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Construction of the Waste Water

Treatment Plant for the City of Raka

EuropeAid/138712/ID/WKS/RS

Technical Solution
Form 4.6.9.2
Process Design & Calculations
Operation Costs

08.03.2017
Version 1.0

file: 359998200.doc
editor: kb
INDEX

1. GENERAL..............................................................................................................4

2. WWTP PLANT CAPACITIES AND PERFORMANCE.......................................5

2.1 Influent Loads...............................................................................................................5

2.2 Hydraulic Load.............................................................................................................6

2.3 Effluent Concentrations...............................................................................................6

3. WASTE WATER TREATMENT STAGES..............................................................7

3.1 General Information.....................................................................................................7

3.2 Mechanical Treatment..................................................................................................8


3.2.1 Coarse Screen Stage..........................................................................................8
3.2.2 Inlet Pumping Station........................................................................................11
3.2.3 Internal Pumping Station..................................................................................12
3.2.4 Storm Water Detention Tank & Pump Station...............................................13
3.2.5 Inlet & Distribution Chamber............................................................................14
3.2.6 Mechanical Treatment.......................................................................................14
3.2.7 Inlet Flow Measurement....................................................................................18
3.2.8 Distribution Chamber 1.....................................................................................18

3.3 Biological Stage...........................................................................................................19


3.3.1 Aeration Tanks....................................................................................................27
3.3.2 Distribution Chamber 2.....................................................................................30
3.3.3 Secondary Sedimentation Tanks.....................................................................30

3.4 Effluent Flow Measurement / Effluent Quality Measurement / Process (Service)


Water 32

3.5 Return Sludge & Excess (Waste) Sludge Pump Station..........................................33

3.6 Sludge Treatment........................................................................................................35

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3.6.1 Excess Sludge Pre-Thickening (Primary Thickening)..................................35
3.6.2 Sludge Stabilisation Tank.................................................................................36
3.6.3 Stabilised Sludge Thickening (Secondary Thickening)...............................40
3.6.4 Mechanical Sludge Dewatering.......................................................................42

3.7 Other Site facilities......................................................................................................44


3.7.1 Roads...................................................................................................................44
3.7.2 Other Buildings...................................................................................................44
3.7.3 Exhaust Air Treatment.......................................................................................46
3.7.4 Others..................................................................................................................46

4. OPERATION COSTS...........................................................................................47

4.1 Loads for Operation Costs Calculation.....................................................................47

4.2 Polymer Mechanical Sludge Dewatering...............................................................47

4.3 Electrical Consumption..............................................................................................48

5. Future Extension of the WWTP (Realisation not Part of Actual Contract).........50

page 3 of 54
1. General

In the present condition, the wastewater is derived without adequate


purification into receiving water. In order to change this situation to positives
and the law situation is sufficient to do, the responsible persons decided to
implement a new wastewater treatment plant.
According to the Tender Documents, the plant has to be designed as a
wastewater treatment plant including mechanical pre-treatment, biological
treatment and sludge treatment.

The Tenderer offers a plant designed on base of the Employer`s Requirements


and the Employer`s Clarifications, on the state of the art, in accordance to the
required and relevant rules and norms and in accordance to best practise for
operation and maintenance needs.
Design standards required by Tender Documents (if applicable) are fulfilled.

Interface of the works is as defined by the Employer resp. the Tender


Documents.
In accordance to the Employer`s Requirements, the new WWTP is lifted at
minimum on a level of 393,00 m.a.s.l. (resp. 393,90 m.a.s.l. for the coarse
screen & inlet pump station). The effluent of the future plant is ensured for the
high water level of the recipient of 392,50 m.a.s.l. according to the Tender
Documents.

page 4 of 54
2. WWTP Plant Capacities and Performance

The WWTP is designed on loads, flows and effluent limits provided by Tender
Documents. The loads and flows for the design calculations are stated below.

2.1 Influent Loads

As design values, the following inlet loads are defined by the Tender
Documents:
COD 1.980 kg/d
BOD5 990 kg/d
SS 1.155 kg/d
Ntot 198 kg/d
Ptot 33 kg/d

The biological degradability of the wastewater is presumed. All process-


engineering warranties are based on the fact, that the resulting
sewerage is biologically degradable and there are not as much
nitrification and carbon inhibitions contained in wastewater, that
biological activity and biological degradability of wastewater are
disturbed significant.

page 5 of 54
2.2 Hydraulic Load

Following hydraulic load is defined for design by tender documents:


Qd 3.136 m/d
Qmax. (PWWF) 334 m/h
Qmax. (dry weather flow) 232 m/h
full profile flow of main feeding collector 1.290 m/h
Qmax. (PWWF-extraordinary) 640 m/h

