Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology

Department of Chemical Engineering
Intramuros, Manila

CHE 521: INDUSTRIAL WASTE

MANAGEMENT AND CONTROL

AEROBIC AND
ANAEROBIC SLUDGE
DIGESTION

SUBMITTED BY:
ENRIQUEZ, MARIA ANGELYN C.
DE GUZMAN, KHAYE-ANNE F.
GARCIA, MARIA CECILLE G.
VELASCO, DIANA ISIS S.
BSCHE V

SUBMITTED TO:
ENGR. APRIL ANNE TIGUE

FEBRUARY 23, 2017

 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

TABLE OF CONTENTS

SLUDGE TREATMENT FLOW DIAGRAM 2

HEAT DRYING OF SLUDGE 11

FINAL DISPOSAL METHODS 16

AEROBIC DIGESTION 19

SAMPLE PROBLEM 23

AUTOTHERMAL THERMOPHILIC AEROBIC DIGESTION (ATAD) 27

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

SLUDGE TREATMENT FLOW DIAGRAM

Sludge Treatment describes the processes used to manage and dispose of sewage sludge
produced during sewage treatment. Sludge is mostly water with lesser amounts of solid material
removed from liquid sewage. Primary sludge includes settleable solids removed during primary
treatment in primary clarifiers. Secondary sludge separated in secondary clarifiers includes treated
sewage sludge from secondary treatment bioreactors.
Sludge treatment is focused on reducing sludge weight and volume to reduce disposal costs,
and on reducing potential health risks of disposal options. Water removal is the primary means of
weight and volume reduction, while pathogen destruction is frequently accomplished through heating
during thermophilic digestion, composting, or incineration. The choice of a sludge treatment method
depends on the volume of sludge generated, and comparison of treatment costs required for
available disposal options. Air-drying and composting may be attractive to rural communities, while
limited land availability may make aerobic digestion and mechanical dewatering preferable for cities,
and economies of scale may encourage energy recovery alternatives in metropolitan areas.
Energy may be recovered from sludge through methane gas production during anaerobic
digestion or through incineration of dried sludge, but energy yield is often insufficient to evaporate
sludge water content or to power blowers, pumps, or centrifuges required for dewatering. Coarse
primary solids and secondary sewage sludge may include toxic chemicals removed from liquid
sewage by sorption onto solid particles in clarifier sludge. Reducing sludge volume may increase the
concentration of some of these toxic chemicals in the sludge.

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Figure 1: Sludge Treatment Flow Diagram

Figure 2: Sludge Treatment processes and functions

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

1. Sludge Thickening (Blending)

The term thickening, herein, will be used to describe an increase in solids concentration,
whether it occurs as the objective of a separate process, or as a secondary effect of a process
provided essentially for a different purpose.

Thickening is often the first step in a sludge treatment process. Sludge from primary or
secondary clarifiers may be stirred (often after addition of clarifying agents) to form larger, more
rapidly settling aggregates. Primary sludge may be thickened to about 8 or 10 percent solids, while
secondary sludge may be thickened to about 4 percent solids. Thickeners often resemble a
clarifier with the addition of a stirring mechanism. Thickened sludge with less than ten percent
solids may receive additional sludge treatment while liquid thickener overflow is returned to the
sewage treatment process. Thickening Methods (Blending) are as follows:

Gravity
Flotation
Centrifugation

Table 1: Occurrence of thickening methods in solids processing

FREQUENCY OF USE AND RELATIVE
METHOD TYPE OF SOLIDS
SUCCESS
Gravity, co-settling Primary and waste Occasional use; may negatively impact the
in clarifier activated effectiveness of primary clarifier
Untreated primary sludge Commonly used with excellent results;
sometimes used with hydroclone degritting of
sludge. Can be odorous
Untreated primary and Often used. For small plants, generally
Gravity, thickening
waste-activated sludge satisfactory results with solids concentrations
in separate tank
in the range of 4 to 6 percent. For large plants,
results are marginal. Can be odorous in warm
weather
Waste activated sludge Seldom used; poor solids conc. (2-3%)
Untreated primary and Limited use; results similar to gravity
waste-activated sludge thickeners
Dissolved air
Waste activated sludge Commonly used, but use is decreasing
flotation
because of high operating cost; good results
(3.5-5% solids conc.)
Solid-bowl Waste activated sludge Often used in medium to large plants; good
centrifuge results (4-6% solids conc.)
Gravity belt Waste activated sludge Often used; good results (3-6% solids conc)
thickener

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Rotary-drum Waste activated sludge Limited use; good results (3-6+% solids conc.)
thickener

Recognition of the need to uniformly blend or combine the two principal types of wastewater
sludges (primary and excess activated), and to keep them combined in plants where joint processing
is practiced, is not as widespread as it should be. Normally, sludge blending can best be
accomplished in a separate sludge thickening process.

Application

Sludge thickening is achieved at all wastewater treatment plants in some manner in the primary
clarifiers, in sludge-digestion facilities, or in specially designed separate units. If separate units are
used, the recycled flows arc returned normally to the wastewater treatment facilities. In treatment
plants of less than 4000 m3/d capacity, separate sludge thickening is seldom practiced. In small
plants, gravity thickening is accomplished in the primary settling lank or in the sludge-digestion units,
or both. Ii larger treatment facilities, the additional costs of separate sludge thickening are often
justified by the improved control over the thickening process and the higher concentrations
attainable.

