Clarification (Settling): Theory and Applications

Plant Operations Seminar Thursday, July 22, 2010

DeKalb, Illinois Krishna Pagilla, Ph.D., P.E. Illinois Institute of Technology Chicago, Illinois pagilla@iit.edu

Principles of Settling Settling in Grit Tanks Primary Clarifiers Secondary Clarifiers

Principles of Settling

Principles of Settling
Forces acting on particles during settling
Particle Settling Velocity Types of Settling Surface Overflow Rate, Surface Area and Depth of Tank Shape of the Clarifier or Settling Tank Flow Field in the Tank

Forces acting on the particle

Particles must settle by gravity to the bottom of the tank and stay there Forces acting on the particle include: Gravity Overflow up velocity Drag force by fluid Fgravity Fdrag + Fbuoyancy + Fflow

Buoyancy Pushing by the water being displaced Settling velocity of the particle, Vs, is very important and is dependent on the size, shape, and density of the particle

Vs =

2 g(s-)dp

18

Particle Settling Velocity

Effect of Diameter on Particle Settling Velocity
350 300

Normalized Settling Velocity

250

200

150

100

50

0 0 2 4 6 8 10 12 14 16 18 Normalized Diameter

Settling Classes or Types

DISCRETE

II Non-Sticky Particles, e.g., Grit

FLOCCULENT

II Sticky Particles, e.g., Flocs, Primary Solids

HINDERED

III

Concentrated Flocs, e.g., Mixed Liquor Sludge

COMPRESSIVE

IV Sludge, e.g., Return Activated Sludge

Surface Overflow Rate

SOR = Qo A
Clarifier Overflow Clarifier Surface Area

Typical Operating Values: Primary clarifiers: 1,000 gpd/ft2 average Secondary clarifiers: 600 gpd/ft2 average

636 gpd/ft2 = 1.08 m/hr

This is a VELOCITY!

Settling in a Tank
Inlet Zone D, Depth Water Surface Outlet Zone

Sludge Zone L, Length Particles must settle depth D in , Hydraulic Retention Time = V/Q Vs > D/ = DQ/V Independent of depth; == DQ/DWL == Q/WL = Q/A Surface Loading Rate = Q/A = vo

Removal of smaller particles, if vs < vo

Surface Area and Depth in Settling

Non-sticky particles (e.g., grit) Depth is not as important, Surface Area is important Sticky particles (e.g., primary solids, secondary clarifier top layer, coagulated/flocculated solids) Both Depth and Surface Area are important Activated sludge blanket Surface Area is important and Depth may be important

Overflow Rate
Rapidly Settling Particle

Slowly Settling Particle

No Overflow

Low Overflow

High Overflow

Rectangular vs. Circular Clarifiers

Tank shape does not matter to particles, only flow field matters

Process Concerns
Particle Settling Velocity Distribution (PSVD) and flow field in the tank determine primary clarifier performance. Develop reasonable flow field and maximize performance.

Mechanical Concerns
Longitudinal Symmetry vs. Radial Symmetry Rectangular requires bicycle chain, pulley system (or traveling bridge). Circular permits central drive and radial mechanism more mechanical development

Site Footprint Concerns

Rectangular permits common-wall construction. Circular requires less concrete and steel with reduced wall thickness (hoop stress).

Flow Field in the Tank

Flow Field in the Tank is established by the hydraulics
of the tank Inlet-Outlet Structures, Mechanical Equipment within the Tank, and Size/Shape of the Tank The operator has very little control over flow field once the tank is in-place, except to reduce or increase flow Determine flow field by drogue tests, doppler measurement, computational fluid dynamics Perhaps a sludge judge will provide same info

Summary of Theory-Principles
The larger the particle the better for settling Sticky versus Non-sticky particles Four types of settling behavior Overflow rate and surface area and/or depth are important Tank hydraulics and flow field play a major role

Settling in Grit Tanks

Basics of Grit Settling

Sandy material, mostly inorganic, is grit Mostly between 0.05 and 1 mm in diameter Considered to be non-sticky particles, but are mostly sticky particles. Coated with fats, oils and grease in the sewers, increasing buoyancy (upward force) Need to know true grit size to determine the settling velocity wet sieving versus dry sieving If not removed in grit tanks, ends up in digesters Grit characteristics change with flow rates to the plant

Wet Sieving versus Dry Sieving

Eutek Systems, 2006

Cut-Point Particle (CPP) Tank Design

Text book design 200 300 micron Sand Equivalent Size Recommended 60 micron SES

4.5 gpm/ft2 = 6500 gpd/ft2 Eutek Systems, 2006

Aerated Grit Tanks - Operations

Usually see very low <10% grit removal in some cases Best method is see the Fixed Solids (FS) mass balance around the tank In minus Out = Grit Removed Check FS content in the influent at different flows throughout the year First flush is high in grit content Check grit accumulation in the digester Where does the grit settle along the length of the tank?

