ASL

Process Design for the Waterford city Waste Water Treatment Plant
Bid for contract Nr. 5
Activated Sludge Limited

12

Activated Sludge limited 1 Process Design for the Waterford city Waste Water Treatment Plant

EXECUTIVE SUMMARY
Activated sludge limited (ASL) is grateful to the Waterford city council for the opportunity to participate in the bidding process for the Waterford city waste water treatment plant (Contract Nr 5). Activated sludge limited was incorporated in 1982 as small civil engineering consulting company. We are pleased to note that we previously designed and build a number of works for Waterford city council such roads, sewerage and the city council building which we completed ahead of schedule in 1991. Our works therefore speak for themselves. Like Waterford city, we have grown in leaps and bounds. We are now a publicly traded company quoted on the London stock exchange (LSE: ASL). We have interests and expertise in virtually all fields of engineering. ASL is the first company in the UK to extract struvite, a slow-release nitrogen and phosphorus based fertilizer from sewage digestate liquor. This novel process is being piloted at the Birmingham water treatment plant which we designed and built. The plant is already saving money on environmental remediation and the government has just approved struvite for sale as a save environmentally friendly fertilizer. Struvite recovery is built into this design we are submitting for the Waterford scheme. Using our patented technology, we are ahead of the competition in our efficiency at combining primary and secondary sludge thickening with digestate sludge drying in the same facility. In this way, we have saved our clients millions of pounds in operational costs. Our general design principles lay emphasis on functionality, sustainability and optimum return on investment. We have assigned our director of engineering design, Dr Nigel Horan to oversee the implementation of this project. Dr Horan is renowned expert on waste water engineering with a lot of publications to his name. His appointment underscores the value we attach to this bid. Given that as a company, we have grown with the city of Waterford, we look forward to another opportunity to cement this long-term relationship we have had with Waterford city.

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Activated Sludge limited 2 Process Design for the Waterford city Waste Water Treatment Plant Eng. Adamu Onakpa BSc. MsE. Ceng. Senior Process Design Engineer Activated sludge limited

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Activated Sludge limited 3 Process Design for the Waterford city Waste Water Treatment Plant

Contents
EXECUTIVE SUMMARY ............................................................................................................................ 1 INTRODUCTION ....................................................................................................................................... 4 General Requirements from the Tender document ............................................................................... 5 INFLUENT ............................................................................................................................................ 5 Nutrient Removal .............................................................................................................................. 11 PERFORMANCE STANDARDS............................................................................................................. 11 PROCESS DESIGN REQUIREMENTS .................................................................................................. 12 PRELIMINARY TREATMENT ................................................................................................................... 18 INLET WORKS .................................................................................................................................... 18 PRIMARY TREATMENT .......................................................................................................................... 20 Tank shell design ............................................................................................................................... 20 Design of tank internals .................................................................................................................... 21 THE ACTIVATED SLUDGE PROCESS DESIGN .......................................................................................... 22 Design calculations............................................................................................................................ 23 SECONDARY TREATMENT TANKS .......................................................................................................... 27 Tank design calculations ................................................................................................................... 27 Design of tank internals .................................................................................................................... 28 SLUDGE ARISINGS ................................................................................................................................. 28 Sludge storage prior to digestion...................................................................................................... 29 Sludge thickening and dewatering.................................................................................................... 29 MESOPHILIC ANAEROBIC DIGESTION ................................................................................................... 30 Design of the anaerobic digester ...................................................................................................... 30 Gas Generation ................................................................................................................................. 30 Gas storage ....................................................................................................................................... 31 CHP Power output............................................................................................................................. 31 Dewatering........................................................................................................................................ 31 Nutrient recovery .............................................................................................................................. 32 CONCLUSION......................................................................................................................................... 33 REFERENCES .......................................................................................................................................... 34

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Activated Sludge limited 4 Process Design for the Waterford city Waste Water Treatment Plant

INTRODUCTION
This bid document is intended to communicate the technical process design for the water form waste water plant. Each unit process is preceded by a brief explanation followed by calculations used to arrive at each design specification. It begins with a complete summary of design requirements and everything is extracted from the tender document. Other parameters not contained in the tender are derived from generally accepted engineering standard tables. The plant is designed to treat projected incremental load input up to the 2025 with a maximum flow rate of 1.687m3/s. the design BOD and TSS loads are 11,436Kg/d and 8005Kg/d respectively. Both primary and secondary sludges are to be thicked to 6% dry solids. The dried sludge is to be 23% dry solids. The CHP plant has a designed power output of 4.1MW. A single element of the design is at the minimum up to the tender requirement and to compy with stringent environmental regulations

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Activated Sludge limited 5 Process Design for the Waterford city Waste Water Treatment Plant

General Requirements from the Tender document

The following information provided in the Tender has been used to design the Plant as specified:

INFLUENT
The Works shall be designed for the projected domestic and commercial waste water inputs for the Year 2025 with an allowance for industrial wastewater, infiltration and storm water. The design flows have been calculated as multiples of dry weather flow (DWF) using the formula below: DWF = (P x Q/1000) + C + E (m3/d) Where: P - Resident population Q- Per capita sewage discharge including infiltration, litres/day C-commercial flow rate, m3/day E- Industrial waste water flow rate, m3/day The estimated resident populations for the catchment area of the Waste Water Treatment Plant is as follows: Year 2005 Year 2025 51,640 67,905

