Waste Water Manual 2012 PDF

WASTEWATER TREATMENT MANUAL
FOR POULTRY PROCESSING FACILITIES
Alkalinity
Feed System Skimmings Screens
(SPN)
Plant
Feather
Pressure
DAF Unit
Tank
Wet Well
Plant
Blowers
Alkalinity Offal
Feed System
MH Air Compressors
Aeration Clarifier
Tank Final
Anaerobic Flowmeter Filter
Lagoon Screw Pumps
Flowmeter
Flowmeter
Biogas
MH MH MH
Waste
Sludge SO2 Cl2
Feed Feed
Re-use
Flame Flame Boiler Pumps
Trap Trap PRV
Contact
Waste Chamber
Sediment Blower Gas
Trap Burner
Propane Cascade
Tank Re-aeration
Steps
Discharge to
Stream
POULTRY PROCESSING FACILITIES
U.S. POULTRY & EGG ASSOCIATION
ACKNOWLEDGEMENTS
The initial framework for this manual was prepared by Vaughn, Coltrane &
Associates under contract to Gold Kist, Inc., for the Gold Kist facility located in
Sanford, NC. The review team for that initial effort included Steven Woodruff,
Warren Howe, Mark Nouvel of Gold Kist – Atlanta; Bruce Morgan and Mike
Beale of Gold Kist – Sanford, and Paul Bredwell, Vaughn, Coltrane & Associates.
Gold Kist graciously consented to allow this work to be expanded to an industry-
wide operations manual.
In the Spring of 2001, USPOULTRY’s Environmental Impact Committee strongly

endorsed preparation of a generic operations manual and training program. A
draft manual was sent out in February 2002 for review and comment by the
following individuals:
Gary Wolfe, Tyson Allen Youngblade, ConAgra

Katie Kirkpatrick, Gold Kist Brenda Flick, Sanderson Farms
John Chlada, Perdue Steven Woodruff, WHEE, Inc.
Phil Willis, Wayne Farms Warren Howe, WHEE, Inc.
Comments and suggestions from these individuals were incorporated into the
manual, and sent out for a wider review in July 2002. The last set of comments
was received in January 2003. Individuals commenting on this final review were:
Art Riddick, Reid Engineering Joel Pounders, Gold Kist

Bob Mitchell, Allen Family Foods Katie Kirkpatrick, Gold Kist
Brenda Flick, Sanderson Farms Phil Willis, Wayne Farms
David Sewell, Cagles Roger Smith, American Proteins
Gary Wolfe, Tyson Foods Steven Woodruff, WHEE, Inc.
Jim Walsh, Georgia Tech Tim Dooley, OK Foods
Jim Moore, ADEM Tim Maupin, Cargill
Jim O’Gorek, Tyson Foods Tim Wier, Pilgrim’s Pride
Warren Howe, WHEE, Inc.
The comments from these reviewers were most helpful, and almost always
incorporated into this manual, with two notable exceptions. First, some
commenters encouraged inclusion of a “Safety and Health” section. Due to the
diverse nature of the plants, and the variances between company safety programs,
this was not done, although obvious safety hazards are pointed out in the manual.
Second, some commenters desired to see a basic math section in the manual. The
question then becomes “How basic should the math be?” As a compromise, this
manual includes a section on common calculations and formulas used in the
industry, and typical calculations in many of the unit operations sections.
i
Kim Miles and Elaine Hilliard typed (and retyped and retyped) the manual. Ms.
Hilliard also assisted on many of the PowerPoint drawings.
The final, and most important acknowledgement, is to the many dedicated

operators I have been privileged to work with over (almost!) the last quarter
century. To the extent there is practical knowledge and wisdom in this manual, it
is theirs.
John E. Starkey, P.E.

President
U.S. Poultry & Egg Association
Tucker, Georgia
Second Edition, Eighth Printing, April 2012

Copyright© 2003 by U.S. Poultry & Egg Association
ii
TABLE OF CONTENTS
I. Introduction to Poultry Processing Water Treatment
II. Process Overview
II.1. Wastewater Generation

II.2. Wastewater Treatment Components
II.3. Pretreatment System
II.4. Dissolved Air Flotation
II.5. Anaerobic Lagoon
II.6. Aeration Basin
II.7. Clarification
II.8. Final Filtration
II.9. Disinfection
II.10. Flow Measurement/Re-aeration
II.11. Performance
III. Overview of Regulatory Requirements
IV. Applied Microbiology
IV.1. Anaerobic Lagoon Treatment

IV.2. Activated Sludge – Carbonaceous BOD Removal
IV.3. Activated Sludge – Nitrification
IV.4. Activated Sludge – Denitrification
V. Applied Chemistry and Math
V.1. Chemical Glossary

V.2. Coagulation/Flocculation
V.3. Mathematical Formulae, Data and Conversions
VI. Dissolved Air Flotation (DAF) and Chemical Addition Systems
VI.1. Full Flow Pressurization Dissolved Air Flotation System

VI.2. Pressurized Recycle Dissolved Air Flotation System
VI.3. Chemical Feed Systems
VII. Anaerobic Lagoons and Waste Gas Burner Systems

U.S. POULTRY & EGG ASSOCIATION iii.
Table of Contents (cont’d.)
VII.1. Anaerobic Lagoon
VII.2. Waste Gas Burner System
VIII. Unit Operations – Activated Sludge
IX. Tertiary Filtration
IX.1. Sand Filtration

IX.2. Upflow Filter
IX.3. Cloth Filtration
X. Disinfection
XI. Final Flow Measurement
XII. Process Data Collection
XIII. Facility Design Data

U.S. POULTRY & EGG ASSOCIATION iv.
TABLE OF FIGURES
Figure II.1 Typical Water Use Schematic for Broilers

Figure II.2 Typical Poultry Plant – Full Treatment Facility
Figure IV.1 Stages of Anaerobic Decomposition
Figure IV.2 Activated Sludge Schematic
Figure V.1 The Nitrogen Family in Poultry Wastewater
Figure V.2 Coagulation of Colloids
Figure V.3 Floccuation of Colloids
Figure VI.1 Full Flow Pressurization DAF
Figure VI.2 Pressurized Recycle DAF
Figure VI.3 Ferric/Anionic Polymer System
Figure VI.4 Acid/Cationic/Anionic Polymer System
Figure VI.5 Three Polymer System
Figure VI.6 Jar Testing Set-Up Procedures
Figure VI.7 Jar Testing Procedure for Ferric Sulfate/Anionic Polymer
Figure VI.8 Jar Testing Procedure for Acid/Cationic/Anionic Polymer
Figure VI.9 Jar Testing Procedure for Three Polymer Systems
Figure VII.1 Anaerobic Lagoon Schematic
Figure VII.2 Typical Flare System
Figure VIII.1 Activated Sludge
Figure VIII.2 Common Activated Sludge Configurations
Figure VIII.3 Phases of an SBR System
Figure IX.1 Shallow Bed Sand Filter
Figure IX.2 Upflow Filter Cycles
Figure IX.3 Disk Filter Operation
Figure X.1 Chlorination/Dechlorination System
Figure X.2 Two-Bank UV Disinfection System
Figure XI.1 Typical V-Notch Weir
Figure XI.2 Typical Rectangular Weir
Figure XI.3 Typical Parshall Flume
Figure XI.4 Typical Palmer-Bowlus

U.S. POULTRY & EGG ASSOCIATION v.
TABLE OF CHARTS
Chart VI.1 Full Flow Pressurization DAF System

Chart VI.2 Recycle Pressurization DAF System
Chart VII.1 Anaerobic Lagoon Decision Chart
Chart VII.2 Flare System
Chart VIII.1 Activated Sludge System
Chart IX.1 Shallow Bed Granular Filter Systems
Chart IX.2 Upflow Filter Systems
Chart IX.3 Disk Filter System
Chart X.1 Chlorination/Dechlorination System
Chart X.2 UV Disinfection System

U.S. POULTRY & EGG ASSOCIATION vi.
TABLE OF TABLES
Table II.1 Typical Poultry Plant – Unit Operation Performance

Table III.1 Typical Permit Limits for Full Treatment Poultry Plants
Table III.2 Typical Permit Limits for Pretreatment Poultry Plants
Table V.1 DO Concentration as a Function of Temperature, Salinity
and Pressure
Table V.2 Approximate pH of Various Substances
Table VI.1 Comparison of Chemical Addition Systems
Table VII.1 Anaerobic Lagoon Sizing and Performance
Table VII.2 Burner System Maintenance
Table VIII.1 Typical Design Operating Values
Table VIII.2 Sludge Wasting Volumes
Table VIII.3 Activated Sludge Visual Observations
Table VIII.4 Alkalinity Control Chemicals Commonly Used in Poultry
Wastewater Treatment Facilities
Table VIII.5 Typical Activated Sludge Maintenance Schedule
Table XI.1 Discharge Rate for V-Notch Weirs
Table XI.2 Discharge Flows for Rectangular Weirs
Table XI.3 Parshall Flume Flow Rates
Table XI.4 Palmer-Bowlus Flume Flow Rates
Table XII.1 Summary of Sampling Handling Requirements
Table XII.2 XYZ Poultry Company Wastewater Process Control Data

U.S. POULTRY & EGG ASSOCIATION vii.
I. INTRODUCTION TO POULTRY PROCESSING
WATER TREATMENT
The discharge of pollutants into surface waters (“Waters of the United States”) is
carefully controlled by the Federal Clean Water Act to ensure against adverse impact
on the environment. Regulations have been developed that institute a discharge
permit program under the direction of the U.S. Environmental Protection Agency.
In most cases, EPA delegates permitting authority to a state environmental agency.
These agencies subsequently issue NPDES (Natural Pollutant Discharge Elimination
System) permits to facilities that discharge into a river, lake or stream. Further, the
stage agency, or a delegated municipality, will issue an indirect discharge permit to a
facility that discharges into a POTW (Publicly Owned Treatment Works).
Poultry processing facilities are subject to these permitting requirements. A particular

facility may hold an NPDES permit issued by the state environmental agency, or
EPA, or a pretreatment permit issued by the state or municipality for discharge to a
POTW.
The type and level of treatment provided at a given facility depends on many factors,
including whether it is a direct or indirect discharge, local water quality standards or
ordinance limits, size of the receiving stream or POTW, etc. However, the actual
"unit operations" utilized to perform various treatment functions do not vary
significantly across the industry. For example, most poultry processing wastewater
treatment facilities utilize dissolved air flotation as a unit operation. Similarly, most
direct discharge facilities utilize activated sludge.
The intent of this manual is to provide operators of poultry processing wastewater

treatment facilities with a basic understanding of the unit operations utilized in the
industry. This information is provided in the following Sections:
 Process Overview
 Overview of Regulatory Requirements
 Applied Microbiology
 Applied Chemistry
 Unit Operations - Pretreatment
 Unit Operations - Full Treatment
 Process Data Collection and Assembly
 Facility Design Data
Please note that the operator has the option of only reviewing the unit operations in
use at his facility. Please further note that this manual hopes to provide the basic
building blocks for understanding the processes and unit operations utilized in
poultry processing wastewater treatment. Specific operational procedures will vary

U.S. POULTRY & EGG ASSOCIATION I.1
from facility to facility. This manual is not intended to be comprehensive to all
process variations employed in the industry; rather, it is intended to provide the
operator with a basic framework of these operations which the operator can then
adapt to the specific needs at his facility.

U.S. POULTRY & EGG ASSOCIATION I.2
II. PROCESS OVERVIEW
Provided below is a description of the processes generating wastewater in a poultry

plant and a typical pretreatment and full treatment system.
II.1. Wastewater Generation

A typical broiler processing facility utilizes six to nine gallons of
potable water per bird each process day to produce a wholesome
sanitary dressed poultry product. Similarly, a typical turkey facility will
utilize 20 – 30 gallons per hen, and 30 – 40 gallons per tom turkey.
Figure II.1 illustrates a typical poultry processing flow diagram. Most
operations in poultry processing involve the consumption of water.
The largest consumers of water include evisceration, chilling and clean-
up. Evisceration involves the removal of the heart, liver, gizzard and
exposure of viscera for USDA inspection. Water is used throughout
the evisceration process to wash birds and transport inedible material
to the wastewater facility. Chilling is typically accomplished in large
tanks to cool bird temperature to 36o F for microbiological control.
Water is utilized in cut-up, packaging and further processing operations
primarily to clean product, conveyor belts and equipment. A clean-up
shift occurs following either one or two processing shifts. This
sanitation shift includes the disinfection of all processing equipment
using various cleaning agents and disinfectants.
Water used in processing operations is collected and routed to the

wastewater treatment facility. In the production process, this potable
water becomes contaminated with feathers and offal, blood, viscera,
fecal material, etc. These constituents represent pollutants and are
normally expressed in terms of BOD (Biochemical Oxygen Demand),
COD (Chemical Oxygen Demand), TSS (Total Suspended Solids),
TKN (Total Kjeldahl Nitrogen), Ammonia, FOG (Fats, Oils and
Greases), Phosphorus and fecal coliform.
II.2. Wastewater Treatment Components

In order to remove these pollutants from the wastewater and satisfy
the conditions of the Clean Water Act, poultry processors have
equipped their facilities with various wastewater treatment processes.
A complete typical wastewater treatment flow schematic is presented in
Figure II.2 and is briefly described below.
II.3. Pretreatment System

Wastewater typically exits the processing area via multiple lines or
flumes (typically, one line for viscera/meat, one line for feathers and a
separate line for cooking plant discharge) and enters the offal

U.S. POULTRY & EGG ASSOCIATION II.1
Figure II.1
TYPICAL WATER USE
SCHEMATIC FOR PRODUCTION RATE
X BIRDS/MIN
BROILERS 16-20 HRS/DAY
POTABLE WATER 5-6 DAYS/WK EVAPORATION
7 GALLONS/BIRD (GPB) 0.10 GPB
RECEIVING
0.05 GPB
KILLING
BLOOD TO
BLEEDING PROTEIN RECOVERY
0.25 GPB
SCALDING
0.30 GPB TO
DEFEATHERING SCREENING PROTEIN RECOVERY
0.35 GPB TO WASTE TREAMENT

WHOLE BIRD WASH DAF’S 6.55 GPB
2.00 GPB SPN TO
EVISCERATING PROTEIN RECOVERY
TO
0.80 GPB SCREENING PROTEIN RECOVERY
FINAL BIRD WASH
0.56 GPB
CHILLING
0.8 GPB
CUT-UP DE-BONE
0.30 GPB
PACK-OUT ICE PACKAGING AND NOTE: The steps employed,
PRODUCT MOISTURE ADDITION and the proportion of water used
1.56 GPB 0.20 GPB in each operation, is similar for
CLEAN-UP
turkeys
0.15 GPB
SANITARY TO WASTE TREATMENT
WASTEWATER TREATMENT MANUAL 0.15 GPD
U.S. POULTRY & EGG ASSOCIATION II. 2
Figure II.2
TYPICAL POULTRY PLANT
Full Treatment Facility
Alkalinity
Feed System Skimmings Screens
(SPN)
Plant
Feather
Pressure
DAF Unit
Tank
Wet Well
Plant
Blowers
Alkalinity Offal
Feed System
MH Air Compressors
Aeration Clarifier
Tank Final
Anaerobic Flowmeter Filter
Lagoon Screw Pumps
Flowmeter
Flowmeter
Biogas
MH MH MH
Waste
Sludge SO2 Cl2
Feed Feed
Re-use
Flame Flame Boiler Pumps
Trap Trap PRV
Contact
Waste Chamber
Sediment Blower Gas
Trap Burner
Propane Cascade
Tank Re-aeration
Steps
Discharge to
Stream
area. Once in offal, these lines discharge onto either the feather
screens or the meat screens. These screens remove most of the larger
sized solids from the waste stream. The removed solids are conveyed
to offal trucks (or directly to on-site rendering). These trucks carry the
feathers and meat to an animal feed byproducts plant where they are
recycled into feather meal, poultry meal, pet food, and poultry fat.
Facilities are also equipped with a vacuum system which vacuums
blood and, in some cases, portions of the offal material for direct
loading onto offal trucks.
Screened wastewater from both the feather side and the offal side are
often combined and then flow across a secondary screen. This screen
has a tighter opening - typically 0.020 inches to 0.040 inch - and
removes additional solids for byproduct recovery. The secondary
screened wastewater is normally directed to a flow equalization basin
(FEB) or wet well. This is provided to allow adequate hydraulic surge
protection so that the subsequent treatment unit, Dissolved Air
Flotation (DAF), can occur on a consistent basis.
II.4. Dissolved Air Flotation

Both full flow and pressurized recycled DAF systems are utilized in
poultry processing plants. In a full flow pressurization DAF system,
the entire wastewater is pumped from the FEB under a pressure of
40 psig, saturated with air and released into the DAF (Dissolved Air
Flotation) tank. When water is pressurized, its capacity to dissolve air
greatly increases; when that pressure is subsequently released, the extra
air froths back out of the wastewater in the form of tiny bubbles.
These bubbles of air attach themselves to oils and small solids in the
wastewater and float these items to the surface. Consequently, in the
DAF tank, these oils and solids are separated from the wastewater. A
skimmer mechanism on the DAF tank removes this material to a
holding bin for subsequent shipment to a rendering or land application.
In a pressurized recycle system, the entire plant flow is no longer

pressurized. Rather, a portion of the DAF effluent is pressurized by a
pump to approximately 70 psig, then introduced into a pressure tank.
Air is injected from an air compressor into the pressure tank. At this
higher pressure, water has the capacity to dissolve even greater
quantities of air than in a full flow pressurization system; i.e., the
recycle stream is supersaturated with air. Because of the greater air
dissolving capabilities, a reduced volume of water needs to be
pressurized. Typically 25-50% of plant flow is recycled in this manner.
When this pressurized recycle is introduced into the DAF tank, this
supersaturated air comes out of solution, causing the flotation effect.

