9-Secondary Sedimentation Tank-Zone Settling F12

1
Secondary Sedimentation Tank

Zone Settling

1. Application

a) Concentrated suspension of flocculent particles; e.g., biological sludge (activated sludge)
b) Secondary clarifier in WWT

2. Characteristics

a) A distinct interface
- A distinct interface is formed between the mass of settling solids in the sludge zone and the
clear supernatant above formed from the water of separation.

b) A settling blanket
- A suspension settle as a blanket without inter-particle movement
- individual particles of all size move downward at the same velocity.

c) Hindered Settling
- the coalescence of the suspended solids occurs during hindered settling of a sufficiently
high concentration of flocculent particles.

3. Zone Settling Velocity, v

is the rate of downward movement of the sludge-blanket surface after reaching a constant
velocity characteristic of the suspension.

decreases with increasing initial concentrations of the same solids.


log v
i
vs. log C
i

intercept = log a
v
1
v
1
v
2 slope = - n
v
3
C
5
v
i
v
2

v
i
C
4
v
4
C
3
v
3

C
2
v
4
v
5
C
1
v
5

Time C
1
C
2
C
3
C
4
C
5
C
1
C
2
C
3
C
4
C
5
C
i
log C
i
I
n
t
e
r
f
a
c
e

l
e
v
e
l
l
o
g

v
Settleometer
log v
i
= log a - n log C
i

C
1
< C
2
< C
3
< C
4
< C
5

v
i
= a (C
i
)
-n

9-Secondary Sedimentation Tank-Zone Settling F12
2

2. Solid Flux (SF, F, G)

a. Ability of solids concentration to transfer mass

mass / unit time M/T
b. Unit of solid flux = --------------------- = --------
unit area L
2


c. Two types of mass fluxes

1) Gravitational Solid Flux = solid flux due to gravity (Fg, SFg, Gg )
2) Under Flow Solid Flux = solid flux due to underflow (Fu, SFu, Gu )


A = surface area of clarifier
Q
f
= inflow to the clarifier
Q
u
= withdrawal flow from clarifier
C
i
= conc. of solids in inflow to the clarifier
C
u
= under flow conc.

v = zone settling velocity, v = Q
f
/A
v
i
= settling velocity of the solids at conc of C
i.

u = underflow rate, u = Q
u
/A
= underflow rate
= sludge pumping rate
= bulk downward velocity




Zone Settling and Solids Flux Diagrams



(a) Zone Settling, v

- Settling velocity vs. solids concentration for coalescing
flocculent suspensions.

- Incremental increases in the suspended
solids content at high concentrations
have a greater influence on retarding
the settling velocity.





v
i
vs. C
i
v
i
C
i
Q
f
C
i
A
v
i
C
L
Q
u
C
u
u
9-Secondary Sedimentation Tank-Zone Settling F12
3


(b) Gravitational Solids Flux, G
g
, F
g
, SF
g


- Gravitational flux G
g
vs. solids concentration C
i
calculated from the v vs C
i
curve.

SF
g
= C
i
v
i


where G
g
= F
g
= SF
g
= solids flux, lb/ft
2
/hr (kg/m
2
/h)
C
i
= solids concentration i, lb/ft
3
(kg/m
3
)
v
i
= zone settling velocity at solids
concentration C
i
, ft/hr
(m/h) = Q
f
/ A
Q
f
= inflow to clarifier


f
g i i
Q
SF C C
i
v
A
= =

unit:
M L M/T
----- ---- = -------
L
3
T L
2





(c) Underflow solids flux, G
u
, SF
u


- Underflow solids flux (SF
u
) versus solids concentration (C
i
) resulting from the withdrawal of
sludge from the bottom of the sedimentation tank.

SF
u
= C
i
u

where Gu = Fu = SFu = under flow solids flux, lb/ft
2
/hr
(kg/m
2
/h)
C
i
= solids concentration, lb/ft
3
(kg/m
3
)
u = underflow rate, ft/hr (m/h)

Note: Solids flux resulting from withdrawal of sludge is directly
proportional to the concentration of solids in the sludge.

u
u i i
Q
SF C C u
A
= =
where u = Q
u
/A
SF
g
vs. C
i
SF
g
C
i
C is too low
SF
u
vs. C
i
SF
u

C
i
9-Secondary Sedimentation Tank-Zone Settling F12
4

The total solids flux, G, SF
T

- The sum of the gravitational flux and the underflow flux:


SF
T
= SF
g
+ SF
u
= C
i
v
i
+ C
i
u


f u
T i i
Q Q
SF C C
A A
= +










5. Limiting Solids Flux, Maximum allowable solids flux, SF
L
, G
L


a. Limiting Solids Flux - maximum allowable solid flux- design criteria
b. Defines the maximum solids loading that can be applied to the clarifier

Solids flux diagrams of zone settling.


