University ofChE

San
545 Agustin
INDUSTRIAL WASTE MANAGEMENT &
CONTROL
(Wastewater Treatment Facilities Design
and Calculation)

Lecture 4
Dr. Nolan C. Tolosa
BSc. ChE, MSc. EnE, PhD EnE
MISSION

The University of San Agustin is an Augustinian,

Catholic and Filipino educational institution that
aims to form the members of its academic
community in Virtus et Scientia to serve Western
Visayas, the Philippines, and the world.
VISION

A premier academic community of life–long

learners working with one mind and one heart to
search for, discover and share the Truth
(Gaudium de Veritate) for the promotion of
Authentic human and societal development.
BIOLOGICAL TREATMENT SYSTEMS
 Many industries generate high BOD and COD wastewater
 Biological treatment most cost effective for these wastes
 All bio systems rely on mixed cultures of micro-organisms
 Two major classes of micro-organisms:
 Heterotrophs- use organic carbon as energy source
 Autotrophs- use inorganic carbon as primary energy source
 All require macro and micro nutrients:
 Macro – nitrogen, phosphorus, sulphur
 Micro – potassium, magnesium, calcium, iron and trace elements
Biological Treatment - Fundamentals

 Major Environmental Factors:

 Temperature – reaction rates double each 10 degrees C , up
to 45 deg C
 pH – Most need pH range of 6.5 to 8.5. Note it is reactor pH
that is important
 Toxicants - many industrial effluents contain toxics such as
CN, Cr, Cu, phenols, sulphides etc.. There are threshold levels
of toxicants for both aerobic and anaerobic bacteria – above
these thresholds, systems fail.
 Treatment Train
wastewater

Screening / Biological
physical treatment
treatment
Waste sludge

Stabilisation / Polishing /
dewatering disinfection
residuals

Treated effluent
Aerobic vs. Anaerobic Processes
• Aerobic process uses Sludge
50%
O2 as electron acceptor
Aerobic
process
Wastewater 50% Heat
BOD / COD
~ 0.5

Methane
• Anaerobic process uses
90%
SO4, PO4 and organics Anaerobic
as electron acceptors process
Sludge
10%
Selection of Aerobic vs. Anaerobic treatment
Parameter AEROBIC ANAEROBIC

Influent characteristics < 2,000 mg/L BOD > 2,000 mg/L BOD
Low alkalinity needed 1500 mg/L alkalinity needed
100 BOD : 5 N : 1 P 100 BOD : 2 N : 0.4 P
5 – 30 oC > 20 oC
Oxygen requirements Related to BOD, high Nil
Reactor conditions 6.5 – 8.5 pH 6.5 – 7.5 pH
1.5 mg/L DO 0 mg/L DO
Sludge production 0.6 – 1.1 kg TSS / kg 0.2 – 0.4 kg TSS / kg BOD
BOD reduced reduced

Other features 80 – 99 % BOD reduction 75 – 90 % BOD reduction

Greater tolerance More prone to process upset
Smaller space, fast Bigger space, slow process
process recovery recovery
Foam potential Low Foam potential
Energy intensive Low energy requirements
Aerobic Treatment

• Used to treat low and medium strength wastewaters

(BOD < 300 - 2,500 mg/L)
• Aerobic Systems:
• Suspended Growth: Activated sludge (conventional, SBR, MBR)
• Attached Growth:
• Trickling filter, RBC
• Hybrid: MBBR
Aerobic Treatment

• Requires careful control to maintain stable performance

and avoid process failure
• High energy reqt to provide aeration to reduce BOD
Benefits :
• Produces high quality effluent (BOD < 20 mg/L)
• Significant BOD reduction > 95 %
• Can remove nutrients
Biological Growth Processes
(aerobic)