The flotation effect, removal of pollutants, and the use of chemicals to
enhance performance are otherwise the same for a recycle
pressurization system as with a full flow pressurization system.
Regardless of the type of DAF a facility has, the DAF is designed to

remove much of the free oil and grease, as well as some suspended
solids, from the wastewater. Chemicals (flocculants and coagulants)
can be used in the DAF system to enhance removal of solids, fats, oils
and greases. Often, these chemicals are so effective that the DAF is
the only treatment prior to discharge to a POTW.
II.5. Anaerobic Lagoon

The anaerobic lagoon allows further reduction of pollutants in the
waste stream through bacterial and chemical reactions occurring in the
lagoon. The anaerobic lagoon promotes an environment that lacks
“free” oxygen in which pollutants are broken down in three steps. The
first step is called hydrolysis and consists of the breakdown of complex
protein and fat molecules into smaller, simpler fatty and amino acids
and monosaccharides. The second step is performed by a group of
bacteria called acidogens. They transform the end products of the first
step into simple organic acids such as acetic acid. The third step is
performed by a group of bacteria called methanogens and consists of
the conversion of these organic acids to methane gas and carbon
dioxide. Ammonia and hydrogen sulfide are produced as byproducts
of the anaerobic process.
The lagoon will reduce BOD and TSS levels. Please note the anaerobic
lagoon will have minimal impact on Total Kjeldahl Nitrogen levels,
although much of the organic nitrogen will be converted over to the
ammonia nitrogen form.
II.6. Aeration Basin

The aeration basin is intended to pick up treatment where the DAF
unit or the anaerobic lagoon left off. Unlike the oxygen-free
environment of the anaerobic lagoon, the aeration basin provides an
ecosystem with free elemental oxygen (O2) and chemically bound
oxygen (NO2, NO3). Blowers or aerators are utilized to supply oxygen
(O2) to the basin. This oxidizes BOD to carbon dioxide, water and
additional cellular mass. In addition, if the system is designed
appropriately, biomass can convert ammonia nitrogen (NH4-N) to
nitrate in a process called nitrification. Nitrate can also be removed by
turning off the blowers or aerators enabling the biomass to utilize
oxygen bound up in nitrate. The conversion of nitrate to nitrite and
finally nitrogen gas is called denitrification.

II.7. Clarification
Discharge from the aeration basin flows to the clarifier. The purpose
of the clarifier is to produce a clearwater effluent via separation from
the bacterial cells. Consequently, the clarifier is a quiescent tank where
the heavier bacterial cells settle and the clearwater effluent overflows
the weirs. Most of the bacterial cells that settle are returned back to the
aeration basin. These returned bacterial cells, referred to as Returned
Activated Sludge (or RAS), provide sufficient bacteria back to the
process to continue virtually complete BOD and TKN removal, if
desired. To keep the process in balance (i.e., to prevent an oversupply
of bacteria and prevent a build up of solids), a portion of the settled
cellular mass in the clarifier is removed from the system. This process
is called wasting and it allows the system to stay in balance without an
unhealthy build-up of bacterial solids. The cells wasted are normally
thickened and then land applied as a soil amendment.
II.8. Final Filtration

Polishing of the clarified effluent is sometimes necessary. In such
cases, clearwater effluent from the clarifier flows to a final filter. As
the clarified effluent passes through the media, solids are filtered out.
This allows a very high level of suspended solids removal and
“polishes” the clarifier effluent.
II.9. Disinfection
Clarified effluent or filtered effluent discharged from the filter enters
the UV disinfection system or the chlorination/dechlorination
chamber. In UV disinfection, the water flows through a channel
containing ultraviolet light lamps which kills or sterilizes pathogens
present. In chlorination/dechlorination systems, chlorine is injected at
the headworks of this unit to allow the disinfection of the treated
effluent. At the discharge of the unit, sulfur dioxide is injected to
remove residual chlorine prior to release to the river receiving stream.
II.10. Flow Measurement/Re-aeration

A flume or weir following disinfection records effluent flow. In
addition, effluent flow is often aerated by cascading down over a series
of steps, or with an aeration device in a small pond or tank, in order to
increase Dissolved Oxygen levels. The fully treated, re-aerated effluent
is then released to the receiving stream.
II.11. Performance
Performance of those various unit operations can vary significantly
from plant to plant. Given that each facility has its own permit limits,
it is not surprising that the level of treatment required from each unit

operation varies. For example, at one facility, a DAF may be used
without chemicals prior to an anaerobic lagoon and activated sludge
system merely to remove free oil and grease. At another facility, the
exact same model DAF may be used with chemicals to reduce
pollutant loading to a level acceptable for discharge to POTW.
Nonetheless, Table II.1 provides typical performance data for the
various operations described above.

Table II.1
TYPICAL POULTRY PLANT
Unit Operation Performance
Activated
Screened DAF DAF with Anaerobic Sludge Filter
Parameter
Wastewater Effluent Chemicals Effluent Effluent Effluent
(mg/l) (mg/l) (mg/l) (mg/l) (mg/l) (mg/l)
BOD 3000 1800 350 200 20 10
TSS 2000 900 250 200 30 10
TKN 150 130 100 100 8 4
NH3 50 40 30 90 <5 1.0
FOG 500 200 30 20 7 3

III. OVERVIEW OF REGULATORY REQUIREMENTS
The discharge of pollutant to waters of the United States is governed by the Federal
Water Pollution Control Act, commonly called the Clean Water Act, and its
subsequent amendments. Under the Act, the Environmental Protection Agency is
the designated federal authority for determining appropriate discharge limits,
instituting permitting processes, designating preferred treatment methods, etc.
EPA often develops Effluent Limit Guidelines – or ELG’s – to assist permit writers
in determining the appropriate limits for a particular type of facility. Although ELG’s
were proposed for the poultry industry in the early 1970’s, they were not adopted at
that time except for poultry rendering plants. Consequently, regulatory limits for
poultry processing plants were based on Best Professional Judgement (BPJ), or on
specific water quality (WQ) models, with limits based on the more restrictive of these
two approaches. However, in 2004, EPA did issue new effluent limit guidelines for
poultry plants, that will be fully phased in by 2009.
Most states have been delegated the authority by EPA to issue discharge permits.
These states have demonstrated to EPA they have the ability to achieve, through
their state environmental agency, the requirements of the Clean Water Act. (If a state
has not received this delegation, EPA will directly issue permits to a discharger.)
States, in turn, often delegate the authority for issuing indirect discharge permits to
municipalities, who then set permit limits for industries discharging into a Publicly
Owned Treatment Works (POTW).
Discharge of pollutants from poultry processing facilities is carefully controlled by the

permitting authority – be it EPA, the state environmental agency, or the local POTW.
Further, USDA inspected facilities are required to demonstrate to USDA the
adequacy of sewerage facilities.
A poultry processing facility will normally hold one (or more) of the following types
of discharge permits:
- Direct Discharge
- Indirect Discharge
- No Discharge
Each of these is reviewed in greater detail below:
Direct Discharger:
A direct discharger is a poultry processing facility that fully treats its effluent
prior to release to surface water, such as a creek or river. These dischargers are
required to hold a National Pollutant Discharge Elimination System (NPDES)

U.S. POULTRY & EGG ASSOCIATION III. 1
permit, that specifies the terms and conditions under which the discharge is
allowed. The NPDES permit is most commonly issued by the state
environmental agency, but some poultry facilities in non-delegated states must
obtain the permit direct from EPA.
A direct discharge permit will contain the more restrictive of the 2004 ELG, BPJ
or WQ limits. Typically, the permitting authority will run a computer water
quality model to determine the assimilative capacity of the receiving stream
consistent with the use of the stream. Such models then develop specific
effluent values, with an appropriate safety margin, for the plant. Normally,
pollutants covered in these models include BOD, TSS, TKN, NH3, DO and
phosphorus. The permit writer will then compare the WQ limits to the ELG’s,
and select the more restrictive of the two as the permit limit. The only variation
to this process would be if a discharger showed a facility had “fundamentally
different factors” than were considered by EPA in the development of the
ELG’s. Where there is no specific WQ or ELG standard, the permit writer may
employ BPJ to include additional permit limits.
Presented in Table III.1 below are typical ranges for effluent limits for direct
discharge poultry processing plants. Note the WQ limits are stream specific and
therefore will vary, and further that BPJ limits for BOD, TSS and ammonia are
being replaced in permits with the 2004 ELG limits.
TABLE III.1
TYPICAL PERMIT LIMITS FOR FULL TREATMENT
POULTRY PLANTS
WQ Limits WQ Limits for 2004 ELG

BPJ Permit, for Nitrogen & Limits Poultry
No WQ Nitrogen Phosphorus Processing
Limits (mg/l) (mg/l) (mg/l) (mg/L)
BOD 25 - 45 20 - 30 10 - 20 16
TSS 25 - 45 20 - 30 10 - 25 20
TKN 10 - 20 4-8 2-5
Ammonia 3 - 10 1-4 0.5 - 2 4
Nitrate N/A N/A <50
Total Nitrogen N/A N/A <60 103
Phosphorus N/A N/A 0.5 - 1.5
Oil and Grease <10 <10 <5
ph (S.U.) 6.0 - 9.0 6.0 - 9.0 6.0 - 9.0
Fecal Coliform
(MPN) <1000 <200 <200

In addition to the actual permit limits, an NPDES permit contains numerous
other requirements, in particular regarding samples, recordkeeping and facility
operation and maintenance. Violation of any of these requirements is just as
much a violation of the permit as exceeding permit limits. Therefore, it is
critically important that a facility know and understand all terms and conditions
of its permit, not merely the discharge limitation, and to establish procedures to
ensure collection and maintenance of required information.
Further, holders of NPDES permits are subject to “citizens suits” for

enforcement of permit conditions. Activist groups frequently sue NPDES permit
holders who have had non-compliance, particularly in instances where the activist
groups believe federal or state enforcement action has been lax.
Indirect dischargers:
An indirect discharger is a poultry processing facility that partially treats its

effluent prior to discharge to a POTW. Most larger indirect dischargers are
required to apply for, and obtain a discharge permit, normally issued by the local
municipality or authority, or, in some cases, by the state environmental authority
(or, in rare cases, by EPA itself). Smaller facilities sometimes do not need to
obtain a specific discharge permit; they are regulated instead by the requirements
of the local sewer-use ordinance.
Limits for discharge to a POTW are locally set, normally by the municipality’s
engineer, in accordance with the design capacity of the POTW. EPA and the
states provide guidance to the POTW on the desirable components of the
POTW’s pretreatment programs. In many instances, poultry facilities have
directly contracted with POTW to provide certain levels of treatment capacity,
and financed that capacity through the monthly sewer bill, a one-time payment to
the POTW, or both.
The poultry processing facility is not normally directly involved with the POTW’s
NPDES permitting process, and is therefore one step removed from the
limitations contained in the POTW permit. However, since these limits ultimately
impact the poultry processor, it is imperative to maintain close contact with the
POTW regarding permit issues, compliance status, etc.
There is no such thing as “typical” pretreatment permits or conditions. They vary

widely across the nation. However, average limitation for indirect discharge
poultry processing limits are as shown in Table III.2.

TABLE III.2
TYPICAL PERMIT LIMITS FOR
PRETREATMENT POULTRY PLANTS
Average Limits
(mg/l)
BOD 200 – 500
TSS 200 – 500
Oil and Grease 100 - 150
TKN No limit – 100
Ammonia No limit – 50
Phosphorus No limit – 10
pH (S.U.) 5.5 – 9.5
As with NPDES permits, pretreatment permits normally contain other conditions

regarding sampling, reporting and facility operation and maintenance. Further, in
some localities, pretreatment permits contain “citizen suit” provisions.
No Discharge:
A “no discharge” facility is one that operates a land application system, where all
applied effluent either percolates into the ground or is lost to the atmosphere via
evapotranspiration.
There is often less federal involvement in a no-discharge permit. In fact, some

states issue non-discharge, land application system permits completely outside the
NPDES process. Other states issue an NPDES permit specifying no discharge.
Permit limitations on no-discharge systems are developed on a case-by-case, site-
by-site basis. Generally, these limits are set to balance the nutrients present in the
effluent with the agronomic demand for nutrients from the crops being produced
or, in some cases, to ensure the ground has the assimilative capacity for the water
applied. In the vast majority of poultry wastewater land application systems, the
cover crop is forage.
Limits are also often set to avoid nuisance conditions (e.g., a BOD limitation for
applied wastewater to avoid septicity on the irrigation field) or to ensure the long
term usability of the site, in addition to the aforementioned nutrient and/or
hydraulic limits.
Further, virtually all of the systems perform groundwater monitoring. This

monitoring demonstrates that the land application system is not adversely
impacting groundwater, usually through analysis for nitrate, bacterial counts,
conductivity and pH.

IV. APPLIED MICROBIOLOGY
The purpose of this section is to provide background information on the

microbiology of biological treatment processes utilized in the poultry industry.
IV.1. Anaerobic Lagoon Treatment

Anaerobic treatment is the degradation, in the absence of free oxygen,
of complex organic compounds – such as proteins, fats, blood,
carbohydrates, etc. present in poultry wastewater – into methane gas,
carbon dioxide and simpler organic compounds (fatty acids, etc.)
amenable to subsequent treatment. To prevent the presence of
oxygen, anaerobic treatment occurs in a sealed or covered vessel. Both
synthetic covers, and natural covers from grease accumulation, are used
in the industry. Methane and carbon dioxide gases are the primary
gases produced in the process. Other gases produced include
hydrogen sulfide and ammonia. All gases are vented and often burned
through a flare system.
Three distinct biological processes occur in the anaerobic lagoon

simultaneously (see Figure IV.1). First, the more complex pollutants
present - such as blood, protein, suspended tissue and meat matter, etc.
- is broken down into simpler organic compounds. This process is
called hydrolysis and is merely the cleaving of relatively large, complex
pollutants into their relatively small, simple component parts – such as
amino acids, simple sugars and fatty acids.
The second group of bacteria present in an anaerobic system consists

of the “acidogens” or “acid formers.” These bacteria degrade the
hydrolysis step products into simple organic acids, such as acetic acid
and hydrogen. The acidogenic bacteria may or may not be strictly
anaerobic.
The third group of bacteria present, and the group that ultimately
controls the rate at which anaerobic digestion occurs, is the
“methanogens” or methane producers. These bacteria take the simple
organic acids (and similar simple organic pollutants) and hydrogen
produced by the acidogens and convert them to methane gas and
carbon dioxide. Methane is highly insoluble in water and leaves the
solution. Often, a gas collection system picks up the methane and
incinerates it. For uncovered anaerobic lagoons, methane escapes to
the atmosphere. Through this process, pollutant load is removed from
the wastewater.

