Activated Sludge

Process Control

by
R. Dale Richwine, P.E.
Richwine Environmental, Inc.

Session Overview
Sludge Quality
Visual Observations
Use of Settlometer

Sludge Quantity
System Inventory
Solids Management

Sludge Quality
Visual Observations
Use of Settlometer

Sludge Quality
Visual Observations
Aeration Basins
Foam Color
Diffuser Pattern

Secondary Clarifiers
Quantity of Foam
Effluent Quality

Visual Observations
Aeration Basin Foam

Fresh Crisp White Foam

Visual Observations
Aeration Basin Foam

Excessive Billowing
White Foam

Visual Observations
Aeration Basin Foam

Thick, Scummy, Dark

Brown Foam
Nocardia Foam (200X)

Visual Observations
Aeration Basin Foam

Proper Foam

Visual Observations
Diffuser Pattern

Fine Bubble

Coarse Bubble

Visual Observations
Diffuser Pattern

Diffuser Problems
Can Cause Dead Spots

Visual Observations
Clarifier Foam

Visual Observations
Effluent Quality Problems

Poor Treatment

Visual Observations
Effluent Quality Problems

Sludge Bulking

Visual Observations
Effluent Quality Problems

Sludge Solids Washout

Visual Observations
Effluent Quality Problems

Clumping
Clumping

Visual Observations
Effluent Quality Problems

Ashing may be a
symptom of
overoxidized
(overaerated) mixed
liquor.

Ashing

Visual Observations
Effluent Quality Problems

Straggler floc is indicative

of a low SRT

Straggler Floc

Visual Observations
Effluent Quality Problems
Pin Floc
Carryover of very fine material in
final effluent
Turbid or milky appearance of final
effluent

Possible Causes
of Pinpoint Floc
Old sludge with poor floc-forming
characteristics
Excessive turbulence shearing the
floc.

Sludge Quality
Use of Settlometer

Settlometer Test
Sample Aeration
Basin Effluent
Run test
immediately
following
sampling
Handle sample
with care

Use of Settlometer
Settlometer Test

Original Test
1 liter graduated
cylinder

Mallory Settlometer
2-liter container
Graduated to 1000 ml/L

10

Use of Settlometer
Settlometer Test
Sample Handling
Collect sample in wide-mouth bottle
Start test immediately
Minimize agitation of sample

Use of Settlometer
Settlometer Test

Four Phases of Settling

Flocculation
Blanket Formation
Settling
Compaction

11

Use of Settlometer
Settlometer Test
What to watch for

Settling
Rate

Clarity of
Supernatant

Characteristics
of Interface

Use of Settlometer
Settlometer Test
Take Readings
Every 5-minutes
Up to 30-minutes
Every 10-minutes
Up to 60-minutes
After 4-hours

Note Observations
Supernatant
quality
Type of interface
Surface

12

Use of Settlometer
Settlometer Test
Settled Sludge Volume
SSV
Cle anwate r Tre atme nt Plant
1200

16

14
1000
12
800

SSC (mg/L)

SSV (cc/L)

10

600

6
400
4
200
2

0
0

10

20

30

40

50

60

Sludge Se ttling Tim e (m inute s )

Use of Settlometer
Settlometer Test
Settled Sludge
Concentration

Cle anwate r Tre atme nt Plant

1200

16

SSC

14
1000
12
800

SSC = MLSS/ SSV

SSV (cc/L)

10

600

SSC (mg/L)

Calculation

6
400
4
200
2

MLSS = 2500mg/L

0
0

10

20

0
30

40

50

60

Sludge Se ttling Tim e (m inute s )

13

Use of Settlometer
Settlometer Test
Fast Settling Sludge
Cle anwate r Tre atme nt Plant
1000

16

900

14

Slow Settling Sludge

800
12
700
10

400

Cle anwate r Tre atme nt Plant

1000

16

900

300

14

800
4

12

200

700
2

MLSS = 2500mg/L

0
0

10

20

30

40

Sludge Se ttling Tim e (m inute s )

50

60

10

600
500

400

SSC (mg/L)

100

SSV (cc/L)

SSV (cc/L)

500

SSC (mg/L)

600

300
4
200
2

100

MLSS = 2500mg/L
0

0
0

10

20

30

40

50

60

Sludge Se ttling Tim e (m inute s )

Use of Settlometer
Sludge Volume Index (SVI)

Data Required
The SSV30 from Settlometer Test
MLSS concentration of the sample

14

Use of Settlometer
Sludge Volume Index (SVI)

The volume occupied by 1 gram of MLSS after

30 minutes of settling.
SVI ( g/ml ) =

SSV30 (mL/L) 1000 (mg/g )

MLSS (mg/L)

Target range: 75 - 150 mL/g

but IT DEPENDS!

