Advanced Training Wastewater Treatment.ppt

Training of Wastewater treatment

1. Advanced Training On
Wastewater Treatment
TRAINING

2. GENERAL

3. What is Wastewater?

4. What is wastewater?
Origin:
Industrial
Sewage
Mixture of (pure) waterand contaminants:
Organicand Inorganic
Dissolvedand Undissolved(= suspended)
Easily biodegradableand Difficult biodegradable

5. Organic Inorganic
Carbohydrates = Sugars
Proteins
Oils & Fats
Fatty acids
Alcohol & solvents
Paper & Wood
Food Industry
Etc…
Sand & Gravel
Kieselguhr (brewery)
Clay
Minerals:
Ammonium
Phosphate
Chloride
Sulphate
Metals
Salt NaCl

6. Soluble Insoluble
Sugar
Alcohol
Salt
Nitrogen & Phosphorus
Compounds
…
Oils & Fats
Kieselguhr
Paper & Wood
Sand, Stones,
Plastic, …

7. Biodegradable Non Biodegradable
Sugars
Alcohols
Proteins
Fatty Acids
…
Sand, Stones, Plastic
Kieselguhr
Minerals
Recalcitrant Organic
Compounds
…

8. Wastewater
Characteristics

9. Raw Wastewater Parameters
pH, T°C
COD, BOD, BOD/COD (kg O
2/m³)
TSS (kg/m³)
Nutrients (N, P, micronutrients)
Flow Rate (m³/day)

10. pH
Degree of Acidity
pHwastewater=> pHbioreactorin range 6,5 –8,5
Extreme pH-values = Toxic
pH will change in bioreactor:
In anaerobic Treatment
-pH Degradation VFA, Ammonification
-pH Acidification, Nitrification, CO
2

11. CODChemical Oxygen Demand
Measure for TotalAmount Organic Contamination
Unit: mg O
2/L Chemical Oxidation
Oxidant: K
2Cr
2O
7
–OXIDATION
Organic matter + O
2-equivalents (k
2Cr
2O
7) CO
2
+ H
2O

12. BODBiochemical Oxygen Demand
Unit: mg O
2/L Biological Oxidation
Measure for Amount Biodegradable Contamination
Organic matter + O
2 CO
2+ H
2O
Oxidant: Bacteria –Inoculation
Micro-WWTP

13. BOD/COD
BOD/COD-ratio
Info Biodegradability
BOD/COD > 65 % Easily Biodegradable
BOD/COD < 50 % More Difficult Biodegradable
BOD vs. bCOD: Sludge Adaptation!

14. Total Suspended Solids (TSS)
TSS = Amount of Un-dissolved Matter (mg/l =
ppm)
Difficult Degradable
To Avoid:
Accumulation in Sludge
Increased Sludge Production

15. Nutrients
Macro-nutrients:
N, P
BOD/N/P = 100/5/1
Assimilative Removal = Biomass Incorporation
Micro-nutrients
Minerals: Ca, Mg, Na, Fe, K, …
Trace-elements: Co, Cu, Zn, Mn, …

16. Nitrogen
Kjeldahl-N: organic bound N + NH
4
+
-N
Ammonium-N (NH
4
+
-N) (mgN/l)
Nitrate-N (NO
3
-
-N) (mgN/l)
Nitrite-N (NO
2
-
-N) (mgN/l)
Total Nitrogen = KjN-N + NO
3
-
-N + NO
2
-
-N

17. Phosphorus
Total P (mgP/l) = organic bound P + PO
4
3—
P
Ortophosphate (PO
4
3-
-P) (mgP/l)

18. Inhabitant Equivalent
Originates from Municipal WWT
1 P.E.
Hydraulic load = 180 l/day
BOD-load = 54 g BOD = 300 mg O
2/l
COD-load = 135 g COD = 750 mg O
2/l
BOD/COD = 40%
SS-load = 63 g TSS = 350 mg/l
N-load = 9,9 g N = 55 mg N/l
P-load = 2 g P = 11 mg P/l

19. Wastewater Treatment
Mechanical
Biological
Physico-Chemical
Combinations

20. Wastewater Treatment
Mechanical (Pre-treatment)
Biological
Aerobic
•Anoxic Conditions for Nutrient Removal
Anaerobic
Physico-Chemical

21. Mechanical Pre-Treatment
Sedimentation (Primary Sludge)
Flotation (Oil & Fat)
Screening (coarse screen, fine screen)
Cyclone
Filtration

22. Mechanical Pre-Treatment
Screening (Coarse screen, Fine screen)
Mechanical Bar Screens Rotary Drum Screen

23. Mechanical Pre-Treatment
Flotation (Oil & Fat) (DAF, IGF,...)
DAF Units

24. Mechanical Pre-Treatment
Filtration (Media Filtration, Mechanical)
Hydrotech Drum
Filter
Hydrotech disc Filter

25. Physico-Chemical
Iron Oxidation
Coagulation (Fe
3+
, Al
3+
, …)
Flocculation (polymer)
Adsorption (active carbon, zeolyte)
Precipitation (heavy metals, phosphate, hardness)
Stripping of NH
3or VOC
Ion exchange