The domestic flow arriving at the waste water treatment plant has been calculated using the following criteria from the tender document. Per capita sewage discharge Allowance for infiltration Commercial flow 150 litres/h/d 50 litres/h/d 24 litres/h/d (i.e. 16% of per capita above)

The industrial contribution comprises the existing estimated industrial flow of 5,424 m 3/d (which is taken to be the loading for year 2005) and the future industrial loading of 12,254 m 3/d (which is taken to be the design industrial loading. Page 5 of 34

Activated Sludge limited 6 Process Design for the Waterford city Waste Water Treatment Plant The estimated existing and design influent are summarised in Table 1.1 below Particular Requirements for design, 2004)

Table 1.1

Contributing Flows

Year

2005 Design DWF m3/d 13,581 1,630 12,254 27,465

Design DWF m3/d

Domestic(P x Q) Commercial (C) Industrial (E) Total

10,328 1,240 5,424 16,992

Flow will arrive at the works from five pumped sources feeding into the main gravity inlet sewer and from a separate collection system servicing the Belview Area. The breakdown of these estimated contributions is given in Table 1.2

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Activated Sludge limited 7 Process Design for the Waterford city Waste Water Treatment Plant Table 1.2 2005 Estimate Feed Source Pumping Station Industrial Flow (m3/d) Waterpark 4,454 Maypark 740 Total DWF (m3/d) 11,040 3,577 Industrial Flow (m3/d) 5,098 740 Total DWF (m3/d) 13,758 4,470 Design Allowance Installed Pump Capacity (m3/s) 0.922 0.358

Rocklands Main Inlet Sewer Slieverue

230

2,302

230

2,955

0.205

7 -

10

0.009

Beacon Quay

25

32

0.009

GravityBelview Sub Total Belview Area Total Ind. Flow

5,424 5,424

16,951 41 16,992

3,370 9,438 2,816 12,254

3,370 24,595 2,870 27,465

0.068 1.577 0.11 1.687

The estimated maximum rate of flow that could arrive at the Works through the main inlet sewer based on installed pump capacities is 1.577m3/sec. It is expected that the domestic and future

industrial flow from the Belview area will arrive at the Works at a flow rate which could be up to 3 x DWF for domestic flows and 2 DWF for industrial contributions and hence an allow for a further flow of 0. 110m3/s from this source will be made. The total design peak flow to the Works is therefore 1.687m3/sec.

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Activated Sludge limited 8 Process Design for the Waterford city Waste Water Treatment Plant All flows arriving at the plant shall receive preliminary treatment. The design flows which are to receive preliminary, primary and secondary treatment are summarised in Table 1.3. Primary and secondary treatment shall be provided for flows up to 3 times the design DWF. The minimum capacity of the primary and secondary treatment facilities will be 0.954 m3/s which could occur on a continuous basis. Flows received at the treatment plant in excess of 0.954 m3/s will be temporarily diverted to storm water tanks.

Table 1.3: Summary of Design flow for Preliminary, Primary and Secondary Treatment Flows Treatment m3/d Flow Preliminary Treatment Flow to Primary Treatment Flow Secondary Treatment Flow to Storm Treatment Upstream of 0.733 to 0.318 3 0.956 0.318 3 0.956 to 27,465 m3/s 0.318 to Design DWF DWF Multiplier Design Peak Flow

To Receive Rate* m3/s Treatment 5.3 1.687

Primary * Return liquors flow rates are not included Treatment

Waste Water Characteristics Industrial Waste Water The survey and analytical results shall be interpreted and the relevant characteristics of the anticipated industrial loads and flows in the context of achieving the required performance standards will be determined. Conclusions will also be drawn concerning the availability of nutrients and trace elements in the waste water to provide for biological treatment. If the nutrients are insufficient, provisions will be made accordingly. Page 8 of 34

Activated Sludge limited 9 Process Design for the Waterford city Waste Water Treatment Plant Domestic Wastewater: The average domestic pollutant loads have been estimated based on per capita contributions of: 60 g BOD/capita/day 126g COD/capita/day, 70g SS/capita/day, These have been applied to the design domestic population for the Year 2025 which is 67,905 persons.

Pollution Loading: Table 1.4 below summarises the estimated pollution loading for 2005 and the Design Pollution Loading. The loads given shall be considered as maximum 7 day moving average loads. Table 1.4: Estimated Pollution Loading Estimated Pollutant Unit Load 2005 6,254 12,508 4,378 Design Load *

BOD COD SS

kg/day kg/day kg/day

11,436 22,872 8005(I)

(I) Based on percentage of industrial waste water with low SS. * Return liquors and any contaminated site drainage loads are to be added to the above figures.

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Activated Sludge limited 10 Process Design for the Waterford city Waste Water Treatment Plant Table 1.5 gives an estimated breakdown of the contribution from the main sectors contributing to the organic loading to the waste water treatment plant. Table 1.5 Estimated Domestic Commercial Industrial Total 2005 Design Load(kg BOD/d) 4,074 652 6,710 11,436

Loading(kg BOD/d) 3098 496 3060 6,254

Variation in loading The Works shall be capable of treating the design peak flow rate arriving at the plant as given in

Table 1.3 and be capable of treating the Design Load for the various pollutants as given in Table 1.4. The design shall allow for increases and decreases in the pollutant concentrations within the catchments and for the variations in infiltration within the collection system.

