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OPERATION
OF
WASTEWATER
TREATMENT
PLANTS
Volume II |
sa + ENVIRONMENTAL P aE eanonacrn
OFFICE OF wate roe : Environmental Protection Agency Review Notice
This training manual has been reviewed by the Office of Water Program
Operations, U.S. Environmental Protection Agency, and approved for publi-
cation. Approval does not signify that the contents necessarily reflect the
views and policies of the Environmental Protection Agency. Mention of trade
names or commercial products does not constitute endorsement or recom-
mendation for use by the Environmental Protection Agency, California State
University, Sacramento, Callfomia Water Pollution Controt Association, au-
thors of the chapters or project reviewers and directors. OPERATION OF WASTEWATER
‘TREATMENT PLANTS
Second Edition
Volume tt
‘A Field Study Training Program
prepared by
California State University, Sacramento
(formerly Sacramento State College)
Department of Civil Engineering
in cooperation with the
California Water Pollution Control Association
Indi idee dd
Kenneth D. Kerri, Project Ditector
Bill B. Dendy, Co-Director
John Brady, Consultant and Co-Director
William Crooks, Consultant
ISI ESHEETS III IIIA II
for the
Environmental Protection Agency
Office of Water Program Operations
Municipal Permits and Operations Division
First Edition, Technical Training Grant No. STT1-WP-16-03 (1970)
‘Second Edition, Grant No. T800690010
1980 This manual is revised and updated before each printing based on com-
ments from persons using the manual.
First printing, 1071 500
Second printing, 1972 7,000
Third printing, 1973
Fourth printing, 1874 6
Filth printing, 1975 4
‘Sixth printing, 1977 11,000
Seventh printing, 1979 4,900
SECOND EDITION, Volume H
First printing, 1980 7,000 PREFACE TO THE SECOND EDITION
VOLUME II
Volume Il is a continuation of Volume I. In Volume |, the emphasis was on the knowledge and skills needed by
new operators and the operators of smaller treatment facilities. Volume I! stresses information needed by these
operators, but shifts emphasis towards larger conventional treatment plants. This volume also will be helpful to
operators in supervisory and management positions.
All operators need to know how to perform basic arithmetic calculations and laboratory procedures to measure
wastewater characteristics. Chapter 16 outlines in detail the step-by-step procedures to measure wastewater
characteristics. Chapter 17 contains example problems showing how to solve most arithmetic problems that
operators may have to work while operating their plant. You can solve all of these problems by the use of addition,
subtraction, muttipication and division. All of these problems can be easily worked by the use of pocket electronic
calculators. Many operators have looked at and actually started these two chapters while they were working on
Volume
Regardless of the size or type of treatment plant that you operate, all of the chapters in Volume I! contain
information you need to know to do your job. Every treatment plant requires the operator to know how to treat and
handle solids, dispose of the plant effluent, conduct your duties following safe procedures, maintain the equipment,
keep records, analyze data and write reports. if your plant has advanced waste treatment processes, unusual solids
handling or disposal facilities, or treats industrial wastes, you will want to continue to Volume I after you have
completed Volume Il
For information on:
1. Uses of this manual,
2. Instructions to participants in home-study course, and
3, Summary of procedure,
please refer to Volume |.
Kenneth D. Kerri
John Brady
1980 OPERATION OF WASTEWATER TREATMENT PLANTS
VOLUME |, SECOND EDITION
Tople
Activated Sludge
(Conventional Activated Sludge Plants)
‘Sludge Digestion and Solids Handling
Effluent Disposal
Plant Safety and Good Housekeeping
Maintenance
Laboratory Procedures and Chemistry
Basic Arithmetic and Treatment Plant Problems
Analysis and Presentation of Data
Records and Report Writing
Final Examination
Glossary
Index
TECHNICAL CONSULTANTS, FIRST EDITION
William Garber Frank Philips
George Gardner Warren Prentice
Carl Nagel Ralph Stowell
Joe Nagano Larry Trumbull
‘TECHNICAL CONSULTANTS, SECOND EDITION
George Gardner Cart Nagel
Lamy Hannah Al Petrasek
Mike Mulbarger
Page
a
205
239
327
515
847
877
607 Chapter
exneonren +
10
BRERBRRBR
‘COURSE OUTLINE
VOLUME |, SECOND EDITION
Tople
The Treatment Plant Operator
Why Treat Wastes?
Wastewater Treatment Facilitios
Racks, Screens, Comminutors and Grit Removal
‘Sedimentation and Flotation
Tricking Fitters
Rotating Biological Contactors
Activated Sludge
(Package Plants and Oxidation Ditches)
Waste Treatment Ponds
Disinfection and Chiorination
Final Examination
Index
VOLUME III, SECOND EDITION
‘Odor Control
Activated Sludge
(Pure Oxygen and Operational Control Altematives)
Solids Handling and Disposal
Solids Removal from Secondary Effiuents
Phosphorus Removal
Wastewater Reclamation
Instrumentation
Industrial Waste Monitoring
Industrial Waste Treatment
‘Support Systems
Final Examination
Glossary
Index 2 Treatment Plants
OBJECTIVES.
GLOSSARY
LESSON 1
TABLE OF CONTENTS
Chapter 11. Activated Sludge
Volume tl. Operation of Activated Siudge Plants
14.0 Basic Variables and Record Keeping
11.00
1104
11.02
11.03
11.04
11.05
LESSON 2
11.1 Aeration Systems
11.10
wa
ae
Need for Record Keeping
Variables in Collection System ....
11.010 Combined Sewer Systems
11.011 Waste Dischargers to the System
11.012 Maintenance of the Collection System
Operational Variables
Plant Records
‘Typical Lab Resuts for an Activated
‘Siudge Plant
Design Variables
11.050 Aeration Methods
11.051 Variation of Activated Studge Process...
Purpose of Aeration
Mechanical Aeration Systems
Diffused Aeration Systems
11.120. Air Filters
11.121 Blowers (Process Air Compressors) -
11,122 Air Distribution System
41.123. Air Headers
11.124. Diffusers
Page
3
8
3
3
13
8
5
16
16
6
- 16 Safety ..
11.20
121
11.22
11.23
1124
11.25
LESSON 3.
13
Aeration Tanks and Clarifiers
Surface Aerators
A Fitors
Blowers
‘Air Distribution System
‘ir Headers and Dittusers ..
Checking Out a New Plant.
11.30
1131
11.32
11.38
LESSON 4
Process Start-Up Procedures
14
11.40
141
11.42
1143
1148
LESSON 5
Routine Operational Control
18
11.50
1151
‘A New Activated Sludge Plant: Description
Aerator
11.810 Control Gates
11.311 Storm Flow Gates and Pedestal
Lit Gates
11.312 Weirs
11.313 Movable Gates
11.814 Water Sprays for Froth Control
14.818. Alt System. .
Air Fiters
Blowers (Compressors)
Air Headers
Ditfusers
pope
E. Blower Testing
‘Secondary Clariiers
Return Sludge and Waste Sludge Pumps
General
First Day
‘Second Day
‘Third through Fifth Days
Sixth Day.
How to Control the Process.
