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ABSTRACT: The modem trickling filter typically includes the following major components: (1) rotary distributors with speed control; (2)
modular plastic media (typically cross-flow media unless the bioreactor is
treating high-strength wastewater, which warrants the use of vertical-flow
media); (3) a mechanical aeration system (that consists of air distribution
piping and low-pressure fans); (4) influent/recirculation pump station; and
(5) covers that aid in the uniform distribution of air and foul air
containment (for odor control). Covers may be equipped with sprinklers
that can spray in-plant washwater to cool the media during emergency shut
down periods. Trickling filter mechanics are poorly understood. Consequently, there is a general lack of mechanistic mathematical models and
design approaches, and the design and operation of trickling filter and
trickling filter/suspended growth (TF/SG) processes is empirical. Some
empirical trickling filter design criteria are described in this paper.
Benefits inherent to the trickling filter process (when compared with
activated sludge processes) include operational simplicity, resistance to
toxic and shock loads, and low energy requirements. However, trickling
filters are susceptible to nuisance conditions that are primarily caused by
macro fauna. Process mechanical components dedicated to minimizing the
accumulation of macro fauna such as filter flies, worms, and snail (shells)
are now standard. Unfortunately, information on the selection and design
of these process components is fragmented and has been poorly
documented. The trickling filter/solids contact process is the most
common TF/SG process. This paper summarizes state-of-the art design
and operational practice for the modem trickling filter. Water Environ.
Res., 83, 388 (2011).
KEYWORDS: trickling filter, trickling filter/suspended growth, trickling filter/solids contact, biofilm, nitrification, design, operation.
doi: 10.2175/106143010X12681059117210
Introduction
Until the 1950s, trickling filter design protocol was scattered
and empirical in nature. Then, during the 1950s and 1960s, the
Dow Chemical Company began experimentation with modular
synthetic media (Bryan, 1955). Numerous trickling filter process
studies were conducted during the same period (Eckenfelder,
1961; Galler and Gotaas, 1964; Germain, 1966; Schulze, 1960),
which led to the development of generally accepted design
criteria. After the U.S. Environmental Protection Agency issued
its definition of secondary treatment standards in the early 1970s,
the trickling filter process was regarded as being unable to
1, CH2M HILL, 9191 South Jamaica Street, Englewood, CO 80112; e-mail:
Glen.Daigger@CH2M.com.
2 CH2M HILL, Tampa, Florida.
388
Underdrain
FRP
Grating
AirpipeEffluent
N Influent
Figure 1-Typical trickling filter cross section and bioreactor components.
desired instantaneous flushing rate to the trickling filter. Figure 2
depicts both a modem hydraulically driven rotary distributor that
uses gates (controlled by variable frequency drive) that either
open or close distributor orifices to adjust rotational speed and an
electrically driven rotary distributor. Use of a variable-speed drive
and electronic controller allow for the more precise conrol of
distributor-arm speed. Electrically driven rotary distributors have
motorized units that control distributor speed independent of the
wastewater pumped flow.
Biofirm Carriers. Ideal trickling filter biofilm carriers, or
media, provide a high specific surface area, low cost, high durability,
Figure 2-Hydraulically propelled (left) and electrically driven rotary distributor (right).
May 2011
389
Material
Nominal Size
m
()
Bulk
Density
kghr 3
Spedfic Surface
Area
(m2/m3)
Void
Space
(%)
(lbs/) )b
Rock
1442
(90)
0.024 - 0.076
River
(0.08 -0.25)
Slag
62
(19)
50
0.076 -0.128
(0.25 - 0.42)
1600 (100)
24-45
(1.5 -2.8)
95
24-45
(1.5 -2.8)
95
0.185 o x 0.051 H
(7.3" o x 2" H)
27
(1.7)
98
(30)
95
46
(14)
60
Plastic'
Cross flow
PVC
Vertical flow
PVC
Random2
polypropylene
Notes:
1 Manufacturers of modular plastic media: BF Goodrich (formerly), American Surf-Pac, NSW, Munters, Brentwood Industries (currently),
Jaeger Environmental, and SPX Cooling.
2 Manufacturers of random plastic media: NSW Corp. (formerly) and Jaeger Environmental (currently).
a ibs/ft 3 x 16.02 = kg/m 3 .
