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Design and operation of

UASB for treatment of


domestic wastewater

Jules B. van Lier


Wageningen University /
Lettinga Associates Foundation (LeAF)

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

General lay-out of an anaerobic WWT plant


biogas use

Post treatment
influent effluent
UASB
screening grit chamber - polishing pond
- Trickling filter
- RBC
- etc.

water reuse
sludge sludge drying bed
biogas

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

1
The UASB Reactor
Distribution box
gas
collector biogas
wastewater

treated
water
effluent
gutter biogas

settling zone aperture

baffle

sludge blanket

sludge bed

feed
inlet
deflector sludge
beam withdrawal

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Internal view 1200 m3 UASB, Cali, Colombia

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

2
Design Criteria for the UASB Reactor
Distribution box
number
biogas
wastewater
upflow velocity
Treated water
effluent
gutter
biogas loading rate
detention time
gas
settling zone collector aperture velocity

angle
baffle

sludge blanket
concentration
sludge bed
concentration
feed
inlet
deflector sludge
density beam withdrawal
minimum SRT angle

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Critical Parameters for Design of a UASB Reactor


Vieira et al, 1986

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

3
SRT as prime design criterion:
SRT is directly linked to the amount of viable, active biomass in the
system:

SRT = X / (dX/dt),
with X = concentration of viable biomass (e.g.methanogens ).

SRT is determined by:

- incoming suspended solids


- solids digestion in the reactor
- filtering capacity sludge bed (upflow velocities + sludge characteristics)
- growth of new sludge
- sludge retention in the settler (upflow velocities)
- withdrawal of excess sludge

SRTmin. ≥ 3 * Td (doubling time) of critical biomass (e.g. methanogens)


WAGENINGEN UNIVERSITY Lettinga Associates
Sub-department of Environmental Technology
Foundation

Required SRT for Hydrolysis in Reactor

180
SRT for stabilized sludge [days]

160

140

120

100

80

60

40

20

10 15 20 25 30 35 40 45

Temperature [°C]

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

4
Impact of Reduced Hydrolysis

At low temperatures (< 15ºC) and/or strong temperature


fluctuations between summer (25ºC) and winter (15ºC), the single
step UASB design needs reconsideration:

Limited Hydrolysis

Accumulation of particulate
organic matter

Deterioration of the reactor performance

Low removal efficiency

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Conventional Design of
Single Stage UASB reactors

Temperature.: > 20 °C
COD infl.: < 1000 mg/l
SS-influent: < 500 mg/l

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

5
Assessment of the size of a UASB Reactor
Relationship between pollution strength and reactor volume

2000
Vr (m3)

Normal COD- range


for domestic sewage
1500
Assumptions:
Θ min = 4 h
Q = 250 m3 · h-1
rv= 15 kg COD · m-3 · d-1
1000
hydraulic load = 6 m3 · m- 3 · d-1

500 Vr = Θ · Q Vr = (c · Q) · rv -1

0
0 1 2 3 4 5
-3
c (kg COD · m )
WAGENINGEN UNIVERSITY Lettinga Associates
Sub-department of Environmental Technology
Foundation

Feed Inlet System

The feed inlet distribution system is a crucial part of the reactor

It is important to accomplish optimal contact between sludge and


waste water, i.e.

to prevent channelling of the waste water through the sludge bed


to avoid the formation of dead corners in the reactor

The danger of channelling will be bigger at low gas production rates


(less than 1 m3 · m-3 · day -1)

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

6
Number of Inlet Points
Rough guidelines for the number of inlet points required in UASB reactors
treating mainly soluble waste waters

Type of sludge Loading rate Area (m2 )


(kg COD . m-3 . day -1) per feed inlet point

<1 0.5 - 1
Dense flocculant sludge
1-2 1-2
(>40 kg DS/m3)
>2 2-3

Medium thick flocculant sludge <1 - 2 1-2

(20 - 40 kg DS/m3) >3 2-5

<2 0.5
Granular sludge 2-4 1-2
>4 >2
WAGENINGEN UNIVERSITY Lettinga Associates
Sub-department of Environmental Technology
Foundation

Drawing of UASB for Sewage Treatment

Influent

Effluent

Influent

Gas

Feed inlet pipes

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

7
Feed Distribution Systems

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Design of a Rectangular Inlet Box

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

8
Full-scale anaerobic sewage treatment
plant, Bucaramanga, Colombia
2nd influent
distribution box

Gas outlet

effluent

3rd influent
distribution boxes

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Full-scale anaerobic sewage treatment


plant, Bucaramanga, Colombia

Concrete plates for


the GSS-device
Problem: leakage!

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

9
Polyester Circular Distribution Box

Clogged inlet pipe


Maintenance (declogging)

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Feed Inlet Tubes

Warning: poor design!