2.3 Effluent Concentrations

The following effluent concentrations are to be kept (actual Contract /


actual extension of plant):
COD 125 mg/l
BOD5 25 mg/l
SS 35 mg/l

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3. Waste Water Treatment Stages

3.1 General Information

In accordance to the requirements of Tender Documents, wastewater


quantities running towards the WWTP are lifted once by the inlet pump
station and pass the subsequent water line by gravity flow.
WWTP is equipped with a mechanical pre-treatment stage including
coarse screens and a compact plant stage with fine screens and an
aerated grit- and grease removal.
As required by Tender Documents, the wastewater purification is made
by the activated sludge process. Water quantities running towards and
running off the plant are measured. Subsequently follows sludge
thickening, stabilisation and dewatering of sludge.
The plant consists of the following main stages:
Coarse screen stage
Inlet pumping station
Storm water retention and pumping
Internal pumping station
Fine screen and aerated grit- & grease removal (compact plants)
Inlet flow measurement (IFM)
Aeration tanks and blower station
Secondary sedimentation tanks
Outlet flow measurement (Venturi open channel type)
Return and excess sludge pump station
Gravity excess sludge thickening (primary thickening)
Aerobic sludge stabilisation

page 7 of 54
Gravity stabilised sludge thickening (secondary thickening)
Mechanical sludge dewatering
Exhaust air treatment
Administration & control building
Emergency Diesel generator

3.2 Mechanical Treatment

3.2.1 Coarse Screen Stage

A coarse screen stage is situated upstream of the inlet pump


station at the river bank opposite to the new WWTP. This
structure is not implemented as a separate building in accordance
to the Employer`s Requirements. It contains one automatic coarse
screen, one manual by-pass coarse screen, a container for
electrical equipment and the inlet pump station.
One automatic coarse screen is situated in front of all other
stages of the water line to protect following stages from large
debris as rocks, etc. Screenings are thrown off into a container
(1,1 m) by a screw conveyor incl. press-zone for screenings. In
total, three containers (1,1 m each) are provided.
In addition, one manual coarse screen is implemented as a stand-
by unit. Therefore, two screen channels are provided with two
manual penstocks each. One crane is provided for the screens.
Both screen channels are covered and connected to the exhaust
air treatment. Therefore, Employer`s Requirements resp.
Clarifications in view of odour are kept.

page 8 of 54
Automatic coarse screen
required flow acc. Tender 1.290 m/h
design flow for installed screen 1.290 m/h
type of screen bar / rotating rake
number of units 1
penstocks per line 2
bar spacing 50 mm
width per screen field 1,0 m
number of screw conveyors incl. press-zone 1
type of screen control level difference

Manual coarse screen


required hydr. capacity acc. Tender 1.290 m/h
design flow for installed screen 1.290 m/h
type of screen bar screen
number of units 1
penstocks per line 2
bar spacing 50 mm
width per screen field 1,0 m

According to Hosang-Bischof (1998), clause 4.4.2.2, third clause,


the amount of coarse screenings is estimated on average 4 l/
(PE*a). Therefore, the amount of coarse screenings for 16.500 PE
is estimated on approx. 66 m/year.

page 9 of 54
Hydraulic loss of coarse screen (max. flow through one line):
ho flowmax. 4 cm

page 10 of 54
3.2.2 Inlet Pumping Station

To lift raw water up to the further treatment of the WWTP, an inlet


pump station is implemented.
The pump sump of the inlet pump station is separated from a
chamber housing the penstocks and non-return valves. Therefore,
all fittings are dry accessible.

Inlet pumps
required capacity acc. Tender per unit 45 l/s
capacity per installed unit 45 l/s
type submersible
number of units 4
duty/standby 4/0
spare pumps (stored) 1
total installed duty capacity 180 l/s
control frequency converter

The inlet pump station is equipped with a safety overflow which


discharges to the river (DN 700, at 389,61 m.a.s.l.). It is equipped
with a mica valve.
The pressure pipe of the inlet pump station is equipped with an
air-valve at its high-point. In addition, an inductive flow meter is
installed to ensure proper flow towards the new WWTP. Pumps
are lifted by a manual lifting device.
The pump sump of the inlet pump station is covered and
connected to the exhaust air treatment. Therefore, Employer`s
Requirements resp. Clarifications in view of odour are kept.
According to the Employer`s Requirements, an acceptance for
septic sludge is implemented, which discharges directly to the
pump sump.

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3.2.3 Internal Pumping Station

To lift raw water collected from right bank of river Ibar and all
waste water collected at the new WWTP up to the further
treatment of the WWTP, an internal pumping station is
implemented.
The pump sump of the internal pump station is separated from a
chamber housing the penstocks and non-return valves. Therefore,
all fittings are dry accessible. Pumps are lifted by a manual lifting
device.