Microbiological process and product formation

new bacterial
cells
organic
waste bacteria
matter

nutrients
degradation products
energy NH4, P, etc.
CO2, H2, NO3 ,
inorganic solids
• Municipal wastewaters commonly contain sufficient
concentrations of
• Carbon
• Nitrogen
• Phosphorus
• Trace elements
to support growth of a microbial culture

• Theoretical BOD:N:P ratio of 100/5/1 is adequate for

aerobic treatment
• Large volume of nutrient-deficient industrial waste
- Nitrogen supplied by addition of anhydrous NH3 or NH4NO3
- Phosphate supplied by addition of H3PO4

• Diffused and mechanical aeration basins supply

sufficient air to maintain DO for biota to use in
metabolizing the waste organics
• Rate of microbial activity is independent of DO concentration
above a minimum value, below which rate is reduced by
limitation of oxygen required for transpiration

• Conventional activated sludge system is

- Combination of physical and biological processes
- Designed to remove organic matter and solids from solution
Conventional Activated Sludge System
Treatment Components

• Preliminary / Primary treatment

• Secondary / Biological treatment

• Tertiary treatment (filtration / disinfection)

• Sludge Management
PRELIMINARY TREATMENT
• First steps in processing a municipal wastewater
• Flow measurement
• Screening
• Pumping
• Grit removal
• Chlorine solution or ferric chloride may be added to raw wastewater
• Odor control
• Improve settling characteristics of solids
Flow Measuring
• All treatment plants are required to monitor influent wastewater
flow
• Best system is Parshall flume that is equipped with an automatic flow
recorder and totalizer
• Advantages of a flume
• Low head loss
• Smooth hydraulic flow to prevent deposition of solids
Screens and Shredders
• Mechanically cleaned screens have clear bar openings of between 10 and 25
mm
screen
Grit Chambers
• Grit includes sand and other heavy particulate matter which
settle from wastewater when the velocity of flow is reduced
• Grit in primary settling tanks can cause
• Abnormal abrasive wear on mechanical equipment and sludge pumps
• Clog pipes by deposition
• Accumulate in sludge holding tanks and digesters
• Grit chambers are designed to remove particles equivalent to a
fine sand, defined as
- 0.2 mm-diameter particles with a specific gravity of 2.7, with a minimum
of organic material included

• Variety of systems are employed depending on

- Quantity of grit in the wastewater
- Size of the treatment plant
- Expenditure allocated to installation and operation
• Standard chambers
include
• Channel-shaped settling
tanks
• Aerated units with
hopper bottoms
• Forced vortex tanks
• Calculation of volume of grit removed using a grit
pump

 Peak flow (m / d) 3

Grit (kg/m /d)  
3
3
 1  670
 Average flow (m / d) 
[11  1]
SEDIMENTATION
• Settling (clarification)
• Performed in rectangular or circular tanks
• Wastewater is held quiescent to permit particulate solids to settle out of
suspension
• Flow enters behind a baffle to dissipate inlet velocity to prevent
• Short-circuiting
• Hydraulic disturbances in the tank
• Overflow weirs are
• Placed near the effluent channel
• Arranged to provide a uniform effluent flow
• Mechanical skimmer collects and deposits the scum in a
pit outside the tank
• Criteria for sizing settling tanks are
• Weir loading rate
• Overflow rate (surface settling rate)
• Tank depth at side wall
• Detention time
Primary Clarifiers
 Settled WW
Degritted or
Scum baffle / trough
Wastewater Primary WW

scraper
scraper

Sedimentation tank
Sludge
O’flow weir
Rectangular horizontal-flow

· Tanks use less space

· Forward velocity 10 - 15 mm/s

· Weir loading rate < 300 m3/m.d

· Length: width ratio 3:1

Circular Radial Flow Tank
• Calculation of average daily overflow rate

Q
V0  [11 - 2]
A

where V0 = overflow rate surface settling,

m3/m2 · d

Q = average daily flow, m3/d

A = total surface area of tank, m2

• Calculation of detention time

V
t  24 [11 - 3]
Q

where t = detention time, hours

V = tank volume, m3

Q = average daily flow, m3/d

24 = number of hours per day

• Clarifier depth varies for
- Primary, intermediate, biological filters
- Activated-sludge secondary clarifiers

