The sample was spiked with a known concentration of
Cryptosporidium and Giardia, and then filtered and analyzed in an identical method to the
field samples. The number of cysts and oocysts detected was used to calculate the method
recovery for the field samples. Results for the spike are given in Table 2.

Table 2
Analytical Method Recovery Limit Results
Volume Organisms Organisms %
Spiked Spiked Count Recovery

Cryptosporidium 10 L 99 33 33.3

Giardia 10 L 99 30 30.3

The spiking trial using Giardia and Waterborne stock Cryptosporidium solution was diluted
into a volume of 13.7 L of filtrate to produce the working solution. This was then pumped
into the pilot plant at a flow rate of 50.6 ml/min. The results are listed in Table 3.

Recovery for Cryptosporidium was taken as 33.3% and for Giardia as 30.3% as
determined by the matrix spike of the filtered water sample. The log removal figures are
listed below. Influent concentration figures have been calculated from the working spiking
solution concentration, the spiking solution flow rate, and the pilot plant flow. As shown, no
oocysts or cysts were detected in the filter effluent. The log removal figures have been
calculated in Table 4 using the laboratory limit of detection for the method and represent
the removal across the entire system.

The F.B. Leopold Company, Inc.

W H I T E P A P E R
5
Table 3
Spiking Trial Results
Cryptosporidium Giardia
Working Solution
Oocysts/ml Cysts/ml
Run Start 3,680 1,540

Run Stop 782 326

Cryptosporidium Giardia
Clari-DAF
Oocysts/100 L Cysts/100 L
Sample 1 2.2 3.2

Sample 2 5.7 0
Cryptosporidium Giardia
Filter
Oocysts/100 L Cysts/100 L
Filter Sample 0 0

Table 4
Spiking Trial Log Removal
Cryptosporidium Giardia Log Removal Log Removal
Oocysts/100 L Cysts/100 L Cryptosporidium Giardia
Influent 87,967 36812

Treated

Clari-DAF 1 2.2 3.2 4.12 3.58

Clari-DAF 2 5.7 0 3.7 3.99

Filter 0 0 4.88 4.46

The data confirms that the Leopold Clari-DAF system provided exceptional Giardia and
Cryptosporidium removal. Log removals across the Clari-DAF system were between 3.7
and 4.12 for Cryptosporidium and between 3.58 and 4.31 for Giardia. Total log removals
across the whole system were between 4.46 and 4.88.

SIGNIFICANT CHEMICAL AND OPERATING COST SAVINGS

The Greenville Water System draws water from three sources: the Table Rock Reservoir
on the South Saluda River, the Poinsett Reservoir on the North Saluda River, and Lake
Keowee. The source waters were so clear that for over 70 years the water from the
mountain reservoirs was unfiltered and only treated with chlorine. However, in the mid-
1980s, the Adkins Plant, designed at 30 MGD and employing conventional settling basin
clarification technology, was built to filter water drawn from Lake Keowee. This plant was
expanded in 2003 to increase capacity to 60 MGD using the same settling basin

The F.B. Leopold Company, Inc.

W H I T E P A P E R
6
clarification technology. Increasing regulations required all surface water systems to be
filtered, so in July 2000 a new, state-of-the-art filter plant was placed in service to provide
filtration for all of the water drawn from the Table Rock and Poinsett Reservoirs. This new
Table Rock/North Saluda filter plant, designed at 75 MGD, uses a Leopold Clari-DAF
system for clarification in the treatment scheme.

The raw water quality of the two plants is very similar with low turbidity, low hardness, and
low alkalinity. The average water quality data for raw, clarified, and finished water for
August 2003 to July 2004 is listed in Table 5.

Table 5
Average Water Quality Data for the Adkins and
Table Rock/North Saluda Water Treatment Plants
Adkins TR/NS
Raw
pH 6.63 6.57
Alkalinity 8.83 mg/L 8.91 mg/L
Temperature 21.75C 19.75C
Hardness 4.95 mg/L 4.25 mg/L
Turbidity 1.00 NTU 0.45 NTU

Clarified
Turbidity 0.37 NTU 0.20 NTU
Chlorine 1.36 mg/L 0.18 mg/L

Finished
pH 7.14 7.58
Alkalinity 10.31 mg/L 11.28 mg/L
Temperature 21.43C 19.76C
Hardness 5.53 mg/L 4.28 mg/L
Turbidity 0.04 NTU 0.03 NTU
Chlorine 2.48 mg/L 2.57 mg/L

The average chemical dosage for August 2003 through July 2004 is listed in Table 6.

Table 6
Average Chemical Dosage, Adkins vs. Table Rock/North Saluda
Water Treatment Plants
Adkins TR/NS Difference % Difference
Alum 11.86 ppm 11.12 ppm 0.74 ppm 6.24
NaOH 13.49 ppm 9.05 ppm 4.44 ppm 32.91

The F.B. Leopold Company, Inc.

W H I T E P A P E R
7
The filter performance data listed in Table 7 was collected from one filter at Adkins and one
filter train (three total filters) at Table Rock/North Saluda for August 2003 through July
2004.

Table 7
Filter Performance, Adkins vs. Table Rock/North Saluda
Water Treatment Plants
Adkins TR/NS Difference % Diff
Average Filter Run 90 hr 113 hr 23 hr 25.56
113 hr
113 hr
Average Gal/Backwash 288 gal 257 gal 33 gal 11.46
258 gal
250 gal

The average in-plant water usage rates for the same period are compared in Table 5.

Table 5
Average In-Plant Water Usage, Adkins vs. Table Rock/North Saluda
Water Treatment Plants
Adkins TR/NS Difference % Difference
10.53 million gal 2.62 million gal 7.91 million gal 75.12

Table 6 compares the expenses incurred and the total water production at each treatment
plant for August 2003 through July 2004.

Table 6
Comparison of Expenses, Adkins vs. Table Rock/North Saluda
Water Treatment Plants
Adkins TR/NS Difference % Difference
Total Flow x 1,000 7,092,365 gal 14,686,418 gal 7,594,053 gal 51.71
Treatment Expense $2,405,851 $2,985,752 $579,901 19.42
Cost/1000 gal 34 20 14 41.17

The F.B. Leopold Company, Inc.

W H I T E P A P E R
8
In consideration of similar raw water conditions, with the capability of producing effluent
water below MCL (Maximum Contaminant Level) along with the potential of efficient sludge
handling, the use of the Leopold Clari-DAF system instead of conventional sedimentation
technology at the Table Rock/North Saluda Water Treatment Plant has resulted in
significant chemical and operating cost savings for Greenville Water System.

2006, The F.B. Leopold Company, Inc. All Rights Reserved.

The F.B. Leopold Company, Inc.

W H I T E P A P E R
9