2
3
b f92/ft3 X 3.281 = m /M .
------
...........
*'0
P4
Pip,
W WS
*W_
4W
* * .0
'4W 4W 410
6 g.NrWrQ:&
4*
1W
'0'
*
4%.Wo.
,j:W4:,O P
-b
A.
4W
V .4 P,
-1b
bd.
4k. 41k. Ow 4-
bdb I
Figure 3-Adjustable plastic stanchions and fiberglass-reinforced plastic grating on the concrete floor of a bolted
steel containment structure (left), and a high-density polyethylene mat used to support random synthetic
media (right).
sively. Pump intake screens are usually unnecessary because
recirculated flow is typically free of clogging solid materials.
Hydraulic computations are always necessary. Computations for
minimum flow are necessary to ensure adequate head to drive
hydraulically driven distributors; computations for maximum flow
indicate the head required to ensure adequate discharge capacity.
The net available head at the horizontal center line of the
distributor's arm and other points may be calculated by deducting
the following applicable losses from the available static head:
entrance loss, friction losses in the piping to the distributor, proper
allowance for minor head losses, head loss through distributor riser
and center port, friction loss in distributor arms, and velocity head of
discharge through nozzles necessary to start the hydraulically driven
rotary distributor. Trickling filter distribution head requirements are
set by the system manufacturer. Despite head loss due to the
trickling filter commonly being the greatest in a given WWTP,
power requirements for the process (including recirculation
pumping and auxiliary powered equipment) are typically significantly less than those for the activated sludge process.
Process Flow Sheets and Bloreactor Configuration
Trickling filter and combined TF/SG processes typically consist
of preliminary treatment (including screening and grit removal),
primary clarification, trickling filter, bioreactor, secondary
clarification, and disinfection unit processes. Trickling filter
recirculation methods influence the process flow. Generally, there
are two types of trickling filter recirculation. The first allows for
direct recirculation to the trickling filter and the second passes
flow through a primary clarifier. Four trickling filter process flow
diagrams, including both single- and two-stage trickling filters, are
shown in Figure 4. Combined TF/SG process flow sheets are
similar, but include a suspended growth reactor and return
activated sludge (or return sludge for the TF/SC process) stream
that is directed to the head of the suspended growth reactor.
Recirculation of trickling filter underflow or settled effluent
dilutes influent wastewater, dampens the influent organic loading
variability resulting from diurnal fluctuations, and maintains
required trickling filter hydraulic application rates. Clarifying
trickling filter effluent may enhance the performance of a
subsequent trickling filter in two-stage operation, but the designer
392
must ensure that the recirculation flow required for trickling filter
wetting and biofilm thickness control does not exceed the limiting
hydraulic loading rate for the intermediate clarifier. The design of
settling tanks in two-stage trickling filter systems is also affected
by the recirculation pattern.
Sludge wasting and recirculation streams affect the trickling.
filter process. Each of the process flow diagrams illustrated in
Figure 4 directs waste biological sludge (which is sometimes
referred to as humus in the trickling filter process) to the primary
clarifiers where it is co-settled with primary sludge prior to being
withdrawn from the system. Many facilities exist that withdraw
and thicken primary and biological sludge separately.
Bioreactor Classification. Trickling filters can be classified
as roughing, carbon oxidation, carbon oxidation and nitrification,
and tertiary nitrification. Table 2 summarizes characteristics of
each trickling filter. The performance ranges are associated with
average design condition. Single-day or average-week observations may be significantly greater.
Hydraulics. Recirculation and distributor operation are
important to good trickling filter performance and may be used
to achieve proper media wetting, flow distribution, biofilm
thickness control, and to prevent macro fauna accumulation.