• Detention time represents a balance between

- Overflow rate AND
- Clarifier depth
• Rectangular tanks are popular where space is limited because they can be
constructed together using common wall construction

• Circular tanks are generally preferred to rectangular tanks in new

constructions because of
- Lower installation costs
- Lower maintenance costs

• Greater weir lengths can be more easily achieved around the periphery of a
circular tank than across the end of a rectangular one
• Calculation of detention time using overflow rate and depth
24  H
t [11 - 4]
V0

where t = detention time, hours

H = depth of water in tank, meter

V0 = overflow rate, m3/m2 · d

24 = number of hours per day

• Weir loading is the hydraulic flow over an effluent weir

Sample Problem #1
Two primary settling tanks are 29 m in diameter with a 2.1 m side water
depth. Single effluent weirs are located on the peripheries of the tanks. For an
average design flow of 32000 m3/d and peak flow of 58000 m3/d, calculate
the overflow rate, detention time, and weir length.
Intermediate Clarifiers
• Intermediate clarifiers are sedimentation tanks in two-stage secondary
treatment that are between
• Trickling filters OR
• Filter and subsequent biological aeration

• GLUMRB Standards recommend the following criteria for sizing

intermediate settling tanks:
• Overflow rate should not exceed 41 m3/m2 · d
• Minimum side water depth is 2.1 m
• Weir loading ≤ 80 m3/m·d for plants of 3800 m3/d or smaller, and ≤ 250
m3/m·d for larger plants
Final Clarifiers
• Purpose of gravity settling following an aeration tank or trickling filter
• Collect biological growth (humus) flushed from aeration tank or filter media

• Gravity separation of biological growths suspended in the mixed liquor of

aeration systems is more difficult
• Greater viability of activated sludge results in floc that has reduced settling
velocities
• Advantages of rapid uniform withdrawal of sludge across the entire bottom
of an activated-sludge final clarifier
• Retention time of solids that settle near the tank’s periphery is not greater than
those that land near the center
• Aging of biological floc and floating solids due to gas production are eliminated
• Direction of activated-sludge return flow is perpendicular to the tank bottom,
rather than horizontal toward a centrally located sludge hopper
 • Downward flow through a sludge blanket enhances gravity settling of floc and increases
sludge density

• Compared to other wastewater sedimentation tanks, activated-sludge

clarifiers are/have
• Deeper to accommodate the greater depth of settled solids
• Lower overflow rate to reduce carryover of light biological floc
• Longer weir lengths by the installation of an inboard weir channel to reduce the
approach velocity of the effluent
Sample Problem #2
Determine the recommended size of a new circular final clarifier for an
activated-sludge system with a design flow of 26,000 m 3/d with a peak
hourly flow of 32,000 m3/d. Use maximum overflow rates of 33 m3/m2 · d at
design monthly flow and 66 m3/m2 · d at peak hourly flow.
 Secondary (Biological) Process
Primary Wastewater
Aeration Tank Secondary
or Bioreactor Clarifier

Secondary
Effluent

Return activated Sludge Waste

(RAS) Activated
Mixed Liquor Sludge (WAS)
Bioreactor – aerobic activated sludge
reactor
Advantages
Process is robust
Common, proven process
Adaptable to many types of
wastewater
Large dilution capacity for
shock and toxic loads
Design is relatively
uncomplicated
Comparatively easy to
operate and maintain
Disadvantages
If not maintained well, the
following might occur
Susceptible to filamentous
sludge bulking that may cause
excessive suspended solids
and turbidity in the effluent and
high chlorine demand
Poor mixing and short –
circuiting may adversely affect
effluent quality
Comparatively high land area
requirement
Aeration Tank Loadings
• An activated sludge process is defined by
• Aeration period
• BOD loading per unit volume
• Food-to-microorganism ratio
• Sludge age

