Wastewater and Sewage Sludge A Basic Introduction

What Im going to talk about

Brief introduction to the history of wastewater What a wastewater treatment plant looks like The basic wastewater treatment processes Sewage sludge a whole new world

Why Treat Sewage?? A Potted History of Sewage Treatment in the UK

The Early Days

14th Century - First mention of river pollution in UK in the River Fleet Up till 1800 most rivers clean last Salmon caught in the River Aire 1820 - Industrial Revolution created large conurbations discharging untreated sewage to rivers and unregulated trade discharges to rivers of organic and toxic pollution metals and chemicals

The Early Days

1850s
The great stink in London that affected even the proceedings in parliament.

Bazalgette built the first large scale public sewers in the world and created the London embankment.
But no treatment, he just moved the point of discharge to further downstream Cholera rampaged the land throughout the period 1850 -1870

Dr Snow in Soho
1860s -Dr Snow established that Cholera is waterbourne and spread by contaminated drinking water.(Koch did not isolate the bacillus until 1891)

He noticed that a single water pump was causing a large amounts of deaths..

He removed the pump handle stopping the outbreak and preventing the spread of a cholera to a much wider area

Bazalgettes London
1865 Bazalgettes first pumping stations completed converting London from an open sewer to a city with proper sewerage, transporting sewage to lower down in the Thames. Designed with enough capacity that it is still enough capacity in it to still be in use today The Thames Tideway is the modern equivalent and is being constructed now, almost 150 years later and is going to cost 3.6 billion taking 15 years (the same as Bazalgette) to build 22 miles of sewer (compared to 100 miles for Bazalgette)

Still quite early for wastewater treatment

1850s Typically water abstraction downstream of sewage discharge points Water treatment problem resolved by building moorland catchment reservoirs and distribution system to take the clean water to peoples taps. 1876 - Rivers Pollution Prevention Act good idea but ahead of its time because nobody knew how to treat sewage. Get out clause which meant no improvements

Early beginnings in Manchester

1880s Sewage farms First primary settlement tanks (horizontal flow) with Ferrous Sulphate/Lime addition which reduced BOD by 40-50%. Used soil as a media for secondary treatment but not possible to aerate soil and soil went rapidly anaerobic and provided very little treatment 1892 Stone- First percolating filters at Salford 1914 Arden and Lockett first activated sludge plant at Davyhulme

Sewage gets the Royal Treatment

Royal commission set up in 1898 to review methods of sewage treatment Took 17 years and ten reports to complete their findings Trade waste should be treated in admixture with sewage Consent standard 30:SS 20 BOD proposed where a minimum of 1 in 8 dilution in clean water is available

Set river water classification based on BOD

Things can only get better

Local Councils prevented trade discharges to sewer because it Spoilt the municipal effluent quality 1936 Public Health Act enabled traders to discharge to sewer but gave them deemed consents So no control except for new traders who also were charged for discharge. However some councils only applied a temperature limit (43 C) 1951 Rivers Prevention of Pollution Act required consents for new discharges (trade and municipal 1961 Public Health Act extended charges to deemed consents

..and better
1960s Mogden Formula introduced for traders as a method of controlling trade loads by charging 1961 Rivers Prevention of Pollution Act extended this to all existing discharges 1974 Control of Pollution Act An enabling Act which was brought into law by Statutory Instruments. Act covered discharges to air, water, land and noise.

1977 Pre 1937 discharges to sewer at last consented From 1977 to present day most environmental law has been through EC Directive although some of it has been included in 1991 Water Act EC produced a black list of chemicals to be banned from discharges Also a red list of Chemicals to be controlled in discharges e.g. toxic metals

..and better
1990 & 1995- Environment Act and Environmental Protection Act 1998 UWWTD required wastewater treatment for all areas above 15,000 PE River Quality Objective standards set to ensure rivers achieve required classification. Standard dependant on available dilution in river and upstream quality. Today standards are set by Stochastic models (statistically based e.g Monte Carlo Models) 2005- UWWTD increased to cover all works >2000 PE 2007 Environmental Permitting Regulations introduced 2009 First River Basin Asset Management Programmes for the Water Framework Directive. Environmental Permits get tighter

Sewage Treatment
What is Sewage and how do we treat it?

What is Sewage?
Screenings
Grit Faecal matter Urine Water

What is Sewage?
Once all the screenings are removed, the 0.5% that isnt water is: The consent is usually centred around BOD Ammonia Solids and sometimes Phosphorus, organic chemicals and metals

The Wastewater Treatment Process

Preliminary Treatment Primary Treatment

Secondary Treatment
Tertiary Treatment

Sludge Handling & Treatment

So what does a
Sewage Treatment Works look like?