Modular Expansion Increased Loadings (+10%, +20%) The design assumption to be made with respect to influent for the+10% and +20% increases in BOD, COD and SS load is shown in Table 1.6 below. The loads given shall be considered as maximum 7 day moving average loads. Table 1.6 Load Pollutant BOD COD Ss Unit Kg/day Kg/day Kg/day +10% Load 12,580 25,160 8,806 +20% Load 13,723 27,446 9,606

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Activated Sludge limited 11 Process Design for the Waterford city Waste Water Treatment Plant Note I Return liquors and contaminated site drainage flows and loads are to be added to the above figures. Note 2 The increased loads could arise from any part of the catchment.

Nutrient Removal
The design influent flow to be assumed for the purposes of expanding the design for nutrient removal (nitrogen and phosphorus) is given in Table 1.3 and 1.4. The total nitrogen concentration in waste water shall be assumed to be 40mg/l (all as organic nitrogen and ammonia). The concentration of phosphorus shall be assumed to be 6mg/litre.

PERFORMANCE STANDARDS
General The Works shall meet the environmental standards with respect to final effluent quality, sludge quality as well as satisfying odour and noise requirements. The Works shall meet the Works performance Guarantees, and the performance standards specified for individual process units in this tender. Final Effluent Discharge Standards The Works shall be capable of producing final effluent meeting the standards specified in Table 1.7 below. Table 1.7: Final Effluent Discharge Requirements Standard Parameter Target A BOD, mg/1 25 Target Target A B 50 No more than three daily samples per 60 days with COD, mg/l 125 250 a value for any one parameter TSS, mg/l 35 87.5 or all TargetB Compliance Criteria

No value

samples for

with any to

one be the

parameter greater standard

parameters to be greater than the standard

than

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Activated Sludge limited 12 Process Design for the Waterford city Waste Water Treatment Plant Compliance with the above standards shall be monitored by daily flow proportional sampling. The above final effluent standard shall apply to the effluent stream from the secondary treatment plant i.e. excluding storm tanks overflow. Sludge Quality Standards The sludge at the time of its use or disposal, shall meet the standards shown in Table 1.8. Table 1.8: Sludge Quality Requirements (Digestion & Dewatering)

Parameter Faecal coliform

Standard 1 000 MPN/gds

Compliance Criteria Continuously less than the

concentration Dry solids 23% (w/w)(IJ

standard than the Greater standard Continuously greater than the

concentration Retention time in pasteurization unit Temperature sludge of

Min.2 hours

during

Min. 55C

standard. Continuously greater than

pasteurization.

PROCESS DESIGN REQUIREMENTS

Degree of Treatment Required for Particular Flows The following degree of treatment is required for influent flows: All flows arriving at the Works shall receive preliminary treatment comprising grit removal and screening. Flows up to the design peak flow rate in Table 1.3 shall receive primary treatment and secondary biological treatment. Flows in excess of the design peak flow rate for primary and secondary treatment in Table 1.3 shall be diverted as storm water to holding tanks and, shall be returned to the primary and secondary treatment processes whenever the flow to the Works drops below the Page 12 of 34

Activated Sludge limited 13 Process Design for the Waterford city Waste Water Treatment Plant capacity of the primary and secondary treatment stages. The possibility that the wastewater arriving at the Works may be septic shall be taken into account and provisions made in the design accordingly.

Preliminary Treatment Screening Screening equipment shall be installed within a building. The screens shall have maximum apertures of 5 mm in either direction. The design velocity through the apertures shall not exceed 1.2 m/s. Grit Removal The grit separators shall be capable of removing at least 95% of particles with a specific gravity of 2.65 g/cm3 and with a diameter of 0.2 mm and greater. Storm Water Treatment The treatment plant shall include for the storage of storm water in holding tanks with a minimum capacity of2, 640m3 representing 1 day storage at maximum overflow rate. Primary Treatment Primary settlement tanks shall be designed for flows up to the design flow stated in Table 1.3. Tanks shall have a minimum straight wall height of 2.5 m as measured from the top water level to the top of the base and shall provide a minimum retention period of 1.5 hours at maximum flow conditions. The inlet pipe shall discharge within a stilling box or diffusion mechanism located at the centre of the tank. Where stilling boxes are used these shall occupy a minimum liquid surface area 10% of the liquid surface area of the tank Secondary Treatment Secondary biological treatment shall be provided for flows up to the design flow stated in Table 1.3. Biological treatment systems shall be designed to achieve a treated effluent standard in accordance with the requirements stated in Table 1.7.

