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;tat. Res. Vol. 26. No. 2. pp.

139-I,1-I, 1992

0043-1354,,92 $5.00 + 0.00

Pnnted in Great Britain. All rights r--~crvcd

Copyright ~ 1992 Pergamon Prt~..splc

THICKENING OF WASTE ACTIVATED SLUDGE BY


BIOLOGICAL FLOTATION
SIMON^ {~I~INSK~, i ViT M^T~J6, t CLAESW~E, z Y v o N r ~ KLASSON,z
JAKUB KREICi~and GUNNEL DALHAMMAR3
~lnstitute of Microbiology. Czechoslovak Academy of Sciences, Videnska 1083, 142 20 Prague 4,
Czechoslovakia. :Alfa Laval A. B., Department of Waste Streams. P.O.B 500. 147 80 Tumba and ~The
Royal Institute of Technology. Department of Biochemistry and Biotechnology,
100 4.1 Stockholm. Sweden
(First recen'ed JanuaO" 1991: accepted in recised form August 1991)

Abstract--Waste activated sludge was thickened by biological flotation without polymer flocculant
dosage. The BIOFLOT tt process utilizes the denitrifying ability of activated sludge bacteria. Gaseous
products of anaerobic nitrate reduction cause spontaneous flotation of the sludge suspended solids.
Laboratory tests confirmed the dependence of sludge thickening el~ciency on available nitrate concentration, flotation time and temperature. Full-scale experiments were performed in a fully automatized unit
for discontinuous sludge thickening from wastewater treatment plants with a capacity of up to 5000 I.E.
Waste activated sludge from wastewater treatment plants at Pisek, Milevsko and Bj6rnlunda was
thickened from 6.2, 10.7 and 3.5 g/I MLSS to 59.4. 59.7 and 66.7 g/I MLSS, respectively. Concentrations
of COD, ammonium and phosphate ions were decrea~d in sludge water. The average nitrate consumption
for bioflotation was 21.2 mg NOr per I g of MLSS of activated sludge. Flotation time ranged from 4 to
48 h.
Key wordy--waste activated sludge, thickening, dcnitrilication, flotation

IN'I'RODU('nON

Primary and waste activated sludgcs are formed


during the mcchanico-biological treatment of wastewater. Their treatment and handling account for up
to 50% of the total operating costs (Spinosa et al.,
1984). Waste activated sludge contains 99.0--99.5% of
water. If it is co-settled with the primary sludge it
contains 95.0-98.0% of water. However, at many
treatment plants activated sludges are thickened independently and are then combined with primary
sludges for further treatment (Eden, 1983).
It has often been assumed that handling costs can
be minimized by thickening or dewatering of sludge
at the treatment plant. Economic assessments show
that the installation of sludge thickening often represents considerable cost benefits, especially where
the sludge is finally transported in liquid form to its
disposal outlet (Bruce and Davis. 1989). The choice
of the ways of thickening or dewatcring depends on
properties and the quantity of the sludge but also on
the desired water content for its following treatment
or the best and environmentally most acceptable
disposal. Where liquid sludge is disposed of on land
or at sea it is often thickened to 4--6*/, solids to reduce
transport costs. When sludge is to be digested anaerobically there are advantages in thickening primary
or mixed sludges to as much as 10%. Incineration
requires a moisture content sufficiently low to permit
combustion of sludge to continue with little or no
auxiliary fuel (Eden. 1983)

Since simple scdimcntation is unable to remove


sufficient water from sludge some other treatment is
required. The use of thickening has been relatively
limited in the past. But now there is a surge of interest
in thickening and considerable numbers of new thickeners are being designed (Bruce and Davis, 1989).
Flotation is very often used for the thickening of the
sludge. Flotation methods can be divided according
to the operation and the way the bubbles are formed,
to the pressure, vacuum, chemical and electrolytic
flotation.
To enhance effects of thickening or dcwatering
chemical flocculants are usually added to the sludge.
They are one of the major cost factors (Bruce and
Davis, 1989) and they can have toxic and other
adverse influence on aquatic organisms (Biesinger
and Stokes, 1986).
The thickening of waste activated sludge only by
flotation is suitable especially for small wastewater
treatment plants for economic reasons. The costs and
dilliculties of sludge thickening and dewatering call
for optimization of these processes, especially with
regard to polymer dosage.
We developed a new thickening process using
biotechnologicai methods. The process involves two
steps--flocculation and flotation (Barta et al., 1983).
The new thickening process takes advantage of a
denitrifying capability of bacteria present in a mixed
population of activated sludge, in the activated
sludge process a wide variety of common facultative
bacteria such as Pseudomonas, Micrococcus, Achro139

SimoN^ ~t~sNsr~ et ~.

