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Sequencing Batch Reactor Power Savings
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1. INTRODUCTION
In alleviating the problem of natural water body
contamination, the Philipine law under DAO-35
mandates that all used water shall be treated
before released in the public sewer. The most
reliable water treatment is the Sequencing Batch
Reactor Activated Sludge (SBR) process, since it
requires less infrastructure footprint and utilizes
organic mechnism to breakdown the water
contaminants. The process is costly in terms of
electric power usage. It is shown that from among
the different stages in the SBR, the aeration stage
consumes large amount of power. There are ways
to gain substantial savings when operating the
SBR. Aside from the use of computerized process
controls, the solid waste from the SBR can be
utilized for on-site power generation which can be
cheaper. The alternative power source can provide
substantial savings from the lower power cost by
43%. This paper describes and presents the
method used.
2. CMAS
Activated Sludge Reactor-Complete mix.
Influent wastewater decomposes in solids that
settles at the bottom as sludge. Sludge particles
produced by the growth of organisms (including
zoogleal bacteria) in tanks in the presence of
dissolved oxygen. The term activated comes from
the fact that the solid particles are teeming with
fungi, bacteria, and protozoa. Activated sludge is
different from primary sludge in that the sludge
particles contain many living organisms which can
feed on the incoming wastewater. In this biological
aerobic reactor, it is assumed that complete mixing
occurs instantaneously and uniformly throughout
the reactor as fluid particles enter the reactor. Fluid
particles leave the reactor in proportion to their
statistical population. The actual time required to
achieved completely mixed conditions will depend
on the geometry and power input.
2.1 Reaction
, (8-15a)
DECANT\DRAW : tD = 15%CT, = 1h
typical
IDLE : 5%CT
Total CT = tf + tA + tS + tD = 8h
Number of cycle /tank/d = 24h/d/ 8h/cyc = 3
Total number of cyc / d = 2 tank *3cyc/tank = 6
Where:
AOR =total oxygen required, g/d
Pxbio = biomass as VSS wasted, g/d
1.42g O2 / g VSS mass of oxygen consumed
during carbonaceous substrate,BOD oxidation
(bacteria metabolization).
4.33 g O2 /g NH3-N, mass of oxygen consumed
during ammonia-nitrogen oxidation.
For typical SRTs of 5 to 10 days, the g of oxygen
per g of BOD removed varies, from 0.92 to 1.07.
A value of 1.0 pound of oxygen per pound of BOD
removed is commonly used. For conservative
value, 1.1 g of oxygen per g of BOD removed.
Vt = 1.2*Vs
Vt = Vf + Vs
Vf / Vt = 0.4 as acceptable value.
Total volume per tank, Vt = Vf / 0.4
3.4 Sludge Volume Index, SVI
Sludge Volume Index , SVI, mg/L, is usually taken
from 100 to 150 mg/L , with 150mg/L as typical
value.
4.2 SOR
To determine the amount of process air required to
satisfy the biological treatment oxygen demands.
AOR shall be converted to standard oxygen
requirements (SOR) to properly apply the aeration
equipment because aeration equipment
manufacturers can provide information to engineers
and designers on the oxygen transfer capability of
particular equipment and configurations when the
equipment is aerating clear tap water. (SOR of
equipment). Laboratory tests, when corrected for
temperature and elevation to standard conditions,
become the basis for determining the equipments
standard oxygen requirement or SOR.
Equipment manufacturers cannot guarantee the
oxygen transfer capability of aeration equipment in
wastewater. Each wastewater treatment plant has
its own unique field conditions and waste type that
preclude this type of guarantee.
The general accepted formula to convert AOR to
SOR is:
SOR=AOR / [(B*{Csth*0.5*((Pd/PatmH) +(Ot/21)}
CL) / Cs20)*1.024^(T-20)*a*F ]
Where:
AOR = actual oxygen requirement (field conditions)
SOR = standard oxygen requirement (standard
conditions) Standard conditions are zero elevation
(29.92 barometric pressure), 20 C and zero DO
(dissolved oxygen in liquid).
Beta, B = surface tension correction (Saturation)
Factor, 0.95 0.98.