26. Biological Treatment
Aerobic
Lagoon
Activated sludge systems
•Suspended Sludge
Biorotor, biofilter, MBBR
•Fixed Bed
Biological nutrient removal
•N/dN, P-accumulation
Anaerobic
UASB, CSTR, EGSB

27. Biological
Wastewater Treatment

28. Why Biological
Wastewater Treatment?
Produces a clear effluent, harmless for
the environment:
Removes organic compoundsfrom the
wastewater
Removes nutrients (eutrofication risk!)
like N and P (partially)
Economical most feasible

29. Organic Compounds
C
Negative effect of WW on surface water:
Oxygen demand raises
•Microbial growth
•Water organisms die due to O
2-deficiency!
Possibly toxic compounds

30. Eutrophication
N & P
Negative effect WW on surface water:
Nutrients (N & P) cause algae growth
(autotrophic: C-source = CO
2)
During night these algae consume O
2
Fishes and other water organisms die due
to O
2-deficiency!

31. Biological WWT
Removal organic contaminants by
bacterial metabolism:
Substrate (= C-source) is “uptaken”
End-products:
•CO
2(anaerobic: CO
2+ CH
4)
•H
2O
•Minerals
•Biomass

32. Bacterial Metabolism
Substrate degradation:
Catabolism or Dissimilation = Energy Production
Anabolism or Assimilation = Biomass growth
•C
•N, P & Micronutrients
•Energy
Survival
Reproduction

33. Bacterial Metabolism:
Schematic
End Products
CO2 + H2O + Minerals
Biomass
Proliferation + Reserves
Substrate
C + nutrients
Energy
Cell
Maintenance
Catabolism
Anabolism
Survival
Reproduction

34. Aerobic versus Anaerobic
Oxygen = final e
—
-acceptor
Molecular: O
2
Bound: NO
3
-
(= de-N)
Activated sludge (flocks)
Final e
—
-acceptor = no O!
Carbon (= fermentation)
CO
2
Granular sludge (UASB, EGSB)
Main difference: O
2

35. Aerobic versus Anaerobic
Advantages
No post-treatment:
•Low effluent COD
•Bio-N and -P removal
No heating:
•range = 0 -40 °C
Very robust process
Short start-up
Disadvantages
Post-treatment needed?
•COD-removal max. 85-90%
•No bio-N and -P removal
Heating needed?
•range = 25 -40 °C
More sensitive toxic
shocks
Relative long start-up

36. Aerobic versus Anaerobic
Disadvantages
Higher exploitation cost:
•Aeration energy
–1,1 kWh/kg bCOD
•Sludge disposal
–0,3 kg sludge/kg bCOD
Large footprint
•Relatively low V
b
•Sedimentation tank
No CH
4production
•No energy production
Advantages
Low exploitation cost:
•No aeration
–0,3 kWh/kg bCOD
•Sludge disposal
–0,05 kg sludge/kg bCOD
4 x smaller footprint!
•High V
b
•No sedimentation tank
CH
4production
•Energy source!

37. Energy Balance:
Schematic
Aerobic Anaerobic
Biochemical reactions with O
2as e
-
-acceptor:
More energy gain for biomass!!!
More sludge growth
No energy-rich end product

38. Aerobic
Wastewater Treatment

39. Design Parameters
Flow rate –Hydraulic Retention Time
Temperature 10
O
C –40
O
C
Organic loading (kg BOD or COD/day)
(kg BOD or COD/m³.day)
Sludge loading
(F/M: Food to micro-organisms)
(kg BOD or COD/kg DS or MLSS.day)
MCRT (days) Mean Cell Retention Time
= amount of sludge in reactor (kg)
daily amount of wasted sludge (kg/d)

40. Temperature 10
O
C –40
O
C
Nitrification / De-nitrification Rate. « mg
N/g MLVSS/hr »
Available MLVSS.
Reactors Volumes (Anoxic & Aeration).
Design parameters « Nutrient Removal

41. Aerobic WWT
In general:
Wastewater CO
2+ H
2O
Activated sludge Energy
For glucose:
5 C
6H
12O
6+ 30 O
230 CO
2+ 30 H
2O + energy
Micro-organisms use this energyfor:
Cell Processes/Cell Maintenance (Survival)
Biomass Growth (Reproduction)
Substrate Respiration = Oxidation of Substrate
Endogenous Respiration = Oxidation of Biomass Reserves
O
2

42. Fundamental Process Steps
Feeding + Aeration
Accumulation-Regeneration
•Reduce Filaments
Active Volume
Settling + Discharge
Passive Volume

43. Extra Process Steps
For biological nutrient removal:
N-removal
•deN in anoxic step
P-removal
•Alternation aerobic-anaerobic steps
For hybrid WWTP’s:
Settling Phase
•intermediate phase before discharge!
Rinse Phase
•sludge evacuation from effluent weir

