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Anaerobic Digester - Qasim
Anaerobic Digester - Qasim
3
Characteristics of Sludge
Reaching Anaerobic Digester
Average Extreme Extreme
Factors flow low flow high flow
Sludge production, kg/day 8,180 6,952a 8,681b
Solids concentration, % dry wt 6 8 4
Specific gravity 1.03 1.04 1.02
Average daily flow rate, m3/day 132 84 213c
Pumping rate into each digester 0.85d 0.85 0.85
during the pumping cycle
Influent temperature, °C 21 30 12
Volatile solids fraction before digestion 0.71 0.71 0.71
aExtreme low solids to the digester = 85% of the average solids loading
bExtreme high solids to the digester = quantity of thickened sludge withdrawn
under sustained loading = 10,213 kg/day (p. 664 Step A.3) × 0.85 (solids
capture) = 8,681 kg/day
c8,681 kg/day×103 g/kg(0.04 g/g×1.02×1 g/cm3×103 L/m3) = 213 m3/day
dThe pumping rate of 0.85 m3/min gives a velocity of 0.8 m/sec in the 15-cm
diameter pipe.
4
Design Example
A. Digester Capacity and Dimensions
1. Compute digester capacity at average flow condition using 15
days digestion period
Assume average flow to the digester = 132 m3/day
Digester volume = 132 m3/day × 15 days = 1,980 m3
2. Compute digester capacity using volatile solids-loading factor
Assume VS loading at ave. flow condition = 2.5 kg/m3·day
Total VS reaching the digester = 8,180 × 0.71 = 5,808 kg/day
Digester volume = 5,808 kg/day × 2.5 kg/ m3·days = 2,323 m3
3. Compute digester capacity using volume per capita allowance
Assume 0.03 m3 digester capacity per capita
Population served = 80,000
Digester capacity = 80,000 × 0.03 m3 = 2,400 m3
4. Compute digester capacity using volume reduction method
Volume of the digested sludge = 97 m3/day (Table 13.13)
Volume of raw sludge to the digester = 132 m3/day
Digester capacity = [132 - 2/3 (132 – 97)] × 15 = 1,630 m3
5
Design Example - continued
5. Select digester capacity
Select active digester capacity of 2,500 m3.
B. Digester Dimensions and Geometry
1. Correct for volume displaced by grit and scum accumulations,
and floating cover level
Provide 1-m depth for grit accumulation
Provide 0.6-m depth for scum blanket
Provide 0.6-m min. space between floating cover and max.
digester level
Total displaced height = 1 + 0.6 + 0.6 = 2.2 m
Assume that the active side water depth is 8 m (26.3 ft).
additional volume will be available in the cone.
Volume of each digester = 1,250 m3
6
Design Example - continued
Area of each digester = 1,250 m3 8 m = 156.3 m2
Diameter of each digester = (4/ × 156.3 m2)0.5 = 14.1 m
Because floating covers come in 1.5-m (5-ft) diameter
increments, provide digesters with 13.7-m (45-ft) diameter.
Revised side water depth = 1,250 m3 [4/ × (13.7 m)2]
= 8.5 m (27.9 ft)
Provide two digesters each 13.7 m (45 ft) diameter and 8.5 m
(28 ft) side water depth.
2. Check the active vol. of the digesters, including vol. of cone
The floor of the digester is sloped at 1 vertical to 3 horizontal.
The bottom cone depth of 2.3 m adds additional volume.
Active digester volume = (Vol. of active cylindrical portion)
+ (Total vol. of the cone) - (Allowance for grit
accumulation) = /4 (13.7 m)2 × 7.3 m† + 1/3 × /4 ×
(13.7 m)2 × 2.3 m - 1/3 × /4 × (6 m)2 × 1 m
= 1076.1 m3 + 113 m3 - 9.4 m3 = 1,179.7 m3
†8.5 m – Scum blanket (0.6 m) – Space below floating cover (0.6 m) = 7.3 m 7
8
9
Design Example - continued
Active vol. of two digesters = 2 × 1,179.7 m3 = 2,359.4 m3
Total vol. of two digesters = 2 × (/4 × 13.7 m2 × 8.5 m +
113 m3) = 2,732 m3
Active vol. ratio including cone = 2,359.4 m3 2,732 m3
= 0.86
C. Actual Solids Retention Time and Solids Loading
1. Compute actual digestion period at average, extremely low, and
extremely high flows
Digestion period at average flow = 2,359.4 m3 132 m3/day
= 17.9 day
Digestion period at extreme high flow = 2,359.4 m3 213 (#4)
m3/day = 11.1 day
Digestion period at extreme low flow = 2,359.4 m3 84 (#4)
m3/day = 28.1 day
2. Compute actual solids loading at average, extreme low, and
extreme high conditions
10
Design Example - continued
Solids loading at ave. loading condition = 8,180 kg/day × 0.71
VS 2,359.4 m3 = 2.5 kg VS/m3·day
Solids loading at ave. loading condition = 6,952 kg/day × 0.71
VS 2,359.4 m3 = 2.1 kg VS/m3·day
Solids loading at ave. loading condition = 8,681 kg/day × 0.71
VS 2,359.4 m3 = 2.6 kg VS/m3·day
D. Gas Production
1. Calculate gas production
BOD5 in the thickened sludge (Stream 10) = 4,253 kg/d
BODL in sludge = 4,253 kg/d × BOD5/0.68 BODL = 6,254 kg/d
Assume 65% solids are biodegradable and 1 g of biodegradable
solids = 1.42 g BODL, Y = 0.05, kd = 0.03 1/day, and E = 0.8.
