AD Applications to Sewage Sludge

Reference: MetCalf & Eddy, Inc., Wastewater Engineering, 5th ed., McGraw Hill, 2014
 Raw Sewage

Bar Rack

Pretreatment Grit Chamber

Primary Equalization
Treatment Basin

Pump
Secondary
Primary Settling Treatment Tertiary
Treatment
Biological
Treatment

Secondary
Settling

Advanced Waste Treatment

e.g., Nutrient removal

Receiving Water Body

Typical Activated Sludge Treatment Plant
Preliminary Primary Activated sludge system
treatment settling
Secondary
Screens Grit Chamber Aeration basin settling
Outlet

Biogas

Anaerobic
digester

Energy
production
from biogas
Typical Trickling Filter Treatment Plant
Sludge Treatment and Disposal

Sludge dewatering
 Importance of Anaerobic Digestion in
Municipal Wastewater Treatment
Domestic waste
Anaerobic digester
(100)
(60)
Bar screen, Comminutor Preliminary treatment
Grit chamber etc.
(100)

Primary sludge
Primary sedimentation
(35)

(65)
Activated sludge,
Trickling filter, Aerobic treatment
RBC, etc. Oxidized to CO (30)
2
Converted to sludge (35)

Secondary sludge
Secondary sedimentation (25)
Effluent (10)
Importance of solids retention time

(From Parkin and Owen, 1986)

From Parkin and Owen, 1986)
(From Parkin and Owen, 1986)
 VS Destruction based on Volatility
Volatile Solids (VS/TS) Fixed Solids (FS/TS)
% %

Untreated Sludge (Xf) 70 30

Digested Sludge (Xd) 50 50

Assume: 1. Fixed solid remain the same

2. Use 1 Kg of dry untreated sludge for calculations
3. X Kg of VS after digestion

FS of digested sludge, 50% = [ (0.3 Kg) * 100 ] / (0.3 Kg + X Kg)

X = 0.3 Kg

=> Weight of digested solids = FS + VS = 0.3 + 0.3 = 0.6 Kg

 Cont..
Total Solids (TS) Volatile Solids (VS) Fixed Solids (FS)
Kg Kg Kg

Untreated Sludge 1.0 0.7 0.3

Digested Sludge 0.6 0.3 0.3

TS destruction, % = (1.0 0.6) / 1.0 * 100 = 40%

VS destruction, % = (0.7 0.3) / 0.7 * 100 = 57.1%

VS % Destruction Equations:
Xf - Xd 0.7 - 0.5
VS, % = ( ---------------- ) x 100 = --------------------- = 57.1%
Xf Xf Xd 0.7 0.7 x 0.5
 STUDIES WITH MUNICIPAL WASTEWATER SLUDGE

Determination of optimal HRT/SRTs and other operating

conditions

Evaluation of performance characteristics at optimal SRTs

Destruction of indicator organisms
Volatile solids removal
Biogas production

Full-scale performance
Data from published sources as well as information
collected from the involved treatment plants
 CHARACTERISTICS OF PRIMARY AND
WASTE ACTIVATED SLUDGES

PS WAS
Total Solids (%) 3.0 5.0 3.7 4.2
Volatile Solids (%) 2.9 3.2 3.0 3.3
Fecal Coliforms (MPN/g TS) 106 - 109 105 107
Alkalinity (mg/L as CaCO3) 800 - 1500 1000 - 1700
VFA (mg/L as Acetic Acid) 900 - 1400 400 - 650
pH 5.0 6.5 5.5 6.5
 DIGESTER SIZING AND HEAT REQUIREMENT EXAMPLE
A. Digester Sizing Example

