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A trickling filter consists of a bed of highly permeable media on whose surface a mixed
population of microorganisms is developed as a slime layer. The word "filter" in this case is not
correctly used for there is no straining or filtering action involved. Passage of wastewater
through the filter causes the development of a gelatinous coating of bacteria, protozoa and other
organisms on the media. With time, the thickness of the slime layer increases preventing oxygen
from penetrating the full depth of the slime layer. In the absence of oxygen, anaerobic
decomposition becomes active near the surface of the media. The continual increase in the
thickness of the slime layer, the production of anaerobic end products next to the media surface,
and the maintenance of a hydraulic load to the filter, eventually causes sloughing of the slime
layer to start to form. This cycle is continuously repeated throughout the operation of a trickling
filter. For economy and to prevent clogging of the distribution nozzles, trickling filters should be
preceded by primary sedimentation tanks equipped with scum collecting devices.
Primary treatment ahead of trickling filters makes available the full capacity of the trickling filter
for use in the conversion of non-settleable, colloidal and dissolved solids to living microscopic
organisms and stable organic matter temporarily attached to the filter medium and to inorganic
matter temporarily attached to the filter medium and to inorganic matter carried off with the
effluent. The attached material intermittently sloughs off and is carried away in the filter
effluent. For this reason, trickling filters should be followed by secondary sedimentation tanks to
remove these sloughed solids and to produce a relatively clear effluent.
The primary factors that must be considered in the design of trickling filters include: (1) the
type of filter media to be used, (2) the type and dosing characteristics of the distribution system,
and (3) the configuration of the underdrain system.
1. Filter Media: The ideal filter medium is a material that has a high surface
area per unit volume, is low in cost, has a high durability, and does not
readily clog. The choice of filter media is more often governed by the
material locally available which may include field stone, gravel, broken
stone, blast furnace slag and antracite stones. Stones less than one inch in
diameter do not provide sufficient pore space and may therefore result in
plugging of the media and ponding. The tendency is to use larger sizes
with 2 1/2 inches in diameter now considered the minimum size. Large
diameter stones tend to avoid ponding situations but also limit the surface
area per unit volume available for the slime layer to grow. An upper size
limit of about 4 inches is therefore recommended.
2. Distribution System: The rotary distributor has become standard for the
trickling filter process because of its reliability and ease of maintenance.
The rotary distributor consists of a hollow vertical center column carrying
two or more radial pipes or arms, each of which contains a number of
nozzles or orifices for discharging the wastewater onto the bed. All of
these nozzles point in the same direction at right angles to the arms and the
reaction of the discharge through them causes the arms to revolve. The
necessary reaction is furnished by a head of 18" to 24". The speed of
revolution will vary with the flow rate, but it should be in the range of one
revolution in 10 minutes or less for a two-arm distributor. A dosing tanks
and siphon should be provided for standard rate trickling filters to shut off
the flow when the head falls below that necessary to revolve the arms at
the required speed. In some cases positive drive mechanisms are being
used.
A clearance of 6 to 9 inches should be allowed between the bottom of the distributor arm and top
of the bed. This will permit the waste streams from the nozzles to spread out and cover the bed
uniformly, and it will also prevent ice accumulation from interfering with the distributor motion
during freezing weather.
Fixed spray nozzles were used when trickling filters were first developed. The nozzles were
attached to pipes laid in the filter medium and were fed intermittently from a siphon controlled
dosing tank. By this method, wastewater is applied to the filter for short periods of time.
Between applications the filter has rest periods while the dosing tank is filling. Many types and
shapes of nozzles were developed and the siphon dosing tank was designed to attain the best
possible even distribution of wastewater over the entire surface of the filter. At best, the
distribution was not even and there were areas of the filter on which very little wastewater was
sprayed.
In addition, due to the greater number of nozzles used for the distribution of the wastes, clogging
and increased operational and maintenance problems were encountered.
The organic load on a filter is the BOD content in pounds applied to the filter. This is usually
expressed as pounds of BOD per day per 1000 cubic feet of filter medium or pounds of BOD per
day per acre foot. The hydraulic load, including recirculation flow if used, is the gallons of flow
per acre of filter surface per day.
Low-rate filters are relatively simple treatment units that normally produce a consistent effluent
quality even with varying influent strength. Depending upon the dosing system, wastewater is
applied intermittently with rest periods which generally do not exceed five minutes at the
designed rate of waste flow. With proper loadings the low-rate trickling filter, including primary
and secondary sedimentation units, should remove from 80 to 85 percent of the applied BOD.
