WASTEWATER TREATMENT PLANT DESIGN

Influent Wastewater Treatment

Effluent

Raw sludge, grit, cleanings

Sludge Treatment
What goes here depends on the method of final disposal: Solids concentration Pathogen reduction

Processed sludge
Sludge treatment and disposal may account for up to 80% of the total wastewater treatment cost.
11/30/2008

Sludge Disposal
Land application Landfill Incineration
1

Preliminary

Primary Treatment

2 Treatment

Disinfection

11/30/2008

Jae K. (Jim) Park

Page 1

WASTEWATER TREATMENT PLANT DESIGN

Sludge A mixture of organic and inorganic solids in water Color : from brown to black Treated sludge Incineration, landfilling Contain low levels of toxic compounds
Typical Sludge Concentration Source Primary sludge, without thickening Waste activated sludge Waste trickling filter sludge Digested sludge
11/30/2008

Typical concentration, % 2-7 0.5-1.5 1-5 4-10 12-50

3

Dewatered sludge

Sludge Types
Primary sludge
3 to 8% solids About 70% organic material

Secondary sludge
Consists of wasted microorganisms and inert materials About 90% organic material WAS: 0.5 to 2% solids Trickling filter sludge: 2-5% solids
11/30/2008 4

Jae K. (Jim) Park

Page 2

WASTEWATER TREATMENT PLANT DESIGN

Sludge Types
Tertiary sludge
If secondary clarifier is used to remove phosphate, this sludge will also contain chemical precipitates (more difficult to treat) Denitrification sludges - similar to WAS sludge

Sources of sludge Primary sedimentation tank Aeration basin or secondary clarifier Screening and grinder Filter backwash water

11/30/2008

Sludge Treatment
Reduction Ash

Sludge

Thicken

Condition

Dewater

Sanitary Landfill

Stabilize

Condition

Dewater

Soil Incorporation

11/30/2008

Jae K. (Jim) Park

Page 3

WASTEWATER TREATMENT PLANT DESIGN

Sludge Thickening
Reducing the water in primary and secondary sludges. Methods Gravity thickening : using an additional clarifier to remove more water Dissolved air flotation (DAF) Used to concentrate secondary sludges Sludge is pressurized and injected with air releasing into a settling tank (when the pressure is released, the extra air comes our of solution, attaching to the sludge particles as microscopic bubbles) the sludge is floated to the surface in a concentrated form the underflow returns to the head of the plant.
11/30/2008 7

Gravity Thickener
11/30/2008

Flotation
8

Jae K. (Jim) Park

Page 4

WASTEWATER TREATMENT PLANT DESIGN

Thickening
Gravity thickening Flotation
Especially effective on activated sludge Increases solids content from 0.5 - 1% to 3-6%
Primary Sludge Secondary Sludge
11/30/2008

Best with primary sludge Increases solids content from 1-3% to 10%

Gravity Thickening Further processing Flotation

9

Gravity Thickening
Accomplished in circular sedimentation basins Degree of thickening: 2~5 times the incoming solids conc. Max. achievable solids concentration: < 10% Chemical and waste activated sludges are difficult to thicken under gravity.

11/30/2008

10

10

Jae K. (Jim) Park

Page 5

WASTEWATER TREATMENT PLANT DESIGN

Gravity Thickener Design Criteria

Type of sludge Primary Trickling filter WAS Combined primary + WAS Inf. solids conc., % 1~7 1~4 0.2~1.5 0.5~2 Thickene d conc., % 5~10 2~6 2~4 4~6 Hydraulic Solids Solids Overflow loading, loading, captured TSS, mg/L 3/m2d 3/m2d m ,% m 24~33 2~6 2~4 4~10 90~144 35~50 10~35 25~80 85~98 80~92 60~85 85~92 300~1,000 200~1,000 200~1,000 300~800

m3/m2d 24.57 = gal/ft2 d kg/m2 d 0.2048 = 1b/ft2d

Gravity thickener side water depth: 3 m (10 ft) Detention period: 24 hrs Hydraulic loading rate: 10~30 m3/m2d = 250~740 gpd/ft2 To achieve the hydraulic loading rate, secondary effluent is often blended with the sludge fed into the thickener. The sludge-blending tank may utilize mechanical mixing or air mixing. 11 11/30/2008

