Activated Sludge

Introduction

Term "activated sludge" refers to wastewater being mixed with air or oxygen for a length of time to develop a brown floc which consists of billions of microorganisms and other material Process provides the environment to keep these aerobic microorganisms under controlled conditions so they can remove most of the suspended or dissolved organics from the wastewater The environment is provided by four basic systems: aeration, sedimentation, return

Introduction: Typical Activated Sludge Process

Introduction: Definitions of Terms

ACTIVATED SLUDGE

floc of microorganisms that form when wastewater is aerated mixture of activated sludge and wastewater in the aeration tank

MIXED LIQUOR

MIXED LIQUOR SUSPENDED MATTER (MLSS)

measure of the amount of suspended solids in the mixed liquor expressed in mg/l

Introduction: Terminology

MEAN CELL RESIDENCE TIME (MCRT) inverse of the net growth rate and is equal to the average time a microorganism spends in the treatment process. The MCRT is an important kinetic parameter that is very useful in process control FOOD TO MICROORGANISM RATIO (F/M) ratio of the amount of food expressed as pounds of COD (or BOD) applied per day, to the amount of microorganisms, expressed as the solids inventory in pounds of volatile suspended matter. The F/M is mathematically related to the MCRT, and is also an important process control tool RETURN ACTIVATED SLUDGE (RAS) settled mixed liquor collected in the clarifier underflow and returned to the aeration basin

Introduction: Terminology

WASTE ACTIVATED SLUDGE (WAS) excess growth of microorganisms which must be removed to keep the biological system in balance. Various control techniques have been developed to estimate the amount of WAS that must be removed from the process COMPLETE MIX ACTIVATED SLUDGE an ideal mixing situation where the contents of the aeration tank are at a uniform concentration PLUG FLOW ACTIVATED SLUDGE an ideal situation where the contents of the aeration tank flows along the length of the tank

Introduction: Terminology

BACK MIXING mixing the contents of a tank in the longitudinal or flow oriented direction TRANSVERSE MIXING (or CROSS ROLL) mixing in a direction across the direction of flow SLUDGE REAERATION practice of aerating the RAS before it is added to the mixed liquor PROCESS LOADING organic loading range as measured by the F/M CONVENTIONAL LOADING process loading of 0.2 to 0.5 lbs BOD applied/lb MLVSS/day HIGH RATE LOADING process loading of two to three times the conventional loading rate

Introduction: Terminology

EXTENDED AERATION LOADING

low rate loading that is one half to one tenth of the conventional loading rate
measure of the volume occupied by the mixed liquor after settling in a graduated cylinder for 30 minutes. Settleability is generally expressed as a percentage based on the ratio of the sludge volume to the supernatant volume amount of volatile suspended solids in the treatment system

SETTLEABILITY

SOLIDS INVENTORY (VOLATILE SOLIDS)

Solids Inventory

Suspended matter (SS) that makes up the mixed liquor consists of living and nonliving organic matte The living organic matter is referred to as being active and contains microorganisms responsible for treating the wastewater The more accurately the concentration of active microorganisms is known, the more consistently the activated sludge process can be controlled Many attempts have been made to accurately measure the "active" concentration of the SS

Solids Inventory Common means of estimating the microorganism concentration is the measurement of volatile suspended matter (MLVSS) All the organic material in the SS burns to carbon dioxide and water in the MLVSS determination Typically, 70-80 percent of the MLSS will be MLVSS The MLVSS determination provides an approximation of the concentration of living biological solids, because the MLVSS also includes a nonliving fraction Even so, the MLVSS has been found to be an acceptable representation of "active" living microorganisms in activated sludge

Treatment Flow

Return Activated Sludge (RAS) from the clarifier underflow is combined with the influent wastewater in the aeration tank to form the mixed liquor The mixed liquor is usually aerated for a period of several hours in the aeration tank

Treatment Flow

During aeration, organic material in the wastewater is converted into new microorganisms, adsorbed onto floc particles and converted (oxidized) to various other products, including carbon dioxide. Mixed liquor flows through the aeration tank into the clarifier, where it settles to form the RAS. Clear liquid remaining above the settled mixed liquor is called the secondary effluent, which is discharged from the process.

Aeration Systems

Aeration provides

dissolved oxygen and mixing of the mixed liquor and wastewater in the aeration tank.

Factors influencing aeration requirements:

Organic loading MLSS concentration Temperature Other

Aeration Systems

Aeration is provided by either diffused or mechanical aeration systems. Diffused air systems consist of a blower and a pipe distribution system that is used to bubble air into the mixed liquor. Mechanical aeration systems consist of a pumping mechanism that disperses water droplets through the atmosphere.

Activated Sludge Diagram

Diffused Air System

Diffused air systems are the most common types of aeration systems used in activated sludge plants. Diffusers are designed to either produce fine or coarse bubbles.

Fine Bubble Diffusers

The fine bubble diffusers are easily clogged by biological growth and by dirty air, resulting in high maintenance costs. The air supply for all fine bubble diffusers should be filtered.

