WASTEWATER TREATMENT

SECONDARY OR
BIOLOGICAL
PROCESSES
FIGURE 6-1: GENERAL WASTEWATER FLOW DIAGRAM
SUPPLEMENTARY NUTRIENTS CATIONIC FLOCCULANT
(PHOSPHATE AND NITRATES) POLYMER POLYMER

TRICKLING
POLYMER FILTER

TERTIARY
WASTE EQUALIZATION ACTIVATED TREATMENT
STREAMS TANK SLUDGE TANKS (CHLORINATION)
FILTRATION
PRIMARY SECONDARY CARBON
CLARIFIER CLARIFIER ADSORPTION
SLUDGE SLUDGE

AERATED LAGOON

POLYMER RECIRCULATED SLUDGE POLYMER

FILTER LAND FILL FILTER

DRYING BEDS
CENTRIFUGE CENTRIFUGE

COMBUSTION

FIELD SLUDGE PRESS

IRRIGATION
POLYMER POLYMER

LAGOONS

W&W/KH03315/DMB/3-31095
 Why Secondary Treatment?
Removal of Soluble Contaminants
Organic Compounds
 glycol
 phenol
 methanol
 mercaptan
 cyanide

Nitrogen Compounds
 ammonia
 Organic / Nitrogen Compounds

Atm.

Microorganisms + Food + O2 + Nutrient

More
= Microorganisms + CO2 + H2O
 Organic Compounds = BOD

The amount of O2 required to biologically oxidize the

biodegradable organic material present in the water.

Conditions: aerobic, 20 C, 5 days

BOD Removal
Easy Efficient

Nature’s Microorganisms

Biological Oxidation
Aerobic (Yes O2)
Anaerobic (No O2)
 Aerobic Biological Oxidation

* * *
FOOD (BOD) + bacteria + O2 + Nutrients

Cellular matter + more

bacteria + CO2 + H2O +
energy
Aerobic Biological Oxidation

•Lagoons
•Aerated Lagoons
•Facultative Lagoons

•Activated Sludge
 Activated Sludge Process

Effluent
Waste Aeration
Sedimentation
Water

Waste
Recycle Activated Sludge Activated
(RAS) Sludge
(WAS)
 Activated Sludge

Healthy Bacterial Environment

•Food (BOD)
•Dissolved O2
Control
•Time
•pH and
•Temperature
Optimization
•Nutrients
•Toxicants
 MICROORGANISMS

Active, Metabolizing, Floc-forming Bacteria

Filamentous Bacteria and Fungi

Protozoa
 Metabolizing Bacteria

Most important group : form “Floc”

Floc are irregular, heterogeneous particles that

contain, in addition to bacteria:
Inert Minerals
Insoluble VOC and Oils
MB Binding Materials (biopolymers)
Byproducts of Cellular Decay/ Lysis
 Filamentous Types

Filaments serve as “Backbone” to Floc Structure,

allowing the formation of larger, stronger floc

Excessive Filaments, however, hinder Sludge

Settling and Compaction, causing Bulking and
Foaming

Must identify Filaments immediately at the

onset of Bulking
 Protozoa

Diverse group of single celled animals, larger

than bacteria, which also consume BOD:
Amoeba (e.g. Sarcodina)
Flagellates (e.g.Mastigophora)
Ciliates (free, stalked, crawling)
Suctoria
Rotifers (e.g. Metazoa)

Used as Indicator Organisms

 Protozoan Diversity

Each Microorganism prefers different Activated

Sludge Conditions (BOD, Pollution, Floc Size,
Sludge Age, Mixing)

Diversity and Appearance of Key Indicator

Organisms are important in determinng the
overall health of the biological population. A
shift signals imminent changes in treatment
results.
 Activated Sludge Factors

FOOD (OR BOD)

•Insufficient - Microorganism
Population decrease

•Excessive - Geometric Microorganism

Reproduction rates (log growth)