Esholt WwTW
Treats a population of 487k
Treats 280 million litres a day Generates 33 tonnes of sludge Processes 51 tonnes of sludge Consumes 60,000 kWh

Generates 20,000 kWh

A little more detail..

The Wastewater Treatment Process

Preliminary Treatment

Preliminary Treatment Inlet works

Sewer

Coarse Screens (optional)

Grit Removal (optional)

Fine Screens

Primary treatment

Screenings treatment

Grit treatment

Screenings treatment

What comes down the sewer?

Getting the big stuff out

Coarse Screens
Usually around 25mm bars to take the big stuff out

Taking out the fine stuff

Fine screens
Typically a function of the consent and are normally specified as 6mm in 2 dimensions

What comes off the screens?

Screenings Treatment
The washer/dryer of the sewage treatment world

Grit Whys it a problem?

Problems with flow measurement Erosion and wear of downstream equipment, pumps etc Settles and takes up volume in sludge storage Reduces volume in digesters reduced gas/energy production

Better here

Than here

How is Grit removed

What happens when preliminary treatment goes wrong

And when it goes right

The Wastewater Treatment Process

Preliminary Treatment Primary Treatment

Primary Treatment
Settlement

Preliminary Treatment

Primary Settlement

Secondary Treatment

Sludge Treatment

Primary Settlement

Rely on gravity to settle out lighter SS material Circular or Rectangular constructions Usual designs : minimum 2 hours retention at peak flow 30-50% removal of organic load and 60% of solids High calorific value removed and goes off to digesters to produce energy

The Science
Stokes Law

In practice this means: A residence time in the primary settlement stage of 2 hours An upflow velocity of 1.2m3/m2/hr with all tanks in service

What tanks are there?

Septic tanks Rectangular Dortmund Upflow (cone)

Radial Flow

So what happens?
Fluid retention time of at least 2 hours Scraper bridge scrapes it into the hopper

Sludge collects in the bottom

Sludge removed by pump periodically either manually, by timer, solids mode or level control

The Wastewater Treatment Process

Preliminary Treatment Primary Treatment Secondary Treatment

Secondary Treatment
The engine room of wastewater treatment

Primary Treatment

Secondary Treatment

Tertiary Treatment/ Outfall

Sludge Treatment

Secondary Treatment A Biological process

Soluble organic fraction removed by biological treatment typically by either trickling filters or activated sludge plant (ASP) but could be something else.

Trickling Filters
Fixed film process meaning the bacteria grows on the rocks and settled sewage is applied to it The most common type of all treatment work with excess of 50% of all treatment works in the UK ranging from a few hundred people to a hundreds of thousands served Settled sewage is dosed onto the filters using mechanical distributors. Parts of the slime regularly break away from the media surface and final settlement in humus tanks is required to produce a high quality final effluent.

Trickling Filters
Filter Media The filter media provides a surface for the biomass to grow upon and is generally made of slag, stone or plastic. The biomass requires air to survive and this is achieved through natural ventilation within the filter. This relies on fresh air having a direct path to the base of the filter which is achieved through vent pipes, holes or open centre wells. It is important that these are kept clear. Recirculation To maintain good wetting of filters most sites recirculate a flow of final effluent. This improves performance by a mixture of dilution and better distribution of flow throughout the filter

Trickling Filters
Advantages Simple and easy to operate Low or no power Relatively cheap to build Resilient and robust to change and toxic shock Very good for small works Adaptable Disadvantages Large land take Not as efficient a removal process as suspended growth Not resistant to the cold Overgrowth and ponding

Activated Sludge (ASP)

Activated sludge consists of a mass of micro-organisms which feed on pollutants in the sewage. The bacteria is suspended in liquid and is called mixed liquor, it is mixed with sewage and aerated in aeration basins before passing to final settlement tanks where it is settled and the sludge returned. The effluent produced is of a high quality.

Activated Sludge (ASP)

Sewage enters the aeration tank and mixes with mixed liquor Bacteria eat the sewage and need to be fed with air More bacteria are bred and old sludge needs to be wasted to maintain a balance Sludge recycled around to ensure the mass of bacteria is maintained.

ASP
Surplus Activated Sludge

Denitrification NO3 NO2 N2

Anoxic Zone

(SAS)

Nitrification NH4 NO2 NO3

Aeration Lane Grows sludge on dissolved organics FST

Selector

50%

50%

Aeration adds O2

Return Activated Sludge (RAS)

Activated Sludge (ASP)

Advantages Very efficient producing a high quality effluent Common technique with a lot of industry knowledge Very adaptable to increasing loads Can be adapted for Nutrient Removal
Disadvantages Energy intensive More complicated to operate than fixed film processes Produces more sludge than fixed film

Wait!theres more
Tertiary Treatment
As consents get tighter and tighter or populations increase or things change there is sometimes the need for further treatment. Typically this includes: Sand Filters (RGF & COUF) Drum filters Nitrifying Trickling Filters SAFs HSAFs BAFFs and many others..