Determination of Sludge Age
Activated Sludge 3
28
8
35
35
- 95
8888
8e8ee88
8s &
at
BEG 6SS
68 4 Treatment Piante
11.52 Wasting Activated Sludge
11.53 Determination of Waste Sludge Pumping Rate
11.54 Operational Strategy
11.540 Influent Characteristics
11.541 Aeration Tank Environment .
11.542 Secondary Clarifier 2.2... seseseee
11.543 Plant Effient ..... ee
11.55 Actual Operation Under Normal Conditions,
11.550 Initial Inspection
11.551 Process Adjustment
11.56 Actual Operation Under Abnormal Conditions ..
11.87 Summary.
geesgsessesse ese s
LESSON 6
11.8 Operational Problems (Abnormal Operation)...
11.60. Typical Probloms .
11.61 Plant Changes...
11.62 Sludge Bulking .
11.63, Septic Siudge ..
11.64. Toxic Substances...
11.65. Rising Studige
11.88 Foaming Frothing
LESSON7
11.7 Aerator Loading Guidelines
11.70 Use of Loading Guidelines .........
11.71. FoodiMieroorganism Ratio
11.72. Calculation of FoodMicroorganism
‘Aerator Loading
411.73 Mean Coll Residence Time (MCRT)
11.74 Caloulaton of Mean Cell Residence Time
‘Activated Sludge Process Equipment
11.80 Need for Understanding Equipment .
114.81 Shutdown...
11.810 Surtace Aerators -
11.814. Positive Displacement Blowers
11.812 Centrtugal Blowers
11.813 Air Distribution System
11.814 Air Hoadors and Ditusors ..
RR
RRSEKLGERSBBR Activated Sludge 5
11.82 Abnormal Conditions
11.820. Surface Aerators
11.821. Air Fits
11.822, Blowers
11.823 Air Distbution System
11.828 Air Headers
11.825. Air Diftusors
11.83 Maintenance
11.830 Surtace Aerators
11.831 Air Filters
SSSSSsSRsszReee
11.832 Blowers
11.833 Air Distibution System
11.834. Air Headers
11.895 Dittusers
LESSON 8
11.9 Modifications of the Activated Siudge Process:
11.90 Reasons for Other Modes of Operation -
11.91 Contact Stabilization
11.92. Kraus Process
11.83. Step-Feed Aeration
11.94 Complete Mix
11,95 Moditied Aeration
11.10 Acknowledgment
11.11 Additional Reading.
11.12. Metric Calculations:
14.120 Conversion Factors «2... sess estes
11.121 Problem Solutions 6 Treatment Plants
OBJECTIVES
Chapter 11.
“The activated sludge process is a very important wastewater
treatment process. For this reason, the chapters on activated
sludge have been divided into three parts and will be pre-
‘sented in three separate volumes.
|. Package Plants and Oxidation Ditches
|. Typical Activated Sludge Plants
IL. Pure Oxygen Plants and Operational Control
ltyou are the operator of a package plant or oxidation ditch,
Volume I will provide you with the information you need to
know to operate your plant. Volumes II and Il will help you
better understand your plant and do a better job. i you operate
‘a conventional activated sludge plant or a modification, Vol
lume | will help you understand the activated sludge process
‘and Volume I! wil tell you how to operate your plant. Volume Il
vill explain to you alternative means of operational control that
‘may work very well for your plant. f you operate a pure oxygen
plant, Volume Il wil tell you what you need to know to operate
the pure oxygen system. All three parts contain information
important tothe proper operation of your plant. Volume Ill also
‘contains information helpful to operators using the activated
sludge process to treat special wastes such as industrial
wastes.
‘The following list of objectives apply to the treatment plants
‘covered in each of the three parts. After completion of the
‘appropriate part on activated sludge you should be able to:
1
ACTIVATED SLUDGE,
Explain the principles of the activated sludge process and
the factors that influence and control the process,
Inspect a new activated sludge fait for proper installa.
tion,
Place a new activated sludge process into service,
‘Schedule and conduct operation and maintenance duties,
Collect samples, intorprot lab results, and make appropr-
ate adjustments in treatment processes,
Recognize factors that indicate an activated sludge pro-
‘cess is not performing propery, identify the source of the
problem, and take corrective action,
‘Conduct your duties in a sate fashion,
1. Determine aerator loadings and understand the applica-
tion of different loading guidelines,
1. Keep records for an activated sludge plant,
Identity the common modifications of the activated sludge
Process, and
Review plans and specications for an activated sludge
plant. Activated Sludge 7
GLOSSARY
Chapter 11. ACTIVATED SLUDGE
ABSORPTION (ab-SORP-shun) ‘ABSORPTION
“Taking in or soaking up of one substance into the body of another by molecular or chemical action (as ree roots absorb dissolved
nutrients in the soil.
ACTIVATED SLUDGE (ACK-ta-VATE-ed siu)) ACTIVATED SLUDGE
Sludge particles produced in raw or settled wastewater (primary effluent) by the growth of organisms (including zoogleal bacteria) in
aeration tanks in the presence of dissolved oxygen. The term “activated” comes from the fact that the particles are teeming with
bacteria, fungi, 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.
ACTIVATED SLUDGE PROCESS (ACK-ta-VATE-ed sluj) ACTIVATED SLUDGE PROCESS
‘A biological wastewater treatment process which speeds up the decomposition of wastes in the wastewater being treated. Activated
sludge is added to wastewater and the mixture (mixed liquor) is aerated and agitated. Alter some time in the aeration tank, the
Activated sludge is allowed to settle out by sedimentation and is disposed of (wasted) or reused (returned to the aeration tank) as
Needed. The remaining wastewater then undergoes more trealrment.
ADSORPTION (add-SORP-shun) ‘ADSORPTION
‘The gathering of a gas, liquid, or dissolved substance on the surface or interface zone of another substance.
‘AERATION LIQUOR (air-A-shun) AERATION LIQUOR,
Mixed liquor. The contents of the aeration tank including living organisms and materia carried into the tank by either untreated
wastewater or primary effuent.
AERATION TANK (air-A-shun) AERATION TANK
The tank whore raw or settled wastewater is mixed with ratum sludge and aerated. The same as aeration bay, aerator or reactor.
‘AEROBES. ‘AEROBES
Bacteria that must have molecular (dissolved) oxygen (00) to survive.
‘AEROBIC DIGESTION (AIR-O-bick) AEROBIC DIGESTION
“The breaking down of wastes by microorganisms in the presence of dissolved oxygen. Waste sludge is placed in a large aerated
tank where aerobic microorganisms decompose the organic matter in the sludge. This is an extension of the activated sludge
process,
AGGLOMERATION (a-GLOM-er-A-shun) AGGLOMERATION
The growing or coming together of small scattered particles into larger flocs or particles which settle rapidly. Also see FLOC.
AIR LIFT ‘AIR LIFT
‘A special type of pump. This device consists of @ vertical riser pipe submerged in the wastewater or sludge to be pumped.
Compressed air is injected into a tal piece at the bottom of the pipe. Fine air bubbles mix with the wastewater or sludge to form a
mixture lighter than the surrounding water which causes the mixture to rise inthe discharge pipe tothe outlet. An ait pump works
similar to the center stand in a percolator coffee pot.
ALIQUOT (AL-i-Kwot) ALIQuOT
Portion of a sample.
‘ANAEROBES ‘ANAEROBES,
Bacteria that do not need molecular (dissolved) oxygen (DO) to survive. 8 Treatment Plants
BACTERIAL CULTURE (back-TEAR--al) BACTERIAL CULTURE
{nthe case of activated sludge, the bacterial cuture refers to the group of bacteria classed as AEROBES and facultative organisms,
which covers a wide range of organisms. Most treatment processes in the United Siates grow facultative organisms which utiize the
carbonaceous (carbon compounds) BOD. Facultative organisms can live when oxygen resources are low. When “nitrification” Is.