Internal pumping pumps


required capacity acc. Tender per unit 12 l/s
capacity per installed unit 12 l/s
type submersible
number of units 2
duty/standby 1/1
total installed duty capacity 12 l/s
control direct

page 12 of 54
3.2.4 Storm Water Detention Tank & Pump Station

The storm water detention tank is implemented in accordance to


the Employer`s Requirements. For feeding the tank, a separate
line from the inlet & distribution chamber is implemented. The tank
is equipped with two submersible mixer units. A storm water pump
station returns the content of the tank to the water line in case that
hydraulic flow is appropriate. Because of the positioning of the
pump station, the storm water detention tank can be emptied
totally. An overflow towards the outlet of the WWTP ensures
deduction of exceeding water quantities. This overflow is
equipped with a scum baffle.

Storm water detention tank


required volume acc. Employer`s Clarification 650 m
type circular tank
number of units 1
inner diameter 15,0 m
ave. water depth 3,8 m
usable volume 650 m
overflow capacity min. 367 m/h

Storm water pumps


type submersible
capacity per unit 12 l/s
number of units 2
duty/standby 1/1
total duty capacity 12 l/s
control direct

page 13 of 54
3.2.5 Inlet & Distribution Chamber

This chamber is collecting the flows from the inlet pump station
and the internal pump station. In addition, the pump station from
the storm water detention tank returns stored storm water to the
chamber in case that incoming flow is appropriate. Three manual
adjustable overflow weirs ensure proper flow distribution towards
the mechanical treatment and the storm water detention tank.
Measurements for water level, pH-value, temperature and
conductivity are installed at the chamber. For the subsequent
laboratory analyses, an automatic 24 hours or 2 hours flow
proportional sampling device is positioned at the chamber as
required by the Employer`s Requirements.

3.2.6 Mechanical Treatment

For the fine screening and removal of grit & grease, two compact
plants are implemented downstream of the inlet & distribution
chamber. Both plants are positioned out-door on a concrete slab
in accordance to the Employer`s Requirements. In accordance to
the Employer`s Clarifications, both compact plants are fully
covered / capsulated and designed for proper outside installation
and proper outside operarion. Blowers are noise insulated to keep
the requirements in view of noise. Both compact plants are
connected to the exhaust air treatment. Therefore, Employer`s
Requirements resp. Clarifications in view of odour are kept.
Removed screening is washed, compacted and discharged in to
containers (1,1 m). Removed grit is treated by grit classifiers and
is discharged into containers (1,1 m).

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Grease is pumped into a grease pit. In total, 6 containers with a
volume of 1,1 m each are provided for the screenings and grit.
The blowers for aeration system are situated beside the compact
plants. In accordance to Employer`s Requirements, an actuated
crane for the screens is provided.

Compact plants for fine screening and aerated grit & grease
removal
required flow per unit 181 m/h
design flow per unit 181 m/h
type compact plant
number of units 2
number of fine screens per unit 1
spacing of fine screen 6 mm
by-pass for fine screen manual
number of compacting conveyors per unit 1
screening compacting efficiency 40 % compaction
screening compacting efficiency 25 % DS
number of grit and grease removal per unit 1
separated solids (grit removal) 0,2 mm
number of grit classifiers per unit 1
number of blowers per unit 1
total number of grease pits 1

According to Hosang-Bischof (1998), clause 4.4.2.2, table 20, the


amount of compacted fine screenings is estimated on average
5,7 l/(PE*a). Therefore, the amount of fine screenings for
16.500 PE is estimated on approx. 94 m/year.

page 15 of 54
Blower
capacity per unit 58 Nm/h
number per compact plant 1
control direct

Grease pump
capacity per unit 3 m/h
number per compact plant 1
type eccentric screw pump
operation direct

dimensioning diagram
Abscheideleistung = separation degree
Verweilzeit = retention time

page 16 of 54
fine screen
Q max 50,3 l/s
type of screen Ro1 ----
size of screen 780 ----
bar space 6 mm

dimensions of longitudinal grit channel


length 4.300 mm
width 1.250 mm
volume 7,23 m

grit separation
separation degree 90 %
grain size 0,20 mm

check of design
Q max 50,3 l/s
calculated retention time 145 s
required retention time 140 s

grease removal
grease removal yes
length 4.300 mm
width 400 mm

page 17 of 54
3.2.7 Inlet Flow Measurement

Downstream of the mechanical treatment, pre-treated wastewater


quantities are measured by an inductive flow measurement
installed at a shaft in front of distribution chamber 1. Permanent
filling of the unit and proper flow velocity are ensured.