44. Nutrient Removal
Biological:
Nitrogen: N-deN
Phosphorus: Phosphate Accumulating Bacteria
Physico-Chemical:
Phosphorus: Precipitation of Al-/Fe-phosphates

45. Nitrification -Denitrification
Nitrification:
NH
4
+
+ 2 O
2 NO
3
—
+ H
2O + 2 H
+
Nitrosomonas & Nitrobacter: Autotrophs
Aeration
Denitrification (heterotrophs):
NO
3
—
+ 5 e-+ 6 H
+
½ N
2+ 3 H
2O
CH
2O + H
2O CO
2+ 4 e-+ 4 H
+
No O
2=No Aeration!!!
Easy biodegradable COD: Feeding + Mixing
Atmosphere

46. Phosphate Accumulat. Organism
PAO
Acinetobacter Species
Phosphate Release
+ C-uptake
Phosphate Uptake
+ C-metabolism
Net
P-uptake

47. Phosphate Accumulat. Organism
PAO

48. Phosphate Accumulat. Organism
PAO

49. Phosphate Accumulat. Organism
PAO
Following conditions affect the growth of PAO & Bio-P:
•High retention time and longer non aerated zones. Max retention time is
around 1 hour and sludge age of max. 1.5 –2 days (based on MLSS
concentration).
•High Temperature (> 28
O
C).
•Low TKN.
•Low BOD (VFA source). BOD to TP ratio is 20:1 or 7-10 mg/l of VFA are
required per 1 mg of phosphorus removed by bio-P.
•Low pH in aerobic zone (Keep pH > 7.2).
•Secondary release of phosphorus (i.e inside clarifiers) due to high RT.
•Minimize free O
2& NO
3recycle to anaerobic zone.

50. Phosphate Accumulat. Organism
PAO

51. Microbiology of
Activated Sludge

52. Activated Sludge Parameters
Aerobic sludge:
Bacteria
Water
Protozoa, Metazoa, Fungi
Inorganic matter
Sludge concentration: MLSS (g/L), DM (g/L), Ash-%
Settling Capacity: Imhoff Cone
SV (ml/l) Sludge Volume
SVI (ml/g) Sludge Volume Index = SV/MLSS

53. Activated sludge
99% Water
Particles (non bacterial)
Microbiology (= Active Component!!!)

54. Microbiology
Bacteria
Pseudomonas, Escherichia, Flavobacterium, …
Sludge Flocks
Filaments
Higher (= Predator or Indicator) Organisms
Protozoa (ciliates, flagellates, amoeba, …)
Metazoa (rotifers, worms, …)
Fungi and Yeasts

55. Flocks vs. filaments
Substrate gradient (place time)
Accumulation
Regeneration (“starvation phase”)
Sufficient D.O.
Sufficient Substrate

56. Flocks vs. Filaments

57. Higher Organisms
Amoeba
“Grazing” Worm

58. Process Control
Optimal Circumstances for Activated Sludge

59. Process Control
Feeding
Oxygen
pH
Nutrients
T°C
Toxicity

60. Feeding
Respect Design Load
Organic Load (kg COD/day): Design Aeration System
Hydraulic Load (m³/day): Design Sedimentation Tank
Overload Removal efficiency
Organic Overload
•Failure Aeration -Odour Nuisance
Hydraulic Overload
•Insufficient Pump Capacity
•Upflow Velocity Settler -Sludge Wash-Out

61. Oxygen
Aeration for O
2-Input + Mixing
Min. D.O. = 1 mg O
2/L
O
2-deficiency:
Removal Efficiency
Sludge Bulking (filaments)

62. Fine Bubble Aeration
Blowers
Aeration Disc
Distribution
System

63. Surface Aeration
Settling
Aeration

64. pH
pH activated sludge in range 6,5 -8,5
Effluent-pH

65. Nutrients
Check Effluent
Shortage => N-and/or P-dosage
N > 2 mg/L
P > 1 mg/L

66. T°C
Mesophilic: 5 –40 °C
Determines Biodegradation Rate
Avoid: > 40 °C

67. TemperatureMesophilic temperature-activity correlation
0 10 20 30 40 50
Temperature
Biodegradation rate

68. Toxicity
f(concentration)
To Avoid:
Extreme pH-values
Heavy Metals
Detergents (Cationic)
Solvents
Halogens
Strong Oxidants
…

69. Formulas for Activated
Sludge Processes

70. Formulas for Activated Sludge
Processes
Active Volume (m
3
)
HRT = hours
Volumetric Load: Vb = kg COD/m³*day
Sludge Load: Sb = kg COD/kg MLSS*day
Removal Efficiency in % (COD, BOD, N, P, …)
MCRT = days
Surface Load = m/h

71. Formulas for Activated Sludge
Processes
Active Volume (m³):
Active Volume => Total Volume / Sedimentation Volume
Aerated Volume!
HRT (hours):
.
Time Span H2O-molecule is Present in Bioreactor 

 hourmQin
mVtotal
hoursHRT
/³
³


72. Formulas for Activated Sludge
Processes
Vb (kg COD/m³*day):
.
Organic day load (kg COD/day) = Qin (m³/day) x CODin (kg COD/m³)
Sb (kg COD/kg MLSS*day):
. 
 