1. Assumptions
a) Domestic wastewater
Flow = 40,000 m3/d
BOD5 = 240mg/L
SS = 260 mg/L
VSS = 210 mg/L
BOD exertion rate, k = 0.11 d-1, base 10
b) Removal efficiencies of primary treatment
BOD5 = 35%
SS = 50%
c) Primary sludge TS = 5%
d) Secondary treatment
Effluent BOD5 = 5 mg/L
O2 consumption in secondary removal = 0.5 g/g BOD5, removed
Secondary sludge production = 1.0 TS g/g BOD5, removed (85% VS)
f) Secondary sludge TS (after thickening) = 3.5%
g) SS = TS, VSS=VS for sludge
h) Digestion HRT (SRT) = 20 days
i) VS destruction in digesters = 50%
j) BOD destruction in digesters = 90%
k) Biogas CH4 content: 60%
2. Calculate Sludge Production
a) Primary sludge production
(0.26kgSS / m3 )(0.5)(40, 000m3 / d )
Vprim 3
104 m3
/d
(50kgTS / m )
b)Secondary sludge production
BOD5, removed = (1-0.35)(0.24 kg/m3) 0.005 kg/m3 = 0.151 kg/m3
(0.151kgBOD / m3 )(1kgTS /1kgBOD)(40, 000m3 / d )
Vsec 173m3
/d
(35kgTS / m3 )
c) Total sludge production=104 m3/d +173 m3/d = 277 m3/d

3. Calculate Digester Working Volume

Vworking = (277 m3/d) x (20 days) = 5,540 m3

4. Dimensions of Cylindrical Sludge Digesters

Assume 3 units
Vol. of each: 5,540 m3 /3 = 1,847 m3
Assume height as 10 m (typically 7.5 to 15 m)
Area = 1880 m3/10 m = 185 m
Diameter = (185 * 4 / 3.14)0.5 = 15.3 m (typically < 38 m)

*** Construct 4 identical digesters with each 10 m deep and 15.3 m diameter
for headspace and safety
5. Check VS Load (kg/m3/day)
VS = [(0.21 kg VSS/m3)(40,000 m3/d)(0.5) +
(0.151 kg BOD5, removed/m3)(1 kg TS/kg BOD5)(0.85 kg VS/kg TS)
x (40,000 m3/d)]
[5,540 m3]
= [(4,200+5,134) kg/day] [5540 m3] = 1.68 kg/m3/day
(Normal range = 1.6-4.8 kg/m3/day )

6. TS concentration in digester
TS, kg/day = volatile solids fed (0.5) + fixed solid fed
= (4,200 + 5,134) (0.5) +
(4,200)(260-210)/210) + (5,134)[(1-0.85)/0.85]
= 6,573 kg/day
TS, kg/m3 = (6,573 kg/day) (20 days) / (5,540 m3) = 23.7 kg/m3
TS, % = 2.37%

7. Calculate Supernatant Wasting with Internal Thickening to 5% TS:

Flow rate @ 5% TS =(6,537 kg/day)/(50 kg TS/m3) =131 m3/d
Supernatant wasting = (Total sludge) (Thickened sludge) = 277-131 = 146 m3/d
8. Calculate CH4 Production:

BODL 1
1.392
BOD5 1 (1/10 0.11(5)
)
BODL loss in secondary treatment = loss by aeration + effluent
Loss by aeration = BODL, removed x O2 consumption
= (0.151 kg BOD5/m3) (0.5 g/g BOD5, removed)
= 0.0755 kg BODL/m3
Loss by effluent = (0.005 kg BODL/m3) (1.392 kg BODL/kg BOD5)
= 0.00696 kg BODL/m3
CH4, m3/day = (0.35 m3/kg BODL)x(40,000 m3/d)
x [(0.24 kg BOD5/m3)(1.392 kg BODL/kg BOD5)
-(0.0755+0.00696 kg BODL/m3)] x(0.9)
= 3,171 m3/d

9. Total gas production

Assume CH4 = 60%
Total Gas = 3,171/0.6 = 5,285 m3/d
To: MJ kcal
10. Energy generation from biogas
multiple by
From:
(CH4=8,560kcal/ m3)
MJ 1 238.8
(3,171 m3/d) (8,560kcal/ m3)
= (27.1 Gcal/d) (4.1868 GJ/Gcal) / (86400 sec/d) kcal 4.1868E-3 1
= 1.32E-3 GJ/sec = 1.32 MW
B. Digester Heat requirement

1. Equation for heat loss from digesters

QLoss = U A (T2 T1)
Where:
Q = Heat flow, W
U = Overall coefficient of heat transfer, W/m2/C
A = Area of surface, m2
T1, T2 = Boundary temps., C