3.2.8 Distribution Chamber 1

This chamber is implemented for equal distribution of flow to the


two biological lines (aeration tanks). Both effluent of the
mechanical treatment and the return sludge flow are discharged
into the receiving chamber of this structure.
Two manual adjustable overflow weirs ensure equal flow
distribution to the aeration tanks.
In accordance to the Employer`s Requirements, a blind
connection for the future extension of the plant is implemented.

page 18 of 54
3.3 Biological Stage

According to the Tender Documents, the design of the biological stage


complies to ATV A 131E. As required for the actual Contract, the
biological stage is designed for carbon removal. According to the
Employer`s Requirements, the WWTP (i.e. the aeration tank stage) is
fully adaptable for biological nutrient removal (biological removal of
nitrogen and phosphorus).
The process calculations for the biological stage are shown below and
include the excerpt of official EDP-application of ATV A-131 along with
all input and output values necessary to be able to relate to the process
design calculation of biological stage and secondary sedimentation
stage of the WWTP.

The design principles are as follows:

Loads at plant inlet


COD 1.980 kg/d
BOD5 990 kg/d
SS 1.155 kg/d
Ntot 198 kg/d
Ptot 33 kg/d

According to Tender Documents, 5 % reloads have to be considered.

Loads for the design of the biological stage (incl. back-loads)


COD 2.079 kg/d
BOD5 1.040 kg/d
SS 1.213 kg/d
Ntot 208 kg/d
Ptot 35 kg/d

page 19 of 54
Flows at plant inlet
Qd 3.136 m/d
Qmax. (PWWF) 334 m/h
Qmax. (dry weather flow) 232 m/h

According to Tender Documents, the design peak flow per tank shall be
181 m/h (conservative approach).

Flows for the design of the biological stage (incl. back-flows)


Qd 3.293 m/d
Qmax. (peak flow) 362 m/h
Qmax. (dry weather flow) 244 m/h

Guaranteed Effluent concentrations (actual Contract)


COD max. 125 mg/l
BOD5 max. 25 mg/l
SS max. 35 mg/l

page 20 of 54
The relevant process design data i.e. volumes, surface areas, sludge
age, sludge loads, hydraulic / surface loads, surplus sludge production
and return sludge ratio are shown within the EDP-excerpt below. The
actual version 2.01 of official ATV-DVWK BelebungsExpert for standard
A-131 is used.

Main Formula used by ATV-A-131:

Required sludge age


tDS, aerob, calc = SF * 3,4 * 1,103 (15-T) [d]
tDS, calc = tDS, aerob * 1/(1-(VD/VAB)) [d]
tDS, calc = SF * 3,4 * 1,103 (15-T) * 1/(1-(VD/VAB)) [d]
VD/VAB = 1 ((SF * 3,4 * 1,103(15-T))/ tDS, calc)
Share of volume for denitrification (not applicable for actual Contract)
SNO3,D = CN,ZB SorgN,AN SNH4,AN SNO3,AN - XorgN,BM [mg/l]
(SNO3,D/CBOD,ZB) = (0,75 * OVC,BOD / 2,9) * (VD/VAB) [mg N/mg BOD5]
Phosphorous elimination
XP,prec = CP,ZB CP,AN XP,BM XP,BioP [mg/l]
Sludge production
SSd = SSd,C + SSd,P [kg TS/d]
SSd,c = Bd,BOD * (0,75 + (0,6 * XTS,ZB/CBOD,ZB) ((1 0,2) * 0,17 * 0,75 * t DS *
FT / (1 + 0,17 * tDS * FT))) [kg TS/d]
FT = 1,072(15-T)
SSd,P = Qd + (3 * XP,BioP + 6,8 * XP,prec,Fe + 5,3 * XP,prec,Al) / 1000 [kg/d]

page 21 of 54
Volume of aeration tank
MDS,AB = tDS, calc + SSd [kg]
VAB = MDS,AB / DSAB [m]
BR = Bd,BOD / VAB [kg BOD5/m d]
BDS = BR / DSAB [kg BOD5/kgTS d]

Oxygen capacity
OVd,C = Bd,BOD * (0,56 + (0,15 * tDS * FT) / (1 + 0,17 * tDS * FT)) [kg O2/d]
OVd,N = Qd * 4,3 (SNO3,D - SNO3,ZB + SNO3,AN) / 1000 [kg O2/d]
OVd,D = Qd * 2,9 SNO3,D / 1000 [kg O2/d]
OVh = (fC * (OVd,C - OVd,D) + fN * OVd,N) / 24 [kg O2/h]

Secondary sedimentation
DSBS = 1000 / ISV * tE1/3 [kg/m]
DSAB = RV * DSRS / (1 + RV) [kg/m]
qA = qSV / (DSAB * ISV) [m/h]
ASST = Qm / qA [m]
h1 = min. 50 cm
h2 = (0,5 * qA * (1 + RV)) / (1 VSV / 1000) [m]
h3 = (1,5 * 0,3 * qSV * (1 + RV)) / 500 [m]
h4 = (DSAB * qA * (1 + RV) * tE) / DSBS [m]

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3.3.1 Aeration Tanks

In order to be able to remove mainly carbon contained in


wastewater, a biological stage with activated sludge system is
implemented. Two aeration tanks are provided (parallel). These
are supplied with waste water and return sludge mixture from the
flow distribution chamber 1. Each tank is enabled to be put out of
operation without stopping the other one. A pump sump in each
tank is provided as required by Tender Documents.