While there is some unloading or sloughing of solids at all times, the major unloadings usually
occur several times a year for comparatively short periods of time.
High-rate filters are usually characterized by higher hydraulic and organic loadings than low-rate
filters. The higher BOD loading is accomplished by applying a larger volume of waste per acre
of surface area of the filter.
When recirculation is used, the hydraulic loading per unit area of filter media is increased. As a
result, higher flow velocities will usually occur causing a more continuous and uniform
sloughing of excess growths. Recirculation also helps to minimize problems with ponding and
restriction of ventilation.
Recirculation can be continuous or intermittent. Return pumping rates can either be constant or
variable. Sometimes recycling can be practiced during periods of low flow to keep the
distributors in motion, to prevent the drying of the filter growths, and to prevent freezing during
colder temperatures. Also, recirculation in proportion to flow may be utilized to reduce the
organic strength of the incoming wastes, and to smooth out diurnal flow variations.
Biofilter: The bio-filter is a high-rate filter, usually 3 to 4 feet in depth, employing recirculation
at all times. The recirculation in this case involves bringing the effluent of the filter or of the
secondary sedimentation tank back through the primary settling tank. The secondary settling
tank sludge is usually very light and can be continually fed back to the primary settling tank
where the two types of sludges are collected together and pumped to the digester.
Accelo-Filter: The accelo-filter includes recirculation of unsettled effluent from the filter back
to the inlet of the filter distributor. It is used for both low-rate and high-rate filters, the former
being applicable if a well nitrified effluent is required.
Aero Filter: The aero-filter is still another process which distributes the wastewater by
maintaining a continuous rain-like application of the wastewater over the filter bed. For small
beds, distribution is accomplished by a disc distributor revolving at a high speed of 260 to 369
rpm set 20" above the surface of the filter to give a continuous rain-like distribution over the
entire bed. For large beds a large number of revolving distributor arms, 10 or more, tend to give
more uniform distribution. These filters are always operated at a rate in excess of 10 million
gallons per acre of surface area per day.
High-rate trickling filters, including primary and secondary sedimentation, should, under normal
operation, remove from 65 to 85 percent of the BOD of the wastewater. Recirculation should be
adequate to provide continuous dosage at a rate equal to or in excess of 10 million gallons per
acre per day. As a result of continuous dosing at such high rates, some of the solids accumulated
on the filter medium are washed off and carried away with the effluent continuously.
High-rate trickling filters have been used advantageously for pretreatment of industrial wastes
and unusually strong wastewaters. When so used they are called "roughing filters". With these
filters the BOD loading is usually in excess of 110 pounds of BOD per 1000 cubic feet of filter
medium.
Generally, most organic wastes can be successfully treated by trickling filtration. Normally food
processing, textile, fermentation and some pharmaceutical process wastes are amenable to
trickling filtration.
Some industrial wastewaters which cannot be treated by trickling filtration are those which
contain excessive concentration of toxic materials, such as pesticide residues, heavy metals, and
high acidic and alkaline wastes.
Since the organisms growing on the media are temperature dependent, climatic changes will
affect the filter's performance. The organisms metabolic rate increases with increasing
temperature and warmer weather. Therefore, higher loadings and greater efficiencies are
possible in warmer temperatures and climates, if aerobic conditions can be maintained in the
filter.
Common Problems
Due to its simple design, in actual operation the trickling filter is one of the most trouble-free
types of secondary treatment processes. It requires much less operating attention and process
control than the activated sludge system, but some problems do exist. The following is a
summary of some of the more common problems and cures:
1. Ponding is normally the result of: (a) excessive organic loading without
a corresponding higher recirculation rate, (b) use of media which is too
small, (c) clogging of underdrain system, (d) non-uniform media size or
breaking up of media, and (e) trash or debris in filter voids.
2. Filter Flies are a nuisance to plant personnel and nearby neighbors. These
tiny, gnat-size flies are called psychoda. They are occasionally found in
great numbers, preferring an alternate wet and dry environment for
development.
The flies are most frequently found in low or standard rate filters with an
intermittent dosing system.
The Modern
Trickling Filter
Old rock trickling filters are being upgraded and rehabilitated with plastic sheet media. The
greater surface area and higher void volume of structured-sheet media provides improved
treatment efficiency, even at the very shallow depths used in old rock filters (typically 3 ft. to
7ft.). In some cases, the walls of the filter beds may be extended upward a few feet for additional
increases in the rated capacity of the retrofitted plant.
