SPX Cooling Technologies Marley MarPak MCR3100 User manual

/Marley MARPAK® Modular Biomedia /

The Marley®MARPAK Difference
SPX Cooling Technologies is a world leader in the design,
manufacturing and construction of cooling products.
The design and production of modular corrugated PVC media
used in Marley cooling products is the same technology and
expertise utilized in the development of the MARPAK product
line of modular PVC media for biological wastewater treatment.
Since the origin of Marley in 1922, we have maintained a
commitment to total quality in engineering, in customer service
and in the close teamwork of our employees and representatives
around the world. This long term dedication is what makes the
Marley MARPAK Difference.

Fixed Film Process
History
For over 100 years the fixed film reactor
(trickling filter) has been used in wastewater
treatment to reduce the biochemical oxygen
demand (BOD) and for nitrification. As the
wastewater passes down through the trickling
filter, microorganisms on the surface of the
media convert the dissolved organic wastes
and ammonia nitrogen into stable by-products
- carbon dioxide, nitrates, nitrites and biosolids
which are removed by clarification.
Advantages
The advantage of the trickling filter process
over other methods of treating wastewater
include:
1. Lower energy consumption (Fig. 3-1)
2. More resistant to hydraulic and organic
shock loads
3. Simple operational procedures
4. Fewer personnel required to operate
5. Reduces sludge bulking problems
Future
With the advent of the highly efficient modular
60° cross flow media (MARPAK MXF Series), the
trickling filter is a viable alternative for complete
secondary treatment (Figs. 8-1 and 8-2) and
nitrification (Fig. 9-1) of municipal wastewater.
As energy and labor costs continue to increase,
the trickling filter process will become even
more cost effective in wastewater treatment.
12 345678
3-1
Relative Energy Consumption
Influent &
Intermediate
Pumping
Secondary
Treatment
Sludge
Treatment
Building
Heating
& Cooling
10ft. Total Head
Aerobic Digestion
Incineration
Extended Aeration
100ft. Total Head
30ft. Total Head
Activated Sludge
Trickling Filter
Preliminary Treatment
Primary Treatment
Thicken &Anaerobic Digestion
Drying Beds
Haul to Landfill
Aerated Ponds
Chlorination
Northern U.S.
Southern U.S.
Source: Water and Sewage Works

MARPAK is a modular PVC corrugated media
specifically designed for biological treatment
applications. MARPAK media is manufactured
from rigid PVC sheets that are UV protected
and resistant to rot, fungi, bacteria, acids
and alkalies commonly found in wastewater.
MARPAK modules are manufactured in various
sheet thicknesses to meet specific structural
requirements. MARPAK includes a full range of
modular PVC media geometries for wastewater
treatment including - complete secondary
treatment (Figs. 8-1 and 8-2), nitrification (Fig.
9-1), denitrification, industrial roughing filters and
anaerobic treatment.
4-3
Retention Time Versus Flow
At A Media Depth Of 10ft.
Source: “Evaluation of Plastic Media In Trickling Filters”,
by T. Richards and D. Reinhart
1.2 2.4 3.6
0 0.5 1.0 1.5
20
16
12
8
4
2
0
Flow m
3
/m
2
/h
60° Cross Flow
Modular Media
Random Media
Flow GPM/ft
2
Retention Time In Minutes
4-2
Retention Time Versus Flow
At A Media Depth Of 10ft.
Source: “Plastic-Packed Trickling Filters” by E. Sarner
2.0 3.0 4.0 5.0 6.0
0.8 1.2 1.6 2.0 2.4
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Retention Time In Minutes
Flow GPM/ft
2
Flow m
3
/m
2
/h
Vertical Flow
Modular Media
0.4
60° Cross Flow
Modular Media
4-1
Flow Configuration
of MARPAK MXF Series Media
Modular Biological Treatment Media
Faster Installation
Extensive testing has proven that taller mod-
ules produce the same water distribution as
alternating 1'-0 modules. This means 4 ft, 6 ft,
or even 8 ft modules can be used to reduce
installation time and minimize the number of
clog-prone module interfaces.