11
Design Example - continued
YQ 0 ES 0 (10 3 kg/g)
Px
1 k dθ c
0.05 112 m 3 /day 0.8 6, 254 g/m 3 (10 3 kg/g)
163 kg/day
1 0.03 1/day 1 7 .9 day
V = 0.35 m3/kg × (EQ0S0 × 10-3 kg/g - 1.42 Px) = 0.35 m3/kg
× (0.8 × 132 m3/day × 6,254 g/m3 × 10-3 kg/g – 1.42 ×
163 kg/day = 1,670 m3/day
If methane is 66% in the digester gas,
Digester gas production = 1,840 m3/day 0.66 = 2,531 m3/day
2. Estimate gas production from other rules of thumb
a. Based on VS loading using VS = 0.75 of TS and gas production
rate of 0.5 m3/kg VS
Gas produced = 8,180 kg/day × 0.71 × 0.5 m3/kg
= 2,904 m3/day
b. Based on VS reduction
12
Design Example - continued
Assume average VS reduction of 52% and gas production of
0.9 m3/kg VS reduced
Total VS reduced = 8,180 × 0.71 × 0.52 = 3,020 kg/day
Gas produced = 3,020 kg/day × 0.94 m3/kg = 2,839 m3/day
c. Based on per capita
Total population served = 80,000
Used gas production rate of 0.032 m3/capita
Gas produced = 80,000 persons × 0.032 m3/person·day
= 2,560 m3/day
Based on the above analysis, assume a conservative gas
production rate of 2,550 m3/day at standard conditions (0°C
and 1 atm).
E. Digested Sludge Production
1. Compute the quantity of solids in digested sludge
TVS = 8,180 kg/day × 0.71 = 5,807 kg/day
TVS destroyed = 5,807 kg/day × 0.52 = 3,020 kg/day
13
Design Example - continued
TS remaining after digestion = Nonvolatile solids + VS
remaining = (8,180 - 5,807) kg/day + 0.48 × 5,807 kg/day
= 5,159 kg/day
2. Compute total mass reaching the digester
Total solids reaching the digester = 8,180 kg/day
Total solids in thickened sludge = 6% by wt
Total mass reaching digester = 8,180 kg/day 0.06 kg/kg
= 136,317 kg/day
3. Compute volume and TSS in digested sludge and the digester
supernatant
Assume that no liquid volume change occurs in the digester
Vol. of influent thickened sludge (Vinf) = Vol. of digested
sludge removed from digester (Vsludge) + Vol. of digester
supernatant (Vsupernatant)
Vsludge = 132 m3/d; Wremaining = 5,139 kg/d
Vsludge = Wsludge/(0.05 g/L × 10-6 kg/mg × 10-3 L/m3
Vsupernatant = Wsupernatant/(4,000 mg/L × 10-6 kg/mg × 10-3 L/m3)
132 m3/d = Wsludge/(0.05 × 1,030) + Wsupernatant/(0.004 × 1,000)
14
Design Example - continued
Wsupernatant = Total solids remaining after digestion in digested
sludge – Wsludge
Wsludge = 5,021 kg/d; Wsupernatant = 138 kg/d; Vsludge = 98 m3/d;
Vsupernatant = 35 m3/d (similar to mass balance)
4. Determine the mass and concentration of the components in digested
sludge and supernatant
Supernatant (Stream 13)
Parameter Digested sludge, kg/d (Stream 12)
kg/d mg/L
Flow, m3/d 97 (98a) a 35 (35a)a -
TSS 5,008 (5,021 ) 140 (138 ) 4,000 (3,942)
BOD5 1,596 105 3,000
Org.-N 320 19 533
NH4+—-N 44 16 453
NO3 N 0 9 0
TN 364 35 986
NPP 67 7.4 211
PP 126 - -
TP 193 7.4 211
TVSS/TSS ratio 0.54
Biodeg. solids/TSS 0.33
Org.-N/TVSS 0.12
NPP/TVSS 0.025
a computed 15
Design Example - continued
5. Select a supernatant selector system
To withdraw liquid from the top.