U.S. POULTRY & EGG ASSOCIATION IV.1
Figure IV.1
STAGES OF ANAEROBIC
DECOMPOSITION
INFLUENT WASTEWATER
HYDROLYSIS
Fats, Greases Proteins Polysaccharides
Fatty Acids Amino Acids Monosaccharides
ACIDOGENESIS
Fatty Acids Amino Acids Monosaccharides
H2,CO2, Formate, Methanol, Methyl Amines, Acetates
METHANOGENISIS
H2,CO2, Formate, Methanol, Methyl Amines, Acetates
Methane and Carbon Dioxide

The acidogens and methanogens have a syntrophic relationship; i.e.,
their individual survival depends on the success of the other bacterial
group. Acidogenic bacteria become inhibited by elevated hydrogen
levels; the methanogenic bacteria remove the hydrogen from the waste
stream to produce methane. The methanogens, on the other hand, rely
on the acidogens to produce the relatively simple organic compounds
on which they can subsist and subsequently convert to methane.
Because of this syntrophic (mutually beneficial) relationship, it is

imperative to keep anaerobic systems in balance. The system must be
kept free of oxygen as all methanogenic bacteria, and many acidogens,
are strict anaerobes. Methanogenic bacteria are also inhibited by low
pH and prefer a pH in the 6.8 s.u. to 7.6 s.u. range. Sufficient alkalinity
needs to be present to insure pH stays in this range. This is particularly
true since the methanogens are the slowest growers. If methanogens
are inhibited and organic acids begin to accumulate and further depress
system pH, then the entire anaerobic degradation process is inhibited.
The presence of some metals can also be inhibitory, as can the absence
of required micronutrients.
The benefits of an anaerobic treatment system include low biomass

yield, no need for oxygen and pathogen control. The low yield leads to
fewer bacterial solids being produced and, ultimately, fewer solids that
need to be “wasted” or removed from the system. The need for no
oxygen contributes to this low yield and is of obvious benefit from an
energy standpoint as pollutants can be removed with significantly lower
energy usage. Anaerobic systems are effective pathogen destroyers
since most pathogens require oxygen.
The disadvantages of an anaerobic system include low biomass yield,

relatively sensitive environment requirements and the need for
additional treatment to complete BOD and TKN removal. The low
yield means that the system is sensitive to shock loads and requires a
larger volume of reactor to achieve the same removal as an aerobic
system. Furthermore, the close relationship between the methanogenic
and acidogenic bacteria requires careful monitoring and adjustment as
it is an inherently unstable relationship. Additionally, sufficient
pollutant matter remains present to require subsequent BOD removal.
And finally, there is minimal nitrogen usage by the bacterial population.
Consequently, subsequent treatment to achieve nitrogen removal is
required. Note that much of the organic nitrogen is converted to
ammonia nitrogen.

IV.2. Activated Sludge – Carbonaceous BOD Removal
Activated sludge systems were invented in the early years of the 20th
century in response to a growing demand for improved waste
treatment. Activated sludge was a natural extension of earlier aerated
lagoon systems. Eventually, it became desirable to install a settling
chamber after the aerated lagoon to improve solids removal. In 1914,
E. Arden and W.T. Lockett published a paper describing the return of
active biomass from this settling chamber and the positive effect upon
process performance. Thus, activated sludge systems were born.
A simple activated sludge system is depicted in the Figure IV.2. Note

wastewater enters the aeration basin and is mixed with the activated
biomass returning from the clarifier. Sufficient oxygen is introduced
into the aeration basin to satisfy the oxygen demand of the incoming
wastewater and support the biomass in an aerobic environment.
Typically, oxygen is supplied via blower/diffuser combinations or
mechanical surface aerators. The biomass in the aeration basin
consumes the pollutants in the waste stream and converts those
pollutants to additional cellular mass. Chemically, this reaction can be
described as follows:
CONH + O2 +  CO2 + NH3 + C5 H7 NO2

(pollutants) bacteria (new bacterial cells)
where CONH = biodegradable matter in the waste stream

O2 = oxygen supplied to the reactor
Bacteria = activated sludge
CO2 = carbon dioxide, what bacteria produce
from the consumption of organic matter
NH3 = ammonia (addressed later)
C5H7NO2 = chemical representation of new biomass
growth
Once the pollutant matter has been stabilized, it is directed to the

clarifier (see Figure IV.2). In this vessel, sufficient retention time is
provided to allow the heavier than water bacterial cells to settle. This
results in the discharge from the clarifier of a clearwater effluent from
which most soluble organic matter has been removed.
In order to sustain the process, most of the settled bacteria in the

clarifier are returned to the aeration basin (hence, “sludge return line”
and “sludge return pumps”). There, the returned sludge continues the
process of consuming influent organic pollutants.

Figure IV.2
ACTIVATED SLUDGE
BULK
SCHEMATIC ALKALINITY
STORAGE
INFLUENT
WASTEWATER
ALKALINITY
MAKEDOWN
SYSTEM
AERATION BASIN
BLOWERS
AIR HEADER DIFFUSERS
CENTERWELL SKIMMER
EFFLUENT TO
DISINFECTION
RETURN ACTIVATED SLUDGE (RAS)

CLARIFIER
WAS TO SLUDGE
PROCESSING
RAS SLUDGE
RAS WET RAKE
PUMPS BLANKET
WELL ARM

IV.2.A. Yield
Note in the equation above, one of the end products of organic matter
destruction is new bacterial cells. As the biomass consumes organic
matter (i.e., as they eat), they grow. This growth is necessary to sustain
the process as bacterial cells are always dying or lost from the system
via clarifier discharge, etc. The rate at which bacteria grow is often
expressed as the yield as follows:
Yield = lbs biomass produced

lbs pollutants (BOD) consumed
A typical number for yield for carbonaceous BOD removal is 0.3 to

0.7, though most poultry operations tend to be on the lower end of
that range. This growth is necessary but must be kept in balance. Left
unchecked, bacterial population would increase to the point a number
of undesirable alternatives could occur. Three examples of this are:
1. Bacterial population could increase to the point where the

additional oxygen demand to simply support the additional bacteria
exceeds the oxygen supplied by aeration system, resulting in
septicity, massive solids loss and system failure.
2. Unchecked biomass build-up could result in insufficient food

(pollutant loss) to support all the bacteria, resulting in biomass die-
off, massive solids loss from the clarifier and system failure.
3. Excessive biomass build-up can produce a poor settling biomass.
In order to prevent these and many other undesirable consequences of

unchecked biomass accumulation, a portion of the settled bacteria
from the clarifier is removed from the system. This process is called
“wasting;” biomass so removed is said to be “wasted”. There are two
common methods of determining how much biomass should be
wasted - sludge age and food to mass ratio.
IV.2.B. Sludge Age

The first method of biomass control is the mean cell residence time
(MCRT) or sludge age. Sludge age is defined as:
Sludge age = Total amount of biomass system

Total amount of biomass removed daily
from system
In other words, sludge age, or MCRT, is the length of time an average

bacterial cell remains in the system.
This equation can be further defined as follows:
Sludge age = Total amount of biomass in system

(Biomass wasted per day)+(Biomass lost in clarifier
effluent per day)
Mathematically, this can be translated to:
Sludge age = VAB  MLSS

FW  RAS + (F)(ESS)
Where sludge age = MCRT, average biomass age in days

VAB = Volume, Aeration Basin, in MG
MLSS 1 = The total suspended solids level in the
aeration basin (mg/l), a measurement of the
biomass quantity
FW = Flow of biomass to be wasted daily (MG)
RAS = The total suspended solids of the clarifier return
sludge
F = Total Plant Flow, MGD
ESS = Effluent Suspended Solids
Aeration basin volume is a fixed, known number. MLSS, RAS and

ESS can be determined analytically and total plant flow is recorded. To
solve this equation to determine how much should be wasted per day,
one picks a desired sludge age (typically 25-60 days). The equation
then can be rearranged as follows:
FW = VAB  MLSS - F(ESS)

Sludge age  RAS RAS
With this equation, some plants simply plug in the site-specific data
and analytical results to provide the appropriate waste flow rate to
maintain a constant sludge age.
However, many plants further simplify the equation by recognizing the

amount of biosolids lost in the final effluent is comparatively minor –
and constant – compared to the amount of solids intentionally wasted.
Therefore, in routine operations this unintentional loss has little impact
1
Some plants use MLVSS instead of MLSS. MLSS is a simpler test, and as long as the MLVSS/MLSS
ratio stays relatively constant, perfectly adequate. Consistently use either MLSS or MLVSS; do not
interchange.
on the calculation. By simply assuming this loss is negligible, the
equation can be reduced to:
Sludge age = Total amount of biomass in system

Biomass wasted per day
Mathematically, this becomes:

FW  RAS
Rearranging this equation to provide a waste rate yields:
FW = VAB  MLSS
Sludge age  RAS
Using a sludge age of 30 days yields
FW = VAB  MLSS
30  RAS
So, one of the advantages of using this method of sludge wasting

calculation is that only two inputs are required (MLSS and RAS) in
order to calculate a wasting rate. Both of these analyses can easily and
rapidly be determined on-site analytically. Further, it allows
development of wasting tables, as provided in Section VIII.1.
normalized per million gallons of aeration basin volume.
IV.2.C. Food to Mass Ratio

An alternative, empirical method of determining the amount of sludge
to be wasted is by using the Food to Mass or F/M ratio. The F/M
ratio is determined as follows:
F/M = Pollutant load, lb/day

Total biomass in system
This can be mathematically defined as:
F/M = BOD  F
MLSS  VAB

Where F/M = Food to Mass ratio
BOD = influent BOD to Aeration Basin, mg/l
F = influent flow to Aeration Basin, MGD
Other terms = as previously defined
Typical values for F/M for most poultry processing activated sludge
systems are 0.03 to 0.10. Using an F/M of 0.04 as a typical value
reduces the equation to:
MLSS = 0.040 (BOD  F)

V
Since both BOD and Flow can be determined analytically, the desired
MLSS can be determined. This value can then be compared to the
actual MLSS. If actual MLSS is below the desired MLSS, either
minimal or no wasting is required. A chart provided in Section VIII.1.
describes the amount of wasting required when the actual MLSS
exceeds the desired MLSS, per million gallons of Aeration Basin
Volume.
IV.3. Activated Sludge – Nitrification

Typically, in activated sludge systems where relatively long sludge ages
(or relatively low F/M ratios) are provided, a bacterial population can
develop capable of converting ammonia nitrogen to nitrate nitrogen.
Much of the emphasis in the poultry wastewater treatment field in the
1980s and 1990s shifted to removing ammonia, since it can be toxic to
fish and other aquatic organisms. This biological conversion of
ammonia to nitrate is called nitrification and is carried out by bacteria
described as nitrifiers. This conversion can be expressed as:
nitrifiers
NH4+ + 2O2  NO3- + 2H+ + H2O
Where NH4+ = the ionized form of ammonia in wastewater

O2 = oxygen
nitrifiers = the bacterial genera, nitrosomonas and
nitrobacter
NO3 = nitrate, the end product of nitrification
H+ = free hydrogen, acid
Three items of interest in this equation are:
1. It takes two O2 molecules to convert one molecule of ammonia to

nitrate. This translates to 4.6 pounds of oxygen required per pound
of ammonia converted. Consequently, in many systems, the
nitrogenous oxygen demand may be as great, or greater, than the
carbonaceous oxygen demand, even though the ammonia level is
only a fraction of the BOD level.
2. The conversion of ammonia to nitrate produces acid. Left
unchecked, this acid will depress pH. Nitrifiers become inhibited at
low pH. Consequently, it is fundamental that sufficient alkalinity be
provided to the system to prevent pH suppression. Aeration basin
pH should be above 7.0 s.u. and residual alkalinity (at clarifier
effluent) should be above 100 mg/l at all times.
3. The nitrogen is not removed from the wastewater, but converted
from an ammonia form to a nitrate form.
IV.4. Activated Sludge – Denitrification
The process of nitrification, as described in the previous section, does
not remove nitrogen from the waste stream – it converts it from an
aquatic toxic, ammonia, to nitrate. The USEPA has established a
public water supply limit of 10 mg/l liter for nitrate. There has been
increased emphasis on removing nitrate from treatment plant effluents
in recent years. Excessive nitrate can contribute to eutrophication
(algae blooms), and nitrite, a precursor of nitrate, can be toxic to
aquatic life, either alone or in combination with other chemicals.
Recent efforts have been directed to adapting or designing activated
sludge plants to remove nitrate from treatment plant effluents.
There are a group of bacteria, which, under the proper environmental
conditions in the aeration basin, are able to utilize the oxygen
contained in nitrate in their respiration process. Many of these bacteria
actually favor the use of oxygen from nitrate rather than oxygen
supplied by aeration equipment. With the oxygen cleaved from the
nitrate molecule, these bacteria are able to consume influent organic
pollutants. They produce carbon dioxide, nitrogen gas and additional
cellular material as a result of this process called denitrification.
Denitrification results in the liberation from the wastewater of nitrogen
as nitrogen gas and can be described as follows:
denitrifiers
NO3 + BOD + H+  N2 (gas) + CO2 + C5H7O2N
where NO3 = nitrate
BOD = organic pollutants
H = acid
N2 = nitrogen gas

CO2 = carbon dioxide
C5H7O2N = additional cellular material
As with the nitrification equation, reviewing the denitrification

equation yields some interesting facts described below:
1. Denitrifiers use the oxygen contained in nitrate to consume BOD.

In Sections IV.2. and IV.3., removal of BOD and conversion of
ammonia to nitrate consumed oxygen supplied by mechanical
aeration systems. Denitrification can significantly reduce the
demand for mechanical aeration, leading to a more energy efficient
plant.
2. Denitrification consumes acid which somewhat counteracts the

affects of nitrification. Therefore, less external alkalinity addition is
necessary, resulting in a lower operational cost.
3. The nitrogen gas that is produced simply escapes to the

atmosphere, thereby completely removed from the process water
stream and, ultimately, from the discharge.
A final point to make is that oxygen levels in the mixed liquor must be
carefully controlled to insure denitrification. Many of the bacteria
responsible for denitrification only work under low DO conditions or
under anoxic conditions. Most systems designed to achieve
denitrification, therefore, either provide an anoxic zone, or an anoxic
time period, to allow denitrification.

V. APPLIED CHEMISTRY AND MATH
The purpose of this section is to briefly introduce and describe the common chemical
parameters utilized to understand the operation and effectiveness of a poultry
wastewater treatment system. Further, this section introduces the coagulation/
flocculation process. Finally, routine mathematical calculations are reviewed.
V.1. Chemical Glossary
V.1.A. Acid
An acid is a substance that will reduce the pH of water. Examples
include well known acids such as sulfuric acid and muriatic acid, but
also include substances which are weak acids such as carbon dioxide or
ferric sulfate.
V.1.B. Alkalinity
Alkalinity is a measurement of the ability to buffer pH changes in water
from the addition of acid. The higher the alkalinity of the water, the
more acid required to reduce the pH of that water.
V.1.C. Anion
An anion is a negatively charged molecule. Examples include sulfate
and chloride (SO4 = , Cl- ) as well as a whole range of anionic polymers
used routinely in wastewater treatment facilities.
V.1.D. Base
A base is a substance that will increase the pH of water. Examples
include well known bases such as caustic soda and lime, but also
include weaker bases such as trisodium phosphate.
V.1.E. BOD (Biochemical Oxygen Demand)

A measurement of the amount of oxygen consumed in a specified time
period by microbial organisms while stabilizing and consuming
pollutants present in water. The specified time period most commonly
utilized is annotated as BOD5, or the five-day BOD.
Poultry wastewater contains significant amounts of blood, grease,

protein and other constituents which can be utilized as a food source
by bacteria or other microbes. Many bacteria require oxygen in order
to consume these pollutants. So BOD is simply an empirical (i.e.,
determined by experience rather than theory) measurement that tells
how much oxygen is utilized by bacteria in consuming the blood,
grease, protein, etc. The higher the BOD, the more oxygen that must
be supplied.
U.S. POULTRY & EGG ASSOCIATION V.1
BOD is measured by saturating water containing the pollutant and
measuring the oxygen level initially, then placing the sealed bottle in an
incubator for five days at room temperature (20°C), and then
remeasuring the oxygen level. The depletion of oxygen, weighted for
the amount of pollutant placed in the bottle, is the BOD5.
BOD, or total BOD, can be subdivided a couple of different ways.