  ³/)(³
/__
*)(/
mkgSSVMLmVactive
daykgCODLoadDayOrganic
daySSVkgMLkgCODSb

  
 
³
/__
*³/
mVactive
daykgCODLoadDayOrganic
daymkgCODVb 

73. Formulas for Activated Sludge
Processes
Removal Efficiency (%):
COD, BOD, N, P, …
Correlation amount X Enters WWTP vs. amount X Discharged
X-removal efficiency (%) = (X
influent-X
effluent)/X
influent
MCRT (days):
Residence Time Sludge in Bioreactor
.
  
   ³/_/³__
³/³
mkgsludgeDMwasteddaymFlowWasteSludge
mkgDMreactormVtotal
daysMCRT




74. Formulas for Activated Sludge
Processes  )
*08.0(
**
()1(*/
d
20)(T1-
20)(T








TRC
YK
BOD
TSS
YkgBODkgSSYobs
Sludge Production Observed Yield
Where;
: 1.07 (Temp. Coefficient)
Y : Assumed Yield, Normally 0.6 kg DS/kg BOD removed
K
d , T
-1
: Endogenous decaycoefficient = 0.072
TRC, d : Mean Cell Residence Time (Sludge Age)
T,
O
C : Actual Water Temperature
T.S.S., ppm : Total Suspended Solids at the inlet of Bio-Reactor
BOD, ppm : Biological Oxygen Demand
Sludge Production (kg/day)= Sludge Production Observed Yield X BOD removed
Sludge Production (kg/day)= WAS (kg/day)

75. Formulas for Activated Sludge
Processes
Rule of Thum.
Return Activated Sludge (RAS) = 0.5 to 1.5 Q
inf(m
3
/hr)
Calculation Formula:
Q
RAS= Q
inf* C / (C
r–C)
Cr : Sludge Concentration at the Bottom of the Clarifier.
C : MLSS Concentration in Aeration Tank
Q
inf: Inlet Flow Rate (it may include other flows beside the
raw water flow)
* Mass Balance is a Must for Correct Calculations.
Sludge Recirculation Rates

76. Formulas for Activated Sludge
Processes
Oxygen Demand BOD, T, Vol., CRT, MLVSS
A) Sustrate Respiration = 0.6 kg O
2/kg BOD * BOD load Removed
B) Endogenous Respiration = (0.0528 kg O
2/kg MLVSS/day)*Vol.*MLVSS*

(T-20)
where = 1.024
Oxygen Calculations in Extd. Aerat. & Low Loaded systems

77. Actual Oxygen Requirment “A.O.R”= Sub. Resp. + End. Resp.
S.O.T.R = (1/) * [C
s/ ((P(mmHg)/760)*(51.6/(31.6+T))* * (C
s-C
actual))] *

(20-T)
* A.O.R * k
1
Formulas for Activated Sludge
Processes
 : 0.65 (Fine Air Diffusers) -0.95 (Surface Aeration)
 : 0.95
Water Level : in m
T : 20 °C
C
actual : 1.0 to 2.0 mgO
2/L
C
20 : 9.07 mg O
2/l "Standard"
H.R.T : in hours
k
1 : 1.0 (Function of HRT > 18 hrthen K
1= 1)
 : 1.024
Atmospheric Pressure : 760 mm Hg Standard
Atmospheric Pressure : 1013 mbar Standard
Atmospheric Pressure on site: 760 mm Hg Standard

78. Formulas for Activated Sludge
Processes
Air Required for Aeration = (S.O.T.R) / (Air Oxygen Content) / (S.O.T.E)
Air Oxygen Content = 0.23 kg O
2/m
3
air @ Standard Conditions
S.O.T.E = Supplier Curve / Data Sheet
Note:
-S.O.T.E is a function of water height

79. Formulas for Activated Sludge
Processes

80. Formulas for Activated Sludge
Processes

81. Formulas for Activated Sludge
Processes
Surface Load (m/h)
Design Sedimentation Tank
Minimum Settling Velocity Sludge Flock
.
 