•Ideal - No Large variation in influent

BOD
 Activated Sludge Factors

Dissolved Oxygen
•Insufficient - anaerobic and facultative
organisms predominate

•Minimum required - 0.5ppm

•Normal - 2ppm in aeration stage effluent

•Needed for metabolic activity

 Activated Sludge Factors

Time:

•Complex oxidation steps take time

•Normal aeration retention - 4 - 10 hrs

- refineries = 15 to 24 hrs.
 Activated Sludge Factors

pH:
•Bacteria can grow in 5.5 - 9.5 range

•Optimum growth between 6.5 - 8.5

•Avoid significant pH changes or shocks

 Activated Sludge Factors

Temperature:

•Metabolic rate increases with temperature

•Avoid high temperatures
•Thermophilic vs. Mesophilic
•Oxidation efficiencies decline @ 100-120 F
 Activated Sludge Factors

Nutrients:

Like humans, microorganisms require “vitamins”

•carbon
•nitrogen
•phosphorus
•trace metals (K, Fe, Ca, Zn, Mg, Mn, Co)
 Activated Sludge Factors

Toxicants:
 Materials that can be oxidized, but require
adaptation time.

 Materials that will “kill” bacteria

 Bacteria susceptible to feedrate changes.

Bacteria Population as a Time
Function of Food
Conventional Activated Sludge

Operates in Initial stages of

Endogenous Phase

Low BOD

Low TSS
 Optimum “biofloc” setteability
 High Rate Process

Bacteria are in Exponential/Log Growth Phase

Excess Food available

Low Capital Investment- Small vessels

Low Retention time= 2 - 4 hrs; High F/M

High BOD & TSS- used as pretreatment usually

 Extended Aeration Process

Long Residence/Aeration Time= 18 - 24 hrs

Long sludge age, Extreme Endogenous Phase

Low F/M, Low effluent BOD, low sludge

Good for Refineries and other Processes

producing hard to treat wastes
 Activated Sludge Plant Control

F + M + O2 + N M + CO2 + H2O

F/M = lb/day BOD5

lb MLVSS
 MLSS
Mixed Liquor Suspended Solids

The suspended solids

in the totally mixed
aeration basin
liquid.
 MLVSS
Mixed Liquor Volatile Suspended Solids

The part of MLSS which will combust.

A good approximation of the active biological

portion of the MLSS.

In a well oxidized sample,

 MLVSS = biomass
 ACTIVATED SLUDGE
CONTROL TECHNIQUES
CONSTANT MLSS

CONSTANT F/M

CONSTANT MCRT OR “SLUDGE AGE”

SLUDGE QUALITY CONTROL

 Basic Control: Sludge Wastage

Maintains balance between number of organisms

and amount of food.

Wastage rate tied to growth rate

Affects: Effluent Quality, Organism Growth

Oxygen consumption
Mixed Liquor Settleability
Nitrification, other specialized operations
 Constant MLSS/ MLVSS

Assumes that any AS system operates at a

certain optimum MLSS conc. (i.e. mass of orgs.)
Simple strategy, Minimum laboratory work
Generally good results, if influent strength is
relatively constant
Operator tries to maintain constant MLSS by
carefully controlling sludge Wastage Rate
MLSS selected based on operating experience,
for good quality effluent, with stable conditions
 Constant F / M Control

Vary sludge recycle to increase/decrease MLVSS

Better with fluctuating W/W Strength

Requires a lot of analytical work

BOD5 is a “historical” test, can use estimates,
e.g. TOC, COD, TC- good historical correlation
needed between BOD & estimate

Widely used; Oldest technique

 Constant SRT/ MCRT

SRT (MCRT)

Sludge (or Mean Cell) Residence Time

Relates solids in system to growth rate
Theoretically “best” control strategy
Based on optimum F/M ratio
 SRT =

MLSS (ppm) * Aeration Vol. (106 lb)

___________________________________
[TSS(ppm) * Eff (106 lb/d)]
+
[RAS MLSS (ppm) * WAS
(106 lb/d)]
SRT assumes MLSS = MLVSS

I.e.,
ignores inerts, inorganics, and non-
biodegradable portions.