Soluble BOD is that fraction of the total BOD which is actually
dissolved in the wastewater. Particulate BOD is that fraction of the
BOD that is associated with solids present in the wastewater. An
example of soluble BOD would be sugar dissolved in water. Clearly,
there would be no suspended solids in the solution, yet bacteria would
still require oxygen to consume the sugar. Particulate BOD would be
represented by the small bits of meat remaining in the wastewater
following screening.
Soluble BOD is determined by filtering a BOD sample and conducting

a standard BOD test on the filtrate (filtered sample). Particulate BOD
is normally determined by subtraction, i.e.:
Particulate BOD = BOD – soluble BOD.
Total BOD can also be separated as carbonaceous BOD and

nitrogenous BOD (also called NOD for nitrogenous oxygen demand).
Carbonaceous BOD represents the amount of oxygen required to
consume the carbon-based portion of those pollutants. Nitrogenous
Oxygen Demand represents the portion of the oxygen utilized in
consuming the nitrogen-based portion of these pollutants, i.e., the
oxygen consumed in nitrification.
V.1.F. Cation
A positively charged molecule, or ion. Common examples are the
ferric ion molecule (Fe+++) or calcium ion (Ca++). There is also a wide
array of synthetic cationic polymers utilized in the poultry industry.
V.1.G. COD (Chemical Oxygen Demand)

A measurement of the amount of oxygen necessary to oxidize organic
matter utilizing a strong chemical oxidant. Like BOD, COD is a
measurement that does not determine a specific chemical component,
yet provides a quantification of the strength of a wastewater.
COD and BOD can be empirically related over a number of samples at

a particular facility. This is particularly useful since COD can be

analyzed in just a few hours, rather than a five-day period like BOD5.
As a rule of thumb, in poultry processing facilities BOD will average
two-thirds of COD for COD levels above 150 mg/l. However, on a
fully treated effluent (COD < 100 mg/l); BOD will average 20% -- or
less – of COD.
Individual plants wanting to use COD as a process control parameter,

and utilize this data to project BOD performance, should routinely run
split samples to determine the facility’s appropriate ratio.
V.1.H. Coagulant
A coagulant is a chemical that causes very small solids (microscopic) in
a wastewater to form larger clumps (or floc) of solids. This process is
called coagulation and plays an important role in both dissolved air
flotation and clarification. Most coagulants used in poultry wastewater
are also cations. Metal salts such as Ferric (Fe+++) sulfate or ferric
chloride are examples of coagulants used in poultry wastewater
treatment, as well as numerous synthetic polymers.
V.1.I. Dissolved Oxygen (DO)

DO is a measurement of the level of molecular oxygen (O2) in water.
Oxygen is essential to many bacteria utilized in poultry wastewater
biological treatment systems. These bacteria absorb oxygen through
their outer membranes and utilize it to consume pollutants present in
the water. They then respire (as humans do) carbon dioxide.
DO is also essential for many other forms of aquatic life. In receiving

streams, fish "breathe in" oxygen through their gills. Fish kills are
often caused when DO levels in a stream are depressed. Fish literally
suffocate from the lack of DO in such cases.
Under normal room conditions, approximately 8 mg/l (or parts per

million, ppm) of O2 naturally dissolves in water. The maximum level
of DO is influenced by temperature and, to a lesser extent, by
atmospheric pressure and salinity. The effect of these factors on DO
level is shown in Table V.1.
Conventional activated sludge systems in poultry wastewater treatment

are normally operated in the range of 2.0 - 2.5 mg/l DO. This level is
normally sufficient to ensure a healthy group of microbes to consume
the pollutants present.

Table V.1.
DO Concentration as a Function of Temperature, Salinity and Pressure
Dissolved-oxygen concentration, mg/L

Temp. Salinity, parts per thousand Barometric pressure, millimeters of mercury
ºC 0 10 20 30 40 740 750 760 770
0 14.60 13.64 12.74 11.90 11.11 14.22 14.41 14.60 14.80

2 13.81 12.91 12.07 11.29 10.55 13.45 13.63 13.81 14.00
4 13.09 12.25 11.47 10.73 10.04 12.75 12.92 13.09 13.27
6 12.44 11.65 10.91 10.22 9.57 12.11 12.57 12.44 12.60
8 11.83 11.09 10.40 9.75 9.14 11.52 11.67 11.83 11.99
10 11.28 10.58 9.93 9.32 8.75 10.98 11.13 11.28 11.43
12 10.77 10.11 9.50 8.92 8.38 10.48 10.62 10.77 10.91
14 10.29 9.68 9.10 8.55 8.04 10.02 10.16 10.29 10.43
16 9.86 9.28 8.73 8.21 7.73 9.59 9.73 9.86 9.99
18 9.45 8.90 8.39 7.90 7.44 9.20 9.33 9.45 9.58
20 9.08 8.56 8.07 7.60 7.17 8.83 8.95 9.08 9.20
22 8.73 8.23 7.77 7.33 6.91 8.49 8.61 8.73 8.84
24 8.40 7.93 7.49 7.07 6.68 8.17 8.29 8.40 8.51
26 8.09 7.65 7.23 6.83 6.46 7.87 7.98 8.09 8.20
28 7.81 7.38 6.98 6.61 6.25 7.59 7.70 7.81 7.91
30 7.54 7.14 6.75 6.39 6.05 7.33 7.44 7.54 7.64
32 7.29 6.90 6.54 6.19 5.87 7.09 7.19 7.29 7.39
34 7.05 6.68 6.33 6.01 5.69 6.85 6.95 7.05 7.15
Adapted from Wastewater Engineering, Treatment, Disposal, Re-Use

3rd Edition, Metcalf & Eddy, 1991.

U.S. POULTRY EGG ASSOCIATION V.4
V.1.J. Flocculants
Flocculants are chemicals capable of bridging together small clumps of
solids into a net-like formation, aiding in their removal via dissolved air
flotation, clarification or fine screening. This process is called
flocculation.
Almost all flocculants used in poultry wastewater are synthetic

chemicals, such as polyacrylamides. Since the coagulants normally used
are positively charged (cationic), most facilities use a negatively charged
(anionic) polymer. Additional discussion on coagulation and
flocculation is provided in Section V.2.
V.1.K. FOG (or Oil and Grease)

Fats, Oil and Grease (FOG or O&G) is a measurement of the amount
of lipid (fatty) material present in a water sample. Note this
measurement does not determine a specific chemical nor does it
distinguish between animal-based and petroleum-based oily materials.
It is commonly determined by mixing a water sample with an organic
solvent, such as hexane. Since fats, oil and grease are more soluble in
hexane than water, they are "extracted" into the hexane (or other
solvent layer) and then weighed. Hence, FOG is occasionally referred
to as hexane-extractable substances.
V.1.L. Nitrogen Family

As in nature, nitrogen is present in poultry wastewater in a variety of
forms and is often changed from form to form in the treatment
process. Figure V.1. depicts the various forms of nitrogen present in
poultry wastewater and their interactions and inter-relation to each
other. Provided below is a summary of the nitrogen compounds
present in poultry wastewater.
V.1.L.1. Nitrogen Gas (N2)

Like oxygen, a certain amount of nitrogen gas naturally dissolves in
wastewater. This natural level of nitrogen gas has little impact on
wastewater treatment operation. However, additional nitrogen gas can
be produced through a process called denitrification. (Denitrification
reviewed in Section IV.4). Planned denitrification can be useful to
remove nitrate from wastewater. Unplanned nitrogen gas production
via denitrification can cause process failure. This occasionally occurs in
final clarifiers at activated sludge facilities. As nitrogen gas is produced,
it bubbles to the surface. In doing so, it becomes attached to and
enmeshed in bacterial solids in the clarifier. This causes the solids to

settle poorly, if at all. Unintentional denitrification can lead to solids
loss over the clarifier weir and subsequent noncompliance.
V.1.L.2. Total Nitrogen

Total Nitrogen, as applied to most poultry wastewater treatment
systems, is the sum of organic nitrogen, ammonia nitrogen, and
nitrate/nitrite nitrogen.
V.1.L.3. Total Kjeldahl Nitrogen

This form of nitrogen, represented as TKN, is the sum of organic
nitrogen and ammonia nitrogen.
V.1.L.4. Total Organic Nitrogen (TON)

Organic nitrogen in poultry wastewater treatment systems is primarily
nitrogen associated with the protein matter from the bird, such as
blood, meat, tissue and feathers.
V.1.L.5. Ammonia Nitrogen

This compound, which can be shown chemically as NH3-N or NH4-N,
is present in poultry wastewater as a result of free ammonia in fecal
material and, to a lesser extent, as a result of ammonia refrigeration
system blowdown. As is indicated in Figure V.1., ammonia is a
breakdown byproduct of organic nitrogen.
V.1.L.6. Nitrate/Nitrite Nitrogen

This form of nitrogen is shown chemically as NO3 (nitrate) and NO2
(nitrite). Ordinarily, very low levels of nitrite-nitrogen are present, so it
is not uncommon to simply refer to these oxidized forms of nitrogen
as simply "nitrate-nitrogen."
Nitrate-nitrogen is formed in poultry wastewater treatment facilities

when TKN is oxidized by bacteria through a process called
nitrification. Nitrification is reviewed in Section IV.3.
V.1.M. pH
The most fundamental poultry wastewater analytical measurement is
pH. Virtually all treatment processes employed in the industry are, to
at least some extent, pH dependent. For example, coagulation and
flocculation in DAF systems, avoiding a sour anaerobic digester, the
ability to achieve nitrification, even the efficacy of disinfection all
depend on proper wastewater pH.

Figure V.1
THE NITROGEN FAMILY IN POULTRY
WASTEWATER
Total N
Total N N2 Gas to
Total N Total N
TKN
TKN Atmosphere
TKN
Org. -N Nitrate
Ammonia
Org. -N Total N
Nitrate
TKN TKN
Ammonia Ammonia
Org. -N
INCREASING CONCENTRATION
Org. -N Org. -N
Nitrate Nitrate Nitrate Ammonia Ammonia
Screened DAF Effluent Anaerobic Activated Sludge Activated Sludge

Wastewater Effluent w/ Nitrification w/ Denitrification
INCREASING LEVEL OF TREATMENT

Measurement of pH is on a logarithmic scale of 0 to 14. Water, of course, is
made up of two hydrogen atoms and one oxygen atom, or H2O. However, a
very small percentage of the hydrogen atoms will “break free” of the water
molecule as an ion, H+. When the H+ ion “breaks free,” or disassociates, it
results in the presence of a hydroxy ion (OH-), as shown in the equation below.
H2O  H+ + OH
pH measures the relative level of hydrogen ion, H+ (acid), in water. When the
hydrogen ion and hydroxyl ion concentrations are equal, water is said to be
neutral and has a pH of 7. When H+ ions exceed hydroxyl ions, the solution is
acidic. Acid solutions will have a pH below 7. When hydroxyl ions exceed H+
ions, the solution is basic. Basic solutions have a pH above 7. Since the scale is
logarithmic, water having a pH of 6 is ten times more acidic than one having a
pH of 7; a pH of 5 is then 10 times more acidic than a pH of 6. Similarly, a
solution that has a pH of 8 is 10 times more basic than one having a pH of 7, and
100 times more basic than one having a pH of 6. Table V.2 lists the pH of some
common everyday substances and chemicals routinely used in poultry wastewater
treatment.
Table V.2
Approximate pH of Various Substances
Substance pH
Acetic Acid (1.0N) 2.4
Beer 4.5
Caustic Soda (1.0N) 14.0
Coca-Cola 3.5
Egg whites 7.8
Ferric Sulfate 0.8
Hominy 7.5
Hydrogen Sulfide (0.1N) 4.1
Lime (saturated) 12.4
Polymer (anionic) 6.7
Polymer (cationic) 6.0
Sulfuric Acid (1.0N) 0.3
TriSodium Phosphate (0.1N) 12.0
Vinegar 3.0

As indicated earlier, adjusting and maintaining pH is fundamental to many of the
processes employed in poultry wastewater treatments. Some examples are as
follows:
• Coagulation/Flocculation in DAF Systems.

As will be described in greater detail in Section V.2., many
coagulation/flocculation systems use pH adjustment to enhance floc
formation. This can be accomplished through the addition of a mineral acid
(normally sulfuric acid) or a metal salt such a ferric
sulfate, ferric chloride or alum. These metal salts are all weak acids which
depress pH. In a few systems, carbon dioxide (CO2) , also a weak acid, is used
to depress pH.
• Anaerobic Lagoons.
As is indicated in Section IV.I., bacteria breaking down pollutants in an
anaerobic lagoon, called acidogens, produce various organic acids. Left
unchecked, this will result in a decrease in the pH of the anaerobic lagoon,
eventually leading to system failure. To “buffer” against pH depression,
various basic chemicals are introduced to the anaerobic lagoon. Their purpose
is to neutralize the acid produced by acidogens and maintain the lagoon pH
around 7.0. The most common basic chemical used is lime; however, other
facilities use soda ash, magnesium hydroxide or caustic soda.
• Activated Sludge Nitrification.

As is discussed in Section IV.3., nitrification (converting ammonia to nitrate)
results in the production of hydrogen ions, H+, which, left unchecked, will
depress aeration basin pH. Again, failure to supply sufficient basic chemicals
to counteract or “buffer” this pH depression will result in process failure. As
with the anaerobic lagoon, the most common chemical utilized to supply
buffering capacity is lime. Soda ash, magnesium hydroxide and caustic soda
are also used.
• Polishing Ponds.
Many facilities have a final “polishing pond” prior to discharge. Algae have
the opportunity to grow in these ponds. During daylight hours, when algae
are performing photosynthesis, they can consume dissolved carbon dioxide
(CO2) in the polishing pond. Stripping CO2 from the water results in higher
pH levels, as CO2 acts as a mild acid. Consequently, many plants find it
necessary to control polishing pond discharge pH in order to achieve effluent
limits. This is most commonly done with sulfuric acid, although some
facilities simply reinject carbon dioxide to bring the effluent into permit limits.
Other facilities control the algae population via algicides to minimize this
phenomena.

• Disinfection.
Many facilities utilize chlorine for disinfection purposes. As will be discussed
in greater detail in Section VII.3, the efficiency of chlorine as a disinfectant is
inversely proportional to pH. In other words, as water pH increases, chlorine
becomes less effective. This can become critical in achieving effluent limits
for fecal coliform. A facility with a final polishing pond as described above,
with algae causing a significant pH rise during daylight hours, is particularly
susceptible to this type of interference. Mineral acids such as sulfuric acid are
commonly used to control pH in the proper range for disinfection purposes.
V.1.N. Phosphorus
Phosphorus, the fifth most common element on earth, is an essential nutrient to
bacteria utilized in a poultry wastewater treatment facility. Similarly, it is an
essential element of poultry itself, and is contained in the blood, tissue, meat, etc.
However, excessive levels of phosphorus can lead to excessive growth of algae
(algae blooms) in some receiving streams.
Two forms of phosphorus are routinely tested in poultry wastewater treatment

facility. The first of these, ortho-phosphorus, or ortho-P, represents the
phosphorus which is readily available for use by the microbes present in a
biological treatment system. Total phosphorus, as the name implies, measure the
total level of phosphorus present without regard to its availability to the biomass.
V.1.O. Suspended Solids

Suspended solids, often abbreviated SS or TSS (T for total), are those solids in
poultry wastewater which cannot pass through a glass fiber filter in a laboratory
test. In raw screened wastewater, they consist largely of small bits of meat and
feathers, sand, grease, blood, fecal matter and grit. By the time the wastewater
has been processed through an activated sludge system, the remaining suspended
solids have been converted to primarily bacterial cells and the inert materials such
as sand and grit.
Suspended solids are calculated by passing a measured quantity of water through

the preweighed glass fiber filter. The filter is dried at 104C, then reweighed.
The resulting weight gain represents suspended solids.
V.1.P. Volatile Suspended Solids

Some facilities take the suspended solids test a step further to determine what
fraction of these suspended solids are organic in nature. To do this, after total
suspended solids has been determined, the sample is placed in a 550C oven.
This high temperature will burn off, or volatize, any organic matter present on
the filter. After cooling, the filter is again reweighed with the weight loss
representing volatile suspended solids (VSS). The remaining solids are

inorganic-silica from sand, for example; and are often called inert or fixed
suspended solids.
Suspended solids measurement is utilized in a variety of ways in poultry

wastewater treatment facility. On a raw screened wastewater, it gives the
operator a relatively quick method of assessing incoming wastewater strength.
As suspended solids increase, representing additional bits of pollutants in the
influent stream, so does BOD and COD.
In biological systems, both TSS and VSS are used to quantify the amount of
bacterial microbial solids are present; i.e., it determines the level of "bugs"
present in the treatment system. Finally, virtually all systems, both pre- and
full-treatment, have a suspended solids limit which must be achieved to maintain
compliance.
V.2. Coagulation/Flocculation
The solids present in raw poultry wastewater are very small and, hence, do not
separate rapidly or easily from the water. Most facilities have screening systems
that remove most solids larger than 1-2 mm; however, the bulk of the suspended
solids are much smaller than this, ranging down to 0.00001 mm. Note solids
smaller than 0.01 mm are not visible to the human eye, but do impact turbidity to
the water. These very fine solids are often called colloids. Because of their small
size, colloids will not separate in a timely manner. These solids - protein, grease,
grit, etc., - cannot be removed from a mechanical wastewater system, such as a
DAF or clarifier, without agglomeration.
Coagulation/flocculation is the two phase process employed in the industry to

accomplish this agglomeration. Please note that even though coagulation and
flocculation are two different phenomena, they often occur simultaneously in a
dissolved flotation unit or clarifier.
Coagulation is the process of bringing very fine particles together by allowing

particle-particle collisions. Colloids in poultry wastewater have by nature a
negative charge. Consequently, the colloidal particles repel each other, like
similar poles on magnets, preventing particle-particle collisions. The strength of
this repelling force is called the zeta potential. The role of coagulation (i.e., the
purpose of adding a coagulant chemical) is to reduce the zeta potential to the
point particle-particle collisions occur. Because, if the collisions occur, then a
second force, called Van der Waals Forces, will hold the particles together.
Van der Waals Forces are a force in nature that draws particles together. So,
coagulation, and adding coagulant, is intended to reduce zeta potential
sufficiently to allow particle-particle collision to occur and Van der Waals Forces
to act to draw and hold those particles together. This is graphically illustrated in

