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Upflow Anaerobic Sludge

Blanket Reactor

Dr. Akepati S. Reddy


Dept. Biotech and Environ. Sci.
Thapar University
Patiala (Punjab) -147 004
Anaerobic treatment process
Anaerobic Treatment process
• Hydrolysis: extracellular enzymes convert complex, heavy,
un-dissolved materials (proteins, carbohydrates, fats) into less
complex, lighter, materials (amino acids, sugars, alcohols...)
• Can be rate controlling step.
• Acidogenesis: dissolved compounds are converted into
simple compounds, (volatile fatty-acids, alcohols, lactic acid,
CO2, H2, NH3, H2S ) and new cell-matter.
• Rarely rate controlling
• Stable activity even at pH <4
• Acetogenesis: digestion products are converted into acetate,
H2, CO2 and new cell-matter.
• Methanogenesis:acetate, hydrogen plus carbonate, formate
or methanol are converted into CH4, CO2 and cell-matter.
• Sensitive to pH >8 and <6.5 (virtually ceases at <6 pH)
Anaerobic treatment process
• Two types of methanogens
– Acetoclastic methanogenesis: use acetic acid as substrate in
methane production
– Autotrophic methanogenesis: uses carbon dioxide and hydrogen
in methane production
• Different from methanotrophs (these are methane
metabolizing)
• Used for anaerobically stabilizing biodegradable organic
matter
– Can also be used for the removal and recovery of metals

SO 4−2 + COD sulfate


  →HS − + CO 2
reducing bacteria

S −2 + M +2 → MS
Doubling Time Cell Yield Cell Activity
days g VSS g-1 COD g COD g-1 VSS
Active Sludge (sugar)
Aerobic Bacteria 0.030 0.40 57.8

Acidification (sugar)
Fermentative Bacteria 0.125 0.14 39.6

Acetogenesis (fatty acids)


Acetogenic Bacteria 3.5 0.03 6.6

Methanogenesis
Autotrophic (H2) 0.5 0.07 19.6
Acetoclastic
When compared (acetate)
with aerobic bacteria anaerobic bacteria have higher doubling
time, and acetogenic and methanogenic
Methanosarcina 1.5 bacteria have still
0.04 higher biomass doubling
11.6
time – indicates requirement of higher7.0
Methanosaete SRT 0.02 5.0
Cell yield is lower for anaerobic bacteria and when compared with acidogenic
bacteria, other anarobic bacteria have lower biomass yield – indicates sludge
generation is lower and acetogenic and methanogenic bacteria can upset the
process very easily
Anaerobic treatment process
Mesophillic or thermophillic process
35±3°C (mesophillic)
55±5°C (thermophillic)
Can be wet process or a dry process
Homogenous mobile slurry of <10% solids – wet process
Heterogenous fixed bed of solids flushed with liquid (>20% solids)
– land fills and invessel anaerobic composting are examples
First generation anaerobic reactors – conventional anaerobic
digesters like biogas plants
2nd generation anaerobic treatment processes (high rate
processes)
Attached growth processes – fixed film, expanded/fluidized bed
Suspended growth – CSTR, contact process, UASB, EGSB, etc.
Hybrid reactors and two and multiphase reactors
Upflow Anaerobic Sludge Blanket
Reactor (UASB)
Developed in the Netherlands in late 1970s by Prof. Gatze
Lettinga
Suitable for high strength wastewater – also suitable for
domestic sewage treatment in warm climates
Differs from other anaerobic reactors in
• Existence of granular sludge
– sludge granules with high mechanical strength and good
sedimentation properties (30-80 m/hr.)
– represent dense and compact balanced microbial community
with high methanogenic activity (0.5-2 COD/VSS.day)
– Resistant to toxic shocks
• Internal 3-phase GSL (gas-solid-liquid) separator system
biogas

