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Activated Sludge Process Control
Activated Sludge Process Control
2009
PREFACE
The Federal Water Pollution Control Act Amendments of 1972 (Public Law 92-500)
established the National goals to restore and maintain the chemical, physical and
biological integrity of the Nations waters.
In August 1973, the US EPA published its definition of secondary treatment. Three
major effluent parameters were defined: 5 day Biochemical Oxygen Demand (BOD5),
total suspended solids (TSS) and pH. Secondary plants treating municipal wastewater are
limited to 30 mg/L monthly average, 45 mg/L weekly average and 85 percent removal of
BOD5 and TSS.
The BOD determination involves the measurement of the dissolved oxygen used by
microorganisms in the biochemical oxidation of organic matter. The BOD test bottle is
incubated for 5 days at 20oC (see Laboratory Summary Appendix A). A typical BOD
curve is shown in Figure P-1. The BOD5 of secondary effluents consists of two major
components a carbonaceous demand resulting from the oxidation of carbon and a
nitrogenous demand resulting from the oxidation of nitrogen. That is,
BOD5 = CBOD5 + NBOD5
Figure P-1 The BOD curve, (a) Normal curve for oxidation of organic matter, (b) The
influence of nitrification.
Page i
Total solids are defined as all the matter that remains as residue upon evaporation at 103
to 105oC. Total solids can be classified as either suspended solids or filterable solids by
passing a known volume of liquid through a filter. The filter is commonly chosen so that
the minimum diameter of the suspended solids is about 1 micron. The suspended solids
fraction includes the settleable solids that will settle to the bottom of a cone shaped
container (called an Imhoff cone) in a 60 minute period and those solids which are
retained on a filter and heated for one hour at 103-105oC (see Figure P-2).
Page ii
Page iii
TABLE OF CONTENTS
PREFACE ............................................................................................................................. i
TABLE OF CONTENTS ...................................................................................................... 1
LIST OF FIGURES............................................................................................................... 2
SECTION
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
XIV.
XV.
XVI.
XVII.
INTRODUCTION ............................................................................................. 3
FUNDAMENTALS........................................................................................... 3
MICROORGANISMS.......................................................................................15
ACTIVATED SLUDGE PROCESS MODIFICATIONS .................................18
SOLIDS ACCUMULATION ............................................................................22
COMPLETE MIX ACTIVATED SLUDGE EQUATIONS .............................28
SOLIDS SEPARATION....................................................................................32
SOLIDS FLUX THEORY.................................................................................35
MASS BALANCE.............................................................................................42
NITRIFICATION ..............................................................................................46
PROCESS CONTROL WHAT CAN BE CONTROLLED? .........................52
AERATION RATE CONTROL........................................................................54
RETURN SLUDGE RATE CONTROL ...........................................................58
WASTE ACTIVATED SLUDGE CONTROL .................................................64
PROCESS MONITORING ...............................................................................70
TROUBLESHOOTING.....................................................................................76
GLOSSARY ......................................................................................................84
APPENDIXES
A. LABORATORY SUMMARY
B. DESIGN AND OPERATING PARAMETERS
C. THE MICROBIOLOGY OF ACTIVATED SLUDGE
D. ACTIVATED SLUDGE MICROBIOLOGY PROBLEMS AND THEIR CONTROL
E. NUTRIENT DEFICIENCY CALCULATIONS
F. RETURN CHLORINATION (BULKING) CALCUALTIONS
G. SETTLEABILITY TEST PROCEDURES
H. OUR TEST PROCEDURES
I. MICROSCOPIC TEST PROCEDURES
J. ACTIVATED SLUDGE OBSERVATIONS
K. ORP RANGES
L. CORE-TAKER PROCEDURES
M. MCRT RELATIONSHIP TO F/M
N. FINAL CLARIFIER SOLIDS FLUX
O. TROUBLESHOOTING CHARTS
P. TROUBLESHOOTING ACTIVATED SLDUGE PROCESSES
Q. NITRIFICATION SRT CALCULATIONS
R. PROCESS CONTROL CALCULATIONS
S. WET WEATHER OPERATING PLAN
T. SAMPLE MANUAL OF OPERATIONS
U. MICROBIOLOGY FOR WASTEWATER TREATMENT PLANT OPERATORS
V. ALKALINIATY AS A PROCESS CONTROL INDICATOR
Page 1
LIST OF FIGURES
Number
Page
Page 2
I. INTRODUCTION
The activated sludge treatment process was developed in England during the early
1900s. In 1914, H.W. Clarke at the Lawrence Experimental Station, Massachusetts,
studied sewage purification through its aeration in the presence of microorganisms. Dr.
G.S. Fowler (Consulting Chemist, Rivers Committee of Manchester Corporation) during
a visit to the United States observed some of the Lawrence experiments and suggested to
Edward Arden and William Lockett (Davyhulme Sewage Works, Manchester
Corporation) that they carry out similar experiments. Arden and Lockett achieved high
purification levels through the use of an aeration process, which incorporated the
recovery of flocculent solids and their recycle to the aeration stage. Thus, was the
activated sludge method of wastewater treatment born.
Many people feel that the activated sludge process cannot be controlled and will not
perform reliably. Assuming that the plant is adequately designed, properly maintained
and operated, the activated sludge process can and does produce an excellent effluent.
Whenever plant operation or, more specifically, process control is discussed, five
questions are very important:
1.
2.
3.
4.
5.
These Notes on Activated Sludge Process Control are organized to answer these five
questions.
II. FUNDAMENTALS What is the process to be controlled?
Stated in fundamental terms, the activated sludge process simply involves bringing
together wastewater and a mixture of microorganisms under aerobic conditions. The
process is a combination of:
Page 3
Figure 1.01
Before cell respiration and synthesis reactions can take place, the organic material
(soluble or non-settleable particles) must be taken inside the bacterium. This proceeds in
the following manner. First, the external food source comes into contact with the
bacterial cell capsular layer (slime layer). The cell capsular layer provides elementary
cell protection and serves as a depository for both food and waste materials.
Notes on Activated Sludge Process Control
Page 4
Next, the food source reaches the cell wall. The cell wall has been likened to the steel
girders of a building. It provides the cell with its basic shape and as a buildings steel
framework has openings in it as does the cell wall. These openings allow food to pass
through the cells semi-permeable membrane.
It is here that two things can occur:
1. The food can pass through this membrane to the interior of the cell for utilization
without any action by the cell to obtain it (passive transport); or
2. The food can be carried across the semi-permeable membrane (active transport). In
this system the cell produces an enzyme (permease) that passes through the
membrane and attaches to the food. This allows a food that may otherwise by unable
to cross through the semi-permeable membrane to be utilized. The enzyme acts as a
catalyst and is not changed in the transfer of food. Once the food is in the interior of
the cell the enzyme becomes detached and is able to go back for more food. The
permeases produced by cells are specific to certain substrates. Consequently, if the
food cannot by utilized by one cell, it passes from cell to cell until one utilizes it or it
passes out the effluent. This is why a biological system must be acclimated and why
a varied group of microorganisms is required to breakdown a complex mixture of
organic matter such as wastewater.
The conversion step is the second step towards the formation of activated sludge. The
conversion step includes oxidation and synthesis. These two reactions make up the
metabolic process. Metabolism is a life process involving a series of reactions in which
some molecules are broken down and others are being formed. Metabolism can be
divided into two parts: anabolism, or reactions involving the synthesis of compounds, and
catabolism, or reactions involving the breakdown of compounds. Essential protein
molecules which catalyze biochemical reactions are called enzymes. Some enzymes are
within the cell (endocellular) and some are secreted to the outside (exocellular).
For a cell to grow and reproduce it requires a source of energy and carbon for the
synthesis of new cells. If an organism derives its cell carbon from carbon dioxide it is
call autotrophic. If it uses organic carbon it is called heterotrophic. Respiration is the
process of deriving usable energy from high energy molecules. Bacteria capture and store
energy in the chemical bonds of energetic compounds such as adenosine triphosphate
(ATP). ATP is built up in special structures within the cells called mitochondria.
The reactions which take place during respiration are called oxidation-reduction. This
involves the transfer of one or more electrons between two atoms. The first step involves
the loss of an electron and is called an oxidation reaction while the second step involves
the gain of an electron and is called a reduction reaction.
The biodegradation of organic matter found in wastewater by microorganisms has been
viewed as a three-phase process with a portion of the removed organic matter being
oxidized to supply energy and a portion being synthesized to new cells together with a
subsequent oxidation of the new cells. These reactions can be illustrated by the following
equations:
Notes on Activated Sludge Process Control
Page 5
Oxidation
microorganisms
organics + oxygen ---------------------> CO2 + H2O + energy
Synthesis
microorganisms
organics + oxygen + nutrients ----------------------> new cells + CO2 + H2O + nonbiodegradable
soluble
residue
Endogenous Respiration
microorganisms
cell matter + oxygen --------------------> CO2 + H2O + nutrients + energy + nonbiodegradable cell residue
Figure 2.01 further illustrates the synthesis and oxidation of organic matter by
microorganisms and the subsequent endogenous respiration.
The amount of food energy used for energy versus synthesis in the synthesis reaction is
dependent on the composition of the organic matter metabolized. In domestic sewerage
about one-third of the food (organic matter) yields energy and two-thirds of the food
yields new cells.
Page 6
Figure 2.01
Notes on Activated Sludge Process Control
Page 7
MW=160
Synthesis
Endogenous
Respiration
Oxygen Required
(lb O2/lb BOD5 removed)
0.5
1.3
Solids Production
(lb SS/lb BOD5 removed)
0.7
0.14
Page 8
1.0 lb BOD5
1.5 lb BODU
0.5 lb 02
Uptake
+
1.0 lb O2 New Cells
0.7 lb New Cells
0.8 lb O2 Uptake
+
0.2 lb O2 Cell
(0.17 lb Cell Mass)
Figure 2.02
Notes on Activated Sludge Process Control
Page 9
Therefore, an optimum sludge age exists which provide an adequate separation of the
cell mass from the liquid. For a specific system the optimum sludge age can be
determined by plotting the sludge volume index (SVI) versus the sludge age (see Figure
2.03). Figure 2.04 shows the SVI versus the F:M ratio.
In order to better understand the activated sludge process, which normally runs in a
continuous flow mode, it is beneficial to first look at the process in a batch operation.
This is done by taking a container of biologically degradable wastewater and aerating it
with an air stone to provide sufficient oxygen and mixing energy. Measuring the number
of microorganisms at constant time intervals, and plotting these numbers versus time, we
get what is known as the growth curve. The growth curve has five distinct phases (see
Figure 2.05).
These are:
1. Adaptation (Lag) Phase This portion of the curve represents the time
required for the organisms to acclimate themselves to the organic material
present in the wastewater. The numbers of bacteria are not increasing,
however, a shift in the population of the different species of bacteria in the
wastewater is occurring so that the bacteria that can best utilize these organic
materials become predominate.
2. Log Growth Phase Once the bacteria have adapted, only the number of
organisms present limit the rate of growth. Because bacterial cells reproduce
by binary fission (i.e., cell division one cell divides and becomes two, these
two divide and become four, then eight, sixteen ), this is known as
logarithmic growth. Food is not a limiting factor for growth in this phase, that
is, for each cell formed enough food is present to allow it to grow and divide.
3. Declining Growth Phase In this phase food becomes a limiting factor to the
growth of the bacterial cell mass because not every bacterium that is formed
has the food required to grow.
4. Maximum Stationary Phase Here the available food is just sufficient to keep
the cell mass at a constant level with a rate of growth equal to zero.
5. Endogenous (Cell Death) Phase When the supply of food becomes
insufficient to maintain the bacterial mass at a constant level, the
microorganisms are forced to metabolize their own protoplasm.
Microorganisms may be classified according to the source of their energy and carbon
requirements. Chemolithotrophs oxidize inorganic substances for their energy needs,
whereas, chemoorganotrophs oxidize organic substances for their energy. Heterotrophs
use organic substances as a carbon source for making cell materials, whereas, autotrophs
use carbon dioxide as the source of carbon. Most of the microorganisms in activated
sludge are chemoorganotrophic and heterotrophs.
Page 10
Figure 2.03
Page 11
Figure 2.04
Page 12
Figure 2.05
Page 13
There are essential elements required for nutrition and they are often classified as 1)
major elements, 2) minor elements, 3) trace elements and 4) growth factors.
The major elements are carbon, hydrogen, oxygen, nitrogen and phosphorus. The minor
elements are sulfur, potassium, sodium, magnesium, calcium and chlorine. The trace
elements are principally iron, manganese, cobalt, copper, boron, zinc, molybdenum and
aluminum. The growth factors include vitamins and amino acids. Generally, in
municipal wastewater all of the essential elements and growth factors are present. Some
industrial wastewaters may be deficient in nitrogen or phosphorus. As a general rule of
thumb, 5 pounds of nitrogen and 1 pound of phosphorus are required for each 100 pounds
of BOD removed.
Another important classification of microorganisms pertains to their respiration
requirements. Microorganisms may be classified as aerobic, anaerobic or facultative.
In aerobic respiration the hydrogen (or electron) acceptor is molecular oxygen and the
end product is water.
organics + bacteria + O2 -------> more bacteria + CO2 + H2O + end products
In anoxic and anaerobic respiration, the hydrogen (or electron) acceptor is combined
oxygen in the form of radicals (carbonate, nitrate, sulfate and organic compounds) and
the end products (for anaerobic respiration) are methane, ammonia, hydrogen sulfide or a
reduced organic compound.
organics + combined O2 + bacteria --------> more bacteria + CO2 + H2O + end
products
The table below shows the energy released during aerobic, anoxic and anaerobic
respiration. As can be seen, more energy is released during aerobic respiration, therefore,
biochemical reactions will take precedence in the order of most to least energy released.
Electron Acceptor
By-products
Energy Released
O2
CO2
25.3 kcal
Nitrate
N2
23.7 kcal
Sulfate
H2S
1.5 kcal
CO2
CH4
0.9 kcal
All organisms naturally seek conditions yielding the greatest amount of energy for their
life processes.
Notes on Activated Sludge Process Control
Page 14
There are several environmental factors that affect microbial activity. They may be
classified as physical, chemical or biological. Three of the important physical factors are
temperature, osmotic pressure and oxygen/mixing.
Temperature has a tremendous effect on the rate of cell growth. An increase in
temperature of 10oC (within the range of temperature that bacteria can grow) can
approximately double the rate of cell growth and substrate utilization. Microorganisms
may be classified according to their optimum temperature range as psychrophils,
mesophils, and thermophils, which have respective optimum temperature ranges of 0 to
10oC, 10o to 45oC and 45o to 75oC.
Because microorganisms feed by osmosis, the osmotic pressure, which is dependent upon
the salt concentration, must be within a certain range. Most microbes are not affected by
salt concentrations between 500 to 35,000 mg/L. In general, a dissolved oxygen of 1.0 to
2.0 mg/L is best for maintaining efficient, healthy microorganisms. If the D.O. drops
below 1.0 mg/L, and especially below 0.5 mg/L, aerobic treatment efficiency will suffer.
A well-mixed aeration basin will keep the microorganisms in suspension and increase the
contact of the microbes with the food source.
The major chemical factors are 1) pH, 2) the presence of acids and bases, 3) the presence
of oxidizing and reducing agents, 4) the presence of heavy metals, and 5) certain
chemicals.
The pH of the wastewater is important because bacteria grow best in a pH range of 6 to 9.
Outside of this range bacterial growth is inhibited. Bacteria can acclimate to long term
changes in pH and to a certain degree they can buffer the wastewater against variations in
pH because of the production of CO2 in the oxidation of organic matter. However, rapid
changes have severe detrimental impacts on bacterial growth. Toxic substances, (e.g.,
phenol, chlorinated hydrocarbons, heavy metals, halogens, acid and bases, etc.) inhibit
cell growth and substrate utilization even at very low concentrations. In general, the
toxicity of metal ions increases with an increase in atomic weight.
III. MICROORGANISMS
The principal microorganisms involved in the breakdown of organic matter in wastewater
are single-celled bacteria. Other microorganisms of importance in biological treatment
are: fungi, algae, protozoa, rotifers and nematodes. The predominant species are
determined by the characteristics of the influent, the environmental conditions, process
design and mode of operation.
Bacteria are small (0.5 1.0 microns by 1.0 5.0 microns), single-celled protista. They
grow in many shapes: round, rod, spiral, comma or budding. They are either aerobic,
anoxic or anaerobic. The majority of the bacteria in activated sludge are facultative, that
is, they can live in either aerobic or anoxic conditions. The bulk of the bacteria in
activated sludge prefer the pH to be between 6.5 and 9.0. Bacteria adsorb to soluble and
particulate wastewater solids and produce enzymes that break down those solids into
Notes on Activated Sludge Process Control
Page 15
nutrient forms that can be absorbed into the cell. Floc-forming bacteria produce compact
flocs which settle well. Filamentous bacteria grow in either an open or bridging floc
structure. It is important for a strong floc to have some filaments growing through it to
act as a backbone. Excessive growth of filaments is known as filamentous bulking.
Floc-forming and filamentous bacteria compete for food, oxygen and nutrients, but differ
in the way they metabolize these compounds. Floc-forming bacteria prefer short
duration, high doses of food whereas filamentous bacteria prefer steady low doses. Flocforming bacteria can survive and, in some cases, prefer alternating aerobic and anoxic
conditions whereas some filamentous bacteria prefer low concentrations of dissolved
oxygen.
Fungi are multicllular, non-photosynthetic, heterotrophic protista. They are strict aerobes
and must have free dissolved oxygen. They predominate at low nitrogen levels and/or
low oxygen levels and grow well at pH values under 6.0.
Algae are unicellular or multicellular autotrophic, photosynthetic protista. They are more
important in lagoons than in activated sludge treatment plants. However, an
understanding of the biochemical reactions for photosynthesis and respiration can be
beneficial.
Photosynthesis
CO2 + 2H2O --------> CH2O + H2O + O2
Respiration
CH2O + O2 ----------> CO2 + H2O
Protozoa are motile single cell protists. They are several hundred microns in size, tend to
be strict aerobes and are more sensitive to toxic materials. There are many types of
protozoa: amoebae, flagellates, free-swimming ciliates, and stalked ciliates, each working
in its own niche in the biological scheme.
Amoebae are single cells of protoplasm that move slowly in search of food by pushing
protoplasm into areas within the cell membrane called pseudopodia, or false feet. The
testate amoebae are usually associated with nitrified conditions where little unionized
ammonia exists.
Flagellated protozoa are very small and propel themselves using a whip-like appendage
called a flagella. Since they move quickly, their energy requirements are much higher
than amoebae or bacteria. Flagellates predominate when bacteria are dispersed and upon
recovery from a toxic spill.
Free-swimming ciliates are much larger and move around using tiny hair-like structures
called cilia. Bulk liquid free-swimmers are found in poorer effluent conditions and in
Notes on Activated Sludge Process Control
Page 16
activated sludge systems that yield turbid effluents. Crawlers are found in medium aged
activated sludge and are usually associated with better effluent quality.
The stalked ciliates are very energy efficient and are found in high numbers in effluents
of very good quality.
Rotifers are much larger multicellular animals which are generally strict aerobes.
Nematodes and annelids (bristle worms) are multicelluar worms. Nematodes occur in
higher sludge age systems. Bristle worms (and water bears) occur in nitrifying systems.
Page 17
aeration tank
aeration source
clarifier,
recycle, and
waste
Aeration tank. A single tank or multiple tanks designed generally for either complete
mix or plug flow with a detention time of as little as 2 hours and up to over 24 hours.
The contents of the aeration tank are referred to as mixed liquor.
Aeration source. Generally either diffused air or surface mechanical aeration used to
supply oxygen and mix the aeration tank contents.
Clarifier. A settling tank where the mixed liquor solids are separated from the treated
wastewater. Most treatment plants employ several secondary clarifiers.
Recycle. Solids that settle in the clairifier and are returned to the aeration tank.
Waste. Excess solids that must be removed from the system.
There are three classic variations of the activated sludge process high rate, conventional
rate, and extended aeration (see Appendix B).
High rate systems have short-term aeration times (2-4 hours) and higher F:M ratios.
These systems must be operated more carefully because the shorter aeration times make
the system more sensitive to washouts.
Conventional is used to define a system of intermediate loading. Plants operating in the
middle range do not nitrify.
Extended aeration plants are characterized by long aeration time (24 hours), high mixed
liquor concentrations, high sludge retention times, total oxygen requirements are higher
and nitrification may occur. The losses of pin floc and heat are common problems.
Page 18
Figure 4.01
Notes on Activated Sludge Process Control
Page 19
Process loading ranges for the activated sludge process are as follows:
Process
Aeration
(hrs.)
High
2-3
Conventional 4-8
Extended
18-30
BOD
#/1000 cu.ft.
100
30-40
10-20
F/M
Return
%
1.0
0.2-0.5
0.01-0.15
100
25-75
50-100
Within these three loading ranges, the mixing regime and flow patterns can be varied (see
Figure 4.02).
Mixing regime:
The complete mix activated sludge process was developed in 1927 to address high
organic and/or toxic loads. In this system, the characteristics of the mixed liquor
are similar throughout the aeration tank. From an operational point of view, tanks
with detention time of 2 to 4 hours can be considered as complete mix. Since
there is a low level of food available to a large mass, complete mix is able to
handle large surges of organic loading.
Plug flow is defined as flow in which individual particles of feed pass through the
reactor vessel in the same sequence they entered. Long, narrow tanks approach
plug flow. This process was developed in 1917 at the Lawrence Experimental
Station.
Flow variations:
In 1951, Ullrick & Smith developed the contact stabilization process. Contact
stabilization uses a short-term contact tank and a sludge stabilization tank with
about six times the detention time used in the contact tank.
Step feed is a modification of the plug flow configuration in which influent is fed
at two or more points along the length of the aeration tank. This process was
developed in New York City in the mid 1930s.
Step Aeration involves distributing the influent wastewater in a stepwise fashion
from the influent to the effluent end.
Tapered Aeration involves distributing the air proportional according to the air
demands from the influent to the effluent end.
As a general rule, plug flow is used under the most lightly loaded conditions. Step feed is
used as the organic or hydraulic load increases. Contact stabilization is used under peak
hydraulic or organic load.
Notes on Activated Sludge Process Control
Page 20
Figure 4.02
Notes on Activated Sludge Process Control
Page 21
V.
SOLIDS ACCUMULATION
Solids will accumulate in activated sludge systems unless they are constantly wasted.