If
solids inventory and losses constant,
SRT control is effective
 If BOD loading constant,

F/M control = constant MLSS

MLSS controlled by sludge wastage

S/d = (Y * BOD5) - (K *TS)
d

TS = Total solids in system

Y = Cell Yield coefficient (.5 - .65)
K = Endogenous decay coefficient
(.04 - .075)
 Sludge Age
(SRT, MCRT)

SA = TS
S/d
 1 = (Y * F/M) - K
SA

Microorganism growth = f (F/M, SA)

Ifone of 2 variables controlled, the other will

seek and find associated value.

Control
F/M SA/SRT
 Sludge Quality Control

Best Effluent when Sludge Quality is good

Combination of several control strategies often

used for best results
Track & Control MLSS/MLVSS levels, F/M
loading & MCRT within prescribed ranges
Indicator Organisms monitored
Sludge Settling tests- can indicate needed
changes to target F/M, Sludge Age, MLSS, RAS
rates and wastage
Aeration Basin Foaming
Foam = gas in liquid emulsion

Stabilized by:
 wastewater surfactants
 solids
 bacterial by-products

Problems
 visual (worker/residential compl.)
 oxygen transfer
 effluent TSS
 Secondary Clarification

Removal of biomass (solids).

A thickening operation (no rapid mix).

Overflow rates and retention times vary to

allow for changes in biomass settleability.

Uniform, quick sludge pick-up from bottom.

 Secondary Clarification

Reduce TSS carryover

Reduce suspended BOD

Increase hydraulic loading

Secondary Clarification Problems

Bulking

 Filamentous Bacteria
 Chlorination (10-20ppm) recycle sludge
 Increase sludge age
 Sufficient N and P
 Increase aeration
 Secondary Clarification

Pin Floc

 Sludge Age Too High

 Floc Shearing
 Toxic Compounds
 Acid Waste
Secondary Clarification Problems

Straggler Floc

fluffy floc in overflow weir

 hydraulicflow
 Sludge Age too low
Secondary Clarification Problems

Floating Sludge (clumps)

 Anaerobic
conditions or air
entrainment

 Sludge too long in clarifier

 Air entering thru polymer pump

 Activated Sludge Plants
Troubleshooting

All problems manifest themselves in

the secondary clarifier.

Usually BOD or TSS excursions.

Either clarifier or aeration malfunctions

 Troubleshooting

1st STEP - Define problem symptoms

2nd STEP - Provide short-term solution

Polymers (TSS/insoluble
BOD)

3rd STEP - Determine long-term

solution
 Troubleshooting
TSS Carryover

 Biological(aeration)
 Mechanical (clarifier)

Sludge Settling Test History

 Troubleshooting

Sludge Settling Tests

Sludge Volume Index (SVI)

SVI = Volume (ml) settled sludge

MLSS (ppm) *
1000
 SVI Example

MLSS = 5000 ppm

SSV30 = 500ml

SVI = 500ml 1000 = 100 ml/g

5000 ppm *
SVI target 50 - 150

1000 ml
Aeration
MLSS Effluent

Sludge

Sludge Recycle
 Troubleshooting

SVI = Normal Mechanical

SVI = High Aeration

Dissolved Oxygen
Microscopic
 Sludge Settling Tests
Can provide a lot of Information about Condition of
Activated Sludge System:

Graph of Rate of Settling (5 min. points)

Supernatant Condition

Production of Gas after 1 - 2 hours

Floating material, Pin-Floc, SVI

Observation Possible Cause Corrective Measure

Low oxygen Poor or plugged Correct design or

in basin diffuser, inadequate mechanical malfunctions
design

Excessive BOD loading Reduce BOD loading

Excessive MLSS Reduce MLSS by reducing

recycle
Observation Possible Cause Corrective Measure

High oxygen Toxicant interfering Identify and eliminate

in basin respiration toxicant

Low MLSS Increase % recycle

Low BOD or nutrients Supplement BOD or

nutrients

Over design Reduce aeration

Cold temperature Increase MLSS by

increasing recycle
 Microscopic Examination

Microorganism Type

Microorganism Number
Balanced Biological Population

Microorganisms vs. Time

 Microorganisms Found in
Biological Wastewater Treatment
 Desired Microorganism Balance

Majority - Free swimming ciliates

stalked ciliates

Minority - Rotifers
Observation Possible Cause

Sarcodina predominate. System starting-up, recovering

from complete toxicity.