²_
/³
/
mSurfaceSettling
hmQout
hmVs  Effluent
denitrification
Influent
Aeration tank
sludge recirculation waste sludge
Upflow
Velocity

82. Trouble Shooting
WWTP Operation

83. Trouble Shooting -Influent
pH
bioreactorOut of Range Acid/Caustic Dosing
Overload Influent Flow
Nutrient Shortage N-and/or P-source

84. Trouble Shooting -Effluent
Increase Effluent-COD and/or -BOD
Biodegradability
Overload or Oxygen Deficit
Nutrient Deficit
TSS => Surface Load
=> Sludge Wasting
=> Sludge Bulking (filaments)
=> TSS influent
Intoxication (pH, H.M., oil, …)

85. Trouble Shooting –Activated Sludge
Sludge Concentration
Degree of Activity
Settling Capacity
Range 3 –6 g/L (3,000 –6,000 mg/L)
•< 3 Stop wasting + Cause
SV/SVI
Prevention Better than Healing!
SVI > 200 ml/g
More Wasting-Longer Settling Phase-Chlorination???
Value (80 –120 ml/g) up to 150 ml/g

86. Trouble Shooting –Activated Sludge
D.O. ±0 mg O2/l Reduce Feed Flow
Cause?
•overload
•oil/fat
•sludge concentration too high
•failure aeration system

87. Aerobic WWTP’s
Lagoon
Biorotor
Biotower/Biofilter
Activated Sludge System
Suspended Growth

88. Reactor Configurations:
Activated Sludge Systems
Conventional Systems
Batch Reactors (Non-Continuous)
SBR
Hybrid Systems
LUCAS
UNI-TANK
Membrane BioReactor
Submerged MBR
Cross-Flow MBR
Sedimentation
Membrane
Filtration

89. Reactor Configurations:
Activated Sludge Systems
Plug-Flow
Oxidation Ditch/Carousel
Completely Mixed
Unitank
Lucas
®
…
Conventional
Systems
Hybrid
Systems

90. Conventional SystemsSupernatant
Aerated sludge
Influent
Waste sludge
Sedimented sludge
Sludge recycle
Effluent
Sedimentation tankAeration tank

91. Conventional Systems
Fundamental Process Steps Separated in Time:
Separate Bioreactor plug-flow, oxidation ditch, …
Separate Settling Tank: High Footprint
Continuous Influent & Effluent Flow
Constant Water Level (Overflow Weir)
Accumulation-Regeneration: Selector, Reactor Design
Control-In-Place: Limited Flexibility
Sludge Recycle

92. Conventional Systems
Plug-Flow
Settlers
Plug-Flow
Buffer
Tank

93. Aerators
Propellor
Mixers
Oxidation Ditch
Sand/Fat
Removal
Oxidation
Ditch
Selector
Clarifiers
Thickener
Drying Beds

94. Overview Oxidation Ditch
Selector
Retour Sludge
Propellor
Mixers
Surface
Aeration

95. SBR
1 Tank Reactor.
No Settling Tank.
Cyclic Operation
‘Aeration’ & ‘Sedimentation’ separated in time
Control In Time.
Variable Volume.
DEFINETION
Equence Batch reactor in which influent, effluent or both are fed to
the biological system in batches with time intervals.

96. SBR Advantages
No Sedimentation Tank
Compact System = Small Footprint
Process Flexibility: “Control-in-Time”
Adjustable Phase Length
Possible Continuous Influent & Effluent Flow
No Need for Sludge Recycle
Substrate Gradient by Time
Accumulation-Regeneration
Flock Formers Favored by Integrated selector effect
Modular Design
Reliable and Robust Treatment System

97. Sequential Batch Reactors
Influent
Effluent
Aerobic Filling
Accumulation
Aerobic React
Regeneration
Decanting
PHASE 1
PHASE 2
PHASE 3

98. Cyclic Operation
Feed & Aeration (Accumolation). >>>> “F + A”
Feed & Mixing (Accumolation) >> if Nit/De-nit is present. >> “F + M”
Aeration (Regeneration). >>>> “A”
Settling. >>>> “S”
Rinse. >>>> “R”
Decanting >>>> “D”
Sludge Waste >>>> “WAS”
Idle >>>> “Id”

99. Cyclic Operation
Single cycle or more can be appllied to SBR system.
1 Cycle 2 Cycles 3 Cycles 4 Cycles
F + A 12 –18 hr 6 –8 hr 2 –5 hr 1 –3 hr
A 4 –10 hr 2 –4 hr 1 –4 hr 1 –3 hr
S ½ –1 hr ½ –1 hr ½ hr ½ hr
R 3 –5 min. 3 –5 min. 3 –5 min. 3 –5 min.
D 1 –1½ hr 1 –1½ hr 1 –1½ hr 1 hr
WAS ½ –1 hr ½ –1 hr ½ hr ½ hr
Id 10 –15 min.10 –15 min.5 –10 min.3 –7 min.
24 hr 12 hr 8 hr 6 hr

100. Multiple SBREffluent
A A
A
Decantationphase
Aerobic phase
MLSS is aerated
Influent
Aerobic phase
MLSS is fed/aerated
ToB
ToB
FromCFromC
PHASE 1
PHASE 2PHASE 3 Effluent
B
B
B
Decantationphase
Aerobic phase
MLSS is aerated
Influent
Aerobic phase
MLSS is fed/aerated
ToC
ToC
FromA
FromA
PHASE 3
PHASE 1
PHASE 2 Effluent
C
C C
Decantationphase
Aerobic phase
MLSS is aerated
Influent
Aerobic phase
MLSS is fed/aerated
ToAToA
FromB
FromB
PHASE 3
PHASE 1
PHASE 2