• Calculation of volume (V) of aeration tank

V
t  24 [11 - 3]
Q
• Calculation of BOD load
settled wastewate r BOD
BOD loading  [11 - 5]
volume of aeration basin
• F/M is a way of expressing BOD loading in proportion to the microbial mass in the system

F Q  BOD
 [11 - 14]
M V  MLSS
where F/M = food-to-microorganism ratio, grams of BOD per day per gram of MLSS

Q = wastewater flow in m3/d

BOD = wastewater BOD, g/m3

V = liquid volume of aeration tank, m 3

MLSS = mixed liquor suspended solids in the aeration basin, g/m 3

• Sludge age (mean cell residence time) is an operational parameter related to
the F/M ratio
MLSS �V
Sludge age  [11-15]
SSe �Qe + SSw �Qw

where sludge age = mean cell residence time, days

MLSS = mixed liquor suspended solids, mg/l

V= volume of aeration tank, m3

SSe = suspended solids in wastewater effluent, mg/l

 Qe = quantity of wastewater effluent,
m3/d

SSw = suspended solids in waste sludge, mg/l

Qw = quantity of waste sludge, m3/d

• BOD loading per unit volume and aeration period are interrelated
parameters dependent on
- Concentration of BOD in wastewater entering
- Volume of aeration tank

• F/M ratio is an expression of BOD loading relating to metabolic state of

biological system rather than volume of tank
- Defines activated-sludge process without reference to aeration period or
strength of applied wastewater
 Calculations
Biological Treatment – Activated Sludge

Organic Loading flow ML/d x BOD conc. kg/ML

kg BOD / m3.day reactor volume, m3
F:M ratio flow ML/d x BOD conc. kg/ML
MLSS, kg/m3 x reactor volume, m3
Hydraulic retention time, d reactor volume m3 / flow m3/d

Clarifier
Surface Loading flow m3 /d
m3 / m2.day Clarifier surface area, m2
 Design Criteria

Activated Sludge (Conventional)

Bioreactor loading rate 0.6 kg BOD /m3.d

Hydraulic Retention Time 6 – 8 hours
Clarifier surface loading 35 m3/m2.d at 3 x average flow

Contaminant reduction, % 80 - 90 % BOD / 80 – 95 % SS /

10 - 30 % nitrogen
• In general, MLSS conc
• < 1000 mg/l does not provide a low enough F/M for good sludge settleability
• > 4000 mg/l results in loss of suspended solids in the clarifier overflow
• Common range is 2500 to 3500 mg/l

• Rate of return sludge from final clarifier to aeration basin is expressed as a

percentage of the raw wastewater influent
Sludge Settleability
• Effectiveness of treatment achieved in an aeration process depends
directly on settleability of the biological floc
• Sludge bulking
• Excessive carryover of floc resulting in inefficient operation
• Caused by adverse environmental conditions created by
• Insufficient aeration
• Lack of nutrients
• Presence of toxic substances
• Overloading
Sludge Volume Index (SVI)
· A criterion for measuring the settleability of sludge

· It is related to the recycling of activated sludge

· SVI is defined as the settled volume of sludge (mL/L) in 30

minutes per unit MLSS (mg/L)

· SVI of 50 - 100 mL/g indicate good dense sludge

· SVI > 150 mL/g are light, poorly compacting (bulking

sludge)
SUSPENDED GROWTH SYSTEM:
Conventional Activated Sludge System
SUSPENDED GROWTH SYSTEM:
Sequencing Batch Reactor (SBR)
 Filling (mixed - aerated)