Csth = oxygen saturation concentration in
cleanwater, mg/L.
Pd = pressure at depth of air release,kPa
PatmH = atmospheric pressure at mean H level
Ot = percent oxygen in tank, 18% to 20%
Working dissolved oxygen concentration in
wastewater
T = Operating temperature of wastewater
Cs20 = Surface DO saturation concentration at 20
C and standard conditions for the particular
aeration equipment at the design submergence
CL = operating oxygen concentration, mg/L at
design temperature T and 1atm for the particular
aeration equipment at the design submergence
(4.2-1)
Where:
Pwb = power required of each blower, kW
w = weight of flow of air, kg/min
8.314 = air gas constant, R, kJ/k mol
T1 = inlet temperature, deg C
P1 = abs inlet pressure, atm
P2 = abs outlet (discharge) pressure, atm
n = 0.283 for air
29.7 = constant
e = blower\compressor efficiency, 0.7 to 0.9
Pressure losses: the pneumatic friction loss
from pipe and fittings plus the head loss for
submerged diffuser at water depth accounts for
the power loss of aerator blower.
Criteria for marginal design: Power Loss = 10% of
Power output that is reflected on the blower
discharge pressure.
5. ANAEROBIC DIGESTER
5.1 Methane production
An anaerobic digester can be utilized to recover the
energy content of wasted sludge for an SBR
wastewater treatment. In the digester its own SRT
starts as some species of bacterial anaerobic
heterotrophic organisms, initiates the digestion by
liquefaction\hydrolysis of the input materials such
as; insoluble organic polymers, such as
carbohydrates broken down to soluble derivatives
and proteins, lipids, polysaccharides nucleic acids
contained in the sludge biomass; that become
available food for other bacteria. Fermentation
process then precedes as Acidogenic bacteria
convert the sugars and amino acids into carbon
dioxide, hydrogen, ammonia, and organic acids
while Acetogenesis bacteria convert these resulting
organic acids into acetic acid, along with additional
ammonia, hydrogen, and carbon dioxide. The final
process of Methanogenesis begins as
methanogens convert these products to methane
and carbon dioxide.
After the SBR SRT period, the wasted sludge
biomass, Pxbio represented in VSS COD terms by
factor of 1.42 gCOD/ g Biomass VSS, shall be the
influent characteristics of the anaerobic growth
suspension process of the digester.
According to section7-12 [1], the required mass
balance is performed to quantify the process as
follows;
9. REFERENCES
[1] Wastewater Engineering Treatment and Reuse
,Metcalf & Eddy 4th Ed.
[2] US-EPA Summary Report Fine Pore (Fine
Bubble) Aeration Systems, EPA/625/885/010,1985.
[3] Handbook of Engineering Calculations, Tyler
Hicks, 3rd Ed
[4] USEPA Onsite Wastewater Treatment
Systems ManualEPA/625/R-00/008 February
2002
Page 7 of 20
10. APPENDICES
Appendix 1 : Sample Calculation
Appendix 2 : Tables
Appendix 3 : Definition of Terms
APPENDIX
APPENDIX 2
Unit
Inland Waters
Category I
Category II
OEI
NPI
OEI
Class C
NPI
OEI
NPI
Color
PCU
(b)
(b)
150
100
200c
150c
Temperature
(max rise in deg. Celsius in
RBW)
C rise
(b)
(b)
(b)
(b)
6.0-9.0
6.0-9.0
6.0-9.0 6.5-9.0
pH (range)
COD
mg/L
(b)
(b)
100
60
150
100
mg/L
(b)
(b)
0.3
0.3
0.5
0.5
5-Day 20 oC BOD
mg/L
(b)
(b)
50
30
80
50
mg/L
(b)
(b)
70
50
90
70
mg/L
(b)
(b)
1,200
1,000
Surfactants (MBAS)
mg/L
(b)
(b)
5.0
2.0
7.0
5.0
(b)
(b)
5.0
5.0
10.0
5.0
Phenolic Substances as
Phenols
mg/L
(b)
(b)
0.1
0.05
0.5
0.1
Total Coliforms
MPN/100mL
(b)
(b)
5,000
3,000
15,000
10,000
(a) Except as otherwise indicated, all limiting values in Tables 2A and 2B are 90th percentile values. This is
applicable only when the discharger undertakes daily monitoring of its effluent quality, otherwise, the
numerical values in the tables represent maximum values not to be exceeded once a year.
