SEWAGE TREATMENT

APPLICATION BACKGROUND
BY

DYNAMIC LOGIC LTD

SEWAGE TREATMENT.
Whilst a treatment works operates as a complete entity, its operation is made up of a number of completely separate functions operating in series. It is necessary to understand what it is that arrives at the works called sewage and what each of the individual functions are within the treatment process. A clear understanding assists in understanding the way forward and how to exploit the discovered opportunities. Sewage may include rainwater that has been collected from roads, roofs and other drained areas, from domestic and places of work, but in all cases is mainly comprised of water. In addition trade effluents produced from commercial premises, as well as farm effluents, are received at treatment works, mixed within the remainder of sewage. Proper safeguards must be taken to allow treatment of this mixture without effect on the controlled process and later disposal of sludge. Large discharges of effluents to small works requires special attention to be given and uncontrolled discharges may give rise to serious problems. Sewage contains a wide variety of waste products of human, animal, vegetable or mineral origin some of which are in solution and others in suspended solids form. There are three forms of solids - those that sink, those that float and those that are so small that they neither float or sink but remain suspended in the water. It is the last of these, sometimes called colloidal matter which makes settled sewage appear cloudy. The sequence of events are set out below in chronological order. . 1. CONVEYANCE of SEWAGE (Sewage Pumping), is the beginning of the process, where regardless of the source the raw sewage, starts its movement to the treatment works to be processed Loss of pump control in ether Fig 1 or Fig. 2 above or blockage of the sewer would lead to public nuisance, especially flooding, odour and possible risk to public health. To carry sewage from where it is produced to where it will be treated and disposed of sewers are laid with a gradual downward slope so that the sewage flows under the influence of gravity. Pumping stations of the type that are illustrated within Figs. 1 and 2 are used to achieve this purpose and have been traditionally almost equally divided between DL and DTS products commencing when the then Water Authorities used agencies to carry out this work on their behalf. Following privatisation, the ten new Water plcs almost all brought this function back into their own resources and now are mainly totally responsible for sewage from source to treatment. Some sewers carry only used water discharged from houses, shops, offices and factories, the majority however carry rainwater run-off from roofs, roads and paved areas that do not allow the rainwater to soak into the sub-soil and ultimately the aquifer, these sewers are known as combined sewers.

Fig 1 Pumping Station and Rising Main with Gravity Inlet

Fig 2 Wet Well / Dry Well Pumping station

In general, all new housing developments will have a pumping station similar to that within Fig. 1 located on or adjacent to the developed site to connect to the nearest neighbouring sewer. Rising mains (or pumped mains) are used to move sewage to a higher level by the use of a pump or pumps, the quantity of pumps generally range from one to three dependent on the flow through the system. The number of pumps is very dependent on the time of day and the requirement is determined by the level as it rises and falls within the wet well in the station type illustrated within Fig. 2. Apart from sensing and controlling the pumps dependent on the wet well levels the telemetry outstation located at the site would also sense alarm levels within the wet well if for any reason the level were to continue to rise

either due to pump failure or where the existing pumps were unable to cope with an inlet flow that was beyond their design capability, usually during severe storm conditions . Other alarms are also provided to warn of such possibilities as three phase failure, phase shifting, loss of single phase supply used for control power and intruder alarms. Fig. 2 illustrates a typical pumping station that employs a dry well within which the pump is located, there is also a third type where submersible pump or pumps are used, this is illustrated in Fig. 3 below. In general the same control philosophy is employed regardless of the style of pump that is used. To monitor the levels within the wet wells the types of sensors that are employed are illustrated in Figs. 4 and 5 below and over page.

Fig 3 Submersible Pumping Station.

Fig 4 Float Switch level sensing

The types of level sensing that are illustrated within Figs. 4 and 5 are used within pumping stations and throughout sewage treatment works where level measurement is required. Flow into treatment works may require a pumped lift similar to that illustrated within Figs. 1, 2 and 3 or alternatively an archimedean screw pump may be used, which is illustrated in Fig. 6 below. The archimedean screw motor drive is fixed speed and operates like other pumping systems illustrated so far within this document purely on an on/off basis, the operation of the screw pump is controlled by the level within the inlet well using level detectors similar to those shown within Figs. 4 and 5.