a. Allow direct visual inspection of sludge
b. Allow removal of clear liquid from the top
c. Permit operation by one person
d. Be extremely reliable
e. Minimize the danger of allowing air
to enter the digester
f. Be easy to serve in
case of blockage
grease, scum or
by sludge
16
16
Design Example - continued
F. Influent Sludge Line to the Digester
Intermittent pump operation at 0.85 m3/min for each
thickener controlled by a timer.
15-cm (6-in) diameter
17
Design Example - continued
G. Digester Heating Requirements
1. Compute heating required for raw sludge
HR = Q0 × Cp (T2 – T1)
where HR = heat required, J/day; Cp = specific heat of sludge
(same as for water = 4,200 J/kg·°C or 1 BTU/lb·°C); T2 =
digestion temperature, °C; and T1 = temperature of the
thickened sludge, °C.
The critical heat requirement for raw sludge is reached when
sludge flow is maximum and influent temperature is lowest:
Heat req. = 8,681 kg/day × 4,200 J/kg ·°C × (35 –
12)°C
0.035 kg/kg = 2.39 × 1010 J/day
2. Compute heat loss from the digester
HL = UA × (T2 – T1)
where HL = heat loss, J/hr; U = overall coefficient of heat
transfer, J/sec·m2 ·°C (BTU/hr·ft2·°F); A = area through
which heat loss occurs, m2 (ft2); T2 = digester operating
temperature, °C (°F); and T1 = outside air temperature,
† Critical
°C average
(°F)†.air and ground temperatures are 0 and 5°C, respectively.18
Design Example - continued
Heat losses from the digester occur from the roof, bottom, and
side walls
a. Compute area of roof
Roof slope = 15:1 = (13.7/2) m:0.46 m
Roof area = D(slant length/2)
2
D
Slant height (Vertical rise of cover)2
2
2
13.7 m 2
(0.46 m) 6.87 m
2
Roof area = ( × 13.7 m × 6.87 m)2 = 147.9 m2
b. Compute area of side walls
Area of side wall above ground level = D × Exposed height
Assume 50% side wall is exposed
Side wall area above ground = ×13.7 m×8.5 m/2=182.9
m2
19
Design Example - continued
Area of side wall below ground = 182.9 m2
c. Computed bottom area
Digester bottom is sloped at 1 vertical to 3 horizontal.
Total drop of the bottom slope at the center = D (2 × 3)
= 13.7 m (2 × 3) = 2.3 m
Bottom area = × 13.7 m × ½ × (13.7 m/2)2 + (2.3 m)2
= 155.5 m2
d. Select overall coefficients of heat transfer for different areas
Digester floating covers and roofing consist of 6.5-mm (1/4-
in.) plate steel, 76-mm (3-in.) rigid foam insulation*, inside air
space, and buildup roofing - 1,236 kg/m2 (70 lb/ft2) – U† = 0.9
J/sec·m2 ·°C (BTU/hr·ft2·°F)
* Common insulating materials are glass wool, insulation
board, urethane foam, lightweight insulating concrete, dead
air space, etc.