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Activated Sludge limited 14 Process Design for the Waterford city Waste Water Treatment Plant Activated Sludge Process Activated sludge systems shall be designed to maximize the settle-ability of the mixed liquor in downstream clarifiers. Plug flow type systems are the preferred option but consideration will be given to other systems. Selector tanks should be provided and systems shall be designed to achieve a Stirred Specific Sludge Volume Index less than 120 ml/g at a mixed liquor suspended solids concentration of3.5 g/l. A minimum sludge age of 5 days shall be maintained at a temperature of 100C and the system shall be designed for a mixed liquor temperature range of 100C - 200C. Dead spots shall be eliminated by providing baffle walls and fillets to corners of tanks where necessary. A minimum freeboard of 0.75 m shall be provided in all aeration tanks. Aeration systems shall be capable of maintaining a dissolved oxygen concentration of 2 mg/litre throughout the full volume of the aeration lank at all times. Suitable arrangements shall be provided for draining aeration tanks. Secondary Settlement Tanks The upward flow method shall be used in the design of the tanks. The upward flow velocity shall not exceed 0.9 m3/m2/h with all tanks in operation and 1.2 m3/m2/h. with one tank out of service for maintenance. The minimum hydraulic retention time shall be two hours and the maximum solids loading rate shall not exceed 75 kg/m2/d. In all cases the following shall apply: Settlement tanks shall incorporate rotating bridge scrapers and scum removal systems Scum removed from the surface of the tanks shall not be returned with the return sludge. The inlet pipe shall discharge within a stilling box or diffusion mechanism located at the centre of the tank. Where stilling boxes are used these shall occupy a minimum liquid surface area of 10% of the liquid surface area of the tank. The Contractor's design shall from the stilling box. Sludge return pumps shall be capable of returning flows in the range not narrower than 0.5 to 1.5 times the average inlet flow or within the range 0.3 to 0.7 m3/m2/h as an underflow rate where the solids flux design method is adopted. Page 14 of 34 include for a means of removing scum

Activated Sludge limited 15 Process Design for the Waterford city Waste Water Treatment Plant The side wall depth of the settlement tanks shall not be less than 2.5m Aeration Systems Aeration systems shall be designed to maximise oxygen transfer and to react to the changing oxygen demands in biological treatment systems. Consideration will be given to the separation of aeration and mixing mechanisms in aeration tanks where appropriate to maximise energy efficiency. Tapered aeration in plug flow systems shall be provided. Aeration systems which incorporate blowers shall comprise at least 3 blowers. Blowers shall be capable of delivering maximum air requirements with the largest single unit out of service. Duty blowers, diffusers and piping shall be capable of delivering at least 150 per cent of the air requirements based on the maximum design loading. The maximum air flow in pipework shall not exceed 15 m/s. Provision of a system for condensate draining and flushing of the air system will be made. Pressure tapping shall be provided to monitor pressure drop for each air valve. Sludge Handling and Treatment Primary Sludge Primary sludge from the primary settlement tanks shall be thickened prior to treatment. Thickening/consolidation tanks shall be designed such that when operating in series with the sedimentation tanks the thickened sludge shall have a minimum dry solids content of 6%. Tanks shall be covered and the air extracted for treatment. Tanks shall be designed to provide a minimum hydraulic retention time of one day at maximum daily sludge flow rates. Secondary Sludge Sludge produced in secondary biological treatment processes shall be thickened to a minimum dry solids content of 5% systems prior to digestion or other sludge treatment processes. Sludge Storage Sludge storage facilities shall be provided for Thickened primary sludge and secondary sludge as well as digested sludge. Page 15 of 34

Activated Sludge limited 16 Process Design for the Waterford city Waste Water Treatment Plant Separate tanks for storage for 3 days production of thickened primary and secondary sludge at maximum design loading will be provided in addition to a minimum of 5 days storage capacity for digested sludge. All sludge storage facilities shall be covered and the headspace will be extracted to the odour treatment plant. Sludge Blending Thickened primary and secondary biological sludge shall be combined and mixed in the sludge blending/buffer tank from where the sludge shall be pumped to the sludge treatment processes. Sludge Pasteurisation Sludge pasteurization will be designed to meet the standards required for disposal of sludge to agriculture. The system shall be designed to handle peak flows generated by the treatment plant. Sludge Digestion The sludge retention time shall be a minimum of 14 days. The digesters shall be equipped with an automatic temperature control systems. In each digester, at least two temperature sensors shall be installed. External heat exchangers shall be utilised. The average daily temperature of the sludge in the digester(s) shall not be outside the range of 350.5C. The instantaneous temperature shall be continuously in the range 352C. The biogas generated during digestion shall be directed to the gas holder. An enclosed flare stack shall also be provided. All necessary safety devices shall be provided. Sludge Dewatering Mechanical thickening and dewatering plants, and associated pumps shall be arranged in at least one duty stream and at least one additional stream of the same size as the duty stream. The duty stream(s) shall be sized to handle at least the average daily sludge quantities over not more than 20 hours per day. The additional stream shall be used to treat the peak loads and serve as a standby during average loading. Polyelectrolyte solution preparation and dosing systems shall be provided for all mechanical devices used for sludge thickening and dewatering. Duty and standby dosing units shall be

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Activated Sludge limited 17 Process Design for the Waterford city Waste Water Treatment Plant provided. The minimum dry solids content following dewatering shall be 23%. Dewatering systems shall be fully enclosed and located in a sludge dewatering building. Solids Disposal The disposal of all screenings, grit and sludge generated shall be carried out in accordance with the requirements of the Waste Management Act 1996 and Implementary Regulations and in accordance with any permits or licences obtained.