C
f
= feed concentration
C
u
= underflow solid conc.
C
L
= limiting solid conc.

(a) Total solids flux as the sum of the laboratory
gravitational flux and the underflow flux.

(b) Maximum allowable solids flux for the limiting layer
of solids concentration C
L
as the sum of the gravitational
flux of the feed solids and the underflow flux.





** There is some solid concentration (C
L
) that has the lowest zone settling velocity. This concentration
(C
u
) limits the solid flux and concentration: C
f
< C
L
< C
u


Every particle must path through the concentration C
L
to C
u
.

SF
T
SF
g
SF
u
C
f
C
L
Cu
C
i
(g/L)
SF
SF
T
SFL
C
f
C
L
C
u
C
i
(g/L)
SF
L
9-Secondary Sedimentation Tank-Zone Settling F12
5

Under steady-state flow condition,

Maximum allowable Gravitational solid flux Gravitational solid flux
solid flux in the feed in the underflow
( ( (
= +
( ( (




Activated Sludge System - Definition for the secondary clarifier design


Q
w
~ 0
Aeration Tank C
f
Q
f
= Q+Q
u
C
e
~ 0
Q Q+Q
u = Q(1 + R) Q
e
=Q - Q
w
C
f
= MLSS C
f
v
i
= Q
f
/A
Q
u
,C
u = zone settlinf velocity
u = Q
u
/A
= under flow rate

Q
r
Q
u
X
r
= C
u
Q
w
~ 0
C
u
R = Qu/Q = Qr/Q


Since Q
u
= RQ, Q
f
= Q + Q
u
= Q + RQ = Q (1+R)

v
i
= zone settling velocity, ft/hr (m/h)

Inflow to clarifier Q
f
Q + Q
u

= ------------------------------- = ------- = ----------
Surface area of clarifier A A

* v is also sedimentation tank application rate and the overflow rare


u = underflow rate, ft/hr (m/h) = sludge pumping rate

Withdrawal flow from clarifier Q
u

= ---------------------------------------- = ------
Surface area of clarifier A
9-Secondary Sedimentation Tank-Zone Settling F12
6

Solid Balance

Solids balance (without reaction) around the secondary clarifier:

f f u u e e
dC
V Q C Q C QC
dt
=

where Q
f
= feed flow
C
f
= feed concentration

At steady state, dC/dt = 0 and C
e
~ 0

Mass in = Mass out

Q
f
C
f
= Q
u
C
u
= M (1)

where M = Solid mass loading

Q
f
= Q + Q
u
(2)


Recirculation Ratio, R

r u
Q Q
R
Q Q
= =

Q
u
= RQ

Q
f
= Q + Q
u
= Q + RQ = Q (1+R)


1) MLSS
From Eqs. (1) and (2)

M = Q
f
C
f
= (Q + Q
u
) C
f


f
u
M
MLSS C
Q Q
= =
+
(3)
or

f f
u u u u
f
f u u u
Q C
Q C Q C M
MLSS C
Q Q Q Q Q Q Q
= = = = =
+ + +





Q
f
= Q+Q
u
C
e
~ 0
= Q(1 + R) Q
e
=Q - Q
w
Q
f
C
f
Q
e
C
e
v
i
= Q
f
/A
Q
u
C
u
u = Q
u
/A

9-Secondary Sedimentation Tank-Zone Settling F12
7



Mass balance around the secondary clarifier

Q
f
C
f
= Q
u
C
u
as QC
e
~0

1
u u u
u
u u u u
f u
u u
f u
Q C Q
C
Q C Q C R Q Q
C C
Q Q Q Q
Q Q Q R
Q Q Q
| |
= = = = =
|
+
+ +
\ .
+

or
( )
( ) 1 1
u
u u
f u
f
RQ C
Q C R
C C
Q Q R R
| |
= = =
|
+ +
\ .


where Q
u
= RQ and Q
f
= Q(1+R)

1
f u
R
MLSS C C
R
| |
= =
|
+
\ .



2) Rate of withdrawal flow from clarifier, Q
u


From (1) and (2)

(Q + Q
u
) C
f
= Q
u
C
u


solve for Q
u


Q C
f
+ Q
u
C
f
= Q
u
C
u


Q
u
(C
u
- C
f
) = Q C
f


f
u
u f
QC
Q
C C
=

3) Underflow rate, u

R = Q
u
/Q or Q
u
= RQ (1)

Q
f
= Q + Q
u
= Q + RQ = Q (1+R) (2)


f f
u u u
f f
Q Q
Q Q Q
u
A Q A Q A
= = = (3)

9-Secondary Sedimentation Tank-Zone Settling F12
8
Substitute (1) and (2) into (3)

( ) 1 1 1
f f
r
Q Q
Q Q RQ R R
u
Q R A R A R A
+ | |
= = =
|
+ + +
\ .