2. Equation for heat requirement to raise Raw Sludge to digester temperature

Qraising= m C (T1-T2)
m: sludge, kg/d
C:specific heat of sludge
T1, T2 = Boundary temps., C

3. Assumptions
Raw sludge temp. = 10oC
Digestion temp. = 35C
Temp. of earth = 4C
Outside Temp. = -10C
Specific heat of sludge = 1 kcal/kg/C (same with water at TS<10%, normally)
Specific gravity of sludge = 1.03
U for roof, floor, and wall =1.42, 0.57, and 1.82 W/m2/C, respectively
4. Heat to compensate heat loss
Calculate surface area of the four (4) digesters:
Roof areas = (4)(3.14)(15.3)2 / (4) = 735 m2
Floor areas = same as roof = 754 m2
Wall areas = (4)(3.14)(15.3)(10) = 1,923 m2
Calculate surface area of the four (4) digesters:
Qroof = (1.42 W/m2/C) (735 m2) (35C-(-10C)) = 46.966 kW
Qfloor = (0.57 W/m2/C) (735 m2) (35C-4C) = 12.987 kW
Qwall = (1.82 W/m2/C) (1,923 m2) (35C-(-10C)) = 157.494 kW

5. Heat requirement for Raw Sludge heating

Q= m C (Tdigester-Traw sludge)
(m: sludge, kg/d, C:specific heat of sludge)
= (277 m3/d) (1030 kg/m3) (1 kcal/kg/C) (4.186 kJ/kcal) (35C-10C)
= (29,588,000 kJ/d) / (86,400 sec/d)
= 345.575 kW

6. Total Heat requirement = 345.575 + 46.966 + 12.987 + 157.494 = 0.56 MW

* Compare with Heat from biogas, 1.32 MW

Anaerobic Treatment Processes
for Dilute Waste
 Anaerobic Process for Dilute Waste (TS<5%)

Low rate anaerobic reactors High rate anaerobic reactors

Anaerobic lagoon Anaerobic contact process

Anaerobic filter (AF)

Septic tank
Upflow anaerobic slugde
Blanket (UASB)
Imhoff tank Fluidized bed Reactor

Standard rate Hybrid reactor: UASB/AF

anaerobic digester
Slurry type bioreactor. Temperature,
mixing, SRT or other environmental
conditions are not regulated except
. digester. Loading
standard rate anaerobic
of 1-2 kg COD/m3-day.
Anaerobic Sequencing Batch
Reactor (ASBR)
Able to retain very high concentration of
active biomass in the reactor. Thus
extremely high SRT could be maintained
irrespective of HRT. Load 5-20 kg COD/m3-d
COD removal efficiency : 80-90% .
 Anaerobic Lagoon
Suspended growth continuously/batch fed system
Typical depth of lagoons range from 4 to 10 m
Lagoons can be covered to collect methane and reduce
odors, but can also remain uncovered.
Lagoons often used in slaughterhouse industry
1-d detention time sufficent for 50-70% BOD reduction
(mainly through settling of suspended solids)
Typical detention times of 1 50 days
Temperature dependent
Ambient Temperature Covered Anaerobic Lagoon
Ambient Temperature Covered Anaerobic Lagoon
Plug Flow Anaerobic Digester
AA Dairy, Candor, NY

TS content: 11 13%
 Traditional AD vs. High-Rate AD

Adequate Mixing
Temperature Control
Effective Way to Retain Biomass
- Separate solids retention time (SRT) from hydraulic
retention time (HRT). SRT >> HRT
SRT = mass of solids in system (g) / daily solids wasted rate
(g/day)
 Anaerobic Contact Process (ACP)
Anaerobic contact process is essentially an anaerobic activated
sludge process. It consists of a completely mixed reactor followed
by a settling tank. The settled biomass is recycled back to the
reactor. Hence ACP is able to maintain high concentration of
biomass in the reactor and thus high SRT irrespective of HRT.
Degassifier allows the removal of biogas bubbles (CO2, CH4)
attached to sludge which may otherwise float to the surface. .

Biogas Biogas
Settling tank

Influent Effluent
Degassifier
Completely mixed
reactor

Recycled sludge
Waste sludge
 Cont..