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Activated Sludge limited 18 Process Design for the Waterford city Waste Water Treatment Plant

PRELIMINARY TREATMENT
INLET WORKS
Approach Channels The approach channels are designed to receive flows up to 5.3DWF from the incoming sewer as requested by the tender document. A flow velocity range of 0.45 to 0.9m/s is chosen to prevent both solids settlement at lower velocities and damage to screens at higher velocities (Horan, 2011a). Screen specification with apertures of 3mm and matching the designed flow channel is obtained from Degremond technologies online. The design calculations for the approach channels are based on an adaptation of the formula A 5.3DWF = 27465M3/d = 1.687m3/s DWF = 0.318m3/s At DWF, Area = At 5.3DWF, Area = = 1.874m2 = 0.707m2 (see table 1.3)

Number of channels required = 2.651 This implies two channels will not be enough and three channels are therefore designed. The total area of the three channels is Flow Velocity = = = 0.9m/s

To maintain flow velocity above 0.45, = 0.471 The width required for the screen is given buy = 1.052m

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Activated Sludge limited 19 Process Design for the Waterford city Waste Water Treatment Plant Taking a depth to width ratio of 1.15, and let the width be 1m, Depth = 1.15 x 1. 052m = 1.21m

Screens Screen specification that fit the design of the channels is obtained from manufacturers. An inficro screen (Degremond Technologies, 2011) climber screen with apertures of 3m will be installed. Such a micro screen has the capacity to remove 95% of debris in the waste water Grit removal A hydrodynamic grit removal system will be installed. This is preferred because it is relatively compact and maintains very high removal efficiencies over a wide range of flows (idswater, 2011). This type of screen is highly efficient in separation, reduces odours, has low wear rate and can remove all grit 0.1mm (140 mesh) and larger. Storm Tanks Design The storm tanks are designed to retain an excess of flow to full treatment of 2.3DWF (tender requirement). Two tanks in series are designed with the first one receiving the first flush. The surface loading is 10m/h, height to breadth ratio is greater than 2 and retention time is 2hrs (Horan, 2011b) The designed volume of the storm tank is V= Q x HRT = 2.3 DWF x 2/24 = 63169.5m3/d x 2/24d = 5263.2m3 Tank area = = = 263.2m2

As stated above, two tanks in series are used in the design, thus, the actual volume of each tank is 2631.6m3. Taking L: W = 3.04, W = 6.58m, L= 3.04 x 6.58 = 20m Tank depth = = = 10m

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Activated Sludge limited 20 Process Design for the Waterford city Waste Water Treatment Plant Formula A weir FFT Inlet works
Primary sedimentation tank

Inlet sewer

>3DWF > 6DWF Water course Storm Tanks

Fig 1: layout of the preliminary treatment works.

PRIMARY TREATMENT
The primary treatment tanks designed are of the radial type. They are preferred because their efficient scraping mechanism and equal flow divisions (Horan, 2011c). The tanks are designed for BOD and TSS removal of 30% and 60% respectively. The tanks are designed such that the influent is discharged towards the centre of the surface area. A stilling basin which is 10% of the tank surface area in size is used to dissipate the velocity or energy of the influent. The treated effluent flows over a v-notch weir while the settled sludge is withdrawn from the tank bottom through a pipe.

Tank shell design

Design data Surface loading rate at FFT = 90m3/m2.d (Horan, 2011d) HRT= 1.5 hrs. (Tender document) Maximum allowable weir overflow rate = 450m3/m2.d (ibid) Flow to primary tank = 3DWF = 82395m3/d Tank surface area= Tank Volume = = = 1.5d/24 = 916m2 82395m3/d = 5150m3

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Activated Sludge limited 21 Process Design for the Waterford city Waste Water Treatment Plant For three tanks, volume required for each will be 1717 m3 with area of 305 m2 As shown in table 2.1 below (Horan, 2011e) Table 2.1: Number of radial tanks and corresponding volumes One Tanks Service (m3) 1 at 5,150 2 at 2,575 3 at 1,717 4 at 1,287 in spare (m3) 5,150 2,575 1,717 1,287 Total Volume (m3) 10,300 7,725 6,868 6,435 Volume saved (m3) 2,575 3,432 3,865

Thus, three tanks each of volume 1717m3 are required. However designing for standard available capacity for floor slope of 7.5 degrees yields the following: Volume of conical portion = 160 m3 (from table) Volume/m of sidewall =346 m3 Assuming a side wall depth of 3.5m, implying volume of cylindrical portion = 3.5 x 346 = 1211 m3 Therefore total tank volume = 1211 m3 +160 m3 =1371 m3 And tank diameter = 21m Three tanks each having a volume of 1371 m3 and area of 346 m2 are to be provided with a spare to same specification. This is ideal for our volume requirement from the tender data.

Design of tank internals

The stilling basin designed to be 10% of the tanks surface area as required by the tender document. In addition, a scum removing mechanism is attached to the stilling basin. The outlet weir which collects settled sewage prior to distribution is located 0.5m from the tank wall. Area of the stilling basin = 346 x 10% =346m2 x 0.1 = 34.6m2 Page 21 of 34

Activated Sludge limited 22 Process Design for the Waterford city Waste Water Treatment Plant Outlet weir length for the three tanks = 3 (21-1) m = 188.5m The weir loading rate = = = 437.2m3/m2.d

Surface loading is high and should be reduced by providing a cantilevered double sided weir. However, this is still within the recommended weir loading rate of 100 to 450m3/m2.d (Horan, 2011c).