gas
cap
Effluent settler

Effluent
gas Recycle
bubble

sludge
granule

Sludge
Bed

Influent
UASB
• Reactor zone
– Sludge bed zone
– Sludge blanket zone
– Contain granular or flocculant sludge
• Settling zone
– 3-phase separator
– Inclusive of Gas system and Effluent system
• Also includes
– influent distribution system
• Flow division and distribution boxes
• Distribution tubes and necessary pipings and fittings
– Sludge discharge system
– Provisions for sampling
STP incorporating UASB
UASB Reactor
Basis for Design
There are no universal design models and no clear
systematized guidelines for the design
• Organic loading rate based approach
– Followed when COD is 5000-15000 mg/L or more
– Typical organic loading rate range: 4-12 kg COD /m3.day (average
loading is 10 kg COD/m3.day - for expanded granular sludge bed,
EGSB, it is 20 kg COD/m3.day)
• Upflow velocity based approach
– Followed when COD is <5000 mg/L
– Typical upflow velocity is 0.6-0.9 m/hr. (Volumetric hydraulic loading
rate is < 5 m3/m3.day and HRT is 4-12 hours)
• HRT, Concentration in sludge blanket and sludge bed,
Minimum SRT required (temperature dependent) and
Velocity through aparture are also considered
Volumetric loading rate
• In case of domestic sewage, when temperature is
>15°C, if sufficient alkalinity is available, organic loading
can be >1.5 kg/m3.day (2.5 to 3.5 kg/m3.day) and HRT
can be >4-6 to 16 hours

Sewage temperature Hydraulic detention time (HRT)


For average flow For peak flow (4 to 6 hr.)

16-19 10-14 7-9


20-26 6-9 4-6
>26 >6 >4
Organic loading rate

• Loads adopted are <15 kg COD per m3.day


• For domestic sewage and for wastewaters with COD
<1000 mg/l, it is 2.5 to 3.5 kg/m3.day
– higher loads result in excessive hydraulic loads, and higher
upflow velocities
– Can be designed on the basis of volumetric hydraulic loads for
substrate concentrations <5000 mg/L
Biological loading rate

• During start-up, depending on the type of effluent, biological


loading rate should be in the range of 0.05 to 0.15 kg COD per
kg VSS.day
– Excessive loading can affect process stability (pH and VFA)
• Maximum biological loading rates depend on the
methanogenic activity of the sludge
– for domestic sewage 0.3 to 0.4 kg COD/kg VSS.day is the limit
Upflow Velocity
Maximum upflow velocities depend on
– type of sludge present
– loads applied
When COD <5000 mg/L granular sludge is hardly formed and
reactor is designed for 0.5 m/hr. upflow velocity and 4 hour HRT
For flocculant sludge and for organic loading rates of 5-6 kg
COD/m3.day average upflow velocity is 0.5 to 0.7 m/hour
– 0.9 to 1.1 m/hr for maximum flows
– Upto 1.5 m/hr for temporary peak flows persisting for 2-4 hr.
Upto 10 m/hr for granular sludge
Reactor height
Reactor height depends on
– Type sludge present in the reactor
– Organic loads applied
– Volumetric hydraulic loads applied
Height includes height of sludge layer and height of
sedimentation
• Sludge layer height is 3-5 m for COD <3000 and 5-7 m for COD
>3000 mg/L and settling zone height is ≥1.2 m
• For the reactors treating domestic sewage sludge layer height is
2.5 to 3.5 m and settler is 1.5 to 2.0 m
Upflow velocity, reactor height and HRT are closely related
– Height is 3 to 6 m for upflow velocities <1.0 m/hr and HRTs
6 to 10 hours
Reactor volume