This accumulation results from: 1) the removal of applied BOD, 2) the production of new
cells through synthesis, and 3) the removal of inert materials. Offsetting this
accumulation are: 1) the endogenous respiration of the new cells, 2) the loss of solids out
the effluent, and 3) intentional wasting.
Mass balances can be used to mathematically define this accumulation. In words, the
equation for mass balance is:
accumulation = inflow outflow + net growth
For solids mass, lbs/day = (flow, mgd)(solids, mg/L)(8.34)
For primary clarifiers, the accumulation of solids is assumed to be zero or the sludge
blanket will increase and the net growth is zero because there is no bio-conversion,
therefore:
inflow = outflow
Q = 1.0 mgd
SS = 200 mg/L
Q = 0.95 mgd
SS = 100 mg/L
Q = 0.05 mgd
SS = 2100 mg/L
For an activated sludge system, the accumulation of biological solids can be expresses as:
accumulation = inflow outflow + net growth endogenous decay
= QXo QX + Um X S - KdX V
Ks + S
where, Kd = endogenous decay coefficient
V= reactor volume
Q = flow rate
Xo = concentration of microorganisms, influent
X = concentration of microorganisms in reactor
Um = maximum specific growth rate
Ks = half velocity constant
S = concentration of the growth-limiting substrate
Page 22
U S
Q
= m Kd
V KS + S
1 Q
=
V
Where = hydraulic detention time
C =
Vx
Qx
U mS
Kd
KS + S
1 Q
=
V
Let
U mS
= Y (F / M )
KS + S
1
= Y (F / M ) K d
c
where,
c = mean cell residence time
Y = sludge yield coefficient
F/M = food to mass ratio
Kd = endogenous coefficient
See Figure 5.01 for a diagram of the derivation of F/M & MCRT relationship.
Note: Growth is related to loading (F/M) and the sludge age. Also control of the F/M
ratio implies control of the sludge age (SRT) and vice versa.
Page 23
1. KINETICS
EXPLAINS BIOCHEMICAL
REACTIONS FOR GROWTH
2. EQUATIONS FOR
GROWTH RATE
STEADY STATE
4. SLUDGE YIELD
5. 1/MCRT = Y F/M - Kd
WHERE:
Figure 5.01
Page 24
Figure 5.02
Figure 5.03
From the relationship above the net growth of biological solids per pound of
organic loading can be given as:
Process
High
Conventional
Extended
lb solids/lb BOD
0.50
0.40 0.50
0.15 0.30
In addition to the net growth of biological solids, activated sludge systems will
accumulate inert solids from the non-biodegradable raw influent TSS. These inert
solids are represented by the inert fraction of the incoming solids and the nonbiodegradable solids (generally 40 percent of the volatile fraction).
Page 25
Example: Calculate the total solids production (accumulation) in a high rate plant.
Given: TSS = 100 lbs/day
VSS = 85 lbs/day
BOD = 100 lbs/day
Solution: Accumulation = net growth + inert + non-biodegradable
100 85
85
(100 lbs / day TSS) + 0.4
(100 lbs / day TSS)
100
100
= 69 lbs / day
An example can be used to illustrate the concepts of sludge inventory, F/M SRT, and
solids production.
Example: Calculate the F/M, SRT, and solids production.
Given: F = 100 lbs/d
M = 300, 100, 1000
Y = 0.55
Kd = 0.02
Solution:
1a) F/M = 100/300 = 0.33
1b) 1/SRT = Y(F/M) Kd
SRT = 1/0.55(0.33) 0.02
SRT = 6.2 days
1c) solids accumulation = Y(F) M(Kd)
= 0.55(100) 300(0.02)
= 49 lbs
Notes on Activated Sludge Process Control
Page 26
Page 27
Fi
Kmt + 1
Where
F
Fi
Km
t
6.1
= unmetabolized BOD in the effluent, mg/L
= influent BOD, mg/L
= metabolism factor, 7.2/hr at 20oC
= raw waste aeration time, hour
The value F represents only the unmetabolized substrate in the effluent and does not
include excess microbial solids carryover.
Effluent BOD is computed from the following equation:
BODeff = F + KbMaeff
where BODeff = BOD in effluent, mg/L
F = unmetabolized BOD from Equation 6-1
Kb = 0.8 (BOD factor)
Maeff = active microbial mass in the effluent, mg/L of VSS
6.2
X Ma
MT
6.3
6.4
John W. Clark, Warren Viessman Jr., Mark J Hammer, Water Supply and Pollution Control, IEP-A DunDonnelley Publisher, 1977
Page 28
KsF
Ke - (1/ts)
6.5
Me = 0.2 KeMats
6.6
Mi = Miinfts/t
6.7
6.8
6.9
Page 29
6.10
Page 30
Figure 6.01
Page 31
VII.
SOLIDS SEPARATION
Q
surface area, ft2
= gpd/ft2
Page 32
Type of Treatment
Primary followed
by secondary
Overflow Rate
(gal/day/ft2)
Average
Peak
800-1200 2000-3000
Solids Loading
(lb/ft2/day)
Average Peak
Depth
(ft)
10-12
600-800
1200-1500
12-15
Activated Sludge
(except extended
aeration)
400-800
1000-2000
20-30
50
12-15
Extended Aeration
200-400
800
5-25
40
12-15
Pure Oxygen
400-800
1000-2000
25-35
50
12-15
Figure 7.01
Page 33
Figure 7.02
Page 34
8.1
Page 35
Figure 8.01
Page 36
solids concentration
temperature
system organic loading
aeration basin DO
8.2
The bulk velocity is a function only of recycle flow rate and, therefore, is a controllable
process variable.
The total flux, as represented in equation 8.3, is the sum of the bulk and settling fluxes.
GT = GS + GB = Ci(vi + u)
8.3
As the sludge thickens from the MLSS concentration to that of the underflow, it passes
through all intervening concentrations. One of these concentrations is critical to clarifier
operation and defines the solids handling capacity or limiting flux, GL. Equation 8.4
defines the applied flux GA which represents the biosolids sent to the clarifier.
GA = Co(QI + QR)/CSA
8.4
Page 37
GB = Ci(u + w)
8.5
where: wastage flow rate (w) is the continuous rate of sludge wastage
The state point method is one of the most useful techniques for evaluating the solids
handling capacity of secondary clarifiers. This method uses a curve representing the
gravitational settling characteristics and two operating lines to define feasible operating
conditions.
The two operating lines constitute a graphical material balance on solids constrained by
the settling characteristics defined by the flux curve. The Y axis of the graph represents
the gravitational flux in lbs/sq.ft.-day. The X axis represents the MLSS concentration in
mg/L. A sample curve is shown in Figure 8.02.
The overflow line begins at the origin and has a slope equal to the plant influent flow rate
(Qi) divided by the clarifier surface area (CSA) on line. The slope is expressed in feet
per day. The overflow rate is the influent flow rate minus the wastage rate divided by the
clarifier surface area on line. Since the wastage rate the generally small in comparison to
the influent flow, the approximation does not cause an appreciable error.
The intersection of overflow rate operating line and a vertical line drawn from the
aeration basin MLSS concentration is known as the state point. The state point acts as a
pivot point for the second operating line. The seconds line represents recycle flow rate
from the clarifier to the aeration basin. The slope of the recycle flow rate operating line
is equal to the negative of the recycle rate (QR) divided by the clarifier surface area on
line, or the negative of the bulk velocity (-u). The intersection of the recycle rate
operating line with the X axis represents the predicted clarifier underflow MLSS
concentration.
The clarifier is under loaded and operates successfully when the shaded area confined by
the two operating lines is completely below the flux curve. The clarifier is overloaded
and solids will be transferred from the aeration basin to the clarifier if a portion of the
shaded area lies above the flux curve. The sludge blanket will rise and the applied flux,
which is directly related to the MLSS concentration, will decrease. After the applied flux
decreases the system will stabilizes with a lower MLSS and a higher sludge blanket.
Operational changes are readily seen by the state point approach. The variation in
influent flow rate is illustrated in Figure 8.03. As the flow rate increases from Q11 to
Q12, the recycle flow operating line moves upward and become critically loaded. An
applied flux greater than these results in the transfer of solids from the aeration tank to
the secondary clarifier. As the flow increase to Q13 the recycle operating line moves
above the flux curve which results in an overloaded clarifier.
The effects of recycle rate changes are illustrated by Figure 8.04. Qr1 depicts the
underloaded condition while Qr2 depicts a critically loaded condition and Qr3 depicts an
Page 38
Figure 8.02
Page 39
40
30
20
10
0
0
10
15
Concentration (g/L)
Figure 8.03
Page 40
40
30
20
10
0
0
10
15
Concentration (g/L)
Figure 8.04
Page 41
overloaded condition. Decreasing the recycle flow rate increases the underflow
concentration and lowers the pumping costs. However, these benefits cause lower
limiting flux thereby less solids handling capacity. Optimizing the performance means
selecting the lowest recycle rate with an acceptable margin of safety.
An increase in organic loading generally means an increase in the MLSS concentration.
The state point analysis can be used to evaluate an increase in the MLSS concentration.
As shown in Figure 8.05 the clarifier goes from an underloaded condition to an
overloaded condition as the MLSS increases. As illustrated the overflow rate line
remains unchanged because the influent flow rate remains the same. Also, the recycle
rate does not change therefore the slope on the recycle operating line remains constant.
However the position of the recycle operating line changes because as the MLSS
increases the state point moves upward.
Many changes can occur that results in deterioration of the sludge settling characteristics
(see Figure 8.06). This deterioration results in changes in the shape and position of the
gravity flux curve. As a result of these changes a clarifier can go from an underloaded to
an overloaded condition at constant MLSS, influent flow and recycle flow (see Figure
8.06).
IX. MASS BALANCE
Where is the Sludge?
How long has it been there?
How much sludge is there?
Sludge Units Definition
Pounds
Concentration X Volume in MG X 8.34
(concentration in mg/L)
Aerator Sludge Inventory (ASI)
ASI, lb = MLSS, mg/L X Volume, MG X 8.34
9.1
9.2
9.3
Page 42
40
30
20
10
0
0
10
15
Concentration (g/L)
Figure 8.05
Page 43
50
45
40
35
30
25
20
15
10
0
0
5,000
10,000
15,000
20,000
25,000
30,000
Figure 8.06
Page 44
9.4
9.5
9.6
9.7
SIL, lb/day = (WSC, mg/L X WSF, MGD X 8.34) + (Q, MGD X TSS, mg/L X 8.34)
Mean Cell Residence Time (MCRT)
MCRT, days = _________TSI, lb_______
WAS, lb/day + ESL, lb/day
9.8
9.9
RSF and WSF are measured separately from the same draw-off point in the clarifier.
SDTc, hours = ____________CSI, lb X 24______________
(RSF + WSF), MGD X RASSS, mg/L X 8.34
9.10
RSF and WSF are measured from separate draw-off points in the clarifier
Page 45
9.11
9.12
Oxidation Pressure
OXP = MLSS, mg/L X SDTa
9.13
X. NITRIFICATION
Nitrogen in the Environment
atmosphere
the Earth's crust
hydrosphere
tissues of living and dead organisms
Nitrogen compounds
Compound
Formula
Oxidation
State
Ammonia
NH3
-3
Ammonium ion
NH4+
-3
Nitrogen gas
N2
Nitrite ion
NO2-
+3
Nitrate ion
NO3-
+5
Fixation: Fixation of nitrogen means the incorporation of inert gaseous nitrogen into a
chemical compound such that it can be used by plants and animals.
N2 ----> biological ----> organic nitrogen
----> lighting -----> nitrate
----> industrial ----> ammonium, nitrate
Notes on Activated Sludge Process Control
Page 46
ammonium
Nitrosomonas nitrate
Nitrobacter nitrite
Nitrogen is most often found in wastewater as ammonia and organic nitrogen in the form
of amines and other nitrogenated compounds. During the wastewater treatment process,
organic nitrogen is converted to ammonia by ammonifying bacteria. Ammonia is
removed in activated sludge processes by 1) stripping to the atmosphere (this can be
significant at pH above 8), 2) assimilation into bacteria cells, and 3) bacterial nitrification
(which may be followed by denitrification). Nitrification is a naturally occurring, twostep aerobic biological process in which autotrophic bacteria oxidize the ammonium ion
to nitrite or nitrate. In the first step, the ammonia is oxidized to nitrite by Nitrosomonas
bacteria.
Step 1:
NH4+ + 3/2 O2 ------> 2H+ + H20 + NO2Oxygen Required = 3.43 lb/lb N oxidized
Alkalinity Required = 7.14 lb/lb N oxidized
Step 2:
Next, the nitrite is oxidized to nitrate by Nitrobacter bacteria.
NO2- + 1/2O2 ------> NO3Notes on Activated Sludge Process Control
Page 47
Page 48
through infiltration and inflow. During the winter, when the ground is frozen, less
nitrifying bacteria will be coming into the system.
Should any of the factors necessary for complete nitrification be missing or in limited
supply, the nitrification cycle may not go to completion during the time the wastewater is
contained in the treatment process. This phenomenon, called "partial nitrification",
leaves ammonia and/or residual nitrite in the effluent. The residual ammonia and nitrite
will exert an oxygen demand during the standard BOD test when sufficient numbers of
nitrifying bacteria are present in the test sample.
Nitrifiers grow slowly compared to most other bacterial populations and therefore must
be retained in the treatment process for a relatively long period of time. The nitrifying
bacteria are mixed together with all other mixed liquor suspended solids. Therefore, their
total retention time in the treatment process is the same as that for the rest of the activated
sludge. The variable describing the total retention time of nitrifiers in the treatment
process if the mean cell residence time (MCRT).
MCRT = Mass of MLSS in the System
Mass of WAS + Mass of Eff. TSS
In treatment processes that include unaerated reactors in addition to aerated reactors, it is
useful to compute the specific amount of time that nitrifiers spend in the aerated reactors.
This is termed the oxic SRT. The equation for computing oxic SRT is:
OXIC SRT =
The appropriate oxic SRT for a treatment process depends on how fast the nitrifiers can
grow under the environmental conditions of the process. As discussed already, important
environmental conditions include dissolved oxygen concentration, pH, and temperature.
(See appendix Q for SRT calculations)
The conditions which promote nitrification in activated sludge treatment systems are:
1.
2.
3.
4.
5.
6.
Denitrification is the biological reduction of nitrate to nitrogen gas. A fairly broad range
of heterotrophic bacteria are involved in the process, requiring an organic carbon source
for energy.
6NO3- + 5CH3OH ---- 5CO2 + 3N2 + 7H2O + 6OH- + cells
Notes on Activated Sludge Process Control
Page 49
Page 50
Organic
Nitrogen
- NH3
Ammonia
Nitrogen
- NH4+
Atmospheric
Nitrogen
- N2
Nitrate
Nitrogen
- NO3-
Nitrite
Nitrogen
- NO2-
Figure 10.01
Page 51
converted to N2. Thus, by monitoring the changes in alkalinity in the influent and
effluent of the aeration basin, it is possible to estimate the extent of nitrification.
Monitoring the pH of the aeration basin and comparing BOD5 results with and without
nitrifying inhibiters can also be used to determine the nitrifying state of the system.
The oxidation-reduction-potential (ORP) relates to measuring the effects of growth. The
ORP uses a pH meter with either a specific ORP probe or a combination pH/ORP probe.
The millivolt scale on the meter indicates ORP. The ORP measures the relative amount
of oxidized versus reduced materials in the system (or capability of the sludge to gain or
release electrons). For instance oxygen or O2 represents the upper end of the oxidation
scale and moves the ORP into the positive or plus range. A positive ORP shows the
system has potential to gain electrons, but nitrate is also an oxidized form of nitrogen and
adds to the positive value. Thus, if there is nitrate and dissolved oxygen available, the
ORP should be positive and large, probably 200-400 mV. Any nitrogen as ammonia will
cause that value to be lower. Any anaerobic conditions will make the value lower yet. A
negative ORP shows the system has electrons to release and contains little dissolved
oxygen or nitrate.
In 1992, Goronszy and his coworkers developed a chart relating the ORP to various
biological processes. Appendix K shows eight different biological growth activities and
the range of ORP within which that activity occurs. For instance oxidation of organic
carbon proceeds when the ORP is between approximately +50 and +225 mV while
nitrification may occur between +100 and +325 mV. If anoxic conditions prevail, the
ORP would range from about -50 and +50 mV. Thus, by periodic readings of the ORP at
the end of the aeration tank and at the clarifier weirs, an operator can tell the amount of
nitrification and denitrification in the aeration tank and clarifier.3
XI. PROCESS CONTROL What can be controlled?
The use of test data in a logical sequence of reactions to modify a process and maintain a
specified result is a process control strategy.
Before we discuss process control strategies, we need to understand that there are many
interrelated factors that limit the performance of wastewater treatment plants.
Performance limiting factors at wastewater treatment facilities can be broadly grouped in
administration, design, operation and maintenance. Administration, design and
maintenance all lead to a plant physically capable of achieving the desired performance.
It is operation, or more specifically the process control that takes a physically capable
plant and produces a good effluent. Figure 11.01 illustrates the relationship between
physical limitations and operations (or process control).
Page 52
Effluent Quality
Environmental Conditions
Capable Plant
Administration
Design
Maintenance
Figure 11.01
Page 53
Page 54
Figure 11.02
Page 55
Figure 11.03
Page 56
required depends on the F:M ratio. At high F:M ratios, the oxygen uptake rate is high
and oxygen is depleted quickly from the bulk solution. This creates oxygen stress and
therefore a higher D.O. residual is required at higher F:M ratios.
If the D.O. drops below 1.0 mg/L and especially below 0.5 mg/L, treatment efficiency
will suffer. On the other hand, if the D.O. is maintained above 2.0 mg/L, a large amount
of power is being wasted. Therefore, careful measurement and control of D.O. in the
aeration tank is necessary.
Most aeration tanks will not have D.O. concentrations that are constant throughout the
tank. There will be locations of high or low D.O. called stratification. Therefore, an
aeration tank D.O. profile is necessary. A D.O. profile should be run 3 to 4 times per
year and should include different times of the day.
Aeration rate control simply means using the D.O. profile information and adjusting the
location of aerators or air flow rates to maintain the desired level of residual D.O.
There are many factors that may affect the oxygen requirements of the microorganisms in
the aeration tank. One of the important relationships is between the influent BOD (food)
and the oxygen demand.
As the influent BOD entering the aeration tank increases, the amount of oxygen required
to maintain a desired level of D.O. also increases.
Another important relationship to remember involves the oxygen demand (utilized) and
the degree of endogenous respiration.
As the endogenous respiration increases (extended aeration), the amount of oxygen
required also increases. In other words, the oxygen uptake rate is decreased, but the total
amount of oxygen increases due to the increased biomass needs for respiration.
The oxygen uptake test is one of the process control tools available to the operator.
Besides monitoring the health of the biomass and its ability to treat wastes, the oxygen
uptake test can also be used to calculate the oxygen consumption of the biomass. The
oxygen consumption can be compared against the capacity of the aeration system. This
may help determine if additional aeration capacity is required or if some other process
adjustment is needed. See Appendix H for OUR/SOUR test procedures.
The fed and unfed tests use the simple OUR test on simulated sludges. Once the two
tests have been completed, a ratio of fed over unfed is calculated. If the ratio is less than
1.0, a toxic effect is shown since the fed would be using oxygen slower than the unfed. A
value of 1-2 is found with very dilute influents or with wastes that contain slowly
degradable materials. A ratio between 2-5 is usually normal for a domestic waste while a
value above 5.0 indicates extremely high loading. Industrial waste can greatly affect this
ratio and their effects must be evaluated on a plant by plant basis. See Appendix H for
fed/unfed test procedures.
Notes on Activated Sludge Process Control
Page 57
The sludge blanket would begin to rise and soon solids would go over the effluent
weirs.
The aeration basin solids level would decrease and result in an insufficient number of
bugs to eat the incoming BOD.
The solids in the final clarifier would quickly become anaerobic.
As you can see, the optimum rate is somewhere between full open and turned off. To
begin discussing return rate control, we need to review typical return rates for various
types of activated sludge processes as a percent of the incoming wastewater flow.
Process
Average
30
Lower
Limit
15
Upper
Limit
75
Conventional
Extended
100
50
200
Contact Stabilization
100
50
150
There are two basic methods for returning sludge to the aeration tank.
Page 58
Adavantage
Disadvantage
1. Simplicity
2. Requires less
operational
time.
Return at a constant
percentage
1. Complexity.
2. Requires more
operational
attention.
For either return flow rate control methods, there are a number to techniques that may be
used to determine the optimum return sludge flow rate. The most commonly used
techniques include:
-
Adavatages
Disadvantages
Sludge Blanket
1. Simplicity
Mass Balance
Settleability/SVI
1. Assumptions
1. Laboratory test
required.
Sludge Quality
1. Opitimize both
1. Laboratory test
Page 59
clarification &
thickening
functions.
State Point Analysis 1. Opitimize both
clarification &
thickening
functions.
required.
1. Complexity
Clarifier Sludge Blanket Depth. Monitoring the depth of the sludge blanket in the
clarifier is both quick and easy. The sludge depth should be checked on a routine basis at
the same time (preferably during the period of maximum flow). The blanket depth
should be kept to less than two feet. The blanket should never be allowed to rise beyond
25% of the nominal sidewall depth of the tank.
Secondary Clarifier Mass Balance. The mass balance approach is useful for calculating
the return sludge flowrate necessary to maintain the solids distribution. However, it does
assume that the system is operating at a steady state and that the sludge blanket in the
secondary clarifier is constant. A side benefit of the mass balance approach is that, in
plants without functioning return sludge metering, the return flow can be estimated from
the measured mixed liquor and return concentrations. The calculations are based on a
mass balance of suspended solids that enter and leave the secondary clarifier.
Solids entering the secondary clarifier can be estimated as:
Solids in, lbs/day = (MLSS)(Q + Qr)(8.34 lbs/gal)
where:
MLSS = mixed liquor suspended solids, mg/L
Q = influent flow, mgd
Qr = return flow, mgd
Assuming negligible solids in the effluent, the solids leaving equals:
Solids out, lbs/day = (RASSS)(8.34 lbs/gal) + (WASSS)(Qw)(8.34 lbs/gal)
where:
RASSS = return sludge suspended solids, mg/L
WASSS = waste sludge suspended solids, mg/L
Qw = waste sludge flow rate, mgd
Mass Balance:
(MLSS)(Q + Qr)(8.34 = (RASSS)(Qr)(8.34) + (WASSS)(Qw)(8.34)
(MLSS)(Q + Qr) = (RASSS)(Qr) + (WASSS)(Qw)
Notes on Activated Sludge Process Control
Page 60
Page 61
Page 62
Figure 13.01
The sludge quality approach is used to establish the proper return rate so the RAS is
removed quickly as well as thickly.