101. Excess Sludge
Treatment
Wasting
Thickening
Stabilisation
Dewatering

102. Thickening & Stabilisation
Thickening: Gravitary Volume Reduction
Stabilisation: Mass Reduction
Aerobic: Aeration (endogenous respiration)
Anaerobic:Sludge Digesters (fermentation)
Thickening & Aerobic Stabilisation can be
Combined in 1 Single Tank (time control)

103. Dewatering
Thickening Drum 5% DM
Filter Press 15-25% DM
Chamber
Belt
Centrifuge 20-25% DM

104. Chamber Filter Press

105. Centrifuge: Principle
Sedimentation
Sedimentation +
Centrifugal Force
Sedimentation + Centrifugal Force +
Continuos Discharge of Sludge Cake

106. Centrifuge

107. Centrifuge

108. Case Study
JUBAIL EXPORT REFINERYSTP

109. CASE STUDY
Jubail Export Refinery STP
Project Name: JERP
Location : Jubail
Client : CCE
Capacity : 10,000 m
3
/day
Water Source: Labours’ Camp
System : Extd. Aeration

110. CASE STUDY
Jubail Export Refinery STP
Influent/Effluent Charachteristics in mg/l
- Influent Load kg/d Effluent
-BOD : 350 3,500 <10
-COD : 800 8,000 <50
-TSS : 400 4,000 <10
-TKN : 60 600 10*
-P : 20 200 -----
-Alkalinity: 250* 2,500 -----
* Assumed Figure

111. CASE STUDY
Jubail Export Refinery STP
Design Parameters:
BOD Load = (350 mg/l) * (10,000 m
3
/day) / 1000
= 3,500 kg/day
TSS = 4,000 kg/day
TKN = 600 kg/day
P = 200kg/day
Alkalinity= 2,500 kg/day

112. CASE STUDY
Jubail Export Refinery STP
Sludge Design Parameters in Extd Aerat. & Low Loaded Systems:
MLSS = 3 g/l (3,000 mg/l)
MLVSS= 2.25 g/l (2,250 mg/l)
MLVSS/MLSS Ratio = 75%
Volume Load = 0.35 -0.40 kg BOD/m
3
/day
(0.3 –0.5 kg BOD/m
3
/day)
Volume Design Parameters:

113. CASE STUDY
Jubail Export Refinery STP
Design Formulas:
Calculated Volume = BOD Load / Volume Load
= (3,500 kg/day) / (0.35 kg BOD/m
3
/day)
= 10,000 m
3
F/M Ratio = BOD load / (Volume * MLVSS)
= (3,500 kg/day) / (10,000 m
3
* 2.25 kg/m
3
)
= 0.15 d
-1
(0.08 –0.2 d
-1
)
Retention Time = Volume / Flow
= (10,000 m
3
) / (416 m
3
/hr)
= 24 hr (18 –36 hr)

114. CASE STUDY
Jubail Export Refinery STP
Simulating Different Design Parameters:
Chosen Volume =7,000 m
3
F/M Ratio = BOD load / (Volume * MLVSS)
= (3,500 kg/day) / (7,000 m
3
* 2.25 kg/m
3
)
= 0.22 d
-1
(0.08 –0.2 d
-1
)
Retention Time = Volume / Flow
= (7,000 m
3
) / (416 m
3
/hr)
= 16.8 hr (18 –36 hr)

115. CASE STUDY
Jubail Export Refinery STP
Sludge Production in Extd Aeration & Low Loaded Systems:
Sludge Production BOD, TSS, T, Vol., CRT, MLSS
Rule of Thumb.
No Pre-Treatment >> Sludge Yield = 0.9 kg DS/kg BOD remov.
Pre-Treatment >> Sludge Yield = 0.6 –0.7 kg DS/kg BOD remov.
Notes:
-Coarse screening & Equalization are not Considered as
pretreatment steps.
-Pre-treatment (grit removal, primary clarification, multiflow,...)

116. CASE STUDY
Jubail Export Refinery STP
Sludge Production in Extd Aeration & Low Loaded Systems:
Sludge Production (WAS*):
= (0.9 kg DS/kg BOD remov.) *(3,500 kg BOD/day)
= 3,150 kg DS/day.
Sludge Concentration = 5.5 g/l (at the bottom of the clarifier)
Sludge Capcity = (3,150 kg DS/day)/(5.5 kg/m
3
) = 572.7 m
3
/day
WAS = 23.8 m
3
/hr 24 m
3
/hr
* WAS = Waste Activated Sludge

117. CASE STUDY
Jubail Export Refinery STP
Sludge Recirculation Rates:
Rule of Thum.
Return Activated Sludge (RAS) = 1 to 1.5 Q
inf(m
3
/hr)
Calculation Formula:
Q
RAS= Q
inf* C / (C
r–C)
Cr : Sludge Concentration at the Bottom of the Clarifier.
C : MLSS Concentration in Aeration Tank
Q
inf: Inlet Flow Rate (it may include other flows beside the
raw water flow)
* Mass Balance is a Must for Correct Calculations.