Fig. 5 Probe Level Sensing

The next consideration is the actual inlet to the works is important when dealing with severe flow conditions particularly on a gravity fed system. Generally this extreme condition is caused by storm conditions where the input to the works exceeds the design flow through the works to ensure proper treatment. If the flow is allowed to pass through the works unchecked it would carry with it untreated sewage and normally where the treated product is discharged to river now could result in severe pollution.
Fig. 6 Archimedean Screw Pump

To cope with this condition storm tanks are used to contain the excess flow until the inlet flow abates when the contained excess is allowed back into the works for treatment in a controlled manner where it can be treated power efficiently by working at optimum flow. The flow into the works is controlled by measuring the flow and diverting the excess over a side weir, the excess then flows through channels into the storm tanks for storage and later processing. The types of flow measuring and diversion are shown in Figs. 7 and 8. The gate in Fig.7 can be replaced with a penstock dependent on the size of the works and the design flow into it, where a penstock is used the control system would make the necessary penstock movements to raise or lower to control the flow. Both methods of flow measurement illustrated above, the flume and V notch, cause the level upstream to rise the flow being measured by monitoring the rise in level which is squarely employed for this style of measurement by noncontact, due to the chemical nature of untreated sewage, since at this stage, there are rags and floating solids such as plastic bottles or pieces of wood contained within the flow that could snag on any intrusive form of flow measurement.
Fig. 7 Flume and Control Gate with Side Weir

The large solids and rags are removed downstream of the works inlet using a screen placed across the flow which is mechanically removed with a rake or scraper bar that lifts the trapped debris into a trough above the screen where it is either raked or washed into a skip for disposal. In small works the rake is operated on a timer that is set against typical conditions found in the works, but in larger works instrumentation is employed to measure the upstream and downstream levels and operates the control system when a pre-set differential in level is reached. Without this the screen becomes a dam as debris builds up and can cause the flow to backup upstream and cause unnecessary flow to be diverted into the storm tanks, or overflowing of sewers due to lack of free flow.
Fig. 8 V Notch and Side Weir

In some of the larger works the solids are shredded in place of being screened either by comminution on maceration. A comminutor system is illustrated on the right where the size of the large solids are reduced so that they are no longer likely to cause problems in later stages of treatment, for example by blocking pumps valves and pipe-work although further to avoid having to dispose of screenings, as described earlier, allowing the whole treatment process to be continuous and preventing the need for replacing the screenings skips which cannot be automated. Comminution is particularly useful before the aeration process, which is this document. A macerator and pump in series will chop up larger solids so that the rising main can safely be of a smaller diameter which reduces the time of flow through the main avoiding septic conditions and reducing cost.
Fig. 10 Macerator Fig.9 Comminutor

described later within

Balancing Tanks are employed at this stage of the treatment process to even out the flow through the works and control it at its optimum regardless of the variable inlet flow. Storm conditions are dealt with separately as and when the condition arises The works is able to treat the sewage more effectively with the flow being controlled by moving forward a controlled amount. This forward flow is drawn from the surface of the balancing tanks by means of a floating suction arm. By drawing from the surface, sludge is allowed to settle at the base of the balancing tank where it is drawn off periodically. By removing the sludge at this stage prevents smell problems. The balancing tanks require emptying down periodically to remove grit, this is normally a manual process, carried out by isolating the selected tank.
Fig. 11 Balancing Tank

Storm tanks receive the excess sewage discharged at the storm overflow as shown in Figs. 7 and 8 earlier. Apart from holding the excess flow until it can be processed later through the works in a controlled manner after the storm has past, the storm tanks allow partial treatment by settlement before discharge. Discharge from the storm tank is from the surface of the tank by the use of a floating suction. Should the in-flow to the works, under severe storm conditions, exceed the capacity of the storm tanks the excess input overflows over a weir and would then discharge to a water course.
Fig. 12 Storm Tank

Grit Channels remove grit and other abrasive materials to prevent pump excessive wear and further to prevent blockage of valves and bends in the pipework by setting of grit deposits. The flow is arranged to be slow through a grit channel, such that the grit is not carried forward with the flow and is given time to settle out and fall to the base of the channel. When the grit deposit builds up in the base of a particular channel, the inlet sluice to that channel is closed and the forward flow allowed to continue to empty the channel. The grit is then removed from the empty channel in a small works by manually raking the grit into side troughs for later disposal as illustrated in Fig. 13. In large works, Fig. 14, where obviously the channels are much greater in size, the process is fully mechanised, where the grit is raked to an end channel for removal.
Fig. 14 Grit Channel in Large Works. Fig .13 Grit Channel in small works