For a slow settling sludge, the optimum settling time is near the inflection point A on the
curve where the increase in concentration begins to diminish. For normal and rapid
settling sludges, the optimum is selected before the break (knee bend) which is shown as
points B and C, respectively.
Steps of Sludge Quality Method
1. Determine the return sludge flow control requirement from the sludge quality and
settled sludge concentration curves.
2. Force the return sludge concentration by proper return sludge flow adjustment to
approach the settled sludge concentration given from the settled sludge concentration
curves. Guideline values:
Rapid 15 30 min. settled sludge concentration (SSC)
Normal 40 60 min. settled sludge concentration (SSC)
Slow 100 140 min. settled sludge concentration (SSC)
The following equation is used to develop settled sludge concentration curves and can be
used to calculate the optimum settled sludge concentration.
Settled Sludge Concentration (SSC) = Aeration Tank Concentration (MLSS) X 1000 ml/l
Settled Sludge Volume (SSV)
Example: Calculate the optimum settled sludge concentration, SSC
Page 63
Given: From the daily settleability curves the optimum settling time is t = 40 min., SSV
at the end of 40 min. = 280 ml/L, ATC = 2500 mg/L, RSC = 8,000 mg/L.
Calculate SSC at 40 min.
SSC40 = (2500)(1000)
280
= 8,930 mg/L
In this example, the actual RSC of 8,000 mg/L is more dilute than the calculated
optimum of 8930 mg/L, therefore, the return sludge flowrate should be decreased to
concentrate the return until it approaches the optimum.
SUMMARY NOTES ON RETURN SLUDGE RATE CONTROL
1. The basic control strategy is: 1) maintain a optimal distribution of solids between the
aeration tank and the secondary clarifier (solids belong in the aeration tank), 2) return
the solids to the aeration tank quickly (avoid anaerobic conditions), and 3) optimize
the sludge concentration (thickly).
2. Check your plants current return sludge flowrate versus typical rates given for your
mode of operation.
3. Select an appropriate control method (i.e., constant rate or constant percentage),
4. All plants should monitor the sludge blankets,
5. Return rate changes should be made whenever: 1) the average daily flow changes, or
2) the sludge settling characteristics change.
6. In most plants, there is a limit to how low the return sludge flowrate can be reduced
before the return sludge piping plugs up.
7. Return sludge flow rate changes should be limited to +/- 15 to 25 percent per day.
8. System response to RAS flow changes are somewhat rapid. Normally, the system
responds within the aeration detention time.
XIV. WASTE ACTIVATED SLUDGE CONTROL
Sludge wasting represents the operators greatest control adjustment. Sludge wasting
affects the following:
-
solids inventory
F/M and Sludge Age
the production of biological solids
oxygen consumption
mixed liquor settleability
nutrient quantities needed
the occurrence of foaming
the possibility of nitrification
Page 64
The fundamental reason that wasting is required in the activated sludge process is the fact
that the net rate of MLSS cell formation exceeds the net rate of MLSS decay.
Accumulation = inflow outflow + netgrowth endogenous decay
These excess solids must be wasted in order to regulate the MLSS inventory at the
desired F/M range. In addition to biological growth, inert non-biodegreable solids from
the raw influent TSS tend to accumulate in the aeration basin and require wasting.
The objective of sludge wasting is to control the wasting rate to maintain steady state. In
other words: wasting equals the accumulation of solids (net growth + inert nonbiodegradable). If sufficient sludge is not wasted intentionally, it will waste itself in the
final effluent until a process equilibrium is reached.
An example can be used to illustrate the concepts of sludge inventory, F/M, SRT and
solids production.
Example: Calculate the F/M, SRT, and solids production.
Given: F = 100 lbs/day
M = 300, 100, 1000 lbs
Y = 0.55
Kd = 0.02
Solution: 1a) F/M = 100
300
= 0.33
1b) 1/SRT = Y(F/M) Kd
SRT =
1
0.55(0.33) 0.02
= 6.2 days
1c) solids accumulation = Y(F) M(Kd)
= 0.55(100) 300(0.02)
= 49 lbs
1d) SRT = M/W
=
300
49
= 6.1 days
2a) F/M = 100
100
Notes on Activated Sludge Process Control
Page 65
= 1.0
2b) SRT =
1
0.5(1.0) 0.02
= 1.9 days
1
0.55(0.1) 0.02
= 28.6 days
Page 66
constant MLSS
constant F/M
constant sludge age (SRT, MCRT)
sludge quality
Page 67
wasting rates. For example: 0.02 units on either side of the target F/M for extended
aeration and 0.05 units on either side for conventional.
The F/M ratio is expressed as:
F/M = influent BOD, lbs/day
solids in the aeration tank, lbs
The example below shows how to calculate the wasting rate, Qw, to operate at a target
F/M.
Given: Target F/M = 0.39
Influent BOD, F = 346 lbs/day
Actual MLSS, M = 1181 lbs/day
MLVSS/MLSS = 0.85
RASSS = 8000 mg/L
Solution:
MLVSS to waste, lbs = actual MLVSS influent BOD
target F/M
= 117 lbs
MLSS to waste = MLVSS to waste
MLVSS/MLSS ratio
117
0.85
= 138 lbs
Constant SRT. The solids retention time (SRT) is widely used and reliable. The SRT is
the average number of days that the microorganisms are kept under aeration. The
expression for SRT is:
SRT = Mass of solids under aeration
Mass of solids leaving the system
The mass of solids leaving the system is defined as:
solids out, lbs/day = SS wasted, lbs/day + SS in effluent, lbs/day
The mass of solids under aeration is given as:
(MLSS, mg/L)(V, mg)(8.34)
The expression for SRT becomes:
Notes on Activated Sludge Process Control
Page 68
SRT = (MLSS)(V)(8.34)
(WASSS)(Qw)(8.34) + (ESS)(Q)(8.34)
where:
WASSS = waste activated sludge suspended solids, mg/L
ESS = effluent suspended solids, mg/L
Qw = waste sludge flow, mgd
Q = influent flow, mgd
MLSS = mixed liquor suspended solids, mg/L
V = aeration tank volume, mg
Re-expressing for formula for SRT and solving for waste sludge, lbs/day.
(ESS)(Q)(8.34)
30
= 139 lbs/day
Qw, gals/day = (139)(1,000,000)
(8000)(8.34)
= 2083 gallons
Sludge Quality Control. Using the sludge quality control method, the aeration tanks and
final clarifiers are studied carefully for informative physical characteristics that help
identify sludge quality and process status. The inferences of these physical findings are
used to supplement the results of the other more specific control methods previously
described. Using an integrated control strategy, the direction and magnitude of the
control adjustments can be made. A basic concept of the method is that the best
performance is achieved by satisfying all interrelated process requirements
Page 69
PROCESS MONITORING
Page 70
Monitoring the process is essential to successful process control. Organized and proper
sampling, measurement, and data collection is used to make proper control decisions.
Monitoring tests are used to evaluate the performance of the system. Monitoring test
include effluent quality test such as BOD and TSS. Process control test include
observations of the aeration tank and secondary clarifiers, flow data, solids
concentrations, sludge quality data, and environmental data. In addition, calculated data
is required for aeration, return sludge and waste sludge (e.g., SRT). Data for plant
process control and monitoring might include the following.
Flow:
- Influent/Effluent
- Return RAS
- Waste (WAS)
- Air
- Recycle Flows
BOD and COD:
- Influent/Effluent
TSS:
-
Influent/Effluent
Observations:
-
Aeration Tank
- Spray patterns
- Flow patterns
- Turbulences
- Color
- Odor
- Foam
Secondary Clarifiers
- Clarity
- Bulking
- Washout
- Clumping/Ashing
- Straggler floc
- Pin floc
Solids concentration:
-
Mixed liquor
Return sludge
Page 71
Waste sludge
Reaeration (for contact stabilization)
Mixed liquor
Return sludge
Turbidity
-
Secondary effluent
Heavy metals
-
Influent/effluent
Influent/effluent
Phosphorus
-
Influent/effluent
Page 72
Alkalinity
-
Influent/Effluent
Note: An alkalinity drop of more than 30 mg/L as CaCO3 usually indicates nitrification.
As you can see there are many process evaluation and control test available to monitor
and control the activated sludge system. The operator must decide which test are
essential, how often to test, where to test and the sample type. Once the test have been
selected, the operator must than identify common ranges or targets for the test data
collected. An example process monitoring plan for a medium size plant (0.5 1.0 mgd)
follows:
Process Mode: Extended Aeration
Log of Events
Loading Data
Avg. Daily BOD
Avg. Daily TSS
Detention Time 20 hrs.
Aeration Tank Loading 10 lbs/1000 ft3
Clarifier Solids Loading 12 lbs/ft2
Clarifier Surface Overflow Rates 220 gal/ft2
Return Rates 100%
Frequency
Location4
Flows:
Influent
RAS
WAS
Recycle
99
99
01/BA
01/BA
1
6
6a
6
CN
CN
ES
ES
50 200%
2700 3300 GPD
-
02/07
02/07
01/01
1,5
1,5
5
CP
CP
CP
Performance:
BOD
TSS
Turbidity
Solids Concentration:
4
See Figure 15.01 for a diagram of the process control test locations.
Page 73
Mixed Liquor
Return Sludge
Waste Sludge
03/07
03/07
03/07
2a,b
6
6a
GR
GR
GR
01/01
01/01
01/01
2a,b
2a,b
2a,b
VI
VI
VI
03/07
03/07
03/07
77/77
77/77
2b
2b
2b
2b
2b
GR
GR
MC
GR
GR
70 - 110
-
02/07
2b
GR
77/77
2a,b
GR
6-12 mgO2/hr/gm
1,5
1
2a,b
GR
GR
GR
1,5
1,5
1
1
GR
GR
GR
GR
2b
GR
1,5
1,5
1,5
1,5
GR
GR
GR
GR
1
2a,b
5
2b, 4
CP
GR
CP
GR
100 mV
Sludge Quality:
Observations
Color
Odor
Foam
Settling Test Data
SSV
SSC
SVI
Settling Velocity
Settling Curve
Microscopic
Examination
Respiration Rate
SOUR
Environmental:
Physical
Temperature
01/07
Salinity
77/77
Oxygen/Mixing
02/07
Chemical
pH
01/01
acidity/alkalinity
77/77
metals
77/77
other
77/77
Biological
microscopic
02/07
Nitrogen (nitrification)
ammonia
77/77
TKN
77/77
nitrite
77/77
nitrate
77/77
Nutrition
BOD/COD/TOC
77/77
Oxygen
02/07
Nitrogen/Phosphorus 77/77
ORP
77/77
Page 74
Aeration:
Observations
Spray Patterns
Flow Patterns
Turbulences
Dissolved Oxygen
Aeration Tank
01/01
01/01
01/01
2a,b
2a,b
2a,b
VI
VI
VI
01/01
2a,b
VI
1 2 mg/L
4
2,4
2,4
2,4
2,4
4
MS
MC
MC
MC
ES
MC
1 2 feet
03/07
77/77
03/07
03/07
2b
2b
2b
2b
MC
MC
MC
ES
05/07
05/07
05/07
05/07
05/07
05/07
05/07
4
4
4
4
4
4
4
VI
VI
VI
VI
VI
VI
VI
Return:
Clarifier Sludge Blanket
05/07
Mass Balance
03/07
Settleability
03/07
SVI
03/07
Sludge Quality
03/07
State Point Analysis 77/77
Sludge Inventory (Wasting):
Constant MLSS
F:M
Sludge Age (MCRT)
Sludge Quality
Secondary Clarifier:
Observations
Clarity
Bulking
Washout
Clumping/Ashing
Straggler Floc
Pin Floc
Gasification
CN = Continuous
ES = Estimate
CP = Composite
VI = Visual
GR = Grab
MC = Math Calculation
99 = Continuous
01/BA = Once per batch
02/07 = Twice per week
Notes on Activated Sludge Process Control
Page 75
Page 76
Figure 15.01
XVI. TROUBLESHOOTING
Good troubleshooting techniques are important for meeting performance objectives in the
most cost effective manner. Troubleshooting is a step-by-step procedure to diagnose and
correct a problem.
Troubleshooting consists of seven major activities:
The first step in troubleshooting is to recognize that there is a problem. All plants should
have Standard Operating Procedures (SOPs) which include procedures for operators to
detect problems. The ability to recognize minor problems and to correct them early can
prevent them from developing into major problems.
Once a problem is detected, an assessment must be made as to its priority over other
existing problems. The three major factors in assigning priorities are seriousness,
urgency, and growth of the problem in terms of impact on process performance or safety
of personnel or equipment.
Gathering facts is a four-step process: stating the problem, defining the boundaries,
noting differences and changes, deciding on cause/effect.
Problem statement. The problem statement should be a precise description of the
problem in terms of observable facts.
Boundary definition. Ask the following types of questions: Where is the problem
observed? When was the problem first detected? What is the extent of the
problem?
Differences and Changes. Note any difference or changes from what is normal.
Cause/effect. Identify probable cause
Page 77
Possible alternative courses of action may be from the following five categories:
contingent, interim, corrective, adaptive and preventive.
Contingent actions. These are taken immediately to minimize the effect of the
problem.
Interim actions. Interim actions are taken while the problem is being solved and
repairs are being made.
Corrective actions. Corrective actions address the cause of the problem.
Adaptive actions. Adaptive actions allow the plant to live with the problem.
Preventive actions. These reduce or eliminate the cause of a problem.
Procedure needs to be established to ensure that facts are recorded so that:
The establishment of a good process control strategy and monitoring program is essential
to troubleshooting the activated sludge process. Before troubleshooting a problem it is
important to review the plants physical capabilities and limitations. A design audit
should be conducted. The design audit should include:
1. Plant loading
a. Organic
b. Hydraulic
c. Industrial
d. Toxic
e. Seasonal variations
f. Infiltration/inflow
g. Return process streams
2. Plant layout
3. Flow measurements
4. Bar Screens
5. Comminutors
6. Grit Removal
7. Primary Clairfiers
8. Aeration
a. Hydraulic detention time
b. BOD loading
c. Oxygen availability
Notes on Activated Sludge Process Control
Page 78
9. Secondary clarifier
a. Surface overflow rates
b. Solids loading rates
c. Depth at weirs
d. Possible RAS flow range
e. Short circuiting
10. Solids handling
Operational problems which are commonly experienced are:
1. Aeration. The operator should observe the entire aeration tank for turbulence.
The extent of turbulence will indicate whether or not all sewage, return sludge,
and mixed liquor are thoroughly mixed throughout the tank.
2. Foaming. The type of foam or scum, if any, accumulated over the aeration tank
surface and to a lesser extent the color of the mixed liquor reveals process status
and indicates generalized long-term sludge wasting requirements.
3. Solids Washout. Excessive solids washout over the final effluent weirs, when the
upper surface of the sludge blanket is more than three feet below the clarifier
surface and when the sludge settles properly in the laboratory, should not be
confused with classic sludge bulking. Solids washout, which differs form classic
sludge bulking, is more frequently caused by hydraulic overloading, toxic
substances (such as high pH, heavy metals, phenols, etc.) or inappropriate
secondary clarifier design.
4. Bulking. Such conditions are evidence by a homegenous appearing sludge
blanket that extends throughout the entire clarifier, and can be observed at the
surface while the mixed liquor solids pour over the final effluent weirs.
5. Clumping/rising sludge. At times, large masses of sludge, possibly one foot in
diameter, may be seen rising, then bursting, and finally spreading over the
clarifier surface.
6. Cloudy secondary effluent. Secondary effluent is cloudy and contains suspended
matter.
7. Ashing. Small particles of ash-like material floating on the surface of the clarifier
and in mixed liquor settleability test.
8. Pinpoint floc. Very small, compact pin floc, usually less than on thirty-second of
an inch in diameter, may be observed suspended throughout moderately turbid
final clarifier tank contents.
9. Straggler floc. Small, almost transparent, very light fluffy, buoyant sludge
particles (one eighth to one-quarter inch in diameter) may be observed rising to
the clarifier surface near the outlet weirs.
The tables in Appendix O list observations, probable causes, necessary checks and
alternatives for these operational problems.
When troubleshooting process problems at an activated sludge plant, it is important to
proceed in an organized manner and to check all of the possibilities.
Page 79
Figure 16.01 shows a diagram of the troubleshooting process. First, the problem(s) are
identified using tools such as brainstorming. Next, a problem is selected and described.
A written statement of the problem is prepared. Baseline data is gathered and
Page 80
Figure 16.01
summarized. Tools include multivoting, selection grid, impact analysis, data-gathering,
run charts, Pareto analysis, and control charts.
Next is the expansion and analysis of the cause. This phase starts with analysis of the
problem from data. A list of the most influential factors is developed and priorities are
identified. The tools for this step include data-gathering, sampling, surveys, Pareto
analysis, fishbone diagram, flow charts, control charts, relationship analysis.
The third step is the expansion and development of the solution(s) and plan. The output
of this phase is a solution(s) to the problem and a plan for implementation. The tools
include technology transfer, cost-benefit analysis, and force field analysis.
The final step is the execution and implementation of the plan. The outputs include
organizational commitment, an executed plan, and a record of the plans impact. The
tools include building individual support, presentations, measuring and monitoring,
descriptive charts, specifications and control limits.
In addition to organizing thoughts on process control figures 11.01 and 11.03 can serve as
a guide to troubleshooting.
The first step is to define the problem in terms of effluent quality. Next, check the
environmental conditions (growth pressures), such as D.O., BOD loading,
MLSS/MLVSS, F:M, temperature, nutrients, toxins, hydraulics (detention time),
alkalinity, ORP, and pH. Next check the process control. This includes good sludge
quality, such as aeration tank/secondary clarifier observations, sludge settling (diluted
settleability), microbiology and respiration rate. Using the microscope check the
viability, floc size, filaments (amount and type), and predominant form of
protozoa/metazoa. And finally check the process control parameters. Check the aeration
tank dissolved oxygen at the inlet/outlet and midpoint. Check the sludge blanket depth.
Check the MLSS, F:M and SRT/MCRT. If the process control looks good, check the
physical capability of the process. This includes administrative, design and maintenance
factors.
Administrative factors include: 1) policies, 2) staffing, and 3) financial. Maintenance
factors include: 1) housekeeping, 2) scheduling & recording, 3) preventive maintenance,
and 4) emergency. See the EPA Handbook on Improving POTW Performance Using the
Composite Correction Program Approach, October 1984.
Problems associated with the activated sludge process can usually be related to four
conditions (Schuyler, 1995). The first is foam, the second is high effluent suspended
solids, the third is high concentrations of soluble materials (BOD and ammonia) and the
fourth is a general problem related to low effluent pH. See Appendix P for a section on
Page 81
Troubleshooting Activated Sludge Processes that was prepared for the Maine DEP and
JETCC by Ronald Schuyler, P.E., Rothberg, Tabburini, and Winsor (RTW).
Blanket Washout
o Controllable Settling
o Uncontrollable Settling
Individual Particle
o Pin-Floc
o Straggler Floc
Controllable Settling
o Hydraulic Overload
o Inadequate sludge return
Uncontrollable Settling
o Good Settling with Diluted Settleometer
Excess old sludge
Glutted system
o Poor Settling with Diluted Settleometer
Bulking
Slime
Filamentous
Filamentous Problems
o Foam Trapping
o Low D.O.
o Low pH
o Nutrient Deficiency
o Sulfides
o Readily Metabolized Substrate
o Slowly Metabolized Substrate
o Surface Seeding
Individual Particle Washout
o Pin Floc
High MCRT
Page 82
Low Effluent pH
Low influent pH
Normal influent pH Nitrification
o Nitrification required
o Nitrification not required
Page 83
XVII. GLOSSARY
Absorption
Accuracy
Acid
Acid-forming bacteria
Acidity
Activated Sludge
Adsorption
Aeration
Page 84
Aeration Period
Aeration Rate
Aerator
Aerobic
Aerobic Digestion
Aerobic Respiration
Air Cleaner
Air Diffusers
Alkaline
Alkalinity
Page 85
Ambient temperature
Anabolism
Anaerobic Respiration
Anoxic
Area
Arithmetic Average
Ashing
Assimilation
Autotroph
Bacteria
Baffle
Barminutor
Page 86
Bar Screen
Base
Billowing Sludge
Biodegradation
Bioflocculation
Biomass
Biosorption
Bulking
Carbonaceous Oxidation
Page 87
Catabolism
Catalyst
Ciliate
Clarifier
Clarifier Sludge Detention Time (CSDT) The time sludge remains in a secondary clarifier.
Clarifier Sludge Flow (CSF)
Colloids
Comminutor
Complete Mix
Page 88
Decant
Deflocculation
Denitrification
Detention Time
Diffuser
Digestion
Dissolved Solids
Endogenous Decay
Page 89
Endogenous Respiration
Enzyme
Extended Aeration
Facultative Organisms
Flocculation
Facultative
Heterotrophic
Page 90
Hydrogen Sulfide
Imhoff Cone
Inorganic
Mechanical Aeration
Mesophilic
Metabolism
Methane
Microonutrients
Microoganisms
Page 91
Mixed Liquor
Mixers
Nematode
Unsegmented worm.
Nitrate
Neutral Solution
Nitrification
Nitrite
Nitrogen
Nutrients
Organic
Organic Loading
Page 92
Organic Nitrogen
Oxidation
Oxygen
Oxygen Utilization
pH
Phosphorus
Photosynthesis
Pin Floc
Plant Balance
Page 93
Pre-Aeration
Precision
Primary Treatement
Process
A sequence of operations.
Process Control
Protoplasm
Protozoa
Microscopic animals.
Reaeration
Recirculation
Page 94
Respiration
Rising Sludge
Rotifer
Secondary Treatment
Sedimentation
Septic
Settleability
Settleable Solids
Settlometer
Page 95
Sewage
Shock Load
Sludge Blanket
Sludge Bulking
Sludge Cycle
Sludge Digestion
Sludge Loading
Page 96
Solids Inventory
Solids Loading
Solids Washout
Sparger
Step Aeration
Straggler Floc
Page 97
Substrate
Synthesis
Tapered Aeration
Thermophilic
Total Solids
Toxic
Ultimate Compaction
Volatile Solids
Wastewater
Page 98
APPENDIX A
LABORATORY SUMMARY
PARAMETER
Biochamical
Oxygen Demand
(BOD), mg/L
[See Appendix W]
HOLDING/SAMPING
24 hr, refrigerate at
4C, grab or
composite
Total Suspended
Solids (TSS), mg/L
7 days, refrigerate
at 4C, grab or
composite
48 hr, refrigerate at
4C, grab
Fecal Coliform
colonies/100mL
30 hr, refrigerate @
4C, grab
Colonies/100 mL
pH
APPARATUS
-300 mL BOD
incubation bottles
-Incubator @ 20C
PROCEDURE
5 days in the dark
@ 20C
COMMENTS
-dilution water
depletion must not
exceed 0.2 mg/L
CALCULATIONS
Settleable Solids
mL/L
E. coli
PRETREATMENT
-pH 6.4 to 7.5
-dechlorinate
- temperature 20C
30 hr, refrigerate @
4C, grab
- well mixed
sample
-dechlorinate if
necessary
-dechlorinate if
necessary
Analysis must be
done immediately,
grab
Total Chlorine
Residual (TRC),
mg/L
Analysis must be
done immediately,
grab
Specific Oxygen
Uptake Rate
(SOUR), (mg/g)/hr
[See Appendix H]
Analysis must be
done immediately,
grab
Settled Sludge
Volume (SSV) mL/L
and Sludge Volume
Index (SVI)
[See Appendix G]
Analysis must be
done immediately,
grab
-filter paper
-filter funnel
-nutrient broth
-culture dishes
-incubator
-filter paper
-filter funnel
-nutrient broth
-culture dishes
-incubator
-pH meter
-spectrophotometer
or colorimeter
-TRC reagents
-adjust temp to
~20C
-oxygenate sample
by vigorous shaking
Dry in oven @
105C 2C until
constant weight is
achieved
Settle for 45 min.,
stir gently, settle
for 15 min. longer
Incubate at 35C
0.5C for 22 to 24
hours
Incubate at 35C
for 2 hrs then at
44.5C for 22 hrs
2 hrs
20 to 80 colony
range desired
Calibrate pH meter
against at least 2
known buffers that
bracket the
expected pH value
-meter must be
accurate to 0.1
units
-sample must fall
between buffer
values
Add reagent to
sample, mix well,
let stand 3-5 min.,
read results
Fill BOD bottle to
overflowing with
sample. Insert
probe and activate
stirrer
Mix sample w/
stirrer, pull striier
gently from
settleometer,
record settled
sludge volume
every 5 min.
20 to 60 colony
range desired
Direct read
Direct read
After DO stabilizes,
read DO level every
minute for 15 min
or until DO <1.0
SVI Calculated from
SSV at 30 minutes
and MLSS
concentration
MLVSS (g / L)
hr
APPENDIX B
DESIGN AND OPERATING PARAMETERS
PARAMETER
CONVENTIONAL
HIGH RATE
ACTIVATED SLUDGE ACTIVATED SLUDGE
EXTENDED
AERATION
CONTACT - STABILIZATION
FORMULA
CONTACT
REAERATION
STEP
AERATION
0.5 - 1.0
3-6
3-6
30 - 70
2,000 3,500
AERATION DETENTION
TIME (hrs)
4-8
2-4
18 - 30
AERATION TANK
ORGANIC LOADING
(lb BOD/1000 cu ft)
25 - 50
50 - 100
5 - 15
MIXED LIQUOR
SUSPENDED SOLIDS
(mg/L)
1,500 3,000
1,200 2,500
2,000 6,000
FOOD-to-MICROORGANSIM
RATIO (F:M)
0.2 - 0.5
0.5 - 1:0
0.02 - 0.10
0.2 0.6
0.2 - 0.5
4 10
2-4
20 - 40
4 - 16
4 - 10
AIR REQUIREMENT
(cu ft/lb BOD REMOVED)
750 1,200
650 - 850
2,000 3,500
750 1,200
600 - 850
AIR APPLIED, cu ft
PRIMARY EFFLUENT. BOD, mg/L)(FLOW, mgd)(8.34 lb/gal)
OXYGEN REQUIREMENT
(lb/lb BOD, REMOVED)
0.8 - 1.1
0.7 - 0,9
1.4 - 1.6
0.8 - 1.2
0.6 - 0.8
7 - 15
15 - 25
3-8
8 - 20
SOLIDS AECUMULATON
RATE (lb/lb BOD REMOVED)
0.7 - 0.9
0.8 1.0
0.65 - O.B
0.9-1.1
0.7 - 0.9
50 150
50 - 150
25 - 110,
50 - 150
50 - 150
RETURN SLUDGE
CONCENTRATION (mg/L)
, 6,000
6,000
7,500
8,000
6,000
RETURN SLUDGE
(% OF INFLUENT)
25 - 75
25 - 100
-50 - zoo
50 - 125
25 - 75
30 - 70
1,000 2,500
4,000 10,000
20 - 30
10 - 30
CLARIFIER OVERFLOW
RATE (gal/sq ft/day)
PRIMARY
FLOW, gal/day
(CKLARIFIER SURFACE AREA, sq ft)l
800-1,200
SECOIWARY
400 - 800
200 - 400
PRIMARY CLARIFIER
DETENT ION TI ME C(hrs)
400 - 800
1-2
(TANK VOLUME, cu ft)(7.5 gal/cu ft)(24 hr/day)
FLOW, gal/day
10 - 12
SECONDARY
1 - 15
CLARIFIER WEIR
LOADING
(gal/ft/day)
SOLIDS LOADING
(lb/day/sq ft)
FLOW, gal/day
(LENGTH OF EFFLUEN WEIR, ft)
20,000
20 30
20 - 30
5 - 25
20 - 30
20 30
Appendix C
Process Control
From: http://dnr.wi.gov/org/water/wm/ww/tech/process.htm
Additional technical assistance with wastewater treatment plant operations is available from the
DNR. Contact Jack Saltes in Madison at (608) 264-6045. For additional help from the DNR, you
might also try the Laboratory Certification Program at
http://www.dnr.state.wi.us/org/es/science/lc/
Bacteria
A growing bacterium has flagella (hair-like structures on the outside of the cell) which
makes it motile, able to move in search of food.
A bacterium reproduces into two bacteria. The cell splits into two smaller cells and this
process occurs over and over again.
When there is very little food available, the bacteria use the limited food to produce energy and
to maintain the cell. Very little is available for growth so less reproduction occurs.
With little food available, and in an attempt to conserve energy, the bacterium loses it
flagella and thus, its motility.
The waste products start to form a thick slime layer outside the cell wall, making the
cells stick together.
The growth characteristics of bacteria are better understood by studying the growth curve.
Lag-phase During this phase bacteria become acclimated to their new surroundings.
They are digesting food, developing enzymes and other things required for growth.
Accelerated Growth-phase The bacteria are growing as fast as they can, since there is
an excess of food. The cells are mostly dispersed, not sticking together.
Declining Growth-phase Reproduction slows down because there is not an excess of
food. A lot of food has been eaten and there are now a large number of bacteria to
compete for remaining food, so the bacteria do not have enough remaining food to keep
the growth rate at a maximum.
Stationary-phase The number of bacteria is the highest possible, but not much food is
left, so the bacteria cannot increase in number. There is some reproduction, but some
cells are also dying, so the number of bacteria remain relatively constant. The bacteria
have now lost their flagella and have a sticky substance covering the outside of the cell,
allowing them to agglomerate into floc. In fact, the floc get big enough that if aeration
and mixing were stopped, the floc could settle to the bottom.
Death-phase The death rate increases with very little if any growth occurring. Therefore,
the total number of living bacteria keeps reducing. The bacteria are just trying to keep
alive.
The Effects of pH
The enzymes which regulate many of the biochemical reaction in bacteria are very pH
dependent. The optimum pH should be between 7.0 and 7.5 for the proper activated sludge
microorganisms to dominate.
The Effects of Temperature
Biochemical reactions are very temperature dependent. Lower temperatures cause such
reactions to be much slower. Thus, more bugs are required to do the same job during the
winter than in the summer.
The Effects of Nutrients
Microorganisms require certain nutrients for growth. The basic nutrients of abundance in normal
raw sewage are carbon (C), nitrogen (N), phosphorus (P), with the ratio of C:N:P ratio
approximately equal to 100:10:1. In addition to C, N, and P, trace amounts of sodium (Na),
Potassium (K), magnesium (Mg), iron (Fe), and many others are required. In normal municipal
sewage, most of these nutrients are provided.
Most problems with nutrient deficiency occur when there is a lot of industrial wastes present.
When proper nutrients are not available, the metabolism fails and a kind of bacterial fat (slime)
will begin to accumulate around the cell. The cell slows down in activity because it cannot
produce enough enzymes and because needed nutrients cannot penetrate the slime layer as
they should. The sludge will not settle and BOD removal slows down.
Amoebae
Amoebae are the most primitive, single-celled protozoans. They move by false feet.
They are frequently present in raw influent, and their presence is short in the aeration
basin. Amoebae can only multiply when there is an abundance of nutrients in the
aeration tank. They move very slowly and it is difficult for them to compete for the
limited amount of food available. They are only dominant in the aeration basin for a
short time.
Amoebae feed on small organic particulates. When amoebae are present in large
numbers in the aeration basin this usually indicates that there has been some sort of
shock loading to the plant (there must be a lot of food available). Their presence may
also indicate that there is a low D.O. environment in the aeration basin, because they
can tolerate very low amounts of D.O.
Flagellates
Most flagellates absorb dissolved nutrients. The appear soon after amoebae begin to
disappear and while there is still high concentrations of soluble food. Flagellates and
bacteria both feed on organic nutrients in the sewage so as the nutrient level declines
they have difficulty out-competing the bacteria for soluble food so, their numbers begin
to decrease.
If large amounts of flagellates are present in the later stages of the activated sludge
development this usually indicates that the wastewater still contains a large amount of
soluble organic nutrients.
Ciliates
Ciliates feed on bacteria, not on dissolved organics. While bacteria and flagellates
compete for dissolved nutrients, ciliates compete with other ciliates and rotifers for
bacteria. The presence of ciliates indicate a good sludge, because they dominate after
the floc has been formed and after most of the organic nutrients have been removed.
o
Nutrition
Most municipal wastewater treatment plants, however dilute, contains sufficient nutrients to
support most of the protozoan associated with wastewater.
Rotifers
Rotifers are rarely found in large numbers in wastewater treatment processes. The principal role
of rotifers is the removal of bacteria and the development of floc. Rotifers contribute to the
removal of effluent turbidity by removing non-flocculated bacteria. Mucous secreted by rotifers
at either the mouth opening or the foot aids in floc formation. Rotifers require a longer time to
become established in the treatment process. Rotifers indicate increasing stabilization of organic
wastes.
Beggiatoa spp is only one filamentous bacterium found in activated sludge that is motile.
Intercellular Granules
Some filaments store by-products as intercellular granules (mostly sulfur granules).
Sulfur granules can be seen very clearly under phase contrast and are found usually in septic
wastes. Sulfur granules are commonly found in Beggiatoa, Thiothrix and type 021N.
Branching
Branching may be "true" or "false". If a filament has true branching the intercellular fluids will
flow freely throughout all the branches of the filament. Intercellular fluids cannot flow through
false branches. In false branching the filament are simply attached to each other simulating a
branch.
There are only two filaments which exhibit branching; one has true branching and the other
false. Nocardia spp has true branching and Sphaerotilus natans exhibits false branching.
Sheath
The cells of some filamentous organisms are contained in a tight fitting sheath. The easiest way
to detect a sheath is to look for "missing spaces" between the cells.
Some filaments which have a sheath are Haliscomenobactor hydrosis, Sphaerotilus natans, type
1701, type 0041, and type 0675.
Attached Growth
Some filaments have bacterial cells attached along the side, perpendicular to the filament.
There are three filaments on which this commonly occurs. Type 0041, type 0675, and type
1701.
Process Control
Microscopic examinations of activated sludge can help to assess the condition of the biomass in
an aeration basin and the settleability of the sludge. It can also aid in the identification of
filamentous bacteria that may cause problems in wastewater treatment plants.
Additional technical assistance with wastewater treatment plant operations is available from the
DNR. Contact Jack Saltes in Madison at (608) 264-8954. For additional help from the DNR, you
might also try the Laboratory Certification Home Page at http://dnr.wi.gov/org/es/science/lc/.
Dispersed Growth
Dispersed growth is a population of bacteria that is suspended in the liquid portion of the mixed
liquor. These bacteria are still growing rapidly and have not begin to flocculate. Most dispersed
growth is bacterial.
Only a little dispersed growth should be present in a properly operating activated sludge
process.
Ciliated protozoa play an important role in the removal of dispersed growth. Dispersed growth is
also removed from the bulk medium by its adsorption to the surface of floc particles.
A significant amount of dispersed growth is present at the start-up of an activated sludge
process. A lot of food is available, and the bacteria are very active and are multiplying rapidly.
The presence of significant or excessive dispersed growth within the mixed liquor can also be
due to the interruption of proper floc formation.
For more information on the interruption of floc formation see, Floc Particles, Sizes & Shapes.
Slime Bulking
Often in industrial and municipal activated sludge processes a nutrient deficiency may occur.
The nutrients that are usually deficient in these processes are either nitrogen or phosphorus.
This deficiency results in the production of nutrient deficient floc particles, loss of settleability,
and, possibly billowy white or greasy gray foam on the surface of the aeration tank.
During a nutrient deficiency, the bacteria within the floc particles remove soluble BOD from the
wastewater. However, when nitrogen or phosphorus is deficient, the soluble BOD is not
degraded but it is stored within the floc particles as an exocellular polymer-like material. This
slimy material interferes with settling and may cause foam upon aeration.
Operational Considerations
The solution usually involves addition of the limiting nutrient, such as ammonia to provide
nitrogen, or phosphoric acid to provide phosphorus. There is usually enough nutrient if the
ammonia plus nitrate in filtered (0.45 um) effluent is greater than 1 mg/L and the soluble
orthophosphate is greater than 0.5 mg/L. However, in cases where easily degradable, soluble
BOD is available, higher N and P concentrations may be necessary.
Toxicity
Toxicity assessment is one of the most valuable applications of microscopic observation
of microorganisms in activate sludge. The higher life forms, particularly the ciliates and
the rotifers, are generally the first to be impacted by toxic materials and may serve in
essence as an in-plant biomonitoring test for toxicants or other adverse stresses.
The first noticeable sign of toxicity or stress is usually the slowing or stopping of cilia
movement for these organisms and small flagellates and ciliates begin to predominate.
This is an indication of the break up of the floc and an over abundance of free bacteria
used by these organism as a food source.
Indications of toxicity upset include:
Loss of the higher life forms in the activated sludge (these are the most toxic
sensitive microbial components).
A dispersed activated sludge biomass with poor floc formation and pin floc.
Unusually low oxygen use, caused by poor biomass growth.
Poor BOD removal.
What can you expect to see under the microscope if toxic conditions exist?
Toxic wastes generally do not favor filaments directly (except in the case of H2S),
rather upset conditions allow filaments to grow.
Microscopic examination of activated sludge can diagnose toxicity, however, this is
usually "after the fact". A better method of toxicity detection is the use of oxygen
uptake rate testing to detect toxicity early and to find the source.
Factors Promoting
Rapid Growth
Low pH
Septic
Wastewater/Sulfides
Microthrix parvicella
Nocardia spp
type 1863
To determine if aeration tank or clarifier foam is due to the growth of foam- producing
filamentous organisms, a sample of fresh foam should be spread thinly and evenly over a clean
microscope slide, and the slide stained by Gram staining.
Microthrix parvicella and Nocardia spp each stain Gram positive (staining purple or dark blue).
Microthrix is a long thin filament while Nocardia is a short branched filament. So, if you have
foam and slide of mixed liquor stains Gram positive, you can easily determine which filament is
responsible.
Type 1863 stains Gram negative (staining pink). Type 1863 is a long filament which looks like a
dashed line.
If the foam is not due to foam-producing filamentous organisms, it may be due to the presence
of a nutrient deficiency. To determine if a nutrient deficiency is the cause of foam production, a
representative sample of mixed liquor should be treated with India ink and examined under
phase contrast microscopy for the presence of nutrient deficient floc particles.
CONTENTS
I.
Introduction
II.
III.
IV.
Summary
V.
INTRODUCTION
Many problems can develop in activated sludge operation that adversely affect effluent quality
with origins in the engineering, hydraulic and microbiological components of the process. The
real "heart" of the activated sludge system is the development and maintenance of a mixed
microbial culture (activated sludge) that treats wastewater and which can be managed. One
definition of a wastewater treatment plant operator is a "bug farmer", one who controls the
aeration basin environment to favor good microbiology.
This paper will discuss the types of microbiological problems that can occur in activated sludge
operation. These include dispersed (non-settleable) growth, pin floc problems, zoogloeal
bulking and foaming, polysaccharide ("slime") bulking and foaming, nitrification and
denitrification problems, toxicity, and filamentous bulking and foaming. The best approach to
troubleshooting the activated sludge process is based on microscopic examination and oxygen
uptake rate (OUR) testing to determine the basic cause of the problem or upset and whether it
is microbiological in nature. These methods are easy, fast and inexpensive compared to other
approaches, and are generally understandable and accepted.
are <50um in diameter. Pin floc occurs most commonly at starvation conditions -- a very low
F/M and long sludge age. Chronic toxicity can also cause a pin floc condition.
Free floating filaments can, at times, cause a dispersed growth problem. Here, the cause is
filament-specific and is the same as for filamentous bulking (discussed below).
Toxicity
Toxic shocks can be a severe problem in activated sludge operation. In a recent study, toxicity
upset was experienced by approximately 10% of 25 Colorado activated sludge plants examined
during one year. Toxicity problems were found to be a larger problem in small communities
compared to larger cities, due to the lack of dilution of toxic releases in small systems.
Examples of toxicity events were the washing of cement or lime trucks to a manhole, dumping of
congealed diesel fuel to the sewer system, and overload of small systems with septage (which
contains a high amount of organic acids and sulfides which can be toxic).
Sulfide toxicity to activated sludge is more common than currently recognized. Sulfide may
originate from outside the activated sludge system, from septic influent wastewater or from
septage disposal, or it may originate "in-house", from anaerobic digester flows or from aeration
basins or primary or final clarifiers with sludge build-up and anaerobic conditions. Hydrogen
sulfide toxicity is highly pH dependent, due to the H2S form being the toxic agent and not HS-.
The pKa for H2S is 7.0, indicating higher toxicity at a pH of 7 or less when H2S is
predominant, and less toxicity as the pH increases above pH 7 and H2S dissociates. One mg/L
of H2S reduces the activated sludge OUR by 50% at pH 7, and the H2S dose to give a 50%
OUR reduction increases to 100 mg/L at pH values above pH 8. It is advised to add lime or
other alkaline agent to the aeration basin to raise the pH to 7.5 or above if sulfide toxicity is
occurring.
Toxicity can be diagnosed microscopically, often in the following sequence:
1.
2.
3.
4.
5.
Toxic wastes generally do not favor filaments directly (except in the case of H2S); rather, upset
conditions allow filaments to proliferate. For example, bulking by Sphaerotilus natans
frequently follows a toxic upset due to a high F/M condition. Here the "true" F/M value may be
many-fold that calculated based on total biomass present, due to low viability of the biomass.
While microscopic observations can diagnose toxicity after the fact, a better method is use of
the OUR test to detect toxicity early.
3
The OUR of an activated sludge fed increasing amounts of a nontoxic waste will initially rise
with increasing waste additions to the test bottle, followed by no further increase in OUR with
even higher waste additions. In contrast, the OUR of an activated sludge fed a toxic waste may
increase initially with increasing waste strength, but will decrease rather dramatically at waste
additions above a toxicity threshold value. A useful definition of microbial "death" is when the
fed OUR is less than the basal endogenous OUR.
The OUR test is simple (all that is required is as a BOD bottle and a dissolved oxygen probe)
and usually takes less than two hours to perform. The normal OUR of the activated sludge must
be known before hand, so run this test periodically to know what is normal for your plant.
Nitrification and Denitrification Problems
Nitrification can create problems in activated sludge operation. Many plants experience an
upset condition with dispersed growth and filamentous bulking every spring when warmer
temperatures induce nitrification. Some plants experience a loss of chlorine disinfection during
nitrification onset, due to a transient period (weeks) of nitrite build-up. Nitrite has a significant
chlorine demand (one part nitrite consumes one part chlorine) while ammonia and nitrate do not.
A large problem in some plants is a low pH (to as low as pH = 6) caused by extensive
nitrification and low wastewater alkalinity. This often causes pin floc and high effluent turbidity.
Some plants reduce aeration to reduce nitrification or add soda ash, lime or magnesium
hydroxide as a source of alkalinity if this becomes a problem. The use of lower dissolved
oxygen concentration (1.0 mg/L or less) to control nitrification is not without the risk of inducing
filamentous bulking by low dissolved oxygen filaments.
Another problem caused by nitrification is denitrification. Here, bacteria common in the
activated sludge floc respire using nitrate in place of free oxygen when it is lacking and release
nitrogen gas as a by-product. This gas is only slightly soluble in water and small nitrogen gas
bubbles form in the activated sludge and cause sludge blanket flotation in the final clarifier. An
indication of the occurrence of denitrification can be obtained by holding the sludge in the
settling test jar for several hours. If the sludge rises ("pops") within 2 hours or less, denitrification
problems may be occurring. Denitrification problems are more prevalent during the warmer
times of the year and can be more severe if a filamentous sludge is present, due to more
extensive entrapment of the nitrogen gas bubbles by a filamentous sludge.
Control of denitrification is either by control of nitrification (reduced sludge age or reduced
aeration); or by reducing denitrification by removing the sludge faster from the final clarifier
(increased RAS rates) or by increasing the dissolved oxygen concentration in the final clarifier.
This can be done by increasing the aeration basin dissolved oxygen concentration especially at
the clarifier end of the aeration basin. One method useful in severe cases is the addition of
hydrogen peroxide as an oxygen source directly to the center well of the final clarifier.
Nitrification and denitrification problems can be particularly troublesome in industrial waste
systems where ammonia is supplemented. Here, inorganic nitrogen (ammonia or nitrate) must be
4
present in the aeration basin at all times to allow proper treatment and to avoid filamentous or
slime bulking but must be kept below approximately 5 mg/L to avoid nitrification-denitrification
problems (low pH and floating sludge). The common practice of batch addition of nutrients to
the aeration basin often leads to denitrification problems due to periods of high nitrate
concentration (above 5 mg/L).
A number of industries, particularly papermills, have experienced a frothy, floating sludge in the
aeration basin. This can lead to a significant amount of the sludge inventory in the foam,
compromising process control. This problem occurs in systems with a high front-end organic
loading and a long hydraulic detention time (2 days or more). Nitrification and denitrification
occur at the back end of the system due to endogenous conditions there and the release of
ammonia from the biomass. Nitrification and denitrification often occur together within the floc,
with no finding of free nitrate when examined.
Filamentous Bulking
Filamentous bulking and foaming are common and serious problems in activated sludge
operation, affecting most activated sludge plants at one time or another. Filamentous bulking is
the number one cause of effluent noncompliance today in the U.S.
An understanding of filamentous bulking and foaming, the causative filaments and their causes
and control, has steadily increased over the past 20 years since Eikelboom and van Buijsen
published their filament identification system in 1981 (Eikelboom and van Buijsen, 1981). This
approach to filament identification has been updated and modified by Jenkins et al. (1993,
2003) and has become used worldwide. Once the causative filaments could be identified, at
least to a recognized type, their causes could be determined and control measures appropriate
to each filament found.
A bulking sludge is defined as one that settles and compacts slowly. An operational definition
often used is a sludge with a sludge volume index (SVI) of >150 ml/g. However, each plant has
a specific SVI value where sludge builds up in the final clarifier and is lost to the final effluent,
which can vary from a SVI <100 ml/g to >300 ml/g, depending on the size and performance of
the final clarifier(s) and hydraulic considerations. Thus, a bulking sludge may or may not lead to
a bulking problem, depending on the specific treatment plant's ability to contain the sludge within
the clarifier.
A certain amount of filamentous bacteria can be beneficial to the activated sludge process. A
lack of filamentous bacteria can lead to small, easily sheared flocs (pin-floc) that settle well but
leave behind a turbid effluent. Filaments serve as a "backbone" to floc structure, allowing the
formation of larger, stronger flocs. The presence of some filaments also serves to catch and hold
small particles during sludge settling, yielding a lower turbidity effluent. It is only when filaments
grow in large amounts (approximately 107 um filaments per gram of activated sludge) that
hindrance in sludge settling and compaction occurs. In concept, bulking can be envisioned as
6
the physical effects of the filaments on the close approach and compaction of the activated
sludge flocs. Depending on the type of filament involved, two forms of interference in sludge
settling occur: (1) interfloc-bridging - where the filaments extend from the floc surface and
physically hold the floc particles apart; and (2) open-floc structure - where the filaments grow
mostly within the floc and the floc grows around and attached to the filaments. Here, the floc
becomes large, irregularly-shaped, and contains substantial internal voids. The untrained
observer often overlooks this latter type of bulking.
A bulking sludge can result in the loss of sludge inventory to the effluent, causing environmental
damage and effluent violations. In severe cases, loss of the sludge inventory can lead to a loss
of the plant's treatment capacity and failure of the process. Additionally, disinfection of the
treated wastewater can become compromised by the excess solids present during bulking. In
less severe cases, bulking leads to excessive return sludge recycle rates and problems in waste
activated sludge disposal. Many problems in waste sludge thickening are really filamentous
bulking problems.
The true incidence of bulking in the U.S. is unknown but has been estimated to affect at least
60% of plants, either continuously or intermittently. Recent work in Colorado suggests that at
least 90% of activated sludge plants experience a bulking episode at least once during the year.
Bulking may be one of the main reasons why approximately 50% of U.S. activated sludge
plants don't consistently meet their effluent discharge standards.
Early microbiological investigations into filamentous organisms found in activated sludge were
hampered by a lack of knowledge concerning the types of filaments that may occur. Usually,
Sphaerotilus natans was diagnosed, often without adequate identification. However, it is now
known that approximately 25 different filamentous bacteria commonly occur in activated sludge
and each may lead to operational problems. D.H. Eikelboom in Holland (Water Research
9:365, 1975) provided a rational basis to "identify" the different filamentous bacteria found in
activated sludge. This identification system is based on filament characteristics as viewed under
phase contrast microscopy for live samples (in situ) and two simple staining reactions: the Gram
and Neisser stain. Each filament can be "classified" using a four-digit code, avoiding the earlier
problems of lack of specific scientific names. This is important as many of the filaments found in
activated sludge have not been isolated in pure culture and hence their identity remains
unknown. As these filaments are isolated and properly named (a current research thrust),
generic names replace the four digit number code. Hence, the current list of filaments is a hybrid
between numbers and genus names. Currently there are 24 recognized filaments (or groups of
related filaments in some cases) that cause activated sludge bulking or foaming. These are given
in Table 1.
CAUSES OF FILAMENTS
A summary of the conditions that cause filament growth and the filaments associated with each
of these conditions is given in Table 2. There are six environments or growth conditions that
cause the overgrowth of filaments in activated sludge. Four of these occur in municipal
wastewater systems while all six occur in industrial wastewater systems, with two specific only
8
to industrial systems (low nutrients and low pH). Many of the filaments have been associated
with other causes in the past, but recent work has indicated the causes given in Table 2 as the
primary reason for their growth. Other modifying conditions may apply to some filaments, and
these are discussed below.
Filaments
Sphaerotilus natans
type 1701
Haliscomenobacter hydrossis
2. Low F/M
type 0041
type 0675
type 1851
type 0803
3. Septicity
type 021N
Thiothrix I and II
Nostocoida limicola I,II,III
type 0914
type 0411
type 0961
type 0581
type 0092
Nocardia spp.
Microthrix parvicella
type 1863
5. Nutrient Deficiency
Nitrogen:
type 021N
Thiothrix I and II
Phosphorus:
6. Low pH
fungi
----------------------------------------------------------------------------------------------Note that H. hydrossis was previously listed as a low F/M filament. This filament is caused by
low DO, but grows relatively slowly and only occurs at lower F/M and a longer sludge age.
Lower F/M is not its cause, only where it occurs.
9
Six specific causes of filament growth and bulking are currently recognized (see Table 2). The
information in Table 2 is now used in reverse to the way that it was developed -- from the
identification of the most significant filaments present in a bulking sludge, the "cause" for such
growth can be determined. Note that some filaments have more than one cause as shown in
Table 2. The combination of conditions listed may favor bulking by a particular filament more
so than any single condition. It is important to perform filament identification early in a bulking
episode to identify the causative filament. Once bulking continues for some time, process upset
can lead to the proliferation of other filament types (secondary filaments) which can confuse
diagnosis of the real cause.
Today, many activated sludge plants regularly monitor the occurrence and abundance of
filaments in their sludge, which has become an important process control tool. This often leads
to "heading off" a bulking episode before it becomes serious. Since the microbial population in
activated sludge changes slowly in most cases, generally requiring 2-3 sludge ages to radically
change, this microscopic observation needs to be performed only at weekly intervals. However,
during a period of bulking onset or during application of remedial actions such as chlorination,
daily observation of the activated sludge is warranted.
Filamentous Foaming
A brief review of activated sludge foams and their causes is given in Table 3. Use of
microscopic examination can readily diagnose most of these, particularly when filaments are
involved.
Cause(s)
low cell residence time or "young" sludge
(startup foam)
once common due to nonbiodegradable
detergents (now uncommon)
excessive fines recycle from other
processes (e.g. anaerobic digesters)
denitrification
nutrient-deficient foam; foam consists
of polysaccharide material released
from the floc
filament-induced foaming, caused by
Nocardia, Microthrix or type 1863
10
Three filamentous organisms can cause activated sludge foaming: Nocardia and Microthrix
parvicella (commonly), and type 1863 (rarely). Nocardial foaming appears to be the most
common and occurs at approximately 40% of activated sludge plants in the U.S.
Nocardial foam occurs as a thick, stable, brown foam or "scum" inches to many feet thick on
aeration basin and final clarifier surfaces. Normal scum traps (too small) and water sprays (too
weak) may be useless to control this type of foam. This foam consists of activated sludge solids
(flocs) containing large amounts of Nocardia filaments growing from their surface and is quite
stable, compared to most other foams, due to the physical "interlocking" of the Nocardia
filaments. These foams are easy to diagnose microscopically - they are dominated by branched,
Gram positive filaments and a simple Gram stain of the foam is all that is needed. The analysis
should include comparison to the underlying MLSS (prepare both samples for Gram staining on
the same slide). A true Nocardial foam will contain 10-100 fold more Nocardia than the
underlying MLSS. Nocardial foams also contain substantial lipid concentrations (hexane
extractable), up to 40% of dry weight versus 5-10% for Nocardia-free activated sludge solids
(whether this lipid content of foams is due to the Nocardia themselves or to entrapped grease
and fat is not clear). In addition, these foams contain significant entrapped air, with a bulk
density of approximately 7 g/cc.
Nocardial foams occur in all types of plants, with no particular association with specific modes
of operation or aeration. These foams may be more severe in plants with fine bubble or jet
aeration and in oxygen activated sludge plants. These foams also occur equally in plants treating
domestic, industrial and mixed wastes. Industrial wastes promoting Nocardia growth (and
foaming) include dairy, meat and slaughterhouse, food processing, pharmaceutical, and any
others that contain a significant amount of grease, oil or fat. Nocardial foaming is also associated
with high-density restaurant operation in recreational areas (e.g. ski resorts and summer camps).
Nocardial foaming has been observed to be caused by treatment of locomotive and truck
washing wastes.
Severe Nocardial foams cause a number of operational problems. These include aesthetics,
odors, and safety hazards if they overflow basins to cover walkways and handrails. In cold
weather these foams can freeze, necessitating "pick and shovel" removal. Foam may escape to
the effluent, increasing effluent suspended solids and compromising disinfection. In covered
aeration basins, foam can accumulate to exceed the available hydraulic head for gravity flow of
wastewater through the basin. Process control can be compromised if a significant fraction of a
plant's solids inventory is present in the non-circulating foam (e.g. up to 40% of the total solids
inventory can be present in such foams and process control calculations may not be correct).
There should be some concern expressed for the handling of Nocardial foams. The most
common Nocardia species found in such foams, such as N. amarae, are not pathogenic to
laboratory animals; however, other less frequently isolated actinomycete strains are known
opportunistic human pathogens (e.g. N. caviae, N. brasiliensis, N. asteroides and strains of
Mycobacterium). No actual infection has been documented, however, treatment plant workers
and nearby residents may be at risk.
11
12
Chlorination
Two toxicants, chlorine and hydrogen peroxide, have been used successfully to control
filamentous organisms and stop a bulking episode. Chlorine is most widely used as it is
inexpensive and available on-site at most plants, and only this will be discussed here.
Chlorination for bulking control is widespread, used by more than 50% of plants.
The goal of chlorination is to expose the activated sludge to sufficient chlorine to damage
filaments extending from the floc surface while leaving organisms within the floc largely
untouched. Filamentous and floc-forming bacteria do not appear to significantly differ in their
chlorine susceptibility. Chlorine dosage is adjusted such that its concentration is lethal at the floc
surface but is sublethal within the floc, due to chlorine consumption as it penetrates into the floc.
This is analogous to "peeling an orange" and removing the filaments attached to its surface. It
should be pointed out that chlorination is not a cure-all for all activated sludge microbiological
problems. Chlorination will actually make problems worse if the problem is non-filamentous,
e.g. slime bulking or poor floc development.
Chlorine can be applied from a chlorinator using chlorine gas feed or as a liquid hypochlorite. A
separate chlorinator should be dedicated to bulking control and an independent rotameter and
sampling point in this chlorine line is needed. The chlorine addition point is of most importance
and should be at a point where the sludge is concentrated, raw wastes are at a minimum, and at
13
a point of good mixing. Poor initial mixing results in the consumption of large amounts of
chlorine without bulking control. Three common chlorine addition points are: (1) into the RAS
stream at a point of turbulence (elbows in pipes; into the volute or discharge of RAS pumps;
and into and below the liquid level in a riser tube of an airlift RAS pump); (2) directly into the
final clarifier center well or feed channel; and (3) in an installed sidestream where the MLSS is
pumped from and returned to the aeration basin.
Chlorine addition to the RAS line(s) is the method of choice and most generally successful.
Chlorine addition to the aeration basin usually does not work and often causes floc dispersion
and system damage.
The two most important parameters are chlorine dosage and frequency of exposure of the
activated sludge to chlorine. Chlorine dose is measured conveniently on the basis of sludge
inventory in the plant termed the overall chlorine mass dose. Effective chlorine dosages
usually are in the range 1-10 pounds chlorine/1000 pounds MLVSS inventory/day (2-4 should
work). Chlorine dosage should be started low and increased until effective. Sludge settleability
usually improves within 1-3 days if the correct chlorine dosage is applied.
Most domestic waste plants can achieve a frequency of exposure of the activated sludge
inventory to chlorine of three or greater per day (the optimum) in the RAS line. The needed
frequency is a function of the relative growth rates and efficiencies of kill of filamentous and
floc-forming organisms. Success has been achieved at frequencies as low as one per day but
not less, however, this is plant specific.
In plants with long aeration basin hydraulic residence times (industrial waste plants), the daily
solids flux in the RAS line is generally too low for successful bulking control using chlorine at this
point alone. Here, most success has been achieved using multiple chlorine addition points such
as the RAS line(s) and the final clarifier(s) in combination.
A target SVI value (or other sludge settling measure) must be set and chlorine applied only
when this value is exceeded. This is determined by trial-and-error at each plant. It should be
remembered that chlorination controls filament extension from the floc surface and merely
reduces the symptoms of bulking. Filaments will regroup rapidly, often with a vengeance, after
termination of chlorination since the cause of the bulking has not been addressed.
Signs of over chlorination are a turbid (milky) effluent, a significant increase in effluent TSS, a
loss of the higher life forms (protozoa), and a reduction in BOD removal. It is normal to see a
small increase in effluent suspended solids and BOD5 when using chlorine for bulking control.
Microscopic examination of the activated sludge during chlorination is recommended to control
chlorine application. Chlorine effects on filaments include, in order: a loss of intracellular sulfur
granules (in those filaments that have these); cell deformity and cytoplasm shrinkage; and finally
filament breakup. For sheathed filaments, the sheath is not destroyed by chlorine. Here, sludge
settle ability remains poor until the sheaths are washed out of the system by sludge wasting,
which can take 1-2 sludge ages. Chlorine use should be stopped when only empty sheaths
remain and not continued until the SVI falls, which can result in over chlorination. As a general
14
observation, chlorination should be stopped when about 70% of the cells are damaged or
missing in a filament.
One argument to chlorine use in bulking control is the possibility of the production of
chlorination by-products. This is unlikely since the chlorine is short-lived in activated sludge
(minutes) and applied at a low dosage (lower than used in effluent disinfection). Chlorine cannot
be used if waste constituents react with chlorine to form by-products such as petrol-chemical or
phenol wastes.
15
using one of the readily available HACH Chemical Co. test kits. A hydrogen sulfide
concentration >1-2 mg/L causes the growth of type 021N and Thiothrix I and II.
Note that some of the filaments now listed as septicity filaments (i.e. type 0961, type 0581 and
type 0092) were previously listed as low F/M filaments. It has been learned that these filaments
are actually caused by septicity and organic acids, but these grow slowly and only occur at a
lower F/M. Low F/M is not their cause, only where they occur.
There is some selection of these filaments according to the type of organic acids present. Type
021N and Thiothrix I and II prefer simple organic acids such as acetic, propionic and butyric
acids. Type 0581 and type 0092 appear to prefer higher carbon number and more complex
organic acids. For example, type 0092 is a particular problem when the wastewater contains
citric acid from industry.
Influent wastewater septicity can be treated by pre-aeration (which releases odors), chemical
oxidation (chlorine, hydrogen peroxide, or potassium permanganate), or chemical precipitation
(ferric chloride). Septicity in the collection system can be prevented by addition of sodium
nitrate as an oxygen source (commercially available as Bioxide).
If the influent wastewater septicity cannot be reduced, then the aeration basin can be configured
to allow better treatment of organic acids and sulfides. The organic acid concentration and
sulfide concentration in contact with the biomass can be reduced by using completely-mixed or
step-fed aeration basin conditions. A plug flow aeration basin configuration or a sequencing
batch reactor is the worse case for this condition.
Filamentous bulking by the low F/M filaments is most common in completely-mixed aeration
basin systems at low aeration basin substrate (BOD) concentration. Intermittently-fed and
plug-flow systems are more resistant to this type of bulking. This observation has lead to the use
of selectors where the RAS and the influent wastewater mix for a short time prior to the main
aeration basin.
A selector is a mixing basin or channel where RAS and influent wastes mix prior to the aeration
basin. Selector design is empirical at this time. Successful examples involve a 15-30 minute
contact time of the RAS and influent waste; are aerated; and achieve at least an 80% removal of
soluble BOD5 through the selector. Several newer designs are either operated anoxic (no free
oxygen but nitrate present) or anaerobic, however, these are too new to state their general
usefulness. Design and operation of selectors for filament control is beyond the scope of this
paper, and the interested reader is directed to Jenkins et al. (1993, 2003) for further
information.
A selector can be too large or too small in size to properly function. The goal is to provide a
short term, high substrate condition which favors certain floc-formers but which discourages
filaments. These floc-formers appear to rapidly store BOD as cellular storage products in the
selector, which they use later for growth in the main aeration basin (they pack their own "lunch
bags" in the selector). If the selector is too large, the substrate concentration achieved may not
be high enough to encourage these special floc-formers and discourage filaments. If too small,
insufficient time may be available for substrate uptake and storage. Also, a selector that is too
small may cause the floc-formers to shunt carbonaceous substrate to exocellular polymer that
can increase the SVI of the sludge ("slime bulking") and pose problems in waste sludge
dewatering. The best approach is to try several selector sizes, using a larger basin or channel
with movable baffles or exit gates.
Selectors are specific tools to combat low F/M filaments and are not needed by all plants.
There have been many instances of inappropriate selector use where they actually made the
problem worse, for example, where bulking was caused by low DO, nutrient deficiency or
septicity.
Nutrient Deficiency
Nitrogen and phosphorus can be growth limiting if not present in sufficient amounts in influent
wastewater, a problem with industrial wastes and not domestic wastes. In general, a
BOD5:N:P weight ratio in the wastewater of 100:5:1 is needed for complete BOD removal.
Other nutrients such as iron or sulfur have been reported as limiting to activated sludge, but this
is not common.
Signs of nutrient deficiency include: filamentous bulking by several specific filaments (see Table
2); a viscous activated sludge which exhibits significant polysaccharide ("slime") when "stained"
with India ink; and foam on the aeration basin which contains a high amount of polysaccharide
(which has surface active properties). One check for nutrient deficiency is to be sure that at
18
least 1.0 mg/L total inorganic nitrogen (TIN = ammonia plus nitrite plus nitrate) and 0.5 - 1.0
mg/L ortho-phosphorus (soluble phosphorus) remain in the effluent at all times. The best
location to test for nutrient residuals is the feed from the aeration basin to the final clarifier(s).
Sometimes nutrients are released from the sludge at endogenous conditions in the final
clarifier(s), falsely elevating the effluent nutrient concentrations.
If needed, nutrients should be dosed to the incoming wastewater or the aeration basin.
Nitrogen sources include: anhydrous ammonia, urea, and ammonium salts ((NH4)2SO4,
NH4Cl or NH4NO3). Both ammonia and nitrate are nitrogen sources for growth. Phosphorus
sources include: H3PO4, Na2PO4 and (NH4)2PO4 (among others).
In systems treating mixed domestic and industrial wastes, only total inorganic nitrogen (TIN) and
soluble ortho-phosphorus should be used to calculate nutrient availability. Organically
combined nitrogen and phosphorus (Kjeldahl nitrogen and total phosphorus) may not be
hydrolyzed fast enough by the microorganisms in the activated sludge to keep pace with BOD
use. Also, the nutrient addition rate should match the influent BOD strength as much as
possible, as short term BOD spikes can cause an aeration basin to become nutrient limited for
short time periods (which can cause bulking) even though the 24-hour average BOD:N:P ratio
is satisfactory.
Foaming Control
Three filaments cause foaming: Nocardia, M. parvicella and type 1863. All of these filaments
grow on grease and oil, and these can become a problem when grease and oil are high in
amount in the influent wastewater. Systems that lack primary clarification (the main grease and
oil removal mechanism) appear to suffer more foaming problems. Communities with enforced
grease and fat ordinances appear to suffer less from foaming problems. Also, disposal of
septage, which contains substantial grease and oil content, to small activated sludge systems has
been associated with foaming problems.
Note that Nocardia here is used as a group name rather than a specific species. Recent work
has shown that a number of actinomycetes can cause foaming and include Nocardia amarae,
N. pinensis, N. rhodochrus and other Nocardia-like species. These are often collectively
referred to as the Nocardioforms, or the foam-causing actinomycetes.
Nocardia and M. parvicella also occur at a longer sludge age. The sludge age at which these
filaments can be controlled is a function of the wastewater temperature, being lower at higher
temperature. Nocardia appears to be favored at higher aeration basin temperatures and M.
parvicella at lower aeration basin temperatures. Nocardia can usually be controlled by a
sludge age below 6-8 days and M. parvicella at a sludge age below 8-10 days at moderate
wastewater temperatures. However, many plants have had to reduce the sludge age to less than
2 days for Nocardia control, and this may be inconsistent with other process goals, such as
nitrification or sludge handling capability.
19
A third factor in the growth of Nocardia and M. parvicella is septicity or low oxygen
conditions. Note that the combination of grease and oil, longer sludge age, and septicity or low
oxygen conditions is needed for these filaments to overgrow the system and cause foaming. In
this regard, Nocardia and M. parvicella can be considered low DO filaments, although low
DO per sec doesnt cause them without the other two factors.
Nocardia and M. parvicella appear to grow better on unsaturated fatty acids in comparison to
saturated fatty acids. A change in the US diet from saturated to unsaturated fatty acids is one
reason why foaming by these bacteria is more prevalent today than it was 20-30 years ago.
Also, anaerobic bacteria break down fatty acids by first modifying them to an unsaturated form.
This may be why septicity is one of the causes for these bacteria, providing them with a source
of unsaturated fatty acids.
Type 1863 differs in growing at a low sludge age, usually less than 3-4 days. It indicates a high
amount of grease and oil and a young sludge condition. Many type 1863 foaming episodes have
been caused by a reduction in primary clarification when units were removed from service for
repair or cleaning and grease and oil concentration increased in the aeration system.
Control of Nocardia and M. parvicvella foaming is difficult. Chemical antifoam agents have not
proven generally effective, probably because these act on chemical surfactants and not on a
solids-stabilized foam. Many plants reduce aeration to control foaming, but process
performance may suffer if oxygen becomes limiting. Further, low oxygen-induced bulking may
occur when this is done.