Free swimming ciliates Indicates lower efficiency.

predominate, but also
flagellates.

Free swimming ciliates Indicates higher efficiency.

accompanied by some stalked
ciliates.

Stalked ciliates predominate Activated sludge with low BOD

effluent.

Few stalked ciliates and no Stable, well-operating plant.

other protozoa.

Rotifers present. Low BOD loading, approaching

total oxidation.
Typical Activated Sludge Parameters
(Conventional Refinery)

Aeration Retention Time (hrs) 15 - 24

MLSS (ppm) 5000
MLVSS (ppm) 3000 -
Aeration D.O. (ppm) 4000
Sludge (days) 2.0 - 3.0
BOD:N:P 20 - 30
F/M 100:5:1
Sludge Production (lb/lb of BOD) 0.2 - 0.5
% BOD Removal 0.35 - 0.55
pH IN 80 - 99
pH OUT 9.0 - 9.5
Temperature 7.0 - 7.5
80 - 95 F
 Activated Sludge
Refinery Facts
Floating sludge high oil and grease
NH3 NO3
 pH In > 8.5
 D.O. > 2.0ppm
 S.A. >20 days

D.O. > 4.0ppm over oxidation/TSS carryover

Refinery waste deficient in P H3PO4
 Activated Sludge
Refinery Facts

Avoid SHOCKS of any kind

temperature
pH
BOD
phenol
NH3
oil & grease

Bacteria deflocculation
Secondary clarifier carryover
 Activated Sludge
Refinery Facts

Oil & Grease

 < 20ppm OK for bacteria

 20 - 50ppm some bacteria toxicity
 50 - 100ppm severe bacteria toxicity
 >100ppm kills bacteria
Troubleshooting Example

Overheads
 Settling Data

1000
900
800
700
600 Normal
500 Upset
400 Line 3

300
200
100
0
0 5 10 15 20 25 30 45 60
The End of Secondary
Treatment
SOLID WASTE
MANAGEMENT
WET SLUDGE HANDLING
AND DISPOSAL
 WET SLUDGE

SOURCES OF SOLIDS:

 Primary Solids - from primary w/w clarifier

 Secondary Solids - sludge from biological
treatment plant- secondary clarifier
 Metallic Solids - from inorganic coagulants
used in influent clarifier or lime softening,
or w/w from automotive/steel industry
 Oily Solids - waste from refinery, steel or auto
industries
 Solid Waste Management
Refinery Sludge Sources
 Waste Activated Sludge (WAS)
 Slop Oil Sludge

Sludge Treatment
 Digestion
 Dewatering
 WET SLUDGE HANDLING

Thickening
Stabilizationor Digestion
Conditioning
Concentration and Dewatering
Incineration
Wet Oxidation
Disposal
 General Sludge Processing
and Disposal Flow Diagram
-----------
Sludge Digestion
Aerobic
* Anaerobic

By-Products
Gas
Supernatant
Stabilized Solids
 Anaerobic Digestion
Biochemical Processes

Anaerobic/Facultative Bacteria
1. Sugars, carbohydrates, fats, proteins

organic
2. Amino acids, higher proteins

intermediate acids

3. Organic acids, intermediate acids

CH4 + CO2
 Anaerobic Digestion

Biological Balance

Temperature 85 - 95 F
pH 6.7 - 7.4
Volatile Acids 200 - 800ppm
Alkalinity 2000 - 3500ppm
Retention Time 30 - 90 days
 Dewatering
Free Water

