Concept design of micro-hydro turbine for sewage treatment plant.

1. FIRDAUS BIN JULAIHI
ME083542
Final Year Project 2 (MPRB424)
DESIGN OF MICRO-HYDRO
TURBINE FOR SEWAGE
TREATMENT PLANT

2. PRESENTATION OUTLINE
• Overview of the project.
• Problem Statement.
• Objective.
• Methodology.
• Results & Discussions.
• Conclusion.
• Acknowledgement.
• References.

3. INTRODUCTION
• Modern societies are becoming increasing
dependent on reliable and secure electricity
supplies to cater their everyday needs.
• From IEA World Energy Outlook publications
(2012), global energy demand grows by more
than one-third over the period to 2035.
• Concerns of increasing carbon footprint, more
efficient and less carbon intensive forms of
power generation are developed.
• One such resource is hydro source for power
generation. Water can harnessed in large or small
scale

4. • One such resource is the sewage
treatment plant (STP) effluent.
• The research in micro hydro power leads
to potential of harnessing energy from
the waste water treatment plant effluent.

5. HYDROPOWER TO
ELECTRIC POWER
Potential
Energy
Kinetic
Energy
Electrical
Energy
Mechanical
Energy
Electricity

6. BASIC SCHEME OF MICRO HYDRO
POWER PLANT

7. HYDRO VS MICRO-HYDRO
HYDRO
• Large dam.
• Constant flow rate /
speed.
• Not environmental
friendly.
MICRO-HYDRO
• Small run-off river / any
water run-off with
appreciable flow rate.
• Variable speed.
• Low carbon footprint.
Nature is conserved.

8. PROBLEM STATEMENT
• In STP effluent discharge, low head and low
flow poses a challenge to harness the full
potential of energy.
• Also, treated waste water contains
contaminants which may cause corrosion /
erosion to the turbine blade and shorten
operation life.

9. PROJECT OBJECTIVE
• Main objective :
I. To design a micro hydro turbine with 50 kW power
generation capacity to harness the renewable energy
from the STP effluent discharge.
• Specific Objectives :
I. To study the potential of renewable energy source in
the effluent discharge from sewage treatment plant.
II. To analyse the waste water characteristics, flow
dynamics of effluent and the river morphology. (At
site – Pantai IWK STP)
III. To produce concept design of micro hydro turbine
based on the data collected at the site to harness the
electricity.

10. METHODOLOGY
Literature Review
• Search for materials on the literature review about renewable
energy and energy demand in Malaysia.
• Study the latest information of current researches, potentials,
technologies and government policies on micro hydro system.
Especially for special applications such as Sewage Treatment
Plant.
Preparing
Concept Design
• Identify current design limitations.
• Specify problem statement and hypothesis to the problem(s).
• Describe data needed and explain how it is obtained.
Collecting Data
• Acquire site data to identify waste water characteristics,
hydraulic dynamics and river morphology for Klang
River.

11. Analysis Of
Data
• The data is analysed for future concept design of micro hydro
turbine.
Interpretation
of Data
• The data may contain important information for further
improvement of the turbine or the necessity of producing custom-
made turbine. (Turbine Selection, Material Selection, Suitable
Configuration)
Concept Design
• Concept Generation of Micro Hydro Turbine
• Concept Evaluation and Selection.
• Product Design.
• Detail Design and Drawing
Documentation
• Thesis Writing of the Concept Design and Analysis of Micro Hydro
Turbine for Sewage Treatment Plant.

12. PROJECT FLOWCHART
Problems
Definition and
Understanding
Literature
Review
Collecting Site
Data and
Analysis Of Data
Benchmarking
Concept
Generation
Concept
Evaluation and
Selection
Produce
Concept Design
of Micro Hydro
Turbine
Detail Design &
Drawings
CFD ANALYSIS

13. DELIVERABLES
• Ultimately to produce a micro hydro turbine design with
power generation capacity at 50 kW from the STP effluent.
In this case, to install multistage bulb turbine operation to
achieve 50 kW.
• The success of this project will initiate the energy race to
tap the energy from all the available STP in Malaysia.
• In the future, this effort can help to optimize the hydro
power generated at Sewage Treatment Plants .

14. RESULTS

15. POTENTIAL OF GENERATING 50 kW
0
10000
20000
30000
40000
50000
60000
70000
80000
m3/day
Month
Average Effluent Flowrate Per Day
Average Effluent Flowrate Per Year
Graph of flow duration at site.
* Source : Looi M.Y 2012

16. *Effective head is cut into half due to fluctuation of tail water and
effluent flow.
• Minimum flow rate :
54604.86 m3/day.
• Power generation
:17.86 kW.
• Maximum flow rate
:180225 m3/day
• Power generation
:59.25 kW.
* For maximum flow
rate, latest data from
IWK is used.
• Average flow rate
:112320 m3/day.
• Power generation
:34.915 kW.
* For average flow
rate, latest data from
IWK is used.