Fequired, the nittying organisms are OBLIGATE AEROBES (require oxygen) and must have at least 0.5 mg/L of dissolved oxygen
throughout the whole system to function properly
BATCH PROCESS BATCH PROCESS
‘A treatment process in which a tank or reactor i filed, the water is treated, and the tank is emptied. The tank may then be filed and
the process repeated.
BIOMASS (BUY-o-MASS) BIOMASS,
‘Armas or clump or living organisms feeding on the wastes in wastewater, dead organisms and ether debris. This mass may be
formed for, or function as, the protection against predators and storage of food supplies. Also see ZOOGLEAL MASS,
‘BULKING (BULK-ing) BULKING
Clouds of billowing studge that occur throughout secondary clarifiers and sludge thickeners when the sludge becomes too light and
will not settle properiy
CATHODIC PROTECTION (ca-THOD-ick) CATHODIC PROTECTION
‘An electrical system for prevention of rust, corrosion, and pitting of stee! and iron surfaces in contact with water or wastewater,
CHEMICAL OXYGEN DEMAND or COD CHEMICAL OXYGEN DEMAND or COD
[A measure of the oxygen-consuming capacity of inorganic and organic matter present in wastewater. COD is expressed as the
amount of oxygen consumed from a chemical oxidant in mg/L during a specific test. Results are not necessarily related to the
biochemical oxygen demand because the chemical oxidant may react with substances that bacteria do not stabilize,
COAGULATION (ko-AGG-u-LAY-shun) COAGULATION
The use of chemicals that cause very fine particles to clump together into larger parricles. This makes it easier to separate the solds
{rom the liquids by setting, skimming, and draining or fitering
‘COMPOSITE (PROPORTIONAL) SAMPLE. COMPOSITE (PROPORTIONAL) SAMPLE
(com-POZ-i)
‘A composite sample is a collection of individual samples obtained at regular intervals, usually every one or two hours during a
24-hour time span. Each individual sample is combined with the others in proportion to the flow when the sample was collected, The
resulting mixture (composite sample) forms a representative sample and is analyzed to determine the average conditions during the
‘sampling period.
CONING (CONE-ing) CONING
Development of a cone-shaped flow of liquid, ike a whirlpool, through sludge. This can occur in a sludge hopper during sludge
withdrawal when the sludge becomes too thick. Part ofthe sludge remains in place while quid rather than sludge flows out of the
hopper. Also called “coring
CONTACT STABILIZATION CONTACT STABILIZATION
Contact stabilization is a modification of the conventional activated sludge process. In contact stabilization, two aeration tanks are
Used. One tank is for separate re-aeration of the return sludge for at least four hours belore it is permitted to flow into the other
aeration tank to be mixed with the primary offluent requiring treatment.
DECIBEL DECIBEL
‘Aunit for expressing the relative intensity of sounds on a scale from zero forthe average least perceptible sound to about 190 for the
average pain level
DENITRIFICATION DENITRIFICATION
‘[Link] that occurs when nitrite or nitrate ions are reduced to nitrogen gas and bubbles are formed as a result ofthis process.
‘The bubbies attach to the biological flacs and float the flocs to the surface of the secondary clarifiers. This condition is often the
cause of rising sludge observed in secondary clarifiers
DIFFUSED-AIR AERATION DIFFUSED-AIR AERATION
‘A diffused air activated sludge plant takes air, compresses it, and then discharges the air below the water surface of the aerator
through some type of air difusion device.
DIFFUSER, DIFFUSER
‘A device (porous plate, tbe, bag) used fo break the airstream irom the blower systom ino fine bubbles in an aeration tank or
reactor. Activated Studge 9
DISSOLVED OXYGEN DISSOLVED OXYGEN
Molecular oxygen dissolved in water or wastewater, usually abbreviated DO.
ENDOGENOUS (en-DODGE-en-us) ENDOGENOUS
‘Arado vel ol rept (beathing) n which organi break down compound win he cwn colo produce te cxypen
FIM RATIO FIM RATIO
Food to microorganism ratio. A measure of food provided to bacteria in an aeration tank.
Food = BOD, tosiday
Microorganioms MLVSS, ibs
Flow, MGD x BOD, mpl. x 8.34 Ibs/gal
Volume, MG x MLVSS, mg/L x 8.34 toa/gal
or = BOO, teidey
MAL¥86, hg
FACULTATIVE (FACK-uL-TAY tive) FACULTATIVE
‘Facultative bacteria can use either molecular (dissolved) oxygen or oxygen obtained from food materials such a6 eutate or nitrate
tons. in other words, facultative bactoria can live under aerabic or anaerobic conditions.
FILAMENTOUS BACTERIA (FiLL-@-MEN-tuss) FILAMENTOUS BACTERIA
(Organisms that grow in a thread or fiamentous form. Common types are thiothrx and actinomyces.
FLIGHTS FLIGHTS
‘Scraper boards, made from redwood or other rot-esistant woods or plasic, used to collect and move settled sludge or floating scum.
FLoc Floc
‘Groups or clumps of bacteria thet have come together and formed a cluster. Found in aeration tanks and secondary clarifiers.
FLOCCULATION (FLOCK-you-LAY-shun) FLOCCULATION
‘The gathering together of fine parties to form larger particles.
FOOD/MICROORGANISM RATIO FOOD/MICROORGANISM RATIO
Food to microorganism ratio. A measure of food provided to bacteria in an aeration tank.
Food = BOD, tbalday
Microorganisms MLVSS, bs
= __Flow, MGD x BOD, mg/L x 8.34 Iba/gal
Volume, MG x MLVSS, mg/L. x 8.34 Iba/gal
or = BOD, kgiday
MLVES, kg
Commonly abbreviated F/M Ratio.
HEADER HEADER,
‘A large pipe to which the ends of a series of smaller pipes are connected. Also called a “manifold.”
MANIFOLD MANIFOLD
‘A large pipe to which the ends of a series of smaller pipes are connected. Also called a “header.”
MEAN CELL RESIDENCE TIME (MCAT) MEAN CELL RESIDENCE TIME (MCAT)
‘An expression of the average time that a microorganism will spend in the activated sludge process.
MCAT, days = __Sdlde in Activated Studge Process, be
Solids Removed trom Process, beiday 10 Treatment Plants
MECHANICAL AERATION MECHANICAL AERATION
‘The use of machinery to mix air and water so that oxygen can be absorbed into the water. Some examples are: paddle whoels,
‘mixers, of rotating brushes to agitate the surface of an aeration tank; pumps to create fountains; and pumps to discharge water
down a series of steps forming falls or cascades.
MICROORGANISMS (micro-ORGAN-is-ums) MICROORGANISMS
Very small organisms that can be seen only through a microscope. Some microorganisms use the wastes in wastewater for food
and thus remove or alter much of the undesirable matter.
MIXED LIQUOR MIXED LIQUOR
When the activated sludge in an aeration tank is mixed with primary effluent or the raw wastewater and return sludge, this mixture is
then referred to as mixed liquor as long as itis in the aeration tank. When the mixed iquor flows fram the aeration tank it goes Into
the eacondary clarifiers or final sedimentation tanks. Mixed iquor also may refer o the contents of mixed aerobic or anaerobic
jigesters,
MIXED LIQUOR SUSPENDED SOLIDS MIXED LIQUOR SUSPENDED SOLIDS
(MLSS) (Miss)
‘Suspended solids in the mixed liquor of an aeration tank,
MIXED LIQUOR VOLATILE SUSPENDED MIXED LIQUOR VOLATILE SUSPENDED
‘SOLIDS (MLVSS) ‘SOLIDS (MLVSS)
‘The organic or volatile suspended solids in the mixed liquor of an aeration tank
NITRIFICATION (NYE-trfKAY-shun) NITRIFICATION
‘A process in which bacteria change the ammonia and organic nitrogen in wastewater into oxidized nitrogen (usually nitrate). The
‘second-stage BOD is sometimes referred to as the “nitrification stage" (first-stage BOD is called the "carbonaceous stage")
OXIDATION (ox:-DAY-shun) OXIDATION
‘Oxidation isthe addition of oxygen, removal of hydrogen, or the removal of electrons trom an element or compound. In wastewater
‘treatment, organic matter is oxidized to more stable substances. The opposite of REDUCTION.
PLUG FLOW PLUG FLOW
‘A type of flow that occurs in tanks, basins or reactors wien a slug of wastewater moves through a tank without ever dispersing or
‘mixing with the rest of the wastewater flowing through the tank.
DIRECTION
OF FLOW —— Sn
PLUG FLOW
POLYELECTROLYTE (POLY-electro-ight) POLYELECTROLYTE
‘A high-molecular-weight substance that is formed by either a natural or synthetic process. Natural polyelectroiyies may be of
biological origin or derived from starch products, cellulose derivatives, and alignates. Synthetic polyelectrolytes consist of simple
substances that have been made into complex, high-molecular-weight substances. Often called a “polymer.”
POLYMER (POLY-mer) POLYMER
A high-molecular-weight substance that is formed by either a natural or synthatic process. Natural polymers may be of biological
‘origin or derived from starch products, cellulose derivatives, and alignates. Synthetic polymers consist of simple substances that
ave been made into complex, high-molecular-weight subsiances. Otten called a “polyelectrolyte.
PROTOZOA (pro-toe-Z0E-ah) PROTOZOA
‘A group of microscopic animals (usually single-celled) that sometimes cluster into colonies.
REDUCTION (re-DUCK-shun) REDUCTION
Feeduction is the addition of hydrogen, removal of oxygen. o the addition of electrons to an element or compound. Under anaerobic
Conditions in wastewater, sulfate compounds or elemental sulfur are reduced to odor-producing hydrogen suitide (HS) or the
sulfide lon (S"*). The oppesite of OXIDATION.
RISING SLUDGE RISING SLUDGE
Flising sludge occurs inthe secondary clarifiers of activated sludge plants when the sludge settles tothe botiom of the carl, is
compacted, and then stars to rise to the surlace,usvally as a result of denitrification Activated Sludge 11
SECCHI DISC (SECK-key) SECCHI Disc
A fiat, white disc lowered into the water by a rope unti i is just barely visible. At this point, the depth of the dise from the water
surface is the recorded secchi disc reading
SEIZING SEIZING
Seizing occurs when an engine overheats and a component expands so the engine will not run, Also called “freezing.”
SEPTIC (SEP-tick) SEPTIC
‘This condition is produced by anaerobic bacteria. If severe, the wastewater tums black, gives off foul odors, contains litle or no
dissolved oxygen and creates a heavy oxygen demand.
‘SHOCK LOAD ‘SHOCK LOAD
‘The arrival at a plant of a waste which is toxic to organisms in sufficient quantity of strength to cause operating problems. Possible
problems include odors and solids in the effluent. Organic or hydraulic overloads also can cause a shack load.
SLUDGE AGE SLUDGE AGE
‘A measure of the length of time a particle of suspended solids has been undergoing aeration in the activated sludge process.
Sludge Age, _ _ Suspended Solids Under Aeration, Ibs or kg
says ‘Suspended Solids Added, Ibsiday or kg/day
‘SLUDGE DENSITY INDEX (SD!) SLUDGE DENSITY INDEX (SO)
‘This testis used in a way similar to the Sludge Volume Index (SV/) to indicate the settleabilty of a sludge in a secondary clarifier or
effluent. SDI = 100/SVI. Also see SLUDGE VOLUME INDEX (SV)).
SLUDGE VOLUME INDEX (SV1) ‘SLUDGE VOLUME INDEX (SV!)
This is a test used to indicate the setting abiity of activated sludge (aerated solids) in the secondary clarifier. The test is a measure
‘of the volume of sludge compared to its weight. Allow the sludge sample from the aeration tank to settle for 30 minutes. Then
‘calculate SVI by dividing the volume (mi) of wet settied sludge by the weight (mg) ofthat sludge after it has been dried. Sludge with
an SVI of one hundred or greater will not settle as readily as desirable because itis as light or lighter than water.
svi = Wet Settled Sludge, mi _ 1090
Dried Sludge Solids, mg
STABILIZED WASTE STABILIZED WASTE
‘A waste that has been treated or decomposed tothe extent that, i discharged or released, is rate and state of decomposition would
bbe such that the waste would not cause a nuisance or odors.
STEP-FEED AERATION STEP-FEED AERATION
‘Step-feed aeration is a modification of the conventional activated sludge process. In step aeration, primary effluent enters the
aeration tank at several points along the length of the tank, rather than all of the primary effluent entering at the beginning or head of
‘the tank and flowing through the entice tank.
‘SUPERNATANT (sue-per-NAY-tent) ‘SUPERNATANT
Liquid removed from settled sludge. Supernatant commonly refers tothe liquid between the sludge on the bottom and the scum on.
the surface of an anaerobic digester. This liquid is usually returned to the influent wet well or to the primary clarifier.
Toc Toc
Total Organic Carton. TOC measures the amount of organic carbon in water.
TURBIDITY METER. TURBIDITY METER
[An instrument for measuring the amount of panicles suspended in water. Precise measurements are made by measuring how light
is scattered by the suspended paricles. The normal measuring range is Oto 100 and is expressed as Nephelometic Turbity Units
(NTUs)
TURBIDITY UNITS TURBIDITY UNS
Turbidity units, it measured by @ nephelomettic (reflected light) instrumental procedure, are expressed in Nephelometic Turbidity
Units (NTU). Those turbidty units obtained by other instrumental methods of visual mathods are expressed in Jackson Turbidity
Units (JTU} and sometimes as Formazin Turbidity Units (FTU). The FTU nomenclature comes from the Formazin polymer used to
prepare the turbidity standards for instrument calbration. Turbidty units are a measure of the cloudiness of water. 12 Treatment Plants.
VOLUTE (voHLOOT) VOLUTE
‘The spiral-shaped casing which surrounds a pump, blower, or turbine impeller and collects the iquor or gas discharged by the
impelier.
ZOOGLEAL MASS (ZOE-glee-al) ZOOGLEAL
Jolly-like masses of bacteria found in both the trickling fiter and activated sludge processes. These masses may be formed for or
function as the protection against predators and for storage of food supplies. Also see BIOMASS.
(VER 2 PRIT-2e) Activated Sludge 13
CHAPTER 11. ACTIVATED SLUDGE
VOLUME Il. OPERATION OF ACTIVATED SLUDGE PLANTS
(Lesson 1 of 8 Lessons)
NOTE: Review Volume |, Chapter 8, "Package Plants and
Oxidation Ditches” before starting Volume I
11.0 BASIC VARIABLES AND RECORD KEEPING
11.00 Need for Record Keeping
Wastewater flows and contents change daily. The activated
sludge plant operator attempts to maintain the process at
‘some balanced stale that wll be capable of handling the minor
Variations inflows or wastewater characteristics and produce
the desired quality of effluent. To accomplish this goal you
must establish the activated sludge process (Fig. 11.1) on
known data and knowledge obtained at other plants and relate
them to your plant. After your plant becomes operational, you
then must relate the control procedures to actual plant exper
cence. The vatiations that affect the operation are deri
yo sbioos () is decharges ote cofecion susie an
2) in-plant Operafiona vamos —
ao
11.01 Variables in Collection System
11.010 Combined Sewer Systems
During storms the treatment plant wil receive an increase in
flow which may cause the following problems:
1. Reduced wastewater time in treatment units (hydraulic
overload),
2. Increased amounts of grit and silt which lower the volatile
(ood) content of the solids;
3. Increased organic load during intial washout of accumu
lated sewer deposits; and
4, Rapid changes in wastewater temperature and solids con-
tent
11.011 Waste Dischargers to the System
Various industries, businesses, and cesspool or soptic tank
service fims can cause uneven flows and changes in the types.
of wastewater entering a plant. You should become
uainted with the managers of businesses and facities whose
discharges could upset your treatment processes. Convince
these people in a friendly manner how vital it is to your plant
processes and the receiving waters for you to be notified of any
potentialy harmful discharges. Try to obtain their cooperation
‘and request them to notify you whenever an accidental spl, a
process change, or a cleaning operation occurs which could
cause undesirable waste discharges. This requires diplomacy
to obtain cooperation from dischargers to regulate their own
discharges and to reduce the number of midnight dumps.
11.012 Maintenance of the Collection System
‘Advance notice of collection system maintenance crew ac-
tives can be very helpful. Ifa lit station has been out of,
service for a period of time, large volumes of septic wastewater,
‘could cause a shock load on your treatment processes. Similar
problems could be created when a blockage in a lines cleared
(r a new line is connected to the system. Analysis of inflow
‘quantities and characteristics when these flows reach a teat
‘ment plant can indicate whether or not they will cause a seri-
‘ous problem
11.02 Operational Variables
Continual review of laboratory test results is essential in de:
termining whether a treatment plant is discharging eluent of,
the required quality in torms of such WATER QUALITY INDI-
CATORS AS COD, SUSPENDED SOLIDS, AND NITROGEN.
{tthe desired quality of the plant effluent is not achieved, the
‘operator must determine what factor or factors have changed
to upset plant performance and thus reduce efficiency.
Important factors that could have changed include:
1. Higher COD or BOD load applied to the aerator (influent,
load);
2. More dificult to treat wastes have caused a change in in-
fluent characteristics;
3. Unsuitable mixed liquor suspended solids concentration in,
the aerator;
4. Lower or higher rate of wasting activated sludge:
5. Unsuitable rate of returning sludge to the aerator could ad
versely influence mixed liquor suspended solids;
6. Higher solids concentrations in digester SUPERNATANT!
Feturmed to the plant flow, or return too rapid;
* Supamaiat ove per NAY on). qu removed ram sated sludge. Supernatant commonly refers tothe aul boween he shidge anh
Botom endive acum ante suacactan anaerobic geste Ths kad caval eure toe en wt wat ore rinan ata 14 Treatment Plants.
TREATMENT PROCESS
PRETREATMENT
INFLUENT
SCREENING
EUNCTION
__ REMOVES, LO07%, LACS, CANE $ LALOE
LEBELILS (MALL TOA LAN OELL, OLE
POSSIBLE CluMO 8 LEIULN 72 PLANT F0W)
[Geir REMOVAL
REMOVES SAND EGLAVEL
CALL 70 LAND FiLL)
FRESHENS WASTE HATER
POE-AERATION |g ELS LEMOVE O
[FLOW METER | MEASULES % LECORDS row
PRIMARY
TLEATMENT
GEDIMENTATION | LEMOVES SETILEABLE
ANO FLOTATION] | $AZ0A7ABLE MATELALS
SECONDARY || GOLIDS | 7EATS SOLIDS REMOVED
TREATMENT ||WANOLING | Bi OTHER AOCESSES
EMOVES SUSPENDED
& DESOLVEP SOLIDS.
EFFLUENT
DIGINFECTION |K/LL5 LATHOGENIC BACTELIA
ig. 11.1 Flow diagram of a typical plant 7. Dropping of oxygen concentration in the aerator below de-
sirable levels; and
8, Increase or decrease in wastewater temperature.
Examination of plant records should reveal the items which
have changed that could have upset the treatment process.
QUESTIONS
Write your answers in a notebook and then compare your
answers with those on page 82
11.08 What two major variables atfect the way an activated
sludge plant is operated?
‘What problems can be caused in an activated sludge
plant when excessive storm water flows through the
process?
Besides excessive storm water flows, what other vari-
ables in the collection system can affect the operation
of an activated sludge plant?
11.08,
14.03 Plant Records
Accurate daily plant and laboratory records on the items
listed below can help the operator determine the best oper-
ating ranges for operational controls on the basis of plant per-
formance. Records can also indicate when problems develop
and help identify the source of the problem, RECORD THE
FOLLOWING DATA ON A DAILY BASIS. (Also see Monthly
Data Sheet in the Appendix.)
1. Suspended Solids and Volatile Content
a. Primary effluent
1. Aerator mixed liquor
&. Retu sludge
d._ Final clarifier or secondary sedimentation tank effluent
2. BOD, COD, or TOC?
‘a. Plant influent
b. Primary effluent
Final carier or secondary sedimentation tank effluent
te Foe aS ee ne
influent wastewater because Te resulls are available
in Tour hours and can be used fo contro the activa
“Boag pressor many vers opara elena
“Bas Fe BOD at ox operatonal coal but the ist Tas
the following disadvantages:
(1) Procedural errors can cause a large veriation in re-
sults.
(2) Five days of waiting are required before results are
available.
(3) Onyy @ portion of the load on the activated sludge
process is measured by the tes.
10.
1"
‘Activated Sludge 15
Dissolved Oxygen
a. Aerator
. Final clanfer or secondary sedimentation tank (inside
the effiuent weir)
. Final eluent
Settleable Solids
a. Influent
b. Mixed iquor settleabilty test
Digester supernatant
d. Final effluent
>. Temperature
a. Influent
b. Aerator
©. Final efluent
pH
a. Infuent
b. Primary etfvent
©. Aerator
d. Final effluent
Carty (SECCH! DISC) or Turbidity (TURBIDIMETERY*
a. Final clartier
Chlorine Demand
a. Final clare effluent
1. Coliform Group Bacteriat
a. Plant effluent
Moter Readings and Calculations
Dally flow
Pounds of solids under aeration
Pounds of COD or BOD to aerators
Pounds of solids in effluent
Footum sludge rate
Waste sludge rat
Ait to aeralors (diffused air system); hours operated at
(meche
ration}
ludge age (0
‘similar calculations include Food!
Microorganism Ratio and Mean Cell Residence Time,
(600 Sections 11.71 and 11.73)
1. Pounds of solids in sludge to digester
|. Pounds of solids in digester supernatant
k. Power cost
Daily Observations
a. Odors
Influent. Color and level of inlow.
b
c. Primary claiier. Scum and cob.
[Link] tank. Turbulence, color and amount of sur-
‘ace foam and scum.
e. Secondary clarifier. Effluent clear or turbid, type of
solids on surface and influent.
F700 or Total Organic Carbon. TOC measures the amount of organie carbon in water
3 Measure aerator pH inthe aerator or immediately ater sample is collected, because the pH can change very rapidly once the sample is out of
the worator. Do not take sample fo tho lab.
+ Sacchi Disc (SECK-key).
trom the wator surface Is the recorded secon asc reading.
‘Ala, whit disc lowered into the water by @ rope until tis ust barely visible. At this point, the depth ofthe disc
* Turbidty Moter. An Instrument for measuring the amount of paroles suspended in water. Precise measurements are made by measuring
‘how ligtls scattered by the suspended particles. The normal measuring range is 00 100 and is expressed as Nephelometrc Turbidity Units
«nTus),
‘Check with your regulatory agency for test and procedures. Tests approved by agencies include MPN by muliple fermentation tubes,
‘membrane fiter, and fecal coltorm. 16 Treatment Plants
{. Return activated sludge. Color and odor.
Equipment and motors. Smooth operation, vibrations,
‘noises and temperature.
Condition of receiving water upstream and downstream
from point of discharge.
Accurate records will show when you have established!
‘operating procedures that will produce the best possible
effluent. This effluent will be low in COD (or BOD) and sus.
ended solids, and the effluent clarity wil be good. Waste
loadings and operational procedures will change frequently
due to seasonal changes. This requires the operator to con-
stantly review the plant records for changes and to make ap-
propriate changes to maintain the best possible effluent qual-
ity. Process control consists not only of maintaining the equip-
‘ment, but of making a constant daily review of process condi
tions to determine when adjustments must be made to com-
Pensate for the many variables that can influence effluent qual-
ity. Remember that the sight, smell, and touch observations
often are your first indications that problems are developing
and frequently offer indications of appropriate correctve ac
tion
QUESTIONS
write your answers in @ notebook and then compare your
answers with those on page 62.
11,00 Why should the strength or waste load ot the influent
to the activated sludge process be measured by the
‘COD test instead of the BOD test?
11.0 Why should the aerator pH be measured in the aerator
Instead of the lab?
11.0F Sight and smell observations are often the operator's
first indication that process probloms are developing.
‘True or False?
11.04 Typical Lab Results for an Activated Sludge Plant
Typical resuits of lab tests (Table 11.1) for an activated
sludge plant are provided to assist in the evaluation of lab
results and plant performance. Remember that every plant is,
ifferent and is influenced by different conditions.
11.05 Design Variables
‘Several diferent types of activated sludge plants have been
built using various flow arrangements, tank configurations, or
‘oxygen application equipment. However, all of these variations.
are essentially modifications of the basic concept of canven-
tional activated sludge,
11.050 Aeration Methods
‘Two methods are commonly used to supply oxygen from the
air to the bacteria — MECHANICAL AERATION and DIF-
FUSED AERATION. Both methods are mechanical processes
‘with the dtference being whether the mechanisms are at or in
‘the aerator or at a remote location.
‘Mechanical aeration devices agitate the water surface in the
‘aerator to cause spray and waves by paddle wheels (Fig.
7 Siudge Age, days = (Suspended Sol. in Mixed Lia., mgi,) (Aerator Vol, MG) (8:34 Ios/gal)
"ary Et, mail) (Flow, MGD) (8.34 bsigal)
‘Guepended Solin
= Suspended Sol Under Aeration, bs
‘Suspended Solid Added, IbsId6y
TABLE 11.1 TYPICAL LAB RESULTS
Jest Location Common Range
coo intuont 300-700,
Peary EMtuont 200: 400,
ral eftvort 30-70
(Gon Act Si)
800 intuon 150-400 mgit
Peary tuont {oo-280 Mt
Final Eftuent 30-20) male
{Gonv-Act SI)
SUSPENDED —tntuent
SouDs Primary Etont
Mod Luar
orurn Sudge
Final Eftuont
‘Gon Act SI)
DISSOLVED Mixed Lievor 05-4 malt
OxvEEN Pinal EH (Out) 2:8 male
CHLORINE Final Ettuent <01-20 git
RESIDUAL
Goin)
COUFORM Fal Ettuent 2- 700100
Group (Ghorntoa)
BACTERIA, MPN
cuaniry Foal ettvont sen
(Secchi Disc)
TURBIDITY Fal Ettuet 1-aNTu
(Tarbaimeten
oH Intuont os-20
Eihvert 89-88
* Regulatory agencies normally specity a chlorine rasidual remaining
afte a certain tme period
‘<-Means less than. For example, ess than 0.1 mg/L. chlorine re
sidual
11.2), mixers, rotating brushes, or some other method of
splashing water into the air or air into the water where the
‘oxygen can be absorbed.
Mechanical aerators in the tank tend to be lower in instalia-
tion and maintenance costs. Usually they are more versatile in
terms of mixing, production of surface area of bubbles, and
‘oxygen transfer per unit of applied power.
Diffused air systems use a device called a diffuser (Fig
11.3) which is used to break up the air stream trom the blower
system into fine bubbles in the mixed liquor. The smaller the
bubble, the greater the oxygen transfer due to the greater sur-
ace area of rising air bubbles surrounded by water. Unfortu-
nately, fine bubbles will tend to regroup into larger bubbles
while rising unless broken up by suitable mixing energy and
turbulence.
11.051 Variation of Activated Sludge Process
‘The activated sludge plant may be operated in any one of
three ranges or operational zones on the basis of "SLUDGE
AGE"? which is. an expression of pounds of organic loading Fig. 11.2 Mechanical aeration device
(eunoy FLCO NC) 18 Treatment Plants
Fig. 11.3 Air diffuser (tine bubbles)
(Covey Pat alta, Nao Tring Cat, Waar Cuty OmCA/EPA) ‘added per day per pound of organisms maintained in the par-
ticular process. Sludge age is a control guide that is widely
used and is an indicator ofthe length of time a pound of solids
is kept under aeration in the system. If the amount of solids
Under aeration remains fairly constant, then an increase in the
influent solids load will decrease the sludge age. Use of this,
measure of sludge age is recommended for the new activated,
sludge plant operator because of the ease in understanding
this approach. The experienced operator may not accept this
‘method of control because it ignores the soluble BOD that is
related to the solids production but not measured by sus-
pended solids tests on the influent
The following values are typical sludge ages for different
types of municipal activated sludge plants with very ite indus
trial waste, Actual loadings must be related to the type of waste
and local situation.
1. HIGH-RATE. A high-rate activated sludge plant operates at
the highest ioading of food to microorganisms; the sludge
{age ranges from 0.5 to 2.0 days. Due to this higher loading
the system produces a lower quality of effluent than the
‘other types of activated sludge plants. This system is moro
sly upset than others and requires tighter control and
frequent testing.