140

mobacter, Spirillum and Bacillus have been reported


to accomplish denitrification (Delwische, 1956).
In the bioflotation process it is necessary to enhance denitrifying activity by controlled addition of
B I O F L O T x reagent into the waste activated sludge.
In the first step of the process the physical structure
of the sludge floes is changed. When the zeta-potential decreases under a critical limit the flocculation
occurs and dewatering properties o f the sludge are
improved (Maixner, 1985). In the second step gaseous
products of dissimilatory denitrification are released
and flotation occurs. Suspended solids o f the sludge
are thickened considerably. Organic substances present in sludge water serve as a carbon source of
dissimilatory denitrification. It is not, therefore,
necessary to add an external source of organic carbon
(Mattjt3 and ~'i~insk:i, 1988).
After preliminary laboratory and pilot scale tests of
biological flotation at 25 biological wastewater treatment plants with the industrial pollution equivalents
in the range of 0 - 8 5 % , the B I O F L O T ~ unit for
batch biological thickening of waste activated sludge
from small wastewater treatment plants was designed.
MATERAI.N ANt) M E T I l O D S

Full-scale thickening of waste activated sludge by biologigill flotation using a BIOFLOT ~ unit was tested at three
wastcwalcr trcatmcnt plants. The wastewater treatment
plant at Pisck, Czechoslovakia treats wastewatcrs in a
two-stage system, approx. 60*/0 of which is of industrial
origin mainly from food and tcxtile industries. The treatment plant at Milevsko, Czechoslovakia treats wastewatcrs
in a one-stage system, where 36*/0 comes from engineering

works and a dairy. In a small wastewater treatment plant at


Bjtrnlunda, Sweden 850 i.E. are connected and no industrial wastewaters are treated there. A survey of other
technological data of tested plants is given in Table 1.
Bioflotation is initiated by the addition of BIOFLOT ~
reagent in the form of 10% aqueous solution which contains
nitrate ions with a small portion of ammonium ions or, if
need be. trace elements and bases. The addition of trace
elements, bases and ammonium ions is usually not a
condition for bioflotation and they can only increase the
elticiency of the process. The composition of the
BIOFLOT ~ reagent is recommended according to the laboratory tests for each locality separately. The choice of the
nitrate used depends on the price and its availability. It is
enough to use nitrate of technical grade.
Laboratory tests of sedimentation and bioflotation were
carried out in 2-1. graduated cylinders of 8 cm in diameter
and 50cm high. BIOFLOT ~ reagent was added to the
sludge suspension at time zero in order that the initial nitrate
Table I. Technological parameters of wastewater treatment plants

t~t~

soo

Plant

BOD~.
(kg/m |)

B,
(kg/m Id)

B,
(kg/kgd)

SRT
(d)

Pisek

0.170

1.67

0.67

6-6

92

Milcvsko
Bjtrnlunda

0.310
0.153

0.34
--

0.08
0.28

8-10
6

94
91

BOD~ - influen[ total BODs concentration.


B, ,- volumetric loading rate.
B, - sludge loading rate.
SRT - solids retention time.
K~on ~ efficiency of gOD s removal.