Aeration tanks
type circular tank
number of units 2
inner diameter 15,0 m
water depth 5,4 m
usable volume per tank 954 m3
usable volume total, existing 1.908 m3
mixer units per tank 1

Design of biological stage (dimensioning load case 12 C)


suggested SVI acc. Tender Documents 120 l/kg
chosen SVI 120 l/kg
required MLSS acc. Tender Documents 3 4 kg/m
chosen SSAT 3,60 kg/m
required sludge acc. ATV A-131 5,0 d
designed sludge age 5,6 d
excess sludge production 1.237 kg DS/d
SSRS 8,4 kg/m
excess sludge volume 147,3 m/d

page 27 of 54
For process supervision and process control, each tank is
equipped with one online measurement for O 2 and temperature.
One mixer unit per tank serves for proper suspension of activated
sludge.
Both tanks are equipped with a circular effluent weir including a
scum baffle.

Blowers required for aerating the system are positioned in a


blower building. This building is housing in addition an E-room,
the transformer room and the Emergency Diesel generator.
The blowers for the fine bubble disc aerator aeration system are
positioned in the blower room and are equipped with noise
protection hoods. The walls of the blower room are covered with
noise insulation. Therefore, maximum allowed noise level is kept.
According to the Employer`s Requirements, one actuated crane is
provided. Ventilation and heating is provided.
The blowers are equipped with frequency converters and
therefore, the air input to the aeration tanks is regulated by the
oxygen measurements positioned in the aeration tanks. For each
biological tank, 1 duty unit including pressure and flow
measurement is provided. In addition, the building is housing the
blower unit for the aerobic sludge stabilisation. One stand-by
blower is equipped with actuated valves for automatic duty/stand-
by change-over.

page 28 of 54
Blowers for aeration stage
type root type
total number of units 3 (4 incl. sludge stabilisation)
duty/standby 2/1 (3/1 incl. sludge stabilisation)
control frequency converter
alpha factor 0,7
peak oxygen demand acc. ATV-A-131 (wastewater) 75,2 kg/h
peak oxygen demand (clear water) 107,4 kg/h
calc. O2 input / m depth (pure water) 0,018 kgO2/Nm*m
required air amount for peak oxygen demand 19,3 Nm/min
max. designed input capacity per blower 13 Nm/min
max. total designed input capacity 26 Nm/min
max. designed input capacity of stand-by blower 14,7 Nm/min

page 29 of 54
3.3.2 Distribution Chamber 2

This chamber is implemented for equal distribution of flow to the


two secondary sedimentation tanks. Effluent of both aeration
tanks is discharged into the receiving chamber of this structure.
Two manual adjustable overflow weirs ensure equal flow
distribution to the secondary sedimentation tanks.

3.3.3 Secondary Sedimentation Tanks

Two secondary sedimentation tanks are implemented. The


calculation of secondary sedimentation tanks is done in
accordance to ATV A-131. In especially the inlet / inflow from the
aeration tanks is designed according to design recommendations
of ATV A-131. Each tank is enabled to be put out of operation
without stopping the other one.

Secondary sedimentation tanks


type circular tank, horizontal flow
number of units 2
required design flow (incl. return sludge flow) per tank acc.
clarifications
min. 252 m/h
chosen design flow (incl. return sludge flow) per tank 317 m/h
required surface rate acc. Tender Documents max. 1,4 m/h
designed surface rate 1,02 m/h
suggested SVI acc. Tender Documents 120 l/kg
chosen SVI 120 l/kg
required MLSS acc. Tender Documents 3 4 kg/m
chosen SSAT 3,60 kg/m
SSRS 8,4 kg/m

page 30 of 54
required diameter per tank (ATV A 131) 12,38 m
designed inner diameter 15,0 m
water depth (2/3) 4,60 m
sludge clearance blade scraper

The secondary sedimentation tanks are equipped with half-span


scraper bridges with sludge and scum blades for sludge and scum
removal. Scum is deducted to the sludge line by scum pumps
positioned in the scum pit. Bottom sludge is discharged by gravity
to the sludge pump station.