2. CONVENTIONAL. Conventional activated sludge plants are
the most common type in use today. The loading of food to
‘microorganisms is approximately 50 percent lower than in a
TABLE 11.2 AERATION TANK CAPACITIES AND PERMISSIBLE LOADINGS*
“AERATION TANK ORGANIC n
Activated Sludge 19
high-rate plant, and the sludge age ranges from 3.5 to 7.0
‘days. This method of operation produces a high quaity of
effluent and is abie to absorb some shock loads without
lowering efiuent quality
8. EXTENDED AERATION. Extended aeration is often used in
‘smaller package-type plants (Chapter 8) or so-called com-
plete oxidation systems. These are the most stable of the
‘three processes due to the light loading of food to mi-
croorganisms, and the sludge age is commonly greater
than ten days, Effluent suspended solids commonly are
higher than found under conventional loadings.
For a summary of the loadings for different types of activated
sludge processes, see Table 11.2.
There are other variations of activated sludge processes
such as contact stabilization, step-feed, Kraus and complete,
mix which are discussed in Section 11.9.
QUESTIONS
Write your answers in a notebook and then compare your
‘answers with those on page 82.
11.06 List two methods of supplying oxygen from air to bac
teria in the activated sludge process.
11.0H Write the formuta for calculating sludge age
LOADING - Muss"
mgiliter
‘Step Aeration 40 1000 - 3000
Complete Mix _
Contact Stabiization 02-06 ‘1000 - 3000
Extended Aeration
Oxidation Ditch ees! 0.05 -0.1 3000 - 5000
‘pon the surlace area provided for sedimentation and the rato of studge return as wall as the aeration process.
sn eapacly, nckides both contact and roaeration capacties, Normally
bon
contact zane equals 30 to 35% of
city.
‘+ RECOMMENDED STANDARDS FOR SEWAGE WORKS (10 STATE STANDARDS), Great Lakes-Upper Mississippi River Board of State
Sana Eniears, 1078 Eon, pubtenedy Heat Eason Sarce, PO, Box 728, Ary. NewYork 1224. Pre, 1.75 So
shipping and handing
» fp BoBiday per 1
© 1b BOD per dayiib MLSS ~ kg BOD per day
5 cut % 16.02 = gmvday per cum = Kg/day per 1000 cu m
cr daylkg MLSS
END OF LESGON 1 OF BLESSONS
(Vo! (OLUME
FomM
ACTIVATED SLUDGE tas
Please answer the discus
Continuing with Lesson 2.
lon and review questions before 20 Treatment Plants
DISCUSSION AND REVIEW QUESTIONS
Chapter 11. ACTIVATED SLUDGE
(Lesson 1 of 8 Lessons)
[At the end of each lesson in this chapter you will ind some
discussion and review questions that you should work before
‘continuing. The purpose of these questionsis to indicate to you
how well you understand the material in the lesson.
Write the answors to these questions in your notebook be-
fore continuing, Write the numbers for the correct answers to
‘question 1 on your answer sheet in your notebook.
1. During storms an activated sludge plant wil ceive an i
creased inflow which may cause the folowing problems:
1. Dilution of wastes which makes them easy to treat,
2. Reduced wastewater time in treatment units,
3 Increased amounts of git and sil,
4. Increased organic loading, and
‘5. Fluctuating wastewater temperatures.
Which possible answers are correct?
CHAPTER 11.
2. How can the operator attompt to reduce problems caused
by waste discharges into the collection system?
3. How can maintenance activities in a collection system
‘cause operational problems in an activated sludge treat-
‘ment plant?
4. What can the operator determine trom laboratory test re-
sults on the plant effivent?
5. What are some of the disadvantages of using the BOD test
for operational control?
6. The operator of an activated sludge plant must constantly
review plant records and make appropriate changes to ac
count for seasonal changes. True or False?
7. What is the difference between mechanical aeration and
diffused aeration?
ACTIVATED SLUDGE
OPERATION OF ACTIVATED SLUDGE PLANTS
(Lesson 2 of 8 Lessons)
11.1. AERATION SYSTEMS
11.10 Purpose of Aeration
Aeration serves the dual purpose of providing dissolved
‘oxygen and mixing of the mixed liquor and wastewater in the
aeration tank. Two methods are commonly used to disperse
‘oxygen from the air to the microorganisms — MECHANICAL
‘AERATION and DIFFUSED AERATION. Oxygen also may be
provided to the microorganisms by PURE OXYGEN systems
(Gee Chapter 21, Volume II)
14.11, Mechanical Aeration Systems
‘Surface aerators use a motor-driven rotating impeller (Fig
11.4) of a brush rotor (Volume 1, Chapter 8, Fig. 8.11). Both
devices splash the mixed liquor into the atmosphere above the
‘eration tank, Oxygen transfer to the mixed liquor is achieved
by this method of aeration as the mixed liquor passes through
the atmosphere. Surface aerators either float (for use in aer-
‘ated ponds) or are mounted on supports in or above an aera-
tion basin, In ponds they are equipped with draft tubes to im-
prove their mxing characteristics.
AA surface aerator’s oxygen transfer efficiency is stated in
terms of oxygen transferred per motor horsepower per hour
‘Typical oxygen transier efficiencies are about two to three
‘pounds of oxygen per hour per motor horsepower (1.2 to 1.8
kgihrikW). The oxygen transfer efficiency increases as the
‘submergence of the aerator is increased. However, power
Header A large pipe to
‘costs also increase because more power is required to move
the aerator impeller or agitator through the mixed liquor due to,
‘greater submergence and increased load on the drive motor.
‘The turbine aerator (Volume II}, Chapter 21) Is another type
‘of motor-driven mechanical aerator. Turbine aerators are fe
‘quently used in the complete mix or pure oxygen activated
sludge process. An outside source of air is supplied to the
aerator, usualy from a blower or oxygen-generating system.
‘Turbine aorators aro more efficient and use less horsepower
than standard surface aerators because the extra air supply
¢zeates turbulence inthe inmedate area of he rng a bub-
11.12. Diffused Aeration Systems
Diffused aeration systems are the most common type of
aeration system used in the activated sludge process. A di-
{user breaks up the air stroam from the blowers into fine bub
bles in the mixed liquor. The aeration tank distribution system
‘consists of numerous diffusers attached to the bottom of air
HEADERS? and located near the bottom of the aeration tank.
Ditfusers located in this position maximize the contact time of
the air bubbles with the mixed liquor. Also, this location en-
‘courages mixing and discourages deposits on the tank bottom.
‘Athough diftused aeration is used in the aeration tanks of
activated sludge plants, it may also be found in aerated grit
‘chambers, pre-aeration systems, aerated flow channels, and
return sludge wet wall aeration,
ch the ends ofa series of smaller pipes are connected. Also called @ “maniold.” Activated Sludge 21
Fig. 11.4 Bridge mounted surface aerators. Motor, gear
reducer and impeller shown
(Courant Chin Ban Maal Wat tt) 22. ‘Treatment Plants
11.120 Al Filters
Filters (Fig, 11.5) remove dust, dirt, and grease from air
before it is compressed and sent to the various plant pro-
casses. Clean air is essential for the protection of:
1. Blowers:
‘a. Large objects entering the impellers or lobes may
cause severe damage.
b. Deposits on the impellers or lobes reduce clearances:
land cause excessive wear and vibration problems.
2. Process systems
a. Clean air is required by downstream equipment.
. Clean air prevents fouling of air conduits, pipes, tubing
‘or dispersing devices on difusers.
Tho fters may be constructed of a fiber mesh or metal mesh
material that is sandwiched between a screen material and
encased in a frame. The fiter frames are then installed in a
‘ier chamber.
