EPA 625/1-75-003a PROCESS DESIGN MANUAL FOR SUSPENDED SOLIDS REMOVAL, U.S. ENVIRONMENTAL PROTECTION AGENCY Technology Transfer @ January 1975 114329TABLEOF CONTENTS CHAPTER PAGE ACKNOWLEDGMENTS ii ABSTRACT ii TABLE OF CONTENTS LIST OF FIGURES LIST OF TABLES. FOREWARD 1 INTRODUCTION 1.1 Purpose Ll 1.2 Wastewater Solids tl 13 References 13 2 GENERAL DESIGN CONSIDERATIONS 2.1 Applications of Suspended 21 Solids Separation Processes 2.2 Process Selection 21 3 FLOW VARIATIONS AND EQUALIZATION 3.1 Flow Variation 31 3.2 Performance vs. Flow Variation 3-1 3.3 Flow Equalization 3.2 3.4 References 3.2 4 PRINCIPLES OF CHEMICAL TREATMENT 4.1 Introduction 4-1 4.2 Destabilization Mechanisms 4 43 Selection of Chemical Coagulants 42 44 Coagulation Control 4-6 45 References 4-16 5 STORAGE AND FEEDING OF CHEMICALS SL General Sl 5.2. Aluminum Compounds SL 5.3 fron Compounds 5-16 54 Lime 5-24 5.5 Other Inorganic Chemicals 5-34 5.6 Polymers 5-50 5.7 Chemical Feeders 5-59 58 References 5-66 6 CHEMICAL MIXING, FLOCCULATION AND. SOLIDS-CONTACT PROCESSES 6.1 Introduction 61 6.2 Chemical Mixing 63 63 Flocculation 65 64 Solids-Contact Processes 68 65 References 612TABLE OF CONTENTS - Continued CHAPTER 7 GRAVITY SEPARATION 7.1 Introduction 7.2 Configuration of Sedimentation units 7.3 Basic Factors Affecting Settling Tank Design 74 Clarifier Design Considerations 7.5 Primary Sedimentation 7.6 Secondary Sedimentation 7.7 Chemical Sedimentation 7.8 Flotation 7.9 Shallow Settling Devices 7.10 Wedge-Wire Settlers 7.1L References 8 PHYSICAL STRAINING PROCESSES 8.1 General 8.2 Wedge-Wire Screens 83 Microscreening 8.4 Other Screening Devices 8.5 Diatomaceous Earth Filters 8.6 Ultrafiltration 8.7 References 9 GRANULAR MEDIA FILTRATION 9.1 Introduction 9.2 Process Alternatives 9.3 Process Variables 9.4 Selection of Filtration Rate and Terminal Headloss 9.5 Filtration Media 9.6 Filter Controi Systems 9.7 Filter Cleaning Systems 98 Filter Structures and General Arrangement 9.9 Pilot Studies 9.10 Special Designs 9.11 Slow Sand Filters 9.12 References 10 COST ESTIMATES, 10.1 Introduction 10.2 Curve Content 10.3 Operation and Maintenance Costs 10.4 Freight 10.5 Howto Use Cost Curves 10.6 Curve Descriptions 10.7 References vi PAGE Tt Tl 72 7-14 715 7-2 723 720 7-32 735 8-1 8-1 831 8-33 8-36 8-43 ot 9-3 99 9-20 9-26 9-31 9-35, 9-45 9-46 9-48, 9-52 9-54 10-1 10-1 10-1 10-2 10-2 10-2 10-16Figure No. 41 42 43 44 45 46 5-1 5-2 5-3 5-4. 5-5 5-6 5-7 58 5-9 5-10 5-H 5-12 LIST OF FIGURES Jar Test Units With Mechanical (Top) and Magnetic (Bottom) Stirrers Six-Position Sampler Settling Curves Frequently Obtained Jar Test Results Zeta Potential Apparatus Coagulation of Raw Sewage With Alum Typical Dry Feéd System Crystallization of Alum Solutions Viscosity of Alum Solutions Alternative Liquid Feed Systems For Overhead Storage Alternative Liquid Feed-Systems For Ground Storage Freezing Point Curves For Commercial Ferric Chloride Solutions Viscosity vs. Composition of Ferric Chloride Solutions at Various Temperatures Typical Lime Feed System Lime Requirement For pH 211.0 asa Function of the Wastewater Alkalinity Viscosity of Soda Solutions Viscosity of Caustic Soda Solutions Typical Caustic Soda Feed System vit Page 48 4-12 4:13 4-15 5-7 SIL 5-12 S14 514 5-17 5-18, 5-31 5-35 537 5-45Figure No. 5-13 5-14 5-15 5-16 5-17 6-1 6-2 63 6-5 TA 12 13 15 16 77 18 LIST OF FIGURES (continued) Typical Schematic of a Dry Polymer Feed System Typical Automatic Polymer Feed System for Large Plants Positive Displacement Pumps Screw Feeder Positive Displacement Solid Feeder-Rotary Impeller Mixer Mechanical Flocculation Basin Horizontal Shaft-Reel Type Mechanical Flocculator Vertical Shait-Paddle Type Solids Contact Clarifier Without Sludge Blanket Filtration Solids Contact Clarifier With Sludge Blanket Filtration Rectangular Settling Tanks Typical Clarifier Configurations Results of Salt-Injection Tests With Different Types of Sedimentation Tanks Schematic Representation of Settling Zones Sedimentation In a Secondary Settling Tank