(b) Discharging of sewage and/or trade effluents is prohibited or not allowed
Parameter
Color
Temperature
(max. rise in deg. Celsius in RBW)
Inland Waters
Coastal Waters
Class SD &
Other
Coastal
Waters
(Class D)
(Class SC)
Not
Classified
Unit
OEI
NPI
OEI
NPI
PCU
---
---
(c)
(c)
(c)
(c)
C rise
5.0-9.0
6.0-9.0
6.0-9.0
6.0-9.0
5.09.0
5.09.0
pH (range)
OEI NPI
COD
mg/L
250
200
250
200
300
200
5-Day 20 oC BOD
mg/L
150 (d)
120
120 (d)
100
150
(d)
120
mg/L
200
150
200
150
(g)
(f)
mg/L
2,000(h)
1,500(h)
Surfactants (MBAS)
mg/L
15
10
Oil/Grease (Petroleum
Ether Extract)
mg/L
15
10
15
15
Phenolic Substances
as Phenols
mg/L
1.0(i)
0.5(i)
5.0
1.0
Total Coliforms
MPN/100mL
(j)
(j)
(c) Discharge shall not cause abnormal discoloration in the receiving waters outside of the mixing zone
(d) For wastewaters with initial BOD concentration over 1,000 mg/L but less than 3,000 mg/L, the limit may
be exceeded up to a maximum of 200 mg/L or a treatment reduction of ninety (90) percent, whichever is more
strict. Applicable to both old and new industries.
(f) Not more than 30 mg/L increase (dry season)
(g) Not more than 60 mg/L increase (dry season)
(h) If effluent is the sole source of supply for irrigation, the maximum limits are 1,500 mg/L and 1,000 mg/L,
respectively, for old industries and new industries.
(i) Not present in concentration to affect fish flavor or taste or tainting.
(j) If effluent is used to irrigate vegetable and fruit crops which may be eaten raw, Fecal Coliforms should be
less than 500 MPN/100 mL.
NOTES for Table 2A and Table 2B:
1. In cases where the background level of Total Dissolved Solids (TDS) in freshwater rivers, lakes,
reservoirs and similar bodies of water is higher than the Water Quality Criteria, the discharge should
not increase the level of TDS in the receiving body of water by more than ten percent of the
background level.
2. The COD limits in Tables 2A and 2B generally apply to domestic wastewater treatment plant
effluent. For industrial discharges, the effluent standards for COD should be on a case to case basis
considering the COD BOD ratio after treatment. In the interim period that this ratio is not yet
established by each discharger, the BOD requirements shall be enforced.
3. There are no effluent standards for chloride except for industries using brine and discharging into
inland waters, in which case the chloride content should not exceed 500 mg/L.
4.
The effluent standards apply to industrial manufacturing plants and municipal treatment plants
discharging more than thirty (30) cubic meters per day.
From ERPI (1994) Energy Audit Manual for Water and Wastewater Facilities, Electric Power Research Institute, Wastewater Engineering
Treatment and Reuse ,Metcalf & Eddy 4th Ed.
APPENDIX 3
ACTIVATED SLUDGE TERMS:
Vr or Vt = Reactor volume (Mgal) (m3)
F/MV Food-to-microorganism ration,or process loading factor; mass kg of fresh BOD5 applied to the activated sludge
system per day per kg of MLVSS in the aeration basin, (kg BOD / day ) / (kg MLVSS)
SRT = Sludge or Solid Retention Time or the average time that the sludge remains in the reactor (sludge age).
