CYCLIC ACTIVATED SLUDGE TECHNOLGY

Ms. Aparna Kapoor, Ion Exchange (I) Ltd

1. ABSTRACT

Cyclic activated sludge process has gained increasing importance in wastewater treatment, especially on
account of the design flexibility to handle varying daily flow and load fluctuations along with operation
simplicity. The practice of manipulating activated sludge reaction environments to obtain maximum nitrogen
and biological phosporus removal has been optimized using cyclic activated sludge technology. In its simplest
form, the sequences of fill, aeration, settle and decant are consecutively and continuously operated in a
compartment reactor. Low Nitrogen concentrations < 5 gm/lit by co-current nitriflcation denitrification
mechanism and phosphorus < 5 gm/lit by co-current nitrification denitrification mechanism and phosphorus <
5 gm/lit without any chemical addition is achievable with this technology. A detailed technical description,
salient features & advantages of the technology is described in this paper.

2. HISTORICAL BACKGROUND

The C-TECH – System specifically refers to the use of variable volume treatment in combination with a
biological SELECTOR and BIORATE control, which is operated in a fed-batch reactor mode. The Cyclic
Activated Sludge Technology is a parallel development of sequencing batch reactor technology (SBR) and
was invented in Australia. It was later developed for North American climates and extended to meet local
climate and discharge requirements of Central Europe and Asia (Goronszy, 1979, 1985; Demoulin et al. 1997;
Demoulin and Goronszy, 1999). Since then many applications have been implemented with one of the
largest applications being for approximately 4,50,000 population equivalent (210 MLD).

3. EXPLANATION OF CYCLIC OPERATION

A basic cycle comprise:

• Fill-Aeration (F/A)
• Settlement (S)
• Decanting (D)

These phases in a sequence constitute a cycle, which is then repeated. During the period of a cycle, the liquid
volume inside the tank increases from a set minimum operating bottom water level.

Aeration ends at a predetermined period of the cycle to allow the biomass to flocculate and settle under
quiescent conditions. After a specific settling period the treated supernatant is removed (decanted), using a
moving weir DECANTER. The liquid level in the vessel is so returned to the bottom water level after which the
cycle is repeated. Solids are wasted from the tanks during the decanting phase.
 Fig: The C-Tech Cycle

• Fill-Aeration (F/A)

Aeration refers to the air-on time during which influent is received into the basin. Multiple basin facilities can
be operated with different sequences of air-on during the nominal aeration sequence.

Less than design load operation typically requires the interruption of the aeration sequence. Sub-aeration
sequences are available to maximize short term mixing without causing major response to the in-basin
dissolved oxygen concentration or BIORATE.

During the fill-aeration sequence mixed liquid from the aeration zone is recycled into the SELECTOR. The
overall recycle rate (20-30% compared to the daily influent) is therefore significantly smaller than in
conventional systems.
• Settlement (S)

This sequence refers to the initial part of the air-off sequence where setting conditions are created to provide
solids-liquid separation.

The sludge mass forms a definitive sludge level interface, which progressively falls as the solids compact.
The activated sludge floc particles adhere together and the mass settles within the confines of a blanket
leaving an over layer of clear supernatant. The settled sludge layer has a mean biomass concentration of
around 10 g/l in typical domestic waste water facilities.

• Decanting

During decanting there is no inflow to the basin. The moving weir DECANTER is motor driven and travels
slowly from its out of liquid rest position to a designated bottom water level. The weir is returned to its rest
position through reversal of the drive.
 Fig: Decanter of the C-Tech Process

4. SPECIAL FEATURES

a) CO-Current Nitrification & denitrification

Cyclic process makes it possible to process the waste water with Nitrification/Dentrification (N/DN)
without recirculation of liquids and anoxic mixing. Conventionally, nutrient removal reactions in the
activated sludge process require favorable chemical, biological and biochemical environments
 brought about by oxic, anoxic and anaerobic conditioning. Several nutrient removal processes are
based on continuous flow through principles using separate basins for each reaction condition with
significant recycle flows between the separate basins. To favour the required reaction for N/DN, it is
necessary to be able adjust the following parameters: pH, dissolved oxygen, ORP, intrate substrate
and various recycle rates. Also the required process flexibility also needs to consider basin
construction, mechanical equipment and interconnecting piping & mixers. Whereas co-current N/DN
simplifies the necessary recycle and recirculation flows required by conventional systems. A
significant benefit of discontinuous process is the magnitude of the process flexibility that is derived
through the ability to simply adjust the time cycles of operation in cases of extended load deviation.
Nitrification rates are about 35% higher than the conventional system.

Co-current N/DN means operation under reaction conditions which permit nitrification and
denitrification to take place in same time in the same reaction basin without any specific anoxic
mixing sequences for nitrate reduction is achieved by providing a biological selector. Complete
nitrification and denitrification pathways take place in same basin with nitrification taking place
external to the activated sludge flocs and denitrification-taking place within the interior of the flocs.
This denitrification pathway is not bound to the absence of dissolved oxygen in the liquid phase but
requires diffusion of nitrate into the anoxic parts of the floc with a probable use of intracellular stored
or adsorbed organic carbon for denitrification. The storage of intracellular carbon is favoured by the
combination of a biological selector at high organic loading.

b) Biological SELECTOR zone

The incorporation of a biological SELECTOR within the C-TECH- Systems distinguishes it from all
other technologies. This is with this feature of the process there is no need for an ANOXIC-MIXING
sequence and is therefore replaced by a simple FILL-AERATE sequence. The SELECTOR simplifies
the operation of the process and insures biological selection of predominantly floc-forming micro-
organisms over all loadings, particularly at less than design load. The biological

SELECTOR allows process operation at time cycles that are less than other SBR systems with the
direct result of a more economical process design, smaller basins and less cost.