Albertson and Eckenfelder (1984) postulated that the active
biofilm surface area in a trickling filter is dependent on biofilm
thickness and media configuration, and that active biofilm surface
area decreases with increasing biofilm thickness. The researchers
2 3
stated that for medium-density cross-flow media with a 98-m /m
specific surface area, a 4-mm increase in biofilm thickness would
cause a 12% reduction of active biofilm area (assuming that all the
media have been appropriately wetted). Poor trickling filter media
wetting results in reduced effluent water quality. In a study of
rotary distributor efficiency, Crine et al. (1990) found that the
wetted area-to-specific-surface-area ratio ranged from 0.2 to 0.6
with the lowest values for high-density random pack trickling
filter media. Many of the design formulations mentioned later in
this paper incorporate a term that allows for specific surface area
reduction due to distributor inefficiency in trickling filter media
wetting. The interrelationship of liquid residence time, dosing, and
media configuration on BOD 5 removal kinetics has not been
addressed, and additional research is required. Increasing the
Water Environment Research, Volume 83, Number 5
(A)
(B)
(c)
(D)
RS
vWSL
WS
I.
-
May 2011
Carbon Oxidizing
(cBODs removal)
Roughing
Vertical flow
Wastewater Source
Hydraulic Loading
m3 (gpM/ft2)
BOD5 and NH3 -N Load
k3.gd (lb BOD/d1000 f)
2
d (Ib NH3-N/d.1000 ft )
rn2.d
Conversion (%) or Effluent
Concentration (mg/L)
Macro Fauna
Depth, m (feet)
Carbon Oxidation
and Nitrification
Nitrification
Cross flow
Primary effluent
52.8-178.2 (0.9-2.9)
14.7-88.0 (0.25a-1.5)
14.7-88.0 (0.25a-l.5)
35.2-88.0 (0.6-1.5)
1.6-3.52 (100-220)
0.32-0.96 (20-60)
0.08-0.24 (5-15)
NA
NA
NA
0.2-1.0 (0.04-0.2)
0.5-2.4 (0.1-0.5)
50 to 75% filtered
cBOD5 conversion
No appreciable growth
0.91-6.10 (3-20)
20 to 30 mg/L
cBOD5 and TSSb
Beneficial
-s 12.2 (40)
0.5 to 3 mg/L as
NH3-Nb
Detrimental
-<12.2 (40)
Secondary effluent
Notes:
"8Applicable to shallow trickling filters; gpm/ft2 = gallons per minute per square foot of trickling filter plan area.
b Concentration remaining in the clarifier effluent stream
gpm/ft2 x 58.674 = m3/m2 -d (cubic meter per day per square meter of trickling filter plan area).
lb BOD,/d.1000 ft3 x 0.0160 = kg/d-m 3 (kilograms per day per cubic meter of media).
lb NH3-N/d-1000 ft2 x 4.88 = g/d.m 2 (grams per day per square meter of media).
mm
THL" 1,000 SK=
m.Na.od 1,440-ay
day
Where
SK = the Spfilkraft (mrn/pass);
THL = the total hydraulic load = (Qi, + QR)/A,
(m3/m 2/d);
Na = the number of distributor arms; and
coa = the rotational speed (rev/min).
Higher dosing rates are recommended for higher organic loading
rates to provide biofilm thickness control and controlled sloughing
of excess biomass. Besides a normal operating dosing rate, it may
be beneficial to periodically use a higher flushing dosing rate for 5
to 10% of a 24-hour operating period. The flushing dose will
operate at 6 to 15 times the normal operating dose. Albertson
(1995) and Parker et al. (1989) demonstrated that there is benefit
to biofilm thickness control in the trickling filter process. These
Table 3-Operating and flushing dosing rates for
distributors.
Total Organic
Load kglm 3/d
(lb BODs/d/1000 ft3)
<0.4 (< 25)
0.8 (50)
1.2 (75)
1.6(100)
2.4 (150)
3.2 (200)
Operating Dosing
Rate mm/pass
(inches/pass)
25-75
50-150
75-225
100-300
150-450
200-600
(1-3)
(2-6)
(3-9)
(4-12)
(6-18)
(8-24)
Flushing Dosing
Rate mm/pass
(inches/pass)
100 (4)
150 (6)
225 (9)
300(12)
450 (18)
600 (24)
Note: Actual values are site-specific and vary with media type.
394
Figure 5-Trickling filter aeration system: distribution pipes (left) and fans (right).