2. Sludge Stabilization (Reduction)

Sludge stabilization processes are aimed at converting raw (untreated) sludges into a less
offensive form with regard to odor, putrescibility rate, and pathogenic organism content. Major
types of processes are:

Anaerobic Digestion
Aerobic Digestion
Lime Treatment

Anaerobic and Aerobic Digestion

Involves the biological stabilization of sludge through partial conversion of putrescible
matter into liquid, dissolved solids, and gaseous by-products, with some destruction of
pathogens. These processes also reduce the amount of dry sludge solids. Consequently,
these processes result in stabilization and in solids reduction or conversion.
PROCESS DESCRIPTION COMMENTS
The biological conversion of Methane gas can be used beneficially
organic matter by fermentation in for the generation of heat or electricity.
Anaerobic
a heated reactor to produce The resulting biosolids may be suitable
Digestion
methane gas and carbon dioxide. for land application. The process
requires skilled operation as it may be

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Fermentation occurs in the suspectible to upsets and recovery is

absence of oxygen. slow.
The biological conversion of Process is much simpler to operate than
organic matter in the presence of an anaerobic digester, but no usable
Aerobic air (or oxygen), usually in an open- gas is produced. The process is energy-
Digestion tap tank. intensive because of the power
requirements necessary for mixing and
oxygen transfer

Lime Treatment
Lime Pretreatment
Lime pretreatment of liquid sludge requires more hint per unit weight of sludge
processed than that necessary for dewatering. The higher Lime dose is needed to attain the
required pH because of the chemical demand of the liquid. In addition, sufficient contact time
must be provided before dewatering so as to effect a high level of pathogen kill. The
recommended design objective is to maintain the pH above 12 for about 2 h to ensure
pathogen destruction (the minimum U.S. EPA criterion for lime stabilization),
Lime Posttreatment
In lime posttreatment, hydrated lime or quicklime is mixed with dewatered sludge in a
pugmill, paddle mixer, or screw conveyor to raise the pH of the mixture. Quicklime is preferred
because the exothermic reaction of quicklime and water can raise the temperature of the
mixture above 50C, sufficient to inactivate worm eggs.

Stabilization is not practiced at all wastewater treatment plants, but it is used by an

overwhelming majority of plants ranging in size from small to very large. In addition to the
health and aesthetic reasons cited, stabilization is used for volume reduction, production of
usable gas methane) and improving the dewaterability of sludge.

When designing a stabilization process it is important to consider the sludge quantity

to he treated, the integration of the stabilization process with the other treatment units and
the objectives of the stabilization process. The objectives of the stabilization process are often
affected by existing or pending regulations, if sludge is to be applied on land, pathogen
reduction has to be considered.

3. Sludge Conditioning

Sludge conditioning is pretreatment of a sludge to facilitate removal of water in a thickening

or dewatering process. Methods are as follows:
Chemical (Inorganic and Organic)

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Elutriation
Heat Treatment

Chemical Methods

Involve the use of inorganic or organic flocculants to promote formation of a porous, free-
draining cake structure. In this way, the flocculants improve sludge dewaterability, alter sludge
blanket properties, and improve solids capture. In dewatering, flocculants increase the degree of
solids capture both by destabilization and agglomeration of fine particles and facilitate cake
formation. The resultant cake becomes the true filter media. In thickening processes, the
flocculants promote more rapid phase separation, higher solids contents, and a greater degree of
capture.

Elutriarion

The process of washing the alkalinity out of anaerobically digested sludge to decrease the
demand for acidic chemical conditioners and to improve settling and dewatering characteristics.
When used with primary sludge, the process is cost-effective and does not create undesirable
effects. When elutriation is used in a plant which combines primary and excess activated sludge
prior to digestion, the mixed sludge fractionates during the elutriation process, producing a highly
polluted elutriate. The process has been criticized because this elutriate was bypassed into the
plant effluent at some plants. However, use of flocculants in elutriation can eliminate the problem
of the polluted elutnate.

Heat Treatment

Refers to the pressure cooking of sludges in such a manner that little sludge oxidation occurs.
Heat treatment is distinct from wet air oxidation which generally involves higher temperatures and
pressures, with air injection to promote a major degree of sludge oxidation.

4. Dewatering Methods

Any process which removes sufficient water from sludge so that its physical form is
changed from essentially that of a fluid to that of a damp solid, is a dewatering process.

Water content of sludge may be reduced by centrifugation, filtration, and/or evaporation to

reduce transportation costs of disposal, or to improve suitability for composting. Centrifugation may
be a preliminary step to reduce sludge volume for subsequent filtration or evaporation. Filtration
may occur through underdrains in a sand drying bed or as a separate mechanical process in a belt
filter press. Filtrate and centrate are typically returned to the sewage treatment process. After

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

dewatering sludge may be handled as a solid containing 50 to 75 percent water. Dewatered sludges
with higher moisture content are usually handled as liquids.

Methods used in dewatering are best described by the equipment employed and some major
types are:
Rotary vacuum filters
Centrifuges
Drying beds
Filter presses
Horizontal belt filters
Rotating cylindrical devices
Lagoons

DEWATERING METHOD DESCRIPTION

Solid-bowl centrifuge
Belt-filter press
Sludge is fed at a constant flowrate into the rotating
bowl, where it separates into a dense cake containing
the solids and a dilute stream called centrate. The
centrate contains fine, low-density solids and is returned
to the wastewater treatment system.
The sludge cake, which contains approximately 70
to 80 percent moisture, is discharged from the bowl by a
screw feedcr into a hopper or onto a conveyor belt.
Depending on the type of sludge, solids concentration in
the cake varies generally from 10 to 30 percent range.
Sludge-cake concentrations above 25 percent are
desirable for disposal by incineration or by hauling to a
sanitary landfill.

Are continuous feed dewatering devices that use

the principles of chemical conditioning, gravity drainage
and mechanically applied pressure to dewater sludge.

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Recessed-plate filter press

In a filter press, dewatering is achieved by forcing

the water from the sludge under high pressure.
Various types of filter presses have been used to
dewater sludge. The two types used most commonly are
the fixed-volume and variable volume recessed-plate
filter presses.

Sludge Drying Beds

Sludge drying beds are typically used to dewater

digested biosolids and settled sludge from plants using
the extended aeration activated-sludge treatment
process without prethickening. After drying, the solids
are removed and either disposed of in a landfill or used
as a soil conditioner.