Primary Sedimentation is a process where the separation of settleable solid matter that makes up a large proportion of the impurities in sewage takes place. In all sedimentation processes this requires a period of quiescence to allow sludge to settle. All sedimentation processes trap floating solids by means of scum boards for later removal. Tank draining is normally carried out at periods of low inlet flow to the works when plenty of time needs to be allowed for draining. The rapid return of sewage when tank draining may overload the other tanks in service and flush out sludge. The alternative is to pump off the top water to a balancing or other tank for slow return to main flow. In small works where there is only one tank the top water is taken off by gully emptier. There are normally three styles of sedimentation tanks employed The Horizontal Flow Sedimentation Tank Fig. 15. the de-sludged flow spill over an overflow weir, The Upward Flow Sedimentation Tank Fig. 16 which are relatively deep tanks shaped like inverted cones or pyramids; they are constructed of concrete, steel or GRP. Sewage enters the tank near the middle and flows upwards and outwards to a peripheral overflow weir. The Radial Flow Sedimentation Tank Figs. 17 and 18 are circular in plan fitted with a central sewage inlet and stilling box, peripheral weir and effluent channel Sludge settling on the shallow sloping face is scraped to a central hopper mechanically normally using a chain that hugs the sloping wall. Two types of scraper mechanism are found. Smaller tanks have a fixed bridge across the tank and a centrally mounted motor turns the scrapers below. Larger tanks have a rotating bridge across half the tank diameter. The scrapers are fixed below the half bridge and the whole assembly is driven round a central pivot by a motor powered bogey. Some radial tanks are fitted with scum scrapers at the water surface, some have sludge thickening stirrers in the sludge hoppers.

Fig 15 Horizontal Flow sedimentation tank

Fig.16 Upward Flow sedimentation Tank

Fig. 17 Radial Flow Sedimentation Tank (Fixed Bridge).

Fig 18 Radial Flow sedimentation Tank (Rotating Bridge)

The Activated Sludge Process achieves biological oxidation by aeration of sewage with a flocculant mass of living organisms (bacteria) know as activated sludge. The sewage may be screened, comminuted or conventionally settled. Numerous different arrangements for aeration and plant layout are used. For small versions of conventional large plants, volumetric residence times of five to eight hours would be used but for small plants are of the extended aeration type intended to minimise development of excess activated sludge so that the volumetric residence time could be between 18 and 48 hours. Air is introduced either in bubble form (diffused air) or by mechanical surface agitation.
Fig. 19 Aeration Tank

By bringing air into close contact with sewage as bubbles as is shown in Fig. 19, where air is blown from perforated pipes laid at the base of the tank, typical air blowers are illustrated in Fig. 20. These blowers are powerful multi-stage air pumps whose rate of flow is normally monitored using electromagnetic flow-meters inserted into the pipework connecting the blowers and feed pipe leading to the aeration tank. The pipework arrangement is shown in Fig 21 which shows the air inlet from the blowers, often housed some distance away, and how a series of smaller diameter perforated pipes are used to create an even bubble pattern through the volume of each tank. In diffused air systems air may be blown into the sewage through diffuser pipes as shown in Fig 21 or porous diffuser devices shown in Fig 24. Alternatively air may be drawn from the atmosphere and dispersed as bubbles into a pumped liquid stream by one of the various ejector devices Many small activated sludge plants are proprietary package units so that the equipment varies in detail from one supplier to another.

Fig. 20 Air Blower

Fig 20 Multi-stage Air Blower

Vigorous surface agitation Fig. 23 is an alternative method where oxygen in the form of air is introduced in such a way that the living organisms develop as a free floating flocculent sludge.
Fig. 22 Aeration Tank with Bubble Diffuser

Porous diffuser

Fig. 23 Surface Aerator

Biological Oxidation removes from sewage or settled sewage, polluting substances that may be in solution, as settleable particulate matter or as very small particles as a non-settleable colloidal state. Biological oxidation requires close contact the sewage, living organisms and oxygen. Bacteria are the organisms principally responsible for biological oxidation but fungi and various forms of animal life may also be involved. Oxygen will normally be derived from air. This contact is usually achieved either by providing solid surfaces in contact with the sewage and air and on which the living organisms develop.
Fig. 24 Rotating Arm Distributor

There are a number of methods employed to spread the settled sewage on to a biological bed, one of the most commonly used being the rotating arm distributor illustrated in Fig. 24. The other types employed are Water wheel, Fixed notched open Channel and fixed Distributor Pipes, the overall principle remaining the same only the distribution method changing Batches of strong waste from tankers, e.g. septic tank contents, farm waste or tip leachate, because of their concentration, are only introduced gradually into any biological oxidation system and in any event are normally received only at the larger works. Separate reception facilities are made available and control exercised over the rate of addition to the sewage flow. After the biological oxidation process it is usual to find a further stage of treatment to remove the additional solids which have been produced. The processes are not suitable for overcoming basic deficiencies in the biological oxidation process. Biological Filtration Beds achieve biological oxidation using solid surfaces, made up of beds containing stone or a similar medium or plastic material. Sewage feed is normally from settlement or septic tanks as opposed to direct feeds from sewers. The filtered effluent is settled in humus tanks or irrigated over grassland before discharge to streams. Typical arrangements are illustrated in Figs 25 and 26 below.