where Q
f
/A = overflow rate



EXAMPLE 8-11. Application of Solids Flux Analysis (4
th
ME 824)

Given the following settling data for a biological sludge, derived from a pure-oxygen activated-sludge
pilot plant, estimate the maximum concentration of the aerator mixed-liquor biological suspended solids
that can be maintained if the sedimentation tank application rate Q + Q
r
has been fixed at 25 m
3
/m
2
.d
and the sludge recycle rate Q
r
is equal to 40 percent. (The definition sketch for this problem is shown on
Fig. 8-9b on page 691.) As shown, settled and thickened biological solids from the sedimentation tank
are returned to the aeration tank to maintain the desired level of biological solids in the aerator. Assume
that the solids wasting rate Q
w
is negligible in this example.




Secondary
Sed. Tank

Aeration Tank (Q+Qr)/A = 25 m
3
/m
2
d
Q
f
/A = 25 m
3
/m
2
d
Q
V, X
X Xe
Q + Qr Qe = Q - Qw
Q (1+ r)
Qu
Qr = Qu Qw ~ 0
r = Qu/Q = 0.4 Xr






(Solution)

Given:
R_r 0.40 Recirculation ratio
Qf/A OR 25.00 m
3
/m
2
.d Application rate
(25 m/d) (d/24 hr)= 1.0417 m/hr


Example 8-11
MLSS (g/m3)
Initial Settling
Velocity
(m/h)
2000 4.270
3000 3.510
4000 2.760
5000 2.130
6000 1.280
7000 0.910
8000 0.670
9000 0.490
10000 0.370
15000 0.150
20000 0.070
30000 0.027
9-Secondary Sedimentation Tank-Zone Settling F12
9


1. Determine the underflow rate, u

3
2
0.4 25 7.14 0.298 0.3
1 1 0.4
f
Q
R m m m m
u
R A d m d hr hr
| | | |
= = = = ~
| |
+ +
\ . \ .



Note:
R = Qu / Q or Qu = RQ (1)

Qf = Q + Qu = Q + RQ = Q (1+R) (2)

f f
u u u
f f
Q Q
Q Q Q
u
A Q A Q A
= = =
(3)

Substitute (1) and (2) into (3)

( ) 1 1 1
f f r
Q Q RQ R R Q Q
u
Q R A R A R A
+
= = =
+ + +


where Qf /A = overflow rate and Qf = Q + Qr



2. Develop the total flux curve for the system, and determine the value of the limitimg flux and maximum underflow
concentration.


1 Develop the gravity solids-flux curve from the given data and plot the curve.
a.
(1) (2) (3)
MLSS (g/m
3
)
Initial Settling
Velocity
(m/h)
SFg =C
i
v
i
(kg/m
2
hr)
SF
u
=C
i
u
(kg/m
2
hr)
SF
T
= SFg + Sfu
(kg/m
2
hr)
2000 4.270 8.54 0.60 9.14
3000 3.510 10.53 0.89 11.42
4000 2.760 11.04 1.19 12.23
5000 2.130 10.65 1.49 12.14
6000 1.280 7.68 1.79 9.47
7000 0.910 6.37 2.08 8.45
8000 0.670 5.36 2.38 7.74
9000 0.490 4.41 2.68 7.09
10000 0.370 3.7 2.98 6.68
15000 0.150 2.25 4.46 6.71
20000 0.070 1.4 5.95 7.35
30000 0.027 0.81 8.93 9.74
(1) (2000 g/m
3
) (4.27 m/h) (1 kg/1000 g) = 8.54 kg/m
2
hr
(2) (2000 g/m
3
) (0.30 m/hr) (1 kg/1000 g) = 0.6 kg/m
2
hr
(3) (8.54 kg/m
2
hr) (0.6 kg/m
2
hr) = 9.14 kg/m
2
hr
Set up a computational table to determine the solid-flux values corresponding to the given solid
concentration.






9-Secondary Sedimentation Tank-Zone Settling F12
10



0
2
4
6
8
10
12
14
0 5000 10000 15000 20000 25000 30000 35000
S
o
l
i
d
s

f
l
u
x
,

G

(
k
g
/
m
2
-
h
)
MLSS conc. (g/m3)
Solids-flux curve
SFg =Ci vi (kg/m2 hr)
SFu =Ci u (kg/m2 hr)
SFT = SFg + Sfu (kg/ m2 hr)
6.6
C
u
= 21,900 g/m
3


From the solids flux curve, the maximum underflow solids concentration is equal to 21,900 g/m
3
.


3. Estimate the maximum solids concentration (MLSS) that can be maintained in the aeration tank.

( )
0.4
21,900 / 6, 257 /
1 1 0.4
f u
R
MLSS C C mg L mgMLSS L
R
| | | |
= = = =
| |
+ +
\ . \ .


