WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Activated Sludge System

SBR, EA and Conventional Plants
Prof. ZAINI UJANG
PhD (Newcastle), MIEM, C.Eng.(UK), C.Sci. (UK). C.E.W.M. (UK), DNS, PPT

Institute of Environmental & Water Resource Management (IPASA) Universiti Teknologi Malaysia, 81310 Skudai, Johor Bahru zaini@utm.my / http://web.utm.my/ipasa

UNIVERSITI TEKNOLOGI MALAYSIA Institute of Environmental & Water Resource Management (IPASA)

Lecture by Zaini Ujang

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Presentation Outline
Terminology Approach in design Sequencing batch reactors Extended aeration Conventional activated sludge WASDA as a design tool

UNIVERSITI TEKNOLOGI MALAYSIA Institute of Environmental & Water Resource Management (IPASA)

Lecture by Zaini Ujang

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Terminology
Activated sludge
Biological treatment processes in which the microorganisms responsible for the conversion of the organic matter or other constituents in the wastewater to gases and cell tissue are maintained in suspension within the liquid.

Biofilm
Biological treatment processes in which the microorganisms responsible for the conversion of the organic matter, or other constituents in the wastewater to gases and cell tissue are attached to some inert medium, such as rocks, slag, or specially designed ceramic or plastic materials.
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Lecture by Zaini Ujang

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

General Objectives
Small and Decentralized WWTP

To protect public health To protect receiving environment from degradation or contamination To reduce costs of treatment by retaining water and solids near their point of origin through reuse

UNIVERSITI TEKNOLOGI MALAYSIA Institute of Environmental & Water Resource Management (IPASA)

Lecture by Zaini Ujang

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Wastewater Treatment Systems

Physical process (sedimentation, screening, membrane etc) Chemical process (coagulation, neutralization etc) Biological process (activated sludge, biofilm) Hybrid (wetland, MBR etc)

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Lecture by Zaini Ujang

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Biological Wastewater Treatment

Processes
Aerobic Anaerobic Facultative Anoxic

Systems
Activated sludge (suspended growth) Biofilm (attached growth) Pond system Natural system Hybrid system
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Decentralized WWTP
Intermittent Decanted Extended Aeration

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Lecture by Zaini Ujang

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Decentralized WWTP
SBR (Taman Sri Sentosa, JB)

Bio-weapon storage?
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Process Theory
(i) Completely-mixed reactor (ii) Plug-flow reactor

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Lecture by Zaini Ujang

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Process Theory
(i) Completely-Mixed Reactor
Qo+QR, S, X Qo-Qw, Se, Xe

Qo, So, Xo

V, X, S

Secondary clarifier Qu , X u

Bioreactor QR, Xu Qw, Xu

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Mass Balance for Completely Mixed Reactor

Biomass in + Biomass growth = Biomass out
ko XS k X Qo X o + V d = (Qo Qw )X e + Qw X u K +S s

Food in Food consumed = Food out

ko SX = (Qo Qw )S + Qw S Qo S o + V Y (Ks + S )
Qo, Qr, Qw = influent, return and waste-sludge flow rate, m3/d Xo, X, Xe, Xu = biomass concentration in influent, reactor, effluent, underflow, mg/l So, S = soluble food concentration in influent and reactor, mg/l V = volume, m3 Ks = half saturation constant I.e. concentration of limiting food when k = 0.5 ko, mg/l ko = maximum growth rate constant, t-1 kd = endogenous decay rate constant, t -1 Y = yield, i.e. decimal fraction of food mass converted to biomass
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Mass balance
Biomass
ko XS Qo X o + V K + S kd X = (Qo Qw )X e + Qw X u s

ko S Qw X u = + kd Ks + S VX

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Mass balance
Food (Substrate)

ko SX Qo S o + V = (Qo Qw )S + Qw S Y (Ks + S )
ko S Qo Y (So S ) = Ks + S V X

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Mass balance
Combining biomass and food equations

Qw X u Qo Y (S o S ) k d = VX V X
Hydraulic retention time:

V = Qo

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Mass balance
Combining biomass and food equations

Qw X u Qo Y (S o S ) k d = VX V X
Solid retention time or sludge age:

VX c = Qw X u

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Mass balance
Combining biomass and food equations

Y (So S ) = kd c X 1
Mixed-liquor suspended solid:

cY (S o S ) X= (1 + k d c )

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Process Theory
(ii) Plug-flow reactor
Qo+QR, Se, X Qo-Qw, Se, Xe

Qo, So, Xo

X, S

Secondary clarifier Qu , X u

Bioreactor QR, Xu

Qw, Xu

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Mass Balance for Plug-Flow Reactor

c Y (S o S ) X= (1 + k d c )
_

Average MLSS:

Food utilization:

ko S X rs = Y Ks + S

X = average biomass concentration in the reactor. Both equations are applicable only when c/ 5
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Mass Balance for Plug-Flow Reactor

Integrating the food utilization equation over detention time in the reactor and substituting the appropriate boundary conditions and recycle factor yields:

ko (S o S ) = kd c (S o S ) + (1 )(K s ln Si / S ) 1
Where = recycle factor, Q/Qr Si = concentration of substrate after mixing with recycled sludge, mg/l

S o + S Si = 1+
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Design Considerations
Internal factors: - Process variations - Reactors types - Technology know-how External factors: - Construction costs - Operation & maintenance difficulties and costs - Space limitations

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Major Design Parameters

Activated sludge system

 Solid retention time (SRT)  Organic loading rate (OLR)  Food-to-Microorganism ratio (S/X)

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Retention Time
 Solid retention time (SRT)  Hydraulic retention time (HRT) SRT = ratio of the amount of biomass HRT = the residence time in inventory within the system to the for the liquid fraction in growth rate of new microorganisms (Rg): the bioreactor

M SRT = days Rg
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Volume HRT = Flowrate

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Solid Retention Time

Within the limits, a longer SRT results in: More efficient biodegradation Smaller reactor size Lower cost If SRT drops below the cell regeneration time, biomass will wash out faster than it forms new cells. Rule-of-thumb (without experimental data): SRT = 20-30 days with X < 5000 mg/L Higher SRT  clarifier failure
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Common Design and Process Variations of

Activated Sludge Systems

Step aeration Tapered aeration Contact stabilization Pure-oxygen activated sludge Oxidation ditch High rate Extended aeration Sequencing batch reactor
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UNIVERSITI TEKNOLOGI MALAYSIA Institute of Environmental & Water Resource Management (IPASA)

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

STEP AERATION
Influent addition at intermediate points provides more uniform organic removal throughout tank Compressed air Influent Effluent Secondary clarifier

Return activated sludge

UNIVERSITI TEKNOLOGI MALAYSIA Institute of Environmental & Water Resource Management (IPASA)

Excess sludge
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

TAPERED AERATION
Air is added in proportion to BOD exerted Compressed air Effluent Influent Secondary clarifier Excess sludge

Return activated sludge

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

CONTACT STABILIZATION
Biomass adsorbs organics in contact basin and settles out in secondary clarifier; the thickened sludge is aerated before being return to the contact basin

Influent Contact basin Reactor Return sludge Compressed air

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Effluent Secondary clarifier Excess sludge

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

PURE OXYGEN ACTIVATED SLUDGE

Oxygen added under pressure keeps dissolved oxygen level high

Pure oxygen Influent

Oxygen return

Waste gas Effluent Secondary clarifier

Reactor

Excess sludge

Return sludge
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

HIGH RATE
Short detention time and high F/M ratio in aerator to maintain culture in log-growth phase

Influent

Effluent Secondary clarifier Reactor Excess sludge

Return sludge
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

EXTENDED AERATION
Long detention time and low F/M ratio in aerator to maintain culture in endogenous phase

Influent

Effluent Secondary clarifier Reactor Excess sludge

Return sludge (omitted in some system)

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

OXIDATION DITCH
Similar to extended aeration, except the aeration is done by brush-type aerators, thus reducing electricity

Brush-type aerators Influent

Effluent Return sludge

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

SEQUENCING BATCH REACTORS

Only one reactor for both aerobic and anaerobic processes, thus reduce capital cost

Fill

React

Settle

Decant

Idle

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Design Parameters
Process Modification
Conventional plug flow Complete mix Step feed Single-stage nitrification Separate stage nitrification

c,d

Volumetric MLSS,mg/l V/Q, h F/M lb BOD5/lb loading rate, MLVSS.d lb BOD5/ 103 ft3.d
20-40 50-120 40-60 5-20 3-9 0.2-0.6 0.2-1.0 0.2-0.5 0.10-0.20 (0.02-0.15)* 0.05-0.20 (0.04-0.15)* 1000-3000 800-6500 1500-3500 1500-3500 1500-3500 4-8 3.5 3-5 6-15 3-6

Qr/Q

3-15 0.75-15 3-15 8-20 15-100

0.25-0.75 0.25-1.0 0.25-0.75 0.50-1.50 0.50-2.00

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Continue
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Continue