Influent

Mixed -
Aerated

Reaction
Decanting The
SBR-
cycle
Mixed -
Non -aerated

Settling
 Design Criteria

SBR
Bioreactor loading rate 0.06 kg BOD /m3.d
Hydraulic Retention Time 32 – 40 hours
Cycle 2 h aeration, 1 h settling, 1 h
decant
Contaminant reduction, % 80 - 95 % BOD / 80 – 95 % SS /
60 - 85 % nitrogen
Advantages Disadvantages
A higher level of
Process is simplified, final sophistication and
clarifiers and RAS pumping maintenance is required,
are not required especially of larger systems,
of timing units and controls
Operation is flexible, nutrient
removal can be Most of the component parts
accomplished by operational are patented and imported
changes
Comparatively the same land
area requirement as CAS (if
equalisation tanks are used)
SUSPENDED GROWTH SYSTEM:
Membrane Bioreactor (MBR) – Advanced System
Submerged MBR
External MBR
Advantages
Low SS concentration and removal of
large particles in product water enables
effective disinfection to be
accomplished
Can be designed with long sludge age,
hence low sludge production
Secondary clarifiers and tertiary
filtration processes are eliminated,
thereby reducing plant footprint
No reliance upon achieving good
sludge settleability, hence quite
amenable to remote operation
Produces a MF/UF quality effluent
suitable for reuse applications
Disadvantages
Long term history of operation is
not available
Use more electricity: high pressure
systems can be energy intensive
Technical complexity
Limited availability of experienced
operating personnel
High CAPEX and OPEX
Requires replacement of
membranes every five years which
is relatively expensive
All MBR systems make use of
propriety equipment and designs;
there is no standard configuration
Pilot testing is often required for full
– scale design
ATTACHED GROWTH SYSTEM:
Trickling Filter (TF)
ATTACHED GROWTH SYSTEM:
Rotating Biological Contactor (RBC)
STM – Aerotor System (Proprietary system)
HYBRID SYSTEM:
Moving Bed Bioreactor (MBBR)
 ANAEROBIC PROCESS
COMPLEX ORGANIC COMPOUNDS

Stage 1 anaerobic bacteria

(acidogenesis)

Organic acids, alcohols, CO2 + H2

Stage 2 methane forming bacteria

(methanogenesis)

CH4 + CO2 + H2O

ANAEROBIC SYSTEM:
Upflow Anaerobic Sludge Blanket (UASB)
Constructed Anaerobic Digesters
Advantages Disadvantages
No need for any energy Anaerobic treatment alone
consuming mechanical or cannot achieve surface water
hydraulic agitation within the discharge quality without
reactor post-treatment
The process is not widely
Production of biogas that can be used for domestic waste and
converted to electricity is usually optimised for
stronger industrial loads
Much less bio-solids waste
generated compared with
aerobic process because much
of the energy in the wastewater
is converted to a gaseous form
and resulting in very little energy
left for new cell growth
ANAEROBIC SYSTEM:
Anaerobic Lagoons
OTHER SYSTEMS
Lagoons/Ponds
Use where :
• Effluent quality is not stringent (say 70 % reduction in BOD, limited nutrient
reduction requirements)
• Large area available (odours not issue)
• Limited skill base
 Lagoon Treatment

Aerobic Completely-mixed Aerated

Facultative Partially mixed Aerated

CH4
Anaerobic Covered Anaerobic
Reported performance of wastewater
anaerobic ponds 3 – 6 m deep
ponds
BOD reduction 50 to 90 %
0.3 kg BOD / m3.d Nutrient reduction – nil
30 – 40 d HRT SS reduction - limited

facultative and 1.5 – 2 m deep BOD reduction 70 - 85 %

aerobic ponds 100 kg BOD / ha.d Effluent SS 40 – 60 mg/L (can
25 – 40 d HRT be higher from algae / sludge)
Nutrient reduction 20 – 50 %

aerobic 1.5 – 2.5 m deep BOD reduction 60 – 80 %

maturation 50 kg BOD / ha.d Effluent SS 10 – 30 mg/L (can
ponds 20 – 30 d HRT be higher from algae)
Nutrient reduction 20 – 40 %
 Pond Treatment Train – Industrial WWTP

