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Environmental Protection
Agency
Office of Water
Washington, D.C.
EPA 832-F-00-016
September 2000
Wastewater
Technology Fact Sheet
Package Plants
DESCRIPTION
Package plants are pre-manufactured treatment
facilities used to treat wastewater in small
communities or on individual properties.
According to manufacturers, package plants can be
designed to treat flows as low as 0.002 MGD or as
high as 0.5 MGD, although they more commonly
treat flows between 0.01 and 0.25 MGD (Metcalf
and Eddy, 1991).
The most common types of package plants are
extended aeration plants, sequencing batch reactors,
oxidation ditches, contact stabilization plants,
rotating biological contactors, and
physical/chemical processes (Metcalf and Eddy,
1991). This fact sheet focuses on the first three, all
of which are biological aeration processes.
Extended aeration plants
The extended aeration process is one modification
of the activated sludge process which provides
biological treatment for the removal of
biodegradable organic wastes under aerobic
conditions. Air may be supplied by mechanical or
diffused aeration to provide the oxygen required to
sustain the aerobic biological process. Mixing must
be provided by aeration or mechanical means to
maintain the microbial organisms in contact with
the dissolved organics. In addition, the pH must be
controlled to optimize the biological process and
essential nutrients must be present to facilitate
biological growth and the continuation of biological
degradation.
As depicted in Figure 1, wastewater enters the
treatment system and is typically screened
To Solids Handling,
Disposal, or
Beneficial Reuse
Digestion
Return Activated
Sludge (RAS)
Waste Activated
Sludge (WAS)
Influent
Effluent
Flow
Screening/
Grinding Equalization
(if required)
Extended
Aeration
Clarification
Disinfection
Digestion
Effluent
Influent
Screening/
Grinding
SBR
Disinfection
Mixed Fill
Influent
React Fill
Decant
Influent
Mixer
Decanter
Air On
Effluent
Discharge
Wasted Sludge
Settle
React
Air On
To Solids Handling,
Disposal, or Beneficial
Reuse
Waste Activated
Return Activated Sludge (RAS) Sludge (WAS)
Digestion
Influent
Effluent
Screening/
Grinding
Oxidation
Ditch
Clarification
Disinfection
Advantages
C Systems are well-suited for treating typical
domestic waste, have moderate energy
requirements, and work effectively under most
types of weather.
C Oxidation ditches provide an inexpensive
wastewater treatment option with both low
operation and maintenance costs and operational
needs.
C Systems can be used with or without clarifiers,
which affects flexibility and cost.
C Systems consistently provide high quality
effluent in terms of TSS, BOD, and ammonia
levels.
C Oxidation ditches have a relatively low sludge
yield, require a moderate amount of operator
skill, and are capable of handling shock and
hydraulic loadings.
Disadvantages
C Oxidation ditches can be noisy due to
mixer/aeration equipment, and tend to produce
odors when not operated correctly.
C Biological treatment is unable to treat highly
toxic waste streams.
C Systems have a relatively large footprint.
C Systems have less flexibility should regulations
for effluent requirements change.
DESIGN CRITERIA
Table 1 lists typical design parameters for extended
aeration plants, SBRS, and oxidation ditches.
TABLE 1 TYPICAL DESIGN
PARAMETERS FOR PACKAGE PLANTS
Extended
Aeration
SBR
Oxidation
Ditch
BOD5 loading
(F:M)
(lb BOD5/ lb
MLVSS)
0.05 - 0.15
0.05 0.30
0.05 - 0 30
Oxygen
Required
Avg. at 20E
EC
(lb/lb BOD5
applied)
2-3
2-3
2-3
Oxygen
Required
Peak at 20E
EC
(value x avg.
flow)
1.5 - 2.0
1.25 2.0
1.5 - 2.0
MLSS (mg/L)
3000 -6000
1500
-5000
3000 -6000
Detention Time
(hours)
18 - 36
16 36
18 - 36
Volumetric
Loading
(lb BOD5/d/ 103
cu ft)
10 - 25
5 - 15
5 - 30
Aldie WWTP
(monthly
average)
BOD (mg/L)
< 30 or <10
TSS (mg/L)
< 30 or <10
17
TP (mg/L)
< 2*
**
NH3-N (mg/L)
<2
**
Harrah WWTP
%
Removal
Effluent
BOD (mg/L)
10
98
TSS (mg/L)
10
98
NH3 (mg/L)
<1
97
0.6
Ocoee WWTP
With 2
Clarifier
With
Filter
%
Removal
Effluent
CBOD
(mg/L)
#10
> 97
4.8
TSS
(mg/L)
#10
> 97
0.32
TP
(mg/L)
NA
NA
N-NO3
(mg/L)
NA
NA
> 95
0.25
COSTS
Costs are site specific and generally depend on flow
rate, influent wastewater characteristics, effluent
discharge requirements, additional required
equipment, solids handling equipment, and other
site specific conditions. Manufacturers should be
contacted for specific cost information.
Extended aeration plants
As provided by Aeration Products, Inc., smaller
extended aeration package plants designed to treat
less than 0.02 MGD cost approximately $4 to $6
per gallon of water treated, based on capital costs.
For larger plants, capital costs will be
approximately between $2 to $2.50 per gallon of
wastewater treated. Maintenance processes for these
plants are labor-intensive and require semi-skilled
personnel, and are usually completed through
routine contract services.
Maintenance cost
averages $350 per year.
Table 5 provides the cost estimates for various
extended aeration packages. These costs include
the entire package plant, as well as a filtration unit.
TABLE 5 COST ESTIMATES FOR
EXTENDED AERATION
Flow (MGD)
Estimated Budget
Cost per Gallon ($)
0.015
9-11
0.04
1.0
1.3
Flow (MGD)
Estimated Budget
Cost per Gallon ($)
0.01
4-5
0.05
0.2
0.7
1.0
0.25
Flow Range
(MGD)
Budget Price
($)
Estimated
Budget Cost
per Gallon ($)
0 - 0.03
80,000
5.33
0.03 - 0.06
91,000
2.02
0.06 - 1.1
97,500
0.17
1.1 - 1.7
106,000
0.08
1.7 - 2.5
114,700
0.05
Oxidation Ditches
EPA 832-F-00-013
September 2000
Aerobic Treatment
EPA 832-F-00-031
September 2000
Other EPA Fact Sheets can be found at the
following web address:
http://www.epa.gov/owmitnet/mtbfact.htm
Oxidation ditches
Table 7 lists budget cost estimates for various sizes
of oxidation ditches. Operation and maintenance
costs for oxidation ditches are significantly lower
than other secondary treatment processes. In
comparison to other treatment technologies, energy
requirements are low, operator attention is minimal,
and chemical addition is not required.
1.
2.
3.
4.
REFERENCES
Other Related Fact Sheets
Sequencing Batch Reactors
EPA 932-F-99-073
September 1999
5.
Literature
6.
7.
8.
9.
10.
11.
12.
13.
ADDITIONAL INFORMATION
Extended aeration plants
For more information contact:
Ted Jackson (O&M)
Tim Coughlin (General questions)
Manager Engineering Programs
Aldie WWTP
P.O. Box 4000
Leesburg, VA 20177