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Alum Sludge Thickening and Disposal 1973 JAW
Alum Sludge Thickening and Disposal 1973 JAW
Diversion •
f Clarifier- Thickener 1 Clarifier-Surge Tank
Four polymers were selected from Chlorine • ^ * «S — — _t——
Filter
Backwash
these tests for use in subsequent pilot I ^
work. ^/^/ . ^- 1
X NV U««««^.^<^~!J ~
Sludge conditioning methods such 1 f '* /^ 1 Polymer
Polymer N^
as heat and pressure, homogenization,
freezing, and lime treatment were in t
Fig. 4. Reproduction of General Flow Diagram and -Hydraulic Profile of Sobrante Filter Plant Reclamation Facility
TABLE 5 environmental considerations, then a
Economic Analysis of Machines and Operating Parameters drying system will be recommended
for installation at the reclamation fa
Scroll Pressure Basket Vacuum
Parameters Centrifuge Filter Centrifuge Filter cility.
SoUds loadings (dry basis)*
Selection of the scroll centrifuge.
Nominal The scroll centrifuge was chosen as
9,500 34,000 9,500 10,000
Per unit
Total 19,000 19,000 19,000 19,000 the preferred mechanical thickener
Overload (overload conditions for this application. Table 7 indicates
= 60,000 lb/day) per unit 34,000 68,000 22,000 20,000
Total 68,000 68,000 66,000 60,000 that there are several advantages to
Machine requirement the scroll centrifuge over the other
Machine size 28 gpm 64 in. X 81 chambers 120-gal bowl 416 sq ft
Assumed equipment life yr 20 30 20 25 types of machines tested.
VS 2 2
Number for nominal load
Number for overload
2
2 1 3 3
First, it has a greater flexibility of
Solids output operations. This machine will produce
Nominal a wide range of cake solids concentra
Solids by weight per cent 16 30 15 15
Gpd of wet cake 12,700 10,600 13,500 13,500 tions while handling a very high sol
Overload
Solids by weight per cent 16 20 10 10 ids loading.
Gpd of wet cake 45,400 35,300 73,700 73,700 Second, the likelihood exists that a
Polyelectrolyte dose lb/Ti
Nominal load 3.0 4.0 4.5 1.5 liquid sludge may be required from
Overload 8.0 4.0 5.0 2.0 the facility at some future date. The
Initial machine costs $
Machine cost (each) 40,000 400,000 45,000 38,000 clarifier-thickener will produce
Total for overload 80,000 400,000 135,000 104,000 sludge-solids concentrations in the
Annual cost (for 1,700 T/yr) $
Machine capital recovery at range of 3-6 per cent dry solids by
5 per cent 6,420 26,020 10,830 7,380
Operation and maintenance weight. By making an economic
nominal 4,800 4,000 1,500 3,000 comparison similar to Table 5, it can
Power nominal 3,850 1,190 3,210 10,900
Polyelectrolyte cost be determined that it will be con
Nominal (1,200 T/yr) 6,840 9,100 10,300 3,420 siderably less expensive to thicken
Overload (500 T/yr) 7,600 3,800 4,750 1,900
Disposal at $5/cu ydt 56,100 34,400 68,700 68,700 the clarifier-thickener effluent to
Labor (including benefits and 11-12 per cent dry solids for liquid
overhead) based on Vi man-
day/day 9,450 9,450 9,450 9,450 hauling than to haul the sludge di
Total annual cost 95,060 87,960 108,740 104,750
Unit cost $/T 56 52 64 62 rectly from the clarifier-thickener.
•All solids loadings units are lb/day.
The scroll centrifuge proved to be the
tT = ton of dry sludge solids. best of the mechanical thickeners
tUncompacted unit weight In truck haul assumed = 70 Ib/cu ft. tested for producing a liquid sludge.
The third advantage to the scroll
from moisture-laden gases; and (4) an ing system makes it quite attractive centrifuge alternative is its low total
air scrubber for removing fine parti for use in combination with the scroll cost and low initial capital invest
cles from the gas stream. centrifuge. A comparison of the total ment. At an interest rate of 5 per
The entire system can be housed in annual costs in Table 6 with the total cent, the scroll centrifuge is slightly
a structure 20 ft wide, 15 ft high, and annual cost for the pressure filter more expensive than the pressure
40 ft long. shows the drying method to be more filter. At an interest rate of 8 per cent,
Table 6 lists the economic review economical than the pressure-filter the two alternatives are about equal.
of the combined system of scroll cen- operation. Comparison of the unit Use of the pulse-jet drying system in
trifuging with pulse-jet drying. It cost of $52/T for the filter-press al series with the scroll centrifuge indi
should be noted that all energy costs ternative with a unit cost of $51/T cates the likelihood of reducing the
are included in this table. for the scroll centrifuge operated in costs of the scroll centrifuge scheme
The electrical costs shown are for conjunction with the pulse-jet dryer to below those of the pressure-filter
stirring of the sludge in the pulse-jet points up the fact that this is an method.
dryer, which eliminates scorching and economic alternative for sludge dis Last, the scroll centrifuge is expect
burning and reduces drying energy posal at this facility. The frequency ed to operate with very little surveil
requirements and some other small of truck hauling through the sur lance. Of the four types of mechani
energy requirements. The manufac rounding residential neighborhood cal thickeners tested, only the solid
turer states that the total Btu require would be about one half that of the bowl basket centrifuge had a lower
ment can be lowered to 1,000-1,200 pressure filter with the pulse-jet dry surveillance requirement.
Btu/lb H2O removed by recovery of ing system. Pressure filter. The pressure filter
heat lost in the stack gases. A pulse-jet pilot drying unit will be was the most economical of the four
The unit operates at temperatures tested at the reclamation facility soon mechanical thickeners piloted. Table
in the range of 180-240F and pro after it goes into operation early in 5 indicates that the pressure filter is
duces no visible plume of steam un 1974. A pilot unit is available* that slightly more economical to operate
der normal operating conditions. can dry all the sludge produced by than the scroll centrifuge.
Steam can be observed coming from the reclamation facility under nomi The literature review1 ' 10' 17 indi
the unit on foggy or rainy days when nal loading conditions. If these tests cated that the pressure-filter method
the relative humidity in the air is near are successful in terms of cost and is being successfully used in Europe.
100 percent. The Chattahoochee Water Treatment
The economy of the pulse-jet dry •Pulsar Systems, Inc. Plant in Atlanta, Ga., is the only
390 WATER TECHNOLOGY/QUALITY JOURNAL AWWA
plant in operation in the US using mechanical thickening at Sobrante TABLE 6
pressure filters to thicken alum Filter Plant. - Economics of Drying With Scroll
sludge. This plant is using pressure First, there is the possibility of a Centrifuging*—$ / y r
filters* and approximately 10-15 per more economical drying method
Pulse-jet
cent Ca(OH) 2 by weight to condition being available. The pulse-jet drying Annual Costs Scroll Drying
alum sludge for pressure filtering. Ap method has proved successful in tests (for 1,700 T/yr) Centrifuge System
proximately twelve other plants across on other types of wastes. If these re Equipment capital
recovery at 5 per cent 6,420 12,040
the country are under design by this sults are repeated on alum sludge, it Operation and
corporation using the pressure-filter will be more economical to dewater maintenance 4,800 6,000
Power: natural gas
method for thickening alum sludge. with the scroll centrifuge and the for drying 13,600
pulse-jet drying system than to use Power: electricity 3,850 1,000
The Chattahoochee installation is Polyelectrolyte cost 14,440
completely automated and has been pressure filtration alone. Labor 7,450 2,000
Disposal to landfill 15,250
operating successfully with pressure A second reason for selecting the Total annual cost 86,850
filters since May 1972. The pressure scroll centrifuge over the pressure Unit cost J/Tt 51
filters at this installation are remote filter stems from the possibility that a Miscellaneous data: scroll centrifuges (2)
liquid sludge may be required as a cost: $80,000 (20-yr life); pulse-jet drying sys
controlled from the filter-plant opera tem cost: $150,000 (20-yr life); dryer capacity:
tions building. product from the reclamation facility. 2,000 Ib water, removed per hour; natural gas
cost: $0.65/10 Btu; removal energy: 1,400 Btu/
The pressure filter consists basical One of the disposal alternatives open Ib water removed; 1,450 T/yr solids treated by
ly of a number of plates or trays for Sobrante Filter Plant is to trans dryer to 90 per cent dry solids (1,400 cu yd);
250 T/yr solids trucked at 16 per cent dry solids
mounted on a rigid steel frame. port liquid alum sludge from the re (1,650 cu yd); disposal cost: $5/cu yd.
Sludge is pumped into these plates clamation facility by tank truck to the tT =r ton of dry sludge solids.
and subjected to high pressure. After district's pollution-control plant.
TABLE 7
1-2 hr of pressure filtration through There the liquid sludge mass would
be mixed with digested sewage sludge Ranking Chart*
media mounted on the plates, a dry
cake is discharged from the bottom of and transported by barge and railcar Scroll Basket
to the Sacramento-San Joaquin Delta Cen Pressure Cen Vacuum
the unit and conveyed to a storage Parameter trifuge Filter trifuge Filter
hopper for truck overhaul. A 64-in.- area for land disposal. The scroll cen
trifuge produces a liquid sludge with Total costf 2 1 4 3
diameter filterf with 81 chambers Flexibility of
(expandable to 100) was chosen as relative ease and economy, whereas operation
(wide range
the preferred unit for Sobrante Filter the economy of the pressure filter dis of solids
Plant. Each chamber has a cake ca appears when a liquid sludge is re concentrations] 1 2 3 4
Overload
pacity of 2.4 cu ft. quired. capabilities 1 2 4 3
The third reason for rejecting the Surveillance
Pilot pressure-filter tests were con requirement 2 3 1 4
ducted with a 24-in.-diameter filter pressure filter was a combination of Machine life 4 1 3 2
the sparcity of data collected in the Abrasive sludge
with four chambers. Cake thickness handling 4 3 2 1
averaged approximately 1 in. Each field work and the late time at which Initial capital
costs 1 4 2 3
chamber had a capacity of about 0.25 the data were obtained. At the com Production of
cu ft. pletion of pilot testing with the pres uniform sludge 1 3 4 2
Table 8 lists the data obtained on sure filter, design of the reclamation Lower number indicates more desirable.
facility was already initiated based on |See Table 5.
four runs with the pressure filter. The
data listed in this table show the a scroll-centrifuge system. Potential
savings for the pressure-filter method eluding field pilot study at other
pressure filter to be a feasible method water-treatment plants in the US fac
of sludge dewatering; however, more were not high enough to justify
changing the basic design to accom ing restrictions on alum sludge dis
data must be obtained for the pres posal.
sure filter over a wide range of poly modate the pressure filter.
Fourth, the Sobrante installation Basket centrifuge. The basket cen
mer dosages and cycle times. trifuge was initially considered for pi
A diatomaceous earth precoat of will be unmanned most of the time
and as yet the long-term reliability of lot study for the following reasons:
5-8 lb/100 ft2 of filter area is need
ed to facilitate discharge of the cake the automation system for the pres 1. The literature review indicated
and to prevent binding of the filter sure filter has not been fully estab that it is a reliable type of machine
material. The nonionic polymer de- lished. It is suspected that the pres that will operate with very little sur
watered the sludge more economically sure filter requires more routine sur veillance. The reclamation facility
than lime. veillance than the scroll centrifuge. If will not be regularly manned and
If the level of performance listed in the good experience of the Chatta therefore it is essential that the
Table 8 is duplicated or exceeded by hoochee installation is repeated in mechanical thickener operate virtually
later testing, the pressure filter may other locations, the pressure filter will unattended.
replace the scroll centrifuge in future become increasingly attractive as an 2. The effect of abrasives is mini
reclamation facility designs by the alternative to centrifuging. mal in the basket unit. (The abrasive
district. The apparent economy of the pres properties of the sludge were not
There were four basic reasons why sure filter must be emphasized. For evaluated; however, there are some
the pressure filter was not selected for many plants this method of sludge abrasives in the sludge both from set
thickening is probably the most tled filter wash water and sedimenta
•Beloit-Passavant. economical. The pressure filter should tion basin underflow.) Provision was
tBeloit-Passavant Series 6400. be given serious consideration, in- made in the design for adding a cy-