Note:
Qf Cf = Qu Cu = M (1)
Qf = Q + Qu (2)
From (1) and (2)
M = (Q + Qu) Cf

f
u
M
C MLSS
Q Q
= =
+
(3)
or
f f
u u u u
f
f u u u
Q C
Q C Q C M
MLSS C
Q Q Q Q Q Q Q
= = = = =
+ + +
(4)

Since
Qf Cf = Qu Cu (1)

Thus,
( )
( ) 1 1
u u u
f u
f u
RQ C Q C R
MLSS C C
Q Q Q R
| |
= = = =
|
+ +
\ .
(5)

where Qu = RQ and Qf = Q(1+R)


Total solids flux in the underflow, SF
L
, G
L


9-Secondary Sedimentation Tank-Zone Settling F12
11
- the maximum allowable solid flux

Mass loading to the clarifier
Surface area of the clarifier
L L
M
SF G
A
= = =

u u
L L u
M Q C
SF G C u
A A
= = = =

f f
L L f
Q C
M
SF G C v
A A
= = = =

f f
u u
L L
Q C
M Q C
SF G
A A A
= = = =


Total Mass Loading to the secondary settling tank, M

M = Q
f
C
f
= Q
u
C
u
(1)

M = SF
L
A = G
L
A (2)


The Surface area of the Clarifier, A

M Q
f
C
f
Q
u
C
u

From (2) A = ------ = ----------- = ----------- (3)
SF
L
SF
L
SF
L


Feed flow, Q
f


M SF
L
A
From (1) Q
f
= ---- = ---------
C
f
C
f



Withdrawal flow, Q
u


M SF
L
A
Q
u
= ---- = --------
C
u
C
u


Overflow rate (Clarification Rate, Surface Loading Rate), v

- the sedimentation tank application rate

Q
f
SF
L
A / C
f
SF
L
SF
L

Overflow rate, v = ---- = ------------- = ------- = ---------
A A C
f
MLSS
9-Secondary Sedimentation Tank-Zone Settling F12
12


Underflow rate, u
Q
u
SF
L
A / C
u
SF
L
M
Underflow rate, u = ------ = ---------------- = ------ = --------
A A Cu C
u
A

Q
f
Q
u
Q
u
Q
f
RQ Q
f
R Q
f
R Q + Q
r

u = ----- ------ = ------ ------ = ---------- ------ = ------- ------ = ------- ---------
Q
f
A Q
f
A Q (1+R) A 1 + R A 1 + R A

where Q
u
= RQ
Q
f
= Q + Q
u
= Q + RQ = Q (1 + R)

Note: G
L
A = M or G
L
= M/A


Design criteria:

1) An overflow rate is less than the settling velocity of the feed solids

Q
f

---- < v where v = zone settling velocity of the feed solids
A

2) A solids loading rate is less than the limiting solids flux, SF
L


M C
f
Q
f

--- = ---------- < SF
L
or M = (SF
L
) A


A A





9-Secondary Sedimentation Tank-Zone Settling F12
13


Example: What is the required surface area of the secondary clarifier?
Given: Q
f
= 3.6 MGD, C
f
= 2,000 mg/L, SF
L
= G
L
= 20 lb/ft
2
/day


(Solution)

M = SF
L
A or SF
L
= M /A where M = Q
f
C
f
and Q
f
= Q + Q
u

M Q
f
C
f
(2,000 mg/L)(3.6 MGD)(8.34) 60,000 lb/day
A = ----- = -------- = -------------------------------------- = ----------------- = 3,000 ft
2

SF
L
SF
L
20 lb/day/ft
2
20 lb/day/ft
2





Aeration Tank
Q
f
= Q+Q
u
C
e
~ 0
Q Q+Q
u = Q(1 + R) Q
e
=Q - Q
w
C
f
= MLSS C
f
v
i
= Q
f
/A
Q
u
,C
u = zone settlinf velocity
u = Q
u
/A
= under flow rate

Q
r
Q
u
X
r
= C
u
Q
w
~ 0
C
u
R = Qu/Q = Qr/Q


Overflow rate, OFR and OFR*, m
3
/m
2
d

a) Overflow rate based on clarifier inflow, Q + Q
r


u L
f
Q Q SF
OFR
A C
+
= =

b) Overflow rate based on raw flow, Q
*
Q
OFR
A
=

Since Q
u
= RQ
Q
f
= Q + Q
u
= Q + RQ = Q (1+R)

Q + Q
u
= Q (1+R)

9-Secondary Sedimentation Tank-Zone Settling F12
14
Solve for Q
1
u
Q Q
Q
R
+
=
+

( ) ( )
1
*
1 1
u
u
Q Q
Q Q Q OFR
R
OFR
A A R A R
+
+
+
= = = =
+ +


u
Q Q
where OFR
A
+
=