(%)

content could reach concentrations ranging from 100 to


300 m&11NOr. At chosen time intervals the course of sludge
thickening was visually evaluated. The residual concentrations of nitrates and nitrites in sludge water were simultaneously measured and a specific denitrifying rate (qo) was
then calculated. This rate expresses the amount of reduced
nitrate and/or nitrite nitrogen to gaseous dinitrogen per I g
of MLSS of activated sludge per hour as follows:
qo

(NOr - N + NOr - N)0 (mg/gh)


2" M LSS" t0.~

where
(NO/ - N + NO.,- - N)0 = initial nitrate and nitrite nitrogen concentrations (mg/I)
t0.~ = time when half of the initial
nitrate and nitrite nitrogen concentrations are reduced (h).
Full-scale tests were made in a BIOFLOT s prototype unit
which was produced by cooperation between the Swedish
firm Alfa Laval and ZVU Hradec Kralove. Czechoslovakia
(Fig. I). The direction of suspension flow is controlled by
three three-way valves. The filling and emptying of the
bioreactor are automatically controlled by level probes.
When the bioflotation is over the sludge water is pumped
from the bottom of the flotation tank into the inlet of the
wastewater treatment plant. When the layer of the thickened
sludge reaches the optical measuring device the sludge is
pumped into the sludge storage tank. Outside dimensions of
the BIOFLOT ~" unit 3500x 1856 x 2400mm follow the
Europallet standard. The weight of the unit is 1400 kg.
The unit was filled up to 50% at the wastewater treatment
plant Bjtrnlunda because of low production of waste activated sludge. Flotation time w:ls changed in a broad
interval, i.e. at Pi.~k from 4 to 12 h, at Milevsko from 8 to
19 h and at Bj6rnlunda from 20 to 48 h.
Testing and analysis were carried out in general accordance with Standard Method~ (APIIA, 1980). Total nitrogen
was determined using a CiIN analyzer (LECO CIIN-600).
RESULTS

The tests were performed at three wastewater


treatment plants with different treatment technologies and wastewater qualities.

Laboratory tests
The dependence o f both the thickening o f waste
activated sludge and specific denitrifying rate upon
initial nitrate concentration, temperature and
flotation time was investigated. At the same time
thickening of the sludge by bioflotation and simple
sedimentation, i.e. without B I O F L O T ~ reagent
dosage, were compared. The results are summarized
in Tables 2 and 3 as average values.
The efficiency of sludge thickening increased with
increased initial nitrate concentration. There was no
apparent influence o f initial nitrate concentration
upon the specific denitrifying rate. Increasing sludge
suspension temperature accelerated the start of
bioflotation, however, the final concentration o f
M L S S in flotated sludge cake was not influenced
considerably. The rising o f the enzymic reaction rate
with increasing temperature can be expressed by the
Q,0 quotient. The specific denitrifying rate o f the
sludge increased by a factor 1.74-2.00 per 10C
temperature increase. Denitrification proceeded even

Thickening of waste activated sludge

141

Fig. I. BIOFLOT ~ unit dsesign. I, Flotation bioreactor; 2, frame; 3, armatures; 4, BIOFLOT ~ additive
dissolving tank; 5, control panel; 6 platform.

at 5~'C at the Bj6rnlunda wastewater treatment plant.


Prolonged flotation time from 4 to 24 h increased the
MLSS concentration in flotated sludge cake by
49.3% on average. The MLSS concentration in
flotated sludge cake was as much as 150% higher if
compared with the MLSS concentration achieved by
sedimentation. The optimum nitrate dose and
Table 2. The effect of temperattire and flotation lime on sludge
thickening

flotation time for full-scale tests were determined


according to the laboratory test results.
Full-scale tests

The parameters of full-scale biological flotation tests


as well as their results are summarized in Table 4
Table 3. The effect of initial nitrate concentration and flotation time
on sludge thickening

M LSS~.~,
Place
Pisek

Milevsko

M LSS T
(&~l) ("C)

(NO~" }e
(rag/I)

t
(h)

I0
15
20

I00
I00
100

0.85
0.50
0.25

4 1 . 0 6 4 . 5 2.74
4 9 . 0 6 7 . 8 3.87
51.0 6 8 . 2 5.08

10.136 10
10.06 15
10.06 20

200
200
200

3.00
2.00
1.50

230
230
230

3.50
2.50
2.00

5.92
5.92
5.92

Bj6rnlunda 23.10
23.10
23.10
Im

26z 2-8

5
10
15

MLSS~

4h
24 h
qn
(g/I)
(mg/g h)

MLSS
(g/II)

(NOj')o
(mg/l)