Dependence of MLSS Concentration on Secondary Settling Tank Underflow Concentration Typical Flotation Unit Module of Steeply Inclined Tubes viii Page 5-51 5-58 5-61 5-63 5-63 64 6-7 6-7 69 6-10 7-3 14 146 7-10 7-10 TAT 7-25 7BFigure No. 19 7-10 7 Tl 7-13 Bd 8-3 8-4 8-5 8-6 8-7 8-8 8-9 LIST OF FIGURES (continued) Tube Settlers in Existing Clarifier Plan View of Modified Clarifier Tube Settler-Flow Pattern Simple Wedge Wire Clarifier Installation of Wedge Wire Panels in a Clarifier Hydrasieve Unit ‘Schematic Screen Detail Curved Screen Bars Rotating Wedge Wire Screen at North Chicago S.T.P. Typical Microscreen Unit Micro-Matic® Strainer Microscreen Capacity Chart Microscreen Removal at Various Flow Rates Microscreening of Trickling Filter Plant Effluent Microscreen Unit With Pleated Outer Surface The Sweco Concentrator Vertical Leaf Vacuum Filter Vertical Leaf Pressure Filter ‘Schematic Flow Diagram of the Pikes Peak Treatment & Reuse System Page 7-29 7-29 84 8-8 8-10 BIL 8-16 8-23 8.24 8-27 8-35 8-37Figure No. 8-16 9-1 9-2 9-3 94 9-5 9-6 9-7 9-8 9-9 9-10 OL 9-12 9-13 9-14 9-15 10-1 10-2 10-3 LIST OF FIGURES (continued) “Storage Battery” Membrane Modules Typical Rapid Sand Filter Filter Configurations Cross Section of Upflow Filter Typical Pressure Filter Run Length vs. Filter Rate for Various Terminal Headlosses Net Production Rate vs. Filter Rate for Various Run Lengths Grain Size Curve Flow Control Systems Automatic Gravity Filter, Single Compartment Minimum Fluidization Velocity, Vmf, to Achieve 10 Percent Bed Expansion at 25°C Effect of Temperature on Vmf for Sand and Coal and on Absolute Viscosity of Water Underdrains Simater Filter Hydromation In-Depth Filter Hardinge Travelling Backwash Filter Flocculators-Flash Mixers Chemical Feed Systems Sedimentation Page 8-41 9-5 9-6 9-8 9-21 9-24 9-27 9-33 9-36 9.37 9-38 9-40 9-49 9-50 9-51 10-3 10-5 10-7Figure No. 10-4 10-5 10-6 10-7 10-8 10-9 LIST OF FIGURES (continued) Solids Contact Flotation Wire Septums and Settling Tubes Wedge Wire Screens: Rotating and Stationary Microscreens Media Filters xi Page 10-8 10-10 10-11 10-13 10-14 10-15Table No, 2-1 41 Sl 5-2 5-3 5-4 5-5 5-6 5-7 58 5-12 S- Tl 12 7-3 74 LIST OF TABLES Selected SS Separation Process Applications SS Removal Performance For Chemical Coagulation Applications To Phosphate Removal Partial List of Alum Manufacturing Plants Reactions of Aluminum Sulfate Reactions of Ferric Sulfate Reactions of Ferrous Sulfate Partial List of Lime Manufacturing Plants Reactions of Lime Partial List of Caustic Soda Manufacturing Plants CO2Yields of Common Fuels Partial List of Carbon Dioxide Manufacturing Plants Partial List of Polymer Sources and Trade Names Types of Chemical Feeders Performance of Special Settling Tank Inlets Typical Design Parameters For Primary Clarifiers Typical Design Parameters For Secondary Clarifiers Dissolved-Air Flotation Applications Tube Settler Installations xiii Page S15 5-23 5-24 5-28 5-34 5-39 5-46 S47 5-51 5-65 7.14 7-16 7-26 731Table No. 84 8-2 8-3 8-4 8-5 8-6 87 8-8 8-9 8-10 811 8-12 o1 9-2 9-3 9-4 9-5 9-6 LIST OF TABLES (continued) Physical Straining Processes Specifications of Hydrasieves Wed ge-Wire Screens: Municipal Treatment Installations Data Sheet-Wedge Wire Screens Microscreen Design Parameters Microscreen Installations Municipal Microscreen Installations Typical Microscreen Power and Space Requirements Diatomaceous Earth Filtration of Secondary Effluent Results of Ultrafiltration Installations Summary of Pikes Peak Data Typical Membrane Specifications Results of Studies of Filtration of Effluents From Secondary Biological Treatment Results of Studies of Filtration of Chemically Treated Secondary Effluent Results of Studies of Filtration Following Chemical Treatment of Primary or Raw Wastewater Expected Effluent Suspended Solids From Multimedia Filtration of Secondary Effluent Typical Media Designs For Filters Filter Gravel Design xiv Page 8.2 8-5 8-9 8-13 8-17 8-18 8-28 8-36 8-38 8-39 8-42 9-12 9-15 9-16 9.17 9-30 9-43