Scum pumps
type submersible
capacity per unit 7 l/s
number of units 2
duty/standby 1/1
total duty capacity 7 l/s
control direct

Via a circular effluent channel, which is fed by a two-sided toothed


weir and protected from scum by a scum board, the purified waste
water flows towards the effluent of the plant. The whole effluent
channel is hydraulically uncoupled from the units downstream.
Within each secondary sedimentation tank, a sludge blanket level
measurement unit is installed.

page 31 of 54
3.4 Effluent Flow Measurement / Effluent Quality Measurement /
Process (Service) Water

For measurement of effluent flow, an open channel Venturi-flow-


measurement is implemented.

Before purified wastewater flows off the new WWTP, it runs through an
open channel type (Venturi) flow measurement. For the subsequent
laboratory analyses, an automatic 24 hours flow proportional sampling
device is provided.
Downstream of the effluent measurements, one submersible pump for
technical (service) water preparation is provided (25 m/h). Within the
sludge dewatering building, a manual filter unit and an expansion vessel
are installed. The service water serves for internal washing / flushing of
machinery as required by Tender Documents.

page 32 of 54
3.5 Return Sludge & Excess (Waste) Sludge Pump Station

From the secondary sedimentation stage, excess and return sludge is


taken off and supplied on the one hand back to the biological stage and
on the other hand to the sludge line. For each sludge deduction pipe of
the two secondary sedimentation tanks, one manual adjustable penstock
is installed to ensure equal sludge deduction. In addition, these
penstocks ensure that each secondary sedimentation tank can be put
out of operation without stopping the other one.
In accordance to the Employer`s Requirements, both return sludge flow
and excess sludge flow are measured by inductive flow meters. In
accordance to the Tender Documents, the pump sump of the sludge
pump station is separated from a chamber housing the penstocks and
non-return valves. Therefore, all fittings are dry accessible.

Return sludge pump station


type submersible
required flow acc. Tender Documents min. 50 l/s
capacity per unit 76 l/s
duty capacity total 76 l/s
max. return sludge flow acc. ATV A-131 (0,75 RW) 75 l/s
number of units 2
duty/standby 1/1
control frequency converter

page 33 of 54
Excess (waste) sludge pumps
type submersible
required flow acc. Tender Documents min. 8 l/s
capacity per unit 8 l/s
duty capacity total 8 l/s
number of units 2
duty/standby 1/1
control direct

page 34 of 54
3.6 Sludge Treatment

3.6.1 Excess Sludge Pre-Thickening (Primary Thickening)

In accordance to the Employers Requirements, a gravity sludge


thickening tank for excess sludge is provided. The tank is
equipped with a picket-fence-scraper. A peripheral effluent
channel equipped with a scum baffle serves for sludge water
drainage. Sludge water flows by gravity to the internal pump
station.

Primary thickening tank


type circular
number of units 1
diameter 9,0 m
ave. depth 3,13 m
usable volume 200 m
daily sludge production max. 1.237 kg/d
daily sludge production max. 147,3 m/d
max. retention time acc. Tender Documents 2,0 d
designed sludge retention time 1,4 d
max. dry solids load acc. Tender Documents 20 kg/m,d
designed dry solids load 19,4 kg/m,d
max. surface load acc. Tender Documents 1,0 m/h
designed surface load 0,46 m/h
min. thickening acc. Tender Documents 2,0 % DS
designed thickening 2,8 % DS
output sludge flow 44 m/d

The sludge level of the tank is monitored acc. to the Tender


Documents.

page 35 of 54
In accordance to the Tender Documents, a sludge pump station is
adjected to the primary sludge thickening tank which forwards the
thickened sludge to the aerobic sludge stabilisation stage. Pumps
are positioned in a dry chamber according Tender Requirements.
The tank is covered and connected to the exhaust air treatment.
Therefore, Employer`s Requirements resp. Clarifications in view
of odour are kept.

Primary thickened sludge pumps


type progress cavity
required flow acc. Tender Documents min. 30 m/h
capacity per unit 30 m/h
duty capacity total 30 m/h
number of units 2
duty/standby 1/1
control direct

3.6.2 Sludge Stabilisation Tank

In accordance to the Employers Requirements, a tank for aerobic


sludge stabilisation is provided. Disc membrane aeration system
(fine bubble) and a mixer unit are installed. A pump sump is
provided as required by Tender Documents.

Sludge stabilisation tank


type circular tank
number of units 1
inner diameter 15,0 m
water depth 5,5 m
usable volume 970 m3
mixer units per tank 1

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Design of stabilisation tank (dimensioning load case 12 C)
min. thickened sludge flow acc. Tender Documents 39 m/d
designed thickened sludge flow 44 m/d
inlet sludge concentration 2,8 % DS
min. retention time acc. Tender Documents 20 d
designed retention time 22 d
min. volatile solids reduction acc. Tender Documents 40 %
designed volatile solids reduction 40 %
min. aeration capacity acc. Tender Documents
2,3 kg O2/kg VSS destroyed
designed aeration capacity 2,3 kg O2/kg VSS destroyed
min. required output sludge concentration acc. Tender Documents
2,0 % DS
designed output sludge concentration 2,1 % DS

For process supervision and process control, the tank is equipped


with one online measurement for O2 and temperature.
The tank is equipped with a circular effluent weir including a scum
baffle. Effluent to the secondary thickening is ensured by gravity
flow.