The design of the reactor is based on SRT on the assumption that substantially all the substrate (BOD) conversion occurs
in the reactor. Total mass kg (g) of MVLSS in aerator per kg (g) of VSS wasted per day(or net solids produced), days
Q = Average daily influent flow rate (Mgd)
Y= Maximum yield coefficient (mg VSS/mg BOD5). Essentially, Y represents the maximum mg of cells produced per mg
organic matter . For the activated sludge process for domestic wastewater Y ranges from 0.4 to 0.8. S0 = Influent
substrate (BOD5) concentration (mg/L) = 240 mg/L
S= Effluent substrate (BOD5) concentration (mg/L) = 10 mg/L
XVSS= Concentration of microorganisms in reactor = Mixed Liquor Volatile Suspended Solids (MLVSS) in mg/L. It is
generally accepted that the ratio MLVSS/MLSS ~ 0.8, where MLSS is the Mixed Liquor Suspended Solids
concentration in the reactor. MLSS represents the sum of volatile suspended solids (organics) and fixed suspended solids
(inorganics). For a complete-mix activated sludge process, MLSS ranges from 1,000 to 6,500 mg/L.
kd = Endogenous decay coefficient (d -1) which is a coefficient representing the decrease of cell mass in the MLVSS. For
the activated sludge process for domestic wastewater kd ranges from 0.025 to 0.075 d -1.
HRT, hydraulic retention time ( ) in the reactor is the reactor volume divided by the influent
flow rate: Vr / Q . For a complete-mix activated sludge process, is generally 3-5 hours.
Yobs Observed cell yield, Yobs = Y/(1 + kd*SRT ) = 0.6 /(1 + (0.06 d-1)*(8d)) = 0.41 mg/mg represents
the actual cell yield that would be observed. The observed cell yield is always less than the maximum cell yield (Y).
Pxvss is the net waste activated sludge produced each day in (Ib VSS/d).
Px= Yobs * Q * (So - S) * (8.34 Ib/Mgal/mg/L)
MLSS Mixed Liquor Suspended Solids; suspended solids in the aerator mixed liquor, mg/L
MLVSS represents the increase of volatile suspended solids (organics) in the reactor. Of course the total increase in
sludge mass will include fixed suspended solids (inorganics) as well. Therefore, the increase in the total mass of mixed
liquor suspended solids, MLSS, represents the total mass of sludge that must be wasted from the system each day and is
shown by.
(MLSS) = Px(ss) = (g VSS/d)/(0.8)
SCFM or SCMM Standard cubic feet or meter of gas, measured at a dry pressure of 1.0 atmosphere(10.13kPA) and
20degC
SVI Sludge Volume Index; volume in millimeters occupied by 1 gram of activated sludge, after settling the aerated mixed
liquor for 30 mins in a 1000-mL graduated cylinder.
bCOD Biodegradable Chemical Oxygen Demand- the amount of oxygen in mg/L requied to oxidize both organic and
oxidizable inorganic compunds or substances. (This is BOD in terms of COD, COD is used in mass balance operation to
accurately survey characterize the decomposition of cabonaceous material between the amount oxidized and amount
incorporated into cell mass[1])
Ultimate carbonaceous oxygen demand (BODL)
The theoretical oxygen requirements are calculated using the BOD5 of the wastewater and the amount of organisms (Px)
wasted from the system each day. If all BOD5 were converted to end products, the total oxygen demand would be
computed by converting BOD5 to ultimate BOD (BODL), using an appropriate conversion factor. The "Quantity of Sludge
Wasted" calculation illustrated that a portion of the incoming waste is converted to new cells which are subsequently
wasted from the system.
Therefore, if the BODL of the wasted cells is subtracted from the total, the remaining amount represents the amount of
oxygen that must be supplied to the system. From stoichiometry, it is known that the BOD L of one mole of cells is equal to
1.42 times the concentration of cells. Therefore, the theoretical oxygen requirements for the removal of the carbonaceous
organic matter in wastewater for an activated-sludge system can be computed using the following equation:
Ib O2/d = (total mass of BODL utilized, Ib/d) - 1.42 (mass of organisms wasted, Ib/d)
Using terms and quantities that have been defined previously where f = conversion factor for converting
BOD5 to BODL (f = 0.68 is commonly used):
lb O2/d = [Q*(So-S) * (8.34lb/Mgal/mg/L)] / f ] - 1.42*Px
X= Mixed Liquor Suspended Solids (MLSS)
Qr = Return activated sludge pumping rate (Mgd)
Xr = Concentration of sludge in the return line (mg/L). When lacking site specific operational data, a value commonly
assumed is 8000 mg/L.