Figure V.2. In poultry wastewater treatment facilities, several different additives
are utilized that cause coagulation to occur, including the following:
 Sulfuric (and other mineral) acid

 Metal salts (such as ferric sulfate or alum)
 Cationic polyelectrolytes
Regardless of the chemical selected, note the important point is that they all
release cations (positive charge) in the waste streams. This positive charge
reduces the zeta potential, leading to the particle-particle collision that ultimately
allows coagulation. Further, most coagulants are relatively small molecules, i.e.,
they have a low molecular weight.
Even though coagulation "destabilizes" a colloid (i.e., makes a small colloid

"stable" in suspension and causes it to agglomerate with other solids), the
resulting clumps - or floc - are normally not well suited for removal via
mechanical means. The reason is that the small floc formed by coagulation are
very fragile and can become easily torn apart. The turbulence present in many
mechanical separation devices is often sufficient to tear apart the floc -
resuspending or restabilizing the colloidal solids. The fact is that the
Van der Waals Forces holding two colloids together are fairly weak, such that the
addition of mixing energy - whether through turbulence in a pipe or injecting
pressurized air, etc. - will destroy the floc.
Consequently, once colloid solids have been destabilized into small floc by
coagulation, they must be tied together through formation of a structural net.
The process of doing so is called flocculation, and chemicals used to cause
flocculation are called flocculants.
In poultry wastewater treatment facilities, most flocculants are negatively

charged, large molecule (high molecular weight) chemicals. The addition of the
cationic (positively charged) coagulants causes formation of a small floc which, at
its surface, has a positive charge. Flocculants are long-chained, branched
molecules that have a number of locations on the chain with a negative charge.
Consequently, the positively charged small floc are attracted to, and become
attached to, these negative sites. Because the flocculant is such a large molecule,
it can absorb many of these small flocs into its structure. Hence, the flocculant
sweeps through a solution capturing small flocs in its net. This effect is depicted
in Figure V.3.

Figure V.2
COAGULATION OF
COLLOIDS
Colloid
Increasing Coagulant Dosage
Effective Diameter
Depicted in the Figure above are two colloids of primarily

negative charge; the colloids repel. As cationic coagulant is
added, the effective diameter is decreased; ultimately,
particle-particle collision occurs and floc formation begins.

Figure V.3
FLOCCULATION OF
COLLOIDS
Coagulated
Colloids
Active negative charge

sites on polymer
Long chained anionic

polyacrylamide polymer
Coagulated Colloids are attracted to the negatively charged

sites on the long chained polymer. This results in the
agglomeration of colloids into large floc.

The larger floc formed are clearly visible to the naked eye. Because of the
stability of the strong negative charge holding the small floc in place and the
strength of the molecular structure, they are less susceptible to floc breakup or
shear. This strength and structure allows removal of solids via mechanical
means. For example, these large floc are ideally suited to entrap dissolved air
coming out of solution, allowing air bubbles to become entrained in the floc.
This, in turn, increases the buoyancy of the floc, causing it to float to the surface
of a DAF tank, thus removing it from the waste stream.
Far and away, the most common flocculants utilized in poultry facility DAF’s are
anionic polyacrylamides. Their usage with specific coagulant combination is
discussed in Section V1.3.
V.3. Mathematical Formulas, Data and Conversions

An understanding of basic mathematical calculations (addition, multiplication,
subtraction, division, percentages, fractions) is required for the successful
operation of a poultry wastewater treatment facility. It is assumed in this manual
that the operator has such skills, and if not, can obtain such skills through local
or company sponsored GED programs, night classes, etc.
As with most other technical fields, there are a set of formulas, data and
conversions routinely and continually utilized to evaluate system design, loading
and performance. Provided below are the more common mathematical
calculations and conversions necessary in poultry wastewater treatment.
V.3.1. Mensuration Formulae
Circumference of a Circle = π D = 2πr

D
Area of a Circle = π r2 = π D2 r
4
Volume of a Cylinder r
D
h
= π r2 h = π D2 h
4

Volume of a Cone r
D
= 1/3 π r2 h = 1/12 π D2 h h
Area of a Rectangle = L • W W
W
h
Volume of a Rectangular Basin L
•L•W•h
Area of a Triangle = 1/2 b h h
a
Volume of Prism
h
= 1/2 b h a
b
V.3.2. Common Conversions
1 million gallons/day = 1 MGD = 694 gallons/minute = 694 GPM
1 day = 24 hours = 1440 minutes = 86,400 seconds
1 gallon water = 8.34 lbs
1 cubic foot water = 62.4 lbs = 7.48 gallons
1 lb = 454 grams = 454,000 mg
1 part per million = 1 ppm = 1 mg/l = 1 milligram/liter

lbs/day = mg/l x Flow (MGD) x 8.34
= mg/l x Flow (GPM) x 0.012
V.3.3. Common Calculations
Detention or Retention Time = Volume of Vessel

Flow Rate
Ex: What is detention time of a 2 million gallon aeration basin with a

flow of 1.5 MGD?
Detection Time = 2 MG = 1.33 days

1.5 MGD
= 32 hours
KEEP UNITS CONSISTENT!
Velocity of a Pipe = Flow Rate

Pipe Area
Ex: What is the water velocity in a 4 inch pipe flowing 200 gallon/minute?
First: GET UNITS CONSISTENT
Area at Pipe = π r2 = π (2/12) 2 = 0.087 ft.2
Flow = 200 gal/minute x 1 minute x ft3 = 0.44 ft3

60 seconds 7.48 gal. seconds
Velocity = .44 ft3/sc = 5.0 ft/sc

0.087 ft2
Note: Flows of 2 – 8 ft/sec are normally desirable in wastewater

applications
Surface Loading (on a DAF unit or clarifier)

Measurement of flow rate/surface area
Normally expressed in gallons/day/ft2 or GPM/ft2
Ex: A clarifier (100’ diameter) is designed to process 1.5 MGD. What is

the surface loading?

Area of clarifier = (50) 2 x 3.14 = 7850 ft 2
Surface Loading = 1,500,000 gal/day = 191 gallon/day/ft 2

7850 ft 2
Ex: A rectangular DAF (50 feet x 10’ feet) is treating 1000 GPM. What
is the surface loading?
1000 GPM = 2 GPM/ft 2

50’ x 10’

VI. DISSOLVED AIR FLOTATION (DAF) AND CHEMICAL
ADDITION
This chapter will provide a review of each of the DAF’s and chemical addition
systems that can be involved in a poultry wastewater pretreatment system. Note that
this information is presented as a general guideline. Whenever possible the operator
should consult the manufacturer’s literature for more specific information. Each will
be described in terms of:
 Typical design information

 Normal operation procedures
 Instrumentation and control
 Maintenance checklist
 Analytical tests
 Troubleshooting flow sheet
 Typical design and process calculations
VI.1. Full Flow Pressurization Dissolved Air Flotation System

The purpose of the full flow pressurization dissolved air flotation
(DAF) system is to remove a majority of the free oil and grease from
the screened wastewater. Excessive oil and grease can cause build-up
and line clogging problems in subsequent treatment units and interfere
with biological treatment. Suspended solids and BOD removal occurs
incidental to the oil and grease removal.
Note: Chemical addition to the DAF can greatly enhance system

performance. However, chemical (flocculant/coagulant) addition is
covered in Section VI.3. This section deals primarily with the
mechanics of how and why a DAF system works.
VI.1.A. DAF System Design Information
Pumps: Minimum two process pumps, each sized to carry

plant flow at 40 psig
DAF: Surface Loading Retention Time

(GPM/FT2) (minutes)
Typical Design 2.0 – 3.0 30
Maximum 4.0 20
Retention Tank: Minimum 2 minute retention time
Air Requirement: 0.5 – 1.5 SCFM/1000 GPM

U.S. POULTRY & EGG ASSOCIATION VI.1
VI.1.B. DAF System Operation Procedures
Screened wastewater enters the wet well or Flow Equalization Basin
(FEB). A minimum of two identical pumps should be provided to
pump the screened wastewater from the wet well or FEB to the
retention tank and DAF. Each pump should each be rated at full plant
flow at 40 psig, so under ordinary circumstances it is only necessary to
utilize one pump, allowing one pump (at least) to serve as back-up.
These pumps are normally designated as lead and lag. Please refer to
Figure VI.1. The lead pump is always operating during production.
Recycled water from the DAF is supplied via a float valve or other
similar means to insure this pump does not run dry during periods of
reduced flow. Periodic inspection of the float valve mechanism is
necessary to insure it is properly opening and closing to ensure the
pump does not run dry. During periods of extended reduced flow (i.e.,
weekends and holidays) or if no recycle exists, this pump is either
turned on or off by the operator or by a liquid level sensor as needed.
The lag pump is normally operated automatically and controlled by a

float switch liquid level sensor. If the level in the wet well rises to a
certain point, this sensor will automatically turn on the lag pump.
Possible reasons for this occurring include lead pump failure or pump
clogging, unusually high plant water usage, or excessive back pressure
at the throttling valve (discussed later). When the wet well returns to a
normal level, the controller is set to turn the lag pump off.
The screened wastewater is pumped to the pressure tank. Air is

injected into the pressure tank at a rate of 1 SCFM/1000 GPM.
Residual pressure in the pressure tank is maintained at approximately
40 psig. The purpose of the pressure tank is to give the injected air an
opportunity to “dissolve” in the wastewater. When placed under
pressure, water has the capacity to dissolve or absorb more air than at
atmospheric pressure. This phenomenon is what makes dissolved air
flotation work. In effect, pressurizing the wastewater to 40 psig allows
supersaturation to occur. The water pressure is increased via the
pumps, air is injected and dissolved into the high-pressure water in the
pressure tank, then the water pressure is relieved back to atmospheric
pressure by releasing the water into the DAF tank. Since the water is
no longer under pressure, the extra air dissolved at higher pressure
comes back out of solution. As this air froths out of solution, it floats
flocculated oil and grease, and other pollutants to the surface of the
DAF tank.

Figure VI.1
FULL FLOW PRESSURIZATION DAF
SKIMMINGS (SPN)
Throttling Valve
TO ADDITIONAL DAF UNIT
TREATMENT
OR POTW
SLUDGE
TANK
P
AIR ROTAMETER
SLUDGE
AIR COMPRESSOR PUMP
SCREENED WASTEWATER
DAF RECYCLE
TO PROTEIN
PRESSURE RECOVERY OR
TANK LAND APP.
Float
Valve
OFFAL ROOM
Float WET WELL
WASTEWATER TREATMENT MANUAL LAG LEAD

POULTRY PROCESSING FACILITIES PUMP PUMP VI.3
U.S. POULTRY & EGG ASSOCIATION
with an air rotameter or similar air throttling device An adjustable
knob or mechanism is typically provided to allow modifying the airflow
rate, either manually or automatically.
Tank pressure is typically indicated by a pressure gauge located at the

discharge pipe of the tank. Pressure can be manually or automatically
regulated by opening and closing the throttling valve between the
pressure tank and the DAF tank. The target pressure is normally
40 psig (consult manufacturer’s literature), although variation of this
reading is normal and sometimes desirable. For example, a situation
may occur where liquid level in the wet well begins to rise due to high
influent flows. Rather than allowing the lag pump to automatically kick
on, it is usually desirable to open the throttling valve to reduce
pressure. If, for example, pressure was reduced to 35 psig, the pump
can then move more water, which may return the wet well level to its
desired level without having to turn on the second pump.
Alternately, during a period of reduced water usage, it may be desirable

to increase pressure at the throttling valve. Increasing pressure will
reduce pump flow rate. This, in turn, may prevent the wet well from
running dry or from having to shut the entire system down for lack of
water.
Consequently, even though the target pressure for the pressure tank is
40 psig, the operator should feel free to adjust the throttling valve –
and, hence, adjust the pressure – over a range of 30-50 psig if necessary
to maintain a desired water level in the wet well.
Once the wastewater flows through the throttling valve, it is returned

to normal atmospheric conditions. As previously described, this causes
the air dissolved at higher pressure to froth to the surface of the DAF
tank. In so doing, the tiny air bubbles attach themselves to oil/grease
particles and suspended solids and float these pollutants to the DAF
tank surface. These materials (called SPN or secondary protein
nutrients, skimmings, float fat or sludge) are removed from the tank via
a skimmer mechanism into the sludge storage tank.
Many facilities are equipped with chemical feed equipment to enhance

DAF performance if necessary. Chemical treatment is discussed in
Section VI.3.
Wastewater flows over the weirs of the DAF tank, is collected in a

pipe, and flows by gravity to the next component of the treatment
system. In processing facilities which only perform pretreatment, this

next component of the treatment system is actually the POTW. In
most full flow pressurization systems, recycle is returned to the wet
well either from the final weirs or a draw-off pipe line located at the
discharge end of the tank.
VI.1.C. DAF System Instrumentation & Control

Wet well pumps are typically provided with a liquid level control
system to activate the pumps when operated in an automatic mode.
Both ultrasonic and mechanical control sensors can be used. When
liquid level reaches the appropriate elevation, the switch is activated
and a relay signal is sent to the pump control panel activating the
pump.
Air Flow rotameter or throttling valve – This unit is provided to allow

manual or automatic adjustment of the airflow injection rate into the
pressure tank. The unit is normally equipped with a flow indicator. In
manual units, a control knob is used to adjust the flow rate and, hence,
the float indicator.
Pressure gauge – A pressure gauge should be provided at the discharge

of the pressure tank. System pressure is manually or automatically
controlled to a target pressure of 40 psig via the throttling valve. As
discussed in Section VI.1.B., variation over the range of 30-50 psig is
normal. Longer gauge life can be obtained by using a gauge with an
internal oil diaphragm.
VI.1.D. DAF System Maintenance Checklist
Pumping System:
1. Inspect (and clear if needed) recycle line float valve daily.
2. Inspect (and clean as needed) float switch mechanism.
3. Follow recommended maintenance of manufacturer.
Pressure Tank:
1. Inspect and clean air flow meter once a month to prevent float
sticking. Inspect periodically.
2. Maintain extra pressure gauge for pressure tank.
3. Drain and check for debris. Remove accumulated debris from tank
on a periodic basis if possible.
DAF System:
1. Bearings are normally sealed. Do not over grease; once per month is
adequate.