Fine Bubble Diffusers

Coarse Bubble Diffusers

Coarse bubble diffusers are usually made by drilling holes in pipes or by loosely attaching plates or discs to a supporting piece of pipe. Coarse bubble diffusers have lower oxygen transfer efficiencies than the fine bubble diffusers. A typical oxygen transfer efficiency would be about 5 percent.

Coarse Bubble Diffusers

Surface Aerators

There are two types of mechanical aerators in common use today. These include the surface and turbine aerators. Surface aerators use a rotating propeller that pumps the mixed liquor through the atmosphere above the aeration tank. Oxygen transfer is achieved by the aerator propeller spraying the mixed liquor through the atmosphere.

Surface Aerators Surface aerators either float or are mounted on supports in the aeration tank. Materials such as epoxy coated steel are used in the construction of surface aerators to reduce corrosion. The oxygen transfer efficiency of a surface aerator increases as the submergence of the propeller is increased. However, power costs also increase because more water is sprayed. Oxygen transfer efficiencies for surface aerators are stated in terms of pounds of oxygen transferred per horsepower per hour (lb O2/hp/hr). Typical oxygen transfer efficiencies are about 2 lb O2/hp/hr. Surface aerators are sometimes equipped with draft tubes to improve their mixing characteristics.

Mechanical Aerators

Floating or fixed Brush Other

Sedimentation System

As the mixed liquor flows out of the aeration tank, it is transferred to a sedimentation unit which is commonly called a secondary clarifier. The secondary clarifier provides a reduction in flow velocity allowing the mixed liquor to settle by gravity to the bottom. The design and construction of secondary clarifiers for activated sludge treatment incorporates several methods for the removal of settled sludge. These generally include the conventional sludge collection equipment found in rectangular and circular primary sedimentation units which collects to a central hopper, and, in recent years, suction-type collectors as shown in Slide 25.

Wasting & Return Rates

Constant MLVSS Constant F:M Ratio Constant Sludge Age

Return Rates
Constant rate Variable rate Intermittent rate

Process Control

A portion of the activated sludge is purposely removed by wasting it from the process. The wasting of sludge is necessary to maintain the desired quantity (numbers) of active microorganisms in the process. A basic idea behind successful operation of an activated sludge system is to keep a balance of microorganisms to the amount of food in the wastewater. Proper operation makes food the only part of microorganisms' diet that limits their growth.

Process Control

If nutrients or oxygen limit the growth of the microorganisms, they will not settle satisfactorily in the clarifier. The activated sludge process depends on settling the mixed liquor so that it can be returned to the aeration tank to keep in balance with the organic material in the incoming wastewater. This balance is generally related to process loading as expressed by the F/M ratio. Inability to settle the mixed liquor can

Nitrification Cycle

The first step in the process, conversion of ammonia to nitrite and then to nitrate, is called nitrification (NH3 NO2 NO3). The process is summarized in the following equations:

It is important to note that this process requires and consumes oxygen. This contributes to the BOD or biochemical oxygen demand of the sewage. The process is mediated by the bacteria Nitrosomonas and

NH4 + 3/2 O2 NO2- + 2H+ + H2O NO2- + 1/2 O NO3-

Nitrification Cycle
Nitrogen Gas Oxides of Nitrogen Organic - N Decaying Matter
Ammonia Nitrification Nitrate Denitrification Ammonia, Organic - N in WWTP Influent Denitrification in Sediments Biological Growth in Stream

Industrial Fixation
Fertilizer (Ammonia, Nitrate)

Nitrogen Fixing Bacteria

Assimilation

Ammonia, Nitrate in WWTP Effluent

Nitrification in Stream

Nitrification Cycle

Toxicity

Ammonia toxicity

Ammonium Nitrate Nitrite

Process Control

30 minute settleability range 400 to 800 ml/l Aeration basin dissolved oxygen 1.0 to 3.0 mg/l Mixed Liquor Suspended Solids (MLSS) Range

Conventional, Step aeration, Complete Mix 1000 to 3000 mg/l Contact Stabilization 1000 to 3000 mg/l Extended Aeration, Oxidation Ditch 3000 to 5000 mg/l

Mixed Liquor Volatile Suspended Solids 70% of Mixed Liquor Suspended Solids

Process Control

Temperature 8 to 22 degrees Celsius for domestic wastewater. Industrial discharge will significantly increase the temperature. Nitrogen content Total Nitrogen 15-90 mg/L Phosphorus Content averaging around 10 mg/liter

Side Stream Impacts

Return activated sludge (RAS) Supernatant from digester Filtrate from solids processing

Troubleshooting

If conditions in the aeration system deteriorate, undesirable microorganisms may thrive Typical undesirable microorganisms include the filamentous organisms Filamentous microorganisms

long, thread-like organisms with increased surface area more competitive for growth in conditions of low DO or low nutrient concentrations

Troubleshooting

Filamentous organisms hinder settling

cause excessive bridging and matting of the floc result is a mixed liquor which does not settle well

Poor settleability associated with the presence of too many filamentous organisms is known as bulking sludge.