The biological SELECTOR operates under essentially anoxic to anaerobic reaction conditions
whereby the readily degradable soluble organic fraction of the waste water is rapidly removed by
enzymatic transfer mechanisms. These soluble organics, principally acetates, are quickly
transformed to intracellular storage products.

The biological SELECTOR combines to assist with the selection of poly P microorganisms.
Using 4 hr cycles and recirculating activated sludge to this zone exposes the biomass to appropriate
reaction conditions. This favours the selection of phosphate accumulating micro-organisms and floc
forming micro-organisms. The biological SELECTOR is very effective in containing all of the known
low F/M bulking microorganisms. The special method of operation referred to above has been
proven effective in the containment of Nocardia and Microthrix Parvicella which often are the cause of
nuisance surface foaming. Diffusers are located in this zone for periodic flash mixing if required.

The figure below shows the experience with SVI developments in parallel operations with a
wastewater that traditionally favours sludge bulking.
c) BIORATE control

BIORATE control uses dissolved oxygen (DO) measuring to provide a full-scale process
respirometer. In this way, the metabolic activity of the biomass is measured within the actual process
basin and is subsequently used as a control parameter to automatically regulate the duration of the
aeration sequence and the rate of aeration. This methodology provides a true in-basin method for the
efficient use of energy.

A minimum of 15% energy saving (maximum 80%) is realised through the BIORATE operation. The
DO concentration profile is automatically ramped to operate at lightly higher DO concentrations at the
end of the cycle. This feature prevents low dissolved oxygen type filaments from proliferating.
Cycles are set to make sure there is a sufficient degree of oxygen supply to properly meet process
requirements. Process oxygen requirements in a facility can be easily measured by this oxygen
utilisation rate (BIORATE) of the biomass. Continued operation with more oxygen input than is
necessary to meet process needs will result in minimal denitrification and a loss of biological
phosphorus removal. Turbid effluents are frequently caused by over – aeration.

d) Biological Phosphorus removal

During settlement and decant the biomass oxidation reduction potential depletes from a positive value
of around +50 to+100 mV to a negative value of around –150 to – 200 mV.

This reaction circumstance is essential for the biological phosphorus uptake mechanism to take
place. During anaerobic conditions, all phosphorus that is released to the liquid phase is totally
 contained within the biosolids layer. When operated for biological phosphorus removal there is no
diffusional release of phosphorus into the overlying liquid phase.

e) Operational Simplicity

The plant control is essentially automatic which is a major factor in reducing operating costs. The
cycling of each batch process and the regulation of each sequence interval is governed by a
Programmable Logic Control (PLC).Control for the operation of each sludge pump, each decanter
etc. is also included. The automatic basin air distribution system also regulated by the PLC. This
means that optimum operation and performance are synonymous; management of high and low load
circumstances is easily maintained providing for steady state performance.

5. COMPARISON TO CONVENTIONAL SBR SYSTEMS

By comparison with other conventional SBR (sequencing batch reactor) processes, the use of the C-
TECH – System offers significant economies in capital cost, operation and maintenance costs and land
area requirements. The advantages are:

• Simultaneous N/DN allows operating without mixing equipment. Proper oxygen demand/supply operation
control by BIORATE in combination with the SELECTOR allows controlling this process.

• BIORATE reduces aeration time during nighttime automatically. This increases the lifetime of blowers and
diffusers and reduces energy demand.

• A clear water withdrawal system for high rate decanting allows to draw off up to 2.5 m of solids free
effluent without complex valve arrangements. SBR systems are limited to about 1 m of decant depth.

• “Normal” and “High flow” operating protocols are standard features whereas SBR systems typically have
only one cycle with confusing adjustment possibilities for the operator.

• Equalisation basins for influent or effluent equalisation are not necessary.

• C-TECH provides a better BIO-P using the SELECTOR effect.

• Filamentous sludge bulking in SBR systems can only be avoided if shock filling is carried out which
requires influent equalisation and pumping.

• Good references of existing large scale plants.

6. COMPARISON TO CONVENTIONAL ACTIVATED SLUDGE SYSTEMS

Conventional activated sludge systems have the following disadvantages compared to C-TECH.

• As systems have dedicated volumes for biological treatment and sedimentation. Only very limited
flexibility is available in the case that predicated design flows or loadings deviate from the reality
(sludge bulking).

• As systems cannot operate with in basin BIORATE control which leads to increased operation cost,
reduced treatment efficiency and potential of over aeration of the activated sludge.

• As systems show extreme sensibility against peak flow and loadings. Peak flow transfers activated
sludge into the final settling tanks and finally into the effluent. Peak loadings show up in the effluent
without delays as AS systems are typically designed as completely stirred tank reactors (CSTR).
 • As systems do need relatively high amounts of recirculation flows which makes the design of effective
SELECTOR basins impossible. The high initial F/M loading can not be achieved so that AS systems
show a tendency to produce bulking sludge.

• AS systems need a high amount of Electro-mechanical equipment such as pumps, mixing devices,
scraping bridges etc. which are subject to maintenance, repair and replacement. C-TECH avoids
these disadvantages by a reliable and simple automation and control system with BIORATE control.

• As systems cannot detect toxicity of influent until effluent measurements are carried out. At the time
toxic influents are reaching the effluent the conventional AS biomass is either damaged or destroyed
already.

• C-TECH detects toxicity at the beginning of the cycle and does in this case not allow other basins to
be filled.

Reference book:
BTRA & FAITMA Seminar on Conservation of Utilities in Indian Textile Industry
November 26, 2002