Drying lagoons may be used as a substitute for drying

beds for the dewatering of digested sludge. Lagoons are
Sludge Lagoons not suitable for dewatering untreated sludges, limed
sludges, or sludges with a high-strength supernatant
because of their odor and nuisance potential. The
performance of lagoons, like that of drying beds, is
affected by climate; precipitation and low temperatures
inhibit dewatering. Lagoons are most applicable in areas
with high evaporation rates. Dewatering by subsurface
drainage and percolation is limited by increasingly
stringent environmental and groundwater regulations.
If a groundwater aquifer used for a potable water
supply underlies the lagoon site, it may be necessary to
line the lagoon or otherwise restrict significant
percolation.

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION
DEWATERING METHOD ADVANTAGES
Clean appearance, good
odor containment, fast
startup and shutdown
capabilities
Produces a relatively dry
Solid-bowl centrifuge
sludge cake
Low capital cost-to-capacity
ratio
High installed capacity to
building area rot in
Low energy requirements
Relatively low capital and
operating costs
Less complex mechanically
Belt-filter press and is easier to
High-pressure machines are
capable of producing very dry
cake
Minimal effort required for
system shutdown
Highest cakes soIids
concentration
Low suspended solids in
filtrate
Recessed-plate filter
press
Lowest capital cost method
where land is readily
available
Sludge Drying Beds Small amount of operator
attention and skid required
Low energy consumption
ENRIQUEZ, DE GUZMAN, GARCIA, & VELASCO
DISADVANTAGES
Scroll wear potentially a high
maintenance
problem
Requires grit removal and
possibly a sludge grinder in
the feed stream
Skilled maintenance
personnel required
Moderately high suspended
solids content in centrate
High odor potential
Requires sludge grinder in
feed stream
Very sensitive to incoming
sludge feed characteristics
Automatic operation
generally not advised
Batch operation
High equipment cost
High labor cost
Special support structure
requirements
Large floor area required
For equipment
Skilled maintenance
personnel required
Additional solids due to
large chemical addition
require disposal
Requires large area of land
Requires stabilized sludge
Design requires
consideration of climatic
effects
Sludge removal is Labor
intensive
10
 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Low to no chemical
consumption
Less sensitive to sludge
variability
Higher solids content than
mechanical methods
Low energy consumption
No chemical consumption
Organic matter is Further
stabilized
Sludge Lagoons Low capital cost where land
is ova [able
Least amount of skill
required For operation
Potential for odor and vector
problems
Potential for groundwater
pollution
More land-intensive than
mechanical methods
Appearance may be unsightly
Design requires
consideration of climatic
effects

Heat Drying of Sludge

Sludge drying processes involves the application

of heat to evaporate sufficient moisture and render the sludge dry to the touch and relatively free
flowing. It is a normal practice to conserve energy by dewatering the sludge prior to heat drying.
Principal types of dryers are:
A. FLASH DRYERS B. SPRAY DRYERS
C. ROTARY DRYERS

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

FLASH DRYERS
Sludge cakes in flash drying system are
usually pounded and grind in a cage mill or by
another route using atomized suspension
technique surrounded by the presence of hot
gases. The equipment design is made in such a
way that the particles will always stay in contact
with the turbulent hot gases so that maximum
heat transfer of moisture from sludge to the
gases can be achieved. Flash dryers can assist
in the removal of water up to 8 to 10 percent
and typical design usually has a cage mill that
receives input of wet sludge from feed system. Inside the cage, hot gases together with the
sludge are forced through a narrow ducting so that drying can occur and these will then be
transferred to a cyclone in order to remove the vapor solids. The dried sludge has commercial
application either as soil conditioner or it can also be incinerated in the furnace to retrieve
heat or steam.

ROTARY DRYERS
Rotary dryers are
normally used for drying
sludge and other
municipal industrial
waste solid. Basically
there are two different
systems for the rotary
dryers whereby in the
direct-heating method,
the material will always be in contact with hot gases while in indirect-heating dryers, steam is
used instead. The processed municipal solid wastes or the dried sludge can be later sold or
turned into burning fuel. Mechanically, plows can be installed to facilitate lifting and then
assist to agitate the material to achieve better drying operation.

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

SPRAY DRYERS
A spray dryer employs the use of a high-speed
centrifugal bowl to get a good separation
between the moisture and the sludge. Centrifugal
force serves to atomize the sludge into small tiny
particles with wide surface area and then spray
on top a drying chamber. Inside this
compartment, hot gases will be introduced so
that moisture can be removed efficiently.

SLUDGE REDUCTION
Simply pertains to process which primarily
yield a major reduction in the volatile sludge
solids. Principal methods of sludge reduction
are:
Incineration
Wet Air Oxidation
Pyrolysis

INCINERATION
Incineration can be used as means 1) to reduce the
volume of the dry sludge and 2) to produce a sterile non-
harmful residue that is free from volatile content. It provides
a safe alternative solution when facing with problems
dealing with land scarcity available for waste disposal and
apart from that it also helps to recover back some of the
energy used in the combustion process especially in large
treatment plants whereby there is a huge quantity of sludge
generation.

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Normally incineration can help to further reduce and concentrate the solid content
after the sludge thickening process and dewatering happened in the earlier processes have
reduced the moisture level to below 30%. With lower volume this helps to decrease the needs
and requirements later part on disposal at landfills. While operating cost and environmental
impacts related to air pollution will continue to pose major barrier, the advantages in the long
run is still very much worthwhile to be considered. Technologies used in sludge incineration
mainly focused on the use of heath incinerators and fluidized bed incinerators.
Hearth Incinerator

The hearth incinerator is the most widely used

technology in the world and the system usually consists of
multiple hearths stacked together into the furnace.
Incoming sludge is fed from the top and as it drops down
below, the rotating arm extending from a vertical shaft
placed in the middle will distribute the solids evenly
throughout the system. As the sludge travels and move
from one hearth to another, this will help to dispense the
sludge and expose new surface area for gas combustion
which is what makes it efficient compared to the other
methods. Flue gas will exit at another channel located at
the top of the furnace while the residue will collect at the
bottom and then taken out from the system.