Sludge Quantity
System Inventory
Mass of solids in system

Solids Management
Return Sludge Rate
Wasting Rate

15

System Inventory

Aeration Basin MLSS

Clarifier Solids (Blanket)
Goals
Manage Inventory to Match Optimum Growth Rate
Maintain Consistent Inventory of Solids

System Inventory

Manage Inventory to Match Optimum Growth

Determine optimum F/M or Growth Rate

Growth Rate
Sludge Age
Age
MCRT

16

System Inventory
Aeration Basin Solids

Clarifier Solids

System Inventory
Maintain Consistent Inventory

Inventory Management Tools

Return Sludge Rate
Wasting Rate

17

System Inventory
Return Sludge Rate
Desired RAS
Concentration
Cle anwate r Tre atme nt Plant
1200

Optimum Return Sludge

Concentration is determined
by Quality of MLSS

16

14
1000
12
800

SSC (mg/L)

SSV (cc/L)

10

600

6
400
4
200
2

MLSS = 2500mg/L

0
0

10

20

0
30

40

50

60

Sludge Se ttling Tim e (m inute s )

System Inventory
Return Sludge Rate
RAS Rate Calculation
Desired RAS Flow Rate (gpm) =

Current RAS Rate (RASConc MLSS)

(SSCt MLSS)

Where:
Desired RAS Flow Rate (gpm) = Optimum RAS Flow (gpm)
Current RAS Rate = Current RAS Flow (gpm)
RAS Conc = Return Sludge Concentration (mg/L)
MLSS = Mixed Liquor Suspended Solids (mg/L)
SSCt = Settled Sludge Concentration at desired time

18

System Inventory
Maintain Consistent Inventory
Sludge Wasting
Change rate slowly
Use 5-day average

Control Process Using Sludge Age

Sludge Age = Inventory Solids Out

System Inventory
Sludge Age
Data Required
Solids under aeration in the aeration basin, pounds
(lbs)
Clarifier Solids (lbs)
Secondary effluent suspended solids (SESS) from
previous day, lbs/day
Solids intentionally wasted from the process (WAS),
pounds per day (lbs/day)

19

System Inventory
Sludge Age
Sludge Retention Time, Sludge Age, Age

SRT (days) =

Aeration Basin Inventory (lbs)

WAS (lbs/day) + SESS (lbs/day)

Mean Cell Residence Time (MCRT)

MCRT (days) =

Aeration Basin Inventory (lbs) + Clarifier Inventory (lbs)

WAS (lbs/day) + SESS (lbs/day)

System Inventory
Wasting
Data Required
Solids under aeration in the aeration basin (inventory),
pounds (lbs)
Secondary effluent suspended solids from the previous
day (SESS), pounds per day (lbs/day)
Desired sludge residence time (SRT), days

20

System Inventory
Wasting

WAS (lbs/day) =

System Solids Inventory (lbs)

SESS (lbs/day)
Desired SRT (days)

Where:
System Solids Inventory = Aeration Basins Inventory (lbs)
+ Clarifier Inventory (lbs) *** Clarifier Inventory only used if desired
Desired SRT (days) = Sludge Age Set as Process Goal
SESS (lb/day) = Secondary Effluent TSS (mg/L) * 8.34 * Plant Flow (mgd)

System Inventory
Food to Microorganism Ratio (F/M)

Data Required

Primary effluent flow (Q), mgd

Primary effluent cBOD, mg/L
MLVSS concentration, mg/L
Aeration basin volume, million gallons

21

System Inventory
Food to Microorganism Ratio (F/M)

F/M =

F/M =

cBOD Into Aeration Basin (lbs)

Biomass Under Aeration (lbs)

PE Q (mgd ) PE cBOD (mg/L) 8.34 (lb/gal )

Aeration Basin Volume ( MG) MLVSS (mg/L) 8.34 (lb/gal )

F/M =

PE Q (mgd ) PE cBOD (mg/L)

Aeration Basin Volume ( MG) MLVSS (mg/L)

System Inventory
Food to Microorganism Ratio (F/M)

Interpretation of F/M Values

0.04 0.15
0.20 0.50
0.50 1.50

Extended Aeration
Convention Activated Sludge
High-rate Processes

22

Session Summary
Sludge Quality
Visual Observations
Use of Settleometer

Sludge Quantity
System Inventory
Solids Management

Activated Sludge Process Control

Basics
BOD update rate = Bacterial Growth Rate

Growth Factors
Sludge Quality
Visual Observations
Use of Settlometer

Sludge Quantity
System Inventory
Solids Management

23

One Thing to Remember

Rate of Removal = Rate of Biomass Growth

24