Fig. 25 Filter Bed with Stone or Similar Medium.

Fig 26 Filter Bed with Plastic or Similar Medium.

Secondary Sedimentation is used to improve the quality of effluents from biological oxidation. The processes are usually basically physical, but biological action plays a part in sand filters, lagoons and grass plots. The processes are not suitable for overcoming serious deficiencies in biological processes. The process act to settle solids that are discharged from biological filtration beds before the effluent passes to a watercourse. The sludge that is produced is known as humus sludge. Tanks are more commonly of the rectangular horizontal flow type as illustrated in Fig 27 but pyramid upward flow and circular radial flow tanks are also used as illustrated in Figs. 16 and 28.
Fig 27 Horizontal Flow Humus Tank.

In some systems a settling compartment is integral within the aeration tanks that have been discussed earlier within this document. For larger flat or sloping bottom tanks without a scraper, for maintenance, the top water is pumped off to a land area or head of works ideally via a balancing or storage tank the sludge is removed to to a drying bed or to the head of the works for settlement with the incoming sewage. With mechanically scraped tanks the humus sludge is withdrawn without emptying the tank, the tank only being emptied for maintenance, cleaning and to check the scraper blades for wear. Sludge from pyramidal is also withdrawn without emptying the tank.
Fig 28 Circular Upward Flow Sedimentation Tank

Clarifiers strain the solids from effluent after final settlement. Pebble beds with gravel of a size 5 to 7 mm about 150 mm deep are installed in humus tanks or built as small independent units. Alternatively a layer of wedge wire with slats about 1 to 1.5 mm, or 3 mm plastic mesh mounted about 200 mm below the surface are also used. A pebble sludge clarifier is shown in Fig. 29 These strainers remove only distinct particles of solids, they are unlikely to improve turbid or cloudy effluents with fine particles. In which case there needs to be an improvement to the preceding biological filter treatment or other oxidation treatment. Activated Sludge Sedimentation Tanks are employed to settle activated solids with the provision for return of activated sludge to the aeration plant.

Fig. 29 Pebble Bed Clarifier.

Circular radial flow type tanks are commonly used although pyramidal or similar upward flow tanks may be used. In some systems a settling compartment is integral within the aeration tanks.

Sand Filters are used to strain solids after settlement. For small works the usual types are downward flow slow sand filters. The sand grading is normally 8 to 16 mesh. The layout of this type of filter is illustrated in Fig. 30.

Treatment and Disposal of Sludge apart from large works is often centralised and sludge is collected from a number of small works so that treatment, utilisation or disposal may be carried out with greater efficiency. This may involve transporting liquid sludge to a large treatment works where the heated sludge digestion could be carried out, or merely to the largest works among the smaller works, where processes such as mechanical de-watering are carried out. Heated sludge digestion will not normally be found on smaller works. At larger works operation is more economical because methane given off in the digestion process can be used for heating. The type of treatment which sludge will receive at a small works will be governed by the ultimate fate of the sludge i.e. whether for utilisation or disposal. Where utilisation is by spreading on farm or horticultural land, then treatment of sludge becomes more important than it would be if the sludge were discharged to a tip. The diagram Fig 31 summarises the flows through the works which has been described throughout this document and indicates the areas where sludge is generated through the various parts of the treatment process including both the biological and activated sludge processes. Screening of Sludge is to prevent blockages in distribution pipes, rain guns and pumps and to remove plastic and other objects which could be aesthetically objectionable and might harm grazing animals. The main source of such objects often arises from the sludge from un-screened storm tanks and from inefficient detritus tanks which have been sited upstream of the main screen to the works.

Fig. 30 Sand Filter

Fig. 31 Works Flow Diagram

Storage and Thickening of Sludge is to overcome the difficulties encountered in disposing of sludge due to seasonal nature of use, unavailability of land, breakdowns and other circumstances. When combined with thickening by the removal of supernatant water, there is a much smaller volume to handle, since sludge with a water content of 96 percent has only half the equivalent volume of sludge with 98 percent water. Storage of sludge will also effectively reduce the micro-organism level and initiate cold digestion. Thickening Tanks are used to enable sludge to settle and the water to be drawn off possibly at different levels or it may be pumped off. In small works any available tank will suffice. Problems can arise due to the tendency for a crust to form at the top of the tank and for sludge and water layers to form underneath. Finally in addition sludge is also fed to earth walled lagoons and concrete walled drying beds but no instrumentation is normally employed within this final part of the process. End.