2. If rake system is chain driven, check chain drive oil level weekly
and replenish as necessary. Change annually.
3. Maintain spare chain inventory, and spare scraper inventory.
4. Inspect chain monthly for stretching. Tighten chain at tail sprocket

assembly as needed.
5. If rake system is pneumatically operated, check lines for leakage.
Use an air dryer on the supply line.
VI.1.E. DAF System Analytical Testing

Sampling of the DAF system should be conducted in accordance with
company practices. The following is a suggested testing protocol for
the system:
Parameter 1/shift 1/day 1/week 1/month

BOD X
COD X
Alkalinity* X
pH X
TKN X
Phos X
*If facility has full treatment system
VI.1.F. DAF System Troubleshooting Flow Sheet

A troubleshooting flow sheet is included as Chart VI.1 for the Full
Flow Pressurization DAF System.
VI.1.G. Typical DAF Calculations
1. A rectangular DAF (45’ long, 10’ wide, 8’ depth) is processing 900

GPM. Calculate retention time and surface loading.
DAF Area = 45 x 10 = 450 ft2

DAF Volume = L • w • h = 45 x 10 x 8 = 3600 ft3 x 7.48 gal.
ft3
= 26,928 gallons
Surface Loading = F/A = 900 GPM/450 ft2 = 2 GPM/ft2
Retention Time = V = 26,988 gal. = 30 minutes

F 900 GPM

Chart VI.1
FULL FLOW
PRESSURIZATION No
No
Is Pump Maintaining Is Pump On? Turn Pump On
DAF SYSTEM Wet Well Level
Yes
Decision Chart Is Recycle Valve No Repair Recycle
Yes
Operating Properly Mechanism
Yes
Is Air Injection OK Reduce/Increase Not Switch to
No No @ 1 SCFM/1000 GPM
Turn System Pressure OK Other Pump
Is Compressor On?
Compressor On
Yes Yes
Yes
Not
Clean Rotameter Adjust Air Rotameter
OK OK OK OK
Is Pressure at
No Adjust Pinch Not
35-45 psig
Valve OK Replace Gauge
Yes
Adjust Rotameter No No No Skimmings Production

Is Air Injecting? Normal?
To Give 4 SCFM Cease Spill or
Yes Overfill
Clean DAF or No DAF & Retention Tank Yes Yes
Retention Tank Cleaned Regularly? Check Blood Tank
No Is Effluent Yes
Yes Overfill or Proc.
No Is Effluent COD Excessively Red
Adjust System Is Pressure inYes Yes Plant Spill
<3000 mg/l No
Pressure Proper Range No
Excessive Solids Yes
Chemical Treatment
In Effluent
Yes May Be Necessary
No
Continue Routine Repair/Replace
Screens
Monitoring

VI.2. Pressurized Recycle Dissolved Air Flotation System
As with full flow pressurization systems, the purpose of the pressurized
recycle dissolved air flotation (DAF) systems is to remove a majority of
the free oil and grease from the screened wastewater. Excessive oil and
grease can cause build-up and line clogging problems in subsequent
treatment units and interfere with biological treatment. Suspended
solids and BOD removal occurs incidental to the oil and grease
removal. Chemical flocculants can be utilized to enhance unit
performance.
As the name implies, in pressurized recycle systems, a portion of the

effluent is recycled to a pressurization pump. This pump is normally
capable of pressurizing 25-50% of the plant flow rate to 65-70 psig.
(Check manufacturer’s recommendations.) This higher pressure allows
an even greater quantity of air to be dissolved in the recycle stream.
Consequently, the volume of water which must be pressurized is
decreased compared to a full flow pressurization system. Either type
of DAF system can be utilized successfully in the industry. Recycle
pressurization systems generally require less overall horsepower.
Further, they eliminate the need for a return line to the wet well to
ensure the wet well does not go dry. In practice, full flow systems
generally are installed in smaller facilities; recycle pressurization systems
are installed in larger facilities.
VI.2.A. DAF System Design Information
Process Pumps: Minimum two process pumps, each sized to carry

plant flow.
Pressurization Pumps1: Minimum two pressurization pumps, each
sized to handle 25 - 50% of plant flow at
70 psig.
DAF: Surface Loading Retention Time Recycle Flow
(GPM/FT2) (minutes) (%)
Typical Design2 2.0 30 25

Maximum 5.0 20 50
Retention Tank: Minimum 1 minute retention time
Air Requirement: 0.5 – 1.5 SCFM/1000 GPM
1
Dual DAF units can share a backup pressurization pump.
2
Some manufacturers utilize "plate packs" or lamella separators to allow higher
surface loading rates and shorter retention time.

VI.2.B. DAF System Operation Procedures
Screened wastewater enters the wet well or flow equalization basin
(FEB). Two identical pumps should be provided to pump the
screened wastewater from the wet well or FEB to the retention tank
and DAF. These pumps should each be rated at full plant flow at only
the head pressure required to pump the water from the FEB to the
DAF. See Figure VI.2.
These pumps are normally designated lead and lag. Enroute to the
DAF, or in the DAF tank itself, pressurized recycle is mixed with
wastewater pumped from the FEB or wet well.
The pressurized recycle stream is created by first collecting a portion of

the discharge from the DAF tank. It is piped into a pressure pump
which pressurizes the water to 65 – 70 psig. The pressurized recycled
stream is held in a pressure tank to allow sufficient time for the air to
dissolve. Air is often injected into this tank, although in some systems
the air is injected in the pipe between the pressure pump and the
pressure tank, or into the pressure pump itself. An air rotameter or
similar air throttling device should be provided to regulate the flow of
air. A pressure gauge should be provided on the tank or on the
discharge line from the tank. A pressure regulatory valve also needs to
be provided on the pressure tank discharge line.
Pressurized, supersaturated recycle flow is then co-mingled with the

wastewater pumped from the FEB or wet well to the DAF tank. Most
recycle pressurization systems are equipped with floc tubes, or a series
of serpentine piping. Pressurized recycle is normally injected in the
floc tubes. However, some facilities inject the pressurized recycle
directly into the DAF. Once the wastewater and pressurized recycle
stream are co-mingled, the operation of the unit is basically the same as
a full flow pressurization system.
VI.2.C. DAF System Instrumentation & Control

Wet well pumps are typically provided with a liquid level control
system to activate the pumps when operated in an automatic mode.
Both ultrasonic and mechanical units are used. When liquid level
reaches the appropriate elevation, the switch is activated and a relay
signal is sent to the pump control panel activating the pump.
Pressure pumps are typically equipped with a low level shut-off control
to prevent the pump from running dry.

Figure VI.2
PRESSURIZED RECYCLE DAF
SKIMMINGS (SPN)
Throttling Valve
DAF UNIT
TO ADDITIONAL
TREATMENT,
POTW OR RE-USE
SLUDGE
PRESSURIZATION PUMP TANK
P
AIR ROTAMETER
SLUDGE
AIR COMPRESSOR PUMP
RECYCLED EFFLUENT
TO PROTEIN
RECOVERY OR
PRESSURE LAND APP.
TANK
OFFAL ROOM
WET WELL
LAG LEAD
PUMP PUMP

Air Rotameter/Throttling Device – This unit is provided to allow
manual or automatic adjustment of the airflow injection rate into the
pressure tank. The unit is often equipped with a float indicator in a
sight glass. A control knob is used to adjust the flow rate and, hence,
the float indicator.
Pressure Gauge – A pressure gauge is provided at the discharge of the

pressure tank. System pressure is manually controlled to a target
pressure of 70 psig via the throttling valve. Longer gauge life can be
obtained by using a unit with an internal oil diaphragm.
VI.2.D. DAF System Maintenance Checklist

Pumps:
1. Follow recommended maintenance of manufacturer.
Pressure Tank:
1. Inspect and clean rotameter once a month to prevent float sticking.
2. Maintain extra pressure gauge for pressure tank.
3. Drain and inspect for debris. Remove accumulated debris from
tank on a periodic basis, if possible. Purge as needed.
DAF System:
1. Bearings are normally sealed. Do not over grease; once per month is
adequate.
2. If rake system is chain driven, check chain drive oil level weekly
and replenish as necessary. Change annually.
3. Maintain spare chain inventory.
4. Inspect chain monthly for stretching. Tighten chain at tail sprocket
assembly as needed.
5. If rake system is pneumatically operated, check lines for leakage.
Use an air dryer on the supply line.
VI.2.E. DAF System Analytical Testing
Testing of the DAF system should be conducted in accordance with
company practices. The following is a suggested sampling protocol:
Parameter 1/shift 1/day 1/week 1/month

BOD X
COD X
Alkalinity* X
pH X
TKN X
Phos X
*If facility has full treatment system

VI.2.F. DAF System Troubleshooting Flow Sheet
A troubleshooting flow sheet is included as Chart VI.2 for the
Pressurized Recycle DAF System.
VI.2.G. DAF System Mathematical Calculations

Please refer to Section VI.1.G.

Chart VI.2
PRESSURIZED
No
RECYCLE DAF SYSTEM Is Pump Maintaining No
Wet Well Level Is Process Pump On? Turn Pump On
Decision Chart Yes
Yes Is Intake or Discharge No
Turn on 2nd Pump
Clogged or Restricted?
Is Air Injection Yes
OK Not
No No @ 1 SCFM/1000 GPM Switch To
Turn Compressor On Is Compressor On? Clear Obstruction OK Other Pump
Yes Yes
Yes
Not
Clean Rotameter Adjust Air Rotameter No
OK OK No Is Pressurization
Is Pressure At Turn Pump On
Pump On?
65-70 psig Yes
Is Pinch Valve No Adjust Pinch
Yes Adjusted? Valve
Yes
Skimmings Production Pressure Pump No Replace Gauge or
Adjust Rotameter No No Intake Restricted? Overfill
Is Air Injecting? Normal?
To Give 4 SCFM Yes
Yes
Clean DAF or No DAF & Retention Tank Yes
Clear Obstruction
Retention Tank Cleaned Regularly? Cease Spill or
Overfill
Yes
No Yes Is Effluent COD Yes
Adjust System Is Pressure In
< 3000 mg/l Excessive Red Yes Check Blood Tank Overfill
Pressure Proper Range
No In Effluent or Proc. Plant Spill
Yes No No
Excessive Solids Yes Chemical Treatment
Continue Routine In Effluent May Be Necessary
No
Monitoring
Repair/Replace
Screens
VI.3. Chemical Feed Systems
DAF units are fairly effective in removing “free” oil and grease from
poultry wastewater. However, much of the oil and grease present in
poultry wastewater is not “free”, rather, it is partially dissolved or
partially miscible in the wastewater. Further, poultry wastewater
contains suspended solids that are small bits of protein, or other non-
oil substances. These non-oily components of the wastewater are not
effectively removed by DAF alone.
To enhance DAF performance, many facilities add coagulants and

flocculants. A detailed description of the coagulation/flocculation
process is provided in Section V.2. Basically, what these agents do is
cause the small, fine solids and partially dissolved oil present in poultry
wastewater to agglomerate, or clump together. These agglomerated
solids – or “floc” as they are often called, are then large enough to
become entrapped or enmeshed in the air frothing out of solution in a
DAF unit. This causes the floc to rise to the surface of the DAF tank
where it can be removed via the skimmer mechanism.
There are a multitude of chemicals employed in the industry as

coagulants and flocculants. Individual plants choose the appropriate
chemical agents for their facility based on a variety of factors, such as
desired performance, cost, ease of use, and skimming disposition.
Presenting detailed information on the many chemical feed systems
and types is beyond the scope of this manual. However, provided
below is a generalized review concerning the design, operation and
control of three of the more common chemical combinations and feed
systems employed in the industry, as follows:
Ferric Sulfate/Anionic Polymer

Sulfuric Acid/Cationic Polymer/Anionic Polymer
Coagulant/Cationic Polymer/Anionic Polymer
VI.3.A. DAF Chemical Feed System Design Information

Cationic Product or Coagulant Storage (covers ferric sulfate, cationic
polymers, sulfuric acid, coagulant): Bulk synthetic resin tanks, normally
4000 gallon – 6000 gallon, ensure tank material and fittings are
compatible with stored chemical.
Anionic Storage: Product comes in both granulated and liquid forms.
Day Tank – 1000 - 2000 gallon synthetic resin tank with mixing
to allow make-up of approximately one day demand for diluted
polymer. Provide 1.5 HP/1000 gallon tank for mixing.

Note, many facilities use automatic makedown units to dilute,
mix and pump anionic polymer solutions.
Cationic Product/Coagulant Pumps: Typically diaphragm pumps,

with external control capability (i.e., pump rate can be proportionately
controlled by pH or flow meter signal). Progressive cavity or gear
pumps on Variable Speed Drives are also used.
Anionic Pumps: Gear or progressive cavity pumps with Variable

Frequency Drive or automatic makedown system with pumping system
(normally diaphragm).
VI.3.B. DAF Chemical Feed Systems Operating Procedure
VI.3.B.1. Ferric Sulfate/Anionic Polymer

The ferric sulfate/anionic polymer combination was, far and away, the
most prevalent for DAF chemical addition for most of the last quarter
century, and is still utilized today. Its advantages include low chemical
cost, easy control via pH controllers, and the ability to produce an
excellent quality effluent, with BOD’s below 200 mg/l not uncommon.
Disadvantages of this combination primarily center around the
skimmings produced. These skimmings are relatively wet (90%
moisture); difficult to dewater; increased in volume due to hydration of
iron, cause feed discoloration when processed in a protein recovery
facility, and, if not handled expeditiously, can be subject to rapid
rancidity, particularly during the summer months.
Ferric sulfate or iron (+3) sulfate is an inorganic chemical that acts as a

cationic polymer in poultry wastewater. Ferric sulfate is normally
added to the waste stream in the wet well or Flow Equalization Basin
(FEB). Dosage will vary, but generally ranges from 200 – 400 mg/l.
Better blood collection in the poultry plant will reduce dosage.
Addition of ferric sulfate is controlled via a pH controller. (See Figure
VI.3)
The ferric-treated wastewater is pumped from the wet well to either the
pressurization tank or the DAF. Anionic polymer addition points vary
from plant to plant; however, anionic polymer should not be
introduced where it would be subject to extreme turbulence or mixing.
Often, it is introduced after the pressure regulating valve in full-flow
pressurization systems, and directly into the DAF feed line, at the end
of the floc tubes, or the DAF itself, in partial recycle pressurization
systems. Dosage of polymer generally ranges from 3 – 7 mg/l.

Figure VI.3
FERRIC/ANIONIC POLYMER SYSTEM
SKIMMINGS (SPN)
TO ADDITIONAL
TREATMENT,
DAF UNIT
POTW OR RE-USE
SLUDGE
TANK
Flocculation
Tube
ANIONIC TANK
& PUMP
RECYCLED
EFFLUENT
SLUDGE
P PUMP
PRESSURE
TANK
PRESSURIZATION TO PROTEIN
PUMP RECOVERY OR
LAND APPLICATION
pH SAMPLE
LINE
AIR
pH PROBE &
ROTAMETER CONTROLLER
FERRIC
TANK
AIR
pH 4.20
COMPRESSOR
OFFAL ROOM
WET WELL
FERRIC
PUMP
As described in Section V.2, the ferric causes formation of small floc,
the anionic polymer agglomerates these floc into sufficient size to
entrap rising air bubble frothing out of solution. This results in
removal of many pollutants from the wastewater. Typical
performance, and other system characteristics, are presented in Table
VI.1
Ferric sulfate is normally produced in bulk solution, nominally as a

50% solution (50% water, 50% ferric sulfate). Other grades do exist;
the dosage range above is for a 50% solution. This solution has a
freezing temperature of -17 F, so except in extreme cases, it may be
stored outside. Containment must be provided to prevent accidental
release. Ferric sulfate has a pH of less than 2.0 S.U., and is therefore
corrosive. Implementation of containment, and selection of
appropriate materials to handle and contain the ferric sulfate, is
essential. All company safety rules regarding handling a corrosive
substance must be observed.
Anionic polymer is available in dry or emulsion form. It is normally

diluted to 0.25% to 1.5% solution. This can either be done manually in
a day tank or automatically with a polymer makedown system. Storage
of bags or drums should be provided in a dry, non-freezing area.
Polymer is EXTREMELY slippery. Carefully and immediately clean
up spills to prevent injury due to falls. Rock salt often aids in
counteracting slipperiness when cleaning up spills.
VI.3.B.2. Modified Acidulation: Sulfuric Acid/Cationic Polymer/Anionic

Polymer
The petroleum industry has utilized sulfuric acid and various polymers
to “break” oil from emulsions for many years. This practice began to
gain acceptance in the poultry industry in the 1980’s, as alternatives to
ferric sulfate were sought to enhance skimmings quality.
Utilizing sulfuric acid alone with anionic polymers in poultry

wastewater can effectively treat poultry wastewater. However, it
normally requires very tight pH control, and operates at relatively
corrosive pH values. Hence, to overcome these issues, plants began
adding a cationic substance with the sulfuric acid. The cation was
often ferric sulfate, but over time, many facilities have switched to
synthetic polymers. The result was a more stable system, operating
over a wider pH range and at a less corrosive pH. Other advantages
include lower skimmings production; and the skimmings are more
readily dewatered. Further, there is less impact on feed coloration; if

ferric is not utilized the resulting skimmings have virtually no impact
on feed color.
There are several disadvantages compared to ferric systems. For

example, modified acidulation systems are not as effective in removing
BOD and TKN from wastewater as ferric/polymer systems and, even
with cationic polymer addition, the operational pH window is tighter.
Further, sulfuric acid can cause immediate and severe chemical burns
on contact; extreme caution must be exercised for safe handling of
sulfuric acid, and in selection of containment and handling materials.
All company safety procedures regarding the use of extremely
corrosive substances must be followed at all times, including the use of
protective clothing/face gear, in order to prevent serious operator
injury.
Operationally, modified acidulation works very similar to ferric sulfate.