Settling in Primary Clarifiers

Primary Clarifiers
Purpose and Capacity Performance Comparison Performance Improvement Influent Characteristics Impact Enhanced and High Rate Primary Clarification Summary

Primary Clarifiers
Remove organic particles by gravity instead of costly biological treatment Recovery organic solids for biogas production instead of burning them in the aeration tanks Capacity available in the primary clarifiers is a function of the secondary treatment available and settleability of the influent solids Performance varies from plant to plant and from day to day

Comparing Primary Clarifier Performance

Facility/Data Set Metro North Complex Metro South Complex Metro Total Primary Process Littleton Englewood WERF PCPP Edmonds, WA Square PCPP Edmonds, WA Squircle PCPP LOTT WW Characterization Lincoln, NE 1 Historical Lincoln, NE 2 Historical Lincoln, NE 3 Historical Lincoln, NE 4 Historical Lincoln, NE 5 Historical Lincoln, NE 6 Historical TSS Removal, % 59% 53% 57% 53% 57% 59% 54% 63% 64% 66% 67% 67% 66% 35% 38% 34% 36% BOD Removal, % 28% 30% 28% 27% 34% 32% 34%

Archie Elledge: 2001 2006 Archie Elledge: 2006 Dr. David Kinnear, HDR

69% 69%

28% 30%

Comparing Performance
Facility/Data Set TSS Removal, % Bowery Bay Battery 6 Bowery Bay Battery 9 Coney Island Jamaica North River North Battery North River South Battery Oakwood Beach Owls Head Owls Head Port Richmond Rockaway Tallman Island East Battery Tallman Island West Battery Wards Island North Battery Wards Island South Battery 66% 36% 46% 44% 53% 41% 62% 58% 59% 47% 52% 66% 67% 57% 50% BOD Removal, % 44% 30% 44% 28% 29% 29% 45% 22% 23% 35% 38% 29% 33%

Archie Elledge WWTP Primary Clarifier Performance TSS Removal vs. Flow
100%

90%

80%

TSS Removal, %

70%

60%

50%

40%

30% 10 12 14 16 18 20 Flow 22 24 26 28 30

Archie Elledge WWTP Primary Clarifier Performance BOD Removal vs. Flow
90.0% 80.0% 70.0%
BOD Removal, %

60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% 10 12 14 16 18 20 Flow 22 24 26 28 30

Improving Performance

Retrofit TSS Comparison

City of Lincoln, NE Theresa Street Wastewater Treatment Facility Primary Clarifier Performance Comparison
70% 68%

66%

64%
TSS Removal

62%

60%

58%

56% Pre-Retrofit 54% PC1 PC2 PC3 Clarifier PC4 PC5 PC6 Post-Retrofit

Retrofit BOD Comparison

City of Lincoln, NE Theresa Street Wastewater Treatement Facility Primary Clarifier BOD Removal Peformance
50% 45% 40% 35%

BOD Removal

30% 25% 20% 15% 10% 5% 0% PC1 PC2 PC3 Clarifier PC4 PC5 PC6

Pre-Retrofit Post-Retrofit

Effect of Primary TSS Performance on Activated Sludge MLSS and OUR

3,500 450

3,000

440

2,500

430

MLSS, mg/l

2,000

420

1,500

410

1,000

400

500
MLSS OUR

390

0% 10% 20% 30% 40% 50% 60% 70% 80% Primary TSS Performance

380

OUR, mg O/l/hr

Chemically Enhanced Primary Treatment

Coagulant/flocculant addition destabilizes particles and/or strengthen flocs structure (Metal Salts). Increased conversion of Nonsettlable particles to Settlable particles? TSS and BOD removal increases. TSS removal increases from 50% - 60% to 70% - 85%. (20 mg/l FeCl3, 0.25 mg/L polymer)

Vs = g(s-)d2 18

High Rate Primary Clarification

Chemically enhanced primary treatment plus a weighting agent to increase particle settling velocity.

