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Aeration Manual DRAFT P
Aeration Manual DRAFT P
98 ENG 395042
NOPOL
AERATION MANUAL
1 Introduction and Table of Contents
2 Activated Sludge Process
3 Factors Affecting Dimensioning of Aeration Process
4 AOR and SOTR
5 Production of Air
6 Aeration Control
7 NOPOL
DDS 7.26
7.7.3 Air Filtering System for NOPOL
DDS 7.27
7.8 Calculation Examples 7.29
7.8.1 Example 1 7.29
7.8.2 Example 2 7.39
8 NOPOL
100%
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where
E Process efficiency, %
S
i
Influent substrate (BOD) concentration, kg/m
3
S
e
Effluent substrate (BOD) concentration, kg/m
3
This criterion is somewhat misleading as a measure of purification efficiency
since it does not say much about the final quality of the sewage after
purification. For instance, if the efficiency is 90 % and the incoming BOD is
300 mg/l, the resulting BOD will be 30 mg/l. If the incoming BOD is 100 mg/l,
the resulting BOD will accordingly be 10 mg/l.
2.2.5 Sludge Age
Sludge age is defined as the average time during which the micro-organisms
participate in the aerobic biological process. Sludge age
c
is evaluated as
the ratio of total sludge mass in the system to the mass of sludge removed
per day. The value of sludge age affects the final purification result and the
Mohlmann index (SVI) which reflects the sedimentation properties of the
sludge. Sludge age may vary widely - from three to forty days, depending on
what type of process configuration is used. In plants under normal load
levels, sludge age varies from 5 to 10 days. Within this range a good BOD
reduction is achieved and the sludge will have good sedimentation qualities,
as demonstrated in Figure 6. In nitrogen removal processes, the sludge age
varies from 20 to 30 days.
Equation 7
c
w w e e
XV
X Q X Q
+
where
c
Mean cell residence time (sludge age) d
X Concentration of suspended solids in the
aeration basin
kg/m
3
V Aeration volume m
3
X
w
Concentration of suspended solids in excess
sludge
kgMLSS/m
3
Q
w
Excess sludge flow m
3
/d
X
e
Concentration of suspended solids in the effluent kgSS/m
3
Q
e
Effluent flow rate m
3
/d
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Figure 6: BOD removal efficiency and sludge sedimentation quality versus
sludge age
2.2.6 Mohlmann Index or Sludge Volume Index SVI
The sludge volume index (SVI) is used to describe the settling properties of
sludge. It is determined by allowing a suspension of activated sludge to settle
for half an hour in a 1-litre graduated cylinder. SVI is defined as the ratio
between the volume of settled sludge (g/1000 ml). SVI is therefore expressed
as ml/g. SVI value in most cases varies between 50 and 200 ml/g. Values
over 150 ml/g indicate poor settleability of sludge is caused by filamentous
organisms. Poor settleability of sludge is normally related to:
low dissolved oxygen level in aeration
nutrient limitation
septic waste water
low F/M
Nutrient balance is rarely problem in municipal waste water treatment plants
but in industrial waste water treatment plants it is more common. Nutrient
deficiency, particularly for nitrogen or phosphorus, produces poor settling
bulking sludge. The BOD: N: P ratio in the influent to aeration tanks should
be checked and adjusted if needed. A ratio of 100:5:1 should be targeted.
However, deficiencies of other nutrients (such as iron) are also possible.
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Low F/M bulking is often related to complete mixed aeration systems were
sludge load F/M is relatively low. Especially difficult problems are arisen
when waste water contains lots of soluble easily degradable carbon like
waste water from food, pulp and paper industry. Low F/M bulking can be
avoided by using contact zones before main reactor.
2.2.7 Volumetric Load
The volumetric load (F/V) of the activated sludge process or basin is defined
as the ratio between the daily organic load (BOD) fed into the aeration stage
and the volume of the aeration basin.
The volumetric load is expressed as kg BOD/m
3
d and it is defined as follows:
Equation 8
F V
S Q
V
i i
/
where
S
i
BOD concentration in influent
Q
i
influent flow rate, m
3
/d
V volume of the aeration basin, m
3
2.2.8 Sludge Load F/M
Sludge load F/M is the loading ratio of food-to-biomass of the activated
sludge process. Its value is the ratio between the daily incoming organic load
(BOD) of the aeration stage and the suspended solids (MLSS) in the aeration
basin. It is expressed as kg BOD/kg MLSS d.
Equation 9
F M
S Q
XV
i i
/
where
X concentration of activated sludge (MLSS), kg/m
3
Sludge load is often calculated based on organic part of the activated sludge
(MLVSS).
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The various process modifications have optimum sludge load ranges which
give the best process efficiency. Figure 7 illustrates SVI versus sludge load in
a conventional process which only reduces the BOD.
Figure 7: SVI versus sludge load
2.2.9 Mixed Liquor Suspended Solids MLSS
Mixed liquor suspended solids (MLSS) is the concentration of solids in the
activated sludge process. The sludge content (X = MLSS) in the aeration
basin is usually 2 to 6 kg/m
3
. A higher solids content is maintained in the
winter than in the summer to compensate for the lower biological activity due
to lower temperature.
Approximately 60 to 80 % of the total solids content (MLSS) in the aeration
basin is organic matter (Mixed Liquor Volatile Suspended Solids MLVSS).
The organic matter present is lower if primary sedimentation is not used or if
phosphorus is removed chemically. In the simultaneous precipitation process,
the proportion is decreased to 50 - 70 %.
2.2.10 Hydraulic Retention Time
Hydraulic retention time describes the time taken for the micro-organisms to
remove the oxygen-consuming soluble organic matter (BOD).
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Equation 10
i
h
Q
V
where
h
hydraulic retention time, h
Q
i
influent flow, m
3
/h
V aeration volume, m
3
Hydraulic retention time can vary from 2 to 24 hours depending on waste
water composition and process modification. Industrial sewage often requires
considerably longer retention times than municipal waste waters. If retention
time is below the specific value characteristic of the process modification
used, the sewage may be only partially purified.
2.2.11 Sludge Return Ratio
Sludge return ratio is the ratio between the volume of sludge returned to the
aeration basin and the volume of influent water. The sludge return ratio
normally varies from 30 to 100 % in large plants and from 50 to 150 % in
smaller plants, depending on the process modification used and on sludge
settling properties.
The ratio can be approximated by the following formula:
Equation 11
Q
Q
X
X X
r
i r
where
Q
i
influent flow, m
3
/h
Q
r
return sludge flow, m
3
/d
X
r
return sludge suspended solids, kg MLSS/m
3
X aeration basin sludge suspended solids, kg MLSS/m
3
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2.3 Process Modifications
2.3.1 Conventional Activated Sludge Process
In the conventional process, the sewage and return sludge are fed together to
the aeration basin inlet. Purification takes place progressively as the mixed
sludge liquor advances in plug flow across the uniformly aerated aeration
basin.
Table 1: Process characteristics and parameters
Aeration method bottom aeration, constant air feed
Oxygen requirement 1,2 - 1,4 kg O
2
/kg BOD
5
Type of flow plug flow
Purification efficiency 85 - 95 % BOD
5
Sludge age 5 - 10 d
Sludge load 0,2 - 0,4 kg BOD
5
/kg MLVSS d
Volumetric load 0,3 - 0,6 kg BOD
5
/m
3
d
Solids content 1,5 - 3,0 kg/m
3
Hydraulic retention time 4 - 8 h
Sludge return ratio 30 - 100 %
Special features of the process
permits a relatively low sludge load
requires a rather long retention time
oxygen demand is highest in the feeding zone of the aeration basin
sensitive to variation of hydraulic and organic load
a constant sludge content level is maintained
AERATION BASIN
SEDIMENTATION BASIN
INFLUENT EFFLUENT
WASTE ACTIVATED SLUDGE RETURNED ACTIVATED SLUDGE
MIXED LIQUOR
Figure 8: Diagram of conventional activated sludge process
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2.3.2 Tapered Aeration
In tapered aeration, process arrangements other than air feeding are exactly
the same as in the conventional process. The amount of air fed into the
process is reduced in proportion to the decrease in the oxygen demand along
the aeration basin.
Table 2: Process characteristics and parameters
Aeration method bottom aeration, progressively decreasing air feed
Oxygen requirement 1,0 - 1,2 kg O
2
/kg BOD
5
Type of flow plug flow
Purification efficiency 85 - 95 % BOD
5
Sludge age 5 - 10 d
Sludge load 0,2 - 0,4 kg BOD
5
/kg MLVSS d
Volumetric load 0,3 - 0,6 kg BOD
5
/m
3
d
Solids content 1,5 - 3,0 kg/m
3
Hydraulic retention time 4 - 8 h
Sludge return ratio 30 - 100 %
Special features of the process
amount of air fed into the process is proportioned in accordance with
oxygen demand
energy savings are achieved
over and under aeration is eliminated better
AERATION BASIN
SEDIMENTATION BASIN
INFLUENT
EFFLUENT
WASTE ACTIVATED SLUDGE RETURNED ACTIVATED SLUDGE
MIXED LIQUOR
DIMINISHING AERATION INTENSITY
Figure 9: Diagram of tapered aeration
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2.3.3 Step Feed
In step feed process, the incoming sewage is fed to different points along the
aeration basin. Return sludge is normally fed only to the aeration basin inlet.
By distributing the incoming sewage to various feeding points, the absorptive
capacity of aeration sludge can be maintained at such a high level that a
relatively short contact time is sufficient to ensure satisfactory purification.
Table 3: Process characteristics and parameters
Aeration method bottom aeration, constant air feed
Oxygen requirement 1,1 - 1,3 kg O
2
/kg BOD
5
Type of flow plug flow/complete mixing
Purification efficiency 80 - 90 % BOD
5
Sludge age 5 - 10 d
Sludge load 0,2 - 0,4 kg BOD
5
/kg MLVSS d
Volumetric load 0,6 - 1,0 kg BOD
5
/m
3
d
Solids content 2,0 - 3,5 kg/m
3
Hydraulic retention time 3 - 5 h
Sludge return ratio 30 - 100 %
Special features of the process
offers flexibility of application
permits higher sludge concentration levels
not sensitive to sudden peak loads
aeration basin dimensions are smaller than in other process modifications
longer sludge age with same basin volume
effluent quality not as good as in tapered aeration
AERATION BASIN
SEDIMENTATION BASIN
INFLUENT EFFLUENT
WASTE ACTIVATED SLUDGE RETURNED ACTIVATED SLUDGE
MIXED LIQUOR
AERATION
Figure 10: Step feed
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2.3.4 Complete Mixing Process
In the complete mixing process the mixture of incoming sewage and return
sludge is fed uniformly into the whole volume of the aeration basin. Oxygen
demand and sludge concentration are thus constant throughout the basin.
Table 4: Process characteristics and parameters
Aeration method bottom aeration, constant air feed
Oxygen requirement 1,0 - 1,4 kg O
2
/kg BOD
5
Type of flow complete mixing
Purification efficiency 80 - 90 % BOD
5
Sludge age 3 - 10 d
Sludge load 0,2 - 0,6 kg BOD
5
/kg MLVSS d
Volumetric load 0,8 - 2,0 kg BOD
5
/m
3
d
Solids content 3 - 6 kg/m
3
Hydraulic retention time 3 - 5 h
Sludge return ratio 30 - 100 %
Special features of the process
evens out incoming load peaks efficiently
constant conditions are maintained for micro-organism activity
sometimes problems with sludge settling properties
Figure 11: Complete mixing process
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2.3.5 Contact Stabilisation
In the contact stabilisation process, return sludge is fed to the aeration basin
inlet and aerated separately from the incoming sewage until the organic
matter contained in the sludge flocs has been stabilised, that is, used up for
energy release and the production of new micro-organisms. This stabilisation
stage is followed by a contact stage in which the sewage is mixed with the
aerated activated sludge.
Table 5: Process characteristics and parameters
Aeration method bottom aeration, constant air feed in contact and
stabilisation basins
Oxygen requirement 0,8 - 1,2 kg O
2
/kg BOD
5
contact 0,5 - 0,7 kg O
2
/kg BOD
5
stabilisation 0,3 - 0,5 kg O
2
/1 kg BOD
5
Type of flow plug flow
Purification efficiency 80 - 90 % BOD
5
Sludge age 5 - 10 d
Sludge load 0,2 - 0,6 kg BOD
5
/kg MLVSS d (contact stage)
Volumetric load 1,0 - 1,2 kg BOD
5
/m
3
d (contact stage)
Solids content 2,0 - 4,0 kg/m
3
(contact stage)
6,0 - 10,0 kg/m
3
(stabilisation stage)
Hydraulic retention time 1,0 - 3,0 h (contact) 3,0 - 6,0 h (stabilisation)
Sludge return ratio 30 - 100 %
Special features of the process
well suited to sewage containing organic matter in colloidal form (low BOD
of soluble matter)
aeration volume required can be as low as one half of that required by the
conventional process
owing to the sludge buffer effect in the stabilisation section, the process is
able to accommodate load peaks and toxic matter without difficulty
SLUDGE
REAERATION BASIN
CONTACT BASIN
INFLUENT
WASTE ACTIVATED SLUDGE
RETURNED ACTIVATED SLUDGE
SEDIMENTATION BASIN
EFFLUENT
SLUDGE
SEDIMENTATION BASIN
PRIMARY FINAL
Figure 12: Contact stabilisation
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2.3.6 Kraus and Hatfield Processes
In the Kraus process, some of the return sludge (10 -15 %) is fed into a
separate aeration basin into which sludge and supernatant from the digester
plant are also pumped. This mixture is aerated from 8 to 24 hours and
subsequently mixed with return sludge and fed to the aeration basin.
The Hatfield process differs from the Kraus process only in the fact that the
entire return sludge is treated as in the Kraus process.
Table 6: Process characteristics and parameters
Aeration method bottom aeration, constant or tapered air feed
Oxygen requirement 1,0 - 1,4 kg O
2
/kg BOD
5
Type of flow plug flow
Purification efficiency 85 - 95 % BOD
5
Sludge age 3 - 10 d
Sludge load 0,3 - 0,8 kg BOD
5
/kg MLVSS d
Volumetric load 0,6 - 1,6 kg BOD
5
/m
3
d
Solids content 2,0 - 3,0 kg/m
3
Hydraulic retention time 4,0 - 8,0 h
Sludge return ratio 50 - 100 %
Special features of the process
well suited to sewage with low nitrogen content (for example, industrial
waste water containing carbohydrates)
settling qualities of activated sludge are improved by admixture of aerated
sludge which is denser and has better sedimentation characteristics
processes have an improved ability to accommodate peaks in organic load
since the aerated sludge mixture contains nitrogen in the form of nitrate
compounds. This helps to maintain aerobic conditions in the process
REAERATION AERATION
WASTE ACTIVATED SLUDGE
RETURNED ACTIVATED SLUDGE
SEDIMENTATION BASIN
EFFLUENT
INFLUENT
DIGESTER SUPERNATANT
DIGESTED SLUDGE
Figure 13: Schematic representation of Kraus and Hatfield processes
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2.3.7 High-Rate Process
In the high-rate process the mixture of sewage and return sludge is
distributed uniformly over the whole volume of the aeration basin. The
aeration time is 0,5 - 2 h. Owing to the short aeration time the process is
sustained at the logarithmic growth phase in which micro-organisms
reproduce at a very high rate, using large amounts of nutrients and oxygen.
The sludge return ratio has to be maintained at a high level to ensure
sufficient feed of the activated sludge which makes flocculation more
effective.
The principle of the high-rate process is the same as that shown in the
diagram of the complete mixing process (
Figure 11).
Table 7: Process characteristics and parameters
Aeration method bottom aeration, constant air feed
Oxygen requirement 0,5 - 0,8 kg O
2
/kg BOD
5
Type of flow complete mixing
Purification efficiency 60 - 80 % BOD
5
Sludge age 1 - 3 d
Sludge load 0,4 - 1,5 kg BOD
5
/kg MLVSS d
Volumetric load 2,0 - 6,0 kg BOD
5
/m
3
d
Solids content 0,5 - 1,5 kg/m
3
Hydraulic retention time 0,5 - 2 h
Sludge return ratio 100 - 500 %
Special features of the process
best suited to applications where a high-grade purification is not required
suitable as pretreatment for other processes
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2.3.8 Extended Aeration
In the extended aeration process the mixture of sewage and return sludge is
distributed uniformly over the whole volume of the aeration basin, where it is
aerated for 18 - 36 hours. Owing to the extended aeration time the process is
maintained at the phase of endogenous growth in which there is a fierce
struggle for nutrition between micro-organisms. The insufficient availability of
nutrients leads to a situation where micro-organisms use each others cellular
material as a source of nutrition. The principle is the same as in
Figure 11.
Table 8: Process characteristics and parameters
Aeration method bottom aeration, constant air feed
Oxygen requirement 1,5 - 2,0 kg O
2
/kg BOD
5
Type of flow complete mixing
Purification efficiency 85 - 95 % BOD
5
Sludge age 15 - 30 d
Sludge load 0,05 - 0,15 kg BOD
5
/kg MLVSS d
Volumetric load 0,1 - 0,4 kg BOD
5
/m
3
d
Solids content 3,0 - 6,0 kg/m
3
Hydraulic retention time 18 - 36 h
Sludge return ratio 75 - 150 %
Special features of the process
best suited to sewage containing organic matter with slow decomposition
characteristics
evens out sudden load variations efficiently
produces less sludge
high oxygen requirement
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2.3.9 Oxidation Ditch
The purification process takes place in a closed annular channel or oxidation
ditch, into which the mixture of sewage and return sludge is fed. The
circulatory movement of waste water is maintained in the channel normally
with brush aerators, but also large-diameter, slowly rotating propellers can be
used to prevent settling of sludge. In the latter case aeration is achieved by
means of diffusers arranged in groups and laid out in different sections on the
bottom of the aeration ditch.
Table 9: Process characteristics and parameters
Aeration method bottom aeration with submersible mixers and air
feed by zones, surface aeration with brush aerators
Oxygen requirement 1,6 - 2,0 kg O
2
/kg BOD
5
Type of flow plug flow / complete mixing
Purification efficiency 90 - 95 % BOD
5
Sludge age 15 - 30 d
Sludge load 0,03 - 0,10 kg BOD
5
/kg MLVSS d
Volumetric load 0,1 - 0,3 kg BOD
5
/m
3
d
Solids content 3,0 - 5,0 kg/m
3
Hydraulic retention time 18 - 36 h
Sludge return ratio 50 - 150 %
Special features of the process
complete nitrification is achieved in this process
nitrogen is removed from the process through denitrification
mechanical submersible mixers are used to create a sufficient current
velocity in waste water in order to prevent sludge settling
Figure 14: Schematic representation of oxidation ditch
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2.3.10 Carrousel Process
In the carrousel process the incoming sewage and the return sludge are
mixed together in the first aeration zone. Activated sludge moves in the
endless channel through successive aeration zones. This process combines
the features of complete mixing and plug flow. The complete mixing feature
results from the fact that the total liquid volume included in the circulatory
process is about 30 to 50 times greater than the influent flow rate. Thus the
process can provide a marked buffer effect. The plug flow feature is due to
the great distance covered by one circuit. Improved denitrification results in a
reduced oxygen concentration in some parts of the aeration basin.
Table 10: Process characteristics and parameters
Aeration method bottom aeration with submersible mixers and
air feed by zones
Oxygen requirement 1,8 - 2,4 kg O
2
/kg BOD
5
Type of flow plug flow / complete mixing
Purification efficiency 95 - 98 % BOD
5
Sludge age 20 - 40 d
Sludge load 0,05 - 0,10 kg BOD
5
/kg MLVSS d
Volumetric load 0,2 - 0,4 kg BOD
5
/m
3
d
Solids content 4,0 - 7,0 kg/m
3
Hydraulic retention time 18 - 28 h
Sludge return ratio 50 - 150 %
Special features of the process
process can accommodate large variations in both quantity and quality of
incoming sewage
mechanical submersible mixers are used to create sufficient current
velocity in waste water in order to prevent the sludge settling
Figure 15: Principle of carrousel process
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2.3.11 Aerated Lagoons
In this process, sewage is treated either by aeration alone or together with
return sludge. In the latter case the process is equivalent to a normal
extended aeration process. The aerated lagoon method is based on an
aeration basin excavated in the ground and into which sewage and air are fed
in order to oxidate organic matter.
Table 11: Process characteristics and parameters
Aeration method bottom aeration, air feed by zones
Oxygen requirement 0,7 - 1,4 kg O
2
/kg BOD
5
Type of flow complete mixing
Purification efficiency 50 - 75 % BOD
5
Sludge age not applicable
Load 0,002 - 0,05 kg BOD
5
/kg MLVSS d
Solids content 0,3 kg/m
3
Hydraulic retention time 5 - 10 d
Sludge return ratio 50 - 200 % (if return sludge is used)
Special features of the process
low BOD reduction
low investment costs
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2.3.12 Two Stage Activated Sludge Process
This process consists of two activated sludge processes operated in series.
The first stage is operated under high load and the second one under normal
load. These two separate activated sludge systems make it possible to create
two separate biological sludge types which differ from each other as regards
their microbial populations. Hence in the first stage the activated sludge has a
normal microbial composition while in the second stage there is an
abundance of nitrifying bacteria.
Table 12: Process characteristics and parameters
Aeration method bottom aeration, constant air feed
Oxygen requirement 0,5 - 0,6 kg O
2
/BOD
5
(1st stage)
1,5 - 2,0 kg O
2
/BOD
5
(2nd stage)
Type of flow plug flow
Purification efficiency > 95 % BOD
5
Sludge age 1 - 3 d (1st stage) and 5 - 10 d (2nd stage)
Sludge load 0,6 - 2,0 kg BOD
5
/kg MLVSS d (I)
0,15 - 0,3 kg BOD
5
/kg MLVSS d (II)
Volumetric load 2,0 - 3,0 kg BOD
5
/m
3
d (I)
0,3 - 0,7 kg BOD
5
/m
3
d (II)
Solids content 2 - 3 kg/m
3
(I); 1 - 1,5 kg/m
3
(II)
Hydraulic retention time 0,5 - 0,8 h (I); 1,6 - 3,2 h (II)
Sludge return ratio 20 - 50 % (I); 25 - 50 % (II)
Special features of the process
efficient nitrification
high BOD reduction
suitable for concentrated sewage
AERATIONBASIN AERATIONBASIN
SEDIMENTATIONBASIN
INFLUENT
WASTEACTIVATEDSLUDGE
RETURNEDACTIVATEDSLUDGE
MIXEDLIQUOR
SEDIMENTATIONBASIN
EFFLUENT
WASTEACTIVATEDSLUDGE
RETURNEDACTIVATEDSLUDGE
MIXEDLIQUOR
Figure 16: Two stage activated sludge process in schematic form
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2.3.13 Aerobic Anoxic Process
The process has two stages. The first stage is aerobic and results in the
oxidation of organic carbon and ammonia. The second stage is anoxic and is
aimed at denitrification, after which the treated sludge first passes through a
secondary aeration stage before the sedimentation unit.
Table 13: Process characteristics and parameters
Aeration method bottom aeration, constant air feed
Oxygen requirement 3,0 - 3,5 kg O
2
/kg BOD
5
Type of flow plug flow
Purification efficiency 90 - 95 % BOD
5
, 60 - 90 % N
Sludge age 7 - 15 d
Sludge load 0,05 - 0,15 kg BOD
5
/kg MLVSS d
Volumetric load 0,2 - 0,4 kg BOD
5
/m
3
d
Solids content 3 - 5 kg/m
3
Hydraulic retention time 16 - 18 h (12 h, 4 h and 1 h)
Sludge return ratio 75 - 150 %
Special features of the process
sludge produced by the process has poor settling qualities
mixing in the anoxic section is carried out by a mechanical mixer
denitrification rate is low due to limited availability of degredable organic
material in denitrification zone
AERATION MIXING AERATION
INFLUENT EFFLUENT
WASTE SLUDGE
RETURN SLUDGE
SEDIMENTATION BASIN
Figure 17: Schematic representation of aerobic anoxic process
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2.3.14 Anoxic Aerobic Process
The process has two stages. In the first stage, the incoming sewage is mixed
with return sludge. Under anoxic conditions the mixture interreacts, resulting
in the reduction of nitrate, which is released as nitrogen gas. The denitrified
sludge mixture is then nitrified again during the second process stage, which
is aerobic. Following this, part of the sludge is recycled directly back to the
anoxic stage.
Table 14: Process characteristics and parameters
Aeration method bottom aeration, constant air feed
Oxygen requirement 2,0 - 2,5 kg O
2
/kg BOD
5
Type of flow plug flow
Purification efficiency 90 - 95 % BOD
5
, 60 - 90 % N
Sludge age 10 - 20 d
Sludge load 0,05 - 0,15 kg BOD
5
/kg MLVSS d
Solids content 3 - 5 kg/m
3
Hydraulic retention time 18 h (6 h and 12 h)
Sludge return ratio 100 - 150 % and 100 - 300 % for denitrification
recycle
Special features of the process
sludge produced has good settling qualities
process can be implemented by means of small modifications from the
nitrifying plug flow process
reduces the build-up of slime on diffusers
MIXING AERATION
INFLUENT
SEDIMENTATION BASIN
EFFLUENT
WASTE SLUDGE
RETURN SLUDGE
Figure 18: Principle of the anoxic aerobic process
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2.3.15 BardenPho Process
The BardenPho process consists of five separate stages. The first stage is
based on an anaerobic reactor into which the incoming sewage is fed
together with return sludge. Owing to the anaerobic conditions, phosphorus
bound up in the return sludge is released. The second stage, which operates
under anoxic conditions, is fed with a nitrate-rich sludge admixture from the
third stage. The nitrates are reduced and nitrogen gas is released. The third
stage permits nitrification and the rebinding of phosphorus. The fourth stage
consists of another anoxic reactor where denitrification takes place again.