See Figure VI.4. Acid addition is controlled via a proportional pH
controller. Target pH is normally in the range of 4.5 – 5.0. Acid
addition can be either in the wet well, or in line. If introduced in the
wet well, process pumps should be specified in appropriate corrosion
resistant materials.
The cationic product – whether ferric sulfate or synthetic polymers, is

typically injected in line, prior to the pressurization vessel (full flow) or
introducing pressurized recycle (recycle pressurization). In recycle
pressurization system, this generally occurs at the start of the floc
tubes. Dosage will vary dramatically depending on the cationic product
utilized, from 75 ppm for ferric system to 20 ppm for synthetic
cationic polymers. Polymers are generally liquid products and are fed
from a day tank or automatic dilution system.
Anionic polymer is fed identically as in ferric systems; i.e., it is

introduced in a quiescent area after turbulence due to pumping and air
injection has dissipated. Dosage is substantially higher, generally in the
15 – 25 ppm range.
As described in Section V.2., the sulfuric acid/cationic product

combination causes formation of small floc, the anionic polymer
agglomerates these floc to sufficient size to entrap air frothing from
solution, allowing the solids to float to the tank surface for removal via
the skimmer device. Typical performance, and other operating
characteristics, are presented in Table VI.1.

VI.3.B.3 “Three Polymer” Systems
Three polymer systems began gaining widespread usage in the 1990’s.
Development of these systems was driven by the desire to get away
from pH-dependent systems, and enhance the ability to decant extra
moisture from skimmings. Advantages of the three polymer system
include a highly decantable skimmings, often achieving solid levels of
greater than 25%. Disadvantages include a reduced pollutant removal
efficiency, and operating cost, which can run more than 5 times the
cost of ferric or acidulation systems.

Figure VI.4
ACID/CATIONIC/ANIONIC
POLYMER SYSTEM SKIMMINGS (SPN)
TO ADDITIONAL
TREATMENT,
DAF UNIT
POTW, OR RE-USE
SLUDGE
TANK
Flocculation
Tube
ANIONIC TANK
& PUMP
RECYCLED
EFFLUENT
SLUDGE
P PUMP
PRESSURE
TANK
pH SAMPLE
PRESSURIZATION LINE
PUMP TO PROTEIN
RECOVERY OR
CATIONIC LAND APPLICATION
PUMP
AIR
ROTAMETER
ACID
TANK
AIR CATIONIC pH 4.20

COMPRESSOR TANK
pH PROBE &
CONTROLLER
OFFAL ROOM
WET WELL ACID
PUMP
The first step in a three polymer system is introduction of a coagulant.
The coagulant is a high viscosity, low molecular weight cationic
chemical. It is normally injected in-line immediately after the process
pumps (see Figure VI.5), however, some facilities inject into the pump
intake or, with adequate mixing, into the wet well or FEB. Coagulants
normally are purchased as a bulk liquid, although drums and totes are
available. Diaphragm, progressive cavity or gear pumps are utilized to
feed the coagulant into the wastewater line. The pumps should be
variable speed, either through a variable frequency drive (VFD) or DC
controller. A check valve should be placed on the pump supply line to
prevent wastewater from backing up into the bulk tank.
Dosage of coagulant typically ranges from 60 – 90 mg/l. A pump rate

curve should be prepared that compares dosage versus various capacity
settings on the VFD or DC controller. Pumping rates should be
checked at least weekly through measurement, through a pump draw
down tube or similar device.
Coagulant injection is followed by in-line injection of a high molecular

weight, medium charge cationic polymer. It is normally injected at the
influent end of the floc tube, prior to the introduction of pressurized
recycle into the floc tube.
Cationic polymer can be purchased either in a granular or liquid form.

Most facilities find the granular form more economical. Whether
purchased in a granular or liquid form, the polymer needs to be diluted
in a day tank prior to use. A target concentration is 0.25%. As with
the coagulant, a pump rate chart should be prepared and checked
weekly. A typical dose is in the range of 6 – 15 mg/l. Polymer feed
pumps are progressive cavity or gear. Variable speed is essential, either
through a VFD or DC controller. Automatic make-down polymer
systems are also available and often used.
The last polymer injected is a high negative charge, high molecular

weight anionic polyacrylamide. It is normally injected at the end of the
floc tube, or, if provided, in a mix box internal to the DAF unit itself.
The anionic polymer is also available in either granular or emulsion

form, with granular polymer generally more cost effective. Whether
purchased in granular or liquid form, the polymer needs to be diluted
in a day tank prior to use. A typical target concentration is 0.25%.
Again automated make-down systems are available.

Figure VI.5
THREE POLYMER SYSTEM
SKIMMINGS (SPN)
TO ADDITIONAL
TREATMENT,
DAF UNIT
POTW OR RE-USE
SLUDGE
TANK
Flocculation
Tube
ANIONIC
TANK & PUMP
RECYCLED
EFFLUENT
SLUDGE
P PUMP
PRESSURE
TANK
PRESSURIZATION
PUMP TO PROTEIN
RECOVERY OR
CATIONIC LAND APPLICATION
PUMP
AIR
ROTAMETER
COAGULANT
TANK
AIR CATIONIC
COMPRESSOR TANK
OFFAL ROOM
WET WELL
COAGULANT
PUMP
Polymer feed pumps are progressive cavity or gear. Variable speed is essential
through either a VFD or DC controller. As with the other chemicals, a pump
rate chart should be prepared and checked weekly. A typical dosage ranges 6
– 15 mg/l.
Typical performance parameters and other operational characteristics of a 3-

polymer system are presented in Table VI.1.
VI.3.B.4. DAF Chemical Addition System Summary and Table

The selection of a chemical addition system depends greatly upon a plant’s
needs. In addition to the three methods of DAF Chemical Addition described
above, there are numerous other variations and combinations employed
successfully throughout the poultry industry.
Table VI.1 compares the performance level and other operational

characteristics of the three chemical addition systems identified above.
TABLE VI.1
COMPARISON OF CHEMICAL ADDITION SYSTEMS
Parameter/ Ferric/ Acid/Cat/

Characteristic Polymer Anionic 3-Polymer
BOD 200 300 300 - 350

TSS 125 150 150
TKN 50 75 100
FOG < 50 < 50 < 50
TP 8 12 15
% Solids, 7 12 20
Raw Skimmings
% Solids 15 - 18 25 - 30 35
Decanted Skimmings
Chemical Cost Factor 1.0 1.2 3-5
There are numerous other chemical combinations utilized in the industry.

There is no single “right” chemical pretreatment process for poultry
pretreatment facilities. The selection of a chemical process should be
evaluated on an individual plant basis considering, among other things, the
desired level of performance, subsequent treatment units, cost of skimming
handling and ultimate skimmings disposition. What is “right” one year may

not be “right” the next year, so changes are often made to respond to external
changes impacting pretreatment operation.
VI.3.C. DAF Chemical Addition System – Instruments and Control

The most common type of control system used in DAF Chemical Addition
systems is a pH controller with proportional output. These units
manufactured by numerous companies, are routinely utilized to feed sulfuric
acid or ferric sulfate. The output signal from the pH controller speeds up, or
slows down, the chemical feed pump as appropriate.
The arrangement is normally a straight forward pH control loop. A pH

sensor is placed in the influent line to the DAF. As pH increases, the
controller will increase the chemical feed to the wet well. This increased feed
of ferric sulfate or sulfuric acid will depress wastewater pH. This lower pH is
then sensed by the controller, which in turn reduces the pump rate. Many
controllers today have the additional capability of recording the rate of change;
therefore, they can be programmed to prevent the “swing” that happens
utilizing solely proportion control. These programmable controllers can
normally hold pH in a 0.1 S.U. band, as compared to 0.5 S.U. band by simple
proportional control.
Some facilities utilizing three polymer systems utilize a flow controller to

maintain coagulant dose. In these systems, as flow increases, the coagulant
pump rate is increased; as flow decreases, the pump is slowed.
It should be noted that the most important control device for DAF chemical
addition is the human eye connected to the human brain. Chemical addition,
under widely varying loading and flow requirements, is as much art as science.
Operators should routinely observe DAF influent, the tank surface, and the
effluent and note floc appearance and effluent clarity under a wide variety of
circumstances. Over time, an operator will gain the experience and ability to
make chemical feed adjustments by eye, something no other control device
can provide.
VI.3.D DAF Chemical Addition System Analytical Testing

Analyses for a DAF system were previous provided in VI.2 and VI.3.
If a pH controller is utilized should be checked against buffer solutions and a

table top pH meter once per day.

Jar tests are often useful in screening the efficacy of various coagulants and
flocculants. Further, they can also be used as a process control test to adjust
chemical dosage rates on virtually a real-time basis. This may be particularly
useful at a facility that has wide variations in its influent content, such as
further processing and/or cooking facilities where spices, marinades, sauces,
batter, breading, oil, etc. are utilized. Suggested methods for jar testing stock
solution preparation, as well as protocol for a ferric sulfate/anionic polymer
system; an acid/cationic/anionic system, and a three polymer system are
provided in Figures VI.6 – VI.9, respectively. Please note that the suggested
dosages in these figures are merely that, suggestions. Actual plant dosages
may vary significantly from these suggestions.
VI.3.E. DAF Chemical Feed System Maintenance Checklist

As applicable to a given facility, the following inventory of spare parts should
be maintained for the system.
1 spare ferric sulfate, cationic polymer or coagulation dosage

pump
1 spare anionic polymer pump
1 set of manufacturer’s recommended spare parts for polymer
automatic make down system
2 spare pH probes
1 spare pH controller (on-line)
Follow manufacturer’s recommendations on pump

preventative maintenance and lubing. Clean pH probe daily
and calibrate daily.
VI.3.F. DAF Chemical Feed Systems Typical Calculation Examples
1. Jar testing has demonstrated that 250 ppm of ferric sulfate, and 4 ppm of
anionic polyacrylamide, effectively treats a poultry wastewater. If total plant
flow is 1.4 MGD, how many pounds/day of ferric sulfate and polymer are
required?
Ferric sulfate: 250 ppm x 1.4 MGD x 8.34 = 2919 lb/day
Polyacrylamide: 4 ppm x 1.4 MGD x 8.34 = 47 lb/day

Figure VI.6
JAR TESTING SET-UP PROCEDURES
Mixer
Shaft
Paddle RPM
Indicator
Paddle Speed
Control
1000 1200 ml 1000 1000 1000

ml beaker ml ml ml
Mixer
Paddle
1 2 3 4
REAGENT STOCK SOLUTION PREPARATION:

Dry Metal Salts, Coagulants: Prepare a 10 mg/ml (1%) solution. Then each ml of stock solution represents a 10 mg/l dose of the coagulant. Weigh out 10.00
grams of the coagulant on an analytical balance. Dissolve in 1 liter of tap water. Mix as necessary to dissolve.
Liquid Metal Salts, Coagulants: Prepare a 1% solution. Each ml of stock solution then represents a 10 ppm dose. With a graduate cyclinder, measure 10 ml
of neat coagulant. Add to 1 liter of tap water, mix to dissolve.
Dry Flocculants: Prepare a 1 ml/ml (0.1%) solution. Then, each ml of solution represents a 1 mg/l dose of the flocculant. Weigh out 1.00 grams of flocculant
and dissolve in 1 l of tap water. Vigorous mixing will be required to dissolve the flocculant.
Liquid Flocculants: Prepare a 0.1% solution. With a pipet, obtain 1 ml of neat flocculant solution. Dissolve in 1 liter of tap water. Then, each ml of solution
represents 1 ppm when added to 1 liter of sample water. Vigorous mixing may be required for dissolution.
Note: New solutions on all products should be prepared daily.
Sample Preparation: Obtain 3 – 5 gallons of screened wastewater. Mix to ensure sample is homogeneous, then fill each of the beakers to the 1 liter mark.

Figure VI.7
JAR TESTING PROCEDURE FOR FERRIC SULFATE/ANIONIC
POLYMER
Mixer
Shaft
Paddle
Paddle Speed RPM
Control Indicator
1000 1200 ml 1000 1000 1000

ml beaker ml ml ml
Mixer
Paddl
e
1 2 3 4
Procedure: 4. Add 4 ml of 0.1% stock solution of anionic polymer.

1. Pour 1000 ml of well mixed, screened wastewater into each of 5. Mix at 25 rpm for 60 seconds, followed by 5 rpm for 1- 2 minutes.
the four jars. 6. Observe floc formation, water clarity, etc., select best dosage range.
2. Add ferric sulfate over a range of 200 mg/l – 350 mg/l as shown If desired, repeat the testing in 10 mg/l increments between the two
below. best sample jars.
Ferric Sulfate 7. Once the ideal ferric sulfate dose has been established, optimization
of the anionic polymer dose can occur. Pour 1000 ml of screened
Jar ml 1% Stock Solution1 Jar Conc. wastewater into each of the 4 jars, add the optimum ferric sulfate
1 20 200 dose as determined above. Mix vigorously for 1 minute.
2 25 250 8. Add 2 ml, 3 ml, 4 ml and 5 ml of 0.1% anionic polymer stock
3 30 300 solution to jars 1, 2, 3 and 4 respectively. This yields a dose of 2
ppm, 3 ppm, 4 ppm and 5 ppm of anionic polymer in the 4 jars.
4 35 350
1Add via graduate cylinder 9. Mix at 25 rpm for 30 seconds, followed by 5 rpm for 1 minute.
10. Observe floc formation, clarity, etc. Select best dosage. Set
3. Mix vigorously for approximately 1 minute at a speed > 100 chemical feed rates accordingly.
rpm.

Figure VI.8
JAR TESTING PROCEDURE FOR
ACID/CATIONIC/ANIONIC POLYMER
Mixer
Shaft
Paddle RPM
Indicator
Paddle Speed
Control
1000 1200 ml 1000 1000 1000

ml beaker ml ml ml
Mixer
Paddle
1 2 3 4
Procedure:
1. Pour 1000 ml of well mixed, screened wastewater into each of the 5. Add 15 ml of 0.1% stock solution of anionic polymer.
four jars. 6. Mix at 25 rpm for 60 seconds, followed by 5 rpm for 1-2 minutes.
2. Add concentrated H2SO4 to reduce beaker pH to 4.3 S.U. Record 7. Observe floc formation, water clarity, etc.; select best dosage
volume of sulfuric acid required. range.
3. Add cationic polymer over a range of 20 mg/l – 50 mg/l as shown 8. Once the ideal cationic dose has been established, optimization of
below: Cationic Polymer the anionic polymer dose can occur. Pour 1000 ml of screened
wastewater into each of the 4 jars, add the optimum cationic dose
Jar ml 1% Stock Solution1 Jar Conc. 1Add via pipet
as determined above. Mix vigorously for 1 minute.
1 2 20 9. Add 5 ml, 10 ml, 15 ml and 20 ml of 0.1% anionic polymer stock
2 3 30 solution to jars 1, 2, 3 and 4 respectively. This yields a dose of 5
3 4 40 ppm, 10 ppm, 15 ppm and 20 ppm of anionic polymer in the 4
4 5 50 jars.
4. Mix vigorously for approximately 1 minute at a speed > 100 rpm. 10. Mix at 25 rpm for 30 seconds, followed by 5 rpm for 1 minute.
11. Observe floc formation, clarity, etc. Select best dosage. Set
WASTEWATER TREATMENT MANUAL chemical feed rates accordingly.
Figure VI.9
JAR TESTING PROCEDURE FOR
THREE POLYMER SYSTEMS
Mixer
Shaft
Paddle RPM
Indicator
Paddle Speed
Control
1000 1200 ml 1000 1000 1000

ml beaker ml ml ml
Mixer
Paddle
1 2 3 4
Procedure:
1. Pour 1000 ml of well mixed, screened wastewater into each of the four jars. 6. Add 6 ml, 7 ml, 8 ml and 9 ml of 0.1% cationic polymer stock
2. Add 6 ml, 7 ml, 8 ml and 9 ml of 1% coagulant solution to jars 1, 2, 3 and 4 solution to jars 1, 2, 3 and 4 respectively. This yields a dose of 6
respectively. This yields a dose of 60, 70, 80 and 90 ppm of coagulant dose. ppm, 7 ppm, 8 ppm and 9 ppm of cationic polymer in the 4 jars.
3. Mix vigorously for approximately 1 minute at a speed > 100 rpm, followed 7. Mix at 25 rpm for 60 seconds, followed by 5 rpm for 1-2 minutes.
by 25 rpm for 30 seconds. Turn off mixer. 8. Observe floc formation, clarity, etc. Select best dosage.
4. Observe floc formation. Select best concentration. 9. To determine the ideal anionic polymer dose, pour 1000 ml of
5. Once the ideal coagulant dose has been established, optimization of the screened wastewater into jars 1, 2, 3 and 4. Add optimized coagulant
dose and mix > 100 rpm for 1 minute. Add optimized cationic
cationic polymer dose can occur. Pour 1000 ml of screened wastewater
polymer dose, and mix > 100 rpm for 1 minute
into each of the 4 jars, add the optimum coagulant dose as determined
10. Add 5 ml, 10 ml, 15 ml and 20 ml of anionic 0.1% stock solution to
above. Mix vigorously for 1 minute. jars 1, 2, 3 and 4 respectively. This yields a dose of 5 ppm, 15 ppm
and 20 ppm.
11. Mix @ 25 rpm for 30 seconds, followed by 5 rpm for 1 minute.
12. Observe floc formation, floc structure and size, and water clarity.
Select best dosage and adjust chemical feed rates as necessary.