Troubleshooting

Bulking sludge

Settles poorly Operation in a bulking sludge condition may result in the loss of the mixed liquor into the effluent. treating the return activated sludge with oxidizing agents, such as chlorine or hydrogen peroxide improving the treatment conditions so environment is less favorable to the growth of filamentous organisms.

Approaches to cure bulking include:

Settling problems and solids losses can also occur during high flow periods.

Activated Sludge Process Variations

conventional tapered aeration complete mix extended aeration step aeration contact stabilization high rate Sequential batch reactors Fixed film suspended growth Kraus

Activated Sludge Process Variations

Variations involve changes in loading rates or a physical rearrangement of the process. The various levels of process loading are described by the F/M ratio and MCRT. The term "physical arrangements" is used to refer to the structural arrangement of the aeration tank, as well as the various arrangements of the process streams that are used to provide flexibility.

Process Loading Ranges

The three basic ranges of process loading are for a plant operating on a typical domestic wastewater at a temperature of about 20 degrees centigrade. These loading ranges will be referred to as the high rate, conventional rate, and extended aeration.

Process Loading Ranges

Process Modification Aeration, D F:M Conventional High Rate Extended aeration 5 to 15 5 to 10 20 to 30 0.2 to 0.4 0.4 to 1.5 MLSS 1500 to 3000 100 to 1000

0.05 to 0.15 3000 to 6000

High Rate Loading

High rate loading range takes advantage of the settleability of sludge when the treatment system is loaded at a fairly high rate. Level of treatment which results is comparable to a typical high-rate trickling filter plant.

Conventional Rate

For typical domestic wastewater at 20 degrees C, the conventional process operates between MCRT values of 5 to 15 days and F/M ratios of 0.2 to 0.5 lbs BOD applied/lb MLVSS/day. Most large municipal treatment plants operate in the conventional activated sludge zone. Plants operating in the middle of this range produce an excellent effluent quality and do not (in theory) nitrify.

Conventional Rate

At the lower end of this loading range, an even better effluent is sometimes produced, although problems sometimes occur when the plant slips slightly or goes completely into nitrification.

Conventional Rate

Filamentous growth and poor sludge settleability have been associated with the conventional process at the upper loading ranges Dispersed growth and cloudy effluent are also quite common. Usually the operator can see this sort of condition coming by plotting a trend of the organic loading in his treatment process (either the F/M ratio or the actual MCRT) Other signs of a more physical nature may also be used by the operator to evaluate an

Extended Aeration Rate

The lowest range of process loading where successful operation may be accomplished is the extended aeration tank. Generally, plants operating in this range are small in size and do not receive 24 hour supervision. Such plants are very conservative in design and generally operate with an MCRT of 20-40 days and F/M ratio of 0.05 to 0.15 lbs BOD applied/lb MLVSS/day. (The above is based on typical domestic wastewater at a temperature of 20 degrees

Extended Aeration Rate

Extended aeration is sometimes referred to as the "total oxidation process" Term is derived from the fact that these plants are designed with such low loadings that theory predicts that all influent BOD will be converted to CO2 Some manufacturers claim no wasting is necessary In reality, even after extremely long periods of aeration, suspended matter remains in the effluent

Extended Aeration Rate

Although sludge wasting need not be conducted on a daily basis in extended aeration plants, occasional wasting is a necessity Often the effluent of the extended aeration processes contains small pinpoint floc, which may be observed passing over the weirs of the secondary clarifier When loading in an extended aeration plant is in the higher portion of the loading range, a number of operating problems may occur

Extended Aeration Rate

Because the entire aeration range is in the nitrification zone, denitrification and rising sludge problems may result

brown, greasy foam Filaments poor settleability

Activated Sludge With Reaeration

Re-aeration processes are variations in the arrangement of the process streams All sludge re-aeration processes involve stabilization by aeration of the return sludge prior to its contact with the untreated wastewater Most examples require different ratios between the amount of return sludge under aeration and the amount of sludge in the contact section of the process

Activated Sludge With Reaeration

Contact stabilization and step aeration (step feed) are two variations of sludge re-aeration Both processes represent the extremes of the contact/stabilization ratio; however, both have established a successful record of performance Successful process installations with contact/stabilization ratios over the whole range between contact stabilization and step feed can be found in great numbers Most have been shown to greatly increase

Contact Stabilization

Step Feed

Complete Mix

References

Kerri, Kenneth D., et al. Operation Of Wastewater Treatment Plants. Third Edition, 1990, Vol. I, California State University, Sacramento. EPA Process Control Manual. Aerobic Biological Wastewater Treatment Facilities. March 1977. U.S. Environmental Protection Agency, Office of Water Operations, Washington D.C. Water Environment Federation. Design of Municipal Wastewater Treatment Plants. Fourth Edition, 1998, Volume II.