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The blowers for the sludge stabilisation are situated in the blower
room of the aeration stage blowers. The one stand-by unit serves
both for aeration tank stage and sludge stabilisation stage (please
see description of aeration tank blowers).

Blowers for sludge stabilisation stage


type root type
total number of units 1
duty/standby 1/1
control frequency converter
peak oxygen demand (wastewater) 37,8 kg/h
peak oxygen demand (clear water) 84,0 kg/h
calc. O2 input / m depth (pure water) 0,018 kgO2/Nm*m
required air amount for peak oxygen demand 14,5 Nm/min
max. designed input capacity per blower 14,7 Nm/min
max. designed input capacity of stand-by blower 14,7 Nm/min

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3.6.3 Stabilised Sludge Thickening (Secondary Thickening)

In accordance to the Employers Requirements, a gravity sludge


thickening tank for stabilised sludge is provided. The tank is
equipped with a picket-fence-scraper. A peripheral effluent
channel equipped with a scum baffle serves for sludge water
drainage. Sludge water flows by gravity to the internal pump
station.
The tank is covered and connected to the exhaust air treatment.
Therefore, Employer`s Requirements resp. Clarifications in view
of odour are kept.

Secondary thickening tank


type circular
number of units 1
diameter 6,0 m
ave. depth 3,18 m
usable volume 90 m
min. DS of stabilised sludge acc. Tender Documents 2,0 %
designed DS of stabilised sludge 2,1 %
incoming sludge flow 44 m/d
min. retention time acc. Tender Documents 2,0 d
designed sludge retention time 2,05 d
max. surface load acc. Tender Documents 1,0 m/h
designed surface load 0,53 m/h
min. DS of thickened sludge acc. Tender Documents 3,0 %
designed DS of thickened sludge 3,0 %

The sludge level of the tank is monitored acc. to the Tender


Documents.

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In accordance to the Tender Documents, a sludge pump station is
adjected to the secondary sludge thickening tank which forwards
the thickened sludge to the mechanical sludge dewatering stage.
Therefore and in accordance to the Employer`s Clarifications,
these pumps serves as feeding pumps of the sludge dewatering
units. Pumps are positioned in a dry chamber according Tender
Requirements.

Secondary thickened sludge pumps (= mechanical sludge


dewatering feeding pumps)
type progress cavity
required flow acc. Tender Documents min. 4 m/h
capacity per unit up to 6 m/h
number of units 2
duty/standby 1/1 (note simultaneous operation
possible)
control frequency converter

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3.6.4 Mechanical Sludge Dewatering

A separate building is housing the mechanical sludge dewatering


plant. In addition, an E-room and the workshop are situated in the
same building.
The sludge is dewatered according to Tender Documents by two
belt presses. A polymer plant for sludge conditioning is
implemented, too. Liquid polymer is enabled for use. Each sludge
dewatering unit is equipped with a conveyor for sludge discharge
towards the sludge containers. The containers are protected by a
flying roof (2 containers, 5 m each).
The sludge dewatering room is connected to the exhaust air
treatment. Therefore, Employer`s Requirements resp.
Clarifications in view of odour are kept.

Mechanical sludge dewatering


type belt press
daily sludge input 915 kg/d
max. dewatering time 40 h/w
required dewatering capacity at 100 % load 160 kg/h
designed dewatering capacity per unit 160 kg/h
designed dewatering capacity per unit 5,5 m/h
number of units 2
duty/standby 1/1 (note simultaneous operation
possible)
required final DS acc. Employer`s Clarifications min. 18 %
designed final DS min. 18 %

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Polymer plant
number of units 1
max. polymer demand for 18 % DS 8 g AS/kg DS

Polymer feeding pumps (eccentric, dry installed)


number of units 2
duty/standby 1/1 (note simultaneous operation
possible)
control frequency converter

Sludge flow towards each press is measured by an inductive flow


measurement as well as polymer quantity.
Filtrate of dewatering flow by gravity to the internal pump station.
In accordance to Employer`s Requirements, an actuated crane is
provided.

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3.7 Other Site facilities

3.7.1 Roads

In accordance to the Tender Documents, site roads are designed


to enable proper access to the treatment units. The minimum
width is as required 3,5 m. Walkways complete the traffic
infrastructure inside the plant area. Parking spaces are provided
close to the administration building (control centre). A fence is
surrounding both the WWTP and the inlet pump station / coarse
screen structure.

3.7.2 Other Buildings

Administration building / Control centre


The administration building is implemented in accordance to the
room list shown in the Tender Documents.

total dimensions 12,30 x 8,95 m


entrance with toilet 4,63 x 2,80 m
laboratory 4,95 x 4,93 m
control room 4,95 x 3,45 m
kitchen with meeting room 6,60 x 3,75 m
locker room, sanitary block, toilet 4,63 x 3,68 m

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Transformer station
One transformer is situated in a separate room of the blower
building.

Emergency Diesel building


One emergency Diesel power generator is situated in a separate
room of the blower building.
In accordance to the Employer`s Requirements, this emergency
Diesel power generator serves for keeping the coarse screen
stage, the inlet pump station (dry weather flow), internal pump
station (dry weather flow), one line of the mechanical treatment,
all mixers for aeration tanks and sludge stabilisation tank, one
aeration tank blower on minimum capacity, one stabilisation tank
blower on minimum capacity, return sludge flow (min. capacity),
all scraper bridges of secondary sedimentation tanks, process
instrumentation, specific items of administration building
(emergency light, SCADA, video & security, fire & gas detection),
primary thickening picket-fence scraper, secondary thickening
picket-fence scraper in operation.

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3.7.3 Exhaust Air Treatment

According to the Employer`s Requirements and Employer`s


Clarifications, exhaust air from the coarse screen channels & inlet
pump station (inlet works), the compact plants (incl. screens),
grit and grease removal room, both sludge thickening tanks and
the sludge dewatering room are treated by two exhaust air
treatment units. The air purification is done by activated carbon.
Therefore, a removal efficiency (on H 2S) of at least 90 % at all
times is ensured.

3.7.4 Others

Please consider submitted drawings and documents i.e. the PID


for all instrumentation for further information.
Liquid wastes (e.g. press water from sludge dewatering, sludge
liquors from sludge thickening, liquors from screen pressing, site
sewerage) is collected by a site sewer system and are treated in
the new WWTP. This is considered within the design by the back-
loads and back-flow.
Solid waste (e.g. screenings, grit, grease (semi-solid), dewatered
sludge) is stored within containers resp. a pit (grease) for further
disposal. Therefore, Employer`s Requirements in view of waste
containing are kept.

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4. Operation Costs

4.1 Loads for Operation Costs Calculation

Operation costs are calculated for the following inlet loads and flow
towards the plant (= 100 % load, Qd).:
COD 1.980 kg/d
BOD5 990 kg/d
SS 1.155 kg/d
Ntot 198 kg/d
Ptot 33 kg/d
Qd 3.136 m/d
waste water temperature averaged 12 & 20C
Backflow and back-loads are considered for operation cost calculations.

4.2 Polymer Mechanical Sludge Dewatering

daily sludge production 915 kg DS


specific polymer demand 8 g AS/kg DS
total daily polymer demand 7,32 kg AS/d
total yearly polymer demand 2.671,8 kg AS/a
specific polymer costs () 5,00 /kg AS
total yearly polymer costs () 13.359,0 /a

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4.3 Amount of Dewatered Sludge

daily sludge production 915 kg DS


final DS min. 18 %
final sludge amount 5,1 m/d

4.4 Electrical Consumption

The evaluation of the electrical consumption considers the process


related consumers and HVAC of the process related buildings but not
the building services of the administration building and the outside
lightening resp. non-process related consumption.
The power rate of the single aggregates is chosen in accordance to the
mechanical specification and the running times are based on the
process calculations. All necessary base data for the evaluation (e.g.
sludge quantities, DS, air demand, machinery capacities, etc.) are
shown within the process description and the process calculation as well
as in the mechanical specification and the data sheets.
Due to the nominated flow conditions (100 % of Qd), consumers related
to the storm water system are not considered as running units.

daily electrical power demand (100 % plant load) 1.860,8 kWh


specific electrical energy costs () 0,10 /kWh
total yearly electrical energy costs () 67.918,14 /a

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5. Future Extension of the WWTP (Realisation not Part of Actual Contract)

To ensure in future proper biological waste water purification in view of nitrogen


and phosphorus in acc. to the Tender Requirements, the whole plant is
designed to enable an extension of the biological stage.
The extension which is not part of the actual Contract is planned fully in
accordance to ATV A-131.
Nitrogen removal (nitrification and de-nitrification) and normal biological P-
removal is performed in the aeration tanks by intermittent de-nitrification-
process acc. to ATV A-131. Therefore, two additional aeration tanks with the
same geometry as the actual ones are envisaged. Space for two additional
blowers is provided within the blower building.
For enhanced biological P-removal, an anaerobic mixing tank is to be
implemented.
Please see the general layout drawing which shows the relevant structures for
future extension of the plant.

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