The process air is usually drawn directy trom the atmos-
phere. Some treatment plants have pre-treatment and primary
treatment process tanks covered for odor control. In plants of
this type, odorous air is also drawn from under these covered
tanks.
11.121 Blowers (Process Alr Compressors) (Figures 11.6
and 11.7)
Blowers are of the positive displacement type or the cen-
tritugal type that provide air to the various plant processes
through a diffuser system. Usually postive displacement blow-
‘ers operate at low RPMs and produce less than 20,000 CFM
(670 cu m/min) while centritugal blowers operate at high RPMs
land produce from 20,000 to 150,000 CFM (570 to 4300 cu
mvmin)
POSITIVE DISPLACEMENT BLOWERS
The positive displacement blower (Fig. 11.8) provides a
constant volume (cubic feet or cubic meters) output of ar por
revolution of the rotors or lobes. Blower output is varied by
‘changing rotor or lobe speed (Revolutions. Per Minute). The
higher the RPM, the greater the alr output. Usually output from
positive displacomert blowers ranges from 100 to 2,000 cubic
feet per minute (cim) (3 to 57 cu mimin). They are installed to
bo operated at a fixed volume output and directly driven by
electric motors through direct coupings or sheaves and belts.
Changes in air volume may be accomplished by changing
sheaves to Increase or decrease blower rotor or lobe rotation
(RPM), thus increasing or decreasing air output
Large positive displacement blowers (2,000 to 20,000 CFM
(57 to 570 cu m/min) also may be driven by internal combus-
tion engines or variable speed electric motors in order to
change blower volume outputs as required in activated sludge
plants. By increasing or decreasing engine or motor RPM, the
positive cisplacement blower output can be increased or de-
creased.
‘The air ines are connected to the blower through a flexible
coupling in order to keep vibration to a minimum and to allow
{or heat expansion. When air is compressed, heat is gener-
ated, thus increasing the discharge temperature as much as
100 degrees F (56°C), or more.
A check valve follows next which prevents the blower from
‘operating in reverse should other blowers in the same system
be operating while this blower is off
‘The discharge line from the blower is equipped with an air
relief valve which protects the blower from excessive back-
pressure and overload. Air relief valves are adjusted by
"weights or springs to open when air pressure exceeds a point
above normal operating range, around 6.0 to 10.0 psi (0.4 to
0.7 kg/sq cm) in most wastewater treatment plants
‘An aie discharge silencer is also installed to provide DEC-
IBEL® noise reduction. Ear protective devices should be wom
when working near noisy blowers.
Tne impellers are machined on all exterior surfaces for
operating at close tolerances; they are statically and dynami
cally balanced. Impeller shafts are made of machined steel
‘and are securely fastened to the impellers. Timing gears aceu-
rately position the impellers,
Lubrication to the gears and bearings is maintained by a
lube oll pump driven from one of the impeller shafts. An oil
pressure gage monitors the system oil pressure. An oil fiter is,
focated in the oll sump to insure that the ols free trom foreign,
materials. An oll level is maintained in the gear housing so that
‘gears and bearings will receive splash lubrication in case of
lube oil pump failure. Air vents are located between the seals,
‘and the impeller chamber to relieve excessive pressure on the
seal.
CENTRIFUGAL BLOWERS
The centitugal blower (Fig. 11.9) is a motor to speed-
increasing gear criven biower thal provides a variable air out-
put. Minimum through maximum air output is controlled by
‘Guide vanes, which are located on the intake side ofthe blower
{nnd are normally positioned manvally by operating personnel
In many plants they also are controled by plant instumenta-
tion by elther dissolved oxygen levels in the aeration tanks or
by pant influent flows,
‘The blower consists of an impeller, VOLUTE'S casing, shatt
‘and bearings, speed-increasing gear box, and an electric
‘motor or internal combustion engine to drive the unit, Air enters
the volute casing through an inlet nozzle and is picked up by
the whiting vanes of the impelior where it is hurled by cen-
trifugal force into the volute casing. Air enters the volute in its
‘smallest section and moves in a circular motion to the largest
‘section of the volute where itis discharged through the dis-
‘charge nozzle.
Air lines are connected to the blower through flexible cou-
plings in order to keep vibration to @ minimum and to allow for
heat expansion. The air suction line is usually equipped with a
manually operated butterfly valve. Air bypass and discharge
Valves are usually electrically or pneumatically operated.
The impeller is machined on all surtaces for operating at
lose tolerances and is statically and dynamically balanced.
‘The impeller shaft is supported in a shaft bearing stand which
contains a thrust bearing and journal bearings.
Decibel A unt fr expressing the relative intensity of sounds on a scale from zero for the average leas! perceptible sound to about 190 for
the average pain level.
'® Volute(vol-LOOT). The spira-shaped casing which surrounds @ pump, blower, or turbine impeller and collects the liquid or gas dis
‘charged by te impeller. Activated Sludge 23
(ae,
* oar
Dust and dirt fiters in after chamber
Grease fiters at a primary sedimentation inlet channel
4. Fitter elements
2, Filter chamber
3. Filtor chamber inlet presoure tube to manometer or wator
‘column gage
Filter chamber outlet pressure tube to manometer or water
‘column gage
‘Manometer on a fiter chamber (not a U-tube manometer)
reading inches of pressure difference
Fig. 11.5 Air Fitors 24 Treatment Plants
2. As the rotors turn away from each other on the inlet side, air 3. The pockets of air along and around the rotor axes, then
{is drawn into pockets formed between the rotors and the join and diminish in volume, thus compressing the air. The
ceasing wal. airflow is smooth and continuous, without pumping or surg-
ing.
Fig. 11.6 How a rotary positive-displacement compressor,
works
(Parmasion of Creag Pane) Activated Sludge 25
Non rubbing labyrinth seals
“Timing gears synchronize ing labyr
the rotors and maintain at each end of both rotors,
close tolerances, Control outleakage.
Holical rotors.
Oil is force-fed to all gears Slingers are used to keep
and bearings by a builtin oil out of the compression
gear pump. chamber.
‘Antirition bearings.
fay view of rotary posttive-displacement
compressor
(aie ot Cg Pome) 26 Treatment Plants
4. motor
2" belts
3. sheaves
'4© airline (suction)
5. airline (discharge)
6. flexible coupling
7. check valve
8. air rolief valve
9. air discharge silencer
10." impellers.
41. lube oll pump
12. ool prassure gage
43. oll fiter
14. il level indicator and reservoir
15. oll seal air vents,
16. inlet valve
17" discharge valve
18. oil temperature gage
19. belt guard
* Not marked on photos
Fig. 11.8 Positive displacement blower Activated Sludge 27
impolier casing
motor
speed increasing gears
guide vanes.
intake nozzle
discharge nozzle
flexible coupling
‘manual suction line valve
bypass valve
10. discharge valve
11. bearing stand
12, main oll pump
13. auxiliary ol pump
14, oil reservoir
15. couplings
Fig. 11.9 Centnfugal blower 28 Treatment Plants.
Lubrication to the bearings and gears is maintained by a
Positive displacement main oll pump that is driven by the
Speed-inoreasing gear unit. An auxikary electrically operated
Centrifugal oll pump also is used to provide all pressure in the
event of failure ofthe main oll pump and to lubricate the blower
shaft bearings before star-up and after shutdown. The oll e-
senoir is located in the blower baseplate. Cartridge type oF