Compared with rock, plastic sheet media has 2-3 times the specific surface area, which provides
proportionally more area for biomass attachment. Also, the increase in the void volume from
50% to 95% improves the airflow and hydraulic loading capacity, decreases the tendency of the
system to clog with biomass, and reduces odors associated with anaerobic pockets caused by
silting.
Components of Trickling Filter Towers The components shown at the top of the
page are common to most trickling filters, regardless of the type (shallow rock
retrofit, deep BOD roughing tower, or nitrification tower).
Structured-Sheet Plastic Media
Structured-sheet plastic media is the heart of the trickling filter. The specific
type of media to be used in a given system is based on the organic loading
and wastewater treatment objectives: roughing, complete treatment, or
nitrification. The media’s specific surface area, void volume, and distribution
characteristics are important to the specific application and system
performance.
The wetting rate, organic load, ammonia load, temperature of the wastewater, and desired
effluent quality determine the volume of media required.
A typical media installation layout consists of modules 2 ft. wide x 2 ft. high x 4 ft. or 6 ft. long
placed in layers, each layer placed at a right angle to the layer below. The media is cut to fill the
tank at the periphery.
Rotating-Arm Distributor
A rotating arm distributes the mixed wastewater/recycled water over the top of the media. The
distribution arm can be driven by hydraulic reaction or by mechanical means. Typically, the
speed of rotation can be adjusted to effect higher media flushing intensity. Speed change in the
distributor mechanism is particularly valuable in systems that have high organic loads. In
nitrification towers, speed change is used to flush predators, such as snails, from the tower.
Recycle Pump
A collection trough at the bottom of the tower collects the treated wastewater and channels it to a
sump, where it can be recycled as wastewater or discharged to a secondary clarifier.
Mixed Media
The optimal configuration of media in the
modern bio-tower over 16 ft. deep is the
combination of cross flow media in the upper
two layers with vertical media in the lower
layers. This configuration combines the superior
distribution properties of cross flow media with
the reduced potential for clogging of vertical
flow media, to give consistent and efficient
biological wastewater treatment.
Nitrification
Bio-towers intended for ammonia oxidation following BOD roughing can use higher surface area
media with smaller passages, such as the CF-1900 (48 ft2/ft3) alone or in combination with VF-
3800 (40 ft2/ft3) media. Thinner bio-films in the nitrification process are less likely to cause
plugging of the narrow passages.
SURFACE MIXING
ACCUPAC AREA POINTS TYPICAL
PRODUCT ft2/ft3 no./ft3 APPLICATIONS
(m2/m3) (no./m3)
Wastewater
treatment,
CFS-3000 31 (102) 180 (6,356) including BOD
roughing
and polishing
BOD reduction of
VF-5000 30 (98) —
high strength wastes
Nitrification in mixed
VF-3800 40 (131) —
media applications
MIXED MEDIA
Click here for a performance comparison between Rock Filters and PVC Media
Filters. Table will open in a separate window. Trickling Filter Process Design
The first process design approach to use fundamental principles was published by
Velz(1) in 1948. His equation expressed BOD removal as a first order function of
MOP 8 provides a large array of measured values for the coefficients in Germain’s formula for a
variety of wastewater types. The effect of temperature is generally given as:
Wetting Rates
The overall application rate of wastewater to the trickling filter, including recirculation,
expressed as gpm/ft2 of the filter area, is known as the “Wetting Rate.” The desired wetting rate
ranges from 0.05 gpm/ft2 to a maximum of 3 gpm/ft2, but is more typically in the range of 0.25
to 1 for BOD removal systems and 0.75 to 2 gpm/ft2 for
nitrification trickling filters.
If the average wetting rate is too low, the water may not penetrate the depth of the filter bed
uniformly. It may channel away from some areas and leave damp unwetted areas that can act as
incubators for pests like filter flies and snails (in nitrification towers). Also, biological
populations not continuously wetted and fed by wastewater become ineffective. Those areas of
the filter tower will not be available to provide effective treatment of wastewater during periods
of higher flow. Semi-dry biomass can also putrefy and create odor problems.
Recycle of treated wastewater is an effective method of keeping all areas and depths of the
trickling filter biologically active when the influent flow is too low for proper wetting.