6 2 3 7

1
4 5 8

1- Inflow 2- Stilling basin 3- Scum removal 4- Scraper 5- Sludge withdrawal 6- Scraper drive (fixed bridge mounted) 7- Peripheral overflow weir 8- Flow slope

Figure 2: A simple line diagram of the primary sedimentation tank (adapted from Horan, 2011d). The secondary sedimentation tank has a similar design but without the scum removal mechanism

THE ACTIVATED SLUDGE PROCESS DESIGN

The activated sludge process basically involves the oxidation of organic matter (as BOD) by bacteria in the presence of oxygen. The end products are largely new bacterial cells, carbon dioxide as well as relatively smaller quantities of nitrogen and phosphorus compounds. Once the bacteria multiply in huge quantities, the settle to form a floc called the activated sludge. For a brand new treatment plant, the reactor has to be seeded with bacteria from external sources and allowed to grow for a few weeks to a few months. For existing plants, the recycle flow from the secondary tanks return some active sludge to seed the influent coming from the primary tank into the reactor. Manual or mechanized systems keep the reactor chamber supplied with air; allowing bacteria to breakdown the organic matter. A good balance between the substrate in the wastewater

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Activated Sludge limited 23 Process Design for the Waterford city Waste Water Treatment Plant and the microorganism must be maintained for proper working of the system. A certain amount of the microorganisms must be wasted to achieve this (Lin, 2001)

Design calculations
The primary settlement tanks remove 30% and 60% BOD and TSS respectively. Thus, the BOD and TSS load to the aeration tanks are: BOD load = 11436 Kg/d x 70% = 8005.2Kg/d TSS load = 8005Kg/d x 40% = 3202Kg/d Therefore, TSS: BOD = 3202Kg/d: 8005.2Kg/d = 0.4 Population equivalent PE = = = 111,833

With PE greater than 20,000, a sludge age of 12 days is adopted and from table 2.3 below (Horan, 2011f), the yield is worked out as 0.68 Table 2.0: Relationship between TSS: BOD, sludge age and yield TSS:BOD SLUDGE AGE 4 0.4 0.6 0.8 1 1.2 0.74 0.86 0.98 1.1 1.22 6 0.7 0.82 0.94 1.06 1.18 8 0.67 0.79 0.91 1.03 1.15 10 0.64 0.76 0.88 1 1.12 15 0.59 0.71 0.83 0.95 1.07

The food: micro-organism ratio F/M is calculated from the relationship;

Where, = sludge age, Y = microbial yield. Page 23 of 34

Activated Sludge limited 24 Process Design for the Waterford city Waste Water Treatment Plant = 0.12/d The reactor volume is

Where V= Reactor volume, QS = BOD load, X = MLSS V= = 18596m3

Selector design COD loading = 2 x BOD loading COD loading to reactor = 2 x 8005.2Kg/d x 70/100 = 16010.4Kg/d Solids loading = Using floc loading of 150g COD/Kg MLSS (Horan, 2011h)

Solids loading =

= 106,736Kg /d

RAS flow rate =

= 10.6736m3/d

Total flow to selector = RAS flow + influent flow = 10.6736m3/d +82395m3/d = 93068.6m3/d Calculation is made of a volume that yields a retention time of 15 minutes (ibid) V = HRT x Q = = 969.5m3

Area=volume/reactor depth= 969.5/6=161.6m2

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Activated Sludge limited 25 Process Design for the Waterford city Waste Water Treatment Plant Anoxic zone design The normal HRT in the anoxic zone at FTFT is 1hr (ibid). Thus, V = HRT x Q = Area =3433.1/6=557.2 m2 Aerobic volume= 18596m3-969.5m3-3433.1m3=14193.4m3 Area=2365.6 m2 Taking length to breath ratio as 14 (Horan, 2011g) L=14B Area = length x breadth =2365.6+557.2+161.6=3084.4 With B = 15m, L = 210m Depth is usually 6m, but the design adds a freeboard of 0.75m giving a total depth of 6.75m. = 3433.1m3

Calculations for the aeration system Using the WRc equation TOD = 0.0864Q [0.75(S0 Se) + Where S0 = influent BOD = 97mg/l Se = effluent BOD = 12mg/l at 95 percentile Q = flow rate = 963.65l/s Inserting the above values into the WRc equation yields TOD = 5254Kg/d The sewage oxygen transfer rate (SOTR) is

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Activated Sludge limited 26 Process Design for the Waterford city Waste Water Treatment Plant SOTR = N0=

Where N0 = Oxygen transfer into clean water (Kg/d) N = Oxygen transfer into sewage (Kg/d) Cs = Saturated oxygen concentration = Correction factor for the effect of waste water on KLa = Correction factor for the effect of waste water on Cs

TABLE 3.0: Aeration pockets

Height (m) c (mg/L) T (oc) OTR (kg/d) SOTR(kg/d) Diffuser (nr)