4h

Pisek

3.22
3.22
3.22

100
200
0

32.2
46.0
23.0

59.4
65.8
29.0

3.95
3.85
--

38.0 51.0 1.15


4 1 . 5 53.0 1.44
44.5 5 4 . 2 2.00

Milevsko

9.55
9.55
9.55

150
300
0

31.2
35.4
21.0

61.3
63.4
25.5

1.50
1.62
--

31.5
35.0
38.5

Bj6rnlunda

22.50
22.50
22.50

190
300
0

39.5
41.4
28.9

63.0
68.5
41.9

2.51
2.48
--

64.5 1.10
65.5 1.64
6 5 . 7 2.21

24 h
(g/l)

qo
(mg/g h)

142

StMO~:A (~I21NSKA et al.

Table 4. Parameters and results of full-zcal tests of biological


flotation
Parameter

Pisek

Mtkwsko

8j6rnlunda

Number of flotation cycles


13
26
Flotation time (h)
8
14
Waste actirated sludge + BIO FLO T It additir
MLSS (g:l)
6.2
10.7
SS {g/l)
5.6
10.2
Ash (%)
19.5
26.5
Total nitrogen (%)
8.4
6.8
COD (rng, I)
I 12.5
74.2

3.5
3.3
39.0
4.5
225.0

NO~- (mg,r'l)
NO~- (rag,l)
N H ; (mg/I)
POI- (re&l)
T CC)
Thickened sludge
MLSS (g/I)
M L S S , , (g/I)
M L.SSm, (g/l)
Ash (%)
Total nitrogen (%)
Sludge water after flotation
MLSS (g/I)
SS (g/l)
COD (mg/I)
NOr (rag/I)
NO z (mg,,I)
N H ; (rag/I)
PO~ - (mg/I)

22
24

151.1
0.9

188.1
2.4

147.7
1.2

56.6
21.2
23.3

27.2
25.4
14.6

47.1
65.2
9.8

59,4
53.0
74.0
19. I
8.3

59.7
55.2
64.9
31.4
6.7

66.7
42.7
87.4
36.9
--

0.9

1.0

0,8

0.3

0.4

0.2

104.0
35.4
0.6
36.1
20.9

63.7
21.5
1.0
26.2
20. I

25.0
30.5
5.9
44.0
6.3

as average values from all flotation cycles performed.


Waste activated sludge from the wastewater treatment plant at Pisek reached the highest specific
dcnitrifying rates and therefore the shortest flotation
time was chosen. On the other hand short flotation
time in the broad range mentioned in the Materials
and Methods influenced the efficiency of sludge
thickening and consequently the average and minimum values of MLSS at all wastewater treatment
plants.
During the biological flotation the concentration of
organic substances (COD), ammonium and phosphate ions in sludge water were, however, reduced at
each locality to various extents.
The activated sludge was thickened at the wastewater treatment plants at Pisek, Milevsko and Bjfrnlunda by 9.5, 5.6 and 19.1 times, respectively. In
sludge water, concentrations of organic substances as
COD were decreased by 7.5 to 88.9%, ammonium
ions by about 3.7 to 36.2% and phosphates by about
10.3 to 90.3%.
The nitrate consumption per l g of MLSS for
bioflotation was calculated from all flotation cycles.
This consumption was 17.2, 16.7 and 29.7mg NOr
per I g of MLSS at the treatment plants of Pisek,
Milevsko and Bj6rnlunda, respectively.
DISCUSSION

Wastewater treatment plants at Pisek, Milevsko


and Bjfrnlunda operate with high, low and median
loading rates of the aeration tank. Since treatment
technology and the quality of treated wastewater
differ, the diverse microbial community was selected
there.