Process Modification
Contact Stabilization Extended Aeration Oxidation Ditch Intermittent decanted extended aeration Sequencing Batch Reactor

c,d
5-15 20-40 3-15 8-20

Volumetric lb BOD5/lb loading rate, lb

F/M

MLVSS.d
0.2-0.6 0.04-0.10 0.04-0.10 0.04-0.08

BOD5/ 103 ft3.d

60-75 5-15 5-15 5-15

MLSS, mg/l
(1000-3000) (4000-9000) 2000-8000 2000-8000 2000-8000

V/Q, h

Qr/Q

(0.5-1.0) (3-6) 18-36 8-36 20-40

0.5-1.50 0.5-1.50 0.5-1.50 N/A

15-100

0.04-0.10

5-15

2000-8000

12-50

N/A

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Applications of Aerobic Activated Sludge Processes

Aerobic processes
Activated sludge

Common name
- CAS - Aerated lagoons - Aerobic digestion - CAS with trickling filter

Uses
- Carbonaceous BOD removal - Nitrification - Carbonaceous BOD removal - Nitrification

Hybrid (activated sludge + biofilm)

Note: CAS = conventional activated sludge

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Applications of Anoxic Activated Sludge Processes

Anoxic processes
Activated sludge

Common name
- Denitrification activated sludge - Activated sludge with trickling filter

Uses
- Denitirifcation

Hybrid (activated sludge + biofilm)

- Denitrification

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Applications of Anaerobic Activated Sludge Processes

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Anoxic processes
Activated sludge

Common name
- Denitrification activated sludge - Activated sludge with trickling filter

Uses
- Denitirifcation

Hybrid (activated sludge + biofilm)

- Denitrification

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Approach in Design
Standardized design manuals Generic design manuals (e.g. Metcalf & Eddy) Code of practice (e.g. MS 1228) Modeling and simulation

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Common design objectives for municipal WWTP

Organic removal (carbonaceous BOD) Organic removal + nitrification Organic removal + (nitrification + denitrification) (N removal) Organic removal + nitrification + denitrification + P removal (N & P removal)

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Common design objectives for industrial WWTP

Organic removal Organic removal + specific pollutants Removal of persistent organics Specific pollutants

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Approach in Design

Sequencing Batch Reactor

Wastewater characterization. Define design objectives Select number of SBR tanks Select react/aeration, settling, and decant times. Determine fill time and total time per cycle. Determine the number of cycle per day From the number of cycles per day, determine the fill volume per cycle Select MLSS concentration and determine the fill volume fraction relative to total tank volume. Determine the decant depth. Using the computed Continue depth, determine the SBR tank volume.
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Approach in Design

Sequencing Batch Reactor

Determine the SRT Determine the amount of TKN added that is nitrified Calculate the nitrifier biomass concentration and determine if the aeration time selected is sufficient for nitrification efficiency needed Adjust the design as needed additional iterations may be done Determine decant pumping rate Continue
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Lecture by Zaini Ujang

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Approach in Design

Sequencing Batch Reactor

Determine the oxygen required and average transfer rate Determine the amount of sludge production Calculate the F/M and BOD volumetric loading Evaluate alkalinity needs Prepare design summary

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Approach in Design

Sequencing Batch Reactor

Manual exercise WASDA simulation

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Approach in Design
Extended Aeration
Wastewater characterization. Define design objectives Determine the design loading Determine the size of the reactor required and check the actual detention time and organic loading rate Determine oxygen requirement Determine area of secondary sedimentation tank and check the solids loading rate Determine waste sludge production with certain level of yield value for a process with primary sedimentation
Continue
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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Approach in Design
Extended Aeration
Determine the maximum growth rate for nitrifying organisms under the stated operating conditions Determine the maximum rate of substrate utilization, k Determine the design substrate utilization factor, U Determine the concentration of ammonia in the effluent Determine the required hydraulic detention time for nitrification Calculate the denitrification rate Calculate the required residence time for denitrification Combine the detention time required for nitrification and denitrification
UNIVERSITI TEKNOLOGI MALAYSIA Institute of Environmental & Water Resource Management (IPASA) Lecture by Zaini Ujang 47

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Approach in Design
Extended Aeration

Manual exercise WASDA simulation

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Lecture by Zaini Ujang

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WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Approach in Design
Conventional activated sludge for organic removal and nitrification Determine the maximum growth rate for nitrifying organisms under certain operating conditions Determine the maximum rate of substrate utilization, k Determine the minimum and design SRT Determine the design substrate utilization factor, U Determine the concentration of ammonia in effluent Determine substrate removal rate for activated sludge process Determine the required HRT for BOD oxidation and nitrification
UNIVERSITI TEKNOLOGI MALAYSIA Institute of Environmental & Water Resource Management (IPASA) Lecture by Zaini Ujang 49

WET Program on Bioprocess Engineering 17 September 2005 UTM City Campus, Kuala Lumpur

Approach in Design
Conventional activated sludge for organic removal and nitrification

Manual exercise WASDA simulation

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Lecture by Zaini Ujang

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