Qe = Effluent flow rate (Mgd)
Xe = Concentration of solids in effluent (mg/L). When lacking site specific operational data, this value is commonly
assumed to be zero.
Qw = Wasted Activated Sludge (WAS) pumping rate from the reactor (Mgd)
Qw = Waste Activated Sludge (WAS) pumping rate from the return line (Mgd)
Control Parameter
Control of the activated sludge process is important to maintain high levels of treatment performance under a wide range of
operating conditions. The principle factors used in process control are (1) maintaining dissolved-oxygen levels in the aeration
tanks, (2) regulating the amount of Return Activated Sludge (RAS), and (3) controlling the Waste Activated Sludge (WAS). As
outlined previously in Part 5 "Compute the Food to Microorganism Ratio and the Volumetric Loading," the most commonly used
parameters for controlling
the activated sludge process are the F:M ratio and the Sludge Retention Time or mean cell residence time SRT.
The Mixed Liquor Volatile Suspended Solids (MLVSS) concentration may also be used as a control parameter. Return Activated
Sludge (RAS) is important in maintaining the MLVSS concentration and the Waste Activated Sludge (WAS) is important in
controlling the mean cell residence time (0C).
The excess waste activated sludge produced each day wasted from the system to maintain a given F:M or mean cell residence
time. Generally, sludge is wasted from the return sludge line because it is more concentrated than the mixed liquor in the
aeration tank, hence smaller waste sludge pumps are required. The waste sludge is generally discharged to sludge thickening
and digestion facilities. The alternative method of sludge wasting is to withdraw mixed liquor directly from the aeration tank
where the concentration of solids is uniform.
Pump Requirements:
The actual amount of liquid that must be pumped to achieve process control depends on the method used and the location from
which the wasting is to be accomplished. Also note that because the solids capture of the sludge processing facilities (i.e.,
thickeners, di-gesters, etc.) is not 100 percent and some solids are returned, the actual wasting rate will be higher than the
theoretically determined value. Note that the required RAS pumping rate can be determined by performing mass balance around
the aeration tank thus the following equation can be used:
Qw =Vr * X / (SRT * Xr)
Or
Using the ratio of RAS pumping rate to influent flow rate, or recirculation ratio (a), as:
a = Qr / Q ,
Recirculation ratio can vary from 0.25 to 1.50 depending upon the type of activated
sludge process used. Common design practice is to size the RAS pumps so that they are
capable of providing a recirculation ratio ranging from 0.50 to 1.50. the Qr can be calculated
Qr = a * Q
It should be noted that if the control volume were placed around the aeration tank for conventional reactor
or the control volume placed around the settling tank and a mass balance performed, that a slightly higher RAS pumping rate
would result. However, the difference s negligible.
Dissolved Oxygen (DO) is the amount of free oxygen in solution in water, or wastewater effluent. Adequate
concentrations of dissolved oxygen are necessary for fish and other aquatic organisms to live and to prevent offensive
odors.
Effluent is the treated liquid that comes out of a treatment plant after completion of the treatment process.
Eutrophication is the normally slow aging process by which a lake evolves into a bog or marsh and ultimately
disappears. During eutrophication, the lake becomes enriched with nutrients, especially nitrogen and phosphorus, which
support the excess production of algae and other aquatic plant life. Eutrophication may be accelerated by many human
activities.
Floc is a clump of solids formed in sewage by biological or chemical action.
Flocculation is the process by which clumps of solids in sewage are made to increase in size by chemical action.
Gray Water refers to domestic wastewater composed of wash water from sinks, shower, washing machines
(does not include toilet wastewater).
Grinder Pump is a mechanical device which shreds wastewater solids and raises the fluid pressure level high
enough to pass wastewater through small diameter pressure sewers.
Grit Chamber is a small detention basin designed to permit the settling of coarse, heavy inorganic solids, such
as sand, while allowing the lighter organic solids to pass through the chamber.
Incineration involves combustion of the organic matter in sewage sludge, producing a residual inert ash.
Infiltration is the penetration of water through the ground into sub-surface soil or the passing of water from the
soil into a pipe, such as a sewer.