Advantages of MARPAK
MXF Series 60° flow media:
1. Superior oxygen transfer
The MXF Series geometry allows
for the continuous and uniform
horizontal redistribution of air and
water (Fig. 4-1) maximizing oxygen
uptake.
2. High Efficiencies at shallow
depths
The MXF Series 60° cross
corrugated geometry maximizes
hydraulic retention time compared
to other media types (Fig. 4-2 &
4-3). MXF Series media can provide
effective treatment at media depths
as low as 3 ft MXF Series media
can be used as a direct replacement
for rock media to increase both
capacity and efficiency of existing
trickling filters (Fig. 7-1).
3. Wide hydraulic range
MXF Series is effective in reducing
BOD and nitrification at hydraulic
wetting rates of below 0.2 gpm/ft2
to over 2.5 gpm/ft2.
MARPAK MXF Series
MARPAK MXF Series incorporates the well established 60°
cross-corrugated (cross flow) design (Fig. 4-1). This geometry
has proven to be the most efficient for reducing BOD
(biochemical oxygen demand) and for nitrification. Typical
applications are shown in Figure 5-1. MXF Series media is
available in modules 2 ft wide, 2 ft or 4 ft high and 4 ft or
6 ft long.
5-1
MARPAK MCR Series
MARPAK MCR Series is a vertically corrugated clog resistant
media designed to minimize the potential for excessive solids
buildup. The geometry is ideally suited for treating high
strength wastewater. Typical applications are shown in Figure
5-1. MCR Series media is available in modules 2 ft wide,
2 ft, 4 ft, 6 ft or 8 ft high and 4 ft long.
Product
Identification
Specific
Surface Area
ft2/ft3
Void Ratio
(%) Application
MXF 3000 30 95 Secondary
Treatment
Anaerobic
Treatment
MXF 4800 48 95 Secondary
Treatment
Nitrification
MXF 7400 74 95 Secondary
Treatment
Nitrification
MCR3100 31 95 High Strength
Wastewater
Anaerobic
Treatment

Municipal Wastewater
Numerous empirical equations have been
developed in an attempt to mathematically
describe the reaction taking place in the
trickling filter. The most common and generally
accepted empirical equation in use today
for predicting trickling filter performance in
secondary treatment applications is the modified
Velz equation. MARPAK MXF Series media
performance for secondary treatment (Figs. 8-1
and 8-2) can be evaluated using the modified
Velz equation.
For information regarding the application of
MARPAK MXF Series media for nitrification of
municipal wastewater, please reference
Figs. 9-1 and 9-2.
Industrial Wastewater
MARPAK MXF and MCR Series media can
be used to treat a variety of industrial waste
streams. Due to the wide variation in treat ability
of industrial wastes, trickling filter performance
is best determined from data from trickling
filter installations treating similar wastewater;
general design curves for various categories
of industrial wastewater; or pilot studies. In
addition to clarification, pretreatment including
pH adjustment and nutrient addition may be
required. The wastewater entering the trickling
filter should have a pH between 6.0 and 8.5
and a nutrient balance among BOD, ammonia
nitrogen and phosphorous of 100:5:1.
MARPAK MXF 4800
Remove Existing Rock Media
and Underdrain Alternate Support Material:
Clay Tile, Concrete Block, Precast Concrete Beams
Rock Media
MarPier Supports
Media
Depth
Section
General Design Information
MARPAK MXF 3000