Physical control of foams is most widely practiced using enlarged surface scum traps and
forceful water sprays (often containing 50 mg/L chlorine). Many foams reach problem levels
because they build up on these surfaces and are not removed. Foam should be removed
entirely from the system and not recycled back into the plant, for example, into the headworks.
Foam disposal into aerobic or anaerobic digesters can result in foaming there, so this should be
avoided.
Return sludge chlorination has not eliminated Nocardia, although it often helps, due to
Nocardia's growth mostly within the activated sludge flocs where it isn't readily contacted by
chlorine. Also, much of the Nocardia may be present on the aeration basin surface and this
doesnt go through the RAS line to see chlorine. RAS chlorination is more useful for foams
caused by M. parvicella.
Many anaerobic digester foaming incidents may be attributed to treatment of
Nocardia-containing waste activated sludge. A nationwide survey in 1981 by the American
Society of Civil Engineers revealed that as many as half of the anaerobic digesters in use had
experienced foaming at one time or another. It was recently reported that 54% of 26 California
activated sludge plants surveyed had recently experienced anaerobic digester foaming (Van
Niekerk et al.,JWPCF 59:249, 1987). Here, it is important to remember that Nocardia cells
float, dead or alive, due to their hydrophobic cell surface. Even though Nocardia are strict
aerobes, their cells are readily floated and cause foaming even under anaerobic conditions.
20
Nocardia and M. parvicella are controlled by addressing all three causative factors above. A
reduction in the grease and oil content of the wastewater is needed, either through source
control or improved operation of the primary clarifier (if present) to better remove grease and
oil. These filaments are usually controlled by a reduction in the system sludge age as given
above. Septicity, if present, needs to be controlled, and the aeration basin DO concentration
should be raised. Note that higher aeration causes more foam formation, due to the physical
action of more air present. Many operators reduce aeration when foaming occurs to reduce the
foam, but this only causes more filament growth in the long term.
SUMMARY
Most activated sludge upsets and loss of process control are caused by one of several
microbiological problems which include poor floc formation, pin floc, dispersed growth,
filamentous and slime bulking, filamentous foaming, zoogloeal bulking, nitrification and
denitrification problems and toxicity. Use of the microscopic examination and the OUR test are
invaluable tools in troubleshooting the activated sludge process. Once the cause of the problem
or upset is known, specific remedies appropriate for the problem can be used. Short term
control methods such as chlorination are often used to quickly stop a bulking problem.
However, the best approach is to investigate the long-term control methods suitable for the
problem that is occurring to achieve trouble free operation.
Eikelboom, D.H and van Buijsen, H.J.J., Microscopic Sludge Investigation Manual, TNO
Res. Inst. for Env. Hygiene, Delft, The Netherlands, 1981.
Jenkins, D., M. G. Richard and G.T. Daigger, Manual on the Causes and Control of
Activated Sludge Bulking and Foaming, 2nd Ed., Lewis Publishers, Boca Raton, FL, 1993;
3rd Ed., 2003.
Activated Sludge Microbiology, M.G. Richard, Water Environment Federation, Alexandria,
VA, 1989.
Palm, J.C., D. Jenkins and D.S. Parker, Relationship Between Organic Loading, Dissolved
Oxygen Concentration and Sludge Settleability in the Completely-Mixed Activated Sludge
Process, J. Water Poll. Control Fed. 52:2484, 1980.
Walker, I. and M. Davis, The Relationship Between Viability and Respiration Rate in the
Activated Sludge Process, Water Research: 575, 1977.
21
APPENDIX E
NUTRIENT DEFICIENCY CALCULATIONS
(Source: WEF Manual of Practice OM-9)
A nutrient deficiency will sometimes cause a filamentous bulking problem. The following example
shows how to find out if there is a nutrient deficiency, and how to calculate the amount of nutrients
to add to correct the problem. Once the chemical feed rate (in lb/day) is determined, the chemical
must be fed into the secondary influent, preferably in proportion to the flow. The chemical feed
equipment must be set to feed the calculated amount of nutrient during the 24-hour period.
Example A. Calculate the amount of nutrients to add to correct a nutrient deficiency.
Given: Secondary influent BOD5 = 170mg/L
Secondary influent TKN = 4.5 mg/L
Secondary influent P = 1.0 mg/L Secondary
influent Fe = 0.5 mg/L
Suggested ratio by weight, BOD5/N = 100/5 = 20
Suggested ratio by weight, BOD5/P = 100/1 = 100
Suggested ratio by weight, BOD5/Fe = 100/0.5 := 200
Average daily plant flow, Q = 7.5 mgd
Ammonia/nitrogen atomic weight ratio, NH3/N =17/14 = 1.2
Trisodium phosphate/phosphorus atomic weight ratio, Na3PO4/P = 164/31 = 5.3
Ferric chloride/iron atomic weight ratio, FeCl/Fe = 162.5/56 = 2.9
Solution
Step 1. Calculate the amount of nutrients needed to achieve the suggested ratios.
Nutrient needed, mg/L =
N needed, mg/L
BOD5 mg/L
Suggested ratio, BOD/N
BOD5 mg/L
Suggested ratio, BOD/P
BOD5 mg/L
Suggested ratio, BOD/Fe
= 170/20
= 8.5 mg/L
P needed, mg/L
= 170/100
= 1.7mg/L
Fe needed, mg/L
= 170/200
= 0.85 mg/L
Step 2. Calculate the difference between the nutrients available and the nutrients needed. If this answer is
zero or a negative number, there is no shortage and no nutrients need be added.
Nutrient shortage, mg/L = (Nutrient needed, mg/L) - (Nutrient available, mg/L)
N shortage, mg/L
P shortage, mg/L
8.5-4.5
4.0mg/L
1.7 -1.0
0.7 mg/L
Fe shortage, mg/L =
0.85 - 0.5
0.35 mg/L
P to add, Ib/day
Fe to add, lb/day
(4)(7.5)(8.34)
250 Ib/day
(0.7)(7.5)(8.34)
43.8 Ib/day
Step 4. Calculate the weight of the commercial chemical to be added per day to supply the needed
nutrients.
Chemical, lb/day = (Nutrient to add, Ib/day)(Atomic wt ratio) (1 00%)
For anhydrous ammonia commercial grade solution 80% concentration
Anhydrous ammonia, Ib/day = (N to add, Ib/day)(I.2 NH3/N)(80% concentration)
=
(250)(1.2)(100) 100
375lb/day
(43.8)(5.3)(100)
75
310 Ib/day
(21.9)(2.9)000)
39
163 lb/day
APPENDIX F
mg/L X 8.34 =
MLSS Conc.
1000# MLSS
(2)
8.34 =
Return Sludge Flow
RSSS Conc
(4)
5. Calculate frequency of exposure:
divided by
=
(#4)
(#1)
lbs RSSS
Times/day
(5)
Appendix G
Settleability Test Procedures
further compaction?
floating sludge?
Leave on bench and check after 4 hours
Do you observe floating sludge?
Rise in 0.5-1.0 hour indicates significant nitrification/denitrification
No rise in four hours means little nitrification/denitrification
7. Record results in log or on bench sheet
Graph readings, settled sludge volume, ssv in ml, versus time, in minutes
Locate knee of curve to determine the theoretical optimum settling time
SVI=
SSV30 1,000
mg/ g
MLSSmg/ L
SSV
mL/Liter
SSC
mg/L
COMMENTS
OBSERVATIONS
Fill In (a)
10
15
20
25
Fill in (b)
30
40
50
60
90
120
150
180
240
SST: Settled Sludge Time
SSV: Settled Sludge Volume
SSC: Settled Sludge Concentration
MLSS: Mixed Liquor Suspended SOlids
SSC=
MLSS 1000
SSV
SVI=
SSV30 1000
MLSS
Sludge Settleability Chart
1000
900
800
700
600
500
400
300
200
100
0
5
10
15
20
25
30
40
60
90
APPENDIX H
OUR TEST PROCEDURES
(Source Ronald Schuyler, P.E.)
Procedure
1. Measure and record DO and temperature at the sample site.
2. Collect 3-4 liters of fresh sample. Aeration tank effluent and/or influent end after RAS
has mixed with the aeration influent flow.
3. Pour some mixed liquor in the beaker so that when the BOD bottle is placed in the
beaker, the mixed liquor will come up to the neck of the bottle.
4. Thoroughly mix the sample remove an aliquot and aerate it to get the DO above 5 mg/L.
this may be done by filling a 1 liter bottle half full of mixed liquor and shaking the bottle
gently to aerate the sample
5. Fill a 300 ml sample bottle. Fill to overflowing. Some bubbles will gather at the top.
Tilt the BOD bottle to work the bubbles out of the sample.
6. Place the BOD bottle in the beaker. Be sure the mixed liquor level in the beaker remains
just below the neck of the BOD bottle.
7. Place the DO probe in the bottle, making sure not to trap any bubbles. Begin stirring the
sample. Allow a short time (30 60 seconds) for the temperature and the probe to
stabilize.
8. Record the DO every minute for 10 minutes, or until the DO drop becomes consistent or
until the DO drops below 1 mg/L. Make sure that there is at least 1 mg/L difference
between the start and finish of the test.
Note: If the OUR is extremely high values may have to be read every 30 seconds and the initial
DO may have to be increased to 7-8 mg/L. If that does not provide a satisfactory test dilute the
sample with BOD dilution water, reaerate the sample and complete the test again. Calculate the
appropriate dilution factor to obtain the OUR of the original sample.
OUR calculation
1. Graph the results by plotting DO (in mg/L) on the vertical axis and time (in minutes) on
the horizontal axis.
2. Graph the line of best fit of the data. The line should be nearly straight. If there are data
at the beginning and/or end of the test that are significantly different from the straight
line, disregard that data. The straight line represents the actual microorganism activity.
3. Determine the slope of the line. Pick the points at the beginning and end of the straight
line portion. Divide the change in DO between those two points by the change in
minutes between those two points.
4. OUR = DO/Time = mg/L/min if the time is in minutes
5. Multiply by 60 min/hr to get the results in mg O2/L/hr
SOUR calculations and Interpretation
Required Information
OUR of the sample
MLSS or MLVSS of the same sample
Calculation
SOUR = OUR mg/L/hr 1000 mg/g
MLVSS, mg/L
Interpretation
Modification
Conventional Activated Sludge
Step Aeration
Extended Aeration
Contact Stabilization
Aerobic Digestion
SOUR Range
8-20 mg O2/hr/g VSS
8-20 mg O2/hr/g VSS
3-12 O2/hr/g VSS
15-30/5-15 O2/hr/g VSS
<2 O2/hr/g VSS
Values outside these ranges are not necessarily a problem since your plant may work will at a
higher or lower SOUR. However, they would normally mean that one should begin looking for
potential problems.
The fed and unfed tests use the simple OUR test on simulated sludges. A fake activated sludge
is developed to simulate conditions at the influent end of the aeration tank. It is a fake tests
because of the difficulty of collecting a truly mixed sample at that point. Since the results of the
tests must relate to each other, the unfed test uses the same organisms for a fake test to
simulate the conditions at the effluent end of the aeration tank. The unfed test indicates how
active the microorganisms area at rest (endogenous respiration conditions) while the fed test
shows the microorganism activity after feeding.
The fed test mixes the correct amount of influent with an amount of return activated sludge to
simulate the MLSS concentration in the aeration tank. The unfed test mixes unchlorinated final
effluent with the RAS to achieve the same MLSS concentration. The normal OUR test is then
done on each sample. The correct volume of RAS in mL is calculated by:
mL of RAS = MLSS in Aeration Tank 300 mL
MLSS of RAS
Once the two tests have been completed, a ratio of the fed to unfed OUR is calculated. If the
ratio is less than 1.0, there is probably some toxic material in the influent, because the bugs in the
fed sample should be using oxygen at a higher rate than the bugs in the unfed sample. A value of
1.0 to 2.0 is found with very dilute influent samples or waste that contains slowly degradable
materials. A ratio of 2.0 to 5.0 is normal for domestic wastewater, while a ration of greater then
5.0 indicates extremely high loading.
Fed/Unfed Ratios for Domestic Watsewater
<1.0
1.0 2.0
2.0 5.0
>5.0
Toxic effect
Dilute load or hard to stabilize material
Normal
Very high organic load for the MLSS available
Unfed Sample
Time
DO (mg/L)
(min)
Sample Temperature C
Begin ____ End _____
Fed
OUR (mg/L hr) ________
Comments: ___________________________________
4
OUR mg ?L /hr =
(DO 1 DO 2 )
60
T2 T1 )
OUR 1000
SOUR =
MLVSSmg /L
APPENDIX I
MICROSCOPIC TEST PROCEDURES
Count =
2+
5+
5+
2 + etc.
Amoeboids
Flagellates
Free Swimming
Cilliates
Stalked
Cilliates
Rotifers
Filaments
Other
Relative Predominance:
1.
2.
3.
4.
5.
Observation:
10
Total
MICROSCOPIC EXAM
APPENDIX J
ACTIVATED SLUDGE OBSERVATIONS
Characteristics of
Foam
Odor
Comments
Final Clarifiers
Color
Clarity
Appearance
Bulking
Solids Washout
Clumping
Ashing
Straggler Floc
Pin Floc
Comments
TUE
WED
THU
FRI
SAT
SUN
APPENDIX K
ORP Ranges (mV)
APPENDIX L
CORE TAKER PROCEDURES
APPENDIX M
MCRT RELATIONSHIP TO F/M
(Source Bill Olver, P.E.)
APPENDIX N
FINAL CLARIFIER SOLIDS FLUX
(Source: Bill Olver, P.E.)
SOLIDSFLUX =
SOLIDSFLUX=
SOLIDSAPPLIED
TOCLARIFIER
(LBS/DAY
CLARIFIER
AREA(SF)
(INFLUENT
FLOW+ RASFLOW)
MGD MLSSmg?L 8.34
CLARIFIER
AREA(SF)
APPENDIX O
Troubleshooting Charts
Aeration Problems
Observation
Probable Cause
Check
Alternatives
1. Repair as required.
A. Underaeration.
1. Increase aeration.
Probable Cause
Check
Alternatives
1. Check MLSS.
1. Check manufacturer's
recommendation for minimum
submergence
Foaming Problems
Observation
Probable Cause
Check
Alternatives
foam
Probable Cause
Check
Alternatives
1.
a.
b.
c.
d:
1.
a.
b.
c.
d:
1. Check:
a. Secondary influent for oil &
grease.
b. Primary scum collection system.
Probable Cause
Check
Alternatives
Solids Washout
Observation
Probable Cause
Check
Alternatives
A. Equipment malfunctions.
C. Temperature currents.
Probable Cause
Check
Alternatives
Bulking sludge
Observation
Probable Cause
Check
Alternatives
1.
a.
b.
c.
d.
e.
Bulking sludge
Observation
Probable Cause
Check
Alternatives
Clumping/Rising sludge
Observation
Probable Cause
Check
Alternatives
A. Denitrification in clarifier.
Probable Cause
Check
Alternatives
2. Check
process.
recycled
digester
'
Probable Cause
Check
Alternatives
Probable Cause
Check
Alternatives
1.
a.
b.
c.
d.
A. Beginning of denitrification.
1.
a.
b.
c.
d.
Probable Cause
Check
Alternatives
1.
a.
b.
c.
d.
APPENDIX P
TROUBLESHOOTING ACTIVATED SLUDGE PROCESSES
(Source: Ronald Schuyler, P.E.)
Introduction
Review of the literature shows that the activated sludge process has experienced operational problems
since its inception. Although they did not experience settling problems with their activated sludge, Ardern
and Lockett (Ardern and Lockett, 1914a) did note increased turbidity and reduced nitrification with
reduced temperatures. By the early 1920s continuous-flow systems were having to deal with the scourge
of activated sludge, bulking (Ardem and Lockett, 1914b, Martin 1927) and effluent suspended solids
problems. Martin (1927) also describes effluent quality problems due to toxic and/or high-organicstrength industrial wastes. Oxygen demanding materials would bleedthrough the process. More recently,
Jenkins, Richard and Daigger (1993) discussed severe foaming problems in activated sludge systems.
Experience shows that controlling the activated sludge process is still difficult for many plants in the
United States. However, improved process control can be obtained by systematically looking at the
problems and their potential causes. Once the cause is defined, control actions can be initiated to
eliminate the problem.
Problems associated with the activated sludge process can usually be related to four conditions
(Schuyler, 1995). Any of these can occur by themselves or with any of the other conditions. The first is
foam. So much foam can accumulate that it becomes a safety problem by spilling out onto walkways. It
becomes a regulatory problem as it spills from clarifier surfaces into the effluent.
The second, high effluent suspended solids, can be caused by many things. It is the most common
problem found in activated sludge systems. Sometimes a suspended solids problem carries with it a
particulate-matter BOD problem if the effluent TSS gets quite high. Ordinarily, one mg/L of effluent
TSS produces about 0.5 mglL BOD5 At low values of BOD5 plus TSS, the sum of the soluble BOD5
and BOD from TSS values often equals the TSS value.
The third is high concentrations of soluble materials traveling through the system and not being
properly treated. BOD bleed-through is rare in domestic treatment systems where
problems are usually related to particulate BOD contained in suspended solids. However, excess
ammonia can often appear in domestic effluents. BOD bleed-through is much more common in industrial
systems or combined domestic/industrial systems where slowlymetabolized compounds cannot be
stabilized in a short detention-time activated sludge system.
The fourth general problem relates to low effluent pH. It is found most often in geographical areas
with naturally low-alkalinity water supplies where extended aeration and/or nitrification processes are
used. It is usually fairly easy to control. However, the problem can also be caused by low influent pH
and control may be more difficult.
Schuyler (1995) has identified 32 different conditions for one of these four effluent problems to exist.
These are shown in the following two-page troubleshooting guide. There are probably many other
situations, but these represent the vast majority of the significant problems. The following discussion
addresses each of those 32 conditions and the process control changes that should be made to eliminate
the problem. While using this chart, it must be remembered that elimination of one problem may allow
another problem to show up. Further, one condition may overshadow another such that the second
condition cannot be observed until the first is eliminated. Finally, it is difficult to precisely defme
control actions relative to specific numbers, such as an MCRT of 5 days or a return rate of 25 percent of
Q. Therefore, most control actions are discussed relative to the direction iliat change is needed. For
instance, for condition 23, the control action is to decrease wasting and return. The actual amount
depends on actual conditions and cannot be specified here. A plastic laminated wall chart is available
from Rothberg, Tamburini, & Winsor, Inc.
Excess Foam
Conditions 1 through 5 relate to excess foam in the system (Jenkins, et al., 1993). When considering
foam problems the question must be asked, "Is the amount of foam that exists a problem?" If it is not a
problem, the situation may be better left unresolved. Many people observe foam and consider it a
problem when it is not. For instance, a dark leathery Nocardia foam may look bad on an aeration tank
but may not be affecting effluent quality. However, the situation may arise where someone's boss or the
public thinks it's a problem; then it becomes the operator's problem.
would be to develop a selector section that could operate anaerobically, anoxic ally, or
aerobically. Jenkins, et aI. (1993), indicate that any of the three types of selectors will work on
low DO filaments.
Condition 12 - Low pH
Growth of fungi is common in the fruit processing industry where a low pH exists along with a
high sugar concentration. To get rid of low pH bulking, the objective is to increase the pH by
adding either a caustic solution or a buffer solution to increase the alkalinity. A possibly better
alternative is to provide pretreatment to eliminate the low pH initially. A third process control
change would involve decreasing any nitrification that is occurring, since nitrification tends to
depress aeration tank pH. Or as a related solution, increase denitrification in the aeration tank to
increase alkalinity and pH.
Condition 13 - Nutrient Deficiency Bulking
Types 021N, 0041, 0675, and Thiothrix have been known to cause bulking when deficient in
either nitrogen or phosphorus (Jenkins, et aI., 1993). The control objective is to increase
nutrients so the ammonia plus nitrite plus nitrate is greater than 1 mg/L in the effluent, and
phosphate is greater than 0.5 mglL in the effluent.
Condition 14 - Sulfide Bulking
Thiothrix, Beggiatoa, and types 02IN and 0914 oxidize sulfide into elemental sulfur, depositing
sulfur granules within the cell (Jenkins, et aI., 1993). The control objective is to remove the
source of the sulfide. Preaeration oxidizes the sulfide so it is not available to the filaments.
Better aeration and mixing help if the sulfide is being formed in the treatment process itself.
There is also the possibility that addition of iron compounds such as ferric chloride or ferrous
sulfate would chemically bind the sulfide, making it unavailable for the microorganisms.
Condition 15 - Readily Metabolized Substrate Bulking
Types 1851, 021N, Nostocoida limicola, H. hydrossis, S. natans, and Thiothrix species all can
rapidly metabolize short-chain organic acids (Jenkins, et al., 1993). Industrial systems may
receive organic acids directly in the influent and biological nutrient removal (BNR) systems may
produce those acids, as do anaerobic selectors. The control objective is to remove the organic
acid source either through pretreatment or installation of an appropriate selector (aerated, anoxic,
or anaerobic).
Condition 16 - Slowly Metabolized Substrate
Types 0041, 0675, and 0092 along with M. parvicellaare known to grow well on slowly
metabolized food. There are no real answers to controlling this growth to date, but it appears
that maintaining good mixing and proper dissolved oxygen throughout the aeration process
helps. These are also associated with older sludges. Therefore, reducing MCRT often reduces
their growth.
Low Effluent pH
The last general condition that requires consideration is low effluent pH, conditions 30-32. It is
usually caused by one of two reasons, low influent pH or low alkalinity water with nitrification.
Either can cause regulatory noncompliance.
Condition 30. If the influent pH is low (acidic), there is a good chance that the condition will go
through the plant and show-up in the effluent. Chemical addition to raise the pH is the immediate
solution. Lime, soda ash, or sodium bicarbonate are normally used for pH adjustment. However,
the ultimate solution is to eliminate the low pH source from the collection system by enforcing
pretreatment requirements. An industrial system may have to live with pH adjustment.
Condition 31. If the influent pH is satisfactory, then the low effluent pH is usually caused by
nitrification in combination with low natural alkalinity in the wastewater. If ammonia removal is
required, then nitrification must continue. Use of on/off aeration or provision for an anoxic zone
often returns enough alkalinity to satisfactorily raise the pH. However, if neither of these is
possible, then pH adjustment similar to Condition 30 may be required.
Condition 32. With satisfactory influent pH near 7.0 and nitrification not required, the MCRT or
DO can often be reduced enough to inhibit nitrification. With no nitrification, there is no
alkalinity reduction through the aeration process and the pH remains stable. However, in
systems that naturally nitrify, such as extended aeration, a solution for Condition 31 may have
to be applied, if MCRT and DO control cannot provide a solution.
References
Ardem, E. and W. T. Lockett. 1914a. Experiments on the oxidation of sewage without the aid
of filters. J. Soc. 01 Chemical Industry (England), 33:523-539.
Ardem, E. and W. T. Lockett. 1914b. The oxidation of sewage without the aid of filters.
Part II. J. Soc. of Chern Industry (England), 33: 1122-1124.
Martin, A. J. 1927. The Activated Sludge Process. MacDonald and Evans, London.
Jenkins, D., M. G. Richard and G. T. Daigger. 1993. Manual on the Causes and Control of
Activated Sludge Bulking and Foaming. Lewis Publishers, Inc., Chelsea, MI.
Schuyler, R.G. 1995. Activated Sludge Process Control Troubleshooting Chart.
Rothberg, Tamburini and Winsor, Inc., 1600 Stout Street, Suite 1800, Denver, CO 802023126.
APPENDIX Q
Calculations of Target MCRT for Nitrification
(Source: Sterns & Wheeler for New York Department of Conservation)
APPENDIX R
PROCESS CONTROL CALCULATIONS
QMGD MLSSmg/ L
1,000 ,000
MLSSmg/ L
SVI
Qr =
Where:
Qr =
Q =
MLSS
SVI =
MLSSmg/ L
Qr =
RASSSmg/ L
MLSSmg/ L
1
RASSSmg/ L
Qr =
QMGD MLSSmg/ L
RASSSmg/ l MLSSmg/ L
QW inMLVSS= ActualLMLSS
BODinf
TargetF : M
Where:
= Waste sludge flow in pounds
QW
MLVSS = Mixed Liquor Volatile Suspended Solids in mg/L
F:M = Food to Microorganism Ratio = Influent BOD in pounds
MLVSS in pounds
QW =
(MLSS) Va 8 .34
ESS Q 8 .34
T arget SRT
Where:
QW
MLSS
VA
ESS
=
=
=
=
1. Waste sludge control has two goals: 1) to remove tha excess accumulation of sludge in the system;
and, 2) to maintain the good sludge quality.
2. System response to waste activated sludge changes are normally slow; usually from 1 to 2 SRTs.
3. Waste sludge changes should be limited to 15% per day.
APPENDIX S
Wet Weather Operating Plan Guidelines
A wet weather operating plan is intended to provide operators with a guide to minimize the discharge of pollutants
during wet weather and to protect their facilities from upset.
A. Key Elements. Every wet weather operating plan should contain the following key elements:
Goals of the Plan. The goals section will define the overall objectives of the wet weather operating plan with
respect to protecting water quality and plant performance.
Critical Components. The plan should list the critical components of the collection and treatment system that
significantly impact wet weather performance. For each critical component, specific objectives should be
defined.
Operating Guidelines. For each critical component, the plan will contain step by step guidance for operation,
maintenance, and management procedures to be followed before, during and after a wet weather event.
List of Contacts. The plan should contain a list of important contacts that may be of assistance during wet
weather events.
1.
Goals of the Plan. The goals of the plan should define the water quality objectives of the collection and
treatment system. For most systems with combined sewer overflows, operating decisions made during wet
weather events can affect how much flow is treated at the wastewater treatment plant and how much flow is
bypassed through CSOs. Difficult decisions must be made rapidly. These decisions may affect water quality in
the receiving water at the CSOs, water quality in the receiving water at the plant, and performance of the plant
during and after the wet weather event. Well defined goals for receiving water quality will help guide the
development of operating guidelines for the plant and help guide decision making during wet weather events. It
may be necessary to obtain advice from the Maine DEP in setting water quality priorities.
2.
Critical Components. The critical components are processes in the collection system (such as CSO regulators
or pumping stations) or the treatment plant (such as bar screens or aeration tanks) which can significantly affect
treatment of wet weather flow (or can be significantly affected by wet weather flow). The list of critical
components is unique to each facility. One plants critical components may not be critical at another facility.
The Wet Weather Operating Plan is not intended as a substitute for the plants operation and maintenance
manual. Components that have no bearing on wet weather operations will not be listed. As an example, a
collection system may include multiple wastewater pumping stations, but not all stations may le listed as critical
components. Unlisted stations might serve a new portion of the sewer system that has no combined sewers and
little I/I. Though regular operation and maintenance procedures are essential at an pumping stations, no special
procedures may be needed at these stations during wet weather.
Any major unit process in the collection system or the wastewater treatment plant that is handling wet weather
flows should be included on the list of critical components. Even if the process does not normally present
special problems during wet weather it should be included on the list if it is handling wet weather flows. In
addition, auxiliary processes that are impacted by wet weather flows should be included. If, for example,
special provisions for sludge handling must be made during wet weather, a sludge thickening, stabilization or
dewatering processes might be included on the list of critical components.
3.
Operating Guidelines. Operating Guidelines should be developed for each critical component identified in the
collection system and treatment plant. For each component, tasks should be listed for completion before, during
and after a wet weather event. Task descriptions should be brief and specific. The wet weather operating plan
is intended to serve as a quick reference during a wet weather event. This is not the place for a detailed
description of the theory behind a treatment process. The description must be specific enough, however, to
describe exactly what needs to be accomplished. For example, Check water level in influent channel may not
be specific enough. But, Check water level in influent channel. Open feed gate to second bar screen if water
level is above 3-foot mark on staff gauge provides specific direction based upon a required observation.
4.
List of Contacts. Develop a list of contacts who can provide advice or assistance during a wet weather event.
The list should include supervisors, and other involved public officials, equipment representatives and service
organizations, local and state regulatory agencies, utilities, and emergency contacts such as fire department,
police department and ambulance.
5.
Plan Development. The operation and maintenance staff who actually run the facility should develop the wet
weather operating plan. If outside assistance is obtained for plan development, the plant staff should have a
significant role in providing input, guidance, and review of the operating plan. The key steps in plan
development are as follows:
At a large facility, the development team may include a large number of people with diverse roles at the plant. At a
small plant, the development team may include the entire plant staff. Each of the steps in the development process
can be initiated effectively through a brainstorming meeting with ideas contributed by all present. The detailed
procedures can then be further developed in smaller work groups.
The completed Wet Weather Operating Plan should not be considered a final document. The plan should be subject
to revision whenever operating experience at the plant demonstrate improved or additional procedures to be
included. The plan should be kept in a three-ring notebook that can be easily modified as new revisions are
developed. Even after the initial plan is developed, investigate some of the suggestions made in this manual, and
other ideas that are developed at your plant. Test and compare various procedures to find new ways to treat more
flow more efficiently at your facility. Never stop looking for new ways to make your plant provide better, more
efficient performance and further reduce untreated overflows.
APPENDIX T
Sample Manual of Operations
Albertville Municipal
Wastewater Treatment Plant
Manual of Operations
Albertville, Maine
prepared by the
Albertville Wastewater Treatment Plant
and
Maine DEP
September, 2010
TABLE OF CONTENTS
Page
Introduction ...........................................................................................
10
12
13
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INTRODUCTION
Activated sludge is a biological wastewater treatment process that brings together wastewater and
a mixture of microorganisms under aerobic conditions.
The objective of activated sludge is to:
reducing the organic materials using a complex biological community in the presence of
oxygen and converting them to new cell mass, carbon dioxide and energy; and,
producing solids that flocculate and are capable of settling in the clarifier.
It is the wastewater treatment plant operators responsibility to control the treatment process by
maintaining proper operating conditions so that the process meets effluent objectives in a
cost-effective manner.
In the activated sludge process, there are three basic controls:
- waste sludge mass;
- return sludge mass; and,
- dissolved oxygen.
There are many factors used as a basis for control of these variables. One of the first is knowing
how much sludge is in the system, where the sludge is, how long it has been there, and how fast
it is moving from one place to another.
1. pounds = concentration volume conversion factor, or
pounds = mg/L million of gallons 8.34 lb/gal
2. Total Sludge, lbs = Aerator Sludge, lbs + Clarifier Sludge, lbs
3. Mean Cell Residence Time = Total Sludge, lbs/Waste Sludge, lbs, where
Waste Sludge = Effluent TSS, lbs + Waste Sludge, lbs
4. Solids detention time in the clarifier = (clarifier sludge, lbs/return sludge, lbs/d) 24 hrs/day
5. Solids detention time in the aerator = (Aerator Sludge, lbs/(Q + RSF) MLSS) 24 hrs/day
The purpose of this manual is to provide additional guidance to the wastewater treatment plant
staff in order for them to make proper adjustment of the operational controls. Proper adjustment
of operational controls leads to maintaining the proper "growth pressures" (or control variables).
These guidelines will need to be used with operator judgment and updated as the process changes
and new experience is gained over time.
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Wasting
Recycle Sludge Flow
Aeration Rate
Recycle Chlorination
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Effluent quality
The F:M ratio, the Sludge Age (MCRT or SRT), and the mixed liquor concentration (MLSS).
The oxygen consumption
The nutrients required
Aeration basin foaming
Mixed liquor settleability
Adjust the waste activated sludge flow rate to maintain a balance between the aeration basin
solids and the incoming organic loading (BOD).
Produce solids that flocculate and settle properly.
Monitoring:
MLSS: Mixed Liquor Suspended Solids (MLSS) is the concentration of solids in the aeration
basin as determined by standard total suspended solids laboratory analysis. The solids consist
mostly of microorganisms; inert suspended matter and non-biodegradable suspended matter.
The target for aeration basin MLSS concentration is:
Target: 2,800 mg/L (summer)
Target: 3,500 (winter)
Upper Control Limit: 3,800 mg/L
Lower Control Limit: 2,400 mg/L
MLVSS: Mixed Liquor Volatile Suspended Solids (MLVSS) is the volatile or organic portion of
the mixed liquor suspended solids, determined by the standard volatile suspended solids
laboratory analysis.
The target for aeration basin MLVSS concentration is:
Target: 2,300 mg/L (summer)
Target: 2,800 mg/L (winter)
Upper Control Limit: 3,200 mg/L
Lower Control Limit: 2,000 mg/L
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Solids Retention Time (SRT): A mathematical determination of the length of time activated
sludge microorganisms spend in the aeration basin, expressed in days and calculated as:
SRT =
where, WAS is the waste activated sludge in pounds per day (concentration, mg/L)(WAS flow
rate, mgd)(8.34) EFF is the effluent TSS in pounds per day (TSS, mg/L)(Effluent flow rate,
mgd)(8.34)
The target for the solids retention time is:
Target: 12 days (summer)
Target: 14 days (winter)
Upper Control Limit: 18 days
Lower Control Limit: 8 days
Food to Microorganism Ratio (F:M): A mathematical calculation of the mass of food, measured
as BOD, divided by the mass of biological solids under aeration or MLVSS.
(BOD, mg/L)(FLOW, mgd)(8.34)
F:M = ---------------------------------(0.37 MG)(MLVSS, mg/L)(8.34)
where, BOD is the primary effluent BOD concentration and MLVSS is the aeration tank mixed
liquor volatile suspended solids concentration
The target for the F:M ratio is:
Target: 0.14 (winter)
Target: 0.12 (summer)
Upper Control Limit: 0.17
Lower Control Limit: 0.09
Operational Relationship
WAS Rate
Change
F:M Ratio
MLSS
SRT
Increase WAS
Decrease WAS
Increases
Decreases
Decreases
Increases
Decreases
Increases
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The F:M Ratio compares the mass per day of food, measured as lbs. of BOD removed by
the process with the pounds of microorganisms (measured as MLVSS) available to
metabolize the food. The F:M Ratio increases as the SRT get shorter. The F:M Ratio
decreases as the SRT gets longer.
Control Procedure:
Using information from the MLSS, MLVSS, SRT and F:M control charts, in combination with
sludge quality information, the staff should adjust the wasting rate based on the targets and
overall process status. Trends should be noted and knowledge of upcoming events should be
used. The sludge wasting rate should not be changed more than ten to fifteen percent in one day.
Wait one week or until observations and tests reveal a trend before making another change in the
wasting rate.
1. Sample and analyze the mixed liquor to determine the MLSS concentration 3 times per week
and the MLVSS concentration 1 time per week.
2. Calculate the SRT and F:M ratio.
3. Calculate the waste sludge required based on the following equation:
Average pounds under aeration for the pervious week = Waste sludge, pounds
target SRT
4. Evaluate the process based on sludge quality (microscopic, SVI, observations).
5. Determine the process status.
6. Plot the results of the MLSS, SRT, and F:M on control charts.
7. Evaluate the need to increase or decrease the waste activated sludge rate.
a. Are the control variables (MLSS, SRT, and F:M) above or below targets?
b. What is the process status based on sludge quality?
c. Is there a trend upwards or downwards in the primary effluent BOD?
d. Is there an anticipated increase or decrease in the primary effluent BOD?
e. Are the control variables (MLSS, SRT, and F:M) within the range defined by the upper and
lower control limits?
8. Do not make extreme changes in the waste activated sludge rate.
Note: Changes in waste rates will take 10 to 20 days to stabilize.
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SLUDGE QUALITY
Background:
The overall behavior of the biological solids is referred to as "sludge quality". Using the sludge
quality method means that the operator studies the aeration basin, mixed liquor solids and
secondary clarifiers for informative physical characteristics that help identify sludge quality and
process status. The inferences of these physical findings are used to supplement the results of
other process control variables, i.e., MLSS and F:M ratio, to make control variable adjustments.
Objectives for sludge quality:
Produce a mixed liquor that will form a strong floc and settles fairly rapidly as contrasted to a
mixed liquor that settles very fast or very slow.
Normally has a light brown color mixed liquor with a tan foam.
Produce a mixed liquor that is active throughout the basin and stable at the end of the process
as measured by the oxygen uptake rates.
Monitoring:
Microscopic Examination:
The operator should examine a wet mount slide to observe indicator organisms and determine the
abundance of filaments on a weekly basis.
Relative Number of Microorganisms vs. Sludge Quality
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Operational Relationship
Reference: Jenkins et al., Manual on the Causes and Control of Activated Sludge Bulking and
Foaming, 1986, page 73.
Sludge Volume Index (SVI): The volume in milliliters occupied by one gram of activated sludge
after 30 minutes of settling.
SVI =
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Spray patterns
Turbulence
Color
Foam
Clarity
Bulking
Washout
Clumping/Ashing
Straggler Floc
Pin Floc
Secondary Clarifier Effluent Turbidity:
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Adjust the recycle sludge flow rate to maintain a balance of solids between the secondary
clarifiers and the aeration basin.
Adjust the recycle sludge flow rate to obtain the maximum recycle solids concentration while
preventing sludge septicity from developing.
Monitoring:
Mass balance flow rate:
Qr =
(MLSSmg / L ) (QMGD )
RASSSmg / L MLSSmg / L
where,
Q = Influent flow, mgd
Qr = Recycle flow, mgd
MLSS = Aeration basin mixed liquor suspended solids concentration, mg/L
Depth of Blanket (DOB): The distance from the clarifier water surface to the top of the sludge
blanket. When subtracted from the total clarifier depth, this is the equal to the blanket thickness
(BLT).
The target for the blanket thickness is:
Target: 1.5 feet
Upper Control Limit 2.5 feet
Lower Control Limit 0.5 feet
Recycle secondary solids concentration:
The target for the recycle secondary solids concentration is:
Target: 7,500 mg/L
Upper Control Limit 10,000 mg/L
Lower Control Limit 5,000 mg/L
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Control Procedure:
The operator will use the information from the depth of blanket and recycle solids concentration
in combination with judgment to establish the recycle rate.
Recycle sludge flow can be thought of as a solids balancing process in which sludge is
recycled from the clarifier to the aerator.
Operational relationship
Increase RAS
Decrease RAS
Depth of Blanket
Increases
Decreases
Recycle Concentration
Decreases
Increases
Too high or low recycle sludge flow rates can create problems with sludge quality and clarifier
operation. High return rates increase the turbulence in the clarifier, decrease the aeration
detention time for the biomass, and cause a billowing sludge blanket in the clarifier.
Too low return rates allow sludge to accumulate in the clarifier. This degrades sludge quality
when anaerobic conditions in the sludge blanket occur.
In a properly balanced system, recycle sludge flow rate adjustments should not significantly
change the F:M ratio. F:M is controlled by wasting. Good sludge quality results from a
proper sludge wasting strategy. Recycle redistributes sludge.
The strategy of adjusting recycle flow rates does not work when there is a high blanket level in
the clarifier caused by sludge bulking. In this case, the high blanket level would call for
increasing the recycle sludge flow rate to lower the blanket. Increasing the recycle flow rate
when the sludge is bulking will make the problem worse. A bulking sludge requires more
settling time.
1. Determine the sludge blanket level for each clarifier.
2. Determine the recycle sludge concentration.
3. Calculate the minimum recycle rate based on the mass balance calculation.
4. Evaluate the need to increase or decrease the recycle rate for each clarifier.
a. Are the control variables (BLT and recycle concentration) above or below targets?
b. Is the recycle at least the minimum required by the mass balance calculation?
c. Is filamentous bulking a problem?
5. Based on the evaluation, increase or decrease the recycle flow rates by less than +/- 25 percent
per day.
Provide oxygen in proportion to the organic (BOD) loading for proper biological metabolism.
- If necessary, provide adequate oxygen for metabolism of nitrogen compounds
Provide sufficient mixing.
Optimize oxygen feed rates through D.O. aeration basin residual monitoring and
management.
Monitoring:
Dissolved oxygen: The amount of oxygen dissolved in the aeration basin liquid, expressed in
mg/L.
The target for aeration basin dissolved oxygen (D.O.) residual is:
Target: 1.0 mg/L
Upper Control Limit 2.0 mg/L
Lower Control Limit 0.5 mg/L
Dissolved oxygen is monitored at the effluent end of each basin before it discharges over the
weir.
Control Procedure:
1. When the D.O. exceeds 3.5 mg/L, shut the aerators at the effluent end off.
2. The weirs are adjustable (with some difficulty) to either increase or decrease the aerator
submergence.
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"sludge juggling"
polymer addition to the secondary clarifiers
Expose activated sludge to sufficient chlorine to damage filaments extending from the floc
surface while leaving organisms within the floc largely untouched.
The chlorine dosage is adjusted such that its concentration is lethal at the floc surface but is
sublethal within the floc.
Monitoring:
SVI:
The target SVI to begin recycle solids chlorination is:
SVI = 135 (5 day moving average)
The target SVI to end recycle solids chlorination is:
SVI = 135
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Microscopic examination:
The target for filament observation is:
Target: 2 some
Upper Control Limit: 3 common
Lower Control Limit: 1 few
Reference: D. Jenkins, M. G. Richard, and G.T. Daigger, Manual on the Causes and Control of
Activated Sludge Bulking and Foaming.
Control Procedure:
Chlorine dosage should be started low and increased until effective. Sludge settleability usually
improves within 1-3 days if an adequate chlorine dosage is applied.
1. SVI: _________
2. Filamentous Bacteria Amount: ___________
(Enter: Few, Some, Common, Very Common, Abundant, or Excessive)
3. Enter chlorine dosage: ____________ lbs Cl2/1,000 lbs MLVSS in aeration
(Enter: Few or Some = 0, Common = 4; Very Common = 6; Abundant = 8; Excessive = 10)
4. Enter MLSS concentration: __________ mg/L
5. Enter the most recent MLVSS analysis: __________ % MLVSS
6. Calculate the pounds of MLVSS:
0.37 MG 8.34 _____________ (MLSS, mg/L) _____ % MLVSS = __________
7. Calculate chorination rate:
____________ lbs MLVSS X 1/1000 ______ Cl2 Dosage = ____ lb Cl2/ 1000 lb MLVSS/day
8. Round off result of #7 to nearest lb: ______ lb Cl2/day
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APPENDIX U
Microbiology for Wastewater Treatment Plant Operators
Excerpted from a series of articles by Donald Albert, P.E.
in the Maine DEP O&M News
new cells can not develop. The nutrient availability and balance also establish a competitive advantage for
some microbial communities, particularly when nutrients are limited. Experience at wastewater treatment
plants shows that nitrogen and phosphorus must be available at the same time and in proportion to the
BODS loading. As a general rule, for each 100 mg/L of BOD, the microorganisms need 5 mg/L nitrogen
and 1 mg/L phosphorus,
As long as adequate organic matter, air, and nutrients are available, bacteria will continue to grow and
reproduce. Once the organic matter is depleted, endogenous respiration begins. During endogenous
respiration, cells begin to use their own internal cell matter as the source of energy to sustain life.
CSH7NO2P + O2 --------> CO2 + H2O + non-degradable cell residue
We noted that when the source of food is depleted, the microorganisms stop growing at a logarithmic rate.
Ideally, this is the growth where the bugs in a wastewater treatment plant should be. All the organic
matter has been taken up by the bugs but they have not yet begun to die-off. The food (F) to
microorganism (M) ratio (F:M) relates the amount of food available relative to the mass of
microorganisms. The operator can use the F:M ratio to control the growth rate of the bugs in the system.
Thus, F:M is an important factor which operators can use to control the biological treatment system.
>
In addition to organic matter, wastewater contains inorganic compounds such as ammonia-No Certain
bacteria are capable of burning ammonia to release energy for growth and reproduction. These bacteria,
called nitrifying bacteria, use ammonia-N as its source of energy and carbonate alkalinity as the carbon
source. During nitrification the electron acceptor is oxygen, the electron donor is hydrogen in ammonia-N
and the by-products are nitrite, nitrate, water and hydrogen Ions.
Nitrification is a two-step aerobic process. In the first step, ammonia is oxidized to nitrite by
Nitrosomonas.
NH4+ + 3/2 O2 -----> 2H+ + H2O + NO2During the second step, nitrite is oxidized in nitrate by Nitrobacter. N02- + 1/202 ----> N03The overall energy reaction is:
NH4+ + 2O2 -----> NO2- + 2H+ + H2O
During the synthesis reactions,
13NH4+ + 15CO2
Nitrosomonas
10NO3- + C5H7NO2 + H+
Nitrobacter
The total oxygen required is 4.57 pounds oxygen per pound of ammonia-N. By comparison, each pound
of BOD removed requires about 1.3 pounds of oxygen. The total alkalinity required is 7.14 pounds
alkalinity as CaC03 per pound of ammonia-N. Thus, full nitrification requires both oxygen and alkalinity
to be readily available.