Gravity Thickener Equipment

Generally circular concrete tanks with bottom sloping toward the center. Equipment Rotating bottom scraper arm Vertical pickets Rotating scum-collection mechanism with scum baffle plates Overflow weir Other configurations Circular steel tank:
Generally cheaper because of simplicity of construction, equipment installation, and operation and maintenance

Rectangular concrete and steel tanks

11/30/2008 12

Jae K. (Jim) Park

Page 6

WASTEWATER TREATMENT PLANT DESIGN

Gravity Thickener

11/30/2008

13

Dissolved Air Flotation (DAF)

Primarily used to thicken the solids in chemical and WAS Separation of solids is achieved by introducing fine air bubbles created under pressure of several atmosphere into the liquid, attaching to solids to cause flotation of solids Degree of thickening: 2~8 times the incoming solids concentration Max. solids concentration: 4~5% DAF Variations Pressurize total or only a small portion of the incoming sludge Pressurize the recycled flow from the flotation thickener preferred because it eliminates the need for highpressure sludge pumps.

11/30/2008

14

Jae K. (Jim) Park

Page 7

WASTEWATER TREATMENT PLANT DESIGN

Dissolved Air Flotation (DAF)

The released air bubbles become attached to the suspended particles by one of the following mechanisms: 1.Condensation 2.Collision 3.Entrapment

11/30/2008

15

Advantages of DAF
Space requirements are minimal. Capability to treat a wide variety of organic and inorganic solids and dissolved waste streams. Low retention time from wastewater stream to effluent ejection. Superior clarification of most waste streams. Easy to clean and maintain. Higher density sludge with low water content. Installation cost is low for low flows. The unit is typically delivered fully prefabricated. Normal concrete pad installation.
11/30/2008 16

Jae K. (Jim) Park

Page 8

WASTEWATER TREATMENT PLANT DESIGN

Design Parameters
Hydraulic Loading: Effective design ranges from 1.0 to 2.5 gpm/ft2, depending upon the application. Solids Load: Design points for solid loadings range from 0.5 to 3.5 lbs/hr/ft2, depending on the application and the type of solids involved. It should be noted that any chemical additives used to promote coagulation and flocculation are generally included as solids determining the surface loading since the chemicals used are removed with the float from the system. Air-to-Solid Ratio: Generally, air is injected in a range of two percent to eight percent (2% to 8%) by volume. Depending upon the type of solids and application, the airto-solids ratio ranges from 0.020 to 0.1.
11/30/2008 17

Air/solids ratio, A/S

sa= solubility of air at the required temperature, mg/L; Sa = solids in incoming sludges, mg/L; f = fraction of air dissolved at pressure P, usually 0.5~0.8 P = pressure in atmosphere = (p + 101.35)/101.35 (SI units) = (p + 14.7)/14.7 (US customary units); p = gauge pressure, kPa (lb/in2); q = recycle flow or a portion of incoming flow pressurized, m3/d; and Q = sludge flow to the thickener, m3/day.
Solids loading rate, kg/m2d 90~200 50~120 50~90 60~150 Hydraulic loading, m3/m2d 90~250 90~250 60~180 90~250 Polymer added (mg/kg) 1000~4000 1000~3000 1000~3000 1000~4000 Solids captured ,% 85~95 90~98 80~95 90~95 TSS in side stream, mg/L 100~600 100~600 100~600 100~600 18

Type of sludge

Air/solids ratio 0.04~0.07 0.02~0.05 0.03~0.05 0.02~0.05

Primary Trickling filter WAS Combined primary 11/30/2008 + WAS

Jae K. (Jim) Park

Page 9

WASTEWATER TREATMENT PLANT DESIGN

Sludge Stabilization
Aerobic Digestion
Extension of activated sludge Accomplished by aeration of sludge then followed by sedimentation Supernatant goes back to head of plant (high in BOD, TKN, total-P) Treated sludge is 3% solids

Anaerobic Digestion
2 stage: acid fermentation followed by methane production Advantages: produce methane do not add oxygen As with aerobic digestion, supernatant goes to headworks
19

11/30/2008

Sludge Stabilization
Stabilization alters the characteristics of sludge so it can be returned to the environment with a minimum of environmental and health risks. Biological Treatment 1. Aerobic Digestion 2. Anaerobic digestion 3. Lagoons 4. Composting Chemical Treatment 1. Wet combustion 2. Lime stabilization 3. Chlorination 4. Heat stabilization 5. Irradiation
11/30/2008 20

Jae K. (Jim) Park

Page 10

WASTEWATER TREATMENT PLANT DESIGN

Stabilization
Aerobic Digestion
Extension of activated sludge Accomplished by aeration of sludge then followed by sedimentation Supernatant goes back to head of plant (high in BOD, TKN, total-P) Treated sludge is 3% solids

Anaerobic Digestion
2 stage: acid fermentation followed by methane production Advantages: produce methane do not add oxygen As with aerobic digestion, supernatant goes to headworks
21

11/30/2008

Stabilization

Aerobic Digestion
11/30/2008

Anaerobic Digestion

22

Jae K. (Jim) Park

Page 11

WASTEWATER TREATMENT PLANT DESIGN

Aerobic Digestion
Primary sedimentation tank Aeration basin RAS Aerobic digester Decant Sludge Secondary clarifier

Aerate until O2 uptake < 2 mg O2/g VS/hr Sludge age = 10~20 days at 20C Loading = 0.02~0.15 lb VS/ft3day Thermophilic aerobic digestion: 77~122F (25~50C); higher removal of biodegradable fraction (up to 80%) at very short detention times (3~4 days)
11/30/2008 23

Aerobic Digestion - continued

Advantages: VS reduction similar to anaerobic digestion, lower BOD in supernatant liquor, production of an odorless, humus-like biologically stable end product, recovery of more of the basic fertilizer values in the sludge, relatively easy operation, and lower capital cost Disadvantages: high power cost, poor mechanical dewatering characteristics of sludge, and sensitive to temp., location, and type of tank material, and loss of CH4 recovery potential. Process description C5H7NO2 + 7O2 5CO2 + NO3- + 3H2O + H+ pH drop 7.14 lb of alkalinity as CaCO3 lost/lb ammonia oxidized Primary sludge: direct oxidation of organic matter Biological sludge: endogenous oxidation of the cell tissue
11/30/2008 24

Jae K. (Jim) Park

Page 12

WASTEWATER TREATMENT PLANT DESIGN

Aerobic Digestion - continued

Conventional Aerobic Digestion Digester liquid temperatures: dependent on weather conditions and thus can fluctuate extensively use concrete instead of steel tanks, place tanks below grade instead of above grade, provide insulation, or use subsurface instead of surface aeration Design at the lowest expected liquid operating temperature and provide the max. oxygen requirements at the max. expected liquid operating temperature. Tank volume Q (X + YSi ) V= i i X(K d f v+1/ c ) where Y = fraction of influent BOD5 consisting of primary sludge Kd = reaction rate constant, 1/day; and fv = volatile fraction of digester suspended solids.
11/30/2008 25

Aerobic Digestion - continued

Conventional Aerobic Digestion continued Oxygen requirements Biological sludge: 2.3 lb O2/lb of cells Primary sludge: 1.6~1.9 lb O2/lb destroyed DO > 1 mg/L under all operating conditions Energy requirements for mixing Mechanical aerators: 0.75~1.5 hp/103 ft3 Diffused-air mixing: 20~40 ft3/103 ft3min Solids loading: 0.1~0.3 lb VS/ft3min VS reduction: 40~50% Process operation pH may drop to ~5.5 at long HRT filamentous bulking Provide decanting facilities so as to use to thicken the digested sludge solids before discharge to subsequent operations. Consider operator control and visibility of the decanting operation.
11/30/2008 26

Jae K. (Jim) Park

Page 13

WASTEWATER TREATMENT PLANT DESIGN

Anaerobic Digestion
1. Fermentative organisms (50% of viable organisms in anaerobic digester) Cellulose Acetate, alcohols, Strepto cocci Lipids other organic acids, Enterobacteria Proteins H2, CO2, NH3, HSChlostridia 2. Acetogenic bacteria (acid formers) Simple organics (except acetate) (fatty acids, sol. organics) Acetate 3. Methanogenic bacteria (methane formers) Get energy from forming CH4 Need low redox potential O2 toxic Need temp.

11/30/2008

27

Anaerobic Digestion
Anaerobic digestion of sludge decrease the volatile organics by 40-50% and reduce the numbers of pathogenic organisms in sludges. Accomplished by holding the sludge in closed tanks for periods of 10 to 90 days. Old process : unmixed, unheated, long detention time (30-90 days) Recent process : complete mixing, heating (3545), detention time 10-20 days
11/30/2008 28

Jae K. (Jim) Park

Page 14

WASTEWATER TREATMENT PLANT DESIGN

Digester gas Gas storage Gas storage Scum Heater mixer Supernatant
Settled, Digested sludge

Digester gas

Digestion

Separation

Complete mix, or high-rate, anaerobic digester

11/30/2008 29

Advantages
High degree of waste stabilization at high organic loading rates Very little sludge production (< 5% of biodegradable organic matter being converted to cell material) (10% of aerobic sludge production) Easy dewatering of the excess sludge Low nutrient requirement (10% of aerobic process requirement) No aeration equipment Methane production very low energy input (if the methane gas is used to heat the digester)

11/30/2008

30

Jae K. (Jim) Park

Page 15

WASTEWATER TREATMENT PLANT DESIGN

Disadvantages
Low bacterial yield
prolonged periods of biomass build-up, requiring longer start-up period (8 to 12 weeks).

Temperature, pH, toxic sensitive Inherent process instability High capital costs Complex operation requiring skilled operators
11/30/2008 31

Anaerobic Digestion - Theory

Complex organics 100% 60% Intermediates 20% Acetate 72% 28% CH4 50% 15% Propionate 13% 10% H2

Fermentation & hydrolysis

5%

Acetogenic phase 2%

Methanogenic phase

Methanogenic phase

Rate limiting steps Conversion of propionic and acetic acid to CH4 Hydrolysis of organic solids (cellulose)
11/30/2008 32

Jae K. (Jim) Park

Page 16

WASTEWATER TREATMENT PLANT DESIGN

Anaerobic Digestion: Reactions

CH3COOH CO2 + CH4 CH4 + 2O2 CO2 + 2H2O CH3COOH + 2O2 2CO2 + 2H2O

* CH4 has high energy

11/30/2008 33

Anaerobic Contact Process

Recycle increases biomass levels and sludge age, thereby separating sludge age from HRT. Difficult to obtain efficient settling of the biomass. A degasifier is required to aid in solids settling.
11/30/2008 34

Jae K. (Jim) Park

Page 17

WASTEWATER TREATMENT PLANT DESIGN

Egg Shape Digester

35

Mixing Device
Gas injection

Unconfined: collect gas at the top of the digesters, compress the gas, and then discharge the gas through a pattern of bottom diffusers or through a series of radially placed top-mounted lances... Confined: collect gas at the top of the digesters, compress gas and then discharge through confined tubes...
Mechanical stirring: low speed turbine or mixers, suitable for fixed or floating covers Mechanical pumping: propeller-type pumps mounted in internal or external draft tubes or axial flow or centrifugal pumps and piping installed externally, suitable for fixed covers
11/30/2008 36

Jae K. (Jim) Park

Page 18

WASTEWATER TREATMENT PLANT DESIGN

Mixer Types

Unconfined gas injection systems

Confined gas injection systems

Mechanical stirring systems

37

Digester Heating
To raise the incoming sludge to digestion tank temperatures, to compensate for the heat losses through the walls, floor, and roof of the digester, and to make up the losses that might occur in the piping between the source of the heat and the tank. Internal or external heat exchangers Heat requirements q = U A T where q = heat loss, BTU/h (W); U = overall coefficient of heat transfer, BTU/ft2hrF (W/m2C); A = cross-sectional area through which the heat loss is occurring, ft2 (m2); and T = temperature drop across the surface in question, F 11/30/2008 38 (C).

Jae K. (Jim) Park

Page 19

WASTEWATER TREATMENT PLANT DESIGN

Sludge Conditioning
Chemical Conditioning
Add lime, ferric chloride, or alum Can also add polymers Chemicals are added just prior to de-watering stage

Heat Treatment
High temperatures (175230 oC) High pressures (10 to 20 atmospheres) Advantages
bound water is released and sludge is easily dewatered

Disadvantages
complex process highly concentrated liquid stream

11/30/2008

39

Heat Treatment
Heating sludge under pressure to temperatures in the range of 200-300 for a few minutes can effectively sterilize it and convert it to a form that is easily dewatered. Disadvantages Its high energy requirement The production of a high-strength return liquid form the dewatering process Heat treatment is used only in a few large POTWs
11/30/2008 40

Jae K. (Jim) Park

Page 20

WASTEWATER TREATMENT PLANT DESIGN

Dewatering & Drying

Sludge Drying Beds
Most popular method Simple Low maintenance Effected by climate

Filtration
Apply vacuum to pull out water Force out water by essentially squeezing water between two moving filter belts