Applications
Upgrading Existing Rock
Trickling Filters
MARPAK MXF 4800 with its 60° cross fluted
geometry and high surface and void ratio is ideal
for upgrading the performance of existing rock
trickling filters.
With a surface area and void ratio more than
three times greater than rock, upgrading with
MARPAK MXF 4800 can more than double the
organic capacity and improve effluent quality of
an existing trickling filter. A significant amount of
nitrification can also be achieved, depending on
the organic loading.
Unlike rock or random plastic media, MARPAK
MXF 4800 provides continuous and uniform
horizontal redistribution of air and water, with
no short-circuiting. In addition, MARPAK MXF
4800 has no horizontal surfaces, thus minimizing
the potential for excessive solids buildup and
plugging.
MARPAK MXF 4800 modules can be placed
directly on rows of supports (Fig. 7-1) Removal
of the existing clay tile along with the rock media
is recommended. Modifications to the existing
trickling filter structure are generally not required.
Plan
MARPAK MXF 480
0
Remove Existing Rock Media
and Underdrain Alternate Support Material:
Clay Tile, Concrete Block, Precast Concrete Beams
Rock Media
MarPier Supports
Media
Depth
Section

Applications
Complete Secondary
Treatment
MARPAK MXF Series fixed film
biological reactors used in
conjunction with primary and
secondary clarification (Fig. 8-1)
can reduce BOD5and suspended
solids to above 90%.
Trickling Filter/
Solids Contact
(TF/SC)
The TF/SC process utilizes the trickling
filter followed by short term aeration
(Fig. 8-2). The recirculation of sludge to
the aerated contact basin enhances the
agglomeration of fine particles and
improves settling characteristics. At the
same time the aeration continues to
remove soluble organics. The aerated
contact basin, combined with a center-well
final clarifier can readily achieve a 95-plus
percentage reduction in BOD5and total
suspended solids.
Roughing or Pretreatment
MARPAK MXF and MCR Series fixed film
biological reactors (Fig. 8-3) are an effective
method of pretreating difficult wastes and
reducing the organic load on subsequent
biological treatment steps.
Secondary
Clarifier
MARPAK
Reactor
BOD –20
SS –20
8-1
Complete Secondary Treatment
Primary
Clarifier
Aerated
Contact
Basin
Aerated
Contact
Basin
Secondary
Clarifier
MARPAK
Reactor
BOD – 10
SS – 10
8-2
TF/SC Process
Primary
Clarifier
Circulated
Sludge
Waste
Sludge
Aeration
Basin
Aeration
Basin
Secondary
Clarifier
MARPAK®
Reactor
BOD – 20
SS – 20
8-3
Primary
Clarifier
Marpak Plus Activated Sludge

Applications
Nitrification
In the nitrification process (Fig. 9-1) MARPAK
MXF Series fixed film reactor provides an
effective means of oxidizing ammonia nitrogen of
secondary treated wastewater.
Nitrifying trickling filters require less mechanical
equipment, less operating power and less
attention than the activated sludge process
(Fig. 9-3). Nitrifying trickling filters are less
effected by cold temperature than the
activated sludge process (Fig. 9-4).
MARPAK nitrification fixed film reactor,
when preceded by clarified secondary
effluent with the BOD5below 35 mg/l, will
continue to reduce suspended solids and
BOD5to a level below 20 mg/l.
A performance curve for nitrification is
shown in Fig. 9-2.
MARPAK
Nitrification
Reactor
BOD-30
SS-20
NH
4
N-25
BOD<15
SS<15
NH
4
N<1
Effluent from
Secondary
Treatment
9-1
Nitrification
Media
Surface
Area
Required
sq ft/lb of
NH
4
-N
Oxidized
Per Day
12000
10000
8000
6000
4000
2000
0
9-2
1.0 2.0 3.0 4.0 5.0 6.0
Effluent Ammonia-N (mg/L)
12° To 19°C
7° To 11°C
Source: Process Design Manual For Nitrogen Control, U.S. EPA
+
9-3
Cost Comparison
Source: Water Engineering and Management
Activated Nitrifying
Cost Sludge Trickling Filter
Project
Energy (10 year)
Project - present worth
Energy - present worth
Total - present worth
$ 8,497,000
3,450,000
7,423,000
2,847,000
$10,270,000
$ 4,870,000
1,175,000
4,250,000
971,000
$ 5,221,000
Nitrification
Rate
(as % of rate
at 20°C)
100
80
60
40
20
0
9-4
10 12 14 16 18 20
Temperature °C
Effect of Temperature
Activated Sludge
Nitrifying Trickling Filter
Source: Water Engineering and Management