The highest specific denitrifying rates of waste


activated sludge were achieved at Pisek, which was
supported by a two-stage treatment system with a
middle sedimentation tank, appropriate sludge age,
sludge loading rate and low content of ash.
At Milevsko, waste activated sludge partly settled
in the flotation bioreactor (11% of total volume on
the average). It was affected by both low sludge
loading rate and breakdowns in the operation of the
wastewater treatment plant. Settled sludge of lower
MLSS concentration decreased resulting MLSS content of thickened sludge in the storage tank.
The relationship between the specific denitrifying
rate and consequently the efficiency of bioflotation
versus the initial nitrate concentration and temperature is fully in accordance with the theory of denitrification (Juszczak and Domka, 1988; Dawson and
Murphy, 1972; Lewandowski, 1982).
The time period for the starting of sludge flocs
flotation fluctuated between 0.25 and 3.50 h due to
the type and temperature of the sludge. After sludge
is flotated appropriate sludge thickening or compression phase occurs. The desired sludge concentration could be achieved with thc flotation time in
the range of 4-48 h.
Biological flotation resulted in 1.8-2.5 times higher
MLSS concentration of thickened sludge in comparison with gravity thickening of the same sludge.
In full-scale tests the reliability of equipment and
bioflotation technology were verified. Waste activated sludge from wastewater treatment plants at
Pisek, Milcvsko and Bj6rnlunda was thickened from
6.2, 10.7 and 3.5 g/I MLSS to 59.4, 59.7 and 66.7 g/I
MLSS, respectively. Reduction in concentration of
COD, ammonium and phosphate ions is connected
with the biochemistry of denitrification and sorption
properties of the sludge (Payne, 1973; Verstraete and
van Vaerenberg, 1986).
The presence of calcium ions supports phosphate
removal and sludge flocculation (Diamadopoulos,
1984; Kakii et aL, 1985) and therefore calcium nitrate
was used as a constituent of the BIOFLOT z reagent.
Because of the high suspended solids concentration
in sludge water after flotation it is returned to the
wastewater treatment plant inlet.
The possibility of the influence of the BIOFLOT ~
process on the wastewater treatment was studied only
at Bj0rnlunda because at Pisek and Milevsko only
part of the waste activated sludge production was
thickened in the BIOFLOT ~ unit.
It has to be taken into consideration that the sludge
water from the BIOFLOT ~ unit, which is returned to
the treatment plant inlet, is diluted by the influent
wastewater. The influent had an average flow of
314 m~/d. This means that the sludge water volume
amounted to (3/317) x 100 = 0.95% of the total water
amount.
Concerning the sludge water, nitrates, nitrites and
suspended solids are the most important factors.
With a nitrate dose of 100--200 mg/I N O r for the

Thickening of waste activated sludge


bioflotation and at retention time of about 24 h it was
possible to achieve concentrations < 50 mg/I NO/and <8 mg/I NO.,- in the sludge water leaving the
BIOFLOT ~t unit. This means that there is a nitrate
and nitrite increase of 0.0095.50 - 0.47 rag/! NOr
and 0.0095.8 = 0.076 mg/l NOr in the influent to the
treatment plant. These values did not influence wastewater treatment. The nitrate and nitrite concentrations in the effluent from the wastewater treatment
plant were determined during the test period and 2
months after the last running of the BIOFLOT ~ unit.
By comparing these values it can be concluded that
the sludge water does not affect the outlet of nitrogen
into the water recipient at all (Klasson, 1990).
The average value of suspended solids in the sludge
water was 0.2 g/i. The influent wastewater had an
average SS concentration of 0.370g/I and it was
decreased by the BIOFLOT a sludge water to
0.368 g/I. Suspended solids in the sludge water did not
influence the wastewater treatment plant in any way,
i.e. settling properties of mixed liquor passing to final
clarifiers and SS concentration in final effluent. The
same results were obtained in continuous sludge
thickening by bioflotation at the wastewater treatment plant in Pisek during a year test period
(Maixner, 1985).
The specific energy consumption for the
BIOFLOT ~" unit is 0.2 kW per I m' of sludge, thc
installed power input is 4 kW max.
The comparison of bioflotation with the dissolved
air flotation (DAF) indicates that a similar degree of
sludge thickening is achieved, however, bioflotation
requires lower operating costs. When DAF works
without polymer dosage the lower thickening effects
are usually reached. Furthermore, the BIOFLOT s
process is ecologically advantageous because it utilizes only natural properties of sludge microorganisms and it works without polymer dosages. Polymer
use could be helpful only in cases of bad bioflocculation properties of the sludge, which were rarely
observed, but it is not necessary. Because of their high
costs and negative environmental effects (Biesinger
and Stokes, 1986) we cannot recommend their use.
Another advantage of bioflotation is suitable size and
distribution of gas bubbles released during denitrification and also their formation inside sludge flocs.
This enhances adhesion of bubbles and flotating flocs.
According to van Vuuren and Merwe (1989) a solid
concentration of 6-7% was achieved by dissolved air
flotation after 24.--48 h aging time. Leineninger et al.
(1980) reported that waste activated sludge was
thickened by flotation only to 3.0% without polymer
dose and up to 4.0% with polymer dose.
Based on the experimental results obtained and our
experience, some technological parameters of biological wastewater treatment, with positive or negative
influence on the BIOFLOT x process, can be distinguished and some process conditions can be defined.
The BIOFLOT ~ process is positively influenced by
using activated sludge produced in partly or com-

