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Industrial Wastewater Treatment by Activated Sludge

Book · January 2009

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Derin Orhon Fatos Germirli Babuna

Istanbul Technical University Istanbul Technical University
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Özlem Karahan Özgün

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Contents

Foreword xiii

1 INTRODUCTION
1.1 NEED FOR BIOLOGICAL TREATMENT 3
1.2 NEW PERSPECTIVES 5
1.2.1 Hazardous wastes and micropollutants 5
1.2.2 Innovative treatment 7

2 ENERGETICS AND STOICHIOMETRY OF

SUBSTRATE REMOVAL
2.1 ENERGETICS OF SUBSTRATE REMOVAL 11
2.1.1 Introduction 11
2.1.2 Biosynthesis 12
2.1.3 Energy generation and transformation 12
2.1.4 Nutritional classification of microorganisms 14
2.2 THE CONCEPT OF YIELD 16
2.2.1 Assessment of biomass 18
2.2.2 Assessment of substrate 20
2.2.2.1 The BOD parameter 20
2.2.2.2 The COD parameter 21
2.2.3 The definition of yield 22
2.2.4 Expression of yield for different model
components 26
vi Industrial Wastewater Treatment by Activated Sludge

2.2.4.1 VSS as a biomass parameter 26

2.2.4.2 VSS and BOD5 as biomass and
substrate parameters 27
2.3 PROCESS STOICHIOMETRY 30
2.3.1 System defined with biomass COD and
substrate COD 30
2.3.2 System defined with biomass VSS and
substrate COD 31
2.3.3 System defined with biomass VSS and
substrate BOD5 32
2.4 REFERENCES 35

3 MODELLING OF ORGANIC CARBON REMOVAL

3.1 PRINCIPLES OF MODELLING 37
3.2 MATRIX REPRESENTATION IN MODELLING 39
3.3 MASS BALANCE 44
3.4 CHARACTERIZATION OF ORGANIC CARBON 45
3.4.1 Basis for COD fractionation 45
3.4.2 Major COD fractions in wastewaters 46
3.5 MAJOR PROCESSES FOR ORGANIC CARBON
REMOVAL 49
3.5.1 Heterotrophic growth 50
3.5.2 Hydrolysis 52
3.5.3 Endogenous respiration 55
3.5.4 Generation of residual microbial products 58
3.5.4.1 Particulate residual microbial products 58
3.5.4.2 Soluble residual microbial products 59
3.6 MULTI-COMPONENT MODELLING OF ORGANIC
CARBON REMOVAL 61
3.6.1 The endogenous decay model 62
3.6.2 Death regeneration concept – ASM1 64
3.6.3 Substrate storage concept – ASM3 65
3.6.4 Modelling of complex industrial wastewaters –
case studies 67
3.6.4.1 Alternative models 67
3.6.4.2 Expanded COD fractionation 69
3.7 OPTIMUM SYSTEM DESIGN BASED ON
MODELLING – A CASE STUDY 71
3.8 REFERENCES 74
 Contents vii

4 MODELLING OF NUTRIENT REMOVAL

4.1 INTRODUCTION 79
4.2 BIOLOGICAL NITROGEN REMOVAL 80
4.2.1 Modelling of nitrification 81
4.2.1.1 Major nitrogen fractions 81
4.2.1.2 Stoichiometry of nitrification 83
4.2.1.3 Growth of autotrophs 85
4.2.1.4 Decay of autotrophs 86
4.2.1.5 Conversion of organic nitrogen
to ammonia 86
4.2.1.6 Process kinetics 87
4.2.2 Modelling of denitrification 89
4.2.2.1 Stoichiometry of denitrification 90
4.2.2.2 Growth of denitrifiers 93
4.2.2.3 Hydrolysis of the slowly
biodegradable COD 94
4.2.2.4 Decay of denitrifiers 95
4.2.2.5 Process kinetics 96
4.3 ENHANCED BIOLOGICAL PHOSPHORUS REMOVAL 96
4.4 REFERENCES 101