17. ANNUAL POWER PRODUCTION
• Average power production per year
:34.915 kW x 8760 h/year x 0.95
= 290 MWh/year.
• Max. power production per year
: 59.25kW x 8760 h/year x 0.95
= 493 MWh/year.

18. MAIN CHARACTERISTICS
• The outcome of this is a turbine’s power of 34.915
kW .
• Maximum runaway speed of 1920 rpm arises.
• Runner diameter of 0.48m.
*Results from calculation based on net head and
available flow rate.

19. CONCEPT DESIGNS
DESIGN NO 1 DESIGN NO 2
DESIGN NO 3

20. SELECTION
Functional
Requirements
PowerOutput
(kW)
Supply(Headand
Flowrate)
DesiredVoltage
(V)
OverallCost(RM)
DesiredOutput
Frequency(Hz)
Mass(kg)
Dimension
CycleTime(sec)
Shut-OffValve
Requirements
(Explicit and
Implicit)
Generate Power From Sewage
Effluent without much civil
works
● ● ▽
Consistent in Functionality ● ○
Efficient in Operation ○ ○ ○
Operational Smoothness ○ ○ ○
Variable Speed Operation ○ ● ▽
Light Weight ●
Ease of Maintenance ○ ▽ ▽ ●
Relationships
Strong ●
Moderate ○
Weak ▽
* Design NO 3 scored the highest
point based on the criteria.

21. BULB-TURBINE
• Bulb turbine with
5-blades
adjustable
according to the
level and the flow
rate.
• Direct-drive
variable speed
permanent
magnet generator.
• Rotating trash
rake cleaner to
filter out slurry
sludge.
Trash rake
cleaner
Bulb
Housing
Generator
5-blade
adjustable
runner
FINAL CONCEPT SELECTED – DESIGN NO 3.

22. MATERIALS : PROPOSED
Material Density (kg/m3) Strength (kPa) Cost (per kg)
Carbon Steel 7858 425,000 RM 3.25
Stainless Steel 8000 517,017 RM 15.19
Teflon 2320 7580 RM 62.42
ABS 1020 30,000 RM 6.68
pH level of Effluent discharge : 7-8 (Neutral)
Based from material comparisons, carbon steel is chosen as the material
for the turbine.
• Carbon steel is lighter than stainless steel.
• Protective layer can be applied such as overlay stainless steel coat to
overcome the lack in corrosion resistance.
• Ease of fabrication
• Cheaper material as compared to others.

23. FLOW SIMULATION RESULTS
(AT AVERAGE LOAD)
• Pressure contour at average load(rated
discharge 1.3 m3/s)
• It shows gradual reduction in pressure
from inlet of water passage to exit of
runner
• Rise in pressure difference, torque also
increases and hence power output
increases.
• Velocity contour at average load(rated
discharge 1.3 m3/s)
• When water goes though the bulb and
rake cleaner, static pressure drop takes
place. This causes higher velocity at the
exit of the bulb and the runner.
• The change in swirls at inlet of runner
causes shock losses at edge, and
increase flow separation.
Flow Direction

24. ENGINEERING ANALYSIS OF
DESIGN

25. ENGINEERING ANALYSIS OF
DESIGN

26. RECOMMENDATION
• Further improvement would be to develop the
design into a prototype and prepare suitable
test rig to further prove the efficiency of the
design.
• Experimental data can be compared with CFD
analysis to optimize the turbine operation.
• Detail design and analysis to be conducted.

27. CONCLUSION

28. ACKNOWLEDGMENT
Thank You to Ir. Kumaran A/L Palaniasamy for his
guidance and help in this project.
&
Thank You Indah Water Konsortium Sdn. Bhd for their
cooperation.

29. REFERENCES
FM Griffin, “Feasibility of Energy Recovery from a Wastewater Treatment
Scheme”.
Harvey , Micro Hydro Design Manual, A guide to small scale water power
scheme, IT Publications Ltd London ,2006.
Renewable Energy Technologies, Section 8, Small Hydropower, Chenal R.,
Choulot A., Denis V, Tissot N.,Edited by Jean-Claude Sabonnadière, Iste,
Wiley, 2009.
Saket(2008) Design, development and reliability evaluation of micro hydro
power generation system based on municipal waste water”. IEE Electrical
power and energy conference. pp 14.
SEDA (2011), “Renewable Energy Act 2011”, SEDA website.
Available at: http://www.seda.gov.my.(Date visited June 14th 2012)

30. T. Kirk (1999), Small scale hydropower in the UK. Journal of the Chartered.
The Intermediate Technology Development Group (ITDG), „Micro-Hydro
Power‟, 1998 http://www.practicalaction.org/
Wallace,A.R (1996) Embedded mini hydro generation in the water supply
industry , IEE Conference Publication 419, pp 168-171.
World Energy Outlook 2010, Paris: International Energy Agency, 2010.
Adam Harvey, “Micro-hydro Design Manual”, Intermediate Technology
Publications1993.