** Physically Bound Water

Capillaries
Within Floc
Between Particles

Chemically Bound Water

 REASONS FOR DEWATERING

 Reduced Sludge Volume and Weight

 Decreased Hauling and Landfill Costs
Typically in the US, 50% of the op. costs
of w/w plant is sludge handling/disposal
More Cost-Effective Incineration

Recovery of Filtrate for Reuse

Satisfy Transportation & Landfilling

Regulations
Sludge Dewatering

Chemical Conditioning
Rigid Structure (porosity)
Adequate Pore Size

Chemical

Mechanical Assistance
Mechanical Sludge Dewatering
Vacuum Filter
 Belt or Cloth
 Coil
 Precoat
 Disc
Dual Cell Gravity
Multiroll Press
Belt Filter Press
Centrifuge
 Basket
 Solid Bowl
 Disc
Pressure Filter
Diagrams of Filter Presses
 Belt Press Optimization

 Polymer Type - Test properly

 want best free gravity drainage
 Polymer Dosage - Vary on Press
 no side ‘squeeze-out’, no stickiness on belt
 Mixing - intensity is Critical- vary
feedpoint
 Polymer Dilution - as high as possible,
w/o floc shearing or hydraulic overload
 Belt Press Optimization

 Belt Speed - balance between enough

free gravity drainage time, dewatered
cake thickness and throughput.
 Production rates (belt speed) can be
increased by higher polymer
 Belt Type - Different sludges require
different belt weave types- check
 Roll Pressures- Wet cake vs Solids
extrusion & belt wear
Chemical Sludge Dewatering

Inorganics
Fe Cl3
Lime

Polymers
Mechanism of Treatment
Chemical conditioning of sludge can
improve dewaterability via changes in
three of these factors:

 particle size
 bound water content
 particle charge
 Particle Size

 Solids in the 1.0 - 100 µ range can

travel through sludge and plug-off
sources of egress

 Decreased porosity

 Small floc will also result in blinding of

filter material
 Result

 delta-P through sludge exceeds the

available energy - so water does not
flow through

 Sludge gets forced out sides of filter

cloth

 Filter cloth gets plugged

 Bound Water Content

 Biological sludges are 80% water

 Hydration sheath around biological floc

 Polar nature of water
 Polar nature of exocellular secretions of
bacteria
 Result

 Water is retained

 Particles are prevented from coming

closer together and agglomerating
 Sludge Conditioning

Polymers disrupt this polar bonding,

allowing these waters to migrate
away from the floc, allowing for
increased particle agglomeration.
As this occurs, capillary water is
eliminated between particles.
 Particle Charge
Each sludge has its own charge demand:

 Biological sludges are negatively charged

 De-inked sludges are primarily negatively
charged - surfactants, binders, inks

Like charges repel, and therefore

agglomeration of particles to form a rigid
pore structure is inhibited.
 Polymers

 Biological Sludges: High MW cationics

 Inorganic Sludges: High MW cationic or

anionic

 Metallic Sludges: Anionics

Sludge Disposal
Incineration

Land Application
 Fertilizer
 Soil Conditioner

Landfill (Percolation)

Lagoon (Evaporation)
 Polymer Selection

Use the Right Test !

Check existing chemicals as Baseline !

(Overheads)
THE END
 BETZ INTERNATIONAL INC.

YUKONG CUSTOMER SEMINAR

ULSAN, KOREA

JUNE 5 - 6, 1995

REFINERY WASTEWATER TREATMENT

 Review of Testing

Goal:

To try and simulate system conditions

 Use the Right Test !

 BUCHNER FUNNEL GRAVITY

DRAINAGE TEST
 Belt & Screw Presses; Drying Beds

best all purpose dewatering test !

 CAPILLARY SUCTION TIME (CST)

 Fast Prescreening Only
sludge file
S/d = (Y * BOD5) - (K *TS)
TS d
TS

1
____= (Y * F/M) - K
SA