Influent refers to water, wastewater, or other liquid flowing into a reservoir, basin or treatment plant, or any unit thereof.
Inorganic refers to compounds that do not contain carbon.
Interceptors are large sewer lines that collect the flows from smaller main and trunk sewers and carry them to the
treatment plant.
Intermittent sand filter involves a bed of sand or other fine-grained material to which wastewater is applied
intermittently in flooding doses.
Mechanical Aeration uses mechanical energy to inject air from the atmosphere into water to provide oxygen to
create aerobic conditions.
Media Filters involves a bed of sand or other fine-grained material to which wastewater is applied, generally to
physically remove suspended solids from sewage. Bacteria on the media decompose additional wastes. Treated water
drains from the bed. Solids that accumulate at the surface must be removed from the bed periodically.
Microbes is shorthand for microorganisms.
Million Gallons Per Day (MGD) is a measurement of the volume of water.
Mound System is an effluent disposal system involving a mound of soil built up on the original ground surface to
which effluent is distributed.
Nitrification is the biochemical oxidation of ammonium to nitrate.
Nitrogenous Wastes are wastes that contain a significant concentration of nitrogen.
Nutrients are elements or compounds essential as raw materials for plant and animal growth and development.
Organic Matter is the carbonaceous material contained in plants or animals and wastes.
Oxidation involves aerobic bacteria breaking down organic matter and oxygen
combining with chemicals in
sewage.
Pathogens are disease-causing microorganisms, including pathogenic bacteria, viruses, helminths, and protozoans.
Phosphorus is a nutrient that is essential to life, but in excess, contributes to the eutrophication of lakes and
other water bodies.
Polymer is a long chain organic compound produced by the joining of primary units called monomers. Polymers
are used to improve settling of suspended solids, remove solids from wastewater, and improve dewatering of
biosolids.
Primary Treatment is the initial stage of wastewater treatment that removes floating material and material that easily
settles out.
Rotating Biological Contactor (RBC) is a wastewater treatment process involving large, closely-spaced plastic discs
rotated about a horizontal shaft. The discs alternately move through the wastewater and the air, developing a biological
growth on the surface of the discs that removes organic material in the wastewater.
Sanitary Sewer is the collection system for transporting domestic and industrial wastewater to municipal wastewater
treatment facilities. Stormwater is not directed into this system but is handled by a separate system.
Secondary Treatment is the second stage in most wastewater treatment systems in which bacteria consume the organic
matter in wastewater. Federal regulations define secondary treatment as meeting minimum removal standards for BOD,
TSS, and pH in the discharged effluents from municipal wastewater treatment facilities.
Sedimentation Tanks are wastewater treatment tanks in which floating wastes are skimmed off and settled
solids are removed for disposal.
Seepage is the slow movement of water through small cracks or pores of the soil, or out of a pond, tank or
pipe.
Septage refers to the residual solids in septic tanks or other on-site wastewater treatment systems that must
be removed periodically for disposal.
Septic Tanks are a type of onsite wastewater treatment system in which the organic waste is decomposed and solids
settle out. The effluent flows out of the tank to a soil adsorption field or other dispersal system.
Sequencing Batch Reactors (SBR) are a variation of the activated sludge process where all treatment processes occur
in one tank that is filled with wastewater and drawn down to discharge after treatment is complete.
Settleable Solids are solids that are heavier than water and settle out of water by gravity.
Sewers are a system of pipes that collect and deliver wastewater and/or stormwater to treatment plants or receiving
waters.
Soil Absorption Field is a subsurface area containing a trench or bed with a minimum depth of 12 inches of clean stones
and a system of piping through which treated wastewater effluent is distributed into the surrounding soil for further
treatment and disposal.
Suspended Solids are the small particles suspended in water or wastewater.
Trickling Filter is a fixed film process that involves a tank, usually filled with a bed of rocks, stones or synthetic
media, to support bacterial growth used to treat wastewater.
Ultraviolet Radiation (UV) is a disinfection process where wastewater is exposed to UV light for disinfection.
Wastewater Treatment Plant is a facility involving a series of tanks, screens, filters, and other treatment processes
by which pollutants are removed from water.