5 EXPERIMENTAL ASSESSMENT OF BIODEGRADATION

5.1 EXPERIMENTAL BASIS OF BIODEGRADATION 103
5.2 PRINCIPLES OF RESPIROMETRY 104
5.2.1 Concept of oxygen uptake rate (OUR) 104
5.2.2 Interpretation of respirometric data 109
5.3 ASSESSMENT OF BIODEGRADATION
CHARACTERISTICS 112
5.3.1 Assessment of inert fractions 113
5.3.1.1 Estimation of inert fractions
by batch experiments 115
5.3.1.2 Estimation of inert fractions
by respirometry 121
5.3.2 Assessment of biodegradable fractions 124
5.4 EXPERIMENTAL ASSESSMENT OF MODEL
COEFFICIENTS 126
5.4.1 Assessment of yield coefficient 126
5.4.1.1 Heterotrophic growth yield (YH) 126
5.4.1.2 Substrate storage yield (YSTO) 128
viii Industrial Wastewater Treatment by Activated Sludge

5.4.2 Assessment of endogenous decay

coefficient (bH) 130
5.4.3 Assessment of maximum heterotrophic
growth coefficient (m^ H ) 133
5.4.4 Assessment of kh and KX 134
5.5 ASSESSMENT OF INHIBITION AND TOXICITY 135
5.6 MODEL EVALUATION OF EXPERIMENTAL DATA 140
5.7 REFERENCES 146

6 MANAGEMENT OF INDUSTRIAL WASTEWATERS

6.1 NEW TRENDS IN INDUSTRIAL WASTEWATER
MANAGEMENT 151
6.2 BASIC TOOLS 153
6.2.1 Assessment at source – process and pollution
profiles 153
6.2.2 Conventional wastewater characterization 156
6.2.2.1 Assessment of significant pollutant
parameters 156
6.2.2.2 Reliability 158
6.2.2.3 Relationships between major
pollutant parameters 161
6.2.3 COD fractions of industrial wastewaters 165
6.3 RESOURCE MANAGEMENT 167
6.3.1 Material reclamation and reuse 167
6.3.2 Auxiliary chemicals 171
6.3.3 Xenobiotics 175
6.4 REFERENCES 176

7 CONTINUOUS FLOW ACTIVATED SLUDGE TECHNOLOGY

7.1 INTRODUCTION 181
7.2 BASIC PARAMETERS 182
7.2.1 The sludge age 182
7.2.2 The heterotrophic net yield coefficient 183
7.2.3 The food to microorganism ratio 185
7.2.4 The mean hydraulic retention time 186
7.3 ASSESSMENT OF SYSTEM FUNCTIONS 186
7.3.1 Reactor biomass 187
7.3.1.1 Active heterotrophic biomass 188
7.3.1.2 Inert particulate microbial products 189
 Contents ix

7.3.1.3 Inert particulate COD of influent

origin 190
7.3.1.4 Total biomass in the reactor 191
7.3.2 Excess sludge production 194
7.3.3 Effluent quality 199
7.3.4 Oxygen consumption 201
7.3.5 Recycle ratio 202
7.3.6 Nutrient balance 204
7.3.6.1 Nutrient removal 204
7.3.6.2 Nutrient requirements 206
7.4 PROCESS DESIGN FOR ORGANIC CARBON
REMOVAL 209
7.4.1 The concept of pre-treatment 209
7.4.2 Conceptual design procedure 211
7.5 BIOLOGICAL NITROGEN REMOVAL 219
7.5.1 Activated sludge design for nitrification 219
7.5.1.1 Aerobic sludge age 220
7.5.1.2 Nitrification parameters 221
7.5.1.3 Autotrophic biomass 222
7.5.1.4 Autotrophic oxygen demand 222
7.5.1.5 Alkalinity consumption 223
7.5.1.6 Design procedure 223
7.5.2 Activated sludge design for nitrogen removal 232
7.5.2.1 Process configurations 232
7.5.2.2 The overall sludge age 235
7.5.2.3 Denitrification potential 236
7.5.2.4 Oxygen requirement 237
7.5.2.5 System design for pre-denitrification 238
7.6 ENHANCED BIOLOGICAL PHOSPHORUS
REMOVAL 248
7.6.1 Factors affecting EBPR 249
7.6.1.1 Wastewater characteristics 249
7.6.1.2 System parameters 250
7.6.1.3 Environmental factors 250
7.6.2 System design for EBPR without nitrogen
removal 251
7.6.3 System design for EBPR with nitrogen removal 252
7.7 REFERENCES 253
x Industrial Wastewater Treatment by Activated Sludge

8 SEQUENCING BATCH REACTOR TECHNOLOGY

8.1 INTRODUCTION 257
8.1.1 Historical development 258
8.1.2 Current experience 259
8.1.3 Unified basis for modelling and design 260
8.2 PROCESS DESCRIPTION 262
8.2.1 Cycle frequency (m) 262
8.2.2 Nominal hydraulic retention time (HRT) 263
8.2.3 Duration of phases in a cycle 263
8.2.4 Duration of periods in a process phase 264
8.2.5 Number of tanks 264
8.2.6 Sludge retention time (SRT) 265
8.2.7 System modelling 265
8.3 ORGANIC CARBON REMOVAL 267
8.3.1 Basic principles 267
8.3.2 Specific design parameters 269
8.3.2.1 Effective sludge age 269
8.3.2.2 The net yield 270
8.3.2.3 Excess sludge production and
reactor biomass 270
8.3.2.4 Reactor volume 271
8.2.3.5 Design parameters for aeration 273
8.3.3 Process design 275
8.4 BIOLOGICAL NITROGEN REMOVAL 280
8.4.1 Nitrogen balance 281
8.4.2 Selection of process options 283
8.4.2.1 Pre-denitrification 284
8.4.2.2 Step feeding with dual anoxic
phases 284
8.4.2.3 Intermittent aeration 286
8.4.3 SBR design for pre-denitrification 286
8.5 ENHANCED BIOLOGICAL PHOSPHORUS
REMOVAL 296
8.5.1 EBPR without nitrogen removal 297
8.5.2 Simultaneous nitrogen and phosphorus
removal 298
8.6 REFERENCES 299
 Contents xi

9 MANAGEMENT OF TEXTILE WASTEWATERS

9.1 GENERAL ASPECTS 303
9.1.1 In-plant control measures applicable
to textile mills 305
9.1.1.1 Water conservation 305
9.1.1.2 Wastewater reclamation and reuse 305
9.1.1.3 Material reclamation 306
9.1.1.4 Substitution of chemicals 307
9.1.1.5 Process modifications 308
9.1.2 End-of-pipe treatment options applicable
to textile mills 309
9.1.3 Polluting sources and characteristics 310
9.2 A CASE ON WATER CONSERVATION AND
WASTEWATER RECOVERY AND REUSE 323
9.2.1 Characteristics of the plant operation 323
9.2.2 Adopted methodology for in-plant control 325
9.2.2.1 Description of the processes
and evaluation of the segregated
effluent characteristics 325
9.2.2.2 Technical basis of the feasibility
analysis 332
9.2.2.3 Appropriate treatment alternatives 336
9.2.2.4 Feasibility analysis 339
9.3 REFERENCES 345

10 MANAGEMENT OF TANNERY WASTEWATERS

10.1 GENERAL ASPECTS 349
10.2 THE TANNING PROCESS 350
10.2.1 Beamhouse operations 350
10.2.2 Tanyard processes 351
10.2.3 Post-tanning operations 352
10.2.4 Finishing operations 353
10.3 SUB-CATEGORIZATION IN TANNERY INDUSTRY 353
10.4 WASTEWATER GENERATION AND
CHARACTERISTICS 355
10.4.1 Process and pollution profiles 356
10.4.2 Conventional wastewater characterization 356
10.5 IN-PLANT CONTROL MEASURES FOR TANNERY
INDUSTRY 357
 xii Industrial Wastewater Treatment by Activated Sludge

10.5.1 Material substitution and reuse 361

10.5.2 Water use reduction 362
10.6 TREATMENT OF TANNERY EFFLUENTS 362
10.6.1 Treatment requirements 362
10.6.2 Treatment schemes 363
10.6.3 Pre-treatment applications 364
10.6.3.1 Case study-1 364
10.6.3.2 Case study-2 364
10.7 BIODEGRADABILITY CHARACTERISTICS 366
10.7.1 Biodegradability based characterization 366
10.7.2 Activated sludge modelling for tannery
effluents 368
10.8 REFERENCES 374

Index 377

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