Hydraulically-driven rotary distributors in the normal operating mode usually rotate at a rate of 1
revolution per 3/4 to 1-1/2 minutes and have two or four arms. The SK Rate may be in the range
of 0.3 to 0.5 mm per pass in rock filters and from 5 to 30 mm per pass in more modern filters.
If recycle capacity is minimal and the operator has the ability to slow the rotation speed of the
distributor, it is possible to compensate somewhat for low wetting rates by using higher SK
values. Higher SK values will provide more complete penetration of the filter media depth and
keep the bulk of the filter wetted.
Short cycle times of dryness between flushing will not be as detrimental to the biomass as a
general starvation for water in pockets of media that are by-passed at low wetting rates.
Recirculation Benefits
Recirculating treated effluent to the trickling filter dilutes the influent wastewater entering the
trickling filter. Since the BOD removal process is first order (i.e., the rate of removal of BOD is
affected by the initial concentration of BOD), recirculation helps distribute the loading evenly
through the depth of the filter. It also helps to manage the diurnal variation in loading while
maintaining a minimum wetting rate throughout the day. In general, higher recirculation ratios
(recirculation flow rate : influent flow rate) the better the effluent quality, at least to the point
where the hydraulic retention time in the filter bed becomes too short. Typical recirculation rates
are 1-3 times the daily average influent wastewater flow.
When dealing
with nitrification filters, the benefit of recirculation only applies to maintaining high
wetting rates, since the rate of ammonia removal is zero order to ammonia
concentrations down to 2 ppm NH3-N concentrations. This means that only the
availability and mass of the bacteria on the tower
determine ammonia removal as long as the ammonia
is greater than 2 ppm. Media Support Systems
In a typical arrangement, the bottom layer of media
modules are placed on 8 or 10-inch wide support
beams spaced across the tank on 2 ft. centers. In the
case of 10 inch support beams, a 2 inch wide center
channel provides proper drainage. At the tank wall
and around the center distributor column, a ledge 4
incheswide is used to support small pieces of cut media
AccuPier Support System
An alternative to the conventional concrete beam & pier system is the Brentwood
AccuPier® System. This pre-engineered support system, consisting of field-
adjustable plastic stanchions and fiberglass grating, is more economical and offers
better air flow than concrete beam & pier supports. The open structure of the
AccuPier system provides excellent ventilation and drainage. The glass-reinforced
ABS piers have field-adjustable bases to accommodate sloping floors. The PVC pier
stanchions are cut to length for the specific installation. Fiberglass grating in
nominal 12 inch widths x 20 ft. lengths, pre-cut for the tank
dimensions, spans the piers to give a flat, level surface to support
the media. The piers are arranged in rows 2 or 3 ft. apart, and the
spacing between piers within the row varies from 2 to 4 ft,
depending on tower height and grating strength. Media
Strength
Dedicated Bond Joints
Because the modules are constructed of vertical, corrugated sheets of PVC, the
structural strength of the modules is dependent on the bonds between adjacent
panels. Solvent welding at dedicated bond points, formed in the sheets to provide
adequate bonding surface, ensures the structural integrity of AccuPac media
Compressive Strength of Modules
The structural integrity of the media is paramount to the longevity of the filter.
Typically, each layer of the media is constructed to support the static weight of the
media above, including the attached biomass and the transient loading of the
applied wastewater. Industry practice is to use a factor of 40 lb/ft2 per foot of tower
height. The bottom layer is constructed to a minimum standard of 1000 lb/ft2 to
support the full height of the tower on the support beams. The top layer is also
designed to support 1000 lb/ft2 to accommodate possible foot traffic during
maintenance. This can be reduced to 700 lbs/ft2 when protective surface grating is
The hydraulic impact of the wastewater and braking jets of the hydraulic distributor can, over
time, damage the surface of the media. Also, it is often necessary to walk on the surface of a
trickling filter. Good tower hygiene requires removal of debris that accumulates on the top of the
filters. The distributor arms and bearings in the distribution tower also need to be serviced
regularly to maintain proper operation and equipment longevity.
Brentwood AccuGrid
Brentwood AccuGrid™ polypropylene grating provides that additional
protection for the surface of the filter surface. This grid, when placed over the
top surface of the media in the trickling filter system, will provide a non-skid
walking surface that is strong and durable against foot traffic and will help to
reduce the hydraulic impact on the media.
Economic Considerations
While direct economic comparison to other treatment processes can only be made on a case-by-
case basis, some general comparisons can be made.
