OPTIMIZATION OF REMOVAL EFFICIENCY AND OPERATIONAL

COSTS IN URBAN WASTEWATER TREATMENT PLANTS BY USING

BIOMASS CARRIERS

E. Grgn1, G. Insel1, S. Tabak2 K. nal2 and A.O. Erdogan2

1
Istanbul Technical University, Environmental Engineering Department, 34469,
Maslak, Istanbul, Turkey
2
io Environmental Solutions, Research and Development Ltd., Istanbul Technical University,
Ari Teknokent Ari 1 Building, No:3, 34469, Maslak, Istanbul Turkey.
E-mail: egorgun@ins.itu.edu.tr

ABSTRACT
In this study, the use of biomass carriers was found to be economically feasible option in terms of
investment and operational costs together with maintaining organic pollutant removal. A real high-
rate WWTP having an over designed capacity was extended with the use of biomass carriers in
current plant. Finally, after the extension, the system is able to handle approximately 3.4 times COD
load of existing wastewater treatment plant. The main advantages of biomass carriers to be used for
the purpose of the extension of existing urban WWTPs can be summarized as: (i) low operational
cost, (ii) no additional land requirements, (iii) easy to be integrated into nutrient removal plants and
(iv) short start-up period for the construction of the system.

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1. INTRODUCTION

In sensitive areas, appropriate wastewater management is the key issue for maintaining the quality
of the receiving water. The European directives enforces strict effluent nutrient discharge criteria
especially in coastal areas to prevent receiving waters from eutrophication problem. In the past, the
most favorable treatment choice was the conventional activated sludge system for municipal
wastewaters. As a common practice, the activated sludge plants have been designed for organic
carbon removal considering the future capacity extension of the wastewater treatment plant in
parallel to population increase. In this respect, without additional construction of biological stage,
the process extensions can be applied upon existing activated sludge systems that were previously
designed for organic carbon removal.

The promulgation of strict discharge standards requires additional processes such as nitrification-
denitrification for nitrogen in addition to organic carbon removal. In parallel to the pollution
increase, the coupling the nitrification-denitrification process alternatives should be considered in
the context of process performance and cost optimization. However, higher investment costs are
required for upgrading or extension of existing activated sludge systems which have exceeded
maximum capacity. Considering available process alternatives for the extension of existing system
to reach the optimal investment (Capex) and operation cost (Opex) providing sustainable effluent
quality, first issue is to handle the exceeded amount of pollutant loads (organic carbon). The above
mentioned process alternatives might include mainly (i) building of additional activated sludge
modules and (ii) the use of biomass carriers within the biological reactor units.

Biomass carriers are fashionable tools to be used within the biological reactors to maintain organic
carbon removal and alternatively nitrification. In this way, the biomass can grow on the attached
media (polyethylene etc.) without any adjustment of actual sludge age. In this respect, the Moving
Bed Biological Reactor (MBBR) technology aims to remove pollution with minor modifications
made in the aeration basin.

In this study, MBBR technology is analyzed and compared with the conventional activated
sludge system, considering the capacity extension for a real municipal wastewater treatment plant
which discharges into an inner-lake of Turkey. In this regard, the efficiency and overall costs
(Capex, Opex) were investigated for the application of MBBR technology that serves as an
optimum extension option.

2. DESIGN PARAMETERS OF MBBR PROCESS

The MBBR technology is based on specially designed plastic biofilm carriers that are suspended
and completely mixed within reactor of specified volume. The MBBR system design is critical
due to the requirements for efficient mass transfer of substrate and dissolved oxygen. In addition,
the design of aeration system, diffuser pattern, sieves, spray nozzles and other integral parts to the
reactor are of great importance in design [1]. Diffuser grid located at the bottom of the reactor
supplies oxygen to the biofilm along with the mixing energy required to keep the biocarriers
suspended and completely mix within the reactor. Most important design parameters of the system
are material filling ratio and accordingly, the specific biofilm surface area, hydraulic retention time,
organic loading rate (i.e. COD, BOD) and nitrogen. However, the shape and dimensions of
biocarriers do not play significant role in removal efficiency [2].

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 Figure1. Pictures of various biomass carriers (AnoxKaldnes-K1, IFAS-Agar)

After the primary treatment stage, the municipal wastewater is fed to the MBBR system where
biofilm growing attached on the biocarriers. Treated water flows out from the reactor through a
sieve, which retains the biocarriers in the reactor. The biofilm area is the key parameter in design
and therefore the design of the process is based on effective carrier area (g/m2carrier_area.d2). At
standard filling ratio of 67%, the total specific carrier area is around 465 m2/m3 [2]. The biofilm
carrier elements are made of polyethylene (density 0.95 gram/cm3) and shaped like small cylinders
with a cross inside the cylinder and longitudinal fins on the outside (Figure 1) [3]. In order to keep
them in the reactor, a sieve (net opening about 7 mm) is placed at the outlet of the reactor. In
design, the total organic lading should not exceed 65-85 gCOD/m2.day.