Vs = g(s-)d2 18

Five Wastewater Components

1) Soluble

5) Sand

4) Coagulant Ferric or Polymer

2) Nonsettleable

3) Settleable

Flocculation Floc Incorporates Sand

1) Soluble

5) Sand

4) Coagulant Ferric or Polymer

2) Nonsettleable

Energy 3) Settleable

Coagulant Incorporates NS into Flocs

Soluble

Settleable

Settling Velocity Distribution

Waterloo, Canada Settling Velocity Distribution

Weight Class Fraction % 1 2 3 4 5 6 7 8 9 0.15 0.15 0.05 0.05 0.05 0.05 0.05 0.05 0.40 100% mg l-1 37.5 37.5 12.5 12.5 12.5 12.5 12.5 12.5 100.0 250.0 After Alarie, et al. (1980) Concentration* Settling Velocity gpd ft-2 5,054 2,907 1,688 1,122 742 539 283 177 0

*Assumed 250 mg/L TSS Concentration

SVD Effects Behavior in Clarifiers

Weight Class Fraction % 1 2 3 4 5 6 7 8 9 0.15 0.15 0.05 0.05 0.05 0.05 0.05 0.05 0.40 100% mg l-1 37.5 37.5 12.5 12.5 12.5 12.5 12.5 12.5 100.0 250.0 Concentration* Settling Velocity gpd ft-2 5,054 2,907 1,688 1,122 742 539 283 177 0 THESE YOU WILL NOT GET = 137.5 mg l-1 THESE YOU WILL GET = 37.5 mg l-1 THESE YOU WILL GET = 75 mg l-1

Assumed 250 mg/L TSS Concentration

Summary
Best way to remove and recover organic matter from wastewater is by effective primary clarifiers A significant amount of flocculation occurs during testing for particle size or velocity distribution of influent solids Particle size distribution and nature changes with seasons, flows, and other influent conditions Enhance solids removal by adding chemical to some extent Performance varies from plant to plant

Secondary Clarifiers

Secondary Clarifiers
Activated Sludge Process and Clarifiers Purpose and Objectives of Secondary Clarifiers Clarifier Overloading and Consequences Enhance solids removal by adding chemical to some extent Performance varies from plant to plant

ACTIVATED SLUDGE PROCESS

CLARIFIER AERATION TANK INFLUENT MIXED LIQUOR EFFLUENT

RETURN ACTIVATED SLUDGE

WASTE ACTIVATED SLUDGE

Secondary Clarifier Purpose

MLSS Retention Liquids released from system; solids remain. Secondary Effluent Production Permits controlled system wasting and SRT control
Mass distribution between aeration basin and secondary clarifier is critical. Minimizing secondary clarifier resident biomass should be objective. Which components of the MLSS present problems for mass distribution (clarifier overload)?

Secondary Clarifier Design and Operational Objectives

Minimize Total Solids Present in the Secondary Clarifier Through Design And During All Operating Conditions Clarifier is for Solid-Liquid Separation Only

Consequences of Excessive Clarifier Solids

Hydraulic Consequences Interference with settling and scour Biochemical Consequences VFA production Decreased aeration basin nitrifiers Secondary Phosphorus release Denitrification

Secondary Clarifier Performance Influencing Factors

Solids Loading Rate = MLSS x (Q + QR)/Surface Area Hydraulic Loading Rate = Q/Surface Area Sludge Removal RAS Rates and RAS Concentration Hydraulics of the Tank Solids Distribution in the Activated Sludge Process Solids Flux Analysis Settleability of Sludge
Sludge Volume Index or SVI Bulking and Foaming Issues

Loading Rates and Recycle Rate

Solids Loading Rate = 30 to 50 lb/square foot-day Hydraulic Loading Rate = 600 gal/square foot-day Recycle Ratio, R = X/(XR X) = 30 to 100% These values are good when SVI = 50 to 100 range The goal is get the solids back into the aeration tank without storing them in the clarifier. Increase recycle ratio, R or Recycle Rate, QR during storm events

Hydraulics of the Tank Idealized Clarifier Hydraulics

Hydraulics of the Tank

Extended Sampling/Stress Testing Computational Fluid Mechanics Acoustic Doppler Velocity Measurement Sludge Judge Measurement