So what happens to all the sludge..?

Sludge treatment.. a whole world of its own

WHAT IS SLUDGE?

WHAT DOES IT LOOK LIKE

Sludge depending upon its looks, colour, weight and nature depending where its from. It can range from a thin RAS sludge at 0.7% dry solids to dried pellets at 98% dried solids

WHAT IS SLUDGE?
Mainly water (up to 99%) Dissolved solids Settled and suspended solids Faecal matter Bacteria and other micro-organisms Nutrients (N, P, K) Metals Energy

SLUDGE PRODUCTION
Primary 50 to 60g ds/person/day Secondary 18 to 29g ds/person/day Typical total sludge per person 70g/day
PE x yield x 365 = mass (tds) Mass / concentration = volume mass

vol x conc

SLUDGE PRODUCTION
Approx 1.2 million tonnes dry solids produced in UK annually this 165kg per person per year YWS production 150,000tds last year

So what do we do with it all

In 2004 62% 19% 11% 7% 1% Agricultural Land Incinerated Land Reclamation Other (including composting) Landfill

Source: Water UK

SLUDGE TERMINOLOGY
Tonnes dry solids
Volume 1m3

Percent dry solids

990L water 490L water 10kg solids 1% ds 10kg solids 2% ds 240L water 10kg solids 4% ds

SOURCES OF SLUDGE

SOURCES OF SLUDGE
Primary sludge
Typically 3% ds (up to 5%) Primary cause of site odour

1 Bio

2 Tertiary

SOURCES OF SLUDGE
Primary sludge Secondary sludge
Humus typically 2% ds (1-3% ) SAS typically 0.6% ds (0.25-1.25% )

1 Bio

2 Tertiary

SOURCES OF SLUDGE
Primary sludge Secondary sludge Co-settled sludge
Typically 2% ds

1 Bio

2 Tertiary

SOURCES OF SLUDGE
Primary sludge Secondary sludge Co-settled sludge
Tertiary sludge
Normally returned as backwash liquor

1 Bio

2 Tertiary

OBJECTIVES OF SLUDGE MANAGEMENT

Reduce volume (removal of water) Reduce/remove odour Stabilise organic material (BOD removal) Remove pathogens Reclaim useful by-products (biogas, soil conditioners) Safe/appropriate disposal & recycling

BIOSOLIDS

>600 Sewage Treatment Works 50 Sludge Treatment Centres Varying degrees of treatment Varying costs of treatment Varying capabilities (sludge intake, sludge output, day and night operability)

STC LOCATIONS
Colburn Northallerton Leeming Bar

Bridlington Knostrop Esholt Mitchell Laithes Calder Valley Incinerator Wombwell Caldervale Lundwood Blackburn Meadows Woodhouse Mill Sandall Aldwarke Staveley Old Whittington Sutton Selby

Go o le

Naburn Beverley Hull

TYPICAL SITE LAYOUTS

Main types of treatment

Thickening Digestion Advanced Digestion Dewatering Conditioning Phyto-conditioning Incineration

THICKENING
Decreases volume of sludge by removing water to reduce downstream process size Gravity settlement (storage tanks, PFT) Gravity belt thickener* Drum thickener* *Polymer added to improve separation

THICKENING - aim
To achieve target dry solids with minimal solids loss in the filtrate Target solids is 6% ds thicker sludge is difficult to pump Filtrate is returned to the works and excessive solids can cause compliance problems

THICKENING - process
1 Sludge is conditioned with polyelectrolyte 2 Conditioned sludge is fed onto moving belt, water passes through the weave
Belt continuously washed by a high pressure jets to prevent solids accumulation in the belt weave

Standard flow rates are between 10 and 50m3 per m belt per hour Be aware of the maximum solids load for the asset (ie the thicker the feed sludge, the lower the allowable flow rate)

THICKENING - problems
Thin sludge can be due to: Sludge application rate too high Belt speed too high Incorrect polymer dose excessive dose may blind the belt Sludge characteristics eg excessive FOG Solids in filtrate can be due to: Incorrect polymer dose Solids running off the edge of the filter belt Problems with belt tracking, lubrication, tension (AMBS) Poly suppliers will provide support to determine optimum polymer