118. CASE STUDY
Jubail Export Refinery STP
Sludge Recirculation Rates:
Q
RAS= Q
inf* C / (C
r–C)
Q
RAS= (416 m
3
/hr) * (3 g/l) / (5.5 g/l –3 g/l)
= 499 m
3
/hr
Q
RAS= 1.2* Q
inf
% Re-circulation= 120%
Total Sludge in Sludge Draw-off Pipe = RAS + WAS
= 499 m
3
/hr + 24 m
3
/hr = 523 m
3
/hr
3 Duty Pumps each 185 m
3
/hr (RAS + WAS)

119. CASE STUDY
Jubail Export Refinery STP
Oxygen Calculations in Extd. Aerat. & Low Loaded systems:
Oxygen Demand BOD, T, Vol., CRT, MLVSS
A) Sustrate Respiration = 0.6kg O
2/kg BOD * BOD load Removed
=(0.6kg O
2/kg BOD) * (3,500 kg BOD/day) = 2,100 kg O
2/day
B) Endogenous Respiration = (0.1 kg O
2/kg MLVSS/day)*Vol.*MLVSS
= (0.1 kg O
2/Kg MLVSS/day)*(10,000 m
3
)*(2.25 kg MLVSS/m
3
)
= 2,250 kg O
2/day
C) Nitrification Respiration = (4.57 kg O
2/kg TKN) * (TKNload)
= (4.57 kg O
2/kg TKN)*(32.5 mg/l * 10,000 m
3
/day/1000)
= 1,485 kg O
2/day
TKN = TKN
inf–TKN
eff–Assim.TKN = 60 –10 –0.05 BOD

120. Actual Oxygen Requirment “A.O.R”=
Sub. Resp. + End. Resp. + Nitrif. Resp. –Denitrif. Resp.
A.O.R = 2,100 + 2,250 + 1,485 = 5,835 kg O
2/day
Correction Factor (C.F.)
Based on water salinity, type of wastewater, temp., water
height in aeration tanks, alklinity, retention time and altitude
this correction factor can be determined.
As rule of thum.
CASE STUDY
Jubail Export Refinery STP
Oxygen Calculations in Extd. Aerat. & Low Loaded systems:
Surface Aeration >>> 1.5
Air Diffusing System >>> 2

121. CASE STUDY
Jubail Export Refinery STP
Oxygen Calculations in Extd. Aerat. & Low Loaded systems:
A.O.R = 2,100 + 2,250 + 1,485 = 5,835 kg O
2/day
Saturation Oxygen Transfer Rate = S.O.T.R = A.O.R * C.F.
S.O.T.R = 5,835 kg O2/day * 1.5 = 8,752 kg O
2/day= 364 kg O
2/hr
Aerator Efficiency:
-High Speed >> 1.5 –1.8 kw/kg O
2/hr (floating or fixed)
-Low Speed >> 1.8 –2.2 kw/kg O
2/hr (floating or fixed)
Aeration Power= (364 kg O
2/hr) / (1.5 kw/kg O
2/hr)= 243 kw
Total Aerators No. = 8 Aerators
Aerator Power = 243 kw / 8 aerators = 30 kw/aeartor
Mixing Power = 30 kw/aerator * 30% extra = 39 kw/aerator
Based on the Market AvailabilityNearest Aerator was 45 kw.

122. CASE STUDY
Jubail Export Refinery STPInfluent/Effluent COD
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
400.00
450.00
500.00
550.00
600.00
650.00
700.00
750.00
800.00
850.00
900.00
950.00
1,000.00
1,050.00
1,100.00
1,150.00
1,200.00
1,250.00
1,300.00
1,350.00
1,400.00
1,450.00
1,500.00
1,550.00
1,600.00
1,650.00
1,700.00
1,750.00
1/1/20111/11/20111/21/20111/31/20112/10/20112/20/20113/2/20113/12/20113/22/20114/1/20114/11/20114/21/20115/1/20115/11/20115/21/20115/31/20116/10/20116/20/20116/30/2011
mg/l
Inlet / OutletCOD
mg/l

123. CASE STUDY
Jubail Export Refinery STPInfluent/Effluent TSS
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
110.00
120.00
130.00
140.00
150.00
160.00
170.00
180.00
190.00
200.00
210.00
220.00
230.00
240.00
250.00
260.00
270.00
280.00
290.00
300.00
310.00
320.00
330.00
340.00
350.00
360.00
370.00
380.00
390.00
400.00
1/1/20111/11/20111/21/20111/31/20112/10/20112/20/20113/2/20113/12/20113/22/20114/1/20114/11/20114/21/20115/1/20115/11/20115/21/20115/31/20116/10/20116/20/20116/30/2011
mg/l
Inlet / OutletTSS
mg/l

