02 – Wastewater Pre-Treatment Processes

Industrial wastewater:
m These are materials that could be discharged from industrial processes into a collection system include
chemicals, dyes, acids, alkalies, grit, detergents, and highly toxic materials.
m Individual industries present highly individual wastestreams, and these industry-specific
characteristics depend on the industrial processes used
m While many times industrial wastewaters can be treated within public treatment facilities without
incident, often industries must provide some level of treatment prior to their wastestream entering a
public treatment system.
m This prevents compliance problems for the treatment facility. An industry may also choose to provide
pretreatment because their own on-site treatment is more economical than paying municipality fees
for advanced treatment.
Undesirable wastewater characteristics:
m Depending on the nature of the industry and the projected uses of the receiving stream, various waste
constituents may have to be removed prior to discharge. These are summarized as follows:
1) Soluble organics – depletion of DO
2) Suspended solids – cause siltation & if containing organic solids, will progressively decompose, will
deplete DO & produce obnoxious gas.
3) Priority pollutants – such as phenol & other organics can cause odor and color, & in most cases are
carcinogen
4) Heavy metals, cyanide & toxic organics – they are now appearing as specific limitations in most permits.
5) Color & turbidity – aesthetic problems even though they may not be particulatarly deleterious.
6) Nitrogen & phosphorous – enhances eutrophication and promotes algal growth.
7) Refractory substances resistant to biodegradation- refractory nitrogen compounds found in textile
industry. Some refractory are toxic to aquatic life.
8) Oils & floating materials – produce unsightly conditions, are restricted by regulations.
9) Aquatic toxicity – substances present in effluents that are toxic to aquatic life.

Flow Equalization:
A process by which the operating parameters (i.e. the flow, volume, concentrations of suspended solids &
other pollutants, temperature, etc) are made uniform over a given time frame (typically 24 hrs) to reduce
the surges and downstream effects on the treatment facility.
m The objective of equalization is to minimize or control fluctuations in wastewater volume and
characteristics in order to provide optimum condition for subsequent treatment processes.
m The equalization basin should be sufficient in size to adequately absorb the waste fluctuation volume
caused by the plant production schedule and to dampen the effect of concentrated batches
periodically dumped
Types of flow equalization process:
1.) Alternating flow diversion – uses 2 or more basins, designed to collect the flow in one basin for a given
period (usually 4-hr) while the other basin is discharging. The basins successively alternate between
filling and discharging. Mixing is provided so that the content pollutant level is constant as the basin
discharges.

General equation for alternating flow diversion:

3
Vt = (Q)(T)(1+SF) where: Vt = volume of each equalization tank (m )
Q = average flow rate, (m3/day)
T = equalization period, (days)
SF =safety factor (%)
 Example:
An industrial facility with a total daily flow and pollutant (phenol) load is tabulated below.
The assumption is that the facility is operated continously in a 7-day period.

Total Phenol Phenol

Day of month Flow conc. mass Based on the tabulated this data , the size-up
(m3/day) (mg/li) (kg/day) the volume of the the equalization basin.
1 350 2000 0.70 Use 20% for SF.
2 225 2750 0.62
3 200 3250 0.65 Q = average flow rate = 195 m3/day
4 240 2500 0.60 T = equalization period = 1 day
5 300 2250 0.68 SF = safety factor = 25% (0.20)
3
6 320 2500 0.80 Vt = (Q)(T)(1+SF) = (282)(1)(1.25) = 353 m
7 340 2400 0.82
Daily average 282 2521 0.69 Each equalization basin should be designed
Minimum 200 2000 0.6 to hold 353 m3.
Maximum 350 3250 0.816

400

350 flow rate varies widely, ave = 282 (+/-) 59.85 m3/day

300

250

200

150 phenol level ave = 0.69 (+/-) 0.085 kg/day

100

50

0
1 2 3 Day4 5 6 7

Important note: When evaluating the risk that a given flow or load will exceed the average daily flow,
the project team may calculate the standard deviation. The usefulness of this approach in predicting
the short term variation in flow and load may be limited by the lack of short term flow and load data.

2.) Intermittent flow diversion – is designed to allow any significant variance in wastewater parameters
to be diverted to an off-line equalization basin for short periods.The diverted flow is treated or bled
back into the normal wastewater stream at a controlled rate. The rate at which the diverted flow is
returned depends on the wastewater volume & variance. This type maybe used when toxic or difficult-
to-treat flows are occassionally expected because of certain plant operations.
Industries that uses this type are those with scheduled maintenance, refineries, metals finishing
operations, with cyanide or hexavalent Cr batch operation, food and dairy operations during clean-
in-place

Steps for systems design:

1) Determine the frequency and duration of the variance to be diverted (this will allow design of
the equalization basin)
2) Calculate the diverted flow controlled release rate that will maintain normal operation.
3) Use the diverted volume to calculate the surge basin volume so continous flow to the treatment
plant can be maintained.
4) Verify that the equalized flow meets the desired discharge limits.
Example:
An industrial facility with a total daily flow and pollutant (phenol) load is tabulated below. The assumption
is that the facility is operated in 7-day period
This data is a typical 24-hr average of a week (7-day period)
Flow hourly Phenol Phenol for intermittent flow diversion:
Time rate flow conc. mass V = (Q)(T)(f)(k)
(m3/min) (m3) (mg/li) (g/day) where: V = volume to be diverted per time
8:00 AM 0.220 13.20 2800 36.96 period, (m3)
3
9:00 AM 0.280 16.80 2770 46.54 Q = flow rates diverted, (m /hr)
10:00 AM 0.170 10.20 2570 26.21 T = time of diversion, (hours)
11:00 AM 0.452 27.12 2010 54.51 f = frequency of diversion (no./day)
12:00 PM 0.497 29.83 3000 89.50 k = unit conversion constant (min/hr)
1:00 PM 0.520 31.19 2020 63.00 and
2:00 PM 0.161 9.66 2360 22.80 fc = V/Tk
3
3:00 PM 0.132 7.92 2410 19.09 where: fc = controlled discharged rate (m /min)
4:00 PM 0.140 8.40 2180 18.31 V = volume diverted, m3 )
5:00 PM 0.240 14.40 2840 40.90 T = time period for return, (hours)
6:00 PM 0.170 10.20 2510 25.60 k = unit conversion constant (hr/min)
7:00 PM 0.186 11.16 2700 30.13
8:00 PM 0.300 18.00 2360 42.48 Following the solution steps outline above:
9:00 PM 0.260 15.60 2720 42.43 1) Determine the frequency and duration of the
10:00 PM 0.160 9.60 2670 25.63 variance to be diverted (this will allow design of
11:00 PM 0.424 25.44 2910 74.03 the equalization basin)
12:00 AM 0.497 29.83 2180 65.03 * there are surges in flow rates occuring twice:
1:00 AM 0.483 28.98 2290 66.36 > one @11AM - 1PM, and the other @11PM-1AM,
2:00 AM 0.210 12.60 2200 27.72 with combined ave = (0.452+0.497+0.52+0.424+
3:00 AM 0.120 7.20 2790 20.09 0.497+483)/6 = 0.479 m3/min
4:00 AM 0.250 15.00 2870 43.05 * the daily ave flow rate (including the 11AM-1PM,
5:00 AM 0.130 7.80 2710 21.14 & the 11PM-1AM flows) = 0.268 m3/min
6:00 AM 0.290 17.40 2800 48.72 * volume to be diverted (m3), V = (Q)(T)(f)(k)
3
7:00 AM 0.130 7.80 2470 19.27 Q = flow rates diverted, (m /min) = 0.211
Daily ave 0.268 16.056 2547.500 40.40 T = time of diversion, (hours) = 3
Min 0.120 7.200 2010.000 18.31 f = frequency of diversion (#/day) = 2
Max 0.520 31.188 3000.000 89.50 k = applicble conversion constant =
day (24-hr) total = 385.332 m3

140.00

120.00

100.00

80.00

60.00

40.00

20.00

0.00
8:00 AM
9:00 AM

1:00 AM
2:00 AM
3:00 AM
4:00 AM
5:00 AM
6:00 AM
7:00 AM
1:00 PM
2:00 PM
3:00 PM
4:00 PM
5:00 PM
6:00 PM
7:00 PM
8:00 PM
9:00 PM
10:00 AM
11:00 AM
12:00 PM

10:00 PM
11:00 PM
12:00 AM

Plot of the variations of flow and the phenol loadings

* volume to be diverted (m3), V = (Q)(T)(f)(k) = (0.479)(3)(2)(60/1) = 76.059 m3

2) Calculate the diverted flow controlled release rate that will maintain normal operation.
controlled discharged rate (m3 /min), Fc = V/Tk
V = volume diverted, m3 = 76.059 Fc = V/Tk = 76.059 m3/[(24 hrs)(60 min/hr)]
T = time period for return, (hours) = 24 = 0.0528 m3/min
k = applicble conversion constant = 60min/hr

3) Use the diverted volume to calculate the surge basin volume so continous flow to the treatment
plant can be maintained.
Vol. of the diversion vessel is calculated as: V = QTk
Q = average flow rate diversion (m3/min) = 0.211
T = diversion time period (hrs) = 6
k = unit conversion factor (min/hr) = 60/1
 Vol. of the diversion vessel is calculated as: V = QTk = (0.211 m3/min)(6 hrs)(60 min/hr)
= 76.059 m3

4) Verify that the equalized flow meets the desired discharge limits.
The diverted and the mainstream flows can be recombined by mixing just before the downstream
treatment plant

For a day (24-hr period), the total flow is (0.268 m3/min)(60min/hr)((24 hrs) = 385.332 m3, but 76.059 m3 is
diverted (for 6 hrs) to the diversion vessel and recombined again to the flow stream; the average flow
would be : * for 18 hrs w/o flow diversion: (385.332 - 76.059) = 309.273 m3 or 309.273/[(24)(60)] =
= 0.2148 m3/min (on 24-hr basis)
* controlled discharging rate from the diversion vessel = 76.059/[(24)(60)] (24-hr basis) =
= 0.0528 m3/min

QT (total combined flow rate) = QA (average flowrate without diversion)+ QC (controlled discharged from
rate of the diverted volume)
= 0.2148 + 0.0528 = 0.2676 m3/min = 385.34 m3/day

3.) Compelety Mixed Combined Flow – this is the most common equalizing process, designed to address the
variability expected when multiple flows from different sections of the plant combined, often generating
impulse or step changes to the wastewater treatment facility. It continously trims flow and load peaks, as
well as changing the operating parameters more gradually to optimize downstream process. The most
common method of sizing equalization facilities is the mass balance approach using the cummulative flow
or mass diagram. Sometimes called the Rippl diagram. This graphic technique consist of plotting the cum-
mulative flow vs. time for one comlete cycle (i.e., 24 hrs). Two parallel lines, with slope (representing the
tank average outflow rate) are drawn tangent to the high and low points of the cumulative curve. The
required tank size is the is the verical distance between these 2 tangents. A safety factor of 20% should be
aplied to the volume calculation.

Example: These are data from a typical dairy industry

Cumm. Tank ave %
Flow rate flow outflow of cumm
Time (m3/day) (m3) (m3/day) flow
Midnight 120 0 0 0.0%
1 100 120 217.9 2.3%
2 80 220 435.8 4.2%
3 70 300 653.8 5.7%
4 60 370 871.7 7.1%
5 70 430 1089.6 8.2%
6 80 500 1307.5 9.6%
7 150 580 1525.4 11.1%
8 300 730 1743.3 14.0%
9 350 1030 1961.3 19.7%
10 400 1380 2179.2 26.4%
11 400 1780 2397.1 34.0%
Noon 450 2180 2615.0 41.7%
1 350 2630 2832.9 50.3%
2 500 2980 3050.8 57.0%
3 450 3480 3268.8 66.5%
4 400 3930 3486.7 75.1%
5 200 4330 3704.6 82.8%
6 200 4530 3922.5 86.6%
7 150 4730 4140.4 90.4%
8 150 4880 4358.3 93.3%
9 100 5030 4576.3 96.2%
10 100 5130 4794.2 98.1%
11 200 5230 5012.1 100.0%
MN 5230 5230.0
5000

cummulative flow curve

filling
tank outflow
4000 vertical distance between the 2 tangent lines , read line
on vertical axis = 1700, hence the required
equalizing tank vol = 1,700 + 20% safety factor = 2,
040m3
3000

these tangent lines

2000 must be parallel to the
tank outflow line
~ 1700
this line has
1000 same lenght as
this emptying

0
0 MN 1 2 3 45 5 6 7 8 9 10
10 11 N 1 2 315 4 5 6 7 8 209 10 11 MN 25