Fluidized Bed Incinerator

Use of pressurized gas to create fluidized floating

sand bed is the key principle to this technology because
doing this will allow maximum contact with large surface
area available between the sludge and the gas for
incineration. Usually the control of air inlet is very
important because too much gas to sludge ratio will
translate to wastage and the same goes for sludge
entering into the system. Care must also be taken to
prevent the sludge from floating to the top of the bed
and overall, the system allows high utilization of energy
and thus leads to cost saving. Another advantage
regarding the use of the system is that start-up time can

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

also be reduced because once the process stops the whole bed will act as a heat sink that
traps the heat and prevent losses of energy.
WET AIR OXIDATION (WAO)
Aqueous wastes containing organic pollutants can be efficiently treated by wet air
oxidation (WAO), i.e., oxidation (or combustion) by molecular oxygen in the liquid phase, at
high temperature (200--325 C) and pressure (up to 175 bar). This method is suited to the
elimination of special aqueous wastes from the chemical industry as well as to the treatment
of domestic sludge. It is an enclosed process, with a limited interaction with the environment,
as opposed to incineration.

WAO has been demonstrated to oxidize organic compounds to CO2 and their innocuous end
products.
Carbon is oxidized to CO2; nitrogen is converted to NH3, NOX, or elemental nitrogen,
halogen and sulfur are converted to inorganic halides and sulfates. The higher the
temperature, the hIgher the extent of oxidation achieved, and the effluent contains mainly low
molecular weight oxygenated compounds, predominantly carboxylic acids.

PYROLYSIS
Pyrolysis is a thermochemical decomposition of organic material at elevated
temperatures in the absence of oxygen (or any halogen). It involves the simultaneous
change of chemical composition and physical phase, and is irreversible.
Pyrolysis is a type of thermolysis, and is most commonly observed in organic materials
exposed to high temperatures. It is one of the processes involved in charring wood, starting

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

at 200300 C (390570 F). It also occurs in fires where solid fuels are burning or when
vegetation comes into contact with lava in volcanic eruptions. In general, pyrolysis of organic
substances produces gas and liquid products and leaves a solid residue richer in carbon
content, char. Extreme pyrolysis, which leaves mostly carbon as the residue, is
called carbonization.

FINAL DISPOSAL METHODS

The solids that result from wastewater treatment may contain concentrated levels of
contaminants that were originally contained in the wastewater. A great deal of concern must
be directed to the proper disposal of these solids to protect environmental considerations.
Failure to do this may result in a mere shifting of the original pollutants in the waste
stream to the final disposal site where they may again become free to contaminate the
environment.
A more reasonable approach to ultimate solids disposal is to view the sludge as a
resource that can be recycled or reused.
All the sewage sludge produced at a treatment plant must be disposed of ultimately.
Treatment processes such as have been described may reduce its volume or so change its
character as to facilitate its disposal, but still leave a residue which in most cases must be
removed from the plant site.
Like the liquid effluent from the treatment plant, there are two broad methods for the
disposal of sludge - (1) disposal in water, and (2) disposal on land. This applies regardless of
whether or not the sludge is treated to facilitate or permit the selected method of disposal.

1. Disposal in Water

This is an economical but not common method because it

is contingent on the availability of bodies of water adequate
to permit it. At some seacoast cities, sludge either raw or
digested is pumped to barges and carried to sea to be
dumped in deep water far enough off shore to provide huge
dilution factors and prevent any ill effects along shore.
In the past few years there has been an increased problem of pollutional loads, well
above safe standards, affecting the south-shore beaches on Long Island, facilitating the
closing of the beaches to the public. Some of these pollutional loads have been attributed to
sludge deposits coming to shore form off-shore sludge barging operations.

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Where barged to sea, the value of some treatment such as thickening or digestion,
depends on the relative cost of the treatment and savings in cost by barging smaller volumes,
or the value of gas produced by digestion.

2. Disposal on Land

Under land disposal the following methods may be included :

- Burial.
- Fill.
- Application as fertilizer or soil conditioner.

Burial

This method is used principally for raw sludge, where, unless covered by earth, serious
odor nuisances are created. The sludge is run into trenches two to three feet wide and about
two feet deep. The raw sludge in the trenches should be covered by at least 12 inches of
earth. Where large areas of land are available, burial of raw sludge is probably the most
economical method of sludge disposal as it eliminates the costs of all sludge treatment
processes. It is, however, rarely used and even then as a temporary makeshift because of the
land area required. The sludge in the trenches may remain moist and malodorous for years
so that an area once used cannot be reused for the same purpose or for any other purpose
for a long period of time.

Fill
Use of sludge for fill is confined almost entirely to digested sludge which can be
exposed to the atmosphere without creating serious or widespread odor nuisances. The
sludge should be well digested without any appreciable amount of raw or undigested mixed
with it.

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Either wet or partially dewatered sludge, such as obtained from drying beds or vacuum
filters can be used to fill low areas. Where wet sludge is used the area becomes a sludge
lagoon.

When used as a method of disposal, the lagoon area is used only until filled, and then
abandoned. When used as a method of treatment, the sludge after some drying, is removed
for final disposal and the lagoon reused. Lagoons used for disposal are usually fairly deep.
Sludge is added in successive layers until the lagoon is completely filled. Final disposal of
digested sludge by lagoons is economical as it eliminates all dewatering treatments.

It is applicable, however, only where low waste areas are available on the plant site or
within reasonable piping distance. They are frequently used to supplement inadequate drying
bed facilities.