Hydraulics of the Tank Computational Fluid Dynamics

Measuring Solids Distribution

1. Aeration Mass = MLSS * Aeration Volume

2. Sample Clarifier with Sludge Judge at Several Locations

3. Empty Entire Sludge Judge in Bucket and Mix

4. Measure Average Clarifier Concentration (bucket contents)

5. Clarifier Mass = Average Clarifier Concentration * Clarifier Volume

6. Plot Daily as Mab and Mc or %ab and %c

Clarifier Mass, Percent

10%

20%

30%

40%

50%

60%

70%

80%

0%

1/30/2001 2/6/2001 2/13/2001 2/20/2001 2/27/2001 3/6/2001 3/13/2001 3/20/2001 3/27/2001 4/3/2001 4/10/2001 4/17/2001 4/24/2001
Date

5/1/2001 5/8/2001 5/15/2001 5/22/2001 5/29/2001 6/5/2001 6/12/2001 6/19/2001 6/26/2001 7/3/2001 7/10/2001 7/17/2001 7/24/2001 7/31/2001

City of Lincoln, NE West Side Activated Sludge System Solids Distribution

System Mass, lbs.

1,000,000

1,200,000

1,400,000

200,000

400,000

600,000

800,000

1/1/2001 2/1/2001 3/1/2001 4/1/2001 5/1/2001 6/1/2001 7/1/2001 8/1/2001 9/1/2001 10/1/2001 11/1/2001 12/1/2001 1/1/2002 2/1/2002 3/1/2002 4/1/2002 5/1/2002 6/1/2002 7/1/2002 8/1/2002 9/1/2002 10/1/2002 11/1/2002 12/1/2002 1/1/2003 2/1/2003 3/1/2003 4/1/2003 5/1/2003 6/1/2003 7/1/2003 8/1/2003
CAS Clarifiers CAS Biological Reactors Date

Cedar Rapids, Iowa Water Pollution Control Facility Carbonaceous Activated Sludge System Mass Distribution

5 00 /2 /6 12 005 /2 22 9/ 05 20 9/ 7/ 005 /2 25 4/ 05 20 4 9/ 2/ 200 6/ /2 11 004 /2 12 9/ 004 /2 29 6/ 004 /2 15 4/ 004 /2 3 31 1/ 200 7/ /1 11 03 20 3/ 9/ 003 /2 20 6/ 03 20 6/ 4/ 003 /2 21 1/ 002 /2 /7 11 002 /2 24 8/ 002 /2 10 6/ 002 /2 27 3/ 002 /2 1 11 1/ 200 8/ /2 10 001 /2 14 8/ 001 /2 31 5/ 001 /2 17 3/ 01 20 1/ 1/
1,200,000 1,000,000 800,000 600,000 400,000 200,000 0 1,400,000

Hopewell Regional Wastewater Treatment Facility System Mass Distribution

Clarifier Mass
Mass in Secondary Clarifiers, lbs

Unox Mass

Based on 2001-2005 data

6.0

Overflow Rate Operating Line

Solids Flux Analysis

5.0

4.0

G, Kg/m 2 hr

3.0 2 2.0

Aeration Basin Clarifier Solids Transfer

1.0

Underflow Rate Operating Lines

0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0

CL

Co

CL
X, g/l

CU

Activated Sludge Settleability

SVI Batch Test May Not Represent Behavior in a Continuous Clarifier TIME:

30 20 10 0 min

Hindered Settling

Compressive Settling

Pilot Clarifier Operation Demonstrated Secondary Clarifier Behavior

BACTERIA -FILAMENTS AND FLOCS

70 TO 80% OF ACTIVATED SLUDGE IS BACTERIA BACTERIA CONTAINS FILAMENTS FLOCS < 10% OF BACTERIA > 90% OF BACTERIA

FILAMENTS ARE BACKBONE OF ACTIVATED SLUDGE (REBAR IN REINFORCED CONCRETE) FLOC FORMERS ARE BULK OF THE ACTIVATED SLUDGE (GRAVEL, SAND, AND CEMENT IN CONCRETE) FILAMENTS REINFORCE THE FLOCS TOGETHER AND MAKE THEM LARGER

IDEAL, BULKING, AND PIN POINT FLOC STRUCTURE

Bulking Control by Chlorination - KNOW WHEN TO STOP!

CHLORINATION TIME AERATION TANK 10 MGD
5 MG 2000 mg/L 83400 lb SOLIDS

CLARIFIER MIXED LIQUOR

RAS

5 MGD 10000 mg/L 417000 lb/day

WAS

83400/417000 = 0.2 days OR ABOUT 5 HOURS FOR EACH CHLORINE EXPOSURE