Long inlet tubes on bottom may
Sludge discharge pipes cause clogging

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

10
Other Aspects of the Feed Distribution System

The use of specific nozzles or perforated inlet pipes placed


at the bottom of the reactor

Intermittent supply of the feed

Every feed-inlet system should be easy to clean

A conically shaped reactor bottom, or a multi-cone reactor


bottom is attractive

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Main Objectives the Gas Liquid Solids Separator (GLSS) Device

separation of the biogas and discharging this from the reactor


to prevent as efficiently as possible the wash out of viable bacterial
matter
to enable the sludge to slide back into the digester compartment
to serve as a kind of barrier (stopper) for rapid excessive
expansions of a sludge blanket (which is mainly composed of
flocculant sludge) into the settler
to provide a polishing effect
to prevent the wash out of floating granular sludge

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

11
Problems with the GLSS Device

foaming (when proteins and/or fats are present)


Remedy:
install anti-foam sprayers
scum layer formation (particularly in presence of fats) in the settler or
gas bowl
Remedies:
do not place a baffle in front of the effluent launder (will lead to high effluent SS)
install a skimmer in the settler compartment
remove the scum layer from the gas bowl
install agitators for settling down and/or mixing-up floating matter with active sludge

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Tentative Guidelines for the Design of the GLSS Device (1)

The slope of the settler bottom (i.e. the inclined wall of the gas
collector) should be between 45-60o

The surface area of the apertures between the gas collectors


should be 15-20% of the reactor surface area.

The height of the gas collector should be between 1.5-2 m at


reactor heights of 5-7 m.

To facilitate the release and collection of gas bubbles and to


combat scum layer formation, a liquid-gas interface should be
maintained in the gas collector.

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

12
Tentative Guidelines for the Design of the GLSS Device (2)

To avoid up-flowing gas bubbles to enter the settler compartment,


the overlap of the baffles installed beneath the apertures should
be 10-20 cm.

Generally, scum layer baffles should be installed in front of the


effluent weirs.

The diameter of the gas exhaust pipes should be sufficient to


guarantee the easy removal of the biogas from the gas collection
cap, particularly in case of foaming.

In the upper part of the gas cap, anti-foam spray nozzles should
be installed in the case the treatment of the waste water is
accompanied with heavy foaming.

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

UASB design for industrial WW (Biopaq process)

Increase of the (critical) aparture


width by placement of 3 small
settlers above each other

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

13
UASB design for industrial WW (Biothane process)

Effect of “mammoth flow”:


indirect increase of aperture

gas

sludge

water

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Settler Equipped With Tiltable Plate Settler (TPS)

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

14
Tiltable plate settlers (TPS’s) in Biotim UASB-reactors

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Cross-flow TPS of Biotim

gas

sludge

water

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

15
Sludge Discharge

Discharge excess sludge: equip the reactor with sludge


discharge pipes 1) nearby the bottom, 2) halfway and 3)
approximately half a meter beneath the GSS device.

Assessment of the total quantity of sludge in the reactor: install a

number (5 or 6) of valves over the height of the reactor to be able to


make a sludge profile.

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Auxiliary Equipment Requirements (1)

measurement and registration of the influent flow

measurement/control of temperature and pH

measurement and registration of the reactor temperature and pH


(particularly in the lower part of the reactor)

measurement and registration of the gas production rate and the


gas composition with respect to the CO2 content and the H2S
content

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

16
Auxiliary Equipment Requirements (2)

Tentative requirements:

installations for the addition of essential nutrients (N, P and S),


alkalinity, and trace elements

heat exchangers (also desirable for occasionally heating the


reactor content in the case accumulated biodegradable solids
have to be removed from the sludge)

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Corrosion of Construction Materials (1)

1. The biggest problem takes place above the water level:


Air oxygen oxidizes H2S to sulphate. This can lead to very
low local pH conditions. This will affect both concrete and
steel.

2. Corrosion also occurs under the water level:


Corrosion by dissolved CO2: CaO from concrete will
dissolve as H2 CO3 is present.

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

17
Corrosion of Construction Materials (2)

Prevention of corrosion by using proper construction materials:

stainless steel
plastics
proper coatings
coated concrete rather than coated steel
plastic covered with impregnated hardwood for the settler
plastic fortified plywood
asbestos

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Prevention of the Release of Malodorous Compounds

Covering the anaerobic reactor allows:

Collection and treatment of gases

Reduction of corrosion

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

18
Virtual Wastewater Data & Assumptions for UASB Design (1)
Calculation example using an automated approach
Wastewater data
3
Average flow 400 m /h
3
Maximum flow 900 m /h
Peak flow 2 times max. flow
COD 400 mg/l
BCOD (degradable COD) 225 mg/l
BOD 250 mg/l
TSS 200 mg/l
Ash content 40 %
SO 4 25 mg/l
PO 4 3 mg P/l
TKN 25 mg N/l