Dewatered digested sludge from drying beds and vacuum filters can be disposed of by
filling low areas at the plant site or hauled to similar areas elsewhere without creating
nuisances.

The ash from incinerators is usually disposed of by using it for fill. Where fill area is
available close to the incinerator, the ash can be made into a slurry with water when removed
from the ash hopper and pumped to the point of disposal. If the fill area is remote, the ash
should be sufficiently wet to suppress the dust and transported by truck or railroad cars to the
point of disposal.

Soil Conditioning or Fertilizer

Sewage sludge contains many elements essential to plant life, such as nitrogen,
phosphorous, potassium, and in addition, at least traces of minor nutrients which are
considered more or less indispensable for plant growth, such as boron, calcium, copper, iron,
magnesium, manganese, sulfur, and zinc. In fact, sometimes these trace elements are found
in concentrations, perhaps from industrial wastes, which may be detrimental. The sludge
humus, besides furnishing plant food, benefits the soil by increasing the water holding
capacity and improving the tilth, thus making possible the working of heavy soils into
satisfactory seed beds. It also reduces soil erosion.

3. COMPOSTING
Composting can be defined as the aerobic thermophilic decomposition of organic wastes to a
relatively stable humus. Decomposition results from the biological activity of microorganisms
which exist in the waste. A good compost could contain up to 2 percent nitrogen, about 1
percent phosphoric acid, and many trace elements. Its most valuable features, however, are
not its nutrient content, but its moisture retaining and humus forming properties.

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Many types of microorganisms are involved in converting the complex organic

compounds such as carbohydrates and proteins into simpler materials, but the bacteria,
actinomycetes, and fungi, predominate. These organisms function in a composting
environment that is optimized by copying the natural decomposition process of nature where,
with an adequate air supply, the organic solids are biochemically degraded to stable humus
and minerals.
Compost is generally considered as a material to be used in conjunction with fertilizer,
rather than as a replacement for fertilizer unless it is fortified with additional chemical
nutrients.
Compost benefits the soil by replenishing the humus, improving the soil structure, and
providing useful nutrients and minerals. It is particularly useful on old, depleted soils and soils
that are drought-sensitive. In horticulture applications, compost has been useful on heavy
soils as well as sandy and peat soil. It has been commonly applied to parks and gardens
because it increases the soil water absorbing capacity and improves the soil structure.

AEROBIC DIGESTION
Aerobic digestion may be used to treat (1) waste-activated sludge only, (2) mixtures of
waste-activated sludge or trickling-filter sludge and primary sludge, or (3) waste sludge from
extended aeration plants. Aerobic digestion has been used primarily in plants of a size less
than 0.2 m3/s, but in recent years the process has been employed in larger wastewater
treatment plants with capacities up to 2 m3/s.
Advantages and Disadvantages of Aerobic Digestion

Advantages
Volatile soilds reduction in a well-operated
aerobic digester is approximately equal to
that obtained anaerobically
Lower BOD concentrations in supernatant
liquor
Production of an odorless, humus-like,
biologically stable end product
Recovery of more of the basic fertilizer
values in the sludge
Operation is relatively easy and lower capital
cost
Disadvantages
High power cost is associated with supplying
the required oxygen
Digested biosolids produced have poorer
mechanical dewatering characteristics
The process is affected significantly by
temperature, location, tank geometry,
concentration of feed solids, type of mixing/
aeration device, and type of tank material

ENRIQUEZ, DE GUZMAN, GARCIA, & VELASCO 19

 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Suitability for digesting nutrient-rich Useful byproduct such as methane is not

biosolids. In cases where separate sludge recovered
digestion is considered, aerobic digestion of
biological sludge may be an attractive
application.

Process Description
Aerobic digestion is similar to the activated-sludge process. As the supply of available
substrate (food) is depleted, the microorganisms begin to consume their own protoplasm to
obtain energy for cell maintenance reactions. When energy is obtained from cell tissue the
microorganism are said to be in the endogenous phase. Cell tissue is oxidized aerobically to
carbon dioxide, water, and ammonia. In actuality, about only about 75 to 80 percent of the
cell tissue can be oxidized; the remaining 20 to 25 percent is composed of inert components
and organic compounds that are not biodegradable. The ammonia is subsequently oxidized
to nitrate as digestion proceeds. Nonbiodegradable volatile suspended solids will remain in
final product from aerobic digestion. Considering the biomass wasted to a digester and the
formula C5H7NO2 is representative for cell mass of a microorganism, the biochemical changes
in an aerobic digester can be described by the following equation:
Biomass destruction:
C5H7NO2 + 5O2 4CO2 + H2O + NH4HCO3 (1)
Nitrification of released ammonia nitrogen
NH4+ + 2O2 NO3 + 2H- + H2O (2)
Overall equation with complete nitrification
C5H7NO2 + 7O2 5CO2 + 3H2O + HNO3 (3)
Using nitrate nitrogen as electron acceptor (denitrification):
C5H7NO2 + 4NO3 + H2O NH4+ + 5HCO3- + 2NO2 (4)
With complete nitrification/ denitrification
2C5H7NO2 + 11.5O2 10CO2 + 7H2O + 2N2
(5)
If the dissolved oxygen is kept very low (less than 1 mg/L), however, nitrification will
not occur. In situations where the buffering capacity is insufficient resulting in pH depression
below 5.5m it may be necessary to install alkalinity feed equipment to maintain the desired
pH.