The MARPAK Advantage
Fixed film media has traditionally been made in
2 ft height increments due to production
limitations (sizes of thermoformers and molds
to create the media sheets). Marley cooling
tower fill has been produced for over 30 years
and the advantage of taller fill heights has been
recognized. This has resulted in the development
of larger thermoformers to product fill media up
to 6 ft tall.
There are several advantages of taller media,
primarily due to the presence of fewer interfaces
between modules:
• Less deflection under load because the edge-
to-edge interface between modules deforms
more than the internal structure of the media.
• Less clogging by biosolids because module
interfaces produce a blockage location due to
exposed media edges.
• Less air blockage (pressure drop) for better air
distribution.
• Less installation time.
Just as with a cooling tower, water and
air distribution efficiency is critical to the
performance of a trickling filter. For that reason,
SPX advocates minimizing the number of
module interfaces by using taller modules in any
media installation, whether for a cooling tower or
for a trickling filter.
MARPAK Advantages
Taller heights of 4 ft (MXF 4800 and MXF 3000)
and 6 ft (MCR 3100).
Taller MARPAK modules mean:
• Stability—Less settling over you filter's life
• Efficiency—Less clogging by biomass at
module interfaces
• Performance—Less air blockage due to
interfaces
• Quicker Installation—Fewer modules to handle
In third-party test of MXF 3000 media, two 2 ft
tall modules deflected nearly 70% more than
two 4 ft tall modules*. For example, if filter media
with 2 ft tall modules settle by 4 in during its
lifetime, 4 ft tall modules in the same filter will
settle less than 2 3⁄8in.
*Based on percentage of height.

Installation
MARPAK is installed so that the sheets of all
modules in a particular layer are parallel.
Special care should be taken during installation
of the media to protect the modules from
damage. Where necessary, cutting and
trimming of the modules may be performed
within the fixed film reactor. Adequate
protection and precaution should be taken to
insure that no damage is done to the placed
media and that no debris from the cutting
process is allowed to lodge in the placed
media.
Warranty
The media supplier shall certify to the general
contractor and the engineer in writing that
the media to be supplied will meet or exceed
the specifications. Limited warranty shall be
provided by the manufacturer for a period of
one year after installation against defects in
material and workmanship.
For a more detailed specification for your
specific application, please contact
SPX Cooling Technologies at 800 462 7539
and ask for MARPAK.
Media
MARPAK is a Modular PVC media specifically
designed for fixed film biological treatment
applications.
MARPAK is available in both the highly
efficient 60° cross flow design (MXF Series) for
complete secondary treatment and nitrification
and the vertical flow design (MCR Series) for
treating high strength industrial wastewater.
MARPAK media is available in specific surface
areas from 30 to 74 square feet per cubic foot
with a 95% void to volume ratio.
The MARPAK modules are manufactured in
various PVC sheet thicknesses to meet specific
structural requirements.
Material
MARPAK polyvinyl chloride (PVC) sheets are
resistant to rot, fungi, bacteria growth and other
forms of microorganisms and are chemically
resistant to normal concentrations of sewage
acids, alkalis, organic solvents and organic
compounds.
The PVC compound is UV resistant and
specifically formulated to resist long-term
fatigue cracking under continuous loading.
General Specification and Installation Information

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OVERLAND PARK, KANSAS 66213
UNITED STATES
913 664 7400
[email protected]
spxcooling.com
In the interest of technological progress,
all products are subject to design and/or
material change without notice.
©2008 SPX Cooling Technologies, Inc.
Printed in USA | Marpak-08