Natural Draft. Naturally occurring airflow results from a
difference in ambient air temperature and humidity outside and
inside the trickling filter. The temperature causes air to expand
when warmed or contract when cooled, and humidity differences
result in density differences. The result is an air-density gradient
throughout the trickling filter and an air front that rises or sinks
depending on the differential condition. This rising or sinking
action results in a continuous airflow through the bioreactor. If air
inside the trickling filter is colder than the ambient air, the air will
flow downward. Alternatively, if the ambient air is colder than the
air inside the trickling filter, air will flow upward. Schroeder and
Tchobanoglous (1976) state that upward airflow is the worst-case
scenario from a mass transfer perspective because the dissolved
oxygen driving force is lowest in the region of highest oxygen
demand (i.e., the top of the trickling filter).
Natural ventilation may become unreliable or inadequate in
meeting process air requirements when neutral temperature
gradients do not produce%air movement. Such conditions may be
daily or seasonal, and can lead to the development of anaerobic
layers inside the biofilms (near the growth medium) and poor
trickling filter performance. Modular plastic media trickling filters
that rely on natural draft to provide process oxygen for municipal
wastewater treatment should include the following design features:
Drains, channels, and pipes should be sufficiently sized to prevent
submergence greater than 50% of their cross-sectional area under
design hydraulic loading. Ventilating access ports with open-grating
covers should be installed at both ends of the central collection
channel. Large-diameter trickling filters typically have branch
channels (to collect the treated wastewater). These branches should
also include ventilating manholes or vent stacks installed at the
trickling filter periphery. According to Grady et al. (1999), the open
area of the slots in the top of the underdrain blocks should not be less
than 15% of the trickling filter area. One square meter gross area of
open grating .in ventilating manholes and vent stacks should be
provided for each 23 m2 of trickling filter area. Typically, 0.1 m2 of
ventilating area is provided for every 3 to 4.6 m of trickling filter
periphery, and 1 to 2 m2 of ventilation area in the underdrain area per
1000 m3 of trickling filter media. Another criterion for rock-media
trickling filters is the provision of a vent area at least equal to 15% of
the trickling filter cross-sectional area.
Mechanical Ventilation. A majority of new and improved
trickling filters use low-pressure fans to mechanically induce
May 2011
kg/lOOO m * d
0
' ]'
'
100
0 No Redrmatkton
~ID
RackutaIion
10
18
2.0
3.0
20
80
at
60
*0
40
40
20
2D
S I
0
w
10
20
30
40
BODsLoad,b/1000 muWady
1.0
4.0
Figure 6-Nitrification efficiency as a function of BODs load in rock-media combined carbon oxidation and
nitrification trickling filters (Left: U.S. EPA, 1975; Right: Parker and Richards, 1986).
equation, (3) Schulze (1960) equation, (4) Eckenfelder (1961)
formula, (5) Galler and Gotaas (1964), (6) Germain (1966) equation,
(7) Kincannon and Stover (1982), and (8) the Institution of Water
and Environmental Management (1988) formula. A pseudo
mechanistic model called the Logan trickling filter model (TRIFL)
(Logan et al. 1987a, 1987b) has been used to design modular
synthetic media trickling filter processes.
There is a general lack of models describing TF/SG systems.
Daigger et al. (1993) and Takdcs et al. (1996) presented a
mathematical description of TF/SG processes. The model of
Daigger et al. (1993) was developed to characterize nitrification
in TF/SG processes and was established based on performance
observations at the Buck Creek WWTP, Garland, Texas. The model
accounts for suspended growth reactor seeding with detached
biofilm fragments in the trickling filter effluent stream. The TF/SG
process effluent is calculated using the following equation:
(M~T
[~~~max~
+kd
+ [(
kd] . (NH3 .~
=0
(2)
Where
/i = the maximum nitrifier growth rate (lid),
MCRT = the mean cell residence time (d),
kd = the specific decay rate (m/d),
Ks = the ammonia-nitrogen half-saturation constant (mg/L),
NH3.EFF = the ammonia-nitrogen concentration in the
TF/SG process effluent stream (mg1L),
NH3.TFE = the ammonia-nitrogen concentration in the
trickling filter effluent stream (mg/L), and
NH3.pE = the ammonia-nitrogen concentration in the
trickling filter process influent stream
(mg/L).
The model of Daigger et al. (1993) has been independently
evaluated and demonstrated to be effective by Biesterfeld et al.