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Three proven variations of of the process are most commonly used: (1) conventional
aerobic digestion, (2) high-purity oxygen aerobic digestion, and (3) autothermal aerobic
digestion (ATAD). Aerobic digestion accomplished with air is the most commonly used process,
so it is considered in greater detail.
Conventional Air Aerobic Digestion
Factors that must be considered in designing conventional aerobic digesters include
temperature, solids reduction, tank volume, feed solids concentration, oxygen requirements,
energy requirements for mixing, and process operation.
Temperature. Because the majority of aerobic digesters are open tanks, digester liquid
temperatures are dependent on weather conditions and can fluctuate extensively. As with all
biological systems, lower temperatures retard the process while higher temperatures
accelerate it. In considering the temperature effects, heat losses should be minimized by
using concrete instead of steel tanks, placing the tanks below grade instead of above grade
or providing insulation for above-grade tanks, and using subsurface instead of surface
aeration. In extremely cold climates, consideration should be given to heating the sludge or
the air supply, covering the tanks, or both. The design should provide for the necessary degree
of sludge stabilization al the lowest expected liquid operating temperature, and should provide
the maximum oxygen requirements at the maximum expected liquid operating temperature.

Volatile Solids Reduction. A major objective of aerobic digestion is to reduce the mass of the
solids for disposal. This reduction js assumed to take place only with the biodegradable
content of the sludge, although there may be some destruction of the non-organics as well.
Volatile solids reductions ranging from 35 to 50 percent are achievable by aerobic digestion.
Optional criteria for meeting vector attraction requirements are (1) a minimum of 38 percent
reduction in volatile solids during biosolids treatment or (2) less than a specific oxygen uptake
rate (SOUR) of (1.5 mg O2/h)/g of total sludge solids a 200C. To produce well-stabilized
biosolids, atleast 550 degrees-days are recommended for the aerobic digestion system.

Tank Volume and Detention Time Requirements. The tank volume is governed by the
detention time necessary to achieve the desired volatile solids reduction. The digester tank
volume can be calculated by:
( + )
= 1 (6)
( + )

Where: V = volume of aerobic digester, m3

Qi = influent average flowrate to digester, m3/d
Xi = influent suspended solids, mg/L

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Y = fraction of the influent BOD of raw primary solids (expressed as decimals)

Si = influent BOD, mg/L
X = digester suspended solids, mg/L
Kd = reaction rate constant, d-1
Pv =volatile fraction of digester suspended solids (expressed as decimals)
SRT solids retention time, d

The term YS, can be neglected if primary sludge is not included in the
sludge load to the aerobic digester.

Feed Solids Concentration. The concentration of the feed solids digester is important in the
design and operation of the aerobic digester. If thickening precedes aerobic digestion, higher
feed solids concentrations will result in higher oxygen input levels per digester volume, longer
SRTs, smaller digester volume requirements, easier process control (less decanting in batch-
operated systems), and subsequently increased levels of volatile solids destruction. However,
feed solids concentrations greater than 3.5 to 4 percent may affect the ability or the mixing
and aeration system in maintaining well-mixed tank contents with adequate dissolved oxygen
levels necessary to support the biological process. At feed solids concentrations greater than
4 percent, the aeration equipment must be evaluated carefully to ensure adequate mixing
and aeration are achieved.

Oxygen Requirements. The oxygen requirements that must be satisfied during aerobic
digestion are those of the cell tissue and with mixed sludges, the BOD in the primary sludge.
The oxygen requirement for the complete oxidation of cell tissue (including nitrification), is
equal to 7 mole/mole of cells or about 2.3 kg/kg of cells. The oxygen requirement for the
complete oxidation of the BOD contained in primary sludge varies from about 1.6 to 1.9 kg/kg
destroyed. The oxygen residual should be maintained at 1 mg/L or above under all operating
conditions.

Energy Requirements for Mixing. Energy Requirements for Mixing. To ensure proper operation,
the contents of the aerobic digester should he well mixed. In large tanks, multiple mixing
devices should be installed to ensure good distribution of the mixing energy. Typical energy
requirements for mixing are given in Table 1434. In general, because of the large amount
of air that must be supplied to meet the oxygen requirement, adequate mixing should be
achieved; nevertheless, mixing power requirements should be checked, particularly when
feed solids concentrations are greater than 3.5 percent. If polymers are used in the thickening
process, especially for centrifuge thickening, a greater amount of unit energy may be required
for mixing. If fine-pore diffused air mixing is used, considerations for selecting the aeration
system should include limitations of feed solids concentration on achieving good mixing.
Recommendations on feed solids limitations should be obtained from manufacturers of

ENRIQUEZ, DE GUZMAN, GARCIA, & VELASCO 22

 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

aeration equipment. In addition, the potential for diffuser for diffuser fouling should be
evaluated, especially of the process operation requires decanting.

Table 1. Design Criteria for Aerobic Digesters

SAMPLE PROBLEM
Design an aerobic digester to treat the waste sludge produced by the activated-
sludge treatment plant. Assume that the following conditions apply:

Given:
1. The amount of waste sludge to be digested is 2057 kg TSS/d.
2. The minimum and maximum liquid temperatures 15oC are for winter operation and
25oC for summer operation.
3. The system must achieve 40 percent volatile solids reduction in the winter.
4. The minimum SRT for winter conditions is 60 d.
5. Waste sludge is concentrated to 3 percent, using a gravity-belt thickener.
6. The specific gravity of the waste sludge is 1.03.
7. Sludge concentration in the digester is 70 percent of the incoming thickened sludge
concentration.
8. The reaction rate coefficient kd is 0.06 d-1 at 15oC.
9. Volatile fraction of digester TSS is 0.80.

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

10. No primary solids are included in the influent to the digester.

11. Diffused-air mixing is used.
12. Air temperature in diffused air system = 20oC.

Solution:

1. Compute the volatile solids reduction for winter conditions using Fig. 14-31 and
compute the percent volatile solids reduction summer (maximum) conditions.

a. For winter conditions, degree-days from Fig. 1431 are 15oC x 60 d = 900
degree-days. From Fig. 14-31, the volatile solids reduction is 45%, which exceeds
the winter requirements of 40%.
In order to meet the pathogen reduction requirements, the SRT must 60 d;
Volume
therefore, the required volume is 66.6 m3/d x 60 d = 3996 m3.
b. During the summer, the liquid temperature will be 250C, and degree-days will be
25 x 60 = 1500. From Fig. 14-31, the volatile solids reduction in the summer will
be 5O%.