143

pletely treated mixed wastcwaters, however, without


substantial aerobic mineralization, with the sludge
age up to 8 days and with a minimum BOD sludge
loading rate of 0.4 kg/kg d. The absence of primary
sedimentation did not influence the bioflotation. The
BIOFLOT s process is negatively affected by extended aeration with sludge age higher than 15 days.
The presence of denitrifiers, sufficient nitrate and
organic carbon concentrations, appropriate temperature and oxygen conditions are some of the most
important parameters for high efficiency of the
BIOFLOT s process:
--Denitrifiers can be found in nearly all activated sludges, however, in various amounts
and with different denitrifying activities (AIlievi and Ferrari, 1985). Their properties determine flotation time which can fluctuate in the
I and 24 h intervals, 7 h on average. Flotation
time is to be determined for each locality
separately.
--Nitrate consumption for sludge thickening by
bioflotation is about .5-30 mg NOr per I g of
MLSS. The process can be controlled in such
a way that nitrate concentration in sludge
water after flotation will not exceed 20mg/I
NOr.
--Waste activated sludge usually contains sufficient amounts of biodegradable compounds
for dissimilatory dcnitrification or endogenous
respiration takes place (Sutton et al., 1979).
Therefore it is not necessary to add an external
substrate.
--The BIOFLOT ~ unit is designed for discontinuous sludge thickening even when the
sludge temperature could drop below 5C.
That is why it is proposed the device should be
placed in a hall with thermal insulation.
--Dissimilatory denitrification is inhibited by
the presence of dissolved oxygen (Najakima et
al., 1985). The anoxic condition in the
flotation bioreactor is accomplished within a
few minutes.
Discontinuous activated sludge thickening is suitable for small wastewatcr treatment plants. The
BIOFLOT ~ unit is automatically operated and
requires very simple maintenance. The operator only
has to prepare BIOFLOT ~ reagent approximately
once a week.
The BIOFLOT ~ process can be followed by dewatering in centrifuges (Maixner, 1985).
CONCLUSIONS

(i) The BIOFLOT ~ process utilizes the denitrifying capability of bacteria present in the mixed population of activated sludge.
(2) The efficiency of the BIOFLOT ~ process is
influenced, above all, by the technology of treatment,
wastewater quality, nitrate concentration, C : N ratio

S|MONA CI~INSKA et

144

and by temperature. The nitrate consumption for


bioflotation ranged from 16.7 to 29.7 mg N O ; per 1 g
of MLSS.
(3) A fully automated compact unit was designed
for discontinuous biological thickening of waste activated sludge from wastewater treatment plants up to
50OO I.E.
(4) During full-scale tests at the wastewater treatment plants in Pisek, Milevsko and Bj6rnlunda,
waste activated sludge was thickened to 59.4, 59.7
and 66.6 g/! MLSS which means a volume reduction
to 10.4, 17.9 and 1.9%, respectively. Simultaneously
COD, ammonium and phosphate ion concentrations
were partly removed in the sludge water.
(5) The BIOFLOT jt process can ix applied either
independently or in connection with centrifugation.
(6) The BIOFLOT jt process has low energy consumption, small space requirements, very simple
maintenance and does not require polyelectrolyte
flocculants, which may represent an environmental
hazard.
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aL

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