The fifth and last stage comprises an aeration unit where the free phosphorus
is bound to the sludge. This phosphorus-bearing sludge is then settled and
subsequently recycled back to the initial stage of the process.
Table 15: Process characteristics and parameters
Aeration method bottom aeration, constant air feed
Oxygen requirement 1,3 - 0,5 kg O
2
/kg BOD
5
(III)
0,3 - 0,5 kg O
2
/kg BOD
5
(V)
Type of flow complete mixing / plug flow
Purification efficiency 90 % BOD
5
; 80 - 90 % P; 90 % N
Sludge age 14 - 20 d
Sludge load 0,05 - 0,075 kg BOD
5
/kg MLVSS d
Solids content 3 - 5 kg/m
3
Hydraulic retention time 1 h (I); 2 - 3 h (II); 4 - 5 h (III);
2 - 3 h (IV); 1 h (V)
Sludge return ratio 100 % and 400 % (III II)
Special features of the process
provides biological removal of nitrogen and phosphorus
process produces sludge which is biologically stable and easy to treat in
further conditioning
total nitrogen content (nitrates, ammonia, organic nitrogen) of the effluent
leaving the process is very low (2 - 5 mg/l)
ANAEROBIC ANOXIC AEROBIC ANOXIC AEROBIC
INFLUENT EFFLUENT
WASTESLUDGE
RETURNSLUDGE
RECYCLE
SEDIMENTATIONBASIN
Figure 19: Principle of the BardenPho process
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2.3.16 Aerobic Contact Zone
Poor sludge quality is a common problem in an activated sludge plant,
especially in waste water treatment plants treating industrial, easily
degradable, waste water from food, pulp and paper industry.
Sludge settling properties can be improved with a selector basin. In the
selector process the waste water and the return sludge are mixed in a small
basin before it is introduced to the main aeration tank. In the selector-aeration
system the well settling floc-forming bacteria have better conditions to grow.
Therefore, these bacteria are selected into process after microbial
competition. The selector establishes a substrate gradient that allows floc
forming, which posses rapid uptake and storage capabilities, to compete the
filamentous bulking organisms.
The selector basin is dimensioned so that the soluble biologically degradable
organic compounds are either degraded or stored by bacteria in the selector.
Contact times of 10 - 20 min have been used in a selector basin. BOD load in
a selector is usually 3 - 6 kg BOD/ m
3
d. Selector design is strongly
depending on the composition of the waste water.
Oxygen uptake rate in the selector basin is very high. It is affected by process
configuration and type of the waste water. Actual Oxygen Demand can be
estimated on the basis of soluble organic removal in the selector. The oxygen
demand of the selector can be up to 50 % of the total oxygen demand of the
process.
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2.3.17 Sequencing Batch Reactors
Sequencing Batch Reactor SBR technology is a method of waste water
treatment in which all phases (aeration, clarification) of the treatment cycle
occur sequentially in one reactor basin. This basic cycle may be modified by
the designer to achieve the conditions necessary for carbonaceous oxidation,
nitrification, denitrification and biological phosphorus removal.
The various phases in a typical cycle usually comprise the following:
Fill waste water enters the reactor basin and mixes with activated
sludge mixed liquor held in the tank.
React aeration of the tank contents. Biological reactions occur until the
desired degree of treatment has been achieved.
Settle aeration is stopped and the activated sludge suspended solids
settle to form a blanket on the bottom of the reactor vessel.
Decant clarified effluent is removed from the reactor without disturbing
the sludge blanket.
Idle unexpired time between cycles. Surplus sludge wasting may
occur.
Completion of these five phases constitutes a cycle of typically six hours
duration which is then repeated. Influent fill operation is usually interrupted
during decanting to prevent effluent deterioration by short circuiting.
Typical SBR's may use the following modified 6 hour cycle sequence for
nutrient removal:
Time (h) 0 - 1.5 1.5 - 2.0 2.0 - 4.0 4.0 - 5.0 5.0 - 6.0
Fill Fill - Aerate Aerate Settle Decant
For a single basin operating as above, influent flow balancing would be
required to store the waste water during the non-filling aerate, settle and
decant phases.
SBR technology has the advantage of being much more flexible than
conventional activated sludge processes in terms of matching reaction times
to the concentration and degree of treatment required for a particular waste
water.
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The volume between design bottom water level and top water level
represents the volume treated per batch or cycle fill volume. Cycle fill
volumes are typically up to thirty percent of the designated top water level
volume and the overall basin depth is generally sized around 5 to 6 m.
FILL
Mixed liquor
Inflow
Air on or off
(2 hours)
REACT
Mixed liquor
Inflow optional
Air on
(2 hours)
SETTLE
Sludge blanket
Air off
(1 hour)
DECANT
Sludge blanket
Air off
(1 hour)
Decant
IDLE
Sludge blanket
Air off or on
(Remainder of
cycle)
Waste sludge
Figure 20: Sequencing Batch Reactor
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2.4 Summary of Process Modifications
A summary of the above mentioned process modifications is given in Table
16. Purification efficiency, sludge age and volumetric load are given on the
basis of the process parameters.
Table 16: Summary of the process modifications
Modification Purification efficiency % Sludge age Volumetric load
BOD NH
4
/N / N-tot d kg BOD
7
/m
3
d
Conventional 85 - 95 - 5 - 10 0,3 - 0,6
Tapered aeration 85 - 95 - 5 - 10 0,3 - 0,6
Step feed 80 - 90 - 5 - 10 0,6 - 1,0
Complete mixing 80 - 90 - 3 - 10 0,8 - 2,0
Contact
stabilisation
80 - 90 - 5 - 10 1,0 - 1,2
Kraus & Hatfield 85 - 95 - 3 - 10 0,6 - 1,6
High-rate 60 - 80 - 1 - 3 2,0 - 6,0
Extended aeration 85 - 95 > 90 / - 15 - 30 0,1 - 0,4
Oxidation ditch 90 - 95 > 90 / 50 15 - 30 0,1 - 0,4
Carrousel 95 - 98 > 90 / 50 15 - 30 0,1 - 0,4
Aerated lagoon 50 - 75 - - 0,05 - 0,2
Two stage > 95 > 90 / - 1-3 / 5-10 2,0-3,0 / 0,3-0,7
Aerobic anoxic 90 - 95 > 90 / 50 7 - 20 0,2 - 0,4
Anoxic aerobic 90 - 95 > 90 / 50 - 80 7 - 20 0,2 - 0,4
BardenPho 90 - 95 > 90 / 60 - 90 14 - 20 0,1 - 03
P 80 - 90
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3 Factors Affecting Dimensioning of Aeration Process
3.1 Sewage Quantity and Composition ....................................................3.1
3.1.1 Design Flow.................................................................................3.1
3.1.2 Biological Oxygen Demand BOD ................................................3.3
3.1.3 Nitrogen Content, N
tot
and N........................................................3.4
3.1.4 BOD Load....................................................................................3.5
3.2 Waste Water Properties.....................................................................3.6
3.2.1 Coefficient of Total Oxygen Transfer K
L
a....................................3.6
3.2.2 Temperature................................................................................3.7
3.2.3 The Coefficient .........................................................................3.9
3.2.4 The Coefficient .......................................................................3.11
3.3 Aeration System...............................................................................3.13
3.4 Operation Parameters ......................................................................3.14
3.4.1 Dissolved Oxygen Level............................................................3.14
3.4.2 Sludge Concentration................................................................3.15
3.5 Plant Location...................................................................................3.16
3.5.1 Atmospheric Pressure...............................................................3.16
3.6 Summary of Dimensioning Factors...................................................3.17
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3 FACTORS AFFECTING DIMENSIONING OF AERATION
PROCESS
3.1 Sewage Quantity and Composition
3.1.1 Design Flow
Waste water flows may vary markedly hourly, daily and seasonally, and the
variations are typical for each treatment plant.
For the dimensioning of either the whole treatment plant or the aeration
system alone, the following parameters are needed:
hourly design flow, q
dim
(m
3
/h)
daily design flow, Q
dim
(m
3
/d)
maximum daily flow, Q
max
(m
3
/d)
As a general rule it can be said that the smaller the sewage network, the
greater the hourly variations. The daily variations depend on the weekday,
season, weather conditions, etc. The daily variations of the influents
(max/min) may vary in small plants from 5 to 10:1, whereas in large plants
they are much less. A typical curve showing the variation of influents over
one year is presented in Figure 1.
Figure 1: Typical daily variation of the influent.
The daily variations of the influents during the past year or over a longer
period can be depicted as a duration curve (Figure 2). For dimensioning
purposes a certain projected value (m
3
/d) depending on the forecast of the
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sewerage area (10 - 30 years forward) should be added to the duration curve
values.
Figure 2: The variations of the influent presented (as AOR), duration curve.
The daily design flow (m
3
/d) and the maximum daily flow can be derived from
the duration curve values. Normally the design flow can be chosen from the
duration curve as the mean value, but where forecasts are not included in this
curve, the design flow can be greater. The maximum daily flow (m
3
/d) can be
determined by the permissible length of the period during which overflows are
allowed.
To determine the hourly design flow (m
3
/h) the hourly variations should be
taken into account. In Table 1 the hourly variation factor k
dim
is given as a
function of the relation between the maximum daily and average daily flows.
Table 1: k
dim
as a function of Q
max
/ Q
average
Q
max
/ Q
average
k
dim
1...2 1,0...1,2
2...4 1,2...1,4
4...8 1,4...1,6
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If no existing data is available on daily variations, the hourly design flow rate
can be determined using Equation 1, in which factors from Table 1 can be
used.
Equation 1
q k
Q
t
Q
t
Q
d
d
i
i
L
dim dim
+ +
_
,
24
where
q
dim
hourly design flow m
3
/h
k
dim
hourly variation factor
Q
d
domestic sewage flow m
3
/d
t
d
hours of domestic sewage flows per day h
Q
i
industrial sewage flow m
3
/d
t
i
hours of industrial sewage flows per day h
Q
L
leakages m
3
/d
For estimating domestic sewage flow the specific water consumption (l/P.E.
d) can be used. Normally the specific water consumption varies from 150 to
300 l/P.E. d.
Treatment capacity has to be designed to suit each individual case.
3.1.2 Biological Oxygen Demand BOD
The organic load expressed as biological oxygen demand (BOD) indicates
the amount of oxygen required by micro-organisms for the biochemical
oxidation of organic matter. This amount is normally determined as the
oxygen consumption occurring in a period of 5 or 7 days at a temperature of
20 C. In the analytical method nitrification is usually eliminated by the
addition of allyltiourea (ATU). The following equation permits a conversion to
be made from BOD
5
to BOD
u
:
Equation 2
( )
BOD
BOD
e
u
kt
5
1
k 0,20 - 0,25
t time, d
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Figures for BOD
5
can be converted to BOD
7
by means of the following
equation:
Equation 3
BOD BOD
7 5
115 ,
If enough existing data is available on the influent BOD concentrations,
duration curves can be used to determine the design BOD (S
o
) concentration.
Normally these values vary from 200 to 300 mg/l, but in the case of industrial
waste waters the fluctuations may be greater.
If there is no data available other than the population size, the population
equivalent value can be used. Values of 70 to 90 g BOD
7
/d P.E. are
normally used.
The BOD concentration after the treatment process can be evaluated either
by the process efficiency (%) or by the purification requirements (mg/l). In this
case the process modification must be taken account. For normal domestic
sewage the required level can be 10 - 20 mg/l, but for concentrated sewage
(S
o
> 1 000 mg/l) the level is usually 30 - 50 mg/l.
Organic load is expressed as kg BOD/d. The oxygen demand in the aeration
stage is determined by the BOD value of the influent. Chemical and or
mechanical treatment may significantly influence the capacity needed at this
stage.
Organic load can also be expressed as Chemical Oxygen Demand COD.
COD indicates the total amount of organic material which can be oxidised
chemically in high temperature. COD includes both biologically degradable
and undegradable organic compounds. For influent, the COD/BOD
5
ratio
varies normally between 1,7 and 3,0 depending on the composition of waste
water.
3.1.3 Nitrogen Content, N
tot
and N
The total nitrogen content of the influent (N
tot
) is determined by the total
amount of nitrogen compounds (organic nitrogen, ammonium, nitrate, etc.).
Normally it varies from 30 to 50 mg/l in municipal waste water. Sometimes the
nitrogen content is expressed as Total Kjeldahl Nitrogen, which reflects only
the total amount of organic and ammonium nitrogen. During the biological
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treatment process, the organic compounds are transformed to ammonia
(NH
4
+
).
If there is no nitrification (oxygenation of ammonium ions) in the treatment
process, almost all the nitrogen (N) passes through the process as ammonia
(NH
4
+
). Only a certain percentage, normally 20 - 30 %, will be bound in the
sludge and removed with it.
Nitrogen content of the excess sludge depends on the sludge age and sludge
production. Nitrogen content of biological sludge is normally 5 - 10 %.
Where there is nitrification, ammonium is oxidised to nitrate (NO
3
-
) in a
biochemical reaction. Since ammonium is a soluble effluent, the ammonium
concentration may be less than 1 mg/l after efficient nitrification.
Equation 4
NH O H H O NO
bacteria energy
4 2 2 3
2 2
+ +
+ + +
,
Denitrification converts nitrate nitrogen to molecular nitrogen (N
2
), which
being a gas, escapes into the atmosphere.
Equation 5
2 2 2 3
2
1
2 CO O H N H C NO
bacteria
org
+ + + +
+
If denitrification phase is before the nitrification phase in the process, part of
the organic load (BOD) is oxygenated in denitrification. This reduces the
need of oxygen in aeration phase and is expressed as a negative term in the
calculation of actual oxygen demand.
3.1.4 BOD Load
The BOD load is expressed as kg BOD/d. In determining the oxygen demand
of aeration the influent BOD values of the aeration unit are used. Where extra
treatment units exist before the aeration stage the reduced values can be
used. The efficiency (%) of different kinds of pre-treatment units and methods
are quoted in Table 2.
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Table 2: BOD reduction in different pre-treatment methods
Pre-treatment method Efficiency %
Primary sedimentation 25 - 50
Preprecipitation 50 - 70
Biofilter 60 - 80
Nitrogen concentration is reduced in all cases by only 0 - 20 %.
Organic load can be expressed also as a Chemical Oxygen Demand (COD).
COD indicates the total amount of the organic material, which can be oxidised
chemically in high temperature. COD-value includes both biologically
degradable and undegradable organic compounds. For influent waste water,
the COD/BOD
5
-ratio varies normally between 1,7 - 3,0 depending the
composition of the waste water.
3.2 Waste Water Properties
3.2.1 Coefficient of Total Oxygen Transfer K
L
a
The oxygen transfer rate into water (dm/dt) is expressed by the following
equation:
Equation 6
( )
dm
dt
D A
C C
L
K A C C
L
L
L L
*
*
where
D
L
molecular diffusion of oxygen through
boundary fluid film
m/s
A area of air / water boundary surface m
2
C*
* *
where
K
L
a apparent volumetric mass transfer coefficient in clean
water at temperature T
A/V total mass transfer area per volumetric unit, m
2
/m
3
The coefficient K
L
a is specifically characteristic to the whole aeration system.
Among many factors affecting the value of this coefficient the following may
be mentioned:
Temperature
Soluble organic and inorganic material
Aeration method
Renovation rate of the boundary surface (gas/fluid)
Depth and shape of the aeration basin
3.2.2 Temperature
Both the coefficient K
L
a and the saturation concentration of oxygen in water
C
s
are dependent on the water temperature. The value of the oxygen transfer
coefficient K
L
a grows with an increase of water temperature. The temperature
effect is generally expressed by means of the following equation:
Equation 8
( ) ( )
K a T K a C
L L
o T
20
20
_
,
*
2
where
H Henrys constant (mg/l) / (kN/m
2
)
X
o
Molal fraction of oxygen in aeration air 0,209
p Atmospheric pressure 101,325 kN/m
2
Specific weight of water kg/dm
3
h Submersion depth of diffusers m
The values of H and can be calculated from the following table:
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Table 4: Temperature dependence of values H and
Temperature H
0 0,697 9,805
5 0,607 9,807
10 0,540 9,804
15 0,484 9,798
20 0,438 9,789
25 0,393 9,777
30 0,365 9,764
In the aeration process, the temperature of the water affects the oxygenation
capacity of aeration equipment in an analogous way. Thus a water
temperature increase from 10 C to 20 C increases the coefficient K
L
a by 25
%, while the saturation concentration of oxygen simultaneously decreases by
20 %. As a result, the above mentioned change in temperature decreases the
oxygenation capacity of aeration equipment by 3 %, in case the oxygen
concentration maintained in the aeration basin is 2 mg/l. Under the same
conditions, the temperature change from 5 C to 25 C will decrease the
oxygenation capacity by approximately 7 %.
For the calculation of the oxygen requirement the most important temperature
is the highest temperature existing during aeration. It is particularly important
to take this into account in a hot climate and when warm waste water from
industry is being treated.
Waste water temperature in municipal plants is usually between 5 to 25 C. In
industrial plants the waste water temperature can be considerably higher, up
to 40 C.
3.2.3 The Coefficient
The coefficient is defined as the ratio of the mass transfer coefficients
measured in sewage and in clean water:
Equation 10
K a sewage
K a cleanwater
L
L
( )
( )
The value of the coefficient depends on
concentration of surface active agents MBA
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intensity of mixing
geometry of the aeration basin
aeration method
process configuration
process parameters, sludge age
For fine bubble aeration systems it has been suggested that the value of
grows from about 0,4 in the initial section to about 0,9 in the end section of
the plug flow processes. In the high rate processes a figure of 0,5 and in the
low rate complete mixing processes a value of 0,8 can be used.
With submersible mechanical aerators, such as NOPOL
O.K.I. aerator
mixer, the value of varies from 0,70 to 0,95. Value of for O.K.I. aerator is
higher compared to diffusers due to higher turbulence and different shape of
the bubbles.
The high return sludge ratio and the high internal circulation in the
denitrification and phosphorous removal processes dilute the influent and
thus increase the value. In the following tables there are guidelines for in
the most common processes.
Table 5: values for diffusers in complete mix aeration processes
Conventional
non nitrifying
Nitrifying Extended
aeration
SBR
denitrification
High rate 0,50 - - -
Medium rate 0,60 0,75 - 0,75
Low rate 0,75 0,80 0,85 0,80
Table 6: values for diffusers in plug flow aeration reactors
Section Step feed Conventional Extended D/N
Nitrifying Aeration processes
1 0,50 0,40 0,60 0,65
2 0,60 0,50 0,65 0,70
3 0,70 0,60 0,70 0,75
4 0,75 0,70 0,75 0,80
5 0.80 0,80 0,80 0,85
6 0,90 0,90 0,85 0,90
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3.2.4 The Coefficient
The coefficient is defined as the ratio of the saturation concentrations of
oxygen measured in sewage and in clean water:
Equation 11
( )
( )
C sewage
C cleanwater
*
*
The value of depends on the amounts of suspended matter, soluble organic
compounds and dissolved mineral salts. A value of 0,98 is normally used for
municipal waste water. However, the influent waste water may in many cases
contain large quantities of dissolved matter and this considerably decreases
the saturation concentration. For industrial waste waters may be smaller
than 0,95.
The coefficient can be determined by measurements of oxygen saturation
concentration or by evaluation of the amount of the total dissolved solids
(TDS) in the sewage. In the latter case the can be calculated as a ratio:
(dissolved oxygen in salty water)/(dissolved oxygen in clean water). Values
for dissolved oxygen in clean water and in sewage at various TDS
concentrations are given in the following table.
Since a low value generates a higher oxygen requirement, a correct
estimate of the value is important.
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Table 7: Dissolved oxygen concentration in water as a function of
temperature and salinity, barometric pressure 101,3 kPa
Dissolved oxygen concentration, mg/l
Temp Salinity, parts per thousand
C 0 10 20 30 40
1 14,20 13,27 12,40 11,58 10,83
2 13,81 12,91 12,07 11,29 10,55
3 13,45 12,58 11,76 11,00 10,29
4 13,09 12,25 11,47 10,73 10,04
5 12,76 11,94 11,18 10,47 9,80
6 12,44 11,65 10,91 10,22 9,57
7 12,13 11,37 10,65 9,98 9,35
8 11,83 11,09 10,40 9,75 9,14
9 11,55 10,83 10,16 9,53 8,94
10 11,28 10,58 9,93 9,32 8,75
11 11,02 10,34 9,71 9,12 8,56
12 10,77 10,11 9,50 8,92 8,38
13 10,53 9,89 9,30 8,74 8,21
14 10,29 9,68 9,10 8,55 8,04
15 10,07 9,47 8,91 8,38 7,88
16 9,86 9,28 8,73 8,21 7,73
17 9,65 9,09 8,55 8,05 7,58
18 9,45 8,90 8,39 7,90 7,44
19 9,26 8,73 8,22 7,75 7,30
20 9,08 8,56 8,07 7,60 7,17
21 8,90 8,39 7,91 7,46 7,04
22 8,73 8,23 7,77 7,33 6,91
23 8,56 8,08 7,63 7,20 6,79
24 8,40 7,93 7,49 7,07 6,68
25 8,24 7,79 7,36 6,95 6,56
26 8,09 7,65 7,23 6,83 6,46
27 7,95 7,51 7,10 6,72 6,35
28 7,81 7,38 6,98 6,61 6,25
29 7,65 7,26 6,87 6,50 6,15
30 7,54 7,14 6,75 6,39 6,05
31 7,41 7,02 6,65 6,29 5,96
32 7,29 6,90 6,54 6,19 5,87
33 7,17 6,79 6,44 6,10 5,78
34 7,05 6,68 6,33 6,01 5,69
35 6,93 6,58 6,24 5,92 5,61
36 6,82 6,47 6,14 5,83 5,53
37 6,72 6,37 6,05 5,74 5,45
38 6,61 6,28 5,95 5,66 5,37
39 6,51 6,18 5,87 5,58 5,30
40 6,41 6,09 5,79 5,50 5,22
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3.3 Aeration System
Aeration equipment are divided into three classes according to the size of the
air bubbles:
fine bubble aeration equipment (bubbles 1 - 3 mm)
medium bubble aeration equipment (bubbles 3 - 10 mm)
coarse bubble aeration equipment (bubbles > 10 mm)
The coefficient of total oxygen transfer K
L
a increases as the size of the
bubbles decreases. Scientific research shows that this coefficient attains its
maximum value when the diameter of the bubbles is between 1,0 and 2,5 mm.
The increase in the value of K
L
a is due to the increased total mass transfer
surface obtained through the smaller bubble diameter. If the air feed is kept at
a constant level, the decrease of the bubble size from 5 mm to 2 mm will
result in an approximately 6 times larger air-to-water transfer surface area.
Aeration efficiency does not increase in direct proportion to bubble size. As a
general guidance, efficiencies are in relation to each other as follows:
fine bubble 1
medium bubble 0,7
coarse bubble 0,4 - 0,5
The bubble size increases in proportion to an increase in the air flow through
one diffuser.
The decrease in bubble size is caused to a considerable degree by the
surface-active substances contained in the sewage. The increase of the mass
transfer area caused by the decrease in bubble size partially counteracts the
decreased rate of oxygen transfer due to the surface-active substances.
The spherical area of the bubble, which in theory should increase by 5 % for
each metre the bubble ascends, decreases by about 10 % for each metre of
upward movement. The natural reason for this phenomenon is to be found in
the decrease of the partial pressure of oxygen in the bubble owing to gas
transfer from air to water.
The ascent velocity of the bubbles produced by fine bubble diffusers is 25 to
30 cm/s.
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3.4 Operation Parameters
3.4.1 Dissolved Oxygen Level
The dissolved oxygen level in the aeration basin should normally be between
1 - 2 mg/l. If the concentration falls below 1 mg/l, it may limit the growth of
aerobic micro-organisms. Oxygen concentrations exceeding 2 mg/l mean
unnecessary expenditure of energy, as the cellular synthesis of micro-
organisms does not require higher concentrations.
For nitrifying process, the oxygen concentration is usually kept around 2 mg/l.
Concentrations under 2 mg/l limit the growth of nitrifying bacteria. Increasing
of the oxygen concentration from the level necessary for the bacteria is waste
of energy. Aeration efficiency decreases linearly when the oxygen
concentration increases.
The higher the maintained oxygen concentration the smaller the efficiency of
the aeration system. At an oxygen concentration of 1 mg/l the aeration
process operates at 90 % of its maximum performance. At an oxygen
concentration of 2 mg/l the efficiency reaches only 78 % of the maximum
possible (see Figure 3).
The distribution of dissolved oxygen along the length of the basin can be
depicted graphically by an oxygen concentration profile.
Figure 3: Relationship between oxygen concentration and efficiency of the
aeration system
The oxygen profile of the aeration basin should typically be near to the form
of curve B (Figure 4) to achieve considerable savings in aeration energy.
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Figure 4: Two oxygen profiles, A and B, in the aeration basin
The oxygen profile can be adjusted by the proper distribution of aeration
equipment along the length of the basin. The following distribution values for
SOTR (or for number of diffusers) can be used as a guideline. Values for
each zone are percentage (%) of total SOTR (No. of diffusers).
stepped
sewage 34 % 26 % 22 % 18 %
feed
0.25 0.5 0.75 1
Basin length
plug
flow 14 % 28.5% 27 % 17.5% 13 %
0.07 0.25 0.5 0.75 1
basin length
3.4.2 Sludge Concentration
The amount of oxygen required for endogenous respiration depends on the
activated sludge concentration (kg MLSS/m
3
). The higher the concentration,
the higher the oxygen demand due to higher amount of breathing micro-
organisms. Normally the values range from 2 to 6 kg MLSS/m
3
, but in some
applications values up to 10 kg/m
3
are used.
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More precisely, the oxygen demand depends on the organic matter present in
the activated sludge (kg MLVSS/m
3
). In a biological treatment plant this
amounts to 60 - 80 % of the MLSS, and it decreases if primary sedimentation
is not used or phosphorous is reduced chemically. In the simultaneous
precipitation process the proportion is 50 - 60 %.