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Virtual Wastewater Data & Assumptions for UASB Design (2)

Sludge production assumptions


Y total 0.08 Kg VSS.kg CODin
Y methane 0.03 Kg VSS.kg CODin
Degradation non-sludge VSS 40 %
Sludge ash content 55 %
UASB operational aspects
Temperature 22 °C
pH 7.5 -
Biogas aspects
COD conversion effieciency 60 % of BCODin into CH4
CH 4 percentage in biogas 65 % biogas
Dissolved in the water 22 Nml CH4
Dissolved in the water 63 Mg CH4-COD

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

19
Case: Design of UASB Reactors for 50,000 PE (1)
Model output:

Reactor dimensions
Number of reactors 2 -
Width 24.00 m
Length 18.00 m
Height 4.50 m
Definitive number of feed inlets 108 -
Gas collector
Total width 3.00 m
Aperture percentage 23 %
Width gas collector 2.30 m
Plate projection 0.90 m
Plate heightg 1.07 m

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Case: Design of UASB Reactors for 50,000 PE (2)


Model output:

Feed inlet boxes


2
Maximum servicing area 50.00 m
Suitable number of feed inlets per box 12 -
Number of feed inlet boxes 9 -
Minimum feed pipe diameter 47 mm
Effluent gutters
Length of gutters 288 m
V-notches per meter 4 Per m
V-notch depth 8.0 cm
Gutter width 20.0 cm
Gutter depth 20.0 cm
Water depth 10.2 cm

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

20
Case: Design of UASB Reactors for 50,000 PE (3)

Reactor loading
-3 -1
Volumetric loading 0.99 Kg COD.m .d
-3 -1
Volumetric loading rate 0.56 Kg BCOD.m .d
-1 -1
Organic loading rate 0.03 Kg BCOD.kg VSS .d
3 -2 -1
Biogas loading rate 0.40 m .m .d
Biological parameters
Solids retebtion time 67.5 Days
Maximum methanogenic activity 0.09 Kg CH4-COD/kg VSS.day
Actual methanogenic activity 0.02 Kg CH4-COD/kg VSS.day
3
Biogas production 350 m /day
H2S content 0.04 % in biogas
Sludge production
Effluent TSS =>to be set 30 mg TSS/l
Sludge growth 2304 Kg/day
Sludge to be removed 2016 Kg/day
3
Sludge volume to be removed 29 m /day

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Case: Design of UASB Reactors for 50,000 PE (4)

Sludge drying beds


-2 -1
Sludge bed loading => to be set 0.86 Kg.m .day
Sludge dried to => to be set 12.0 %
Sludge production 2016 kg/day
2
Drying bed surface area, total 2358 m
Drying bed side 18.00 m
Drying bed surface area 324 m2
Number of drying beds 9 -
3
Dried sludge to be removed 16.8 m /day

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

21
Economic Evolution of Design Criteria

upflow velocity

feed inlet distance

solids retention time

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Influence of Upflow Velocity on UASB Reactor Costs

140

120
RELATIVE COSTS (%)

100

80

60

40

20

0
0.00 0.50 1.00 1.50
UPFLOW VELOCITY (m/h)

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

22
Treatment Efficiency As a Function of Upflow Velocity

80

70

ECOD (%)
60
BOD-total

50 COD -soluble
COD -total
40

30
0.0 0.5 1.0 1.5 2.0
Vup (m/h)

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Influence of Feed Inlet Distance on UASB Reactor Costs

120
RELATIVE COSTS (%)

110

100

90

80
1.00 1.20 1.40 1.60 1.80 2.00 2.20 2.40
FEED INLET DISTANCE (m)

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

23
Influence of Reactor Size on UASB Reactor Costs

160

RELATIVE COSTS (%) 140

120 surface
height

100

80
80 100 120 140 160

RELATIVE SURFACE/HEIGHT (%)

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

Difficulties in Introducing AWWT for Sewage

Ignorance with the system in practice


Absence of required infra structure, regarding:
Experienced contractors / consultants
non or poorly informed authorities
little if any full scale experience
little experience in research institutes and universities

Commercial disinterest at established consultants


specialised on conventional systems
University research is considered academic (not for
practice)

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

24
Enhancing Implementation of AWWT

Establish contacts with universities, experienced


contractors and consultants
Start co-operation with polluting industries: either for
environmental protection or energy recovery
Acquire subsidiary projects for pilot or demos
Awareness amongst industries, authorities, and politicians
Increase (scientific) research activities at universities
Educate engineers and operators
Raise specialised consultants / contractors
Have well informed engineers in agencies and water
control boards

WAGENINGEN UNIVERSITY Lettinga Associates


Sub-department of Environmental Technology
Foundation

25

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