396
Reference
Media Type
XF
XF
XF
VF
VF
VF
JN(g/m 2/d)
140
140
140
891
891
891
2.3-3.2
1.6-2.8
1.7-2.3
0.9-1.2
1.2-1.8
1.1-1.2
11
13
15
7
18
17
to
to
to
to
to
to
20
20
20
13
22
20
1 Fully corrugated.
Note: XF = cross flow and VF
vertical flow.
(14 -g
(3)
Where
VOR = the volumetric oxidation rate (kg/m 3/d),
Si = the BOD 5 concentration in the influent stream
(g/m 3),
SNOx-N = the nitrate/nitrite-nitrogen concentration in the
effluent stream (g/m 3),
Q = the flowrate, including recirculation streams
(m 3/d), and
VM = the synthetic media volume (mi3 ).
Using eq 3, Daigger et al. (1994) reported the volumetric
oxidation rate for three combined carbon oxidation and nitrification trickling filter (with modular plastic media) processes in the
range of 0.4 to 1.3 kg/m 3/d.
Nitrifying Trickling Filters. Nitrifying trickling filters are a
reliable and cost-effective means for NH 3-N conversion. The
following design practices have been demonstrated in full-scale
application: (1)"use medium-density cross-flow media to optimize
hydraulic distribution and oxygenation, (2) use mechanical ventilation, (3) periodically alternate the lead NTF to avoid patchy biofilm
development in the lower reaches of the second-stage unit, (4) the
influent should be secondary effluent to minimize bacterial
competition for substrates inside the biofilm, (5) maximize wetting
efficiency to avoid the formation of dry spots, (6) dose the NTF at a
rate that will minimize the accumulation of macro fauna, and (7)
equalize NY 3 -N-laden supernatant from solids processing operations
to even out diurnal load variability (Parker et al., 1995; 1997). Benefits
to NTFs include low energy consumption, stability, operational
simplicity, and reduced sludge yield. The reduced sludge yield and
resulting low total suspended solids concentration in the NTF effluent
stream has led some units to be constructed without downstream
liquid-solids separation units. This is dependent on site-specific
May 2011
I N
KN S+SB,
(4)
397
Where
JN(S, T) = the ammonia-nitrogen flux at SB.N (g/m 2/d),
JN,v,
m(T) = the maximum ammonia-nitrogen flux at
temperature T (g/m 2/d) (=Jo
2 ,m.x(T)/4.3),
SB.N = the bulk-liquid ammonia-nitrogen concentration (g/m3 ),
KN = the half-saturation coefficient for ammonianitrogen (g N /m3) (= 1.0 g N /m 3, typical
value), and
T = the temperature (*C).
Based on a "line-fit" relationship, the flux at any depth in the
trickling filter can be calculated as
JN(Z, T)=JN(0, T)'e-k',.
(5)
-e-kz) =Si.,N-SB,I+KN
In (Si, IV (6)
\SB, NI
k-vh
When k = 0,
z--Nn
(7)
Where
a = the specific surface area (m2/m 3),
k = the empirical parameter describing nitrification
rate decrease (1/m) (= 0 to 0.16, typical 0.1),
vh = the hydraulic load (with or without recirculation) (m 3/ m 2 /d),
z = the NTF depth (m), and
N
N. i ---SO, N +-R-SB,
l+R
RS,N
(8)
SM~,N
Si., N S8, N
Where
Where
398
Jo 2,m.(T)
4.3
SB,N
KN+SB, N
(9)
Flshng Mode
SOcnm
TF
Efft~uwl
LEGEND
-
Figure 7-Nitrifying trickling filter operating modes for high-concentration un-dissociated aqueous ammonia dosing
(Lacan et al., 2000).
cross-flow media trickling filters. Initial zones of the Ryder Street
WWTP's aeration basins were improved to provide a zone for the
majority of the shells to settle. An automatic mechanism was
provided to remove the settled shells (Tekippe et al., 2006).
Combined Trickling Filter and Suspended
Growth Processes
Biological processes including both a trickling filter and
suspended growth reactor build on the known performance and
operating characteristics of the parent processes. When the
suspended growth reactor is used as a flocculating unit it is referred
to as the TF/SC process. All other TF/SG processes use the coupled
suspended growth reactor as an oxidizing unit. The activated biofilter
and biofilter/activated sludge processes, which circulate return
activated sludge over the trickling filter (making it a biofilter), are
not discussed as these process options are applicable only to wood
slat media, which is seldom used these days (Grady et al., 1999).