The typical biomass concentration is in order of 2-5 kgSS/m3 as the same as in activated sludge
systems. Since the volumetric removal rate, however, has been demonstrated to be several times
higher in the moving bed process, the biomass of this process must be much more viable than in
similar activated sludge processes [4][5]. In addition, the advantages of MBBRTM technology are (i)
resistant to environmental conditions, (ii) allows necessary oxygen transfer and (iii) does not need
return activated sludge.

3. EVALUATION OF CURRENT WWTP

The full scale municipal wastewater treatment plant under study was built in 1999, as a traditional
high rate activated sludge system [6]. Biological treatment units consist of two aeration tanks with
the volume of 2,800 m3 with 5 aerators each and two secondary clarifiers with activated sludge
return to aeration tanks. Figure 2 gives the current flow scheme of the mentioned WWTP.

Population and design and operational parameters of the WWTP are given in Table 1 and Table 2.
Furthermore the unexpected population growth and development of the city, the capacity extension
time planned in design has already been reached and current wastewater treatment plant is operated
with overcapacity. According to the original design data given in Table 1, the existing WWTP has
to be extended in 2005 and 2015.

TABLE 1. Populations and design parameters for periods

Parameter Years
2005 2015
Population 160,000 231.000
Maximum daily flowrate(m3/d) 37,500 51.000
Design flowrate(m3/d) 26,500
BOD5 charge(kg/d) 8,500
TSS charge(kg/d) 11,100

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 Return Sludge

Coarse & Fine

Screen Grit Chamber Primary Sedimentation
Aeration Tanks

Anaerobic Sludge
Digester

Final Sedimentation
Sludge Thickeners Tanks

Sludge Dewatering

Sludge Storage Tanks

Figure 2. Flow scheme of current WWTP

TABLE 2. Influent wastewater characterization used in design periods

Effluent Quality Years

(mg/L) 2005 2015
BOD5 230 300
COD 470 570
TSS 200 250

4. ALTERNATIVE CONFIGURATIONS FOR EXTENSION

Four different configurations are compared for the extension of existing municipal WWTP. First, a
traditional suspended growth activated sludge system is considered, and then at the rest of three
alternatives, different combinations of the biocarriers system are investigated thoroughly.

4.1 Configuration 1
In this alternative, existing process (suspended growth activated sludge) will be applied for the
extension. Based on the same design assumptions, three additional aeration basins are calculated to
be constructed and equipped with 15 more low speed surface aerators. Figure 3 gives the process
flow schematically. The necessary amount of recirculation flow will be provided by additional
recycle pumps. On the other hand there is a land limitation for this application. The allocated land
for the extension is not sufficient for more than 5 aeration tanks. So that when this alternative
accepted there will be no chance for further capacity increase after the year 2015.

4.2 Configuration 2
The system is designed for two phases. In the first phase (2005-2010), 26% of total aeration tank
volume will be separated with a steel plaque to fill with biofilm material (Figure 4a). This part will
be aerated with blowers and diffuser grid system. The construction of any additional aeration tank is
avoided, in this regard. As depicted in Figure 4a, the remaining part of the tanks are used as
conventional suspended growth activated sludge process as before. The current system will
guarantee the necessary removal efficiency for organic carbon.

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 Figure 3. Flow diagram for Configuration 1

(a) (b)

Figure 4. Flow diagram for Configuration 2

In second phase of Configuration-2 (period of 2010-2015), steel separator plaque will be removed
than whole volume of the aeration tanks will be filled by biofilm carrier materials and aerated with
blowers and diffuser systems (Figure 4b). The reason is that the activated sludge part will not be
able to handle the increased COD load and flowrates after the year 2010, because of insufficient
hydraulic retention time. After this revision the return activated sludge line will be unnecessary
since the biofilm system does not require any sludge recycle.

4.3 Configuration 3
An additional aeration tank with same dimensions will be constructed in this configuration. This
configuration is a combination of biocarriers technology with activated sludge treatment system.
Similar to first configuration 26% of total aeration tank volume will be separated with a steel plaque
to fill with biofilm carrier material. This part will be aerated with blower and diffusers system. The
rest of the tanks will be operating as activated sludge system until end of project time.
Configuration 3 is shown in Figure 5 schematically.

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 Figure 5. Flow diagram for Configuration 3

4.4 Configuration 4
Any additional tank construction is predicted in this configuration. Whole volume of current
aeration tanks will be filled with biofilm carrier materials in two steps. First 1600 m3 of biofilm
materials will be filled and after, 500 m3 will be added in to the aeration tanks on year 2010.
Schematic flow diagram of Configuration 4 is shown in Figure 6.