ACP was initially developed for the treatment of dilute

wastewater such as meat packing plant which had tendency
to form a settleable flocs. ACP is suitable for the treatment
of wastewater containing suspended solids which render
the microorganisms to attach and form settleable flocs.

The biomass concentration in the reactor ranges from 4-6 g/L

with maximum concentration as high as 25-30 g/L depending
on settleability of sludge. The loading rate ranges from 0.5
5 kg COD/m3-day. The required SRT could be maintained by
controlling the recycle rate similar to activated sludge process.
Anaerobic Filter
biogas

effluent

recirculation
media

recirculation
flow distribution pump

influent
 Anaerobic Filter
Anaerobic filter: Young and McCarty in the late 1960s
to treat dilute soluble organic wastes.
The filter was filled with rocks similar to the trickling filter.
Wastewater distributed across the bottom and the flow was in
the upward direction through the bed of rocks
Whole filter submerged completely
Anaerobic microorganisms accumulate within voids of media
(rocks or other plastic media)
The media retain or hold the active biomass within the filter
The non-attached biomass within the interstices forms a bigger
flocs of granular shape due to rising gas bubble/liquid
Non-attached biomass contributes significantly to waste treatment
 Cont..

Originally, rocks were employed as packing medium in

anaerobic filter. But due to very low void volume (40-50%),
serious clogging problem was witnessed. Now, many
synthetic packing media made up of plastics, ceramic tiles
of different configuration have been used in anaerobic filters.
The void volume in these media ranges from 85-95 %.
Moreover, these media provide high specific surface area
typically 100 m2/m3 or above which enhance biofilm growth.
 Cont..

Since anaerobic filter is able to retain high biomass, long SRT

could be maintained. Typically HRT varies from 0.5 4 days &
the loading rates varies from 5 - 15 kg COD/m3-day. Biomass
wastage is generally not needed and hydrodynamic conditions
play important role in biomass retention within the void space .

Down Flow Anaerobic Filter (DAF)

Down flow anaerobic filter is similar to trickling filter in
operation. DAF is closer to fixed film reactor as loosely held
biomass/sludge within the void spaces is potentially washed
out of reactor. The specific surface area of media is quite
important in DAF than Upflow AF. There is less clogging
problem and wastewater with some SS concentration can be
treated using DAF.
 Multi-fed Upflow Anaerobic Filter (MUAF)

Waste is fed through several points along the depth of filter.

Such feeding strategy has unique benefits:

1. Homogeneity in biomass distribution

Effluent
2. Maintenance of completely mixed
regime thus preventing short -
circuiting and accumulation of VFA.

Wastewater
Inlet points
3. Uniform substrate concentration within
the reactor and prevent heavy biomass
growth at bottom thus avoids clogging
4. Effective utilization of whole filter bed
 Upflow Anaerobic Sludge Blanket Reactor

Effluent

biogas

Diameter 0.5 5 mm
Influent
UASB biogas
effluent
three weir
phase
separator effluent

baffles granule
gas bubble
floc particle
gas
bubbles

granular flocculent
sludge sludge

recirculation
pump
distribution
baffle

influent
 original
granule
diameter

Upflow in UASB reactor

Upflow in UASB reactor

buoyancy
force
gravitational
force
gas
bubbles

upflow velocity
 Upflow Anaerobic Sludge Blanket (UASB)

UASB was developed in 1970s by Lettinga in the Netherlands.

UASB is essentially a suspended growth system in which proper
hydraulic and organic loading rate is maintained in order to
facilitate the dense biomass aggregation known as granulation.
The size of granules is about 1-5 mm diameter. Since granules
are bigger in size and heavier, they will settle down and retain
within the reactor. The concentration of biomass in the reactor
may become as high as 50 g/L. Thus a very high SRT can be
achieved even at very low HRT of 4 hours.
The granules consist of hydrolytic bacteria, acidogen/acetogens
and methanogens. Complex organic degrading granules show
layered structure with a surface layer of hydrolytic/fermentative
Acidogens. A mid-layer comprising of syntrophic colonies and
an interior with acetogenic methanogens.
 Anaerobic granular sludge
Physical: dense compact biofilms
high settleability (30-80 m/h)
high mechanical strength

Microbial: balanced microbial community

syntrophic partners closely associated
high methanogenic activity
(0.5 to 2.0 g COD/g VSS.d)
protection from toxic shock
Acetate as Substrate Sucrose as Substrate
(Methanosaeta) (mixed culture)
granular flocculent dispersed
 Cont..