2. Compute the winter and summer volatile solids reduction based on a total mass of
volatile suspended solids

Total mass of VSS (VSSM) = (0.8)(2057 kg/d) = 1646 kg/d

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

a. Winter: 1646 x 0.45 = 741 kg VSSM reduced/d

b. Summer: 1646 x 0.50 = 823 kg VSSM reduced/d

3. Determine oxygen requirements (see Table 1434 for oxygen requirements).

Oxygen requirements = 2.3 kg O2/kg VSS
a. Winter: 741 x 2.3 = 1704 kg O2/d
b. Summer: 724 x 2.3 = 1893 kg O2/d

4. Compute the volume of air required per d at standard conditions. For the density of
air, see Appendix B-l.

1704 3
a. Winter: = = 6100
(1.204 3 )(0.232)

1893 3
b. Summer: = = 6777
(1.204 3 )(0.232)

Assuming an oxygen transfer efficiency of 10%, air flowrates are

6100 3 / 3
Winter: = (0.10)(1440 /) = 42.4

6777 3 / 3
Summer: = (0.10)(1440 ) = 47.1

5. Compute the volume of sludge to be disposed of per day using Eq. (142).

2057 3
= = 66.6

(103 3 ) (1.03)(0.03)

6. Determine the volume of the aerobic digester (winter conditions govern) using Eq.
(14-22).

3
(66.6 ) (30,000 3 )

= = 1318 3
0.06 1
(30,000 3 ) [(0.7) ( ) (0.80) + ( )]
60

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

7. Compute the air requirement per m3 of digester volume.

47.1 3 / 3
= = 0.036
1318 3 3

8. Check the mixing requirements. Because the air requirement computed in Step 7 is
within the range of values given in Table 1434, adequate mixing should prevail.

Comment: The above example is based on a single-stage aerobic digester. If a two-stage or

more digester were used, a significant reduction in tank volume is possible. In a multistage
arrangement, the air distribution between tanks would vary based on the expected demand
as most of the volatile solids reduction will occur In the first stage where the biomass is most
active.

Dual Digestion

A dual digestion consists of two stages which are aerobic thermophilic digestion and
mesophilic anaerobic digestion, respectively. High-purity oxygen is also used in the first stage.
In an aerobic digester, the residence time typically ranges from 18 to 24 hours and the reactor
temperature ranges from 55 to 65oC. For an anaerobic digester the typical residence time is
10 days.

Advantages of using aerobic thermophilic digestion in dual digestion:

(1) increased of pathogen reduction
(2) improved overall volatile solids reduction
(3) increased methane gas generation in the anaerobic digester
(4) less organic material in and odors produced by the stabilized sludge
(5) equivalent volatile solids reduction can be achieved in one-third less tankage than a
single-stage anaerobic digester.

Prior hydrolysis in the aerobic reactor results in increased degradation during subsequent
anaerobic digestion and gas production. Approximately 1020% of the volatile solids is
liquefied in the aerobic digester, while COD reduction is less than 5%. Provisions for foam
suppression and odor control are required (Roediger and Vivoaa. 1998).

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

AUTOTHERMAL THERMOPHILIC AEROBIC DIGESTION (ATAD)

Autothermal thermophilic aerobic digestion (ATAD) represents a variation of both

conventional and high-purity oxygen aerobic digestion. In the ATAD process, the feed sludge
is generally prethickened and the reactors are insulated to conserve the heat produced from
the oxidation of volatile solids during the digestion process. Thermophilic operating
temperatures (generally in the range of 55-700C) can be achieved without heat input by using
the heat released by the exothermic microbial oxidation process. Approximately 20,000 kJ of
heat is produced per kg of volatile solids destroyed. Because supplemental heat is not
provided (other than the heat introduced by aeration and mixing), the process is termed
autothermal.

Within the ATAD reactor, sufficient levels of oxygen, volatile solids, and mixing allow
aerobic microbes to degrade organic matter to carbon dioxide, water, and nitrogen
byproducts.

Major Advantages of ATAD:

(1) Retention times required to achieve a given suspended solids reduction are
decreased significantly (to about 5-6 d) to achieve volatile solids reductions of 30-
50%, similar to conventional aerobic digestion;
(2) Simplicity of operation;
(3) Greater reduction of bacteria and viruses are achieved as compared to mesophilic
anaerobic digestion; and
(4) When the reactor is well mixed and maintained at 550C and above, pathogenic
viruses, bacteria, viable helminth ova, and other parasites can be reduced to below
detectable levels, thus meeting the pathogen reduction requirements Of Class A
biosolids.

Disadvantages of ATAD:
(1) Objectionable odor are formed,
(2) Poor dewatering characteristics of ATAD biosolids, and
(3) Lack of nitrification.

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Figure 3. Authothermal thermophilic aerobic digester (ATAD) system (a) system schematic,
and (b) reactor mechanism

Process Theory. The biochemical conditions in thermophilic aerobic digesters differ

significantly from conventional aerobic digesters. Because of the high operating
temperatures, nitrification is inhibited and aerobic destruction of volatile solids occurs as
described by Eq. (3) without the subsequent reactions described by (4) through (6).
Additionally, most, if not all, ATAD systems may be operating under microaerobic conditions
where oxygen demand exceeds oxygen supply (Stensel and Coleman,2000). Under
microaerobic conditions, proteinaceous cellular material will undergo fermentation where
protein is represented as peptone as by Eq (7) (Chu and Mavinic. 1998):

4CH2NH2COOH + 4H2O 3CH3COOH + 2(NH4)2CO3

(7)