THICKENING - GBT
Gravity belt thickener

THICKENING - PFT

THICKENING - drum

POLYMER
Added to sludge prior to mechanical thickening and dewatering Poly adheres to sludge particles, causing the release of surface water, neutralisation of charge and conglomeration of small particles by bridging. Many different types of polymer used eg cationic, ionic, single chain, cross linked Type used depends on characteristics of solids (eg pH, age, source) type of mixing & dewatering device pH, Alkalinity, water hardness, temperature, can affect performance of polymers

POLYMER
Type of sludge is the primary factor affecting the type and quantity of polymer required Raw Primary sludge requires much less poly than SAS Old sludge requires a higher poly dose than fresh sludge Polymer concentration required for a sludge is determined in the lab by jar tests NB sludge feed will vary therefore poly dose will change

POLYMER - mixing
Mixing of sludge and polymer is essential for effective conditioning Good conditioning depends on polymer addition, retention time and mixing

DIGESTION - requirements
Min 12d primary digestion Min 32C Min 14d secondary digestion

Code of Practice for the Agricultural Use of Sewage Sludge (1989)

DIGESTION - benefits
Reduced odour -conversion of volatile compounds

sludge

Reduced sludge mass -conversion of solids to gases Production of methane -a renewable energy source

volatile inert

solids

DIGESTION
Biogas

Feed
Heat exchanger

Treated sludge

Compressor

DIGESTION - biology
Complex organics

1. Acidogenesis
Clostridium Bifidobacterium Lactobacillus

Volatile acids CH4, CO2

2. Methanogenesis
Methanobaciterium Methanobacillus Methanococcus

DEWATERING
Thickening

990L water 490L water

Dewatering

10kg solids 1% ds

10kg solids 2% ds

40L water 10kg solids 20% ds

DEWATERING
Sludge feed Polymer

Centrate Dewatered cake

DEWATERING
Sludge feed

Polymer

Filtrate

Dewatered cake

DEWATERING

POLYMERS
Chains of molecules that stick sludge solids together to release water Charge type
Charge density

Molecular weight

POLYMERS
Chains of molecules that stick sludge solids together to release water Charge type
Charge density

Molecular weight
Molecular structure

Jet Wet process

LEVEL PROBES

JET WET HEAD

WATER SUPPLY

LEVEL PROBES POWDER HOPPER

AIR / POWDER

POWDER

SCREWFEEDER

VENTURI EDUCTOR AIR

MIXER

TRANSFER PUMP
BLOWER MIXING / AGEING TANK STORAGE TANK

DRY AREA

DEWATERING
Centrifuges
Bowl

Feed

Beach Scroll Weir plate

DEWATERING

CONDITIONING

CONDITIONING - Aim
Provides required secondary retention Allows drainage of free water Forms a stable, friable product Promotes aerobic conditions

CONDITIONING

SPC

SPC
Predation

Transpiration

Competition

Root penetration: enzymic degradation & aerobic conversion

INCINERATION

INCINERATION
Turbo generator

Sludge feed MP steam

Belt presses
Heat recovery section Filtrate Caustic scrubber Induced draft fan Fluidising air fan 2 field Electrostatic precipitator MP steam

Quench scrubber

Fixed bed adsorber

Flue gas stack

Fluidised bed incinerator

Ash to disposal

Sewage sludge The opportunities

Methane Production from Advanced and Conventional Digestion
Energy recovery from incineration or pyrolysis

Nutrient Recovery from sludge liquors

Utilisation of sludge liquors in BNR Processes

Biosolids to agricultural land

Topsoil production from Sludge phytoconditioning

Energy from sludge

Maximising energy throughput from sludges
There are a number of options:

Digestion and advanced digestion Incineration or pyrolysis Physical disintegration techniques CHP v- gas turbines v- biofuel

Sludge as a marketable product

Technology exists its how you produce it and how you sell it

Sludge as a marketable product

Biofert production at 13,200 tDS/annum

Sludge phytoconditioning

Biogas as a biofuel or supply to the gas grid Ringsend 50% of energy from biogas

Sludge liquors as a product

Pearl & Crystal Green

Sludge Treatment as a resource

Sludge liquors PEARL Process
Process that produces fertilizer by removing nitrogen and phosphorus from sludge liquors Works by adding magnesium and caustic soda to phosphorus rich sludge liquors and passing them through an upflow column The sludge liquors pass through pellets of struvite that are recirculated around to act as seeds.

The pellet size is a function of retention time in the reactor

Sludge Treatment as a resource

Sludge liquors PEARL Process
The pellets when ready are removed from the reactor and dried
The pellets are then bought, marketed and sold by OSTARA who developed the process as a fertiliser that they term Crystal Green This creates a marketable product from waste

ANY QUESTIONS??