6 0.2 20 0.4 0.85 3152 9460 438

6 1 20 0.5 0.85 788 2060 95

6 1.5 20 0.7 0.85 525 1038 48

6 2 20 0.8 0.85 525 965 45

6 2.5 20 0.9 0.85 263 458 21

Diffuser performance = 0.15Kg O2/diffuser Number of diffusers = SOTR/Diffuser performance

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Activated Sludge limited 27 Process Design for the Waterford city Waste Water Treatment Plant

SECONDARY TREATMENT TANKS

The secondary tanks are designed according to the tender requirement include making provision for flows up to the design flow rate and using modular construction for ease of expansion. Structurally, secondary sedimentation tanks are constructed the same way as primary tanks. They are however designed to have larger areas to cope with the huge amount of BOD and TSS removal needed. The sewage from aeration chamber flows into the secondary sedimentation tank and remains there for 2hrs. During this period, the sludge settles and thickens into various zones at the bottom of the tank. Part of the thickened sludge is returned to the activated sludge plant to seed the incoming flow from the primary thank with bacteria. The balance of the thickened sludge corresponding to the microbial growth is withdrawn and sent to the anaerobic digestion plant for further processing. Liquid effluents from the secondary thanks typically have nearly all their BOD removed in the tank. They are tested to ensure they have met consent standards before being discharged to the environment.

Tank design calculations

The tank area is given by

Where: A = tank area SSVI = sludge specific volume index = 3500ml/g Qu = underflow rate = 1144.3m3/h Qs =3DWF = 3433.1m3/h Inserting values in the above equation gives A = 7563.8m2 The total flow rate to the tank is Qs + Qu = 3433.1m3/h + 1144.3m3/h = 4577.4 m3/h

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Activated Sludge limited 28 Process Design for the Waterford city Waste Water Treatment Plant Surface loading = = = 0.61m3/m2h

Tank volume = Q x HRT = 4577.5m3/h x 2hrs = 9155m3 Three tanks in service are designed with one spare. Thus the respective volume and area of each tank are Volume of each tank = 9155m3/3 = 3051.3m3 Area of each tank = 7563.8 m2/3 = 2521.3m2 Other calculations of tank parameters shown below were done using standard tables (Horan, 2011d). A floor slope of 100 and sidewall depth of 3.4 meters were used. Tank diameter = 30m Conical section = 653m3 Circular portion = 3.4m x 707m3 =3056.8m3

Design of tank internals

Stilling basin is designed with an area equal to 10% 0f tank surface area (tender requirement). Stilling basin for each tank = 2521.3m2 x 10/100 = 252.13m2 Outlet weir is 0.5m from the circumference of the tank. Therefore, Weir length = 3(D-1) m = 3 x 29 x = 273.3m Weir overflow rate = = 401.9m2/d

This is between the generally recommended range of 100-450m2/d (Horan, 2011). It is however still high and will be reduced using a double-sided weir.

SLUDGE ARISINGS
The primary tanks removed 60% TSS equivalent to 4803Kg/d at 1.5% solids (i.e. 15Kg/m3). Amount of sludge removed = 0.6 x 8005 = 4803Kg/d Page 28 of 34

Activated Sludge limited 29 Process Design for the Waterford city Waste Water Treatment Plant Volume of sludge removed = = 320.2m3/d

The amount of sludge produced by the secondary tank is = Yield x BOD load = 0.68 x 8005.2Kg/d = 5443.3Kg/d SSVI = 120ml/g. This implies 1Kg of the sludge will occupy 0.12m3 of volume. Therefore; Volume of sludge produced = 0.12m3/Kg x 5443.3Kg/d = 653.2 m3/d Total daily sludge production = 320.2m3/d + 653.2 m3/d = 973.4m3/d

Sludge storage prior to digestion

A minimum of three days storage capacity for both primary and secondary thickened sludge based on maximum design loading capacity is provided. For the primary thickened sludge, storage volume = flow x HRT 320.2m3/d x 3d = 960.6m3 Storage capacity provided = 1000m3 For the secondary thickened sludge, storage volume = 653.2 m3/d x 3d = 1959.6 m3 Storage capacity provided = 2000m3

Sludge thickening and dewatering

Primary and secondary sludge are thickened separately. The centrifuge thickening system is used because it is highly efficient at managing large quantities of sludge and dewaters the digested from the anaerobic digestion process. Centrifugal thickeners are also amenable to modular construction(Europy, 2011) Primary sludges are thickened to a dry solids content of 6% with a VSS concentration of 75% while secondary sludge are thickened to a dry solids content of 6% with a VSS concentration of 80%.

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Activated Sludge limited 30 Process Design for the Waterford city Waste Water Treatment Plant

MESOPHILIC ANAEROBIC DIGESTION

Anaerobic digestion involves complex biochemical processes in which micro-organisms breakdown organic matter in the absence of air. Anaerobic digestion that takes place at 35-370C is called mesophilic anaerobic digestion (Vindis, 2009).