HRT * Flow rate


– >4 hours (or hydraulic loading rate is <6 m3/m3.day)
C * Q * rv
– C is COD of the wastewater
– Rv is organic loading rate (<15 kg/m3.day)
Influent distribution system
Feed water distribution should accomplish
– Optimal contact between the sludge and the sewage
– Avoid hydraulic short circuits and formation of dead zones
– Prevent channelling (high gas production rates minimizes)
Even distribution of influent in the lower part of the reactor is more
important at lower temp. for low strength waste water – low
biogas production do not allow proper mixing
Short circuiting can also be caused by
– Short heights of the sludge bed
– Fewer number of influent distributors
– Concentrated sludge with high settling velocity
Distribution system includes (multi-level) distribution compartments
and distribution tubes
Influent distribution system
Distribution compartments are installed over the reactor and
distribution tube are issued from it
– blocking of the tube can be easily detected
Sewage velocity in the distribution tubes should be <0.2 m/sec. for
avoiding air bubbles dragging
– air bubbles can result in potentially explosive air-biogas mixtures in the 3-
phase separator
Diameter of distribution tube should be 75-100mm
– avoids frequent blocking (effluent screening can help)
Lower ends of the distribution tubes should be installed at the fixed
pre-established points
Inlet tubes should allow easy cleaning
Multiple cone bottom of the reactor can be helpful
Influent distribution system
Sufficiently high tip velocity (0.4 m/sec.) is needed to allow
good mixing and greater contact with sludge bed
– Tubes with 40-50 mm diameter nozzle at the tip to achieve
exit velocity of 0.4 m/sec. are used
– as an alternaitive, tubes can be provided with side
apertures (windows) of 25x40 mm size
Number of distribution tubes is decided on the basis of area
of influence of each tube and total area of the reactor
Area of influence usually ranges between 1 and 4 m2 -
– For reactors treating domestic sewage it is 1.5 to 3 m2 (2-3
m2 is recommended when COD is 400 to 600 mg/L)
Area of influence is a function of the type of sludge and the
organic loads applied
– More for flocculating sludge than for granular sludge
– Increases with increasing organic loading
Three phase separator
• Liquid entering the settling zone should be free from
biogas bubbles
– Deflectors overlapping with gas collection hoods ensure this
• Within hoods enough gas-liquid interface is needed to
allow release of gas bubbles breaking the scum layer
– Possible foaming should be taken care of within hoods
• Settling zone should have sloping bottom to allow sliding
of settled sludge into the reactor
– Depth of settling zone and upflow velocity in the settling zone
should ensure efficient clarification of the effluent
– Aparture between hoods should be big enough to allow settled
sludge return into the reactor zone
• For collecting the clarified effluent collection troughs with
enough weir length are needed
– Scum baffles should be provided in front of the overflow weirs
3-phase Separator
Low upflow velocities, absence of gas bubbles, sufficient depth of
sedimentation compartment are important
• Slopes of sedimentation surfaces should be 45-60°
• Depth should be 1.5 to 2 m
• HRT should be 1.5-2.0 hr. for average flow, >1.0 for maximum
flow and >0.6 hr for peak flows
• Aparture area between gas collection hoods is 15-20% and gas
dome edge overlaps should be 10-20 cm
• Hydraulic surface loading rates should be 0.-0.8 m/hr for average
flow, <1.2 for maximum flow and <1.6 for temporary peak flows
• Velocities in apertures are <2.0-2.3 m/hr for average flow, <4.0-4.2
for max. flow and <5.5-6.0 for temporary peak flows
Three phase separator
Effluent collection
• Plates with V-notch weirs and submerged perforated tubes
are used
• Scum baffle submerged 20 cm is inclusive of the launder with
V-notches
• Submerged perforated tubes
– Eliminates the risk of turbulence and release of gases and bad
odors
– Do not need scum baffles
– Solids can accumulate in holes and inside the perforated tubes
– For self-cleaning 1% slope is recommended
Three phase separator
Gas system
• Includes provisions for biogas collection, conveyance, storage,
metering and disposal (either used or burnt)
– Collection includes a sealed compartment with hydraulic seal and
biogas purge
– Gas production rate and gas composition (CO2 and H2S) may
need monitoring
– metering is essential for evaluating process efficiency
– If biogas is to be flared then gas reservoir can be replaced by a
security valve (flame trap!) and gas burner
– For avoiding drag of condensed liquids flow velocity in the piping
is maintained <3.5 m/sec.
• Liquid gas interface is maintained in the gas collection hoods
for facilitating easy release of gas bubbles
• Gas collection hood caps may have antifoam nozzles
Sludge sampling system
Sampling system includes a series of valves installed along
the height of the digestion compartment
• Helps to determine solids profile of the digester and allows
establishment of sludge discharge strategies
• Helps to evaluate specific methanogenic activity and sludge
characteristics and in determining the ideal sludge discharge
points
• Sludge sampling points
– Can be 5 or 6 points, spaced at 50 cm distance, can be 1.5 to 2
inch in diameter and have ball valves for regulation
• Monitoring and control of temperature and pH at different
heights may be needed
Sludge discharge system