• The containment vessel for bio-towers does not need to be constructed to hold the weight of the
wastewater, as do activated sludge tanks. Vessels are often built of low-cost, pre-cast concrete
panels or bolted steel plates.
• Maintenance for bio-towers is limited to the distributor arm and pumps. Blowers, air diffusers,
return sludge pumps, and associated electrical equipment and controls are not needed.
• Less operator labor is needed to monitor, sample, and make adjustments to the process for the
simpler trickling filter.
• Odor containment, if desired, is accomplished with the simple addition of a dome cover to the
bio-tower tank.
The Brentwood Trickling Filter System A complete system for the internal
components of a typical trickling filter includes: media support system; structured
sheet media; and protective surface grating. As a manufacturer of all these
components, Brentwood Industries is capable of supplying a complete system, with
a full structural warranty. All components are engineered by Brentwood to work with
each other and provide the lowest installed cost. In addition to engineering the
system and manufacturing the components, Brentwood can provide on-site
assistance for installation of the system.
--- “Trickling Filter Systems Design and Application.” Brentwood Industries, Inc.
http://www.brentwood-ind.com/water/index.html
Trickling Filters
Trickling filter is an attached growth process i.e. process in which
microorganisms responsible for treatment are attached to an inert packing
material. Packing material used in attached growth processes include rock,
gravel, slag, sand, redwood, and a wide range of plastic and other synthetic
materials.
Process Description
Types of Filters
Trickling filters are classified as high rate or low rate, based on the organic
and hydraulic loading applied to the unit.
Low Rate
S.No. Design Feature High Rate Filter
Filter
Hydraulic loading,
1. 1-4 10 - 40
m3/m2.d
Organic loading,kg
2. 0.08 - 0.32 0.32 - 1.0
BOD / m3.d
3. Depth, m. 1.8 - 3.0 0.9 - 2.5
0.5 - 3.0 (domestic wastewater) upto 8 for
4. Recirculation ratio 0
strong industrial wastewater.
• The hydraulic loading rate is the total flow including recirculation appied on unit area of
the filter in a day, while the organic loading rate is the 5 day 20°C BOD, excluding the
BOD of the recirculant, applied per unit volume in a day.
• Recirculation is generally not adopted in low rate filters.
• A well operated low rate trickling filter in combination with secondary settling tank may
remove 75 to 90% BOD and produce highly nitrified effluent. It is suitable for treatment
of low to medium strength domestic wastewaters.
• The high rate trickling filter, single stage or two stage are recommended for medium to
relatively high strength domestic and industrial wastewater. The BOD removal efficiency
is around 75 to 90% but the effluent is only partially nitrified.
• Single stage unit consists of a primary settling tank, filter, secondary settling tank and
facilities for recirculation of the effluent. Two stage filters consist of two filters in series
with a primary settling tank, an intermediate settling tank which may be omitted in
certain cases and a final settling tank.
Process Design
Generally trickling filter design is based on empirical relationships to find the
required filter volume for a designed degree of wastewater treatment. Types
of equations:
NRC and Rankin's equations are commonly used. NRC equations give
satisfactory values when there is no re-circulation, the seasonal variations in
temperature are not large and fluctuations with high organic loading.
Rankin's equation is used for high rate filters.
NRC equations: These equations are applicable to both low rate and high
rate filters. The efficiency of single stage or first stage of two stage filters, E2
is given by
E2= 100
1+0.44(F1.BOD/V1.Rf1)1/2
where E2= % efficiency in BOD removal of single stage or first stage of two-
stage filter, E3=% efficiency of second stage filter, F1.BOD= BOD loading of
settled raw sewage in single stage of the two-stage filter in kg/d, F2.BOD=
F1.BOD(1- E2)= BOD loading on second-stage filter in kg/d, V1= volume of first
stage filter, m3; V2= volume of second stage filter, m3; Rf1= Recirculation
factor for first stage, R1= Recirculation ratio for first stage filter, Rf2=
Recirculation factor for second stage, R2= Recirculation ratio for second
stage filter.
1. Raw settled domestic sewage BOD applied to filters should not exceed
1.2 kg BOD5/day/ m3 filter volume.
2. Hydraulic load (including recirculation) should not exceed 30 m3/m2
filter surface-day.
3. Recirculation ratio (R/Q) should be such that BOD entering filter
(including recirculation) is not more than three times the BOD
expected in effluent. This implies that as long as the above conditions
are satisfied efficiency is only a function of recirculation and is given
by:
E= (R/Q) + 1
(R/Q) + 1.5