Design of the anaerobic digester

The sludge flow to the digester is = 973.4m3/d Average flow to digester = 1.3 x 973.4m3/d = 1265.42 m3/d The retention time is 14 days (tender document) Digester volume = Flow x HRT = 1265.42m3/d x 14d = 17715.88m3 Taking a side depth of 9m (with 0.5m additional as free board) Tank area = 17716m3/ 9m = 1968.4m2 The design provides for two digesters each of volume 17716m3//2 = 8858m3

Gas Generation
The primary tank generates: TSS = 320.2m3/d x 60Kg/m3 = 19212Kg/d VSS = 19212Kg/d x 75/100 = 14409Kg/d Ash = 19212Kg/d - 14409Kg/d = 4803Kg/d

The secondary tank generates: TSS = 653.2m3/d x 60Kg/m3 = 39192Kg/d VSS = 39192Kg/d x 80/100 = 31353.6Kg/d Ash = 7838 Kg/d Combined TSS = 39192Kg/d + 19212Kg/d = 58404Kg/d Page 30 of 34

Activated Sludge limited 31 Process Design for the Waterford city Waste Water Treatment Plant Combined VSS = 31353.6Kg/d + 14409Kg/d = 45762.6Kg/d Combined ash = 7838.7Kg/d + 4803Kg/d = 12667.4Kg/d

48% of the VSS is destroyed in the digester. VSS Destroyed = 45762.6Kg/d x 48/100 = 21966Kg/d

Gas yield 1kg of VSS destroyed yields 0.45m3 of methane. Total volume of methane produced is therefore VSS destroyed x 0.45m3 = 21966 x 0.45m3 = 9884.7m3

Gas storage
Two inflatable membranes gas storage shall be provided having volumes of 5000m3.

CHP Power output

1Nm3 of methane yields 9.97kWh (Horan, Nigel, 20). Energy produced daily is therefore: 9.97kWh/1Nm3 x 9884.7m3 = 98550.5kWh Power =

Dewatering
The digestate is thickened to a minimum of 23% dry solid as the tender requires. The sludge thickening centrifuge is used for the dewatering process thus keeping operational cost low.

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Activated Sludge limited 32 Process Design for the Waterford city Waste Water Treatment Plant

Nutrient recovery
The digestate from the MAD process is very rich in nutrients especially nitrogen and phosphorus. They can be applied directly to agricultural lands within the limit of local regulations. The digested liquor is also rich enough to precipitate a magnesium ammonium phosphate called struvite (Mg.NH4.6H2O). Struvite has been found to be a good slow-release fertilizer and in the face of global phosphorus shortage (Horan Nigel 22), struvite production will contribute to the economy of the waste water plant operations. The Ostara pearl process (Horan Nigel 22) of manufacturing struvite from digestate liquor is built into this design as part of future expansion plans. Up to 90% phosphorus and 40% ammonia load can be removed from the digestate liquor using this method (Ostara technologies).

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Activated Sludge limited 33 Process Design for the Waterford city Waste Water Treatment Plant

CONCLUSION
4 6

9 10 0

13

12

11

14

Units operations 1. Screen 2. water course 3. Grit chamber 4. Primary Sedimentation tank 5. Storm tank 6. Returned Activated Sludge 7. Secondary sedimentation tank 8. Sludge thickener 9. Blender/storage 10. Digester 11. Digestate store 12. Belt filter press 13. Biogas Storage 14. CHP

Flow (m3/d) 145564.5 >145564.5 145564.5 82,395 >63169.5 27,465 82395 973.4 973.4 973.4 973.4

BOD (kg/d) 11,436 11,436 11,436 8005.2

TSS (kg/d) 8005 8005 8005 3202

988.7

1400.7

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Activated Sludge limited 34 Process Design for the Waterford city Waste Water Treatment Plant

REFERENCES
Horan N. (2011) Approach channels and screens (CIVE 5532 Lecture note), school of civil engineering, University of Leeds. Degremond Technologies. (2011). Infilco climber screen. Available at www.degremont-

technologies.com/IMG/pdf/CLIMBER_SCREEN_US_Infilco.pdf (accessed on 12/1/12)

Idswater. (2011). PISTA Grit Removal System. Available at

http://www.idswater.com/water/us/grit_removal/1037/products.html
12/1/12)

(accessed on

Horan N. (2011) Dealing with drainage (CIVE 5532 Lecture note), school of civil engineering, University of Leeds. Horan N. (2011) Grit Removal (CIVE 5532 Lecture note), school of civil engineering, University of Leeds. Horan N. (2011) Design of radial flow tanks (CIVE 5532 Lecture note), school of civil engineering, University of Leeds. Horan N. (2011) Primary Sedimentation Tanks (CIVE 5532 Lecture note), school of civil engineering, University of Leeds. Lin, S (2001) Water and Wastewater Calculation Manual, London, Mc Graw-Hill. Horan N. (2011) Estimating Reactor Volumes (CIVE 5532 Lecture note), school of civil engineering, University of Leeds. Horan N. (2011) Selectors and Anoxic Zones (CIVE 5532 Lecture note), school of civil engineering, University of Leeds. Horan N. (2011) Reactor Aspect Ratio (CIVE 5532 Lecture note), school of civil engineering, University of Leeds. Euroby. (2011). Centrifugal Thickening. Available at

http://www.euroby.com/cent_thickening.htm?gclid=CIHy2PGd860CFUoifAodjRZ9sA (accessed on 16/1/2012) Vindis et al. (2011). The impact of anaerobic digestion on biogas production. Available at

http://www.journalamme.org/papers_vol36_2/36210.pdf (accessed on 20/1/2012)

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