Both Eqs. (1) and (7) result in the of ammonia that reacts with water and carbon dioxide
to form ammonium bicarbonate and ammonium carbonate to increase alkalinity. Because
nitrification occur, the pH in the ATAD system will typically range from 8 to 9, higher than in

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

conventional aerobic digesters. Ammonia-nitrogen produced will be present in the off-gas and
in solution with concentrations of several hundred mg/L in each. Most of the ammonia
nitrogen will be returned to the liquid process in side streams from the odor-control and
dewatering facilities. The acetic acid (or acetate) produced by the fermentation of proteins is
one of the volatile fatty acids. Acetic acid will be oxidized subsequently in the presence of
sufficient dissolved oxygen as described by Eq (8):

CH3COOH + 202 2CO22H20 (8)

Process Design. ATAD systems are designed to have short hydraulic retention times within
insulated reactors (see Fig. 1b). As long as the ATAD system is well mixed and sufficient
oxygen is provided, the temperature in the reactor will rise until a balance occurs; i.e., the
heat lost equals the heat input from the exothermic reaction and mechanical energy input.
The temperature will continue to rise until the process becomes oxygen mass-transfer-
limited.

ATAD systems must be designed to:

(1) transfer sufficient oxygen to meet the high demand of the reactors, and
(2) supply the required oxygen while minimizing the latent heat lost in the exhaust air.

Factors affecting oxygen transfer:

(1) high temperatures (that would reduce the oxygen transfer coefficient, )
(2) foam layer and low dissolved oxygen levels (that might increase oxygen transfer)

Common types of equipment used for:

Introducing oxygen into reactors: Aspirating aerators - hollow-shaft propeller or
turbine aerators, pumped venturi aspirators, and jet aspirators.
Managing and controlling foam: mechanical foam cutters, spray systems

Table 2. Typical Design Considerations for ATAD System

System Component Design Consideration

Thickening or blending facilities may be required to maintain an
Prethickening system
influent COD to the ATAD reactor greater than 40 g/L
Number of reactors; a minimum of two enclosed insulated reactors
Reactors in series should be provide and equipped with mixing, aeration,
and foam control equipment

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Fine screening, 6- to 12-mm (0.25 to 0.5-in.) clear openings, of

Screening raw wastewater or solids feed stream should be provided for the
removal of inert materials, plastics, and rags
Continuous or batch processing is acceptable, except batch
processing
Feed cycle
provides greater assurance in meeting Class A pathogen reduction
requirements
Foam suppression is required to ensure effective oxygen transfer
Foam control and enhanced biological activity. Freeboard of 0.5 to 1.0 m (1.65
to 3.3 ft) is recommended.
Postprocess cooling is necessary to achieve solids consolidation
and to enhance dewaterability. A minimum of 20 d detention may
Post-ATAD storage/
be necessary unless heat exchangers are used for cooling the
dewatering processed biosolids.

Because of high temperatures in the ATAD system, relatively high

of ammonia ore released. Reduced sulfur also result, which can
include sulfide, carbonyl sulfide, methyl mercaptan, ethyl
Odor control
mercaptan, dimethyl sulfide, and dimethyl disulfide Odor-control
systems may include wet scrubbers, biofilters, or a combination of
both.
Liquid sidestreams from odor-control and dewatering systems,
when returned to the liquid processing system, may contain
Sidestreams
constituents that could affect process performance unless
accounted for or treated separately.
Adapted in part from WEF (1998) and Stensel and Coleman (2000).

Table 3. Typical Design Criteria for ATAD

US. Customary units SI Units

Parameter
Range Typical Range Typical
Reactor:
HRT 4 30 d 68 4 30 d 68

Volumetric loading 320 530 lb/103

5 8.3 kg/m3-d
TSS, 40-60 g/L ft3-d
3.2 4.2 kg/m3-
VSS, 25 g/L-min 200 260 lb/103
d
ft3-d
Temperature

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 AEROBIC AND ANAEROBIC SLUDGE DIGESTION

Stage 1 35 50 0C 40 35 50 0C 40
Stage 2 50 70 C0 55 50 70 0C 55
Aeration and
mixing:
Mixer type Aspirating Aspirating
Oxygen transfer 4.4 lb
2 kg O2/kWh
efficiency O2/kWh
Energy
5 6.4 hp/103 ft3 130 -170 W/m3
Requirement
Adapted in part, from Stensel and Coleman (2000).

Process Control. The basic requirement that needs to be demonstrated is (1) fecal coliform
densities are less than 1O00 MPN/g of total solids (dry weight basis), or (2) Salmonella sp.
bacteria concentrations are below detection limits of 3 MPN/4 g of total solids (dry weight
basis).

For compliance with these pathogen regulations for Class A biosolids:

Batch basis for the withdrawal and feeding of the sludge to reactors
Two or more reactors in a series configuration are typically used
ATAD pumping system is designed to withdraw and feed the daily amount of sludge in
1h or less
Reactor is then isolated for the remaining 23h each day at minimum temperature of
550C.

High-Purity Oxygen Digestion. It is a modification of the aerobic digestion process in which

high-purity oxygen is used in lieu of air. Resultant biosolids are similar to biosolids from
conventional aerobic digestion as well as the recycle flow. Influent sludge concentrations vary
from 2 to 4 percent. This is particularly applicable in cold weather climates because of its
relative insensitivity to changes in ambient air due to the increased rate of biological activity
and the exothermal nature of the process.
This uses open tanks wherein oxygen is to the liquid sludge by a special diffuser that produces
minute oxygen bubbles. The bubbles dissolve before reaching the air-liquid interface.

The major disadvantage of high-purity oxygen aerobic digestion is the increased

cost associated oxygen generation. As a result, high-purity oxygen aerobic digestion is cost-
effective generally when used in conjunction with the high-purity oxygen activated-sludge
system. Also, neutralization may be required to offset the reduced buffering capacity of
the system.

ENRIQUEZ, DE GUZMAN, GARCIA, & VELASCO 31