As discussed above, synthesis and nitrification. Biological denitrification involves the microbial reduction
of nitrate to nitrite, and ultimately nitrite to nitrogen gas. Unlike nitrification, a relatively broad group of
bacteria can accomplish denitrification. Denitrifiers are found in most natural environments, including
municipal wastewaters and sludges. Denitrifiers are facultative organisms: they can use either oxygen or
nitrate as their terminal electron acceptor. In the process of denitrification, nitrate and nitrite act as
electron acceptors in the respiratory electron transport chain in the same manner as oxygen. This
transport chain is the fundamental mechanism by which cells generate energy. By using nitrate in place of
oxygen the bacteria generate less energy. Similarly, more energy is generated using nitrate than sulfate.
Control systems exist within bacteria that ensure the most efficient form of energy generation is utilized.
Thus if oxygen is present, it will be used before nitrate, and if oxygen is not present, nitrate will be used
before sulfate. Denitrifiers are able to switch from oxygen to nitrate. They do this by generating the
enzymes required for denitrification. Between 2 and 3 hours is typically required for the bacteria to switch
from an aerobic to an anoxic environment.
Control of denitrification occurs at the level of enzyme activity. Oxygen will inhibit the activity of the
denitrifying enzymes. The oxygen concentration at which denitrification stops has been reported to be 0.2
mg/L in pure cultures. In activated sludge the reported values are 0.3 to 1.5 mg/L.
Organic compounds serve as organic substrate (i.e., as carbon and electron donor) for denitrification.
Bicarbonate alkalinity is produced during denitrification. The theoretical production is 3.57 mg alkalinity
as CaC03 produced per mg of nitrate reduced to nitrogen gas.
Thus far, we have been discussing the basic metabolic needs of the individual organisms. The term
metabolic needs is used to define all the diverse reactions by which a cell processes food material to
obtain energy and the compounds from which new cell components are made. We must now look at the
diverse microbial population of the wastewater treatment system as a whole. Such systems rely on a
population of many types of bugs to remove the organic and inorganic pollutants from the wastewater. As
the nutritional and physical characteristics of the system change, conditions will favor certain types of
bugs over others. These physical and nutritional conditions select the organisms best adapted to the
environment. Further knowledge of the nutritional and physical factors affecting microbial growth is
necessary to know what types of organisms may be expected to predominate in various environments.
Kinetics is a term use to define the rate and amount of microbial growth. The kinetics of a system are
related to the amount of food, oxygen and nutrients available to the system. Kinetics also depends on
temperature, pH, mixing, MCRT, and hydraulic detention time in the aerator and clarifier. We have
already discussed food, oxygen, and nutrients. Now we will talk about the physical parameters.
Temperature is one of the most important physical factors in the selection of species. Most organisms
grow within a range of 30- 40C. The optimum is generally closer to the maximum than to the
minimum. Growth at the minimum temperature is very slow and increases rapidly with increasing
temperature, reaching a maximum at the optimum temperature and falling abruptly. For most
microorganisms the growth rate increases two-fold for each IOC rise in temperature. On the basis of
their optimal growth temperatures, microorganisms are classified as psychrophile, mesophiles or
thermophiles. Most microbial species are mesophilic, growing best between 20 and 45C. Psychrophiles
have optimum temperatures below 20 C, whereas thermophiles grow best above 45 C.
Another physical factor that, like temperature, influences the growth rate and limits growth is pH. In
general, most bacteria have pH optima near neutral and minimum and maximum near 5 and 9. Most fungi
prefer an acid environment and have minimum pH between 1 and 3 with an optimum pH near 5. Most
protozoa are able to grow in the range 5 to 8, with an optimum pH near 7.
The degree and vigor of mixing can exert profound effects on the selection of species and the behavior of
the species. Mixing tends to prevent localized differences in temperature, nutrients, dissolved oxygen, and
pH. Mixing also impacts the solids separation process.
In an activated sludge plant, new biomass is produced as BOD is removed. This is called sludge yield. For
every pound of BOD removed about 0.5- 1.0 pound of biomass is produced. Mixed liquor suspended
solids (MLSS) results from the development of accumulation of biomass. "Building up" suggest that
biomass can accumulate as it is produced. Biomass increases when the wasting rate is less than the growth
rate. A drop in biomass occurs when sludge wasting exceeds the rate of new sludge growth .. As the
number of microorganisms increases, the amount of food available to each organism decreases, and
consequently, the rate of microbial reproduction decreases. Microbial reproduction varies with the
availability, type and concentration of BOD.
Now that we have discussed biological denitrification and physical and nutritional conditions that
encourage the growth of certain organisms. Sludge age significantly affects the "community composition"
within the mixed liquor. For any species to survive, its growth rate must be greater than its washout rate.
Washout rate" implies that cells are lost from the inventory, and this occurs in at least three ways: 1)
sludge wasting, 2) effluent TSS, and 3) death.
Many terms are used to describe the concept of sludge age. Mean Cell Residence Time (MCRT) is among
the most popular. MCRT refers to how long the average cell remains in a secondary system before being
removed. Secondary clarifier inventory is included, along with effluent suspended solids, in the MCRT
calculation.
The hydraulic detention time is the amount of time the wastewater is retained in each individual unit
reactors. Hydraulic detention times vary depending on the type of system. Suspended growth systems are
normally categorized into three types: conventional activated sludge, with a detention time of 4-6 hours;
extended aeration, with a detention time of about 24hours; and, contact stabilization, with an initial
contact time of less about 30 minutes and a stabilization time of about 8 hours. Systems operating with
detention times outside these detention times typically do not operate efficiently.
There are several different types of environmental shocks that will disrupt the operation of a wastewater
treatment plant. A qualitative shock is a change in the nature of the energy (food) and carbon source in the
influent. A quantitative shock also relates to the carbon and energy source, but involves a change in the
concentration rather than the type of compounds. A hydraulic shock involves a change in the inflow rate
to the treatment plant. A pH shock may have considerable effect on metabolism and on selection of
species. A toxic shock is the introduction of toxic materials, organic or inorganic, into the influent.
Whether an organism will grow and the extent to which it will thrive is determined by the law of the
minimum. According to this law the growth of an organism is limited by the amount of that one of its
requirements which is present in minimum quantity relative to the overall requirements of the organism.
The factor that controls growth in one situation may be food, or it may be phosphorus or nitrogen.
Natural selection of certain organisms and the establishment of competitive advantages are related to
metabolic or kinetic factors. The type of food (organic or inorganic) will determine what types of
microorganisms will thrive. The level of oxygen will determine whether aerobes or anaerobes will
survive. The lack of a nutrient may allow certain filamentous bacteria to out complete other organisms for
essential cell macro nutrients. The presence of sulfur may promote the growth of thiothrix, beggiatoa, and
type 021 N. Fungus requires lower pH in order to function. The ratio of food to microorganism
determines whether floc formers are generated or low F:M filaments such as M parvicella, H. hydrosis,
Nocardia, types 021N, 0041,0675,0092,0581, 0961, and 0803 will dominate.
It is very important for wastewater treatment plant operators understand "growth pressures" so that
metabolic and kinetic factors can be controlled to promote proper treatment. The most common variables
that operators should understand and control include:
Many problems at waste treatment plants are related to a kinetic or metabolic factor(s). Grayish slimy
foam is usually caused by nutrient deficiencies. Nocardia or Microthrix parvicella, grow at high MCRT.
Most filamentous bulking problems are caused by a nutrient or DO deficiency, low pH, sulfide, or high
MCRT. Pin floc is normally caused by high MCRT. Straggler floc is usually caused by low MCRT. A
toxic load can cause dispersed growth.
One way to control unwanted bugs is to change the operation of the plant to bring about a "selector
effect. A selector effect results from differences between floc forming and filamentous organisms. Flocformers have a higher growth rate which provides a kinetic advantage at high substrate concentrations.
Floc-formers have the ability to quickly take up and store substrate which can starve the filaments.
Selectors can also make use of metabolic differences. Anoxic selectors make use of floc-formers ability to
respire under anoxic conditions when dissolved oxygen is lacking but nitrate is present. Anaerobic
selectors make use of floc-formers ability to attain energy through anaerobic fermentation or cleavage of
high phosphate bonds.
Selector effects can be created by adding tanks to the process, by baffling or otherwise isolating a portion
of one tank to achieve anoxic or anaerobic conditions or by operating in an on-off aeration, mode which
promotes anoxic conditions during part of the treatment cycle. If you are considering the use of a selector
to improve the treatment efficiency or to solve a filamentous bulking or other problem at your plant, you
should first try to identify the root cause of the problem. Then you can decide if a selector will solve that
problem or if another treatment pressure may give you better results.
I hope these articles encourage you to learn more about the microbiology of wastewater treatment.
APPENDIX V
Alkalinity as a Process Control Indicator
and/or increasing the waste activated sludge rate (to decrease the solid retention time) will help
remedy this problem.
Alkalinity decreases as bacteria aerobically metabolize organics. In an aerobic digester, sustained
aeration may decrease alkalinity below the system1s buffering capacity and cause the pH to drop
low enough to limit biological activity. Consequently, poor settling and decreased volatile solids
reduction may occur. The operator should establish high and low alkalinity set-points to
maintain optimum digester efficiency. The aerobic digester should be aerated until alkalinity
decreases to the low set-point. The operator should turn the air off to establish an anoxic cycle
and avoid low pH levels. The dissolved oxygen will be depleted and nitrate will be used as the
oxygen source during which alkalinity will correspondingly increase. The aeration is resumed
when alkalinity reaches the high set-point to avoid septicity.
(Adapted from the February 1994 Operations Forum by Fred Dillon - Falmouth WPCF and Don
Albert- MeDEP)
APPENDIX W
Seeded Biochemical Oxygen Demand
Using Seeded Dilution Water
Biochemical oxygen demand (BOD) is usually defined as the quantity of oxygen used by
bacteria while stabilizing decomposable organic matter under aerobic conditions. The BOD test
is conducted for a specific time interval, at a specified temperature, and under specific
conditions. The standard BOO test is incubated in the dark for 5 days at 20 + 1oC. Because
oxygen solubility is limited, strong waste must be diluted to ensure that dissolved oxygen (DO)
is always present. Since the BOD test is a bioassay procedure, it is important that
environmental conditions are always suitable for living organisms to function in an unhindered
manner. This means that toxic substances must be absent and that necessary nutrients must be
present. A diverse group of organisms is required to degrade organic matter biologically.
Therefore it is important that a mixed group of microorganisms, commonly called "seed" be
present in the test. Seeding is necessary when wastewater samples do not contain sufficient
microorganisms. These viable microorganisms may not be present in industrial wastewater, or
they may be killed by high temperature, extreme pH, or disinfecting chemicals. Typical domestic
influent would not require seeding but final effluent which has been chlorinated and
dechlorinated must always be seeded. When the "seed" is added, a small amount of organic
material is also added which can have a measurable BOD itself. Therefore, a "seed correction
factor" must be calculated.
Introduction
BOD calculations can be confusing when it is necessary to use seeded dilution water. In
Standard Methods, 16th Edition, page 531, the formula to be used with the seeded dilution
water is written as follows:
BODmg/ L =
where:
D1 =
D2 =
P =
B1 =
B2 =
f =
=
(D1 D2 ) (B1 B2 ) f
P
Eqn. 1
The most difficult variable to understand in Equation 1 is probably the f-factor. To obtain
appropriate data for the calculation, the laboratory setup is critical. Proper laboratory setup for
seeded BODs will be explained later in this article. First, the theory for the f-factor will be
explained.
Seed
Dilution
Water
Bottle #1
Blank Bottle
Distilled Water
+ Nutrients
Dilution
Water
Bottle #2
Seed Control Bottle
Vol. seed = Vseed2
Vol. DW = 300 - Vseed2
Vol bottle = 300 mL
Sample
Seeded
Dilution
Water
Bottle #3
Blank Bottle
Distilled Water
+ Nutrients
+ Seed
Seeded
Dilution
Water
Bottle #4
Sample Bottle
Vol.
Vol.
Vol.
Vol.
sample = Vsample
seeded DW = 300 - Vsample
seed = (300 - Vsample) SDW
DW = 300 - Vseed4 - Vsample
For the f-factor calculation, only bottle #2 and bottle #4 are needed. The other two
bottles are quality control checks and they will be explained later. Standard Methods defines the
f-factor as shown in the equation below.
f=
Eqn. 2
Vseed4
f=
Vseed2
Eqn. 3
If the total volume of Bottle #4 (300 mls) equals the total volume of Bottle #2 (300 mls), then
V
f = seed4
Vseed2
f=
Eqn. 4
Eqn. 5
The seed concentration in dilution water is the volume of seed per unit volume of
dilution water. Vseed2 is the volume of seed pipetted into the seed control bottle. The seed
should be added to the dilution water rather than pipetting directly into the BOD bottles. Seed
distribution is better and pipetting errors are reduced when seed is added to the dilution water.
This is the proper technique.
By using Equation 5, the f-factor can calculated. After substituting the calculated f-factor
into Equation 1, the BOD of a particular sample can be calculated from the lab data.
Laboratory procedure
Proper laboratory setup is critical in order to obtain valid data. The proper procedure for
seeded BOD analysis is explained in detail in this section.
It is ideal to bring the sample temperature to 20oC. By placing the water tight sampling
containers into a water bath, the sample can be warmed or cooled quickly.
Dilution water is prepared in the same manner as for unseeded BOD analysis. Sufficient
distilled water must be at 20 loC and aerated.
Sometimes the distilled water is stored in the BOD incubator for 24 hours to standardize the
temperature. Do not add the nutrients before storing the distilled water. Add the nutrients prior
to setting up BOD samples. Be sure to allow sufficient time for the nutrients to dissolve. Swirl
the container for mixing. The mixture is now called standard dilution water. Fill Bottle #1 with
this dilution water completely. This is called the blank and is used to provide quality assurance
for this analysis.
The second bottle is prepared by filling the BOD bottle with standard dilution water to
approximately halfway first. Pipette a known volume of seed into the BOD bottle and then fill
the bottle with dilution water. In this example, five milliliters of seed are pipetted into the
bottle. This is called the seed control bottle.
After the first two bottles are set up, seed is added to the dilution water. Three milliliters of
seed per liter of dilution water is the ratio used for this example. Swirl the mixture gently
making sure not to over agitate the mixture. Swirling will prevent further aeration and avoid
over-saturating the seeded dilution water with dissolved oxygen. Bottle #3 is completely filled
with this seeded dilution water.
Seed can be obtained from several locations within the wastewater treatment facility.
Settled domestic influent and secondary clarifier effluent are two of the most popular sources of
seed. Also artificial seed can be purchased from some laboratory supply houses. The preferred
seed is effluent from a biological treatment plant treating the waste. If the choice of seed is the
influent domestic wastewater, allow the seed to settle for at least 1 hour but no more than 36
hours at 20C. Consistent settling time is ideal in this case.
Dechlorinate the samples to neutralize the chlorine residual, if necessary,. at this point.
Dechlorination can be accomplished by adding sodium sulfite (Na2S03), or a dechlorinating
tablet purchased from supply houses can be utilized. The volume of sodium sulfite required
must be determined by titrating with 0.025N Na2S03 to the starch-iodine end point. The
temperature of the samples should now be about 20oC. Samples which are alkaline or acidic
must be neutralized to a pH of 6.5 to 7.5 with a solution of sulfuric acid or sodium hydroxide.
The next step in the BOD setup process is to estimate the BOD of the sample. As a guide,
typical domestic influent wastewater has a BOD of about 200 to 300 mg/L. Secondary
wastewater treatment effluent has a BOD of about 5 to 50 mglL. For most wastewater analysis,
three sample dilutions are setup for each sample to be tested. For the influent sample, typically
3, 6, and 9 milliliters of sample into a 300 milliliter BOD bottle should provide sufficient range.
Referring to the Table 1 on the next page, this influent setup covers a BOD range from 70 to
560 mg/L. As for the effluent sample, 24, 50, and 100 milliliter sample are chosen. This volume
selection covers a BOD range from 6 to 70 mg/L.
After you have chosen the dilutions to setup, fill the remaining BOD bottles allocated for
receiving samples to about a quarter of the total volume with seeded dilution water. These BOD
bottles are ready to receive wastewater samples. Before the samples are transferred to their
respective BOD bottles, each sample must be thoroughly mixed.
It is important to mix the sample bottle by shaking vigorously (not only stirred) before pipetting
any sample from the sample bottle to the BOD bottle to ensure homogeneous transfer of
sample. The BOD bottles are then filled up with the seeded dilution water. After measuring
initial DO, the BOD bottles are then sealed with glass stoppers, water sealed, and capped with
plastic covers before incubation. Make sure that there are no air bubbles trapped in the BOD
bottles. Top off with dilution water, if necessary, to eliminate air bubbles.
Table 1
Expected BOD Range
Sample added to 300-ml
bottle
3
6
9
12
15
18
21
24
27
30
50
75
100
150
Min. (mgjL)
Max. (mgjL)
210
105
70
53
42
35
30
26
24
21
12
8
6
4
560
280
187
140
112
94
80
70
62
56
42
22
21
12
The results for this example after 5-day incubation are presented in Table 2. The lab
prepared three different dilutions each for influent and effluent samples.
TABLE 2 - Lab Results
Bottle
Number
1
2
3
Influent
4
5
6
Effluent
7
8
9
Sample
Volume
dilution water
seed control
seeded
dilution water
Initial
DO
9.05
8.90
Final
DO
9.00
3.30
DO
Depleted
0.05
5.60
BOD
Mg/L
336
8.95
7.95
3 mL
6 mL
9 mL
8.95
8.85
8.85
5.95
3.75
1.25
3.00
5.10
7.60
201
206
221
24 mL
50 mL
100 mL
7.75
7.8
7.8
4.25
5.0
7.3
3.5
2.8
0.5
32
12
-
Standard Methods recommends that the following criteria are met for BOD analysis.
When performing the dilution water check, DO depletion in the blank should not exceed 0.2
mg/L and preferably not more than 0.1 mg/L. In this case, DO depletion for the blank is 0.05
mg/L; therefore it meets the first criterion. If the blank depletion of your test is greater than 0.2
mg/L, you must not subtract this depletion from the BOD depletion. Normally, dirty glassware,
contaminated nutrients, contaminated distilled water, and contamination from handling the
water can contribute to this problem. Therefore, it is important to clean the glassware after use,
dry BOD bottles with the mouths facing downwards and avoid any contact with the hands when
aerating the distilled water. Place a piece of laboratory film with the clean side facing the mouth
of the dilution bottle to eliminate any contact with the palm during aeration. If you must
temperature equalize the distilled water in the incubator, pierce a few holes through the
laboratory film and leave the laboratory film in place as a cover. These precautionary steps
described above should help to eliminate this problem. If the problem persists, then it normally
can be resolved by improving the quality of the lab water used to prepare the dilution water
and perhaps a new batch of nutrients. The lab distillation apparatus may need cleaning, for
example.
The seeded dilution water has depleted 1 mg/L of oxygen. This indicates good seed source.
This depletion needs to be accounted for in the BOD calculations. Standard Methods
recommends that the seeded dilution water depletion should be between 0.6 mg/L and 1.0
mg/L. If there is no depletion after S-day incubation, then the seed could be bad or the seed
volume must be increased until the criterion is met.
The DO depletion in the seed control should be at least 2 mg/L and must have 1 mg/L
residual after the 5-day incubation. If the seed control depletes all of the DO, then the seed is
excellent but the volume of seed pipetted into the BOD bottle has to be reduced. In this
example, Bottle #2 depleted 5.6 mg/L of dissolved oxygen and had 3.3 mg/L of DO residual
after 5 days of incubation. Therefore, it satisfies this criterion.
Moving along in the table, you will notice that the initial DO concentrations for the influent
dilutions are approximately the same. Another observation is that the water is not supersaturated with oxygen. At 20C, the solubility of oxygen in water at atmospheric pressure is
about 9.1 mg/L. Therefore, you can use this as a guide for initial DO concentration and take
care not to exceed this concentration.
The next consideration is checking for at least 2 mg/L of DO depletion and a DO residual of
at least 1 mg/L after 5-day incubation. Bottle #9 did not meet both requirements as it has only
0.5 mg/L of DO residual. The remaining bottles did meet these two criteria. Any bottles that do
not have 2 mg/l depletion and 1 mg/L residual after 5-day incubation should be deleted from
BOD calculations.
Now we can calculate the BOD for each sample dilution. First we have to determine the ffactor for each valid test using Equation 5. The bottle volume and seed concentration in the
seed control are shown for purposes of clarity only.
f4
f5
f6
f7
f8
=
=
=
=
=
The BOD for each valid dilution can now be determined using Equation 1.
BOD4
BOD5
BOD6
BOD7
BOD8
Effluent BOD shows a decreasing trend as the sample volume increases. This indicates
toxicity in the sample. If this type of decreasing trend occurs consistently in your BOD testing,
then the source of possible toxicity must be identified. In this example, the toxic substance
could be from an in-plant source because influent BOD testing does not show a decreasing
trend as sample volumes increase.
The actual BOD for each sample should be the average of all of the satisfactory tests. In
this example, the influent BOD is 209 mg/L and effluent BOD is 22 mg/L.
It is important to note that the DO depletion in the seed control cannot be used in the BOD
computation directly without first considering the f-factor like the example shown in this article.
The f-factor decreases as the sample volume increases.
Data from our example was used with a second formula which was obtained from Simplified
Laboratory Procedures for Wastewater Examination. Second Edition. This was to verify that the
BOD result obtained from either formula is identical. The formula modified for seeded BOD is as
follows:
(L) (BODseed)
300
BOD5 = (D1 D2 )
Eqn. 6
300
samplevolume
where,
L = Volume of seed in the bottle that contained sample
D1 = DO of diluted sample immediately after preparation, mg/L,
D2 = DO of diluted sample after 5 day incubation at 20 e, mg/L,
BODseed = Calculated BOD for the seed control, mg/L.
The following will show the BOD computation using a modification of Equation 6 which deletes
the seed correction step. This is possible because the seed control bottle measures the BOD of
the seed material directly.
BODseed = ((B1 B2 ) /( Volumeofse
ed)) 300
BODseed = ((8 .9 3 .3 ) /( 5 )) 300
BODseed = 336
where,
B1 = DO of seed control before incubation, mg/L,
B2 = DO of seed control after incubation, mg/L.
The volume of seed transferred from the seeded dilution is calculated by multiplying the volume
of seeded dilution water to fill the BOD bottle with the seed concentration used.
L4 = (300-3 /1000) = 0. 891
L5 = (300-6) (3/1000) = 0.882
L6 = (300-9) (3/1000) = 0.873
BOD7 = 32 mg/L
BOD8 = 12 mg/L
Note that using either formula will produce the same BOD results. The analyst must
understand how to properly use whichever formula is chosen.