Facultative pond

Aerobic pond
(polishing)

Anaerobic pond
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DISINFECTION for RE-USE or
DISCHARGE
Wastewater
Aim:
Disinfection
• To remove bacteria from treated final effluent

• In order to allow re-use (protection of public and environmental

health):

• Total Coliforms 1000 / 100 mL (agriculture)

• Total Coliforms 10 / 100 mL (non-potable)
Options
• Chlorination (gaseous chlorine or hypochlorination)
• UV irradiation
• Ozonation
• Microfiltration
• Maturation Ponding (die-off)
 Comparison

Process Design Criteria

Requirements
Chlorine Contact (reaction tank) Approx 30 – 60 minutes
Chorine dose RT
5 – 10 mg/L
Ozonation Contact (reaction tank) Approx 5 – 15 minutes
Ozone dose RT
3 – 7 mg/L
UV Irradiation Reaction tank 3 – 8 seconds
UV wavelength 254 nm
Dose rate 20 – 40 mJ/cm2

Microfiltration Contact reaction time 20 seconds

Surface loading flux
50 – 120 L/m2.hr
Maturation Ponding Hydraulic retention time 20 days
Depth of tank
1–2m
 EFFLUENT RECYCLING
USES
• Agricultural or horticultural applications
• Landscape irrigation
• Industrial use (cooling)
• Toilet Flushing

CONSIDERATIONS
• Quantity (volume – generated & requirements),
• Quality (effluent characteristics)
• Volumetric needs (soil studies if agricultural)
• Environment - Slope of land / proximity to surface and
groundwater
• Economic analysis
Industrial re-use
 IndustrialUses of recycled water include:
Production (non-food)
Washing and cleaning
Service water for heating and cooling
Boiler water make-up
Irrigation

 Saving water will save money in the long term

 Environmental & economic benefits cleaner production
SLUDGE MANAGEMENT
TYPE OF SLUDGE'S GENERATED BY INDUSTRY

CHEMICAL ORGANIC
- Meat processing
- Mineral processing - Dairy
- Metal coating / - Food and beverage
electroplating manufacturing
- Sewage treatment
- Pulp & paper
plant residuals

HAZARDOUS WASTES
- Toxic
- corrosive
- biohazardous
Basic sludge principles
• Minimise volume
• Understand source and inputs and minimise ingress of contamination
• Destroy organic material through stabilisation process
• Recover energy from processing
• Reduce volume through dewatering
• Re use material streams beneficially (application of organic matter)
Chemical Sludges
Specific to industry

Test for characteristics, contaminants

Biological sludges
Options include: Easiest to re-use (but dependent on
stability and contaminants).
• Landfill

• Reclamation
Typical options include:
• Incineration
•Treat / stabilise
• Chemical or thermal stabilisation •Animal feed
•Landfill
All after dewatering •Land application
•composting
 Sludge treatment and disposal
• stabilisation (to provide treatment
and prevent putrefaction)
 Lime stabilisation, biological
digestion, composting

• dewatering (will reduce volume)

 Belt press, centrifuge, drying bed

• disposal / recycling of final

sludge product (check
contaminants)
 Land fill, horticulture, land
application
Other Types of Sludge Dewatering
Equipment

Drying Bed

Filter Press
 Sludge Management (Typical for STP)
• Stabilisation
•Anaerobic digestion

• Dewatering to produce a
dewatered product
Oily Sludge (petrochemical industry)
• Difficult to dispose of
• Emulsions of oil-in-water

• Typically treated with centrifuging (with or without heat), and the addition
of treatment chemicals (coagulants, flocculants, water-soluble and oil-
soluble demulsifiers).  

• 3 phase centrifugation – oil recovery, water removal and centrifuged solids

• Solids could be used for cement kiln fuel (after drying), thermal desorption (drying
process to generate sludge)
“vitus et scientia”