Figure 6. Flow diagram for Configuration 4

5. EVALUATION OF THE ALTERNATIVES

All the alternatives were evaluated technically and economically. To calculate the costs of Opex
and Capex, local construction and electro-mechanical equipment prices were used. Table 3 gives an
overview for the comparison of the alternatives while Figure 7 depicts the cost breakdown,
considering the Net Present Value (NPV) figures.

Table 3 shows that the conventional suspended activated sludge system has a number of
disadvantages when compared with the various biocarriers system configurations. Regarding to the
land requirement for current and future phases, the new technology has obvious advantages beside
its operational cost figures.

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 TABLE 3. General overview of the comparison of the selected alternatives

Advantages Disadvantages
Configuration 1
Minimum investment cost Maximum operation cost
Operators are familiar to this system Maximum construction period
Maximum land requirement
No available area for the next extension (2015)
No chance for upgrading N&P removal due to lack of area
Configuration 2
No additional construction cost. New technology for operation.
No additional space demand. Additional investment cost in 2010
Low energy consumption. Rather high investment cost
Easily integrated to nutrient removal.
No activated sludge return in 2nd phase.
Operational conveniences
Short time to commence to operation
Low operational cost and net present value
Configuration 3
Only one more additional aeration tank. New technology for operation.
Low energy consumption. Rather high investment cost
Easily integrated to nutrient removal.
Operational conveniences.
Short construction period
Low operational cost and net present value
Configuration 4
No additional construction cost. New technology for operation.
Low energy consumption Rather high investment cost
Easily integrated to nutrient removal Current superficial aerator will be removed.
No activated sludge return.
Operational conveniences
Short time to commence to operation
Low operational cost and net present value.

Figure 7. Comparison of Capex, Opex and NPVs of all alternatives

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Figure 7 gives an overall view related to the investment and operational costs of the all alternative
configurations. In order to evaluate the Capex and Opex of the systems together for the whole life
time period, NPV figures were calculated by using a discount rate of 10 % which is a realistic value
for Turkey. As can be seen from the figure clearly, while investment costs were rather close to each
other, because of the drastic gap between two different technologies, the NPV values for biocarriers
system configurations were far cheaper than suspended activated sludge systems.

6. CONCLUSIONS

The activated sludge plants are designed considering the expected population increase, in turn, the
organic loading. Thus, the design of AS systems using underestimated loads leads to severe
operational problems to maintain effluent quality. In this respect, several extension or upgrade
alternatives of activated sludge systems are required.

In this study, the capacity of a real full scale urban wastewater treatment plant was evaluated. As a
result, the use of biomass carriers was found to be economically and technically feasible option
considering the investment and operational costs together with maintaining sustainable organic
carbon removal. A real high-rate activated sludge plant having an over designed capacity was
extended with the use of biomass carriers within current activated sludge reactors. Finally, after the
extension, the system is able to handle approximately 3.4 times COD load of existing wastewater
treatment plant. Another major advantage of this system is considered as that it can be easily
upgraded to N and P removal according to the EU discharge criteria in sensitive areas.

The main advantages of biomass carriers to be used for the purpose of the extension of existing
urban WWTPs can be summarized as: (i) low operational cost, (ii) no additional land requirements,
(iii) easy to be integrated into nutrient removal plants and (iv) short start-up period for the
construction of the system.

7. REFERENCES

1. Rogalla, F., Johnson, T.L., MacQuarrie, J. 2005, Fixed Film Phosphorus Removal Flexible
Enough?, The Conf. Proc. of IWA Specialized Conference on Nutrient Management in
Wastewater Treatment Processes and Recycle Streams, pp. 271-285.
2. degaard,H., 2005, Combining CEPT and Biofilm Systems, The Conf. Proc. of IWA
Specialized Conference on Nutrient Management in Wastewater Treatment Processes and
Recycle Streams, pp. 257-269.
3. degaard,H., Rusten B. and Badin H. (1993) Small Wastewater Treatment Plants Based On
Moving Bed Biofilm Reactors, Wat. Sci. Tech. 28 (10) pp. 351-359
4. Rusten, B., J.G.Siljudalen, B.Nordeided (1994) Upgrading to Nitrogen Removal With the KMT
Moving Bed Biofilm Process, Wat. Sci. Tech. 29 (12) pp. 185-195.
5. Dulkadirolu, H. (2003) Kinetics of Carbon and Nutrient Removal in Moving Bad
Sequencing Batch Reactors, PhD Thesis, Istanbul Technical University.
6. Gorgun E., O.A.Erdoan, S.Tabak, K.nal (2005) Capacity Extension Project for Isparta
Municipality Wastewater Treatment Plant, Final Report, io Environmental Solutions R&D Ltd.