• Sludge discharge system (meant for the removal of inert


material accumulating at the bottom)
• At least two sludge discharge points:
– one close to the bottom to remove sludge from sludge bed zone
– another at 1-1.5 m height to remove sludge from blanket zone
– a third one can be 0.5 m below the settling zone
• Sludge discharge piping can be of >100 mm diameter
Sludge discharge system: SRT
• Prime design criterion specially for dilute sewage
• SRT required depends on temperature and it is 140 days
for 15°C, 100 days for 20°C, 60 days for 25°C, 30 days
for 30°C, 20 days for 35°C and 15 days for 40°C
• Minimum SRT required is 3xTd
• Td is doubling time for methanogenic biomass
• Determined by incoming TSS, TSS lost in effluent, TSS
hydrolyzed and TSS withdrawn as sludge
• Should be greater than 3 times the methanogens
doubling time
Sludge discharge system: generation
and treatment
Y (yield coefficient) is taken as 0.1 to 0.2 of the COD
applied
Sludge is sufficiently stabilized, has good dewaterability , its
density is 1020-1040 kg/m3 and consistency is 3-5%
Sludge discharged in one batch should not be beyond 20-
25% of the total sludge present in the reactor
Can be sent directly to the dewatering units
Sludge drying beds used are designed based on surface
solids application rates (kg/m2.day)
Materials of Construction
Risk of corrosion is high
– Above liquid level by H2S (oxidized to SO4- & cause corrosion)
– Below water level CO2 dissolves concrete at lower pH
Concrete and steel with an internal coating in an epoxy base – plastic
fortified plywood
Measures to minimize corrosion
– Selection of appropriate cement
– Low water cement ratio
– Rigorous vibration of the concrete
– Adequate curing
– Use of special additives
– Acid resistant coatings/linings
– Painting with chlorinated rubber or bituminous epoxy
PVC, fibre glass and stainless steel for the solids and gas separator
(most exposed to corrosion)
Efficiencies
• Can remove COD by 70-80%, TSS by 70-80%,
pathogens by 70-90% and helminth eggs with 100%
efficiency in case of domestic sewage
• Not effective in nutrient removal
• Treatment efficiencies are very low at <10-15°C –
hydrolysis of particulate matter limits the process
• At 13-17°C for 14-17 hour HRT COD removal is 55-70%
• For 23-25°C at 4-6 hours HRT the removal is 80%
• Estimated by means of empirical
relations (
ECOD = 100 1 − 0.68 ×τ −0.35
)
• Applicable to domestic sewage for
20-27°C (
E BOD = 100 1 − 0.70 ×τ −0.5 )
• Substantially affected by HRT
ES 0
• 40 to 70% for COD and 45 to 90%
for BOD
Ceffluent = S0 −
100
Efficiencies

TSS in the treated effluent


• 40 and 140 mg/L and depends on
– Concentration and settling characteristics of the sludge
– Sludge wastage frequency and height of sludge bed and
blanket
– Efficiency of the gas, solids and liquid separator
– Presence or absence of scum baffles
– Loading rates and HRTs in the digestion and
sedimentation compartments
• Can be given by
TSS = 102 × t −0.24
Operation and control
Sensetive to wastewater composition (concentration of
various ions and presence of toxicants like phenols) and
strength, temperature, pH, etc. influence
Biomass washout can be a problem
Optimal pH for methanogens is 6.8-7.2 but acid forming
bacteria favour acidic pH
Temperature effect is insignificant on hydrolysis and
acidogenesis
– Temperature >5C
– Digestion rates are very low at <15C
Operation and control
COD:N:P ratio in feed wastewater 350:5:1 (C:N:P ratio of
200:5:1)
– Nutrient addition as NH4H2PO4 or (NH4)2CO3
Sulfur, potassium, calcium, magnesium, iron, nickel, cobalt,
zinc, manganese and copper are also required
– Methanogens apparently have higher iron, nickel and cobalt
concentrations
Buffering capacity of wastewater may have to be increased
to provide alkalinity of 1000-5000 mg/L
– Sodium bicarbonate can supplement alkalinity
TSS in feed should be <500 mg/L
• 50% of the COD in domestic sewage is contributed by suspended
solids
• Insoluble matter can occupy volume, suspended solids can form
scum layer and fats and lipids can cause foaming
Operation and control
• Startup time is 2-3 weeks for >20°C, otherwise 3-4 months
• Hydraulic loading during startup is <50%
• Startup needs sufficient amount of granular sludge
• During start-up, depending on the type of effluent, biological loading rate should be in
the range of 0.05 to 0.15 kg COD per kg VSS.day
– Excessive loading can affect process stability (pH and VFA)
• Maximum biological loading rates depend on the methanogenic activity of the sludge
– for domestic sewage 0.3 to 0.4 kg COD/kg VSS.day is the limit
UASB reactors: Advantages &
disadvantages
Advantages
– Compact and require less land
– Low energy consumption and low operating costs
– Low sludge production, and high concentration and good
dewatering sludge
– Satisfactory COD removal efficiencies (65-75%)
Disadvantages
– Bad odours
– Inability to tolerate toxic loads
– Start-up requires quite long time
– Wastewater needs further treatment

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