The concentration of sludge in the aeration basin affects also the oxygen
transfer rate. The higher the sludge concentration, the lower the resulting
oxygen transfer coefficient (K
L
a). An increase in sludge concentration results
in increased viscosity and a reduced oxygen transfer rate from the gaseous to
the fluid state (dissolution of oxygen into water). Since the area of the mass
transfer rate is reduced by the increase in viscosity, the total oxygen transfer
rate is decreased.
3.5 Plant Location
3.5.1 Atmospheric Pressure
The elevation of the treatment plant with respect to sea level is an important
aspect of the design of the aeration system. This is due to the fact that at
higher elevations the ambient atmospheric pressure and the oxygen content
of the air are lower.
The oxygen content of the air can be calculated from the equation:
Equation 12
X
P
T
O
2
80 0 ,
where
X
O2
oxygen content of air kg O
2
/m
3
p atmospheric pressure bar
T air temperature K
The effect of plant elevation on atmospheric pressure is shown in Table 8.
A low atmospheric pressure must be taken into account in the dimensioning
of both the blower units and the oxygenation capacity of the diffuser system.
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Table 8: Atmospheric pressure at different elevations
Elevation from sea level Pressure
m bar
0 1,013
100 1,001
200 0,989
400 0,966
600 0,943
800 0,921
1000 0,899
3.6 Summary of Dimensioning Factors
All the factors mentioned in this chapter affecting dimensioning of the
aeration process are summarised in Table 9.
Table 9: Summary of dimensioning factors for aeration process
Factor Normal value
Q
dim
-
q
dim
-
S
o
200 - 300 mg BOD/l
70 - 90 g BOD/dP.E.
S 10 - 20 mg BOD/l
N
o
30 - 50 mg N/l
12 - 15 g N/dP.E.
BOD load efficiency of pre-treatment must be taken account, kg BOD/d
N load efficiency of pre-treatment must be taken account, kg N/d
Temperature T
max
in aeration basin
1,024
varies 0,4 - 0,9
0,98
C*
depends on T
max
and submersion depth
MLSS 2 - 5 kg MLSS/m
3
e
2
depends on the type of diffuser chosen
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4 AOR and SOTR
4.1 Introduction.........................................................................................4.1
4.2 Actual Oxygen Requirement AOR......................................................4.2
4.2.1 Eckenfelder O'Connor .................................................................4.3
4.2.2 Stall & Sherrad............................................................................4.4
4.2.3 "Abwassertechnik".......................................................................4.5
4.2.4 Eckenfelder - Boon......................................................................4.6
4.3 Standard Oxygen Transfer Rate SOTR..............................................4.7
4.4 Clean Water Tests .............................................................................4.8
4.4.1 General .......................................................................................4.8
4.4.2 Summary of Method ....................................................................4.8
4.4.3 Definitions and Nomenclature.....................................................4.9
4.4.4 Apparatus and Methods ..............................................................4.9
4.4.5 Chemicals..................................................................................4.10
4.4.6 Samples ....................................................................................4.10
4.4.7 Air Flow Measurement...............................................................4.10
4.4.8 Timing Criteria...........................................................................4.11
4.4.9 Calculations...............................................................................4.11
4.5 Selection of Aeration Equipment ......................................................4.11
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4 AOR AND SOTR
4.1 Introduction
In Chapter 2 the principles of estimating the process parameters and in
Chapter 3 the dimensioning values were introduced. In this chapter the
calculations will be continued from AOR to SOTR. The air flow needed,
number of aerators / diffusers and the layout depend on the aeration
equipment selected. There are separate chapters for designing an aeration
system using either NOPOL
+
1 42 4 57 1 7
1 42 4 57 1 7
4 4
4
, , ,
, , ,
,
where
Q water flow m
3
/d
S
O
BOD
5
of influent kg/m
3
S
e
BOD
5
of effluent kg/m
3
NH
4,O
ammonia nitrogen concentration in influent kg/m
3
NH
4
ammonia nitrogen concentration in effluent kg/m
3
NH
4
ammonia nitrogen reduction kg/d
f coefficient of the conversion BOD
5
(0,86)
P
X
net production of biomass kg MLSS/d
N
R
total nitrogen reduction kg N/d
S BOD
5
reduction kg/m
3
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4.2.3 "Abwassertechnik"
In Germany, current dimensioning practice is generally based on the method
presented in the Lehr - und Handbuch der Abwassertechnik manual:
Equation 4
( )
[ ]
OV a B b x TS f q N NO N
R R R r R
A
D
+ + +
*
, , 4 6 1 7
3
where
OV
R
actual oxygen requirement
AOR V 1/24 kg O
2
/m
3
h
a* substrate respiration rate (0,4 - 0,65)
B
R
volumetric load kg BOD / m
3
d
purification efficiency (0,7 - 1,0)
b endogenous respiration rate, 0,24 kg O
2
/kg TS
R
d
x proportion of active biomass (organic
matter)
TS
R
concentration of suspended solids in
the aeration basin
kg/m
3
f
r
temperature correction coefficient,
1,072
T-15
q
R
hydraulic load m
3
of sewage /m
3
of basin d
N(NO
3
)
A
nitrate concentration of effluent kg/m
3
N
D
total nitrogen concentration of effluent kg/m
3
Equation 5
N N N N N N
D ges Z NH A org A us NO A
( ) ( ) ( ) ( )
4 3
where
N
(ges)Z
total nitrogen of influent (0,040) kg/m
3
N
(NH4)A
ammonium nitrogen of effluent (0,028 - 0,0) kg/m
3
N
(org)A
organic nitrogen of effluent (0,002) kg/m
3
N
s
nitrogen bound to excess sludge (0,010) kg/m
3
N
(NO3)A
nitrate concentration of effluent (0 - 0,027 - 0,017) kg/m
3
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4.2.4 Eckenfelder - Boon
In the United Kingdom the following equation is generally used:
Equation 6
R a B N N b X V
H T
+ +
*
, , 4 34 2 85
where
R actual oxygen requirement kg O
2
/d
a* substrate respiration (0,75 - 1,0)
B amount of BOD removed kg/d
N
H
amount of ammonium nitrogen removed kg N/d
N
T
total amount of nitrogen removed kg N/d
b endogenous respiration (0,048) kg O
2
/kg MLSS d
q temperature coefficient (1,024)
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4.3 Standard Oxygen Transfer Rate SOTR
The next step is to convert the actual oxygen requirement (AOR, kg O
2
/d) to
the Standard oxygen transfer rate (SOTR, kg O
2
/h) which is the clean water
requirement in specified standard conditions. The following equation is
normally used:
Equation 7
SOTR
C
C C
AOR k
L
T
1 1
24
20 20
1
,
*
*
where
AOR actual oxygen requirement kg O
2
/h
SOTR standard oxygen transfer rate (101.3 kPa, 20 C) kg O
2
/h
alpha coefficient, generally 0,4 - 0,9
beta coefficient, generally 0,9 - 1,0
temperature correction coefficient, 1,024
k
1
flow rate correction coefficient
C*
= C
ST
(1 + 0,035 (h - 0,25))
mg O
2
/l
C
ST
table value for dissolved oxygen (DO) at temperature T
at surface level
mg O
2
/l
C*
, 20
steady state dissolved oxygen (DO) saturation
concentration attained at infinite time at water
temperature 20 C and standard atmospheric pressure
(101.3 kPa). The value can be estimated as follows:
C*
, 20
= C
ST20
(1 + 0,035h)
mg O
2
/l
C
ST20
table value for dissolved oxygen (DO) at temperature 20
C at surface level, 9,07
mg O
2
/l
C
L
actual oxygen concentration in aeration basin mg O
2
/l
The value of the flow rate correction factor k
1
depends on the retention time
of waste water in aeration basin. The shorter the retention time, the bigger is
the value k
1
.
The retention time t is calculated as follows:
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Equation 8
t
V
q
dim
where
V aeration basin volume m
3
q
dim
dimensioning water flow m
3
/h
Guideline values for k
1
are shown in Table 1. Note that these values are for
smaller waste water treatment plants. Larger plants have smaller variations
and normally value for k
1
is known in the design stage.
Table 1: Flow rate correction factor
t 24 12 8 4 2
k
1
1.10 1.25 1.35 1.40 1.50
4.4 Clean Water Tests
4.4.1 General
The SOTR guarantee tests for NOPOL
Aeration Systems.
In the following text some of the important factors are collected from ASCE-
standard. Following text do not include all the necessary information that is
needed for a correct SOTR test. Therefore ASCE standard shall be studied
carefully before testing the aeration equipment.
4.4.2 Summary of Method
The test method is based upon removal of dissolved oxygen (DO) from the
water volume by sodium sulfite followed by reoxygenation to near saturation
level. The DO inventory of the water volume is monitored during the
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reaeration period by measuring DO concentrations at several determination
points selected to best represent tank contents. These DO concentrations
may be either sensed in situ using membrane probes or measured by the
Winkler or probe method applied to pumped samples.
The data obtained at each determination point are then analysed by a
simplified mass transfer model to estimate the apparent volumetric mass
transfer coefficient, K
l
a, and the equilibrium concentration, C*. The basic
model is the following:
Equation 9
C = C
* - (C
*-C
0
) exp (-K
L
a * t)
Non-linear regression is employed to fit equation to DO-profile measured at
each determination point during reoxygenation. In this way, estimates of K
L
a
and C
*.
4.4.9 Calculations
Non-linear method for calculation the result shall be used. This method is
based on non-linear regression of the model (Equation 9) through the DO
versus time. The best estimates for parameters are selected as values which
drive the model equation through the DO concernation versus time data
points with a minimum residual sum of squares.
Best fit log deficit method is acceptable to evalute the SOTR result. The cief
advantage of the method is that in can be applied with relatively simple
calculation procedure with normal spredsheet program. The method is based
on linear regression of the logaritmic form of the model equation using
logaritmic function of DO data. The logaritmic equation shall be fit to the DO
data for each determination point by performing a linear regression of
ln(C
* - C) versus time.
Other calculation methods are not acceptable for evaluating result according
ASCE standard.
4.5 Selection of Aeration Equipment
In normal waste water applications both disc diffusers and O.K.I. aerators are
often alternatives. O.K.I. aerator is more adequate to heavy industrial
applications were a disc diffuser system cannot grant reliable operation.
Examples on applications especially suitable for O.K.I. aerators are the
following:
- mixing without air is needed (two speed motors, AM-models)
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- liftable system is needed (plants having only one aeration line)
- water contains compounds which can clog the disc diffusers
- water contains compounds, such as oil, that can damage the EPDM
membrane
- installation in waterfilled basin is required
- deep basin (from 8 meters)
- sludge handling solutions
Applications especially suitable for DDS disc diffuser systems:
- standard aeration solutions
- very high efficiency is needed
- lower investment cost is demanded
- normal municipal waste water
- maintenance of aeration equipment by emptying the basin is possible
Guidelines given above are not strict. For instance liftable systems can be
made mounting disc diffusers on stainless steel grids. Chemical resistance of
the diffuser is characteristic that varies from one diffuser type to another.
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5 Production of Air
5.1 Properties of Air..................................................................................5.1
5.2 Calculation of Blower Air Flow............................................................5.3
5.2.1 Cooling of Compressed Air in Pipework......................................5.3
5.2.1.1 Equation and Coefficients....................................................5.4
5.2.1.2 Temperature Loss in a Pipe Surrounded by Air...................5.7
5.2.1.3 Temperature Loss in a Pipe Surrounded by Earth...............5.8
5.2.1.4 Temperature Losses in a Pipe Surrounded by Water..........5.9
5.3 Air Intake ..........................................................................................5.15
5.4 Silencers...........................................................................................5.17
5.5 Anti-vibration Control........................................................................5.17
5.6 Air Filtration......................................................................................5.18
5.7 Different Types of Blowers ...............................................................5.18
5.7.1 Positive Displacement Blowers .................................................5.18
5.7.2 Dynamic Type Blowers..............................................................5.21
5.8 Delivery Control of Blowers..............................................................5.23
5.8.1 Rotary Blowers..........................................................................5.23
5.8.2 Centrifugal Blowers ...................................................................5.24
5.9 Blower Selection...............................................................................5.24
5.9.1 Capacity Requirements.............................................................5.25
5.9.2 Delivery Control Requirements .................................................5.25
5.10 Blower Plants................................................................................5.26
5.10.1 General Design Principles.........................................................5.26
5.10.2 Blower Accessories...................................................................5.27
5.11 Air Piping ......................................................................................5.28
5.11.1 Selection of Pipe Materials........................................................5.28
5.11.2 Properties of Different Materials................................................5.28
5.11.3 Design Principles ......................................................................5.29
5.12 Examples of Air Supply Systems ..................................................5.30
5.12.1 Waste Water Treatment Plant, Population Equivalent 40,000..5.30
5.12.2 Waste Water Treatment Plant, Population Equivalent 200,0005.30
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5 PRODUCTION OF AIR
5.1 Properties of Air
Air is a mixture of several permanent gases, in which nitrogen, oxygen, argon
and carbon dioxide predominate. Together they account for about 99,9 % by
weight of the air.
The composition of the atmosphere is fairly constant throughout the world,
but changes markedly with altitude. At higher altitudes, the concentration of
the heavier gases, notably oxygen, decreases.
Table 1: Composition of air, main components
Gas Symbol Content % by weight Content % by volume
Nitrogen N
2
75,51 78,08
Oxygen O
2
23,15 20,95
Argon Ar 1,28 0,95
Carbon dioxide CO
2
0,046 0,03
Air normally also contains varying amounts of water vapour and solids. At low
temperatures the water vapour content of the air ranges from a minimum of
nearly 0 % to maximum of about 3 % by weight or about 4 % by volume. In
larger cities the solids content of air may be up to 500 000 particles per m
3
.
Air possesses some physical constants:
molecular weight 28,96 kg/mol
density (+ 20 C, 100 kPa) 1,188 kg/m
3
gas constant 287,1 J/K kg
The density of air is dependent on its temperature. The following values apply
to dry air at a pressure of 101,3 kPa.
temperature, C density, kg/m
3
-50 1,534
-30 1,453
0 1,293
20 1,2045
40 1,1267
60 1,0595
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The standard atmosphere (U.S., 1962) is based on a constant reference
distribution of atmospheric pressure in normal conditions and at different
altitudes, as follows (dry air).
Table 2: Altitude dependence of atmospheric pressure, temperature and
density of air
altitude, m pressure, bar temperature, C Density, kg/m
3
0 1,013 15,00 1,225
100 1,001 14,95 1,213
200 0,989 13,70 1,202
400 0,966 12,40 1,179
600 0,943 11,10 1,156
800 0,921 9,80 1,134
1000 0,899 8,50 1,112
2000 0,795 2,00 1,007
3000 0,701 -4,50 0,909
4000 0,616 -11,00 0,819
Compression affects air temperature. A rapid compression of air with a
mechanical blower causes a significant temperature rise of the air. The rise is
about 10 C per each 10 kPa (0.1 bar or approximately 1 m water depth)
pressure increase: For instance, if the air temperature at the intake is 15 C
and the pressure on the delivery side of the compressor is 55 kPa (quite
normal for an aeration basin of about 4 m depth) the temperature of the air
will be approximately 70 C.
The relationship of the different units used in regard to air pressure is
presented in Table 3.
Table 3: Air pressure units
mmHg bar mbar N/m
2
kp/cm
2
kPa
760 1,0132 1013,2 101325 1,033 101,325
750,1 1 1000 100000 1,020 100,000
735,6 0,9807 980,7 98070 1 98,070
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5.2 Calculation of Blower Air Flow
The actual air flow required from the blower is calculated as follows:
Equation 1
q q
p
p
T
T
a a
s
i
i
s
,
where
q
a
Blower air flow in real conditions at maximum
summertime temperature at the altitude of the
treatment plant
m
3
/h
q
a
Air flow calculated under standard conditions m
3
/h
p
i
Atmospheric pressure at the plant altitude kPa
p
s
Standard atmospheric pressure, 1.013 kPa
T
i
Maximum intake air temperature during summer,
expressed as absolute temperature
K (= t
i
C + 273)
T
s
Air temperature under standard conditions K (20 C = 293 K)
5.2.1 Cooling of Compressed Air in Pipework
When compressing air adiabatically in the blowers, temperature increases by
about 10 C per each 10 kPa ( equivalent to 1 m of water column ). E.g. in a
10 m deep basin, when ambient air is 30 C, the temperature of the air
leaving the blower is about 130 C.
High temperature may be harmful for the materials of the systems having
polymer components.
Air is cooled down in a different way for each stage of the pipework: blower
room, main header and distribution header in open air (in sunshine and in
rain) and especially in the dropleg pipes. Sometimes the pipes are buried in
the ground, sometimes isolated in order to reduce noise. Heat transfer differs
considerably according to circumstances and it has to be calculated
separately for each section of pipe, when accuracy is required.
In the following pages there are the basic equations for calculating cooling in
various conditions. Values for the essential parameters are given and
examples of calculations in selected common applications are calculated.
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5.2.1.1 Equation and Coefficients
5.2.1.1.1 Main Equation
T
0
= Temperature of surrounding medium ( C
o
) (air, earth, water)
T
1
= Temperature of air after compressor ( C
o
)
T
2
= Lower air temperature ( C
o
)
L = length of pipe (m)
m = Air flow, mass (kg / h)
c = Specific heat of air = 0.25 kcal / kg C
o
k = Heat flow rate through a pipe wall per one meter of pipe
length
(kcal / m . h . C
o
)
d
i
= Inside diameter of pipe (m)
d
o
= Outside diameter of pipe (m)
= Heat transfer coefficient between air and inside surface of
pipe (kcal / m
2
. h . C
o
)
s1
= 2900 . w
1
0.85
( 1+ 0.14 t
m
) (kcal / m
2
. h . C
o
)
w
1
= Velocity of water ( m / s ) = 0.3 m/s
t
m
= Average temperature of water ( C
o
) = 20 C
o
s2
= 2900 . 0.3
0.85
( 1+ 0.14 . 20 ) = 1336 kcal / m
2
. h. C
o
to be chosen 1100 kcal / m
2
. h . C
o
(mixture of air and water)
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5.2.1.1.3 Cooling Off of Air, Pipe Surrounded by Earth
Earth calculated as insulation :
e
= 2 kcal / m . h . C
o
b = 2 m
Heat loss :
0 0
0
0 1
1
ln 2
1
) (
D d
D
T T
Q
e
T
1
= Temperature of air ( C
o
)
T
0
= Temperature of earth ( C
o
)
d
0
= Outside diameter of pipe (m)
D
o
= Outside diameter of insulation = d
0
+ 4 (m)
e
= Thermal conductivity of earth = 2 (kcal / m . h. C
o
)
= 1.6 . ( T
1
T
0
)
0.24
( kcal / m . h . C
o
)
Temperature loss
c m
L Q
t
t = T
1
T
2
Q = Heat loss (kcal / m . h)
L = Length of pipe (m)
Nopon Oy Aeration manual Document level 4 Date:07.04.1998
5 Production of Air Page: 5.7 (30)
Revision: 1 Written by: MR Inspected by: Accepted by:
m = Air flow, mass (kg/h)
c = Specific heat of air = 0.25 (kcal/kg C
o
)
5.2.1.2 Temperature Loss in a Pipe Surrounded by Air
Example
Pipe d
0
= 406.4 mm, d
i
= 400.4 mm
Pipe material : stainless steel, = 22 (kcal / m . h . C
o
)
T
0
= + 30 C
o
T
1
= + 80 C
o
L = 100 m
m = 9920 kg/h
w = 15 m/s
w
n
= 16.6 m/s (in normal conditions)
c = 0.25 kcal / kg C
o
35
400 . 0
15
8 . 3
25 . 0
75 . 0
a
kcal / m
2
. h . C
o
3 . 3
400 . 0
) 30 80 (
3 . 0
233 . 0
1
s
kcal / m
2
. h . C
o
(immobile air)
8 . 3
ln
1
400 . 0
406 . 0
22 2
1
3 . 3 4 . 0
1
35 4 . 0
1
+ +
k
m C e
T
100 / 1 . 7
30 80
30
25 . 0 9920
8 . 3 100
2 o
2
T
2
/ m kcal
2
/ m kcal
c
o
Nopon Oy Aeration manual Document level 4 Date:07.04.1998
5 Production of Air Page: 5.10 (30)
Revision: 1 Written by: MR Inspected by: Accepted by:
5.2.1.4.2 Pipe Material: Carbon Steel
Length L = 10 m T
1
= 30 + 100 = + 130 C
o
( air )
pressure = 2.0 bar abs. T
0
= + 20 C
o
( water )
T
2
= lower air temperature C
o
Pipe diameters ( mm )
42,4 60,3 88,9 114,3
38,4 55,7 83,1 107,9
A 0,116 0,244 0,542 0,914
5 m / s m kg / h 36 75 168 284
10 72 150 336 568
15 108 225 504 852
20 144 300 672 1134
25 180 375 840 1420
7,25 m / s 38 35 31 29
14,5 64 58 52 49
21,75 86 79 71 67
29,00 107 98 88 83
36,25 126 115 104 126
free air
5 m / s k 4,44 5,94 7,87 9,58
10 7,31 9,64 12,96 15,90
15 9,65 12,81 17,41 21,40
20 11,81 15,76 21,27 26,15
25 13,69 18,24 24,80 30,49
5 m / s 21 25 37 49
10 22 28 44 56
15 23 31 48 60
20 24 33 51 66
25 25 36 54 67
0
d
i
d
2
dm
a
2
T
2
/ m kcal
2
/ m kcal
o
C
Nopon Oy Aeration manual Document level 4 Date:07.04.1998
5 Production of Air Page: 5.11 (30)
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5.2.1.4.3 Pipe Material: Stainless Steel
Length L = 5 m T
1
= 30 + 50 = + 80 C
o
(air)
pressure = 1,5 bar abs. T
0
= + 20 C
o
(water)
T
2
= lower air temperature C
o
Pipe diameters ( mm )
42,4 88,9 114,3 168,3 219,1 273
38,4 84,9 110,3 164,3 215,1 268
A 0,116 0,566 0,955 2,12 3,63 5,64
5 m / s m kg / h 28 134 226 502 860 1336
10 55 402 452 1004 1720 2672
15 83 536 678 1506 2580 4008
20 110 670 904 2008 3440 5344
25 138 375 1130 2510 4300 6680
5,54 m / s 31 26 24 22 20 19
11,08 52 44 40 36 34 32
16,62 71 59 55 49 46 43
22,16 88 73 68 61 57 54
27,7 104 87 80 72 67 64
free air
5 m / s k 3,64 6,76 8,16 11,10 13,25 15,66
10 5,99 11,25 13,32 17,92 22,21 26,10
15 8,00 14,89 18,07 24,10 29,70 34,63
20 9,80 18,19 22,08 29,67 36,41 43,04
25 11,47 21,41 25,69 34,50 42,39 50,52
5 m / s 25 42 49,53 59 64 67
10 27 46 55 62 66 69
15 29 49 57 64 68 70
20 30 50 58 65 69 71
25 31 52 54 66 69 72
a
2
T
C m kcal
o 2
/
o
C
C m kcal
o 2
/
do
di
dm
2
Nopon Oy Aeration manual Document level 4 Date:07.04.1998
5 Production of Air Page: 5.12 (30)
Revision: 1 Written by: MR Inspected by: Accepted by:
5.2.1.4.4 Pipe Material: Stainless Steel
Length L = 10 m T
1
= 30 + 100 = + 130 C
o
(air)
pressure = 2.0 bar abs. T
0
= + 20 C
o
(water)
T
2
= lower air temperature C
o
Pipe diameters ( mm )
42,4 88,9 114,3 168,3 219,1 273
38,4 84,9 110,3 164,3 215,1 268
A 0,116 0,566 0,955 2,12 3,63 5,64
5 m / s m kg / h 36 176 296 658 1127 1750
10 72 351 592 1316 2253 3500
15 108 527 888 1974 3380 52500
20 144 702 1184 2632 4506 7000
25 180 878 1480 3290 5632 8750
7,25 m / s 38 31 29 26 25 23
14,5 64 52 49 44 41 39
21,75 86 71 67 60 56 53
29,00 107 88 83 75 70 66
36,25 126 104 98 88 82 78
free air
5 m / s k 4,43 8,03 9,76 13,06 16,47 18,89
10 7,30 13,21 16,19 21,74 26,60 31,53
15 9,63 17,78 21,77 29,21 35,81 42,28
20 11,79 21,64 26,58 36,01 44,16 52,00
25 13,65 25,22 30,97 41,76 51,15 60,77
5 m / s 21 37 94 70 81 92
10 22 44 57 77 89 97
15 23 49 61 81 92 100
20 24 52 65 84 94 102
25 25 55 68 86 97 103
a
2
T
C m kcal
o 2
/
o
C
C m kcal
o 2
/
do
di
dm
2
Nopon Oy Aeration manual Document level 4 Date:07.04.1998
5 Production of Air Page: 5.13 (30)
Revision: 1 Written by: MR Inspected by: Accepted by:
5.2.1.4.5 Pipe Material : PVC PN 10
Length L = 5 m T
1
= 30 + 50 = + 80 C
o
(air)
pressure = 1.5 bar abs. T
0
= + 20 C
o
(water)
T
2
= lower air temperature C
o
Pipe diameters ( mm )
63 90 110 140 160 225
57 81,4 99,6 126,6 144,6 203,4
A 0,255 0,52 0,779 1,26 1,64 3,25
5 m / s m kg / h 60 123 185 299 3,89 770
10 120 246 369 597 777 1540
15 180 369 554 896 1166 2310
20 240 492 738 1194 1554 3080
25 300 615 923 1493 1943 3850
5,54 m / s 28 26 24 23 22 20
11,08 48 43 41 39 37 35
16,62 64 58 56 52 50 47
22,16 80 72 69 65 63 58
27,7 94 86 82 77 74 68
free air
5 m / s k 3,15 3,73 4,02 4,43 4,61 5,15
10 4,16 4,80 5,17 5,53 5,67 6,23
15 4,86 5,41 5,79 6,07 6,22 6,70
20 5,31 5,82 6,18 6,45 6,59 7,00
25 5,63 6,14 6,47 6,71 6,82 7,20
5 m / s 41 53 59 65 67 73
10 47 61 65 70 72 75
15 55 65 69 72 74 77
20 59 67 71 74 75 77
25 61 69 72 75 76 78
a
2
T
C m kcal
o 2
/
o
C
C m kcal
o 2
/
do
di
dm
2
Nopon Oy Aeration manual Document level 4 Date:07.04.1998
5 Production of Air Page: 5.14 (30)
Revision: 1 Written by: MR Inspected by: Accepted by:
5.2.1.4.6 Pipe Material : PVC PN 10
Length L = 10 m T
1
= 30 + 100 = + 130 C
o
(air)
pressure = 2.0 bar abs. T
0
= + 20 C
o
(water)
T
2
= lower air temperature C
o
Pipe diameters ( mm )
63 90 110 140 160 225
57 81,4 99,6 126,6 144,6 203,4
A 0,255 0,52 0,779 1,26 1,64 3,25
5 m / s m kg / h 79 161 242 391 509 1009
10 158 322 484 782 1018 2018
15 237 483 726 1173 1527 3027
20 316 644 968 1564 2036 4036
25 395 805 1210 1955 2545 5045
7,25 m / s 35 31 30 28 27 25
14,5 58 52 50 47 46 42
21,75 79 71 68 64 62 57
29,00 98 88 85 80 77 71
36,25 115 104 100 94 91 83
free air
5 m / s k 3,60 4,11 4,50 4,85 5,04 5,61
10 4,66 5,19 5,57 5,89 5,07 6,53
15 5,29 5,80 6,15 6,42 6,68 6,98
20 5,70 6,18 6,53 6,76 6,88 7,25
25 5,99 6,45 6,78 6,98 7,09 7,42
5 m / s 38 60 72 87 94 108
10 54 78 90 102 107 117
15 65 88 98 108 112 120
20 73 95 104 113 116 122
25 80 100 108 115 118 124
a
2
T
C m kcal
o 2
/
o
C
C m kcal
o 2
/
do
di
dm
2
Nopon Oy Aeration manual Document level 4 Date:07.04.1998
5 Production of Air Page: 5.15 (30)
Revision: 1 Written by: MR Inspected by: Accepted by:
5.3 Air Intake
The following recommendations are given for air intake location:
air intake distance from the ground should be at least 2.5 m
intake air flow velocity in icy conditions must not exceed 2 m/s
intake should be located leeward of the prevailing wind direction
intake should be oriented in the direction where air impurities, humidity and
also direct solar radiation are the smallest.