Trickling Filter/Solids Contact. A majority of organic
matter in municipal wastewater is colloidal or particulate material
(Levine et al., 1985, 1991; and Boltz and La Motta, 2007).
Trickling filters are poor bioflocculating reactors (Boltz et al.,
400
AERATED SOLIDS
CONTACT TANK
SECONDARY CLARIFIER
FLOCCULATOR
CENTER WELL
TREATED
EFFLUENT
Mode I
TRICKL ING
FILTER
PRIMAR EII1N
SECONDARY CLARIFIER
MIXED LIQUOR
PRIMAPV~
L#E
__
R TR
FLOCCULATOR____
NSLUDGE;
REAERATION TANKS
Mode II
TRICKL NG
FILTER
AERATED
AKFLOCCU
COTC SOLIDS
SECONDARY CLARIFIER
LATOR
C8ETER WELL
' TREATED
EFFLUENT,
PRIMAR.Y
UP I IEMIT______
WASTEE
ETU RN 'SLUDGE1
REAERATION TANKS
Mode 1II
Figure 8-Three modes of TF/SC process operation (after Parker and Merrill [1984]).
contact basin for colloidal and particulate organic matter
bioflocculation, and the oxidation of residual soluble organic
matter. Mode II relies exclusively on a return sludge aeration
chamber. The aerated return sludge is mixed with trickling filter
effluent for colloidal and particulate organic matter bioflocculation. Mode III makes use of both the solids contact basin and a
return sludge aeration tank. A typical TF/SC process operates as
mode I; however, as of 2001, more than one-half of the TF/SCbased WWTPs were operating as mode III (or had the operational
flexibility to operate as mode I or I1). It should be noted that
mode II is seldom used and is typically not recommended as it
does not have a solids contact basin and only a sludge reaeration
tank (Parker and Bratby, 2001). These operational modes are
illustrated in Figure 8.
If the solids contact basin follows a carbon oxidation and
nitrification trickling filter(s), autotrophic nitrifiers will detach
from the biofilm surface and, essentially, bioaugment the solids
contact basin biomass inventory. Despite the short duration solids
retention time characteristic of the solids contact basin, the
bioaugmentation will cause nitrification, which will exert
additional oxygen demand (i.e., increased airflow, blower size,
and air piping). In some instances, this may be desirable; however,
May 2011
Range
Common
0.7-0.9
0.1-2.0
20-75
18-22
45-120
15-30
1.0-2.0
1500-3000
500-1000
0.6-1.2
0.7
1.0
50
20
60
30
1.0
2000
800
0.8
Summary
The modem trickling filter typically includes the following
major components: (I) rotary distributors with speed control; (2)
modular plastic media (typically cross-flow media unless the
bioreactor is treating high-strength wastewater, which warrants
the use of vertical-flow media); (3) a mechanical aeration system
(that consists of air distribution piping and low-pressure fans); (4)
influent/recirculation pump station; and (5) covers that aid in the
uniform distribution of air and foul air containment (for odor
control). Covers may be equipped with sprinklers that can spray
washwater to cool the media during emergency shut down
periods. Trickling filter mechanics are poorly understood.
Consequently, there is a general lack of mechanistic mathematical
models and design approaches, and the design and operation of
trickling filter and TF/SG processes is empirical. Some empirical
trickling filter design criteria and semi-empirical NTF models
have been described in this paper. Benefits inherent to the
trickling filter process (when compared to activated sludge
processes) include operational simplicity, resistance to toxic and
shock loads, and low energy requirements. However, trickling
filters are susceptible to nuisance conditions that are primarily
caused by macro fauna. Process mechanical components dedicated to minimizing the accumulation of macro fauna such as filter
flies, worms, and snail (shells) are now standard. Unfortunately,
Range
Common
0.8-1.2
0.8-5.0
75-300
12-24
120-480
40-120
1.0-12.0
1500-6000
500-1000
0.6-1.2
1.0
1.0
150
18
240
90
8.0
3000
800
0.8
404
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