11/30/2008

41

Dewatering and Drying

By applying the sludge to sand drying beds Consist of a layer of sand with an underdrain system The sludge is pumped onto the bed The sun and wind dry the material further Used at smaller POTWs By using mechanical dewatering equipment Used medium size plants, larger POTWs The sludge is applied to a metal, cloth, or systhetic rubber surface This equipment is automated but and experienced, welltrained operator is required.
11/30/2008 42

Jae K. (Jim) Park

Page 21

WASTEWATER TREATMENT PLANT DESIGN

De-watering

Sludge Drying Beds

11/30/2008

Vacuum Filtration
43

Filter Press
Dewatering is accomplished by pumping sludge into chamber (A) surrounded by filter cloths (B). As pumping pressure is increased, the filtrate is forced through the accumulated filter cake (C) and cloth, leaving the chambers full of solid filter cake. The chambers in HEI presses are formed by two recessed plates held together under hydraulic pressure. The hydraulic ram (D) moves the follower (E) against the stack of filter plates (F) closing the press. The ram continues to apply pressure of sufficient force to counteract the high internal compaction pressures. The head stock (G) and tail stock (H) are held in place by specially engineered side rail supports bars (I). The filtrate passes through the filter cloth and is directed by channels in the plates and drain ports (J) to the head stock for discharge. The filtrate typically contains less than 15 ppm suspended solids. The filter cake is easily removed by simply reversing the hydraulic ram, thus opening the press. The lightweight plates may then be moved apart permitting the compacted cake to fall from the 11/30/2008 44 chamber.

Jae K. (Jim) Park

Page 22

WASTEWATER TREATMENT PLANT DESIGN

11/30/2008

45

45

Centrifuges
Centrifugation is the process of separating solids from liquids by the use of centrifugal force. The centrifuge is a cylindrical drum that rotates to develop the separating force. When the slurry enters the interior of a rotating centrifuge, it is thrown out against the bowl wall. The denser materials are separated first, and hug the interior wall of the rotating machine.

11/30/2008

46

Jae K. (Jim) Park

Page 23

WASTEWATER TREATMENT PLANT DESIGN

Centrifuges - continued
A helical screw conveyor fits inside the bowl. Rotating at a slightly lower rate that the bowl, it conveys solids from the zone of settling to the dewatering beach, where it is discharged to screw conveyors located below. The main bowl is turned by an electric motor while the screw conveyor inside is controlled or slowed down using a hydraulic backdrive. Prior to entering the centrifuge, sludge would have been conditioned with polymer. Larger and heavier particles are most easily captured by the centrifuge. Fine particles that cannot be settled separately must be agglomerated by chemicals (polymer) to a size that will settle.

11/30/2008

47

Sludge Volume Reduction

Wet Oxidation Incineration
Complete evaporation of water from sludge Requires fuel Solid material is inert Exhaust air must be treated prior to discharge Treated sludge is wet Requires energy Solid material is inert Exhaust air must be treated prior to discharge

11/30/2008

48

Jae K. (Jim) Park

Page 24

WASTEWATER TREATMENT PLANT DESIGN

Volume Reduction: Fluidized Bed Incineration

11/30/2008

49

Sludge Ultimate Disposal

Ultimate disposal the return of the material to the environment. Landfilling Land application & Land Spreading:
gardens agricultural land forest land golf courses and other public recreational areas

Incineration Other methods Care must be taken in applying sludge to land, so that excessive concentrations of heavy metals or other toxic materials do not accumulate in the soil Incineration : lager municipalities Maximum volume reducing, detoxification, and energy recovery Capital and operating costs are high There are environmental effects (air discharges, scrubber sludge generation), operation problems, and the continuing need for trained operating personnel.
11/30/2008 50

Jae K. (Jim) Park

Page 25

WASTEWATER TREATMENT PLANT DESIGN

Wastewater Sludge and Biosolids

11/30/2008

51

Wastewater Sludge and Biosolids

11/30/2008

52

Jae K. (Jim) Park

Page 26

WASTEWATER TREATMENT PLANT DESIGN

Wastewater Sludge and Biosolids

11/30/2008

53

Wastewater Sludge and Biosolids

+ Biosolids =

11/30/2008

54

Jae K. (Jim) Park

Page 27

WASTEWATER TREATMENT PLANT DESIGN

11/30/2008

55

Jae K. (Jim) Park

Page 28