The following factors should be taken into account in the design of the air
intake:
the air intake should be located so that air enters it at right angles and
without turbulence
the air intake should be equipped with a screen against leaves and similar
matter
a properly located shield helps to avoid the effects of snow and rain (see
Figure 1)
in summertime, intake air may be conducted through cool structures or
spaces in order to lessen the risk of overheating the blowers
in wintertime, intake air may be conducted through heated premises
in case where a sudden clogging by ice (or other agent) is possible, the air
intake should be equipped with a bypass gate which opens automatically if
the pressure drops too low
steel and lightweight alloys are the most suitable materials for the air
intake
Nopon Oy Aeration manual Document level 4 Date:07.04.1998
5 Production of Air Page: 5.16 (30)
Revision: 1 Written by: MR Inspected by: Accepted by:
Figure 1: Air intake, schematic representation
Figure 2: Air intake opening can be widened without increasing the duct size
Typical location errors for the air intake include
air intake located too near the ground
air intake located in a gravel- or dirt-covered area with traffic dust (causes
wear to pipework)
air intake exposed to corrosive chemical vapours
air flow velocity too high
large water areas located near the intake (humidity)
intake located near a wall exposed to sunshine
intake exposed to flue gases
intake exposed to airborne pollen and seeds causing obstruction of filters
Nopon Oy Aeration manual Document level 4 Date:07.04.1998
5 Production of Air Page: 5.17 (30)
Revision: 1 Written by: MR Inspected by: Accepted by:
Figure 3: Two examples of air intake locations
5.4 Silencers
The inlet and discharge noise of the blowers has to be silenced for
environment and work safety reasons. The inlet and discharge silencers have
to be selected according to the silencing needs and requirements and blower
type. Usually the package type blowers are equipped with silencers as a
standard.
Rotary piston blowers are recommended to be equipped with pulsation
dampers to reduce the noise of the downstream piping. Centrifugal and turbo
blowers do not need pulsation dampening.
Many blower manufacturers are providing the blowers with acoustic hoods to
reduce the noise radiation from the machine casing. Noise radiation can be
reduced also by noise insulation of the blower room.
5.5 Anti-vibration Control
The blowers are normally installed on flexible machine mountings. This is
done in order to reduce the solid borne noise and vibrations. The dampening
of the solid borne noise and vibration is especially important when using
rotary piston blowers.
Nopon Oy Aeration manual Document level 4 Date:07.04.1998
5 Production of Air Page: 5.18 (30)
Revision: 1 Written by: MR Inspected by: Accepted by:
If the blower is installed on flexible machine mountings the connection to the
plant piping has to be flexible as well. The connection can be a rubber sleeve
coupling in normal air temperatures. In higher temperatures a stainless steel
bellow type joint is used.
5.6 Air Filtration
The purpose of air filtration is to avoid internal clogging of aeration equipment
and excessive wear to both blowers and piping.
A waste water treatment plant must be operated continuously 24 hours a day.
Hence filtration should preferably consist of several units so that any one of
them may be shut off for maintenance while the others are working. Another
important point is for the unit under maintenance to be isolated from the
others so that there is no risk of short circuit air flows.
Large plants are normally equipped with a combined system, where the air
intake and filters are connected to blowers by piping. In this kind of a system
there is enough spacing for maintenance work. The pressure difference
between different rooms must be taken into account when designing their
doors and sealing. All surfaces must be made of dust free materials.
All air filters must be equipped with control accessories to avoid overloading
of the filters and possible damage to the installation. In large plants, the
pressure difference of the various filters and their alarms are usually
indicated in the control system of the plant.
Detailed information on air filtration requirements of NOPOL
DDS AND
NOPOL
DDS...........................7.26
7.7.3 Air Filtering System for NOPOL
DDS......................................7.27
7.8 Calculation Examples.......................................................................7.29
7.8.1 Example 1..................................................................................7.29
7.8.2 Example 2..................................................................................7.39
We reserve the right to make technical changes.
Nopon Oy Aeration manual Document level 4 Date:29.04.1998
7 NOPOL
where
q
a air flow in NTP (+20 C, 101,3 kPa) m
3
/h
C
i oxygen content of the air (+20 C, 101,3 kPa)
0,280 kg O
2
/m
3
e standard oxygen transfer efficiency, SOTE %
The value of e depends on the choice of diffuser type, aeration depth, air flow
rate and diffuser spacing. Efficiency curves of NOPOL
_
,
2
2
100
where
Nopon Oy Aeration manual Document level 4 Date:29.04.1998
7 NOPOL
where
N' number of diffusers
q
a
total air flow m
3
/h
q
a,d
air flow / diffuser m
3
/h
The maximum and minimum air flow per diffuser must be checked from the
technical data given for the particular diffuser type (dimensioning value).
Technical data for the diffusers is in the NOPOL
'
where
DD area density of diffusers 1/m
2
l length of aeration basin m
w width of aeration basin m
Diffuser density can also be calculated as a percentage:
Equation 7
DD
N d
l w
a
'
100
where the value for d
a
is 0.025 m
2
for the NOPOL
_
,
2
2
100
where
e oxygen adsorption at the chosen aeration depth %
h aeration depth m
h
2
depth of the oxygen absorption curves measured m
e
2
degree of oxygen absorption given by the curves %
n exponent
1,0 for aeration depths 2 - 5 m
0,8 for aeration depths 5 - 8 m
Oxygenation efficiency (kg O
2
/kWh) remains constant within the normal
submersion depths (3 to 8 m). Even though the oxygen transfer rate is higher
at greater submersion depths, the effect of improved absorption is
counteracted in terms of economy. This is caused by the increased energy
consumption of blowers owing to increased hydrostatic pressure.
The normal submersion depth of diffusers ranges from 3 to 6 m. If very limited
ground space for the aeration plant is available, submersion depths of up to
12 m can be used. Submersion depths of less than 3 m are not advisable
owing to the process technology.
The attachment distance from the basin bottom is from 0,2 to 0,35 m with disc
diffusers.
7.4.4 Diffuser Layouts in Various Basins
Bottom diffusers can be installed in various types of aeration basins. A
rectangular form is the most common, round and other types of aeration
basins are also available.
Nopon Oy Aeration manual Document level 4 Date:29.04.1998
7 NOPOL
DDS
product manual. For example, a typical value is 5 kPa for a KKI 215 diffuser
at 3 m
3
/h air flow. The head losses for inlet filters and valves are usually
about 2 kPa.
Thus, the total pressure for the blower design in a typical 4 m deep basin
would be the water pressure, plus the above, or about 6 + 5 + 2 + 40 = 53
kPa (0.53 bar).
Having defined and calculated the above, the power requirement of the
blowers can also be calculated. Normally with the above figures, the blower is
chosen from manufacturers catalogues, and power thus specified according
to the type of blower chosen.
Nopon Oy Aeration manual Document level 4 Date:29.04.1998
7 NOPOL
_
,
1
]
1
1
1
0 000278
1
1
2
1
,
,
where
P Power kW
p
2
Blower discharge pressure kPa
k Constant factor for blowers 1,395
total efficiency %/100
This is the combined value of the blower, electric motor
and transmission efficiencies (=
kj
v
)
Equation 11 for calculating blower power can also be expressed in the
following form:
Equation 12
P p q
p
p
i a
i
_
,
1
]
1
1
0 000982
1
2
0 283
,
,
,
Blower efficiency (
k
) varies between 0,65 and 0,75 in rotary displacement
blowers and between 0,7 and 0,8 in turbo blowers. The value 0,9 can be used
for the combined efficiency of the electric motor and transmission (
m
v
).
7.7.1.1 Pressure Losses in the Pipework
Pressure losses in the pipework of an aeration system can be evaluated on
the basis of a nomogram (Figure 10). This nomogram is proposed for straight
pipes.
Nopon Oy Aeration manual Document level 4 Date:29.04.1998
7 NOPOL
DDS
The recommended actual air flow velocity ranges for different air distribution
pipes are as follows (see Figure 13):
main header (1) 6 - 9 m/s
distribution headers (2) 10 - 15 m/s
droplegs (3) and zone headers (4) 18 - 25 m/s
Figure 13: Recommended actual air flow velocities in distribution pipes
Even distribution of air flow to different aeration basins and diffuser groups is
achieved by an appropriate grading of flow velocities. Smaller flow velocities
and larger pipe diameter also reduce vibration and noise.
Air flow velocity can be calculated using Equation 13 which corrects the
pressure and temperature change caused by the compression of air:
Equation 13
v q
D
T
T
P
P
a
D
p
s
s
4
3600
2
2
DDS
The purpose of air filtration is to avoid internal clogging of the diffusers and
excessive wear to both blowers and piping.
Fine bubble diffusers have a specific need for air filtration. The pores in the
porous discs and rubber membranes are very small, ranging from a few
microns to a hundred microns. Therefore, in order to avoid even partial
clogging, with a consequent loss of performance and increase in back
pressure, filtration should always be included in the air production plant.
Feed air must be conducted through a fine filter. In order to reduce the load
on fine filters and to prolong their life, coarse filters should always be used as
pre-treatment before fine filtering.
There are many types of filters available on the market, but here is a
combination suggested for normal cases:
For MKL 215 and HKL 215:
Coarse filter G3 CEN Class (European Committee for Standardisation) with
an efficiency of 38 42 % at 2.0 - 3.0 m particle, and fine filter F8 CEN
Class with an efficiency of 95 - 99 % at 0.75 - 1.0 m particle.
For PIK 300, KKI 215 and PRK 300:
Coarse filter as above. Fine filter F6 (35 40 % at 0.75 - 1.0 m particle and
80 - 85 % at 2.0 - 3.0 m).
If the intake air contains excessive amounts of harmful gases like SO
2
, Cl
2
or
H
2
O, it may be necessary to complement the air filtering system, for instance
Nopon Oy Aeration manual Document level 4 Date:29.04.1998
7 NOPOL
O.K.I. aerator of
aerator mixer must not contain condensed water. Water may cause excessive
corrosion inside the unit.
Condensed water has to be removed from protection air before connection of
the protection air hose. If protection air is taken directly from the process air
pipe protection air connection should be upwards. If the process air
connections are downwards, condensed water is removed with process air.
Figure 8: Protection air taken from process air pipe
In case there is a separate pipe for the protection air, a water separator
should be installed. The separator must be situated before the protection air
connections of the aerators. A water trap is recommended to collect the
condensed water of the protection air.
Figure 9: Water separator installed to water trap of separate protection air
pipe
Process air containing condensed water does not affect the operation of a
NOPOL
O.K.I. aerator.
Nopon Oy Aeration manual Document level 4 Date:30.04.1998
8 NOPOL
O.K.I. aerators
is likewise relatively easy. Without emptying the basin hoisting the machines
from the basin and following the service instructions the aerators can be
serviced without interrupting the process.
8.11.3 Installation Supervision
In order to secure that the installation has been done properly Nopon has
created easy to use forms which the installation crew has to fill in during the
installation. Following these instructions and filling in these forms safe and
correct installation is secured. In some cases it wise to buy installation
Nopon Oy Aeration manual Document level 4 Date:30.04.1998
8 NOPOL
Aeration Systems,
the Sellers responsibility covers defects occurring within two years from the
taking into operation of the aeration system, however, not later than after 30
months from the delivery.
It is the Purchasers responsibility to take care that the installation and
operation of the equipment is carried out in accordance with the Sellers
instructions. Guarantee terms are valid only under the following conditions
1. The evenness of air distribution has to be checked. If unevenness occurs
necessary measures have to be undertaken to secure even distribution.
2. The guarantee is valid only if the installation and operation of the
equipment is carried out according to the Seller's instructions and the
Installation Supervision Document which is included in the installation
instructions, has been returned to the Seller, duly signed by the person in
charge of the assembly.
3. After the equipment has been taken into operation, a data log has to be
maintained showing the operational conditions for the full operating
period. The data log shall include at least following: quantity of air used,
pressure loss of the aeration system and quantification of failures in the
air supply. The Seller may at reasonable time and forewarning without
causing unreasonable work for Purchaser review the data records.
The aeration efficiency of O.K.I. aerators is guaranteed in clean water on
standard conditions. Standard temperature for water is 10 C and for process
air 20 C. Standard pressure for process air is 101,3 kPa. SOTR values are
calculated according to ASCE (1984) standard. SOTR guarantee is valid only
if installation has been done according the instructions of the manufacturer.
Nopon Oy Aeration manual Document level 4 Date:17.07.1998
9 Aeration in Pulp and Paper Industry
Written by: MR Inspected by: Accepted by:
9 Aeration in Pulp and Paper Industry
9.1 Design of the Activated Sludge Plant for the Pulp and Paper
Industry
9.2 Waste Water Treatment in Pulp and Paper Industry
NOPON OY Design of the activated sludge plant for the pulp and paper industry Date: 09.07.1998
Written by: MR Inspected by: Accepted by: Page: 1 (23)
DESIGN OF THE ACTIVATED SLUDGE PLANT
FOR THE PULP AND PAPER INDUSTRY
ENVIRO DATA OY
Engineering & Consultants
NOPON OY Design of the activated sludge plant for the pulp and paper industry Date: 09.07.1998
Written by: MR Inspected by: Accepted by: Page: 2 (23)
1 INTRODUCTION
The pulp and paper production affects the environment in a number of ways.
Pollutants are discharged into the air and water, noise is generated and the
mill buildings and stacks constitute a feature of the landscape.
The air and water pollutants originating from the wood components and from
the escaping process chemicals may be formed process discharges.
Most of the solid water pollutants from pulp and paper mills consist of fibers
from the process. There are also inorganic salts, bark and wood fragments,
mineral fillers etc. these suspended solids are removed from the effluents
using sedimentation flotation and filtration processes. The common name for
them is the primary treatment.
The dissolved water pollutants from the process can be classified into easily
and slowly biodegradable materials. There are also some coloured
compounds, toxic material and salts.
Part of the material emitted from pulp and paper mills is rapidly degraded by
the micro-organisms in the water. In the biological degradation of organic
material dissolved oxygen is consumed. In extremely cases this can lead to
oxygen depletion, which severely affects aquatic life.
Biological destruction of the dissolved organic compounds is also widely used
for the purification of the pulp and paper mill effluents.
There are several biological methods and probably the most widely used of
them are:
- aerated lagoons
- trickling filters and biodisc filters
- activated sludge
- several anaerobic methods
The fundamental characteristics of the different biological treatment methods
are approximately the same. However, the basic design and facilities used for
different methods differ greatly. In this paper the activated sludge process is
discussed in details. This method utilises an active mass of flocculent micro-
organisms to convert organic matter aerobically into cellular material. It can be
efficiently separated from its suspending liquid by physical processes. Waste
water and micro-organisms are aerated in an aeration basin using nowadays
mostly diffused aeration.
The activated sludge process is widely used for many waste waters. However,
there are remarkable differences in design when the method is used for
different kind of effluents. The design of the activated sludge plant for the pulp
and paper mill effluents are discussed in this paper.
NOPON OY Design of the activated sludge plant for the pulp and paper industry Date: 09.07.1998
Written by: MR Inspected by: Accepted by: Page: 3 (23)
2 EFFLUENT LOADINGS
The main raw material for pulp is normally plant fibres. A constantly increasing
part of these fibres is recycled. Most of the pulp is still produced from
temperature zone softwoods but the utilisation of hardwoods has increased
rapidly over the last decade. Today approximately 40 % of total amount of
wood used for industrial purposes is hardwood. Another source for raw
materials is recycled paper which in 1985 made up about 30 % of the total
fiber consumption. Since that the consumption of recycled paper has
increased little faster than the consumption of virgin fibres.
Non wood fibers (bagasse, bamboo, straw etc) in 1985 supplied less than 7 %
of the total fibre consumption. However, in certain regions non-wood fibres
constitute an important raw material for the pulp and paper industry.
2.1 Chemical Composition of Fibrous Raw Materials
Wood substance is essentially composed of carbon, hydrogen and oxygen.
There are also various amounts of inorganic constituents (ash). The
elementary composition of the organic part of dry wood, with small variations,
is about:
- carbon 50 %
- hydrogen 6 %
- oxygen 44 %
The composition of annual plants (grass etc) is very similar, the carbon
content being a little lower and the oxygen content a little higher than the
values shown above.
The wood and plant fibres consist of the following main components:
cellulose, hemicelluloses, lignin, extractives and inorganics (see Table 2.1).
The distribution of these components varies between plant and wood species.
There are also differences within the same species because of variation in the
composition of the soil.
NOPON OY Design of the activated sludge plant for the pulp and paper industry Date: 09.07.1998
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Table 2.1 Chemical character and content in woods plants of fibre components 1.
Fibre component Approximate compo- Approximate degree Degree of Aproximate content of :
sition of base of polymerization DP crystallization soft- hard- annual plants
molecules woods % woods% ( straw, bagasse ) %
cellulose 1000-10 000 crystalline 35-45 40-50 30-40
hemicellulose 50 - 500 amorphous 25-30 20-40 20-35
holocellulose - - - 65-70 60-80 70-80
lignin 5 - 100 amorphous 26-33 19-40 12-20
extractives terpenes 1 - 3 - 2-4 1-5 1-3
resin acids
fatty acids
phytosterols
inorganics alkali carbonates silica - - 0.2-0.6 0.2-4 2-18
( ashcontent )
C H O
6 12 6
C H O
6 12 6
C H O (OCH )
9 9 2 3
C H O
5 10 5
(C H O etc )
18 32 2
(C H O etc )
29 50
(C H ) ,etc
5 8 n
(C H O etc )
20 30 2
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If the species are classified into three groups: Softwoods, hardwoods and annual
plants, it is found that the quantitative distribution of five component groups falls
within approximate limits indicated in Table 2.2.
Table 2.2 Chemical composition of fibrous raw material
1
.
Group Raw cellulose lingnin hot water alcoholbenzen ash
material soluble soluble
Grasses Cereal
straw 34 - 40 16 - 20 9 - 15 2 - 5 4 - 11
rice
straw 28 - 41 10 - 17 13 - 17 1 - 7 14 - 22
bamboo 35 - 47 22 - 30 16 - 21 3 - 6 1 - 5
soft- Norwegian
woods spruce 43 29 2.3 1.8 0.4
Scots
pine 43 29 3.9 4.8 0.4
Southern
pines 41 - 44 25 - 28 2.5 - 2.4 2.5 - 3.6 0.2
hard- American
woods aspen 52 19 2.1 2.9 0.4
Eucalyptus
globulus 47 20 2.4 1.5 0.4
Birch 41 20 1.5 2.8 0.4
Gmelina
arborea 46 na 6 4 0.8
Before making paper and board, the fibrous raw material must be pulped. There are
several different types of pulping methods used for making different kind of pulps.
Chemical and dissolving pulps are both of the chemical type, which means that the
fibres are liberated by chemical dissolution of the lignin middle lamella. Thus no
chemical action in refinors or beaters is required for fibre separation.
Semichemical pulps are treated by chemical pulping process followed by a treatment
in mechanical fiberising equipment. When the cooking yield of the semichemical pulp
is as high as 85 - 95 %, the term chemimechanical pulp is used.
It is also possible to make pulps using only mechanical means.
There are no well-defined yield limits between various groups of pulps. The following
table gives a rough indication of the yields for the main pulp groups.
NOPON OY Design of the activated sludge plant for the pulp and paper industry Date: 09.07.1998
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Table 2.3 The yield for the main pulp groups
1
.
Pulp group Pulp yield
%
Process
examples
mechanical 90 - 97 GWD, TMP, RMP
chemimechanical 85 - 95 CTMP, Cold soda
semimechanical 60 - 85 NSSC
chemical 40 - 60 kraft, sulphite
dissolving 30 - 45 kraft, sulphite
For the NSSC, Kraft and sulphite pulping methods the chemical recovery is common
practice.
2.2 Effluent Loadings of Some Pulping and Paper Making Methods
The aim of this study is to describe the design of the activated sludge plant for the
pulp and paper industry.
This biological treatment of wastewater is primarily to reduce the content of soluble
organic compounds.
The content of soluble organic compounds is expressed using effluent parameters
like BOD (biological oxygen demand) and COD (chemical oxygen demand). The use
of these parameters is based on the great importance of oxygen level in the receiving
water.
The effluent loadings from different pulping and paper making processes greatly raw
material, the process type and the equipment used. For the design of the activated
sludge process a very important part of the work is the gathering of the effluent
loading data. The following kind information will be needed:
- monthly averages
- weekly averages
- daily averages
- daily minimum and maximum values
- for flow data also hourly maximum and minimum values
This kind of information is possible to collect from existing plants but it is also needed
for the Greenfield mills. Many serious mistakes have been made especially
concerning the short time minimum and maximum values.
The major part of the suspended solids (SS) in the mill effluents usually consists of
fibres or fibre particles.
Fibres are detrimental because they tend to settle in the receiving water forming fibre
banks in which fermentation may occur. This may cause oxygen depletion for the
NOPON OY Design of the activated sludge plant for the pulp and paper industry Date: 09.07.1998
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decomposing. Mechanical pulp fibres decompose slowly while chemical fibres
decompose more rapidly.
The pulp mill effluents also contain suspended solids like lime mud and the paper mill
effluents various kind of fillers like china clay, talc etc.
The contents of easily biodegradable compounds are usually measured by the BOD
test. A considerable part of the wood components dissolved in the pulping and
belching processes is easily biodegradable. Examples of such compounds are low
molecular (molecular weight less than 700 daltons) hemicelluloses, methanol, acetic
acid, formic acid, sugars etc.
Slowly biodegradable compounds in the mill effluents mainly consist of high
molecular substances (molecular weight over 1000 daltons) of lignin and
carbohydrate origin the amount of such compounds can be estimated by measuring
the COD-value and subtracting the BOD-value from it. Living organisms can slowly
degrade and also absorb them. The may also cause to living organisms biological
changes.
There has been also noticed some toxic effects of the pulp and paper mill effluents.
The most well known toxic compound is resin acids and also some unsaturated fatty
acids. Much work has also been done to evaluate the toxic effects of the bleach plant
effluents.
The discharges from the pulp industry may have pH-changing effects in the receiving
waters.
Dissolved inorganic salts from the pulp and paper processes are usually harmless to
aquatic life. However the salts containing nitrogen and phosphorus act as fertilizers in
the recipient. They must also be added during the activated sludge treatment.
The pulp and paper making processes and the effluent loadings from the sub
processes will not be discussed in details. For giving an idea and summarising some
loading example are given there is also the Table 2.4 concerning the present total
effluent loadings of some pulp and paper making processes.
Before cooking or refining the fibrous raw material it is prepared in a section of the
mill called the wood room, barking house etc. The effluent loadings from the dry and
wet debarking of Scandinavian softwoods and hardwoods are given in Table 2.4
Table 2.4. Effluent loadings from dry and wet debarking of Scandinavian soft- and
hardwoods. Figures kg / tonne dry wood.
Debarking BOD COD SS
Softwoods ( dry ) 0-2 0-5 0-5
Softwoods ( wet ) 1-5 5-10 2-5
Hardwoods ( wet ) 1-5 7-15 2-7
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Figures are for the effluents after good mechanical screening. Sedimentation can
greatly decrease these figures.
The environmental effects from mechanical pulping are mainly limited to effects of
dissolved organic substance and fibres. There is a certain BOD-value and the
effluents are normally also toxic to fish.
The bleaching of the mechanical pulp especially with the peroxide greatly increases
the effluent loading.
Table 2.5 gives a summary of discharges from ground-wood and TMP process lines.
Table 2.5 Effluent loadings from ground-wood and TMP- processes. Figures are in
kg / tonne air dry pulp.
Process Raw
material
BOD COD SS
Groundwood spruce 10 - 20 20 - 50 10 - 30
TMP spruce 15 - 30 25 - 60 10 - 30
Sedimentation decreases dissolved and solid materials.
The loading of the mechanical pulps greatly also depends on the yield.
The type of fibrous raw material has only little influence on the COD and also on the
BOD values (see Figure 1).
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Figure 1. Chemical oxygen demand as a function of pulp yield.
In chemical pulping the fibers are liberated by breaking down and dissolving the
lignin by chemical reactions semichemical pulping (NSSC) is characterised by a
combination of chemical and mechanical attack.
In mechanical and semimechanical pulping a recovery system for the chemicals is
normally used. Most of the effluent loading is coming from the bleaching of the pulp.
A number of in-plant technologies are available to reduce the discharge to water from
the cooking-washing-screening section of the mills. Likewise the pollution due to
condensates and accidental spills can be reduced efficiently. When these measures
have been carried out the bleach plant effluent is the dominating source of pollution
(Table 2.6).
R
e
l
e
a
s
e
d
C
O
D
k
g
/
d
r
y
p
u
l
p
Mi croscal e cooki ng - col d soda
Alder
Beech
Eucal yptus
Persi mmon
Spruce
Laboratory - scale
Gmel i na - col d soda
Mixed hardwoods - bisulfite
Adjustment to a straight line produces at all points
COD = 1.365 * TS - 9.4 r = 0.997
For mi croscal e cooki ng al one
(the line in the figure):
COD = 1.296 * TS + 0.36 r = 0.9991
For labrotary-scale cooking alone
COD = 1.369 * TS - 7.7 r = 0.994
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Table 2.6 The discharges (in kg / t air dry pulp) to the water from different mill
departments. Softwood sulphate pulping.
Source of discharges BOD
4
2
16
3
Cooking-washing-screening
Condensates
Bleaching
Accidental spills
25
There are, however, available measures for the decreasing the effluent loading from
the bleach. Basically there are three ways to reduce the bleach plant discharge:
- using of the more effective delignifying methods like cooking and the
oxygen bleaching
- external treatment of the bleach plant effluents (ultrafiltration, lignin
removal process LRP etc.)
- use of bleaching chemicals which give rise to less polluting material
Some of these methods are also widely used (especially belonging to the first
category) and the effluent loading from the bleaching have been greatly reduced.
Wastepaper is an increasingly important raw material for production of newsprint,
tissues and some printing and writing papers.
The greatest portion of wastepaper is not chemically treated but is pulped
mechanically. Processing with chemicals (deinking) is, however, necessary for
newsprint and writing paper.
The important distinction between these systems is, that in deinking some of the
fillers ink particles, hot melts etc. are removed. The effluent loading is then also
higher. If bleaching is used for these fibers the effluent loading will increase more
(see Table 2.7).
Table 2.7 Approximate BOD, COD and SS ( in kg / ton air dry pulp ) in pulping of
waste paper including deinking and bleaching.
TYPES OF TREATMENT BOD COD SS
Mechanical pulping only 15 40 50
Pulping including deinking 20-40 50-90 150-200
Bleaching 10-20 20-40 -
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Papermaking needs large quantities of water. However, the volume of polluted
effluent varies from mill to mill with the degree of white water system closure. The
pollutants consists of suspended solids (fibers, inorganic fillers) as well as dissolved
substances (dissolved wood components, papermaking additives etc.). Generally the
main part of the dissolved wood origin substances is generated in the pulp mill and
follows the pulp to the paper mill.
Pulp drying is less water consuming and less polluting than paper making.
For summarising the BOD-loading the Table 2.8 has been made.
Table 2.8 The typical water consumption and effluent loading for some pulp and
paper mills. Figures kg or m
3
/ tone air dry products before mechanical treatment.
Effluent
Volume
SS BOD
Kraft pulp, unbleached 40 - 60 10 - 20 8 - 20
Kraft pulp, bleached 50 - 80 10-40 20-40
Kraft pulp, bleached ( O
2
delignification ) 50 80 10 - 40 12 - 18
Sulphite pulp, unbleached ( Ca ) 80 - 100 20 - 50 30 - 70
Sulphite pulp, bleached ( Ca ) 150 - 180 20 - 60 45 - 85
Groundwood 10 - 15 10 - 30 8 - 14
RPM 8 - 15 10 - 40 12 - 18
TMP, unbleached 10 - 30 10 - 40 15 - 25
TMP, bleached 10 - 30 10 - 40 20 - 30
Chemimechanical (NSSC) 30 - 60 15 - 50 10 - 25
Newsprint 20 - 30 8 - 20 2 - 4
Magazine paper 20 - 30 10 - 20 2 - 4
Woodfree printing paper 30 - 50 12 - 25 3 - 6
Kraft paper 10 - 20 8 - 15 1 - 3
Folding board 20 - 30 2 - 8 2 - 5
Liner board 10 - 20 10 - 25 1 - 3
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3 COMPREHENSIVE ACTIVATED SLUDGE PROCESS DESIGN
The activated sludge process is a continuous system in which aerobic biological
growth are mixed with wastewater, then separated and concentrated in a gravity
clarifier. The relationships that govern the activated sludge process are
2
,3
.
cells
Organics + aO
2
+ N +P new cells + CO
2
+ H
2
O +
non-degradable soluble residue
Cells + bO
2
CO
2
+ H
2
O + N + P + Non degradable cellular residue
The parameter necessary to generate a process design are the fraction of organics
removed oxidised for energy, denoted by the coefficient a, the fraction of organics
and synthesised into biomass, denoted by the coefficient a, a reaction rate coefficient
K, and the rate of endogenous oxidation b. These coefficients are obtained from
literature, from experience elsewhere, or from laboratory or pilot plant studies on
specific wastewaters. The design parameters employed in this chapter are shown in
Figure 2.
Flow = Q AERATION BASIN FLOW = Q+R FLOW = Q
VOLUME = V
BOD =
o
S MLVSS = X
V
BOD = S
e
MLSS = X VSS = X
e
RECYCLE FLOW = R VSS =X
V
Figure 2. Design parameters
There are several design methods but the basic features are very similar.
The following system is originally expressed by Adams et al.
Organic removal characteristics
The overall reaction batch oxidation conditions can frequently be expressed as an
exponential of the form:
S
e /
S
= e
KX
v
t/s
( 3 -1)
CLARIFIER
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where:
S
e
= Influent total BOD, COD or TOC, mg/l
o
S = Effluent soluble BOD, COD or TOC, mg/l
X
v
= Average MLVSS concentration, mg/l
t = Aeration time, days
K = organic removal rate coefficient, day
1
There is an increasing use of the completely mixed activated sludge system,
particularly in the treatment of the industrial wastes. In this case the soluble organic
concentration in the effluent is equal to that in the aeration tank. Organic removal in a
completely-mixed reactor under steady state conditions is defined by the relationship:
) (
) (
y S K
t X
S S S
e
v
e
o o
( 3 2 )
In cases where COD or TOC is used and non-biodegradable organics are present, y
represents the concentration of none-biodegradable organics in mg/l. For BOD data,
y is usually equal to zero. Equation 3 2 implies that as the concentration of organics
remaining in the reactor decreases, the rate removal also degreases since the
organics remaining are progressively more difficult to remove. The reaction rate
coefficient, K has been found to be temperature dependent and can be corrected for
temperature by a coefficient, , as follows:
K
2
= K
1
( T
2
-T
1
)
Where :
K
2
organic removal rate coefficient at temperature, T
2
, C
o
,day
-1
K
1
organic removal rate coefficient at temperature, T
1
, C
o
,day
-1
tempereture coefficient
Although usually varies from 1,02 to 1,09 for activated sludge systems, it is
recommended that should be experimentally defined for the specific waste water in
question.
The performance of the activated sludge process and the characteristics of the
sludge are related to the organic loading (F/M) and to the sludge age (G). High
loadings (low sludge ages) can lead to dispersed or filamentous sludges with poor
settling properties. Low loadings (high sludge ages) can result in floc oxidation and
dispersion.
The organic loading is defined by the relationship:
F / M = S
/ X
v
t
And the sludge age by the relationship:
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Where:
F / M food to micro-organism ratio, kg organics applied / kg MLVSS- day
S
0
influent total BOD, COD or TOC, kg / day
X
v
average MLVSS in the aeration basin, kg / day
G sludge age, days
v
X Excess biological volatile sludge production, kg VSS/ day
The biomass solids generated in the process are composed of approximately 50 70
percent biodegradable organic material and 30 50 percent non-biodegradable
organic material.
As the sludge age in the process is increased, the non-biodegradable accumulates
and the biodegradable fraction of the volatile suspended solids, x, decreases. The
biodegradable fraction can be following relationship:
v
r v v r v r
bX
aS bX X aS bX aS
x
2
) 7 , 0 )( 4 ( ) (
2
+ +
( 3-5 )
where :
X biodegradable fraction of MLVSS
a sludge synthesis coefficient, kg VSS produced / kg organics removed, normal
values between 0,3 0,5
S
r
organics ( BOD, COD or TOC ) removed, kg / day
b sludge auto-oxidation coefficient, kg VSS oxidiSed /day-kg MLVSS in the
aeration basin, normal values between 0,05-0,2
X
v
average MLVSS in the aeration basin kg.
Nutrient requirements
The growth of the biomass and sludge settleability can be adversely affected if
nitrogen and phosphorus are not supplied in supplied in sufficient amounts. The
biomass (volatile solids) generated in the activated sludge process usually contains
approximately 12 - 14 % nitrogen and 2,5 - 3 % phosphorus. However, as the organic
loading degreases (the sludge age increases) and the biomass becomes more
endogenous, the nitrogen content will approach 5 - 7 % of the total weight of biomass
and the phosphorus content, 0,8 - 1,0 %.
The nitrogen and phosphorus requirements can be estimated by the nutrient losses
with the excess bio-sludge and the effluent.
G
X
X
v
v
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Oxygen requirements
It has been shown previously that the total oxygen requirements in a biological
system are related to the oxygen consumed to supply energy for synthesis and the
oxygen consumed for endogenous respiration. This assumes that oxygen must be
supplied to the system in order to:
1. provide oxygen for biological organic removal ( aS
r
);
2. provide oxygen for endogenous respiration where cells lyse and release soluble
oxidizable organic compounds ( bxX
v
);
3. provide oxygen requirement for chemical oxidation as measured by the immediate
oxygen demand test ( R
c
);
4. provide oxygen for the oxidation of ammonia to nitrate ( R
n
).
This expression is : R
r
= aS
r
+ bxX
v
+ R
c
+ R
n
Where :
R
r
total oxygen utilisation, kg O
2
/day
a oxygen utilisation coefficient for synthesis, kg O
2
utilisation/kg organics
removed ( normal values 0,5 - 0,9 )
b oxygen utilisation coefficient for endogenous activities, kg O
2
utilised / day
kg MLVSS ( normal values 0,05 - 0,2 )
R
c
chemical oxygen demand as measured by the immediate oxygen demand
test, kg O
2
/day ( normal value 0,5 5% from the total COD )
R
n
oxygen utilised in the oxidation of ammonia to nitrate, kg O
2
/day
X
v
average MLVSS in the aeration basin, kg
Excess sludge production
In the activated sludge system, excess sludge must be periodically wasted. Wasted
is sludge is usually digested and dewatered before final disposal. The mathematical
relationship used to compute sludge accumulation includes the following
components:
1. increase in sludge attributable to influent SS which are not degraded in the
process ( fX
1
);
2. increase in biological volatile sludge due to cellular synthesis ( aS
r
);
3. decrease in biological volatile sludge due to cellular oxidation or endogenous
respiration ( bxX
v
);
4. decrease in sludge due to suspended solids lost in the effluent ( X
e
)
The expression for computing excess biological volatile sludge production,
v
X , is :
v r
bxX aS X ( 3 10 )
The expression for computing total sludge production, X , is :
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e
v
v
x
X
f
X
fX X
where:
X total excess sludge production, kg SS/day
f non-biodegradable fraction of the influent suspended solids
X
1
influent suspended solids, kg SS/day
f
v
volatile fraction of MLSS in aeration basin, MLSS
X
e
effluent suspended solids, kg SS/day
v
X excess biological volatile sludge production, kg VSS/day
X
v
average MLVSS in the aeration basin.
It must be once again pointed out that the required design parameters, especially the
kinetic parameters, must if possible be developed from comprehensive bench and
sometimes also pilot scale studies. For calculating the oxygen transfer see also the
appendix 1.
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4 DESCRIPTION OF FACILITIES
The activated sludge plant consists of several sub-processes (bioreactor,
sedimentation etc.). It also necessary to have some preliminary treatment before
passing to the main treatment plant. The mill wastewater treatment includes normally
the following unit process and operations:
- Screening
- sand trap
- primary clarification or flotation
- emergency spill pond
- cooling system
- equalization pond
- nutrient addition facilities
- aerated bioreactors
- secondary clarification
- primary and secondary sludge collection and pumping
- sludge thickening and dewatering facilities
- treated effluent pipeline, foam control facilities and submerged
receiving water outfall and diffuser
The screening equipment are normally medium coarse screens with spacings from
10 - 25 mm. Sand removal is normally designed for sand particles with diameter
bigger than 0,3 mm.
The design of the primary clarification is normally based on the surface loading and
retention time. The maximum loadings are measured with the proper bench scale
testes.
The volume of emergency spill pond is normally 4 - 8 hours and it is designed as big
as possible, taking into the consideration the site layout.
The volume of the equalization pond is based on the variation of COD and BOD of
the influent.
The design of the activated sludge plant is described more in details chapter 3.
The calculations necessary for the aeration are expressed in appendix 1. It is
possible to use surface aerators, but in many cases it is more economical and also
from the technical point of view more practical to use submerged aerators.
The construction materials normally used for the pulp and paper effluent are selected
according the construction, corrosion and economical reasons.
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5 INSTRUMENTATION
The effluent treatment plant will be monitored very often by the mill distributed control
system (DCS) from the mill control room or from the water treatment plant control
room. The control is often also divided so that the sludge handling will be controlled
from the boiler house and the other parts of the plant from the effluent plant control
room the present trend is also to develop and use expert systems. The kind of work
has started some years ago and the results are encouraging.
Process variables such as pH, conductivity, dissolved oxygen and temperature are
monitored throughout the plant and displayed on the DCS. A DCS l/O rack is located
in the electrical substation.
Primary sludge, waste activated sludge to the thickening, the adding of nutrients and
polymers are all flow controlled.
The cooling system is temperature controlled.
Important control parameter for the waste activated sludge removal is also the sludge
age. A new parameter for the same purpose is also the rotation number.
The DCS provides the operator interface to remotely START / STOP pumps and to
remotely OPEN / CLOSE sluice gates.
All kind of reports are also distributed through the DCS system.
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6 COST ESTIMATES
The investment cost for the activated sludge plant depends on the effluent flow,
BOD-loading, the necessary pre-treatment, mill site conditions etc. The variation is
great. One example of the distribution main activities for the investment costs is
following:
%
Civil works and underground piping 33
Main equipment and piping 33
Instrumentation and electrification 15
Design and project managments 9
Contingencies 10
Total 100
Figure 4 Investment costs for the activated sludge plants constructed in Finland in
1980s, the price level 1990.
To the Figure 4 has collected the investment costs for the activated sludge plants of
some Finnish pulp and paper mills. The prices are revised with the construction index
and correspond to the price level of 1990.
10 20 30 40 50 60 70
50
100
150
200
250
Effluent loading, BOD t/d
I
n
v
e
s
t
m
e
n
t
,
1
0
m
k
7
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The operating and maintenance costs also depend greatly on the local conditions.
One example of the percent age distribution of the operating costs is the following:
%
Energy 30
Chemical 35
Manpower 10
Monitoring 5
Sludge transport 10
Maintenance cost (1,5-2,5% from the
investment)
10
Total 100
Operating cost for some pulp and paper industry activated sludge plants has been
shown in Figure 5.
Figure 5 The operating cost mk/t BOD
7
removed. The information is based on the
Finnish experience. The price level is 1990.
10 20 30 40 50 60
400
500
600
700
800
900
O
p
e
r
a
t
i
n
g
c
o
s
t
,
m
k
/
t
B
O
D
-
r
e
d
Effluent loading, BOD t/d 7
NOPON OY Design of the activated sludge plant for the pulp and paper industry Date: 09.07.1998
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7 TRAINING AND START-UP
The training and the start-up periods are important for the successful operating of the
activated sludge plant. It is necessary to give different kind of training for the all mill
personality. Especially effective it is naturally for the plant operators.
It has been noticed that it is most easy to learn the operating of all equipment. More
difficult is to understand the bioprocesses and control of the plant. This part of the
training needs special attention.
The start-up period is always difficult and it should be reserved time enough (3-4
months) for this part of work. It should also be noted the limitations given by the cold
season.
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Appendix 1
OXYGEN REQUIREMENTS AND THE AERATION SYSTEM
1 OXYGEN REQUIREMENTS
The oxygen requirements are normally calculated for the average influent BOD
multiplied with the factor 1,1 - 1,3 and for the summer conditions.
For calculating the oxygen consumption it is possible to use following formula:
This expression is: R
r
= aS
r
+ bxX
v
+ R
c
+ R
n
Where:
R
r
total oxygen utilisation, kg O
2
/day
a oxygen utilisation coefficient for synthesis, kg O
2
utilisation/kg organics
removed (normal values 0,5 - 0,9)
b oxygen utilisation coefficient for endogenous activities, kg O
2
utilised / day
kg MLVSS (normal values 0,05 - 0,2)
R
c
chemical oxygen demand as measured by the immediate oxygen demand
test, kg O
2
/day (normal value 0,5 5 % from the total COD)
R
n
oxygen utilised in the oxidation of ammonia to nitrate, kg O
2
/day
X
v
average MLVSS in the aeration basin, kg
2 OXYGEN TRANSFER EFFICIENCY OF AERATORS AT FIELD CONDITIONS
Manufactures rate their equipment in tap water at standard atmospheric pressure,
zero dissolved oxygen and 20 C
o
. The following equation is used to correct the
stated transfer capacity for actual design conditions.
( ) [ ]
w T
s L sw
C C C N N
20
/
o
ratio of oxygen transfer rate in waste water to that in clean water
ratio to dissolved oxygen concentration at saturation in waste water to that in
clean water (usually 0,9 to 0,95 for most waste waters)
temperature correction coefficient: for diffused air system between 1,02-1,03
T
w
effluent temperature
C
sw
saturation oxygen concentration, temperature T
w
C
s
oxygen concentration, temperature 20 C
o
, pressure 1 bar
N
oxygen transfer capacity kg O
2
/h or kg O
2
/kW at standard conditions
N oxygen transfer capacity (temperature T
w
and waste water)
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It is also possible to use nomogram or other graphic calculation methods for the
transformation.
3 OXYGEN DEMAND DISTRIBUTION AND MIXING
If a plug-flow or a selector type aeration tank is used it is important to check and
calculate the oxygen demand distribution along the length of the tank. These
calculations should be based on the oxygen utilisation rate measurements made
during the pilot tests. It is also possible to get valuable information from the existing
full size plants.
Very often 40 50 % of the total oxygen input is needed in the first 1/3 of the tank
volume. In the last 1/3 the oxygen consumption will be only 15 - 20 % of the total
oxygen consumption.
In a real plug-flow tank the length to width ratio (L:W) is over 1:8 often 1:10 - 1:20.
It is also important to remember the mixing requirements. Normally 10 - 30 W/m
3
effect input is needed for keeping the aeration tank mixed.
1
UNEP manual Environmental Management in the Pulp and Paper Industry, volumes 1 and 2
2
Jrgensen E, Gromiec M (editors): Mathematical Models in Biological Waste Water Treatment,
Development in Environmental Modelling, Elsevier, Amsterdam 1985
3
Adams C E, Eckenfelder W, Jr.: Process Design Techniques for Industrial Waste Treatment, Enviro
Press, Nashville 1974
NOPON OY Waste Water Treatment in Pulp and Paper Industry Date: 09.08.1997
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WASTE WATER TREATMENT
IN PULP AND PAPER INDUSTRY
PREPARED FOR NOPON OY BY HEIKKI SIITONEN, DUOPLAN OY
NOPON OY Waste Water Treatment in Pulp and Paper Industry Date: 09.08.1997
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TABLE OF CONTENTS
1 SHORT DESCRIPTION OF MAIN PULP AND PAPER MAKING
PROCESSES................................................................................................. 1
1.1 GENERAL .............................................................................................. 1
1.2 PULPING PROCESSES............................................................................. 1
1.2.1 General ...................................................................................... 1
1.2.2 Sulphate Pulping........................................................................ 2
1.2.3 Sulphite Pulping ......................................................................... 5
1.3 PAPERMAKING PROCESSES..................................................................... 7
1.3.1 General ...................................................................................... 7
1.3.2 Newsprint................................................................................... 8
1.3.3 LWC .......................................................................................... 9
1.3.4 Other Paper Grades................................................................... 9
1.3.5 Board Manufacturing.................................................................. 9
1.3.6 Effluent Loads from Paper and Board Making Processes ......... 10
2 EFFLUENT DISCHARGE REGULATIONS FOR PULP AND PAPER
INDUSTRY IN EUROPE, NORTH AMERICA AND FAR EAST..................... 11
2.1 GENERAL ............................................................................................ 11
2.2 EUROPE.............................................................................................. 11
2.2.1 Finland..................................................................................... 11
2.2.2 Sweden.................................................................................... 12
2.2.3 Norway .................................................................................... 13
2.2.4 Germany.................................................................................. 13
2.2.5 France ..................................................................................... 15
2.2.6 United Kingdom........................................................................ 17
2.2.7 Italy.......................................................................................... 17
2.2.8 Spain ....................................................................................... 18
2.3 NORTH AMERICA.................................................................................. 19
2.3.1 The USA.................................................................................. 19
2.3.2 Canada.................................................................................... 21
2.4 INTERNATIONAL CONVENTIONS.............................................................. 21
2.4.1 The Helsinki Convention (HELCOM) ........................................ 21
2.4.2 Proposals of the Nordic Council of Ministers............................. 24
2.5 FAR EAST............................................................................................ 25
2.5.1 Japan....................................................................................... 25
2.5.2 China ....................................................................................... 27
2.5.3 Indonesia ................................................................................. 34
3 MAIN PRINCIPLES OF BIOLOGICAL OXIDATION................................... 35
3.1 GENERAL ............................................................................................ 35
3.2 MAJOR PHASES OF ORGANIC MATERIAL BIO-OXIDATION........................... 35
3.3 MOLECULAR OXYGEN DEMAND.............................................................. 35
3.3.1 General .................................................................................... 35
3.3.2 Determination of AOR.............................................................. 36
3.3.3 Determination of SOTR............................................................ 37
ABBREVIATIONS
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AD Air Dry Pulp
AOR actual oxygen requirement
AOX adsorbable organic halides
BAT Best Available Technology
BCT Best Conventional Pollutant Control Technology
BMP Best Management Practices
BOD
7
Biological oxygen demand
BPT Best Practicable Control Technology
COD
Cr
chemical oxygen demand
CMP chemi-mechanical pulp
CTMP chemi-thermo-mechanical pulp
ECF elemental chlorine free
EPA Environment Protection Agency
HELCOM Helsinki Convention
ISO brightness
LWC light weight coated
MLVSS mixed liquor volatile suspended solids
NSPS New Source Performance Standards
NSSC neutral sulphite semi-chemical
P.E. population equivalent
PSES Pre-treatment Standards for Existing Sources
PSNS Pre-treatment Standards for New Sources
RCF recycled fiber
SOTR standard oxygen transfer rate
SS suspended solids
TCF total chlorine chemical free
TMP thermo-mechanical pulp
TSS total suspended solids
VSS volatile suspended solids
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1 SHORT DESCRIPTION OF MAIN PULP AND PAPER MAKING
PROCESSES
1.1 General
In the following, an overall description of significant current pulp and paper
making processes is presented. Also, effluent release and loads will be
specified in each process modification.
Main pulping processes consist of sulphate (or Kraft), sulphite and semi-
chemical (NSSC) processes.
In a world-wide scale, main paper making processes are those producing
newsprint, fine papers (e.g. LWC, uncoated printing and writing papers) and
paperboards (e.g. packaging boards, liner and fluting). In this context, only
basic main production phases are discussed, as the actual paper machine
installations contain various details depending on e.g. the machine supplier.
1.2 Pulping Processes
1.2.1 General
The aim of all pulping processes is to separate or dissolve lignin derived
material from raw material, wood (e.g. spruce, pine, birch, aspen, oak) or non-
wood species (e.g. straw, bagasse, hemp), and release valuable cellulose
fibers to be recovered and processed for further use. Various pulping
modifications are in use and the processes are chosen mainly depending on
the type of the raw material and the quality requirements of the end product.
All pulping methods consist of the following subprocesses (note. small mills
can lack some operations, e.g. bleaching or recovery of cooking chemicals):
- debarking (or raw material handling)
- chipping
- cooking (or digesting)
- washing and screening
- bleaching and screening
- drying
- recovery of cooking chemicals
Common mill operations for all pulping modifications are briefly outlined in the
following.
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In debarking, bark and other impurities like sand, are removed. Cutted wood
logs are fed to a rotating debarking drum, where bark is separated by the
friction of the logs and the drum wall. Fresh or recirculated water can be
introduced into the debarking drum and the process is called wet debarking.
Wet debarking is needed when high quality end products, e.g. viscose pulp
are produced. In dry debarking, the drum operates without water, and the
debarked logs are washed at the outlet of the debarking drum. Dry debarking
is widely used in modern pulp mills world-wide. Effluent loads from wet and
dry debarking are shown in Table 1.
Table 1: Effluent loads from debarking
Load Dry debarking Wet debarking
Flow, m
3
/ADt 0 - 1 1 - 3
TSS, kg/ADt 0.5 - 3 2 - 5
BOD
7
, kg/ADt 0 - 2 1 - 5
COD
Cr
, kg/ADt 0 - 5 5 - 10
In chipping, the debarked logs are chipped to small particles to be fed to
cooking. Chipping can take place directly after debarking or after log storage.
No process effluent exist from chipping.
Drying of pulp can be carried out by a cylinder or a fourdrinier type machine.
Dry section can be steam heated cylinder or air float dryer type. Flash drying
after mechanical dewatering, using hot gases from a separate burner system
is also a common application. Effluent amount from drying varies depending
on the type of the machinery, typical values being 2-4 m
3
/ADt in modern mills.
Other more specific mill operations are described in each process concept
below.
1.2.2 Sulphate Pulping
In sulphate (Kraft) processes, major part of organic lignin material present in
raw material is separated from cellulose in heated pressurised vessels, using
alkaline sulphur containing liquor, so-called white liquor. This process is
called cooking. Current cooking modifications consist of batch and continuous
systems. In modern mills, no process effluent exist from cooking, except floor
drains.
After cooking, the pulp (or brown stock) is washed and screened. The
purpose of washing is to clean the pulp prior to bleaching and also to recover
cooking chemicals. Washing machinery consists of drums or presses in
series, also so-called diffusers are used. The aim of screening is to separate
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impurities (knots, bark etc.) from pulp to maintain high quality of the end
product. Common screening equipment are pressure screens and
hydrocyclones. No effluent exist from modern washing and screening plant,
except accidental floor drains.
Bleaching and post screening follows washing, when e.g. market pulps are
produced. Bleaching can be understood as a continuation stage after
cooking, where the rest of the lignin material is removed from pulp. At the
same time, chromophoric compounds, which cause the dark colour of the
brown stock, are dissolved or turned to non-colour compounds. Often in
modern Kraft mills, so called oxygen bleaching is used as a pre-bleaching
stage before final bleaching. Oxygen bleaching occurs in pressurised alkaline
circumstances with molecular oxygen gas. Oxygen stage is incorporated in
the black liquor recovery cycle and thus no effluent is released from oxygen
bleaching.
In modern mills, major part of a Kraft mill's effluent loads is originated from
final bleaching. Bleaching applications include systems which use chlorine
chemicals (chlorine gas, chlorine dioxide and hypochlorites) and non-chlorine
chemicals like hydrogen peroxide, ozone, peracetic acid or mixture of these.
Today, bleaching systems are divided into ECF (elemental chlorine free) and
TCF (total chlorine chemical free) bleaching plants. ECF bleaching means
bleaching without chlorine gas using chlorine dioxide. TCF bleaching
sequence includes e.g. ozone and peroxide stages. Chlorine gas use is
decreasing dramatically e.g. in Europe, but in North American mills gaseous
chlorine is still a relative common bleaching chemical. When gaseous
chlorine is used in bleaching, so-called chlorinated organics are released in
the effluent. These compounds can be toxic to aquatic life depending on their
molecular weight. Total amount of chlorinated compounds are measured
using AOX (adsorbable organic halides) test method. Chlorinated compounds
are decomposed to some extent in aerobic waste water treatment, e.g. in
activated sludge plants. In Table 2, ECF and TCF bleaching effluents are
compared.
Table 2: Effluent loads from ECF and TCF bleaching
Load ECF
1
TCF
2
Flow, m
3
/ADt 20 - 30 10 - 15
TSS, kg/ADt 2 - 5 1 - 3
BOD
7
, kg/ADt 10 - 15 10 - 15
COD
Cr
, kg/ADt 30 - 40 20 - 30
AOX, kg/ADt < 0.8 0
1
Bleaching: softwood, kappa(in) 13 - 15, sequence D-EOP-D-D, brightness 90 % ISO
2
Bleaching: softwood, kappa(in) 8 - 10, sequence AZ-EOP-P, brightness 85 - 90 % ISO, no
recovery of effluents
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Chlorinated phenols, kg/ADt < 0.1 0
Screening after bleaching typically consists of pressure and centrifugal
screens.
Recovery of cooking chemicals begins in pulp washing where the reacted
lignin-containing liquor, so-called black liquor, is separated from pulp. Black
liquor is collected into storage tanks from which it is pumped to evaporation
for water removal and increasing dry solids content. After evaporation, the
strong black liquor is incinerated in the recovery boiler. The recovery boiler
produces energy for the pulp mill and recovers also the inorganic cooking
chemicals (sodium and sulphur) as smelt. The smelt is dissolved in weak
white liquor (recycled from causticizing plant) and the formed green liquor is
fed to causticizing. In the causticizing department, burnt lime is added to the
green liquor and the end product is cooking liquor, so-called white liquor.
White liquor is a mixture of sodium sulphide and sodium hydroxide solution.
In causticizing, burnt lime reacts with sodium carbonate in green liquor and
calcium carbonate, or lime mud precipitation occurs. Lime mud is washed,
dewatered and led to lime kiln for recovery of lime. In modern Kraft mills, no
continuous process effluent exist from the cooking chemicals recovery cycle.
Momentary spills as black liquor and white liquor leakages can occur.
Currently these spills are collected in a storage tank and recycled to process.
In Table 3, typical effluent loads from Kraft mill operations are shown.
Table 3: Typical effluent loads from Kraft pulping (softwood, ECF bleaching)
Mill department Flow BOD
7
COD
Cr
AOX
m
3
/ADt kg/ADt kg/ADt kg/ADt
Debarking 2 2 5 -
Bleaching
3
30 10 30 1
Condensates
4
2 2 4 -
Spills 5 3 6 -
TOTAL 39 17 45 1
In Figure 1, fresh water and effluent flows of a typical ECF Kraft mill are
presented.
3
Includes brown stock washing loss and drying machine
4
From cooking and evaporation
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Figure 1: Water recycling in bleached Kraft pulp mill
1.2.3 Sulphite Pulping
In sulphite processes, delignification or cooking takes place typically in acidic
circumstances, with sulphite and bisulphite ions present and calcium,
magnesium, ammonium or sodium as base options. Also, alkaline sulphite
pulping methods using e.g. antraquinone as accelerator are in use. Also,
high-yield semi-chemical processes are in use, e.g. NSSC (neutral sulphite
semi-chemical) modifications.
After cooking, the pulp is washed and screened. In modern sulphite mills,
washing and screening equipment are similar to those used in Kraft mills. No
process effluent is released from cooking, washing and screening.
Common bleaching methods of sulphite pulp are ECF (chlorine dioxide) and
TCF processes. Sulphite pulp is generally easier to be bleached than Kraft
pulp and modern mills use 100 % TCF bleaching sequences to reach
bleached market pulp brightness. In the past, when producing e.g. viscose
pulp, effluent flows and loads were huge from bleaching plant. Today,
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pollution loads from sulphite bleacheries are close to the loads of respective
Kraft bleaching plants. In case of TCF bleaching, effluent loads are practically
equal to the Kraft pulp TCF bleaching.
Recovery of cooking chemicals is possible if the base is sodium or
magnesium. The recovery systems consist of several phases and cooking liquor
is prepared by absorbing sulphur dioxide to alkaline base solution. Waste pulping
liquor is evaporated and incinerated in a furnace. For different bases, possible
recovery systems are shown in Figure 2. As an example, in case of magnesium
base, recovery block diagram is presented in Figure 3.
Figure 2: Recovery systems
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Figure 3: Recovery block diagram
Typical effluent loads from sulphite pulping are specified in Table 4.
Table 4: Typical effluent loads from modern sulphite pulping (waste liquor
recovery degree over 97 %)
Mill department Flow BOD
7
COD
Cr
AOX
m
3
/ADt kg/ADt kg/ADt kg/ADt
Debarking 2 2 5 -
Bleaching
5
30 - 40 10 - 15 20 - 40 < 0.8
Condensates
6
4 - 8 20 - 30 40 - 60 -
Spills 5 5 10 -
TOTAL 41 - 55 37 - 52 75 - 115 < 0.8
1.3 Papermaking Processes
1.3.1 General
In the following, main principles of producing of various paper grades are
discussed.
Main typical waste water flows from a paper machine can be summarised as
follows:
Rejects originated from screening:
Rejects contain various impurities depending on the stock preparation and
pulp quality (bark, sticks, sand, inorganic suspended solids). Rejects are
released to main sewer or dewatered separately.
Excess white water:
5
Modern ECF bleaching includes washing loss. If TCF bleaching is used, effluent amount is
at the same level as in Kraft pulping, 10 - 15 m
3
/ADt.
6
BOD load caused mainly by evaporator condensates consisting of acetic acid.
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In paper machine circuits, white water is needed to transport pulp and
additives to paper machine wet end. At first, white water and pulp mixture
enters the head box, from where it is distributed to the wire section. Major part
of the white water is removed at the wire and final water removal occurs in the
press section. After pressing, rest of the water is evaporated from the final
product in the drying section.
Major part of the white water is recycled as dilution water and as cleaning
shower water in the paper machine operations. Part of the shower water is
fresh water, and respective amount of excess white water will be discharged
through a fibre recovery unit to the mill's effluent treatment system. Use of
fresh water, or specific waste water amount (m
3
/ADt), determines the degree
of closure of the white water system. The smaller the figure, the better is the
closure degree. Overflow of excess white water is responsible for the main
continuous effluent load from a paper mill.
Spills:
Temporary discharges consist of overflows from pulp and white water storage
and pump tanks and floor drains. The key design principle in modern paper
mills is that volumes of white water and broke (low-quality paper/pulp during
paper machine disturbances and shut-downs) storages are equal.
Main paper and board making processes are briefly described in the
following. Also, a summary table consisting of main pollutants is presented.
1.3.2 Newsprint
In newsprint production, raw materials are typically unbleached mechanical
pulp, semibleached Kraft pulp or unbleached sulphite or recycled fiber (RCF).
Stock preparation consists of two pulp lines with necessary fresh and white
water systems. Mechanical pulp line includes typically pulp storage,
equalising tank and post-refiner unit. Broke line has various pulpers, a broke
storage, a thickener, a screen and a deflaker.
Typical newsprint machine has wire, press and dryer sections, calender stack
and reeler for finished product.
White water system is composed of dilution circuits in stock preparation and a
fiber recovery filter (disc filter) for all fibercontaining effluents. Continuous
effluent from a newsprint mill originates from disc filter, so-called clear filtrate.
Clear filtrate contains 10 - 50 mg/l suspended solids, mainly fiber, and
dissolved organic compounds.
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1.3.3 LWC
Raw materials for LWC (light weight coated) paper are bleached mechanical
pulp, bleached sofwood Kraft pulp and coating chemicals (pigment, latex,
starch).
Stock preparation contains two pulp lines, a broke line, necessary fresh and
white water systems and dosing of coating chemicals.
Typical LWC machine has wire, press and dryer sections followed by
calender and reeler. Coating can be part of the LWC machine (so-called on-
machine coater) or a separate unit (off-machine coater).
Coating chemicals are prepared in a coating kitchen. Coating clay and filler is
delivered as bulk material and mixed with water. The coating solution is made
in batch runs. Starch is converted and dosed to the mixing tank with other
additives.
1.3.4 Other Paper Grades
Other significant paper grades currently are uncoated printing and writing
papers (SC and MF papers), packaging papers (sack papers) and tissue
grades.
1.3.5 Board Manufacturing
Liner
Liner board is typically made of two layers, the top layer is conventional Kraft
pulp and the bottom layer is high-yield Kraft pulp or recycled fiber (paper or
board).
Stock preparation includes two pulp lines, a broke line and fresh and white
water systems. White water system consists of white water storage, dilution
water distribution and fiber recovery unit for effluent to be released to main
sewer.
The board machine has two head boxes, top and bottom wires, press and
dryer sections followed by calender and reeler.
Fluting
Fluting, or corrugated medium board is made of unbleached NSSC pulp or of
recycled paper.
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Stock preparation is composed of NSSC pulp and recycled paper lines, broke
line and fresh and white water systems. White water system consists of
dilution water distribution equipment and fiber recovery system for the excess
fiber-containing effluent.
The board machine has conventional wire section, press and dryer sections,
machine calender and reeler.
Other board grades
Other common board grades are packaging paperboards (e.g. folding
boxboard).
1.3.6 Effluent Loads from Paper and Board Making Processes
In Table 5, typical effluent loads from paper and board mills are presented.
Table 5: Effluent loads from modern paper and board mills and recycled fiber
mills (note: figures include loads from mechanical pulping and necessary raw
material processing in each mill case)
Mill type Effluent SS BOD
7
COD
Cr
m
3
/ADt kg/ADt kg/ADt kg/ADt
Newsprint (TMP) 10 - 25 20 - 30 15 - 18 30 - 40
LWC 10 - 40 10 - 40 10 - 15 10 - 30
Liner and fluting 5 - 15 10 - 50 10 - 30 20 - 60
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2 EFFLUENT DISCHARGE REGULATIONS FOR PULP AND
PAPER INDUSTRY IN EUROPE, NORTH AMERICA AND FAR
EAST
2.1 General
In Europe, the current waste water regulations can differ considerably
between one country and another. In the near future, the regulations can be
expected to be uniform as various European Union's pollution control
directives will come into force in the member countries by the end of 1990s.
In the USA and Canada, the effluent regulations will be revised after the
Cluster Rule regulations will be promulgated, most probably by the end of
1997. The Cluster Rule standards will be applied in the USA, but later they
also may have certain effects on the federal and provincial regulations in
Canada.
In the Far East, Japan is the key country as to the development of
environmental regulations. The pulp and paper industry is currently in a rapid
evolving phase in the Asean region, and at the same time also pollution
control regulations will be developed and tightened.
2.2 Europe
2.2.1 Finland
A basic law for water pollution control (the Water Act) came into force in
1961.
With respect to pulp and paper industry, the basic law includes rules and
regulations for granting a waste water discharge permit. The Water Act does
not include any general standards for pollution loads of pulp and paper
industry waste waters. Instead, the Water Act demands specifications (e.g.
allowable pollution loads, measures to decrease water pollution and
monitoring programme to follow the effects of the pollutants on the receiving
water course) to be made in the operating licence of every individual waste
water discharge permit granted by a regional Water Rights Court. Most
commonly, restrictions for pollutants like COD
Cr
,(BOD
7
), AOX and phosphorus
are demanded.
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The basic law allows discharge permits for certain periods only and a new
application must be prepared before the expiry of the existing permit.
For pulp and paper industry in Finland, also Helsinki Convention (HELCOM)
recommendations and Nordic Council of Ministers recommendations are
important to be followed (see Chapters 2.4.1 and 2.4.2).
2.2.2 Sweden
No general effluent standards or norms are presently applied. In case of
individual discharge permits the authorities usually introduce two types of
allowable discharge values: so-called limit values and guide values. The limit
value is not allowed to be exceeded. The guide value may be exceeded, but
in these conditions necessary measures have to be put in use to avoid further
exceeding. Limit and guide values are typically defined as annual or monthly
average absolute loads. Water pollutants which are usually required to be
specified are COD
Cr
, BOD
7
, AOX, P-tot and N-tot. In Table 6, frequency and
analysing standards are presented.
Table 6: Effluent monitoring requirements and standards in Sweden
Pollutant Sample type and frequency Analysing method
COD
Cr
Alternative 1: SS 02 81 42
4 daily and one weekend sample per
week. Analyses of COD value of each
sample (non-settled and non- filtered)
Alternative 2:
4 daily and one weekend sample per
week. Analyses of COD value of each
sample after removing coarse particles
and fibers
Filtering according to
SS 02 81 38
filter fabric 70 m
in addition:
one weekly sample per week. Analyses of
COD of non-settled and non-filtered
sample
P-tot one weekly sample per week SS 02 81 02
N-tot one weekly sample per week SS 02 81 01
BOD
7
one monthly sample per month SS 02 81 43
AOX one weekly sample per week in bleaching
plants which use chlorine chemicals
SS 02 81 04
one weekly sample per quarter in paper
production
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In some cases, also suspended solids and chlorate loads are required to be
measured and reported.
2.2.3 Norway
No general limits are applied. The restrictions for each individual mill are
determined based on the conditions of the receiving water course and the
available technology. The regulated water pollutants are suspended solids,
COD
Cr
, phosphorus and AOX.
2.2.4 Germany
The current federal minimum requirements for pulp and paper industry
effluent discharge standards are according to a separate regulation shown in
Table 7.
Table 7: Effluent discharge limit values for pulp and paper mills in Germany
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Production TSS
2)
COD
Cr
BOD
5
N
3)
P
tot
AOX
basis mg/l kg/t mg/l /kg/t mg/l mg/l kg/t
Chemical pulp
(sulphite) - 70 -/5 10
4)
2
5)
1
Paper and
board
1)
- class 1 50
6)
3 25/1 10
4)
2
5)
0.04
7)
- class 2 50
6)
6 25/2 10
4)
2
5)
0.04
7)
- class 3 50
6)
9 25/3 10
4)
2
5)
0.04
7)
- class 4 50
6)
12 -/6 - 2
5)
0.025
7)
- class 5 - 2 25/- 10
4)
2
5)
0.02
7)
- class 6 - 3(5)
8)
25/- 10
4)
2
5)
0.01
7)
- class 7 - 5 25
9)
/- 10
4)
2
5)
0.012
7)
1)
Paper and board mills are divided into the following groups:
1 Woodfree unsized
2 Woodfree sized
3 Woodfree, highly refined and special paper (with more than one quality
change per working day as annual average)
4 Pergament
5 Woodfree, coated, more than 10 g coating/m
2
(integrated)
6 Woodcontaining (integrated with mechanical pulping), end product
predominantly not from recycled fibre
7 Recycled paper, mainly based on recycled fibre
2)
filterable solids
3)
ammonium-, nitrate- and nitrite-N
4)
when effluent amount exceeds 500 m
3
/d
5)
when effluent amount exceeds 1000 m
3
/d
6)
in cases where effluent is subjected to biological treatment
7)
at specific conditions regarding the use of chlorohydrine-containing wet-strength papers
the limit value is 0.12 kg/t or 0.2 kg/t
8)
5 kg/t when over 50% of the pulp is TMP or when a substantial part of the pulp is bleached
with hydrogen peroxide
9)
if effluent amount is below 10 m
3
/t, the limit value is 50 mg/l and the specific limit value
0.25 kg/t, respectively
According to Waste Water Charges Act amendment, industrial plants are
liable to pay discharge fees, if certain limit values are exceeded. The fees are
based on damage units (Schade einheit) as presented in Table 8.
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Table 8: Damage units for determination of discharge fees, applicable to pulp
and paper mills in Germany (1991)
Pollutant Damage unit Limit value (as concentration
or annual load)
COD
Cr
50 kg 20 mg/l, 250 kg/a
AOX 2 kg 100 g/l, 10 kg/a
Phosphorus, as P 3 kg 0.1 mg/l, 15 kg/a
Nitrogen, as N 25 kg 5 mg/l, 125 kg/a
Acute toxicity to fish
- effluent amount 3000 m
3
G
F
1)
= 2
Metals and their compounds
- Hg 20 g 1 g/l, 100 g/a
- Cd 100 g 5 g/l, 500 g/a
- Cr 500 g 50 g/l, 2.5 kg/a
- Ni 500 g 50 g/l, 2.5 kg/a
- Pb 500 g 50 g/l, 2.5 kg/a
- Cu 1000 g 100 g/l, 5 kg/a
1)
G
F
is the dilution factor by which the waste water turns to non-toxic
to fish, according to a specified test method.
The present fee (since January 1, 1997) per damage unit is DEM 80. From
1999 the fee will be increased to DEM 90.
2.2.5 France
In the 1994 decree, some general requirements for the quality of the effluents
to be released to the watercourses are specified. Main requirements are the
following:
pH to be held between 5.5 - 8.5
temperature inferior to 30
o
C (35
o
C if anaerobic waste water treatment is
used)
colour inferior to 100 mg Pt/l
phenolic type substances 0.3 mg/l or 3 g/d
phenols 0.1 mg/l or 1 g/d
AOX 5 mg/l or 30 g/d
hydrocarbons totally 10 mg/l or 100 g/d
additional specific requirements for toxic and bioaccumulative substances
listed in the Annex 4 of the decree (several organic and inorganic
compounds)
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For pulp mills, the current regulations are shown in Table 9.
Table 9: Effluent discharge limit values for pulp mills in France. The values are
expressed as kg/ADt, monthly average max. values.
new mills existing mills
Mill type TSS BOD
5
COD
Cr
TSS BOD
5
COD
Cr
MECHANICAL
- unbleached 0.7 0.7 1.5 0.9 0.9 2.0
- bleached 0.7 0.7 3.0 0.9 0.9 3.9
TMP
- unbleached 0.7 0.7 4.5 0.9 0.9 5.9
- bleached 0.7 0.7 6.0 0.9 0.9 7.8
CTMP
- unbleached 0.7 3.0 12.0 0.9 3.9 15.6
- bleached 0.7 4.0 16.0 0.9 5.2 20.8
KRAFT (hardwood)
- unbleached 5.0 1.5 15.0 6.5 2.0 19.5
- bleached 5.0 2.0 25.0 6.5 2.6 32.5
KRAFT (softwood)
- unbleached 5.0 2.0 20.0 6.5 2.6 26.0
- bleached 5.0 3.0 50.0 6.5 3.9 65.0
BISULPHITE 5.0 5.0 35.0 6.5 6.5 45.5
WASTE PAPERS (deinking) 0.7 0.7 4.0 0.9 0.9 5.2
AOX restriction for bleached pulp mills is 1 kg/ADt.
The current restrictions for paper mills are presented in Table 10.
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Table 10: Effluent discharge limit values for paper mills in France. The values
are expressed as kg/ADt, monthly average max. values
New mills Existing mills
End product/capacity TSS BOD
5
COD
Cr
TSS BOD
5
COD
Cr
Capacity inferior to 60 Adt/d 2.0 4.0 8.0
Paper with more than 90%
virgin fibre, without fillers
0.7 0.7 2.5 1.5 1.0 4.0
Paper with more than 90%
virgin fibre, with fillers or
coating
0.7 0.7 3.0 1.5 1.5 6.0
Paper with more than 90%
virgin fibre with fillers and
coating
0.7 0.7 3.0 1.5 2.0 8.0
Paper with more than 90%
waste paper, without fillers
0.7 0.7 3.0 1.5 1.5 6.0
Paper with more than 90%
waste paper, with fillers or
coating
0.7 0.7 4.0 1.5 2.0 8.0
Paper with more than 90%
waste paper, with fillers and
coating
0.7 0.7 4.0 1.5 2.0 8.0
Fluting 1.9 1.9 8.0
In each case the daily maximum value can be twice as high as the monthly
average maximum value in the above-mentioned tables.
2.2.6 United Kingdom
Emission limits for point sources, e.g. industrial plants, are determined to
maintain the quality objectives of the receiving water, taking into account all
others discharges to the same water course as well. Typically, regulations are
set for waste water flow, TSS, BOD, COD and pH. These requirements vary
to some extent depending on the type of the receiving water (e.g. river, inland
lake, estuary).
Discharges of waste water to public sewers are controlled by the Water
Industry Act and the Trade Effluents (Prescribed Processes and Substances)
Regulations 1989. A consent is also required, when waste water is released
to a common sewer.
2.2.7 Italy
According to the Law 1976, waste water standards are divided into three
categories:
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Tabella A Industrial waste waters when discharged directly to water
course
Tabella B Industrial waste waters when discharged to municipal sewage
treatment plant
Tabella C Municipal sewage (over 50 P.E.)
In Table 11, limit values according to Tabella A are presented.
Table 11: Industrial effluent discharge limits in Italy according to Tabella A
(direct release to water course)
Object Limit value Remarks
pH 5.5 - 9.5 After dispersion, 50 m from the discharge point
6.5 - 8.5
Total suspended
solids (TSS)
80 mg/l Filter openings 0.45
m
Settleable solids 0.5 ml/l Imhoff cone, 2 hours
BOD
5
40 mg/l For certain industrial effluents, the limit may be
equal to 70% of the total BOD
5
release
COD
Cr
160 mg/l
Temperature increment < 3
o
C In rivers, after the dispersion zone
Colour non-visible When dilution is 1:20
Total phosphorus 10 mg/l In certain lakes and dams 0.5 mg/l
2.2.8 Spain
General limit values for industrial effluent discharges are given in the Law
1985. These limit values also form a basis for a discharge fee (tax) system.
The annual fee (F) is determined by the following equation:
F = C x P, where C = annual contaminating units
P = contaminating unit price
C = K x Q, where C = annual contaminating units
K = quality factor, dependent on the pollutants in
the effluent
Q = annual effluent flow, m
3
(Note. so called clean
waters, e.g. from cooling units, can be
excluded)
The discharge tax system is applied for mills which release their effluents to a
river or a lake.
In Table 12, limit values divided into three categories, are presented.
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Table 12: Effluent discharge limit values for calculation of discharge fees in
Spain
Subject Max. limit value
Category 1 Category 2 Category 3
pH
1)
5.5 - 9.5 5.5 - 9.5 5.5 - 9.5
Suspended solids, mg/l
2)
300 150 80
Settleable solids, ml/l
3)
2 1 0.5
Coarse solids none none none
BOD
5
, mg/l
4)
300 60 40
COD
Cr
, mg/l 500 200 160
Temperature increment,
o
C
5)
3 3 3
Colour, non-visible
6)
1:40 1:30 1:20
Total phosphorus, mg/l
7)
20 20 10
1)
After dispersion, 50 from the discharge point resp. level 6.5-8.5
2)
Filter openings 0.45
m
3)
Imhoff cone, 2 h settling
4)
For certain industrial effluents, the limit may be equal to 70% of the total
BOD
5
release
5)
In rivers after dispersion zone. In lakes, max. effluent temperature is 20
o
C
6)
Colour to be determined through 10 cm of diluted effluent in each category
7)
In certain lakes and dams the limit value is 0.5 mg/l
The authorities determine the quality factors for each categories. The most
polluting substance as specified in Table 12 determines the category and
resp. quality factor to be used.
The general minimum requirements have been issued primarily to be able to
be used in the discharge tax system. Additional regulations can be set up e.g.
based on the type and use of the receiving water.
2.3 North America
2.3.1 The USA
The EPA issues technology-based effluent limit values guidelines on a
federal level for effluent discharges. These are mainly adopted as such in the
state legislation.
Concerning the current effluent discharge regulations, various technological
concepts are determined as a basis for the requirements. In the following,
these definitions are presented:
BPT (Best Practicable Control Technology) effluent guidelines apply to
discharges of conventional pollutants (BOD
5
, TSS, pH, fecal coliforms, oil
and grease)
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BCT (Best Conventional Pollutant Control Technology) presently is equal
to BPT
BAT (Best Available Technology) standards define for the direct discharge
limits of toxic and non-conventional pollutants. Presently, the BAT concept
has limited significance as it only concerns mills which use chlorophenol-
based biocides.
NSPS (New Source Performance Standards) are applied to new or rebuilt
mills discharging their effluents directly to watercourses. NSPS regulations
include conventional, non-conventional and toxic pollutants.
PSES and PSNS (Pre-treatment standards for existing and new sources)
are specific standards for discharges from existing and new mills to
publicly-owned sewage treatment works.
In addition, the Cluster Rule includes the following definition for all mills:
BMP (Best Management Practices) for spent pulping liquor management
and spill prevention and control in chemical pulp mills
The current effluent discharge restrictions were adopted in 1982 and they
were determined for 24 mill types. In Table 13, an example of effluent
restrictions for major production groups are presented.
Table 13: Effective EPA effluent restrictions for six production groups,
expressed as annual averages, kg/ADt, in USA
Mill type/Group BPT NSPS
BOD
5
TSS BOD
5
TSS
A Unbleached kraft and paper 2.8 6.0 1.8 3.0
B Bleached market kraft pulp 8.05 16.4 5.5 9.5
H Bleached kraft pulp and fine paper 5.5 11.9 3.1 4.8
J Bleached sulphite pulp and paper 16.5 23.5 2.36 3.03
L TMP and paper 5.55 8.35 2.5 4.6
N Groundwood pulp and newsprint 3.9 6.85 2.5 3.8
Allowed pH range of treated effluent is 5 - 9. In wet debarking, additional BOD
load of 1.2 kg/ADt and TSS load of approximately 3.1 kg/ADt is allowed. The
NSPS restrictions include also loads from debarking plant.
State regulations can be tighter and also may include other parameters (e.g.
AOX, colour, dioxins/furans, heavy metals).
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In the Cluster Rule proposals, the production groups are planned to be
decreased to 12 and new restrictions for all production groups are to be
determined.
2.3.2 Canada
The federal regulations 1992 define the maximum BOD and TSS discharge
levels for pulp and paper mills. Also acute toxicity of the effluent is regulated
by the Federal Government.
In Table 14, the current waste water discharge limits according to the Federal
regulations are summarised.
Table 14: Effluent discharge limits (expressed as kg/ADt) by Federal
Regulations in Canada
Mill type BOD TSS
Daily Monthly Daily Monthly
Dissolving sulphite mills 45.0 27.0 62.5 37.5
Other pulp and paper
mills
12.5
(24.75)
1)
7.5
(14.85)
1)
18.75 11.25
1)
Maximum BOD that can be authorised for old mills, built before 1970
The provinces may set their own more stringent regulations.
2.4 International Conventions
2.4.1 The Helsinki Convention (HELCOM)
The basic Convention on the protection of the marine environment of the
Baltic Sea area was made at Finland's initiative in March 1974 in Helsinki.
The current amendment of the Convention includes also the definitions of
BAT and BEP. The parties agree to promote the use of BAT and BEP. BAT is
to be used for point polluting sources and BEP for all pollution sources.
Concerning pulp and paper industry, the following HELCOM recommen-
dations are adopted as revised in March 1996:
HELCOM recommendation 17/8 (Reduction of discharges from the Kraft
pulp industry)
HELCOM recommendation 17/9 (Reduction of discharges from the sulphite
pulp industry
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Discharge limits according to HELCOM 17/8 are presented in Table 15.
Table 15: Annual average discharge limit values for the Kraft pulp industry
according to HELCOM recommendation 17/8
The following annual average discharge limit values in kg per tonne of Air Dry Pulp (kg/t
ADP) produced are not exceeded from 1 January 2000 for any mill which has started to
operate before 1 January 1997:
Pulping process COD
Cr
AOX Tot-P Tot-N
Bleached pulp 30 0.4 0.04 0.4
Unbleached pulp 15 - 0.02 0.3
In countries in transition, the following annual average discharge limit values (kg/t ADP)
produced are not exceeded from 1 January 2005 for any mill which has started to operate
before 1 January 1997:
Pulping process COD
Cr
AOX Tot-P Tot-N
Bleached pulp 35 0.4 0.04 0.4
Unbleached pulp 20 - 0.02 0.3
For any mill, starting to operate or considerably increasing its capacity (by more than 50%)
after 1 January 1997, the following annual discharge limit values (kg/t ADP) exist:
Pulping process COD
Cr
AOX Tot-P Tot-N
Bleached pulp 15 0.2 0.02 0.35
Unbleached pulp 8 - 0.01 0.25
In Attachment 1, HELCOM 17/8 determines BAT for the Kraft pulp industry,
1995:
1. Dry debarking with minor waste water discharges
2. Closed screening
3. Stripping of most concentrated condensates and reuse of most
condensates in the process
4. Systems which enable the recovery of almost all spillages
5. Extended delignification in the digester followed by oxygen delignification
6. Efficient washing before the pulp leaves the closed part of the process
7. At least secondary treatment for waste water discharges
8. Partial closure of bleach plant. The main part of the discharge from the
bleach plant is piped to the recovery system
9. Use of environmentally sound chemicals in the process, for example use of
biodegradable chelating agents wherever possible
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In Attachment 2, analysing methods to be applied for AOX, COD
Cr
, Tot-P and
Tot-N are presented (all analyses should be made on unsettled, unfiltered
samples).
Discharge limits according to HELCOM 17/9 are presented in Table 16.
Table 16: Annual average discharge limit values for the sulphite pulp industry
according to HELCOM recommendation 17/9
The following annual average discharge limit values (kg/t ADP) produced are not
exceeded from 1 January 2000 (for countries in transition from 1 January 2005) for any
mill which has started to operate before 1 January 1997:
Pulping process COD
Cr
AOX Tot-P Tot-N
Bleached pulp 70 0.5 0.08 0.7
Unbleached pulp 45 - 0.06 0.6
For any mill, starting to operate or considerably increasing its capacity (by more than 50%)
after 1 January 1997, the following annual discharge limit values (kg/t ADP) exist:
Pulping process COD
Cr
AOX Tot-P Tot-N
Bleached pulp 35 0.1 0.04 0.4
Unbleached pulp 20 - 0.03 0.3
In Attachment 1 of HELCOM 17/9, BAT for the sulphite industry 1995 is
determined:
1. Dry debarking with minor waste water discharges
2. Closed screening
3. Neutralising of weak liquor before evaporation followed by re-use of the
main part of condensates in process
4. Systems which enable the recovery of almost all organic substances
dissolved in the cook (a total U-value of about 98 % is achievable)
5. No discharge from the bleach plant when the sodium based processes are
being used
6. At least secondary treatment for waste water discharges
7. Partial closure of the bleach plant when another process than sodium
based is used
8. Use of environmentally sound chemicals in the process, for example use of
biodegradable chelating agents wherever possible
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2.4.2 Proposals of the Nordic Council of Ministers
The Nordic Council of Ministers established a working group comprising
experts from Sweden, Finland, Norway and Denmark to evaluate the impacts
of the pulp and paper industry on the environment and to compile a report on
these impacts by 1993.
Based on this report, among others, the following proposals related to
environmental protection and pollution control were presented:
Effluent loads, as shown in Table 17, expressed as annual averages,
should by the end of this century not to be exceeded for any mill. For
integrated mills producing mechanical or recycled fibres pulp the figures
are kg per tonne of product, whereas for the other types of mills the figures
are kg per tonne of air dry pulp.
Table 17: Annual average limit values of effluent loads (kg/ADt) according to a
proposal by the Nordic Council of Ministers 1993. Limit values to be reached
by the end of this century
Type of mill AOX COD
Cr
Tot-P Tot-N
1)
Bleached kraft 0.4 30 0.04 0.2
Unbleached kraft - 15 0.02 0.2
Bleached sulphite 0.3 70 0.08 0.6
CTMP - 30 0.02 0.2
Mechanical
2)
- 10 0.01 0.2
Recycled fiber - 10 0.01 0.2
1)
Any nitrogen discharge associated with the use of complexing agents should be
added to the figure for tot-N given above
2)
"Mechanical" means integrated mills producing newsprint or magazine paper
In case of any new or considerably enlarged (in the order of 30 %) mill,
the following levels, as shown in Table 18, should not be exceeded as
annual averages.
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Table 18: Annual average limit values of effluent loads according to a
proposal by the Nordic Council of Ministers 1993. New and enlarged mills
Type of mill AOX COD
Cr
Tot-P Tot-N
1)
Bleached kraft 0.2 15 0.02 0.15
Unbleached kraft - 8 0.01 0.15
Bleached sulphite 0.1 35 0.04 0.3
CTMP - 15 0.01 0.1
Mechanical
2)
- 5 0.005 0.1
Recycled fibre - 5 0.005 0.1
1)
Any nitrogen discharge associated with the use of complexing agents should be
added to the figure for tot-N given above
2)
"Mechanical" means integrated mills producing newsprint or magazine paper
2.5 Far East
2.5.1 Japan
Based on the historical background and the development of the
environmental legislation and policy, Japan has been the key country in the
region since the 1960s.
The latest revision of the Water Pollution Control Law took place in June
1996. The main effort in Japan in water pollution control has put on the
protection of three water areas, namely: Tokyo Bay, Ise Bay and Seto Inland
Sea. COD restrictions announced by the Government to reduce COD loads
from industry and municipalities.
General water quality standards can be divided into two categories:
environmental quality standards for protection of human health and the
standards for the conservation of living environment. Depending on the type
and use of the watercourse, different regulations are issued (e.g. for fishery,
agricultural, water supply purposes of natural lakes, rivers and artificial
reservoirs).
Similarly, waste water standards are also applied for the protection of human
health and for the protection of the living environment.
For the protection of human health, the permissible limit values are shown in
Table 19.
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Table 19: Effluent limit values for the protection of human health in Japan
Pollutant Permissible limit, mg/l
Cadmium and its compounds 0.1
Cyanide compounds 1
Organic phosphorus compounds 1
Lead and its compounds 1
Hexavalent chromium compounds 0.5
Arsenic and its compounds 0.5
Total mercury 0.05
Alkyl mercury compounds not detectable
1)
PCB 0.03
Trichloroethylene 0.3
Perchloroethylene 0.1
1) According to the analysing method issued by the Director General of the Environment
Agency.
For all industrial facilities, the general waste water standards are shown in
Table 20.
Table 20: Effluent limit values related to the protection of living environment in
Japan
Pollutant Unit Limit value
pH 5.8 - 8.6 (release to other than coastal
waters)
5 - 9 (release to coastal waters)
BOD, COD mg/l 160 (daily average 120)
SS mg/l 200 (daily average 150)
N-hexane mg/l 5 (mineral oil)
mg/l 30 (animal fat and vegetable oil)
Phenols mg/l 5
Copper mg/l 3
Zinc mg/l 5
Dissolved Fe mg/l 10
Dissolved Mn mg/l 10
Chromium mg/l 2
Fluorine mg/l 15
Coliforms pcs/cc 3000 (daily average)
Nitrogen mg/l 120 (daily average 60)
Phosphorus mg/l 16 (daily average 8)
Note: Prefectures may, by decree, set more stringent standards locally
It must be emphasised, that in individual mill cases, the limit values as to
BOD and COD often are more stringent than those presented in Table 20. As
an example of very tight current Agreement category restrictions for a pulp
and paper mill can be presented:
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BOD: max. 10 mg/l (daily average 8 mg/l)
COD: max. 30 mg/l (daily average 18 mg/l)
SS: max. 15 mg/l (daily average 10 mg/l)
In the end of 1980s, the release of dioxins in pulp mill effluents became
concerned as a major environmental hazard, related to the use of chlorine
gas in bleaching. In December 1990, the industry issued a voluntary target for
AOX release being 1.5 kg/ADt to be reached by the end of 1993. The actual
AOX discharge in 1993 from 31 bleached Kraft mills and from 2 dissolving
pulp mills was on the average 0.8 kg/ADt (min. 0.4 and max. 1.3 kg/ADt).
2.5.2 China
The recent key effluent regulations are the following:
Regulations on prevention and cure of water pollution for paper industry
(issued by Environmental Protection Committee of State Council, Ministry
of Light Industry, Ministry of Agriculture and Ministry of Finance on
December 20, 1988)
Standards of discharge of water pollutants for paper industry, GB 3544-92
(in force after July 1, 1992)
The 1988 regulations include, among others, the following definitions and
requirements for pulp and paper industry:
Classification of pulp and paper mills:
The so-called large enterprise means a mill with pulp production more than
30 000 ADt/a. The middle enterprise has a production between 10 000 to
30 000 ADt/a and a small enterprise produces less than 10 000 Adt/a.
Before 1995, large and middle size enterprises using alkaline pulping
processes, should have a chemical recovery system. The efficiency of the
chemical (black liquor) recovery must reach the following percentages:
wood pulping > 90%
bamboo, reed, silver grass, bagasse > 80%
straw > 75%
Before 1995, the small chemical pulping enterprises with alkali recovery
unit, must reach the following chemical recovery efficiency levels:
production from 7000 to 10000 ADt/a > 70%
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production from 4000 to 7000 ADt/a > 60%
production from 3000 to 4000 ADt/a > 50%
Before 1995, the small chemical pulping enterprises without alkali recovery
unit, should control and decrease the black liquor discharges with respect
to COD and BOD
5
loads as follows:
production from 5000 to 10000 ADt/a > 60% reduction
production from 3000 to 5000 ADt/a > 50% reduction
production less than 3000 ADt/a > 30% reduction
Enterprises that are based on chemi-mechanical, alkaline half-chemical
pulping or lime straw pulping, or alkaline hemp/cotton pulping (including
viscose pulping), should have waste water treatment and these mills
should decrease organic pollution loads more than 50 % before 1995.
The enterprises that are based on acid sulphite pulping process must use
acid recovery process or waste water must meet the standards regulated
by the state or local governments before 1995.
Waste water originating from neutral sulphite pulping process should be
used in agriculture or should have other utilisation. Before 1995, the
utilisation degree should be 60 % or more.
Any enterprise that has not reached the 1988 regulation standards before
the end of 1995, must propose a plan consisting of optional measures to
decrease effluent loads to acceptable levels. The plan will be checked,
accepted and executed by local people's government.
GB 3544-92 standard determines the characteristics of effluents from pulp
and paper mills. The acceptable pollution loads depend on the type of the mill
and the watercourse the effluent is released. The water quality standards,
applied in the GB 3544-92, are:
GB 3097 Quality Standards of Sea Water
GB 3838 Environmental Quality Standard of Surface Water
GB 6920 Water Quality. Determination of pH Value. Glass
Electrode Method
GB 7488 Water Quality. Determination of Biochemical Oxygen
Demand for 5 Days (BOD
5
). Dilution and Inoculation Methods
GB 11901 Water Quality. Determination of Suspended Substance.
Gravimetry.
GB 11914 Water Quality. Determination of Chemical Oxygen Demand
(COD). Dichromate Method.
Waste water quality standards are divided into three categories:
NOPON OY Waste Water Treatment in Pulp and Paper Industry Date: 09.08.1997
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1
st
class The first class standards are applied to waste waters discharged
to III grade water area specified in GB 3838 (except protection areas of
water bodies) and to II grade marine area according to GB 3097.
2
nd
class The second class standards are applied to waste waters
discharged to IV and V grade water area in GB 3838 and to III grade
marine area in GB 3097
3
rd
class The third class standards are applied to waste waters
discharged to sewers of cities or towns having a waste water (sewage)
treatment plant.
The standard values are given as the allowable maximum concentrations and
specific effluent amounts.
In Table 21, Table 22 and Table 23, waste water restrictions for pulp and
paper mills implemented before January 1, 1989 are shown.
Table 21: First class limit values for effluent discharges from pulp and paper
mills implemented before January 1, 1989 in China
Mill type I Class limit values
Effluent amount BOD
5
COD
Cr
SS
m
3
/ADt mg/l mg/l mg/l
Integrated pulp and paper mills:
Wood-based
Unbleached 220 150 350 200
Bleached 320 150 350 200
Non-wood-based
Unbleached 270 150 350 200
Bleached 370 150 350 200
Non-integrated paper mills:
Paper and paperboard 80 60 150 100
Note. Allowable pH range for all types of waste waters is 6 - 9
NOPON OY Waste Water Treatment in Pulp and Paper Industry Date: 09.08.1997
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Table 22: Second class limit values for effluent discharges from pulp and
paper mills implemented before January 1, 1989 in China
Mill type II Class limit values
Effluent amount BOD
5
COD
Cr
SS
m
3
/ADt mg/l mg/l mg/l
Integrated pulp and paper mills:
Wood-based
Unbleached 220 180 400 250
Bleached 320 180 400 250
Non-wood-based
Unbleached 270 200 450 250
Bleached 370 200 450 250
Non-integrated paper mills:
Paper and paperboard 80 80 200 250
Note. Allowable pH range for all types of waste waters is 6 - 9
Table 23: Third class limit values for effluent discharges from pulp and paper
mills implemented before January 1, 1989 in China
Mill type III Class limit values
Effluent amount BOD
5
COD
Cr
SS
m
3
/ADt mg/l mg/l mg/l
Integrated pulp and paper mills:
Wood-based
Unbleached 220 600 1000 400
Bleached 320 600 1000 400
Non-wood-based
Unbleached 270 600 1000 400
Bleached 370 600 1000 400
Non-integrated paper mills:
Paper and paperboard 80 500 1000 400
Note. Allowable pH range for all types of waste waters is 6-9
Respective waste water restrictions for the pulp and paper mills implemented
between January 1, 1989 and June 30, 1992 are presented in Table 24,
Table 25 and Table 26.
NOPON OY Waste Water Treatment in Pulp and Paper Industry Date: 09.08.1997
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Table 24: First class limit values for effluent discharges from pulp and paper
mills implemented between January 1, 1989 and June 30, 1992 in China
Mill type I Class limit values
Effluent amount BOD
5
COD
Cr
SS
m
3
/ADt mg/l mg/l mg/l
Integrated pulp and paper mills:
Wood-based
Unbleached 190 30 100 70
Bleached 280 30 100 70
Non-wood-based
Unbleached 230 30 100 70
Bleached 330 30 100 70
Non-integrated paper mills:
Paper and paperboard 70 30 100 70
Note. Allowable pH range for all types of waste waters is 6 - 9
Table 25: Second class limit values for effluent discharges from pulp and
paper mills implemented between January 1, 1989 and June 30, 1992 in
China
Mill type II Class limit values
Effluent amount BOD
5
COD
Cr
SS
m
3
/ADt mg/l mg/l mg/l
Integrated pulp and paper mills:
Wood-based
Unbleached 190 150 350 200
Bleached 280 150 350 200
Non-wood-based
Unbleached 230 150 450 200
Bleached 330 150 450 200
Non-integrated paper mills:
Paper and paperboard 70 60 150 200
Note. Allowable pH range for all types of waste waters is 6 - 9
NOPON OY Waste Water Treatment in Pulp and Paper Industry Date: 09.08.1997
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Table 26: Third class limit values for effluent discharges from pulp and paper
mills implemented between January 1, 1989 and June 30, 1992 in China
Mill type III Class limit values
Effluent amount BOD
5
COD
Cr
SS
m
3
/ADt mg/l mg/l mg/l
Integrated pulp and paper mills:
Wood-based
Unbleached 190 600 800 400
Bleached 280 600 800 400
Non-wood-based
Unbleached 230 600 1000 400
Bleached 330 600 1000 400
Non-integrated paper mills:
Paper and paperboard 70 500 500 400
Note. Allowable pH range for all types of waste waters is 6 - 9
For new mills and mills built after July 1, 1992, the waste water restrictions
are specified in Table 27, Table 28 and Table 29.
Table 27: First class limit values for effluent discharges from new pulp and
paper mills implemented after July 1, 1992 in China
Mill type I class limit values
Effluent
flow
BOD
5
COD
Cr
Suspended
solids
AOX
m3/ADt kg/t mg/l kg/t mg/l kg/t mg/l kg/t mg/l
Integrated pulp
and paper mils:
Wood-based
unbleached 150 4,5 30 15 100 10,5 70
bleached 240 7,2 30 24 100 16,8 70 1,5 8
Non-wood
based
unbleached 190 5,7 30 19 100 13,3 70
bleached 290 8,7 30 29 100 20,3 70 1,5 7
Non-integrated
paper mills:
paper and
paperboard
60 1,8 30 6 100 4,2 70
Note: Allowable pH range for all types of waste waters is 6 - 9
NOPON OY Waste Water Treatment in Pulp and Paper Industry Date: 09.08.1997
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Table 28: Second class limit values for effluent discharges from new pulp and
paper mills implemented after July 1, 1992 in China
Mill type II Class limit values
Effluent
flow
BOD
5
COD
Cr
Suspended
solids
AOX
m
3
/ADt kg/t mg/l kg/t mg/l kg/t mg/l kg/t mg/l
Integrated pulp
and paper mills:
Wood-based
Unbleached 150 15 100 52.5 350 30 200
Bleached 240 28.8 120 84 350 48 200 2.5 10
Non-wood-
based
Unbleached 190 28.5 150 85.5 450 38 200
Bleached 290 43.5 150 130.
5
450 58 200 2.5 9
Non-integrated
paper mills:
Paper and
paperboard
60 3.6 60 9 150 6 100
Note. Allowable pH range for all types of waste waters is 6 - 9
Table 29: Third class limit values for effluent discharges from new pulp and
paper mills implemented after July 1, 1992 in China
Mill type III Class limit values
Effluent
flow
BOD
5
COD
Cr
Suspended
solids
m
3
/ADt kg/t mg/l kg/t mg/l kg/t mg/l
Integrated pulp
and paper mills:
Wood-based
Unbleached 150 75 500 120 800 60 400
Bleached 240 120 500 192 800 96 400
Non-wood-based
Unbleached 190 114 600 171 900 76 400
Bleached 290 174 600 261 900 116 400
Non-integrated
paper mills:
Paper and
paperboard
60 400 500 400
Note. Allowable pH range for all types of waste waters is 6 - 9
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2.5.3 Indonesia
Since 1991, effluent restrictions applicable to currently operating pulp and
paper mills using Best Practicable Technology (BPT) have been in force.
These regulations should be applied and reached by all mills in 1995, see
Table 30 below.
Table 30: Effluent restrictions for pulp and paper industry in Indonesia in 1995.
Figures represent maximum values which are not to be exceeded.
Load Pulp mills Paper mills Integrated mills
mg/l kg/ADt mg/l kg/ADt mg/l kg/ADt
BOD
5
150 15 125 10 150 25.5
COD 350 35 250 20 350 59.5
TSS 200 20 125 10 150 25.5
pH 6 - 9 6 - 9 6 - 9 6 - 9 6 - 9 6 - 9
Effl. flow 100 m
3
/ADt 80 m
3
/ADt 170 m
3
/ADt
Regulations based on Best Available Technology (BAT) have been issued for
design of new or rebuild pulp and paper mills to be in force from 1995. These
BAT regulations are planned to be applied to all mills by the year 2000.
These limit values are shown in Table 31.
Table 31: Effluent restrictions for pulp and paper industry in Indonesia in 2000.
Figures represent maximum values which are not to be exceeded.
Process Flow BOD
5
COD TSS
m
3
/ADt mg/l kg/ADt mg/l kg/ADt mg/l kg/ADt
PULP
Kraft unbl. 50 75 3.75 200 10 60 3
Kraft bl. 85 100 8.5 350 29.75 100 8.5
Dissolving 95 100 9.5 300 28.5 100 9.5
CMP and
groundwood
60 50 3 120 7.2 75 4.5
Semi-chem. 70 100 7 200 14 100 7
Soda pulp 80 100 8 300 24 100 8
De-inked 60 100 6 300 18 100 6
PAPER
Fine bl. 50 100 5 200 10 100 5
Coarse 40 90 3.6 175 7 80 3.2
Cigarrette 175 60 10.5 100 17.5 45 7.8
Other bl. 35 75 2.6 160 5.6 80 2.8
Note. pH in all process effluents should be between 6 - 9
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3 MAIN PRINCIPLES OF BIOLOGICAL OXIDATION
3.1 General
The following summary concerns mainly biological oxidation of organic
compounds present in pulp and paper industry effluents. Pulp and paper
industry effluents differ e.g. from municipal sewage treatment, as the quality
of the effluents can vary a lot and in general, complete nitrogen removal
needs not to be included in the aeration design (except in case of ammonium
sulphite process effluents).
3.2 Major Phases of Organic Material Bio-oxidation
In biological treatment, microbes degrade and remove organic material
present in mill effluents in the following ways:
1. capturing of organic suspended matter by biosludge
2. adsorption of colloidal substances on the bioflocs
3. biosorption of soluble organic compounds by microbes
Also sorption of non-degradable organic compounds on biosludge can occur.
Sorptive properties depend on the treatment method, e.g. plug-flow systems
have better sorptive biosludge than completely mixed systems.
It is clear, based on the above-mentioned phenomena, that removal of
organic matter from waste waters is a complex multi-stage process. Molecular
oxygen supplied by the aeration equipment, is needed mainly to satisfy 3.
organic matter removal stage. The biosorption rate is directly proportional to
the concentration of biosludge, the sludge age and the characteristics of the
soluble organic compounds. Degradation of compounds in stages 1. and 2.
can also occur and in this way additional soluble organic material for
metabolism of microbes can be generated.
3.3 Molecular Oxygen Demand
3.3.1 General
Much discussion takes place today about the reliable basis of the design
criteria for aeration equipment (BOD, COD or TOC). The two essential stages
in the design procedure of an aeration system are:
Determination of actual oxygen requirement (AOR)
Determination of standard oxygen transfer rate (SOTR)
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In this context, main emphasis is laid on the AOR procedure. SOTR value,
and the respective aeration system, depends on many specific items, such as
the shape and depth of the aeration basin and the type of the aeration
equipment. SOTR value must be determined and tested by the aeration
equipment supplier in each case.
3.3.2 Determination of AOR
In case of pulp and paper mill effluents, AOR value includes dissolved
molecular oxygen needed in aerobic biological processes for:
assimilative respiration
endogenous respiration
chemical oxidation of some inorganic compounds, e.g. sulphides
biological oxidation of ammonia to nitrate (if present)
AOR requirements vary considerably depending on the efficiency degree of
the process, sludge and organic volume loadings, detention time of the
effluent in the aeration basin, sludge age etc. Determination of correct AOR
value for each pulp and paper mill effluent type requires a profound long term
field experience of similar effluent treatment plants. The aeration equipment
supplier should ask for the AOR value from the client to be able to give proper
guarantees for the oxygenation capacity of the aeration equipment.
The general equation for oxygen demand is:
AOR = a' x BOD
rem
+ b' x MLVSS
aer
+ k x COD
Cr
+ 4,6 x NH
4
(rem)
where a' oxygen consumed in assimilative respiration (pulp
and paper mill effluents typically 0,5 - 0,8)
BOD
rem
BOD removal in treatment, kg/d
b' oxygen consumed in endogenous respiration
(range 0,05 - 0,2)
MLVSS
aer
active biomass in aeration
k fraction of COD which requires molecular oxygen
capable to oxidise certain inorganic compounds
(typically 0,01 - 0,1)
NH
4
(rem) ammonium nitrogen removal, kg/d
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Denitrification is not needed in the treatment of pulp and paper mill effluents
and thus anoxic stage is not required. However, in case of ammonium
sulphite mills, nitrogen restrictions may require also denitrification. Presently,
no experience of total nitrogen removal from pulp mill effluents is available.
As indicated earlier, coefficients a' and b' are specific for each type of pulp
and paper mill effluent. Even within a certain effluent category, e.g. newsprint
mill effluent, the coefficients can vary to some extent mill by mill. If pilot trials
can be carried out, the coefficients a' and b' can be determined as follows:
equation between specific BOD removal (kg BOD/kg VSS,d) and oxygen
consumption (kg O
2
/kg VSS,d) will be made based on the pilot tests in
different loading conditions. Typically, the function will be linear, and the
coefficient a' can be obtained as the angle coefficient and b' can be
obtained when the specific oxygen consumption = 0 (ordinate value).
No clear categories of a' and b' for e.g. for pulp mill effluents and paper mill
effluents can be shown. If no pilot trials are possible to be made, as a first
assumption for both pulp and paper mill effluents, a' = 0,6 and b' = 0,1 values
can be used.
For safety reasons, specially in case of pulp mill effluents, coefficient k = 0,1
is recommended to be used.
3.3.3 Determination of SOTR
The following equation between AOR and SOTR exists:
AOR = SOTR x (( c
T
x - c
L
)/c
S
) x x
T-20
)
where c
T
oxygen saturation concentration in temperature T
actual O
2
saturation conc. in effluent/clean water O
2
conc.
c
L
dissolved oxygen concentration in aeration
c
S
saturated O
2
concentration in clean water at temp. T
mass transfer coefficient, K
l
a(effl.) / K
L
a(tap water)
temperature coefficient for mass transfer
T temperature in aeration
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10 Glossary Page: 1.1 (18)
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10 Glossary
10.1 Symbols ........................................................................................10.1
10.2 Terms............................................................................................10.4
10.3 Conversion Factors.....................................................................10.17
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10 GLOSSARY
10.1 Symbols
a Total mass transfer area per volumetric unit
a* Substrate respiration rate
a Coefficient caused by pressure
A Area of air/water boundary surface m
2
AOR Actual Oxygen Requirement kg O
2
/d
b Endogenous respiration rate
B Quantity of removed BOD kg/d
BOD Biological Oxygen Demand mg/l
BR Volumetric load kg BOD/m
3
d
C
* = C
ST
{ 1+0.035 (h-0.25)} mg O
2
/l
where:
C
ST
= the table value for dissolved oxygen (DO)
at the temperature T at surface level mg O
2
/l
C*
10
Saturation dissolved oxygen concentration
at 10 C g O
2
/m
3
C
*
20
Steady state dissolved oxygen (DO) saturation
concentration attained at infinite time at water
temperature 20 C and standard atmospheric
pressure (101.3 kPa).
The value can be estimated as follows:
C
*
20
= C
ST,20
(1+0.035 h) mg O
2
/l
where:
C
ST,20
= the table value for dissolved oxygen (DO)
at the temperature 20 C at surface level = 9,07 mg O
2
/l
C
L
Actual oxygen concentration in aeration tank g O
2
/m
3
C
t
Dissolved oxygen concentration at time t g O
2
/m
3
D Diameter of the pipe m
DD Area density of diffusers m
2
/m
2
D
L
Molecular diffusion of oxygen through boundary
fluid film
DO Dissolved oxygen mg O
2
/l
e Standard oxygen transfer efficiency at chosen
aeration depth %
e
2
Oxygen absorption given by the curves %
E Process efficiency %
EPDM ethylene-propylene-diene
f Coefficient of BOD conversion
f
r
Temperature correction coefficient
F/M Food-to-micro-organism loading
(sludge loading) kgBOD/kgMLSS d
F/V Volumetric load kgBOD/m
3
d
G Velocity gradient 1/s
h Submersion depth of diffusers m
h Depth of the oxygen absorption curves measured m
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H Henrys constant (mg/l)/(kN/m
2
)
HDPE hihg density polyethylene
k Constant factor for blowers 1.395
k Ammonium oxygenation coefficient
k
1
Flow rate correction factor
k
dim
Hourly variation factor
K
L
Mass transfer coefficient of boundary fluid film
K
L
a Apparent volumetric mass transfer coefficient
in clean water at temperature T 1/d
l Length of aeration tank m
L Imaginary thickness of boundary fluid film m
MLSS Mixed liquor suspended solids kg/m
3
MLVSS Mixed liquor volatile suspended solids kg/m
3
n exponent
N Number of diffusers
N, N
D
Total nitrogen concentration of effluent kg N/m
3
No Total nitrogen concentration of influent kg N/m
3
NH
4,o
Ammonium concentration of influent kg N/m
3
NH
4
Ammonium concentration of effluent kg N/m
3
NH
4
, NH Ammonium reduction kg N/m
3
N
R
, N
T
Total nitrogen reduction kg N/d
N(NO
3
)
A
Nitrate concentration of effluent kg N/m
3
N(ges)
Z
Total nitrogen concentration of influent kg N/m
3
N(NH
4
)
A
Ammonium concentration of effluent kg N/m
3
N(org)
A
Organic nitrogen of effluent kg N/m
3
N
s
Nitrogen bonded to excess sludge kg N/m
3
O
C
Oxygenation capacity kg O
2
/h
OVR Actual oxygen requirement kg O
2
/m
3
h
p Atmospheric pressure kPa
p Water pressure above the diffuser kPa, mmHg
p
2
Blower discharge pressure kPa
p
a
Head loss in diffusers kPa
p
b
Head loss in inlet valves and filters kPa
P.E. population equivalent
PE polyethylene
p
h
Hydrostatic pressure at the diffuser kPa
p
i
Atmospheric pressure at the altitude of the plant kPa
p
p
Head loss in pipework including control valves kPa
PP polypropylene
p
s
Atmospheric pressure at standard conditions kPa
P Required power kW
P
X
Net production of biomass kg MLVSS/d
q
a
Air flow m
3
/h
q
a
Blower air flow in real conditions m
3
/h
q
a,d
Air flow/diffuser m
3
/h
q
dim
Hourly design flow m
3
/h
q
i
, q Influent flow m
3
/h
Q
d
Domestic sewage flow m
3
/d
Q
dim
Daily design flow m
3
/d
Q
e
Effluent flow m
3
/d
Q
e
, Q Influent flow m
3
/d
Q
I
Industrial sewage flow m
3
/d
Q
L
Leakages m
3
/d
Q
max
Maximum daily flow m
3
/d
Q
r
Return sludge flow m
3
/d
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Q
w
Excess sludge flow m
3
/d
R Actual oxygen requirement kg O
2
/d
S Substrate (BOD) reduction kg/m
3
S
e
, S Effluent substrate (BOD) concentration kg/m
3
S
i
, S
o
Influent substrate (BOD) concentration kg/m
3
SOTE Standard Oxygen Transfer Efficiency %
SOTR Standard Oxygen Transfer Rate kg/h
SVI Sludge volume index ml/g
t time min, h
t
d
Hours of domestic sewage flow per day h
t
I
Hours of industrial sewage flows per day h
T Temperature of clean or process water C, K
T
i
Maximum intake air temperature during
summertime K
T
p
Average temperature in distribution pipes K
T
s
Air temperature in standard conditions K
TS
R
Concentration of suspended solids in the
aeration basin kg MLSS/m
3
v Air flow velocity in pipe m/s
V Aeration volume m
3
w Width of aeration tank m
x Proportion of active biomass
X Concentration of suspended solids in the
aeration tank kg MLSS/m
3
X
o
Mol fraction of oxygen in aeration air
X
O2
, C
i
Oxygen content in the air kg O
2
/m
3
X
e
Concentration of suspended solids in the
effluent kg SS/m
3
X
r
Return sludge suspended solids kg MLSS/m
3
X
w
Concentration of suspended solids in
excess sludge kg MLSS/m
3
Proportion of the total oxygen transfer
coefficient measured in sewage and in clean water
Proportion of the DO saturation coefficients
measured in sewage and in clean water
Specific weight of water kg/dm
3
Dynamic viscosity Ns/m
2
Temperature correction coefficient
c
Mean cell residence time (sludge age) d
h
Hydraulic retention time h
Total efficiency of blower %
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10.2 Terms
acid clean a general expression for cleaning DDS systems by volatile acid (HCI,
HCOOH) during operation
acidity the capacity of a solution to react with hydroxyl ions. Acidity is
measured by titration with a standard alkaline solution (base) to a
specified end point. Typically, it is measured in milligrams of calcium
carbonate per litre.
activated sludge Sludge withdrawn from a secondary clarifier following the activated
sludge process. Activated sludge consists mostly of biomass, with
some inorganic settleable solids. Return sludge is recycled to the
head of the process; waste (excess) sludge is removed for
conditioning.
activated sludge loading The kilograms (pounds) of biochemical oxygen demand (BOD) in the
applied liquid per unit volume of aeration capacity or per kilogram
(pound) of activated sludge per day.
activated sludge process A biological waste water treatment process by which a mixture of
waste water and activated sludge is agitated and aerated. The
activated sludge is subsequently separated from the treated waste
water (mixed liquor) by sedimentation and wasted or returned to the
process as needed.
advanced waste water
treatment
Any physical, chemical, or biological treatment process used to
accomplish a degree of treatment greater than that achieved by
secondary treatment (see also tertiary treatment).
aeration The initiation of contact between air and liquid by one or more of the
following methods: (a) spraying the liquid in the air; (b) bubbling air
through the liquid; (c) agitating the liquid to promote surface
absorption of air.
aeration group a grid of pipes with diffusers installed forming a closed pipework
connected by one flange to the dropleg air feed pipe
aeration method a method of dissolving oxygen into water, e.g. bottom aeration, fine
bubble aeration, surface aeration, jet aeration, etc.
aeration period The time, usually expressed in hours, during which mixed liquor is
subjected to aeration in an aeration basin.
aeration system a combination of aeration equipment (aeration groups or aerators)
designed to dissolve oxygen into water (activated sludge)
aeration tank A tank in which waste water or other liquids are aerated (also called
aeration basin).
aerator aeration equipment, typically used for mechanical aeration equipment;
like O.K.I. aerators, surface aerators
aerobes Organisms that live only in aerobic conditions.
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aerobic Living or occurring in an environment containing oxygen.
aerobic respiration The breakdown of organic substances by aerobes in the presence of
oxygen.
air lift A device for raising liquid by injecting air in and near the bottom of a
riser pipe submerged in the liquid to be raised.
air lift pump A pump used for lifting activated sludge from the aeration basin or
clarifier to waste or return activated sludge. Fine-pressured air
bubbles are discharged to the water at the bottom, and the denser
surrounding water pushes up in the discharge pipe to the outlet (also
called air-lift or air-lift returns).
algae Photosynthetic, microscopic plants that can seriously deplete oxygen
in the presence of sunlight.
alpha ratio of mass transfer coefficient in waste water and clean water
ammonia A chemical combination of hydrogen (H) and nitrogen (N) occurring
extensively in nature and expressed as NH
3
.
ammonia-nitrogen Quantity of elemental nitrogen present in the form of ammonia (NH
3
).
amoeba Small, one-celled organism using pseudopodic (false feet) for
movement (see Sarcodina).
amperometric titration The electronic detection of the equivalence point in a titration, through
observation of the change in diffusion current at a suitable applied
voltage as a function of the volume of titrating solution.
anaerobes Organisms that live in the absence of oxygen.
anaerobic A condition in which no oxygen is available in the environment (for
example, a septic clarifier).
anaerobic respiration The breakdown of organic substances in the absence of oxygen.
AOR Actual Oxygen Requirement (in waste water)
bacteria A group of universally distributed, rigid, essentially unicellular
microscopic organisms lacking chlorophyll. Bacteria perform a variety
of biological treatment processes, including biological oxidation,
nitrification, and denitrification.
bacterial analysis The examination of wastewater to determine the presence, number,
and identity of bacteria (also called bacterial examination).
bacterial examination Examination of waste water to determine the presence, number, and
identity of bacteria. Also called bacterial analysis.
bacteriological count A means for quantifying numbers of organisms.
beta ratio of oxygen saturation value in waste water and clean water
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biochemical oxygen demand
(BOD)
(1) The quantity of oxygen used in the biochemical oxidation of
organic matter in a specified time, at a specified temperature, and
under specified conditions. (2) A standard test used in assessing
waste water strength.
biochemical oxygen demand
(BOD) load
The BOD content, usually expressed in kilograms (pounds) per unit of
time, of wastewater passing into a waste treatment system or to a
body of water.
biodegradable The destruction of organic materials by organisms and waste water
treatment systems.
biomass The amount (usually measured in kilograms or pounds) of biological
material contained in the treatment system.
bottom mounting bracket device for fixing and levelling an aeration system pipework on basin
bottom
centrifuge Mechanical device used to separate solids from water using a
centrifugal force (commonly called spin test when used as a process
control test).
chemical oxygen demand
(COD)
A quantitative measure of the amount of oxygen required for the
chemical oxidation of carbonaceous (organic) material in waste water,
using inorganic bichromate or permanganate salts as oxidants in a 2
hour test.
ciliated protozoa Small, one-celled organisms possessing cilia (hairlike projections used
for movement).
clarification Any process or combination of processes, the primary purpose of
which is to reduce the concentration of suspended matter in a liquid.
The term was formerly used as a synonym for settling or
sedimentation. In recent years, the latter terms are preferable when
describing the settling process.
clarified waste water Waste water from which most of the settleable solids have been
removed by sedimentation (also called settled waste water).
complete-mix Activated sludge process whereby waste water is rapidly and evenly
distributed throughout the aeration tank, unlike the conventional
aeration process (plug flow).
concentration (1) The amount of a given substance dissolved in a unit volume of
solution or applied to a unit weight of solids. (2) The process of
increasing the suspended solids per unit volume of sludge as by
sedimentation.
connection for water
drainage
a cross junction in a water collection pipe or in zone header for
connecting drainage hose (pipe)
connection sleeve part for joining pipes of the diffuser aeration system
contact stabilisation A modification of the activated sludge process using a short contact
time for adsorption of BOD followed by a long contact time for
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synthesis or stabilisation by bacteria.
contact time The period of time a substance remains in a basin (see detention
time).
conventional aeration Process design configuration whereby the organic loading in the
aeration tank is higher at the influentend than at the effluent end. The
flow passes through a serpentine system of tanks, typically side-by-
side, before passing on to the clarifier (also called plug flow).
core sampler A long, slender pole with a foot valve at the bottom end that allows the
depth of the sludge blanket to be measured (also called sludge judge).
cross junction X or T type coupling for connecting pipes of the same or different size
in straight angle
DDS disc diffuser system
declining growth phase Period of time between the log-growth phase and endogenous phase,
where the amount of food is in short supply, leading to ever-slowing
bacterial growth rates.
denitrifcation The anaerobic biological reduction of nitrate nitrogen to nitrogen gas.
Also, removal of total nitrogen from a system (see also nitrification).
depth of blanket (DOB) The level of sludge, typically measured in metres (feet), in the bottom
of the clarifier (see also sludge blanket).
design flow Engineering guidelines that typically specify the amount of influent
flow that can be expected on a daily basis over the course of a year.
Other design flows can be set for monthly and peak flows.
detention time The period of time a waste water flow is retained in a basin for storage
or completion of physical, chemical, or biological reaction (see also
contact time).
Diffuser aeration device forming air into small bubbles, used for fine bubble
bottom aeration systems
dissolved oxygen (DO) The oxygen dissolved in waste water, usually expressed in milligrams
per litre, or percent of saturation.
dissolved solids Solids in solution that cannot be removed by filtration; for example,
NaCI and other salts that must be determined by evaporation (see
also total dissolved solids).
distribution header air distribution pipe from main header to dropleg pipes
drainage connection, junction Part(s) in water collection pipe for connecting purge hose (pipe)
drainage coupling A coupling for condensate purge hose (pipe) in water drainage
connection
dropleg, dropleg pipe a pipe connecting zone header of an aeration group and distribution
header (a pipe coming from blower)
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dynamic equilibrium See population dynamics.
effluent Waste water partially or completely treated, flowing out of a basin,
treatment plant, or industrial treatment plant.
effluent quality The physical, biological, and chemical characteristics of waste water
or other liquid flowing out of a basin, pipe, or treatment plant.
effluent standard Specification of the allowable concentration or mass of a constituent
that may be discharged.
effluent stream A stream of treated waste water.
element, diffuser element a pipe (of max. 5 m length) with assembled diffusers mounted on
endogenous phase See endogenous respiration.
endogenous respiration The internal digestion of stored food within the organism occurring
when the external food sources are limited.
EPDM elastomer material used in membrane diffusers, ethylene-propylene-
diene
excess sludge The sludge produced in an activated sludge treatment process, or any
other process that requires sludge recirculation, that is not needed to
maintain the process and is withdrawn from circulation (also called
waste sludge or waste activated sludge WAS).
extended aeration A modification of the activated sludge process that provides for
aerobic sludge digestion within the aeration system. The process
includes the stabilisation of organic matter under aerobic conditions.
Effluent contains finely divided suspended matter and soluble matter.
extended aeration process A modification of the activated sludge process using long aeration
periods to promote aerobic digestion of the biological mass by
endogenous respiration.
facultative The ability of an organism to live in aerobic or anaerobic conditions.
filamentous growth Intertwined, threadlike biological growths, characteristic of some
species of bacteria, fungi, and algae. Such growths reduce sludge
settleability and dewaterability.
filamentous organisms Bacterial, fungal, and algal species that grow in thread-like colonies,
resulting in a biological mass that will not settle and may interfere with
drainage through a filter.
filamentous sludge Activated sludge characterised by excessive growth of filamentous
bacteria, resulting in poor sludge settling.
flange drilled plate for joining pipes, e.g. dropleg and zone header
floc Collections of smaller particles agglomerated into larger, more easily
settleable particles through chemical, physical, or biological treatment
(see also flocculation).
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flocculation In water and waste water treatment, the agglomeration of colloidal and
finely divided suspended matter after coagulation by gentle
mechanical or hydraulic stirring. In biological waste water treatment
where coagulation is not used, agglomeration may be accomplished
biologically.
flow The movement of water or other fluids from place to place.
flow rate Q Volume of liquid that passes through a cross-section of conduit in a
given time; measured in such units as kg/h, m
3
/s, l/d or gallons per
day.
flow recording Documentation of the quantity of rate of flow.
food to micro-organism ratio
FM
In the activated sludge process, the loading rate expressed as kg
BOD
5
/ kg mixed liquor or mixed liquor volatile suspended solids /d.
foot part of bottom mounting bracket, fixed on tank bottom
free-swimming ciliates Mobile, one-celled organisms using cilia (hairlike projections) for
movement.
fungi Small non-chlorophyll-bearing plants lacking roots, stems, or leaves.
Fungi occur in, among other places, water, waste water, or waste
water effluents and grow best in the absence of light.
header (pipe) diffuser row consisting of diffuser elements where diffusers are
mounted, connected to zone header
high-purity oxygen A modification of the activated sludge process using relatively pure
oxygen and covered aeration basins in conventional flow
arrangement.
high-rate aeration A modification of the activated sludge process whereby the mixed
liquor suspended solids loadings are kept high, allowing high food to
micro-organism FM ratios and shorter detention times.
holder pipe support, part of TPK bottom mounting bracket, syn. clamp
hydraulic loading Waste water amount applied to treatment process, usually expressed
as volume / unit time, or volume / unit time / unit surface area.
hydraulic retention time a ratio: total aeration basin volume / influent flow (m
3
/h)
influent Waste water flowing into a basin, treatment plant, or treatment
process (see antonym effluent).
inorganic compounds All those combinations of elements that do not include organic carbon.
inorganic matter Mineral-type compounds that are generally nonvolatile,
noncombustible, and nonbiodegradable. Most inorganictype
compounds, or reactions, are ionic in nature; therefore, rapid reactions
are characteristic.
Kjeldahl nitrogen test A standard analytical method used to determine the concentration of
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organically bound ammonia nitrogen state.
K
L
a Overall mass transfer coefficient of aeration system (of oxygen)
layout drawing of the placement of diffusers/aeration groups in basin bottom
log growth phase The initial stage of bacterial growth, during which there is a plentiful
supply of food, causing bacteria to grow at the maximum rate.
main body a saddle like part of diffuser for fixing diffuser to a header pipe;
diffuser disc is fixed to main body
main header air distribution pipe from the blower(s)
maximum flow The greatest volume of influent to a treatment plant within a given
time period (see peak flow).
mean cell residence time
MCRT
Average time a given unit of cell mass stays in the activated sludge
aeration tank. Mean cell residence time is typically calculated as ratio
of total mixed liquor suspended solids in aeration tank to that of waste
water.
mean flow The arithmetic average of the discharge at a given point or station on
the line of flow for some specified period of time (see design flow).
mechanical aeration (1) The mixing, by mechanical means, of wastewater and activated
sludge in the aeration tank of the activated sludge process to bring
fresh surfaces of liquid into contact with the atmosphere. (2) The
introduction of atmospheric oxygen into a liquid by the mechanical
action of a paddle, paddle wheel, spray, or turbine mechanism.
mechanical aerator A mechanical device used for introducing atmospheric oxygen into a
liquid (see also mechanical aeration).
membrane diffuser diffuser of elastic (rubber) disc or tube used as a bubble forming
device
metazoa Group of animals having bodies composed of cells differentiated into
tissues and organs and usually a digestive cavity lined with
specialised cells.
micro-organisms Microscopic organisms, either plant or animal, that are invisible or
barely visible to the naked eye. Examples are algae, bacteria,
fungi/protozoa, and viruses.
microbial activity The activities of micro-organisms resulting in chemical or physical
changes.
microbiology The study of microscopic organisms of living matter and their
processes.
microscopic examination (1) The examination of wastewater to determine the presence and
amount of plant and animal life such as bacteria, algae, and protozoa.
(2) The examination of wastewater to determine the presence of
microscopic solids. (3) The examination of microbiota in process
water, such as the mixed liquor in an activated sludge plant.
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minimum flow (1) Flow occurring in a stream during the driest period of the year
(also called low flow). a) The lowest quantity of influent to a treatment
plant or within a sewer within a given time period (see antonym peak
flow).
mixed liquor Mixture of raw or settled waste water and the activated sludge
process.
mixed liquor suspended
solids MLSS
The concentration of suspended solids in activated sludge mixed
liquor, expressed in milligrams per litre.
mixed liquor volatile
suspended solids MLVSS
That fraction of suspended solids in activated sludge mixed liquor that
can be driven off by combustion at 550 C (1022 F); indicates the
concentration of active micro-organisms available for biological
oxidation.
moving average A tool used in trend analysis for determining patterns or changes in
treatment processes. For example, a 7-day moving average would be
the sum of the datum points for 7 days divided by 7.
National Pollutant Discharge
Elimination System permit
NPDES, Permit that is the basis for the monthly monitoring reports
required by most states in the U.S.
nematodes Any of a phylum (Nematoda) of elongated cylindrical worms parasitic
in animals or plants or free-living in soil or water.
nitrate An oxygenated form of nitrogen, typically written NO
3
(see nitrogen).
nitrification The oxidation of ammonia nitrogen to nitrate nitrogen in wastewater
by biological or chemical reactions (see also denitrification).
nitrite An intermediate oxygenated form of nitrogen typically written (NO
2
).
nitrogen An essential nutrient often present in waste water as ammonia, nitrate,
nitrite, and organic nitrogen. The concentrations of each form and the
sum, total nitrogen, are expressed as milligrams per litre elemental
nitrogen. Nitrogen is also present in some ground water as nitrate and
in some polluted ground water in other forms.
NOPOL
O.K.I.
Aeration Systems (use capital letters)
NOPOL