† J/sec·m2 ·°C × 0.1763 = BTU/hr·ft2·°F
20
Design Example - continued
Exposed digester side 300-mm (12-in.) concrete, 76-mm (3-
in.) urethane foam insulation, 100-mm (4-in.) brick siding – U
= 0.68 J/sec·m2 ·°C
Buried digester side 300-mm (12-in.) concrete surrounded by
moist soil – U = 0.8 J/sec·m2 ·°C
Digester bottom surrounded by moist soil – U = 0.62 J/sec·m2
·°C
e. Computed heat loss from the digester
Heat loss from the cover and roofing = 147.9 m2 × 0.9
J/sec·m2 ·°C × (35 – 0)°C × 86,400 sec/day
= 4.03 × 108 J/day
Heat loss from exposed wall = 182.9 m2 × 0.68 J/sec·m2
·°C
× (35 – 0)°C × 86,400 sec/day
= 3.76 × 108 J/day
Heat loss from buried wall = 182.9 m2 × 0. 8 J/sec·m2 ·°C
× (35 – 0)°C × 86,400 sec/day
= 4.43 × 108 J/day
21
Design Example - continued
Heat loss from bottom = 155.5 m2 × 0.62 J/sec·m2 ·°C
× (35 – 5)°C × 86,400 sec/day
= 2.50 × 108 J/day
Total heat loss from each digester = 14.72 × 108 J/day
Total heat loss from both digesters, including 20% minor
losses, and 25% emergency condition = 14.72× 108 J/day
× 2 × 1.45 = 5.09 × 109 J/day
f. Compute the heating requirements for the digester
Heat requirements for raw sludge
under critical condition = 2.39 × 1010 J/day
Heat loss from the digester = 42.69 × 108 J/day
Total heating requirement = 2.82 × 1010 J/day
= 1.175 × 109 J/hr
= 1.175 × 106 kJ/hr
22
Design Example - continued
H. Selection of Heating Units and Energy Balance
1. Select external heat exchanger
Provide two heating units each rated as 1.25 × 106 kJ/hr
(1.19 × 106 BTU/hr) with natural gas. The digester gas has
approx. 65% of the heating value of the natural gas (37,300
kJ/m3). Therefore, each unit will be derated at 0.813 × 106
kJ/hr (0.77 × 106 BTU/hr). Total heat provided by two
units = 2 × 0.813 × 106 = 1.626 × 106 kJ/hr.
% extra capacity (1.626 10 6 1.175 10 6 ) 100
6
38%
available 1.175 10
The actual average heat requirements are substantially less.
2. Compute digester gas requirements
At 75% efficiency of heating units
Digester gas 1.626 10 6 kJ/hr 3 3
3
89.22 m /hr 2,141 m /day
needed 0.75 0.65 37,300 kJ/m
23
Design Example - continued
Total quantity of digester gas produced = 2,550 m3/day
This gives approx. 20% excess gas under the most critical
condition when the digester heating demand is greatest.
Excess gas will be used to produce heated water for other
plant uses.
3. Design makeup heat exchangers for external sludge heating
a. Compute average temperature rise of the sludge through the
external exchangers
Provide 23-cm (9-in) diameter sludge recirculation pipe, and
a constant flow recirculation pump for each digester. A
common external jacketed type heat exchanger will be used
to heat the recirculated sludge. If velocity of 1 m/sec is
maintained in the pipe.
Sludge pumping rate π
(0.23 m) 2 1 m/sec 86,400 sec/day 3,590 m 3 /day
from each digester 4
3,590 m 3 /day 1.02 1,000 kg/m 3 3.662 10 6 kg/day
24
Design Example - continued
Average sludge temperature entering the external heat
exchanger = 35°C
Assume average sludge temperature increase after passing
through the heat exchanger = T°C
Assume specific heat of sludge is 4,200 J/kg°C (same as for
water)
Total heat supplied J
4,200 Δ T C 3.662 10 6 kg/day
to the sludge kg C
1.538 1010 Δ T J/day
Total heat required from each digester = 2.82 × 1010 J/d (#22)
= 1.41 × 1010 J/d.
If the efficiency of the heat exchanger is 80%.
1.538 × 1010 × T J/day × 0.8 = 1.41 × 1010 J/day
1.41 1010 J/day
ΔT 10
1.15C
1.538 10 J/day 0.8
25
Design Example - continued
Average temp. of the sludge entering heat exchanger = 35°C
Ave. temp. of the sludge leaving heat exchanger = 36.15°C
Sludge recirculation of 3,590 m3/day (660 gpm) in each digester will
also provide digester mixing.
b. Compute hot water recirculation rate through the external heat
exchanger
Provide one jacketed pipe heat exchanger for both digesters.
Assume that the water enters the jacket pipe at 95°C and leaves at
60°C.
Drop in heating water temperature = 95 - 60 = 35°C
Total heating required for each digester = 1.41 × 1010 J/day
If 25%additional heating is provided to account for heat losses,
Total heat required per digester = 1.41 × 1010 J/day × 1.25
= 1.76 × 1010 J/day
Total heat required for both digesters = 3.52 × 1010 J/day
Total heat available in digester gas = 23,000 kJ/m3 × 1.162 kg/m3
× 2,550 m3/d × 1,000 J/kJ = 6.82
Using specific heat of water = 4,200 J/kg·°C