Loading rate:
15-30 kg COD/m3-day

Important components of UASB:

1. Influent flow distributor
2. Sludge blanket
3. Solid-liquid-gas separator
4. Effluent collector
Type of waste treatable by UASB:
Alcohol, bakers yeast, bakery, brewery, candy, canneries,
chocolate, citric acid, coffee, dairy & cheese, distillery, Domestic
sewage, fermentation, fruit juice, fructose, landfill leachate,
paper & pulp, pharmaceutical, potato processing, rubber,sewage
sludge liquor, slaughter house, soft drinks, starch (barley, corn,
wheat), sugar processing, vegetable & fruit, yeast, etc.
 Important considerations in UASB operation

Initial seeding of some well digested anaerobic sludge could

be used. The seed occupies 30-50% of total reactor volume.
Minimum seeding is 10% of the reactor volume.

Provide optimum pH, and enough alkalinity.

Supplement nutrients and trace metals if needed. Provide
N & P at a rate of COD: N:P of 400:7:1 (conservative estimate).

Addition of Ca2+ at 200 mg/L promotes granulation. Ca2+ conc.

higher than 600 mg/L may form CaCO3 crystals which may
allow methanogens to adhere to and then become washed out
of the system.
UASB (the Netherlands)
Expanded Granular Sludge Bed (EGSB) Reactor

USAB EGSB
(Triple Baffle Internal Settler)
Gist Brocades (yeast, pharmaceuticals) The Netherlands
Internal Circulation Reactor (IC)

Brewery (Switzerland), 20 m height

Anaerobic Sequential Batch Reactor (ASBR)

BIOGAS RECYCLE
BIOGAS

SUPERNAT ANT

DECANT
PORT S
SET T LED
BIOMASS

SET T LE DECANT FEED REACT

EFFLUENT FEED
 Anaerobic Sequencing Batch Reactor
(ASBR)
Batch fed suspended growth system.
ASBR relies on internal clarification for solids retention by allowing
biomass to settle.
Four distinct phases Feed React Settle - Decant
Four phases compose one cycle.
Cycle lengths vary from 3 to 24 hours.
Good system for wastes with high solids.
Studies show that intermittent mixing is as effective as continuous
mixing
Low F/M at end of react cycle allows low gas production during
settle phase.
By lowering settle time selection of better settling granules can occur.
Granulation is key to system (see UASB).
 Expanded Bed Reactor (EBR)
Expanded bed reactor is an attached growth system with
some suspended biomass.
The biomass gets attached on bio-carriers such as sand,
GAC, pulverized polyvinyl chloride, shredded tyre beads
etc.
The bio-carriers are expanded by the upflow velocity of
influent wastewater and recirculated effluent.
In expanded bed reactor, sufficient upflow velocity is
maintained to expand the bed by 15-30%.
The expanded bed reactor has less clogging problem and
better substrate diffusion within the biofilm.
Biocarriers are partly supported by fluid flow and partly
by contact with adjacent biocarriers and they tend to
remain same relative position within the bed.
 Fluidized Bed Reactor (FBR)
FBR is similar to EBR in terms of configuration. But FBR is
truly fixed film reactor as suspended biomass is washedout
due to high upflow velocity.

The bed expansion is 25-300% of the settled bed volume

which requires much higher upflow velocity (10-25 m/hr).

The bio-carriers are supported entirely by the upflow

liquid velocity and therefore able to move freely in the bed.

The fluidized bed reactor is free from clogging problem

short-circuiting and better substrate diffusion within the
biofilm.
 Hybrid system: UASB/AF

Hybrid system incorporates both granular sludge blanket

(bottom) and anaerobic filter (top). Such approach
prevents wash-out of biomass from the reactor. Further
additional treatment at the top bed due to the retention of
sludge granules that escaped from the bottom sludge bed.
UASB reactor facing a chronic sludge wash-out problem can
be retrofitted using this approach.

Hybrid system may be any combination or two types of

reactor