124. CASE STUDY
Jubail Export Refinery STPInfluent TSS / Influent COD
0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
800.00
900.00
1,000.00
1,100.00
1,200.00
1,300.00
1,400.00
1,500.00
1,600.00
1,700.00
1,800.00
1/1/20111/11/20111/21/20111/31/20112/10/20112/20/20113/2/20113/12/20113/22/20114/1/20114/11/20114/21/20115/1/20115/11/20115/21/20115/31/20116/10/20116/20/20116/30/2011
mg/l
mg/l
Inlet TSS / Inlet COD

125. CASE STUDY
Jubail Export Refinery STP
mg/lEffluent TSS / Effluent COD
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
1/1/20111/11/20111/21/20111/31/20112/10/20112/20/20113/2/20113/12/20113/22/20114/1/20114/11/20114/21/20115/1/20115/11/20115/21/20115/31/20116/10/20116/20/20116/30/2011
mg/l
Outlet TSS/ Outlet COD

126. CASE STUDY
Jubail Export Refinery STP
kg/kg MLVSS/dF/MLSS - "BOD" "COD"
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0.55
1/1/20111/11/20111/21/20111/31/20112/10/20112/20/20113/2/20113/12/20113/22/20114/1/20114/11/20114/21/20115/1/20115/11/20115/21/20115/31/20116/10/20116/20/20116/30/2011
kg/kg MLVSS/d
F/M BOD / F/M COD

127. CASE STUDY
Jubail Export Refinery STPInfluent NH
3 / Effluent NH
3
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
55.00
60.00
1/1/20111/11/20111/21/20111/31/20112/10/20112/20/20113/2/20113/12/20113/22/20114/1/20114/11/20114/21/20115/1/20115/11/20115/21/20115/31/20116/10/20116/20/20116/30/2011
mg/l
mg/l
Inlet NH4 / Outlet NH4

128. CASE STUDY
Jubail Export Refinery STPNitrification Rate
0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00
0.51
0.18
0.32
0.28
0.31
1.08
1.01
0.88
0.69
0.83
0.80
0.64
0.61
0.49
0.00
0.20
0.40
0.60
0.80
1.00
1.20
12/8/2010 12/28/2010 1/17/2011 2/6/2011 2/26/2011 3/18/2011 4/7/2011 4/27/2011 5/17/2011 6/6/2011 6/26/2011 7/16/2011
mg N/g MLVSS/hr
mg N/g MLVSS/hr
Nitrification Rate

129. Pre-Treatment Design
Key Factors

130. CASE STUDY
Jubail Export Refinery STP
Pre-Treatment Design Key Factors:
1. Hourly Peak Flow
Hourly Peak Flow m
3
/hr. = Avg. m
3
/hr x Peak Factor
Avg. Flow : 10,000 m
3
/day >>>> 416.6 m
3
/hr
Peak Factor: 2
Peak Flow = (416.6 m
3
/hr) x (2) = 833 m
3
/hr
Why Peak Flow is Important?
>>> To determine the sizing of the following:
-Screening Channels and Screens,
-Equalization Tank HRT, Volume and Air Required.
-Grit Removal Units Volume and Surface Loads (not existing)
-Primary Clarifiers Area and Rising Velocities, (not existing)
-................etc

131. CASE STUDY
Jubail Export Refinery STP
Pre-Treatment Design Key Factors:
2. Total Suspended Solids Load
TSS Loads = (TSS in mg/l) X (Peak Flow m
3
/hr) / 1000 = kg/hr
Why TSS LOAD is Important?
>>> To determine the sizing of the following:
-Types of Screens (Bar, Coarse, Fine)
-Equalization Tank Aeration Type (Diffused Air, Surface Aeration,....etc)
-Grit Removal Units Volume and Surface Loads to determine Grit/TSS
ratio (N/A)
-Primary Clarifiers Type (wiht coag/flocc., with or without lamella
settlers, dense sludge recirculation,.....etc), (N/A)
-Primary Clarifiers Area and Solid Rate, (N/A)
-................etc

132. CASE STUDY
Jubail Export Refinery STP
Pre-Treatment Design Key Factors:
3. Fat, Oil & Grease (F.O.G)
F.O.G. Loads = (F.O.G in mg/l) X (Peak Flow m
3
/hr) / 1000 = kg/hr
Why F.O.G TYPE & LOAD are Important?
>>> To determine the following:
-Higher F.O.G Loads Require F.O.G Removal System. (N/A)
-Types of F.O.G Removal System (DAF, Static Floatation,...etc)(N/A)
-Equalization Tank Aeration Type (Diffused Air, Surface Aeration,....etc)
-Primary Clarifiers Type (wiht acidific./coag/flocc., with or without lamella
settlers, dense sludge recirculation,.....etc), (N/A)
-Primary Clarifiers Area and Solid Rate, (N/A)
-................etc

133. CASE STUDY
Jubail Export Refinery STP
4-Type of Suspended Solids.
5-Temperature (max. 40
O
C) >>>>> Material Selection (Industrial Waste)
6-pH >>>>> Material Selection (Industrial Waste)
N/A: Indicates that the specified unit or application does not exist in this case
study plant.
Pre-Treatment Design Key Factors: