Miguel López Puértolas

A comprehensive mass and energy balance model of a

mechanical-biological wastewater treatment plant
Master thesis
Praca magisterska

Studia: stacjonarne II stopnia

Kierunek studiów: Inżynieria środowiska
Specjalność: Inżynieria sanitarna

Praca wykonana pod kierunkiem

dr hab. inż. Jerzego Mikosza

Recenzent:
dr inż. Małgorzata Kryłów

Ocena pracy:

Kraków, 2018
A comprehensive mass and
energy balance model of a
mechanical-biological
wastewater treatment plant.

Politechnika Krakowska im. Tadeusza Kościuszki

2017/2018

Author: Miguel López Puertolas

Tutor: Dr hab. inż. Jerzy Mikosz
INDEX

• LIST OF SYMBOLS: ..................................................................................................................................................... 1

INTRODUCTION AND OBJECTIVE ............................................................................................................................... 3

ASsumptions ............................................................................................................................................................. 4

THEORETICAL FUNDAMENT ...................................................................................................................................... 5

DOMESTIC RESIDUAL WASTEWATERS .................................................................................................................... 5
GENERAL CHARACTERIZATION OF THE COMPONENTS OF WASTEWATER ............................................................... 7
DISCHARGE PARAMETERS ...................................................................................................................................... 8
OPERATION OF A MEDIUM/LARGE WASTEWATER PLANT ...................................................................................... 8

UNIT PROCESSES SELECTION ................................................................................................................................... 13

DESCRIPTION OF UNIT PROCCESES .......................................................................................................................... 17
PRELIMINARY TREATMENT .................................................................................................................................. 17
PRIMARY TREATMENT ......................................................................................................................................... 18
SECONDARY TREATMENT ..................................................................................................................................... 18
SLUDGE TREATMENT ............................................................................................................................................ 20
OTHERS PROCESSES.............................................................................................................................................. 22

INPUT DATA ............................................................................................................................................................ 23

PRELIMINARY TREATMENT ..................................................................................................................................... 25
PRIMARY TREATMENT ............................................................................................................................................ 27
SECONDARY TREATMENT ........................................................................................................................................ 28
SLUDGE TREATMENT ............................................................................................................................................... 30
OTHERS PROCESSES ................................................................................................................................................ 35

INPUT DATA ............................................................................................................................................................ 37

OUTPUT DATA ........................................................................................................................................................ 38
VERIFICATION ......................................................................................................................................................... 39

• REFERENCES: ........................................................................................................................................................... 44
• LIST OF SYMBOLS:
- [TSSi] Concentration of Total Suspended solids at the current “i” (g/m³).
- [VSSi] Concentration of Volatile Suspended solids at the current “i” (g/m³).
- [CODi] Concentration of Chemical Oxygen Demand at the current “i” (g/m³).
- [TPi] Concentration of Total Suspended solids at the current “I” (g/m³).
- Qi Volumetric flow of the current ”i” (m³/s).
- PPUMP Hydraulic power of the pump (kW).
- H Total high produced by the pump (mca).
- Γ Specific weight (N/m³).
- PBLOWER Blower power, (kW).
- T Air temperature (ºC).
- qair Air flow rate (m³/d)
- pout Air pressure at discharge (kPa).
- pin Air pressure at the inlet (kPa).
- ƞb Blower eficency (-).
- ηTSS Coefficient of total suspended solids removal (%).
- ηCOD Coefficient of chemical oxygen demand removal (%).
- Xs i Coefficient of sludge generation in the settler (1% ≡ 10000 g/m³) (%).
- XTSS Proportion of Volatile Suspended Solids in chemical oxygen demand (g VSS/g COD).
- XCOD Proportion of chemical oxygen demand in Volatile Suspended Solids of biomass (g COD/g VSS
of biomass).
- XTN Proportion of Total Nitrogen in Volatile Suspended Solids (g TN/g VSS).
- XTP Proportion of Total Phosphorus in Volatile Suspended Solids (g TN/g VSS).
- XVSS Proportion of Volatile Suspended Solids in Total Suspended solids (%).
- VR Volume of the biological reactor (m³).
- [TN14] Concentration of Total Nitrogen at the output of the secondary settler (g/m³).
- A Conversion factor of chemical oxygen demand to carbon dioxide (-)
- [TSS11] Concentration of Total Suspended Solids at the effluent (g/m³).
- [PO4] Concentration of Phosphate at the effluent (g/m³).
- XNH3 Portion of the influent nitrogen to be oxidized (-).
- ZO2 Theorical net oxygen demand (kg O2/day).
- PX,BIO Excess sludge production (kg VSS/day).
- [NH3] Concentration of ammonia in influent to be oxidized in the reactor (g/m3).
- ZO2 pract Practical net oxygen demand (kg O2/day).

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- Air Practical net air demand (kg air/h).
- Xg 18 Efficiency of gravity thickener (%).
- Xm 16 Efficiency of mechanical thickener (%).
- Xb 24 Efficiency of mechanical dewatering (%).
- X TSS 22 Proportion of total suspended solids in sludge output on anaerobic digestor (%).
- X COD 22 Proportion of chemical oxygen demand in sludge output on anaerobic digestor (%).
- X BIOGAS 2 Proportion of generation of biogas per kilogram of volatile suspended solid (m³ biogas/kg VSS)

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 INTRODUCTION

INTRODUCTION AND OBJECTIVE

The treatment and purification of wastewater are two of the first measures to implement to
achieve the health of the population. In Europe, the purification of urban wastewater is a mandatory
practice since the publication of Directive 91/271/EEC, as amended by Directive 98/15/EC, whose
compliance has involved the construction and start-up of a multitude of facilities.

Regarding the management of wastewater treatment plants, it is known that the processes that take
place are inherently dynamic because of the large variations in the influent wastewater flow and
composition. The wastewater treatment plant comprises a sequence of individual unit operations,
which are interconnected through a network of flows: the outputs from upstream unit operations
become inputs to downstream unit operations; further, there are different recirculations. This
interconnection of individual unit processes means that design and operation optimisation of one unit
process can have unexpected and sometimes unforeseen consequences on the performance (and
economics) of both upstream and downstream unit processes, and hence on the WWTP performance
as a whole. For these reasons, mathematical models and computer simulations are essential to
describe, predict and control the interactions of the processes.

Modelling is considered to be an inherent part of the design and operation of a wastewater treatment
system. The models used in practice range from conceptual models and physical design models
(laboratory-scale or pilot-scale reactors) to empirical or mechanistic mathematical models. The use of
models and computer simulations, as ADM1 (Batstone et al., 2002), allows to optimize the wastewater
treatment process and ultimately improve efficiency of wastewater treatment plants, also from an
energy point of view, in order to maintain the required effluent quality.

The objective of this project is the development of a computer tool, prior to the use of the models and
computer simulation, which serves as verification of the mass balance data of a water treatment plant,
which has taken into account the main processes present in an urban water treatment plant.

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In addition, in each of the processes have been included the main and necessary equipment to their
correct working in order to estimate the energy and balance of the plant object of the use of the
present tool.

The tool has been developed in MS Excel where have been implemented the different equations,
formulas, constraints and assumptions in order to obtain the response. Moreover, have been used
different utilities and functions as macros in order to make possible the different equations, and the
different relation between the unit process that interacting themselves.

ASSUMPTIONS
With the purpose of developing the tool, create all loops and to avoid numerical problems
related to the solver, several assumptions have been taken into account.

Specifically, the following:

- the model is static, i.e. time is not considered a variable in the model;
- mass balances are based on mass flows of organic matter (COD), total suspended solids (TSS)
and total phosphorus (TP);
- nitrogen flows are included in the model for information purposes only as the model does
not trace the continuity of nitrogen mass flow;
- mass transformations during individual processes are calculated with set values of
stoichiometric coefficients.

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 STATE OF THE ART

THEORETICAL FUNDAMENT

DOMESTIC RESIDUAL WASTEWATERS

There are three kinds of wastewater: domestic, industrial, and storm water. Domestic
wastewater, is also called sanitary, brings used water from houses. Industrial wastewater is used water
from manufacturing or chemical processes. Storm water, is runoff from precipitation that is collected
in a system of collectors or open channels.

Sanitary wastewater is lightly more than 99.9 percent water by weight. The leftover is composed a
wide variety of dissolved and suspended impurities. Despite of we are talking just about the amount
of the 0.01 percent of the wastewater by weight, the nature of these impurities and the huge volumes
(the absolute minimum quantity of wastewater produced per person without any excess water is 4
litres per day) of wastewater in which they are brought make removal of this wastewater a significant
technical problem. The object tool of this work has been designed for domestic residual wastewater.
Storm waters and industrial wastewater are out of the scope of this work.

PRINCIPAL POLLUTANTS
- Organic material
The quantity of this pollutant in wastewater is indicated by the biochemical oxygen demand (BOD) or
chemical oxygen demand (COD).; BOD is the quantity of oxygen required by microorganisms to
decompose the organic substances in wastewater. It is among the most important parameters for the
design and operation of wastewater treatment plants. In our case for the design of the tool the
parameter used in relation of the organic material has been the COD, chemical oxygen demand, this
parameter measures the quantity of carbonaceous matter contained in the different kinds of organic
matter present in wastewater. It is based on the fact that all organic compounds can be oxidized to
carbon dioxide and water, in acid, with strongly oxidizing agents. It indirectly represents a measure of
the concentration of biodegradable organic matter contained in the effluent.

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 - Suspended solids:
Other protagonist in the wastewater is suspended solids, also known as total solids. The amount
of sludge produced in a treatment plant is closely related to the total suspended solids present in the
wastewater.

The total solids are the residual residues after the evacuation of the matter. They are classified as
follows depending on the particle size:

- Non-colloidal suspended solids:

The particles have a size greater than one micron in diameter. can be removed through the application
of single physical treatments.

- Colloidal solids:
The particles have a diameter of 1 to 1x10-3 microns. With the application of coagulant substances that
neutralize the charges or electrokinetic potentials of their colloidal micelles, they can agglutinate their
incipient nuclei, which when flocculated can grow to the limit of being removed in turn by the action
of gravity.

- Dissolved solids:
Formed by homogenous, molecular or ionic dispersion of diameters between 1x10-3 and 2x10-4
microns. Volatile dissolved solids can be removed or transformed by the biological action of the
microorganisms that use them as soluble substrates.

- Nutrients:
Sanitary wastewater contains several compounds of nitrogen and phosphorus, two elements that
are essential nutrients for the growth of plants. In surface water bodies, lakes and rivers, excessive
amounts of this substances, nitrates and phosphates, can trigger the rapid growth of algae in a
process called eutrophication. Nitrogen compounds are present in wastewater in the form of
dissolved and particulate organic compounds, ammonia and, in minimum amount, nitrate and
nitrite. Phosphorus compounds are present in the form of organic compounds and dissolved
orthophosphates.

According to Food and Agriculture Organization of the United Nations (UNFAO) the typical values of
the different parameters of the domestic wastewater are what are showed in the below table.

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 TABLE 1 MAJOR CONSTITUENTS OF TYPICAL DOMESTIC WASTEWATER

Source: Food and agriculture organization of the united nations

GENERAL CHARACTERIZA TION OF THE COMPONEN TS OF WASTEWATER

Below is showed an illustrative diagram of the characterization of organic components in
wastewater:

Volatile fatty acids

Rapidly degraded
(soluble) Complex

COD
biodegradable
Colloidal
Slowly degraded
(particulate) In suspension
Total COD

Non- biodegrable
(soluble)
COD non-
biodegradable

Non- biodegrable
(particulate)

Source: Biology of wastewater treatment (2ond edition) (2011)

FIG. 1 STRUCTURE OF ORGANIC POLLUTANTS IN WASTEWATER

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 DISCHARGE PARAMETERS
The purpose of treating water is to condition it and reduce the concentrations of the
pollutants already discussed, in order not to contaminate the receiving medium and in order to be
within the current legislation. The Urban Wastewater Treatment Directive (91/271/ECC) sets
discharge limits for WWTP. Values for total phosphorus and nitrogen only apply to discharges from
agglomeration larger than 10000 population equivalents (PE) discharging to surface waters in the
areas classed as sensitive to eutrophication. Below is a table with the minimum concentration values
that the effluent has to meet for each of the main pollutants regarding to the Urban Wastewater
Treatment Directive (91/271/ECC):

TABLE 2 DISCHARGE LIMITS FOR WASTEWATER TREATMENT PLANTS

Source: food and agriculture organization of the united nations

OPERATION OF A MEDIUM/LARGE WASTEWATER PLANT

WASTEWATER LINE
In the below figure, it is showed the typical processes present in a municipal wastewater
treatment plant for each one of the stages, preliminary, primary, secondary and tertiary, with the
different inputs and outputs of wastewater and sludges produced.

Source: https://www.watercorporation.com.au/

FIG. 2 DIAGRAM OF WATER LINE IN A TYPICAL MEDIUM/LARGE WASTEWATER PLANT

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 PRELIMINARY TREATMENT
Wastewater treatment begins in the collection station and preliminary screening and grit
removal, intended to remove the larger floating and suspended materials that could interfere and
injure on the treatment process and different machines. Afterwards the water is carried out to the
pumping station, where the water collected takes high to get potential energy in order to be able
to pass through rest of the processes without necessity of supply more energy for this purpose.

PRIMARY TREATMENT
Afterwards starts the primary treatment which consist of a primary settler, sedimentation
removes approximately 60-70 per cent of the suspended solids and because some of these solids
are biodegradable the BOD is typically reduced by 20-35 per cent. Some plants include before the
primary sedimentation a flocculation-coagulation step in order to increase the efficiency of the
sedimentation process

SECONDARY TREATMENT
Then, secondary treatment usually consists on a biological reactor with activated sludge and
a secondary settler. Inside of the biological reactor microorganisms in suspension (activated sludge)
are used to remove biodegradable organic material. In the activated sludge process the majority of
biological solids removed in the secondary settler are returned in order to keep the biological
processes. Secondary treatment processes can remove up to 95 per cent of the BOD and suspended
solids entering the process. Advanced biological treatment utilizes multistage activated sludge
biological reactors that can efficiently remove not only organic compounds but also nitrogen and
phosphorus. Municipal wastewater treatment usually finishes with secondary treatment which
cannot completely eliminate different persistent micropollutants.

TERTIARY TREATMENT
For water reuse tertiary treatment is needed to provide additional removal of contaminants
such as microbial pathogens, particulates, or micropollutants. Depending on the nature of the
contaminant that want to be removed is applied one or other treatments such us UV rays, ozonation

9
and membrane filtration. The level of treatment will depend on the water quality needed for the
proposed use.

SLUDGE LINE
In the below figure, it is showed the typical processes presents in a wastewater treatment
plant for the sludge line with the different inputs and outputs of wastewater and sludges, biogas
and supernatants produced.

Source: https://www.watercorporation.com.au/

FIG. 3 DIAGRAM OF SLUDGE LINE IN A TYPICAL MEDIUM/LARGE WASTEWATER PLANT

In the sludge line the first process in the treatment is the thickening, this treatment is used to get a
sludge with less volume on this way it makes easier deal with it. Primary and secondary sludge are
thickened separately.

Primary sludge is usually thickened in a tank called a gravity thickener. The gravity tank can minimize
the total volume of sludge in a 60-70%. Another option to this process is called tank of flotation in
which air bubbles take the solids to the top of the tank, where is collected for the next treatment.
Secondary (biological) sludge is thickened mechanically with belt presses, decanting centrifuges or
decanting thickeners with volume reduction up to 80%. In order to increase efficiency of the process
different chemicals (polyelectrolytes) are added to the sludge.

After the thickening the mixed primary and secondary sludge is driven to the digestion tank, where the
biodegradable solids are decomposed typically in an anaerobic way generating biogas which can be
used, for example, to get energy for heating the same digestor. With the digestion, the total mass of
sludge is reduced, the sludge is stabilised and bacteria as pathogens are destroyed. However, as a result
of water production in the process the concentration of dry solids in sludge is decreasing and in effect
the digested sludge is more fluid.

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Once the sludge is digested, the sludge has to be dewatered in order to get the minimum value of
humidity on it being in this way easier its gestion. For these kinds of processes there exists several
technics solutions, the most common and efficient is the use of centrifuges, belt presses or chamber
presses. At this stage also chemicals are added to the sludge to improve the process.

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12
 DESIGN OF THE TOOL

UNIT PROCESSES SELEC TION

In this section it is going to be described how has been developed the model, I am going to explain
the script that has been followed. Then it is going to be described for each one of the different stages
of the wastewater treatment plant, preliminary treatment, primary, secondary, and sludge treatment
the different processes that have been selected, and it is going to be listed the different machines and
equips included in each process to get the energy consumption.

The structure that we have followed has consisted in a first unit processes selection, typical for a
medium andlarge wastewater treatment plant. When the different processes have been selected I
started the creation of a useful tool to get the mass balance for the whole plant and each one of the
processes. Once has been verified that the model is working well according to the input and output the
next step was the energy balance.

It has been developed the energy balance, for which have been included the different machines and
equipment that take into account in each one of the processes and consume energy. This step has been
carried out using the data sheet with the facilities features of one wastewater treatment plant of
Valencia, Spain.

After the selection of the different equipment for each one of the stages of the wastewater treatment,
it has been included the power of the equipment and their hours of working to be able to get the total
value of the energy in the plant.

Before starting with the description of the unit processes, I am going to put some screenshots of the
model in order to make understand the lector how it works. Below (figure 4), is showed a figure with
the main sheet of the model, “starting data”.

In “starting data”, is where the future user put all the input data to be verified. This page of the model
contains indicators for mass balance for each one of the currents in each one of the processes and also
indicators of the energy consumption for each one the processes, that means that the future user can
just use this first part of the model to get the results.

The others sheet contained on it is where all equations related to the mass and energy balance are. So
if the user would expect modify the equation of biogas produced on the anaerobic digestor, he or she

13
would have to go to the “Anaerobic digestor” sheet since in “starting data” there just are indicators
and cells to input the data.
As the model is quite big, I have decided to divided into four parts A-D and explain them separately.

FIG. 4 SCREEN-SHOT OF THE WHOLE SHEET “STARTING DATA”

3 5

2 4

1
6

FIG. 5 SCREEN-SHOT OF THE PART A OF SHEET “STARTING DATA”

Marks 1-6 in Fig. 5 representing part A of the model have the following meaning:
1. Input data. Influent wastewater quality parameters: flow, TSS, COD, TP, and TN.

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 2. Input data for the dynamic height of the pump station.
3. Button to enable the supernatants. After putting the input data, the user has to pinch on this
button to make the model converge and be able the recirculation of the supernatants.
4. Indicators of the effluent parameters.
5. Legend of the model.
6. Indicators in the stream “6”.

5
4

FIG. 6 SCREEN SHOTE OF THE PART B OF SHEET “STARTING DATA”

Marks 1-5 in Fig. 6 representing part B of the model have the following meaning:
1. Energy consumption indicator for “Pumping station of collected outputs”.
2. Summary table for the energy consumptions.
3. Different sheets for each one of the processes.
4. Supernatants line.
5. Sludge line.

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 2

1 3

FIG. 7 SCREEN SHOT OF THE PART C OF SHEET “STARTING DATA”

Marks 1-4 in Fig. 7 representing part C of the model have the following meaning:
1. Input data for biological and secondary reactor.
2. Verification of the mass balance according to the input and output.
3. Wastewater effluent
4. Secondary sludge line.

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 2

FIG. 8 SCREEN SHOT OF THE PART D OF SHEET “STARTING DATA”

Marks 1-2 in Fig. 8 representing part D of the model have the following meaning:
1. Biogas line.
2. Processed sludge line.

DESCRIPTION OF UNIT PROCCESES

PRELIMINARY TREATMEN T
For the preliminary treatment have been included the following processes:
- Sieves units and sand-oil-grit interceptor:
The purpose of these equips is to remove the possible big solids carried by wastewater in order to
protecting the rest of the machines, as pumps etc, downstream and to ensure the correct operation
of the wastewater plant. The grit chamber collects sand, grit and grease.

It is important to state that in these processes in terms of mass balance, according to the flow and
quality parameters there are no changes. For the model has been established that the input is equal

17
 to the output, then there is no set values of design etc. The processes have been included regarding
to the energy balance since there is an important consumption in overall in the grit chamber due to
the blower system.

PRIMARY TREATMENT
In primary treatment we have just consider the primary sedimentation.

- Primary settler:
As we have comment above, in the Introduction chapter, the objective and purpose of the primary
settler is to eliminate majority of suspended solids from wastewater.

In this process has been set the typical design parameters of the settler. They are the concentration of
the primary sludge obtained in the process (XS), as well as the values of removal for each one of the
parameters, the total suspended solids (ηTSS), COD (ηCOD) and total phosphorus (ηP). In Fig. 9 is showed
a screenshot of the tool with the set values for the primary settler.

FIG. 9 SCREEN SHOT OF THE PRIMERY SETTLER WITH THE SET VALUES

SECONDARY TREATMENT
In the case of the secondary treatment, the processes implemented in the model have been the
multistage biological reactor with activated sludge and the secondary settler. They have been treated
as a one singular process since from the point of view of the mass and energy balance it is the same. It
is important to state that as we have done this assumption we have had to assume as well the value of
the concentration of the total nitrogen at the output of the plant.

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- Activated sludge reactor and secondary settler.
The most important process in a WWTP, in this process most of the biological material is removed by
a complex set of biological process occurring under different conditions: anaerobic, anoxic and aerobic
This results in biological removal of organic material (COD), nitrogen and phosphorus. Under aerobic
conditions the microorganisms metabolize organic material by oxidation in order to get energy and
ammonia to nitrate. Under anoxic conditions nitrate are reduced to nitrogen gas in a heterotrophic
process. Anaerobic conditions are necessary to stimulate the process of excess biological phosphorus
removal.

FIG. 10 SCREEN SHOT OF THE BIOLOGICAL REACTOR AND SECONDARY SETTLER WITH THE SET AND ASSUME VALUES

As we can observe in Fig. 10, the assumed values include:

- Concentration of total nitrogen in the return sludge stream ([TN14]) and wastewater output of
the secondary settler ([TN11]).
- Total suspended solids in the wastewater output of the secondary settler ([TSS14]).
- Concentration of the phosphate in the wastewater output of the secondary settler ([PO4_11]).
- The proportion of influent nitrogen to be oxidized (XNH3).

The set values in the model include:

- Mass proportion of volatile suspended solids per COD (XTSS).
- Mass proportion of COD per volatile suspended solids (XCOD)
- Mass proportion of total nitrogen per volatile suspended solids (XTN).
- Mass proportion of phosphorus per volatile suspended solids (XTP).
- Mass proportion of volatile suspended solids in total suspended solids (X VSS).
- Volume of the biological reactor (needed to get the power of the aeration supply system) (VR)
- Conversion factor from COD to carbon dioxide (A).
- Proportion of mass flow of sludge according to the inlet stream (X).

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 SLUDGE TREATMENT
With the sludge treatment we differentiate primary sludge, secondary sludge, and mixed sludge
from the primary settler, the secondary one and the anaerobic digester respectively.

PRIMARY SLUDGE
As we have mentioned before, the first process of the sludge treatment is the thickening. In the case
of primary sludge, the device selected and implemented is a gravity thickener.

- Gravity thickener.
This kind of equips work much like decanting tanks: solids decant via gravity and compact on the
bottom, while supernatant flows up over weirs. They also provide some solids equalization and storage,
which may be beneficial to downstream operations. Gravity thickeners work best on primary sludge.

FIG. 11 SCREEN SHOT OF THE GRAVITY THICKENER WITH THE SET AND ASSUME VALUES

In this case the set value is the concentration of the total suspended solids in the sludge line ([TSS18])
at the output and as assumed value is the efficiency of separation of each parameter in the gravity
thickener (Xg 18). That’s because it depends exclusively on the equip.

SECONDARY SLUDGE
As with primary sludge, the first step in treating secondary sludge is thickening, too. A difference
of the primary sludge that usually means approximately 50% of the total sludge from the treatment
plant, the secondary sludge is more dependent on the physical load and the age of activated sludge. It
must be processed with mechanical methods in order to avoid the release of phosphorus accumulated
in microbial cells. In this case we have implemented in the model a generic mechanical thickener as
the centrifugal decanters.

- Mechanical thickener.
In the case of centrifugal decanters, this kind of equips reach separate part of the water contained in
the sludge by centrifugal force.

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 FIG. 12 SCREEN SHOT OF THE MECHANICAL THICKENER WITH THE SET AND ASSUME VALUES

In this case is the same as the gravity thickener, the set value is the concentration of the total
suspended solids in the sludge line at the output ([TSS16]) and as assumed value is the efficiency of
separation of the thickener of each parameter, (Xm 16). That’s because it depends exclusively of the
equip. Once both sludges have been thickened, they are mixed, and passed to the anaerobic
digestion stage for sludge stabilization and energy recovery.

MIXED SLUDGE
Anaerobic digestion is a biological process in which organic matter, in the absence of oxygen,
and by the action of a group of specific bacteria, is broken down into gaseous products or "biogas"
(CH4, CO2, H2, H2S, etc.)., and in digestate, which is a mixture of mineral products (N, P, K, Ca, etc.)
and compounds of difficult degradation. Biogas contains a high percentage of methane, CH4
(between 50-70%), so it is susceptible to energy use by combustion in engines, turbines or boilers,
either alone or mixed with other fuel.

- Anaerobic digester
The anaerobic digester has been included in the model as part of the treatment of the sludge
in order to calculate the value of the energy recovered from the calorific value of the gas.

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 FIG. 13 SCREEN SHOT OF THE DIGESTOR WITH THE SET AND ASSUME VALUES

For this process there are just set values, they are the proportion of total suspended solids in the
output of the sludge (XTSS 22), the proportion of COD at the output of the sludge (XCOD 22), and the
parameter which relates the volume of biogas generated per kilogram of volatile suspended solids
(XBIOGAS 21).

After the digestion and prior to the incineration and the final disposal of the sludge, the digested
sludge has to be dewatering again to reduce its volume as much as it is possible, so in the model has
been included one more stage of thickening, the mechanical dewatering.

- Mechanical dewatering.
As in the secondary sludge, the typical equips used in this stage are centrifugal decanters. Below is
showed a screenshot with the set and assume values to implement the balance and energy balance in
the model.

FIG. 14 SCREEN-SHOT OF THE MECHANICAL DEWATERING WITH THE SET AND ASSUME VALUES

The set value is the concentration of the total suspended solids in the sludge line at the output
([TSS24]) and as assumed value is the efficiency of separation of the centrifugal decanter (Xb 24).

OTHERS PROCESSES
Besides the processes showed above, there are several ones not related with the main
wastewater treatment but with operation of the plant. We are talking about the collection station,
pumping station. They are not important from the point of view of the treatment of the wastewater,
but rather from the point of view of plant’s energy balance.

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 CALCULATIONS
In this chapter is going to be showed and described how the model responds to a random
data, it is going to be showed each one of the different processes for both balances, mass and
energy.

INPUT DATA
In this section is going to be showed the input data and the processes of “collecting station –
pumping station”, processes where water is recollected to be treated and where get the energy to
be able to cross the rest of the plant without the necessity of supply more energy.

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- Collecting station – pumping station; below in Fig. 15 is showed a screenshot with the input
data and a table where is done the mass balance for the process, as well as the table and calculations
needed to get the energy balance.

Mass flow analysis

Inputs (from previous process) Inputs (from previous process) Inputs (from previous process) Outputs (to the next processes)
Wastewater 1 Wastewater 3 Wastewater 25 Wastewater 4
PUMPING STATION
Concentration, Load, Concentration, Load, Concentration, Load, Concentration, Load,
g/m3 kg/d g/m3 kg/d g/m3 kg/d g/m3 kg/d
Flow, m3/d 20000,00 200,00 371,60 20571,60
TSS 300,00 6000,00 1000,00 200,00 1771,69 658,37 333,39 6858,37
COD 600,00 12000,00 2000,00 400,00 14325,91 5323,56 861,55 17723,56
TP 10,00 200,00 100,00 20,00 9,85 3,66 10,87 223,66
TN 50,00 1000,00 15,00 3,00 0,00 0,00 48,76 1003,00

Energy balance

PPUMP = γ · Q · H
γ= 9810,00 kg /(m² · s²)
H= 10,00 m
PPUMP = 23,36 kW

Unit
Operating time,
PUMPING STATION Flow consumption,
hour/day
Input, kWh Output, kWh
kW
Motorized damper 1,50 10,00 15,00 0,00
Pumps - wastewater 4 20571,60 23,36 10,00 233,57 0,00
Rotating sieve - wastewater 4 15000,00 6,40 10,00 64,00 0,00
31,26 312,57
FIG. 15 SCREEN-SHOT OF THE SHEET “COLLECTING STATION – PUMPING STATION” FOR THE INPUT DATA

*Note: the input water line “25” to the pumping station has to do with the supernatants.

For the calculation of the mass balance, the same methodology is applied in all the processes, the
continuity equation. This equation establishes that the mass of fluid through two sections of a conduit

24
or tube of stream establishes that the mass that comes in is equal to the mass that comes out. In this
case, it can be seen in the calculation of the "Wastewater 4" output, that the sum of each of the entries,
"Wastewater 1", "Wastewater 3", and "Wastewater 25", results in the "Wastewater 4" exit, and so,
for each of the wastewater quality parameters. Previously, the mass flow corresponding to each of the
wastewater quality parameters has been calculated for each of the effluent inlets, this has been carried
out from the flow rate and the concentration of the parameter in question.

PRELIMINARY TREATMENT
- Sieves units; in the below Fig. 16 is showed a screenshot with the data of the power
consumed by the different screens in the sieves units and the energy consumption regarding the
operation time.

Energy balance

Unit consumption, Operating time,

SIEVES UNITS Flow kW/ud hour/day
Input, kWh Output, kWh
Coarse screen - Wastewater 4 - 1,10 10,00 11,00 0,00
Fine screen - Wastewater 4 - 0,55 10,00 5,50 0,00
1,65 16,50
FIG. 16 SCREEN-SHOT OF THE SHEET “SIEVES UNITS” FOR PRELIMINARY TREATMENT

25
- Grit chamber; as well as the sieves units, in the below figure is showed a screenshot with the
calculation of the power consumed by the blower system in the grit chamber, etc. and the energy
consumption regarding the operation time.

Energy balance -

PBLOWER = (1,4161 · 10-5 · ( T +273,15) · qair · [(pout/pin)0,283-1])/ƞb

T= 20,00 ºC
qair = 5,00 m³/min
7200,00 m³/day
pout = 80,00 kPa
pin = 108,00 kPa
ƞb = 1,00 -
PBLOWER = 7,49 kW

SAND-OIL-GRITS Unit consumption, Operating time,

Flow kWh// kWh/m³ hour/day
Input, kWh Output, kWh
INTERCEPTOR
Grit suction pump and
- 2,00 10,00 20,00 0,00
scraper - Wastewater 5
Blower system -
- 7,49 24,00 179,65 0,00
Wastewater 5
199,65
FIG. 17 SCREEN-SHOT OF THE SHEET “SAND-OIL-GRITS INTERCEPTOR” FOR PRELIMINARY TREATMENT

* Note: as we have commented before, in the sieves units as well as in the sand-oil-grits interceptor
there is no variation in relation to the mass balance.

26
 PRIMARY TREATMENT
Primary settler; in the below Fig. 18 is showed a screenshot with the input data for the removal
efficiencies, the table with the mass balance and the table of the energy balance with the power
consumed by the different pumps and scraper and the energy consumption regarding the operation
time.

Mass flow analysis

Inputs (from previous process) Outputs (to the next processes)

Wastewater 6 Wastewater 7 Primary sludge 8
PRIMARY SETTLER
Concentration, Load, Concentration, Load, Concentration, Load,
g/m3 kg/d g/m3 kg/d g/m3 kg/d
Flow, m3/d 20571,60 20482,45 89,16
TSS 333,39 6858,37 117,19 2400,43 50000,00 4457,94
COD 861,55 17723,56 648,98 13292,67 49696,64 4430,89
TP 10,87 223,66 10,37 212,48 125,43 11,18

Energy balance

Unit consumption, Operating time,

PRIMARY SETTLER Flow kW// kWh/m³ hour/day
Input, kWh Output, kWh
Scraper motor - Sludge 8 - 2,00 24,00 48,00 0,00
Pump - Sludge 8 - 10,00 10,00 100,00 0,00
12,00 148,00
fig. 18 SCREEN-shot of the sheet “primary settler” for primary treatment

In relation to the mass balance, the input corresponds to the output of the process "Pumping
Station", "Wastewater 4". The calculation is carried out applying the continuity equation, as well as
the set values and assumes values. From the set value, [TSS8], and the mass flow of TSS (resulting
from applying the removal coefficient to the input), the volumetric flow value of Primary Sludge 8
is obtained. Once the volumetric flow of the stream is known, from it and the removal coefficients
of each of the parameters has been calculated to the value of the mass flow and concentration of
COD and TP. The volumetric flow "Wastewater 7" has been calculated as the difference between
the input and the output, that is the difference between "Wastewater 6" and "Primary Sludge 8"

27
volumetric flow. For the rest parameters of the stream "Wastewater 7" has been followed the same
methodology.

SECONDARY TREATMENT
- Biological reactor and secondary settler; below in Fig. 19 is showed the set parameters and
calculations regarding the quality parameters of the wastewater for the mass balance, the table of
the mass balance, the calculations according to the power of the blower system in terms of necessity
of oxygen and the energy consumed by it.

Calculations
COD11 = TSS11 · XCOD + 40
COD11= 49,77 g/m3
VSS11 = Xvss (%) · TSS11
VSS11 = 4,62 g/m3
TP11 = XTP · VSS11 + PO4_11
TP11 = 0,64 g/m3
TSS14 = (Q7 · TSS7 ·(1-0,7)+ Q7 ·(1-A) · COD7 /1,48 - TSS11 · Q11)/Q14
TSS14 = 12673,96 g/m3
COD14 = TSS14 · 1,48 · XVSS(%)
COD14 = 13130,23 g/m3

Mass flow analysis

Inputs (from previous process) Outputs (to the next processes) Outputs (to the next processes)
Wastewater 7 Secondary sludge 14 Wastewater 11
BIOLOGICAL REACTOR
Load, Concentration, Load, Concentration, Load,
Concentration, g/m3
kg/d g/m3 kg/d g/m3 kg/d
Flow, m3/d 13119,55 278,13 12841,41
TSS 211,66 2776,88 12673,96 3525,07 6,60 84,75
COD 626,48 8219,20 13130,23 3651,97 49,77 639,09
TP 10,61 139,20 471,01 131,00 0,64 8,20
TN - - 100,00 27,81 17,00 218,30

28
Energy balance
a/ Net oxygen demand (simplified Eckenfelder equation):

ZO2 = Q · (CODi – CODe)/1000 – 1,42 · PX,BIO + 4,33 · Q · NH3/1000 - 2,86 · ( NH3-10) · Q/1000
Q= 20482,45 m³/d
CODi = 648,98 g/m³
CODe = 57,76 g/m³

PX,BIO = TSS14 · XVSS (%)

TSS14 = 4968,79 kg/d
XVSS (%) = 70,00 %
PX,BIO = 3478,16 kg/d
NH3 = TN4 · XNH3
TN4 = 48,76 g/m³
XNH3 = 0,80 -
NH3 = 39,01 g/m³
4,33 gO 2/g NH3-N - stoichiometric coefficient of oxygen consumption for NH 3 oxidation during nitrification (constant)
2,86 g O 2/ g NO3-N - stoichiometric coefficient of oxygen recovery from NO3 during denitrification (constant)
ZO2 = 8930,839862 kg O2/d

b/ Practical net oxygen demand (incl. altitude, temp., O2 solubility, etc.):

Z O2 pract = 2 · Z O2
Z O2 pract = 17861,68 kg O2/d

c/ Air demand in m³/h:

Air = Zo2O2 pract / (0,35 · 0,27 kg O2/m³)

(0,35 – coefficient of air utilization efficiency ( constant))
(0,270 – mass content of O2 in air (constant))
Air = 189012,48 m³/d

d/ Energy compsumition in kW:

PBLOWER = (1,4161 · 10-5 · ( T +273,15) · qair · [(pout/pin)0,283-1])/ƞb

T= 20,00 ºC
qair = 189012,48 m³/day
pout = 80,00 kPa
pin = 108,00 kPa
ƞb = 1,00 -
PBLOWER = 196,50 kW

Unit consumption, Operating time,

BIOLOGICAL REACTOR Flow kW// kWh/m³ hour/day
Input, kWh Output, kWh
Blower - O2 - 196,50 10,00 1965,00 0,00
1965,00

FIG. 19 SCREEN-SHOT OF THE SHEET “BIOLOGICAL REACTOR AND SECONDARY SETTLER” FOR SECONDARY TREATMENT

In this case, the mass balance has been carried out in several phases. First the concentrations for
the effluent have been calculated from the equations above shown in Fig. 19 in “Calculations"
section. Once calculated, and from the assume values, have been calculated the mass flow values
for each of the water quality parameters for the effluent stream. The volumetric flow has been

29
calculated as the difference between the input flow and the corresponding outflow with the sludge,
which has been calculated as a proportion of mass flow of sludge according to the inlet stream.

SLUDGE TREATMENT
- Gravity thickener; below in Fig. 20 is showed the set and assumed parameters and the mass
and energy analysis.

Mass flow analysis

Inputs (from previous process) Outputs (to the next processes)

Primary sludge 8 Wastewater 17 Primary sludge 18
GRAVITY THICKENER
Concentration, Load, Concentration, Load, Concentration, Load,
g/m3 kg/d g/m3 kg/d g/m3 kg/d
Flow, m3/d 89,16 26,11 63,05
TSS 50000,00 4457,94 1707,32 44,58 70000,00 4413,36
COD 49696,64 4430,89 1696,96 44,31 69575,30 4386,58
TP 125,43 11,18 4,28 0,11 175,60 11,07

Energy balance

Unit consumption, Operating time,

GRAVITY THICKENER Flow kWh// kWh/m³ hour/day
Input, kWh Output, kWh
Energy - scraper motor - 2,00 24,00 48,00 0,00
Energy - pumping sludge 18 - 4,00 2,00 8,00 0,00
56,00

FIG. 20 SCREEN-SHOT OF THE SHEET “GRAVITY THICKENER” FOR SLUDGE TREATMENT

To calculate the mass balance, regarding to the stream, "Primary Sludge 18", has been calculated the
mass flow of each of the water quality parameters from the set value, “Xg 18” efficiency of the process.
From these calculated values and the TSS concentration has been calculated the volumetric flow of the
stream. In relation to the current "Wastewater 17", it has been calculated as a difference between the
other two.

30
- Mechanical thickener; below in Fig. 20 is showed the set and assumed parameters and the
mass and energy analysis.

Mass flow analysis

Inputs (from previous process) Outputs (to the next processes)

Secondary sludge 14 Wastewater 15 Secondary sludge 16
SECONDARY SETTLER
Concentration, Load, Concentration, Load, Concentration, Load,
g/m3 kg/d g/m3 kg/d g/m3 kg/d
Flow, m3/d 307,24 228,56 78,67
TSS 16172,53 4968,79 1086,96 248,44 60000,00 4720,35
COD 16754,74 5147,67 22521,78 5147,67 0,00 0,00
TP 100,00 30,72 6,72 1,54 371,00 29,19

Energy balance
Operating time 8,00 hour/day
Unit consumption,
PRIMARY SETTLER Flow kWh// kWh/m³
Input, kWh Output, kWh
Thickening centrifuges -
307,24 0,95 291,87 0,00
sludge 14
0,95 291,87

FIG. 20 SCREEN-SHOT OF THE SHEET “MECHANICAL THICKENER” FOR SLUDGE TREATMENT

The mass balance has been calculated as the gravity thickener.

31
- Pumping station II; below in Fig. 21 is showed the set and assumed parameters and the mass
and energy analysis.

Energy balance -
Operating time 4,00 hour/day
Unit consumption,
PUMPING STATION II Flow kW// kWh/m³
Input, kWh Output, kWh
Mechanical mixer - sludge 19 - 8,3 33,2 0
Pumps - sludge 19 - 7,50 30 0,00
15,80 63,20

FIG. 21 SCREEN-SHOT OF THE SHEET “PUMPING STATION II” FOR SLUDGE TREATMENT

32
- Anaerobic digester; below in Fig. 22 is showed the set and assumed parameters and the mass
and energy balance. For the energy balance has been considered the heating, the pumping and the
mixing of the sludge.

Mass flow analysis

Inputs (from previous process) Outputs (to the next processes) Outputs (to the next processes)
Tertiary sludge 20 Tertiary sludge 22 Biogas 21
Anaerobic digestion
Concentration, Load, Concentration, Load, Concentration, Load,
g/m3 kg/d g/m3 kg/d g/m3 kg/d
Flow, m3/d 141,72 141,72 -
TSS 64448,75 9133,71 51559,00 7306,97 - -
COD 30952,34 4386,58 18571,40 2631,95 -
TP 284,07 40,26 284,07 40,26 - -
Biogas 21 3105,46 m³

Energy balance
Operating time 24,00 hour/day
Unit consumption,
ANAEROBIC DIGESTOR Flow kWh// kWh/m³
Input, kWh Output, kWh
Mechanical mixer - sludge
- 11,00 264,00 0,00
20*
Pumps - heating sludge 20* - 6,00 144,00 0,00
Pumps - hot water - 4,00 96,00 0,00
21,00 504,00

FIG. 22 SCREEN-SHOT OF THE SHEET “ANAEROBIC DIGESTOR” FOR SLUDGE TREATMENT

For the calculation of the mass balance, have been applied, the set values for TSS and COD, assuming
that there are no changes in the phosphorus concentration. It has been added that the incoming mass
is equal to the salient. And in terms of biogas, it has been calculated from the set value Xbiogas 22, which
relates the amount of biogas generated in cubic meters per kg of volatile suspended solids.

33
- Mechanical dewatering; below is showed the set and assumed parameters, and the mass and
energy balance.

Mass flow analysis

Inputs (from previous process) Outputs (to the next processes) Outputs (to the next processes)
Tertiary sludge 22 Wastewater 23 Tertiary sludge 24
MECHANICAL DEWATERING
Concentration, Load, Concentration, Load, Concentration, Load,
g/m3 kg/d g/m3 kg/d g/m3 kg/d
Flow, m3/d 141,72 116,93 24,79
TSS 51559,00 7306,97 3124,53 365,35 280000,00 6941,62
COD 18571,40 2631,95 1125,45 131,60 10085,52 2500,35
TP 284,07 40,26 17,22 2,01 154,27 38,25

Energy balance
Operating time 8,00 hour/day
Unit consumption,
MECHANICAL DEWATERING Flow kWh// kWh/m³
Input, kWh Output, kWh
Pumps - sludge 22 - 7,50 60,00
Thickening centrifuges -
- 22,00 176,00 0,00
sludge 22
Pumps - sludge 24 - 11,00 88,00 0,00
40,50 324,00

FIG. 23 SCREEN-SHOT OF THE SHEET “MECHANICAL DEWATERING” FOR SLUDGE TREATMENT

The mass balance has been calculated as the gravity and mechanical thickener.

34
 OTHERS PROCESSES
- Processes outputs; below in Fig. 24 is showed the set and assumed parameters, and the mass
and energy balance. In difference with others processes, and as well as the processes “Collected
station-pump station”, the power of the pumps is not fixed, its value is calculated by the typical
equation of the pumps which depends directly of the flow.

Mass flow analysis

Inputs (from previous process) Inputs (from previous process)Inputs (from previous process)Outputs (to the next processes)
PROCCESSES Wastewater 17 Wastewater 15 Wastewater 23 Wastewater 25
OUTPUTS Concentration, Load, Concentration, Load, Concentration, Load, Concentration Load,
g/m3 kg/d g/m3 kg/d g/m3 kg/d , g/m3 kg/d
Flow, m3/d 26,11 228,56 116,93 371,60
TSS 1707,32 44,58 1086,96 248,44 3124,53 365,35 1771,69 658,37
COD 1696,96 44,31 22521,78 5147,67 1125,45 131,60 14325,94 5323,58
TP 4,28 0,11 6,72 1,54 17,22 2,01 9,85 3,66

Energy balance

PPUMP = γ · Q · H
γ= 9810,00 kg /(m² · s²)
H= 2,00 m
PPUMP = 0,08 kW

Unit consumption, Operating time,

PROCCESSES OUTPUTS Flow kW hour/day
Input, kWh Output, kWh
Motorized damper 1,50 10,00 15,00 0,00
Pumps - wastewater 4 371,60 0,08 10,00 0,84 0,00
Rotating sieve - wastewater 15000,00
4 6,40 10,00 64,00 0,00
7,98 79,84

FIG. 24 SCREEN-SHOT OF THE SHEET “PROCESSES OUTPUTS” FOR SECONDARY TREATMENT

In this case, the mass balance has been calculated as in "Collecting station - pumping
station", is the process is treated as a node in which it has several inputs and a single output.

35
36
 VERIFICATION OF THE MODEL
In this chapter is going to be showed and described the verification of the model, that is the
correct work of it. For do it we are going to put some input data from an existing wastewater plant
in Poland (Zamość WWTP), and we are going to verify the mass balances according to the input and
the output for different lines, the effluent, the quality parameters of the effluent, the mass flow of
the primary and the secondary sludge, and the biogas production. Then, I am going to put some
screen-shots of the model showing an example of the input data and also with the outputs, and
then it is going to be a table with the summarize data to verify that the model is working well.

INPUT DATA
In Fig. 25 presented is table with the values of the influent wastewater characteristics for
Zamość WWTP in Poland collected during the period of Jan-Jun 2016 and a screenshot of “starting
data” with that input data.
TABLE 3 INPUT DATA FROM ZAMOŚĆ WWTP

Waters Raw+ Waters After primary settler Effluent

Flow, m³/d 650 13540 13120 12841
TSS, g/m³ 465,7 210 6,6
COD, g/m³ 1103 615 49,3
TP, g/m³ 12,9 9 0,36
TN, g/m³ 86,3 59,4 17,4

FIG. 25 SCREEN-SHOT OF THE SHEET “STARTING DATA” WITH THE INPUT DATA FOR VERIFICATION

37
 OUTPUT DATA
Below is showed several screenshots of the sheet of the model “starting data” with the output
data, for the sludge, the water, and biogas line, which we are going to compare with the output data
of Zamość WWTP in Poland collected during the period of Jan-Jun 2016.

FIG. 26 SCREEN-SHOT OF THE SHEET “STARTING DATA” FOR THE OUTPUT DATA FOR WATER LINE, SECONDARY AND PRIMARY SLUDGE,
AND BIOLOGAS LINE

38
 VERIFICATION
Below is showed table 4 with the output data of the wastewater plant and the output data of
the model in which we can appreciate that the model works in spite of a little differences in some
figures.

TABLE 4 VERIFICATION OF THE MODEL WITH A COMPARATION OF OUTPUT DATA OF THE WWTP AND THE MODEL

VERIFICATION
After primary settler Effluent
WWTP Model Difference WWTP Model Difference
Flow, m³/d 13120 13119,55 0,003% 12841 12841,41 0,003%
TSS, g/m³ 210 211,66 0,790% 6,6 6,60 0,000%
COD, g/m³ 615 626,48 1,867% 49,3 49,77 0,949%
TP, g/m³ 9 10,61 17,894% 0,36 0,64 77,389%
TN, g/m³ 59,4 - - 17,4 17,00 2,299%

WWTP Model Difference

Primary sludge to be thickened, m³/d 420 420,74 0,176%
Biological sludge to be thckened, m³/d 279,73 278,13 0,57%
Mixed sludge to digestion, m³/d 147,33 105,80 28,19%
Biogas production, m³/d 2388 2328,21 2,50%
Digested sludge to be dewatered, m³/d 155,33 105,80 31,89%

FIG. 27 COMPARATIVE GRAPH OF RESULTS OF THE MODEL VS REAL DATA FROM ZAMOŚĆ WWTP

As can be seen in Fig. 27, in relation to the flow of effluent, the suspended solids and COD,
the percentage difference is less than one percent, so we can affirm that the model works quite
well for these three parameters.

39
However, it is not the same for nutrients, nitrogen and phosphorus, since the percentage difference
is notably higher. This fact is because of several reasons, obviously the simplifications, assumptions
and starting hypothesis that we have taken, in order to be able in developing the model, are
reflected in this point. Besides, it should be noted that when dealing with smaller values, such as
phosphorus, the percentage difference is more sensitive, for that reason in spite of existing a
numerical difference smaller than the unit the value of this one is greater.

In relation to the energy balance, we do not have data on the energy consumption of the
wastewater treatment plant in question with which to verify the model. However, we can compare
it with the guideline values of energy consumption as a percentage of a conventional water
treatment plant. Below in Fig. 27 is showed in percentage the common values of energy
consumption in a WWTP on example of Ejby Molle plant.

FIG. 28 EJBY MOLLE WWTP 2011 ANNUAL AVERAGE ELECTRICAL CONSUMPTION

Source: http://www.ch2mhillblogs.com/water/author/access-water/

In the table 5 that is shown below, the energy consumptions for each process is shown based on
the equipment, power, and operating time assigned to them. It also shows the percentage
corresponding to each process of energy consumption of each process in relation to the water line
or sludge line(%r) and in relation to total consumption(%g).

40
 TABLE 5 ENERGY CONSUMPTION

ENERGY CONSUMPTION VALUE (Kwh) %r %g

Colection station - Pumping station I 232,74 11,95% 7,37%
Procceses outputs 80,54 4,14% 2,55%
WATER

Sieves units 199,65 10,25% 6,32%

Sand - oil-girts interceptor 16,50 0,85% 0,52%
Primary settler 148,00 7,60% 4,69%
Biological recator - secondary settler 1269,77 65,21% 40,20%
Total 1947,19 100,00% 61,65%
Gravity thickener 56,00 4,62% 1,77%
Mechanical thickener 264,23 21,81% 8,37%
SLUDGE

Pumping station II 63,20 5,22% 2,00%

Anaerobic digestor 504,00 41,60% 15,96%
Mechanical dewatering 324,00 26,75% 10,26%
Total 1211,43 100,00% 38,35%
TOTAL 3158,62 100,00%

FIG. 28 AVERAGE ELECTRICAL CONSUMPTION OF THE MODEL

In these values, we can appreciate the typical values of energy consumption of a wastewater
treatment plant, being the biological reactor the process that most.

41
 CONCLUSION

This work has had the goal of developing an Excel-based model for verification of mass and
energy balance for simulation of computer wastewater treatment plant. To achieve it, the first step
has been a unit processes selection for a typical medium/large wastewater treatment plant for each
one of the stages, preliminary, primary, secondary, and sludge treatment. Once selected the different
processes to take into account in the model, the tool has been developed in MS Excel.

In Excel, mass balances have been implemented for each of the processes and stages, following the
equations of continuity for both the flow rates and for the different parameters of wastewater quality,
total suspended solids, COD, and phosphorus. To this end, have been implemented the pertinent
equations and necessary calculations as well as have been assumed some parameters and others have
been set. In relation to the supernatants, it is important to highlight the need to use macros to avoid
creating circular equations that cannot be solved in Excel by normal ways. Therefore, a loop has been
created in which the input and output of these supernatants are iterated until the difference between
them is zero and the system then has converged.

The energy balance has been carried out including in each of the processes the main machines and
equipment that take place. For most of the processes, from this list, the operating times, and the unit
power, the energy consumption has been calculated. On the other hand, in relation to the aeration
system of the biological reactor, among others, have been calculated the necessary oxygen according
to the different parameters and from this data, has been calculate the energy consumption.

Once the tool has been developed, it has been verified by putting real input data from an existing
wastewater treatment plant in Zamość (Poland) and comparing the outputs with the real data
producing satisfactory results as presented below.
Difference between outputs of model and real data
Primary sludge to be thickened, m³/d 0,18%
Biological sludge to be thckened, m³/d 0,57%
Mixed sludge to digestion, m³/d 28,19%
Biogas production, m³/d 2,50%
Digested sludge to be dewatered, m³/d 31,89%

42
However, the model fulfils the expectations it still can be improved in many areas., For example, a
more detailed study could be carried out in relation to COD and phosphorus transformations than in
this work because of the complexity of the matter. Biogas production has been calculated in a very
simple way, perhaps simplifying too many aspects. On the other hand, it could be given more versatility
to the tool, enabling pre-created functions that allow you to choose the processes that take place in
the plant instead of only those created.

In conclusion it can be stated that the established objectives have been achieved, and that despite the
limitations of the tool, it is open to possible expansions and improvements. It could become a real and
potential tool for verification of data planned to be utilized during computer simulation of wastewater
treatment plants.

43
• REFERENCES:

AMBULKAR, A., and NATHANSON, J. (2018) Wastewater treatment. Houston. [Consult: 03 of June of 2018]
Available on: https://www.britannica.com/technology/wastewater-treatment#ref593222

GRU GUTIÉRREZ, A. (2010) Diseño de un modelo de planta para tratamiento de aguas residuales
domésticas con tanques fibratank. Tesis. Sartenejas: Universidad Simón Bolíbar [Consult: 04 of June of
2018]

JEPPSSON, U. (1996) Modelling aspects of wastewater treatment processes. Lund: Reprocentralen, Lund
University. [Consult: 03 of June of 2018] Available on: https://www.iea.lth.se/publications/Theses/LTH-
IEA-1010.pdf

MAPAMA, MINISTERIO DE AGRICULTURA, PESCA Y ALIMENTACIÓN; Tratamiento y depuración de aguas. Madrid.

[Consult: 03 of June of 2018] Available on: http://www.mapama.gob.es/es/ceneam/formacion-
ambiental/cursos-y-postgrados/internet/tratamiento-depuracion-aguas.aspx

GRAY, N. (2004) Biology of wastewater treatment (second edition), London: Imperial College
Press Luxembourg. [Consult: 03 of June of 2018]

VOULVOULIS, N. (2018) Water reuse from a circular economy perspective and potential risks from an
unregulated approach. London. [Consult: 04 of June of 2018] Available on: http://www.globaqua-
project.eu/files/repository/20180330153009_waterreusepaper.pdf

WENTZEL, MC., EKAMA, GA., and SÖTEMANN, SW. (2006) Mass balance-based plant-wide wastewater
treatment plant models. Rondebosch. [Consult: 03 of June of 2018]

44