2. A polymer tank has a 5 foot diameter. Dry polymer is mixed in the tank at
1% by weight (i.e., 1 lb polymer/100 lb water). If the polymer tank level
drops by 2 feet in an hour, what is the pump flow rate? What is the polymer
dose in mg/l if wastewater flow is 900 GPM?
A. Pump flow rate
Tank Volume of 2’ = π (2.5)2 (2) = 39.2 ft3 = 294 gal.
Flow rate = 294 gal. x hour = 4.9 GPM

1 hour 60 minutes
B. Polymer dosage
Note 1% = 10,000 ppm
4.9 GPM x 10,000 ppm = 900 GPM x Dose (ppm)
Dose = 54 ppm

VII. ANAEROBIC LAGOONS AND WASTE GAS BURNER
SYSTEMS
This chapter will provide a review of each of the anaerobic lagoon and waste gas
burner systems that can be involved in a poultry wastewater pretreatment system.
Each will be described in terms of:

Please refer to Section IV.1 for a microbiological primer for anaerobic lagoons.
VII.1. Anaerobic Lagoon

The anaerobic lagoon serves two main treatment objectives. First, it
allows an initial carbonaceous BOD removal to reduce loading to the
activated sludge system. Second, it provides flow equalization, allowing
the activated sludge system to be fed a fairly constant flow and loading
each day. Older anaerobic lagoons typically were uncovered, allowing a
visible grease cap to form. Most newer lagoons have a cover. A
covered lagoon is shown schematically in the attached Figure VII.1.
An associated treatment component to the anaerobic lagoon is the gas

collection/flare off system. This system is addressed separately in
Section VII.2.
VII.1.A. Anaerobic Lagoon Design Information

The attached Table VII.1 summarizes anaerobic lagoon design criteria.
VII.1.B. Anaerobic Lagoon Operation Procedures

The anaerobic lagoon requires minimal daily operation attention, other
than pH/alkalinity control and analytical testing. It is essential
alkalinity remains above 200 mg/l in the lagoon, and pH remains in the
6.8 to 7.5 range. Adjustment of alkalinity and pH is accomplished by
varying the amount of sodium hydroxide, lime, magnesium hydroxide
or other basic chemical to the lagoon influent.
The most important operator function for the anaerobic lagoon is

obtaining and interpreting analytical results, particularly with respect to
system acidity. Failure to do so can result in a “sour” lagoon which, in

U.S. POULTRY & EGG ASSOCIATION VII.1
Figure VII.1
ANAEROBIC LAGOON
SCHEMATIC
To Gas Burner
System (if applicable)
MH
pH INDICATOR
pH 7.20
MH MH
ANAEROBIC LAGOON
Discharge Pipes
pH
Influent Pipe
Probe MH
MH
Influent
Flow
Probe
Effluent 700 GPM

FLOW INDICATOR
Lagoon Cover
Gas Collection System Piping

MH MH
Influent Manhole
Effluent Manhole

TABLE VII.1
Anaerobic Lagoon Sizing
and Performance
ITEM VALUE COMMENT

3
Design Load, lb BOD/day/1000 ft 10 - 20 Typical 10-20, excess for future
Retention Time, Days 5 - 20 Volume/Flow
Depth, Low Water Level,ft 10 - 20 Design Decision
Width/Length Ratio 0.46 Design Decision
Side Slope 2:1 Design Decision
Freeboard, ft 2 Design Decision
Total Depth, ft 15 - 25 Design Decision
Process Removal Efficiency,BOD,% 70 - 95 Design Estimate, Typical 85-90 %
Lagoon Effluent BOD,ppm 200 - 600 Typical Results
Lagoon Effluent TSS 100 - 500 Typical Results
Process Removal Efficiency, TKN, % < 5% Design Estimate
Lagoon Effluent TKN 100 - 200 Typical Results

U.S. POULTRY EGG ASSOCIATION VII.3
turn, will not achieve the design criteria, potentially leading to overall
system failure.
Three different tests are used to determine and evaluate system acidity.
The target levels for each of these are provided in the table below.
Parameter Influent Effluent
pH 7.5 to 8.0 6.8 to 7.5

Alkalinity 400 to 1,000 200 to 400
IA/PA ---- 0.5 – 1.0
Influent basic chemical feed rates should be adjusted to ensure

operating results remain within the above guidelines.
Further discussion and description of analytical testing is presented in

Section VII.1.E. below.
Many lagoons are equipped with a floating cover. To prevent cover

billowing, weight pipes are installed and fastened to the cover. The
cover is also equipped with a stormwater sump. Rainwater falling on
the cover is directed to this sump and pumped off the cover. To
prevent excessive rainwater accumulation on the cover, this system
should be operated after each storm event until the cover is essentially
free of stormwater.
VII.1.C. Anaerobic Lagoon Instrumentation & Control

The anaerobic lagoon is a simple unit to operate. Therefore, there are
only two noteworthy instrumentation and control features, described
below.
pH Sensor and Alarm – This unit measures and records effluent pH

from the anaerobic lagoon. Its purpose is to inform and record for the
operator any pH fluctuation rather than acting as a controller. An alarm
is often provided for this unit in the event lagoon pH varies outside
design limits.
Flow Sensor and Recorder – This unit measures and totals flow leaving
the anaerobic lagoon. Again, this unit serves no control function.
VII.1.D. Anaerobic Lagoon Operator Maintenance

The operator should keep the lagoon cover (if applicable) free of sticks,
branches and debris. Excessive stormwater should not be allowed to
accumulate on the cover. The operator should ensure the weight pipes

are on the rub sheets and reposition as necessary. Excessive billowing
of the cover should also be avoided. Vent or burn gas as necessary to
prevent large gas build-up.
Uncovered lagoons can require maintenance to maintain them. A

significant loading reduction can cause the grease cap to discolor,
emitting potentially offensive odors. Such instances can be mitigated by
blowing straw onto the surface of the lagoon until a natural cap
reforms. Influent and effluent manholes should be checked on a
regular basis to verify the absence of detrimental grease or solids build-
up. The pH meter should be calibrated weekly. The flow meter
calibration should be checked annually.
Manufacturer’s maintenance recommendations should be adhered to on

all component units.
VII.1.E. Anaerobic Lagoon Analytical Testing

The following testing protocol is suggested on anaerobic lagoon
effluents. Operators should follow sampling protocol determined
appropriate by the company. Given the extended retention time of
most lagoons, grab samples are acceptable. Samples should be collected
at the closest available manhole or open pipe on the discharge side of
the lagoon.
Parameter 1/Shift 1/Day 1/Week 1/Month
IA/PA X
BOD X
COD X
NH3 X
TKN X
FOG X
Alkalinity X
pH X
Trace Metals 1/yr.
Phosphorus X
The IA/PA (Intermediate Alkalinity/Partial Alkalinity) test is an

important operator tool for assessing the potential for “souring” in the
lagoon. Both the pH and alkalinity will ultimately show the effects of
souring. Unfortunately, by the time pH or alkalinity depression is
noted, it is often too late to prevent interference with the anaerobic
process. The IA/PA test is intended to give early warning to prevent
lagoon upset.

The test is performed as follows:
IA/PA Test Procedure
1. Measure 50 ml sample (anaerobic effluent) into 150 ml beaker.
2. Titrate to a pH of 5.75 with 0.02 N or 0.10 N H2SO4, whichever

normally titrant provides a volume of 10-50 ml. Record the volume
of titrant that was used.
3. Continue to titrate from a pH of 5.75 to a pH of 4.3 with 0.02 N or

0.10N H2SO4, whichever normality titrant provides a volume of
10-50 ml. Record the volume of titrant that was used.
Partial Alkalinity, mg/l (bicarbonate alkalinity)

= A X C X 50,000
ml sample x 1.25
Intermediate Alkalinity, mg/l (volatile acid alkalinity)

= B X C X 50,000
ml sample
Where: A = ml H2SO4 used to drop pH to 5.75

B = ml H2SO4 used to drop pH to 4.3
C = N(H2SO4)
The following can be used as a guideline when interpreting IA/PA

results. Note that individual facilities may vary from these guidelines.
By performing these analyses, an individual facility can create a
historical record that will provide an early warning of potential
anaerobic lagoon upsets.
IA/PA
Value Lagoon Status
< 0.5 Extremely mature, stable system. Maintain operation.

0.5 – 1.0 Normal operating range. Maintain operation.
1.0 – 1.5 Potential acid accumulation. Check operation, including
loading, alkalinity feed, inhibition.

> 1.5 System at or approaching failure. Reduce loading. Check
alkalinity, pH, inhibition.
When an anaerobic lagoon does fail, recovery time can often be

1 -2 hydraulic retention periods.
VII.1.F. Anaerobic Lagoon Troubleshooting Flow Sheet

A troubleshooting flow sheet is included in the attached Chart VII.1.
for the Anaerobic Lagoon.
VII.1.G. Anaerobic Lagoon Typical Mathematical Calculations

Example 1: A 20 MG anaerobic lagoon treats 1.4 MGD with an
influent BOD at 2500 mg/l. What is the organic loading on the lagoon?
Organic loading normally calculated as lb/day/1000 ft3
20 MG ÷ 7.48 gal. = 2,674,000 ft3

ft3
= 2674 (1000 ft3)
Organic loading = 1.4 x 2500 x 8.34 = 29,190 lb/BOD/day

2674 (1000 ft3)
= 10.9 lb BOD/day/1000 ft3
Example 2: What is the retention time of the lagoon in

Example 1?
Retention time = Volume = 20 mg = 14.3 days

Flow 1.4 MGD

Chart VII.1
ANAEROBIC LAGOON No
Is Influent pH>7.2
Decision Chart And Alkalinity >400 ppm
Increase Alkalinity
Feed
Yes
No
Is Influent pH <8.2 Decrease Alkalinity

And Alkalinity < 1000 ppm Feed
Yes
Is Influent COD No Check DAF Operation.

< 3000 ppm May Need
Chemical Treatment.
Yes
No
Are Gas Production
Is IA/PA Ratio No
Volumes Normal Check for Toxicity
Acceptable
Yes
Yes
No Check For Yes Initiate Chemical
Effluent pH, COD in Overloading Pretreatment at DAF
Proper Range
Yes
Continue Routine
Monitoring

VII.2. Waste Gas Burner System
NOTE: HYDROGEN SULFIDE GAS WILL BE PRESENT IN THE WASTE GAS HANDLING
SYSTEMS. THIS GAS IS POTENTIALLY FATAL IF INHALED. OPERATORS MUST
FOLLOW COMPANY GUIDELINES AND USE APPROPRIATE BREATHING APPARATUS
WHEN OPENING THE ANAEROBIC LAGOON SAMPLING PORTS OR WORKING ON
THE BURNER SYSTEM. NO OPEN FLAMES OR OTHER IGNITION SOURCES ARE
PERMITTED NEAR LAGOON INSPECTION PORTS OR THE GAS HANDLING SYSTEM.
This section is only applicable to poultry wastewater treatment facilities

that have an anaerobic lagoon with a synthetic cover. The anaerobic
lagoon system creates methane and carbon dioxide gas (and, to a lesser
extent, hydrogen sulfide and ammonia) which must be removed from
the system. This gas builds up pressure in the lagoon and causes the
synthetic cover to float or bubble. Gas collection pipes are typically
installed in the lagoon beneath the synthetic cover. When sufficient
gas has been collected beneath the cover, the waste gas burner system
is activated to remove excess gas.
VII.2.A. Waste Gas Burner System Design Information

Gas system design specifications are normally supplied by the burner
manufacturer. As a rule of thumb, each pound of COD removed by
the anaerobic lagoon will generate around 5 SCF of methane gas.
VII.2.B. Waste Gas Burner System Operation
NOTE: THE SYSTEM SHOULD ONLY BE OPERATED WHEN AN OPERATOR IS

PHYSICALLY PRESENT AT THE TREATMENT FACILITY.
A typical waste gas burner system is presented schematically in

Figure VII.2. The major components at the system are:
- sediment/water trap
- annubar flow meter
- flame trap
- blower
- pressure relief valve
- burner
- propane fuel storage and feed system

Figure VII.2
TYPICAL FLARE SYSTEM
GAS FLARE
PROPANE
SYSTEM
PRESSURE
RELIEF
VALVE
FLAME ARRESTOR
FLAME SEDIMENT
ARRESTOR TRAP
BLOWER GAS LINE

FROM LAGOON

The system is also normally equipped with a control panel to control
system operation. The operational sequence for the waste gas burner
system is as follows:
 Start-up of the burner system is an operator decision based on the

size of the “bubble” in the anaerobic lagoon cover.
 Prior to start-up, the drain valve on the sediment/water trap should

be opened to remove condensate from the system. Close the valve
after draining.
 At the control panel, turn the pilot ignition system on. This will
automatically direct the auxiliary propane fuel to the burner and
ignite it. The purpose of this step is to bring the burner up to
operating temperature.
 After several minutes, the blower will automatically be started. The

blower “sucks” gas out of the lagoon cover and blows the gas to
the burner. The methane gas is incinerated in the burner.
 Observe the bubble during operation to ensure no water is drawn

into the burner.
 When the bubble has been reduced sufficiently, turn the system off
at the control panel.
 OPERATION SHOULD ONLY OCCUR WHEN THE FACILITY IS

MANNED.
 Operators should stay clear of the burner when in operation.
 No open flames are permitted where gas may be present. Wear

appropriate safety equipment as required by the company.
VII.2.C. Waste Gas Burner System Instrumentation & Control

Waste gas burner systems are normally equipped with the following
instrumentation/control equipment:
 Gas Flow Meter - This device records and totals the quantity of gas
drawn from the anaerobic lagoon to the waste gas system.

 Pressure Gauge - This unit measures gas pressure under the lagoon
cover. The operator can use this gauge to help determine when the
system should be operated.
 Flame Failure Alarm - This unit detects the lack of a flame any time
the unit is in the operating mode. Further, this unit detects if the
pilot light ignition is not realized within an operator adjustable time
limit on system start-up.
VII.2.D. Waste Gas Burner System Analytical Testing

The following tasks are suggested:
 Total gas flow rate should be recorded each day the system is
operated. Approximately 5 cubic feet of gas should be produced
per pound of COD removal by the anaerobic lagoon. Actual values
should be calculated and compared to historical performance.
Lower gas production rates often indicate a “sour” lagoon and
indicate the need for additional alkalinity.
 Annually, a sample of gas should be drawn for gas analysis. If

operational problems in the lagoon are occurring, this frequency
should be increased. This sample should be analyzed for:
- Methane
- Carbon dioxide
- Total sulfide content
VII.2.E. Waste Gas Burner System Operator Maintenance
Operator maintenance on the waste gas burner system is primarily
limited to inspection and replacement of component parts. The
recommended frequency for inspection is provided in Table VII.2.
More involved maintenance on the system should be performed by the

manufacturer or gas handling system provider.
VII.2.F. Waste Gas Burner System Troubleshooting Flow Sheet

A troubleshooting flow sheet is included as Chart VII.2 for the waste
gas burner system.

TABLE VII.2
Burner System Maintenance
Inspection Maintenance
Component Interval Action Required
Pilot Flame 1/month Inspect while burning to confirm optimum.

Adjust air intake as needed.
Ignition Electrode 1/month Check electrode function. Refer to manual
if not operating properly
Pilot Gas Line Filter 1/month Record Differential Pressure and replace
prior to restriction of gas supply
Solenoid Valve 1/month Ensure valve is opening and closing
(Pilot gas shut-off) properly
Propane Storage 1/month Ensure adequate propane inventory
Tank
Trap Auto Solenoid 1/month Ensure valve is opening and closing
properly
Pilot Nozzle 1/ 6 months Inspect for corrosion deterioration.
Replace when needed.
Wiring Connections 1/ 6 months Replace wire/connectors if damaged
for Electrode
Pressure Switch 1/ 6 months Clean the switch then rotate vent drain plug
Dwyer 1950-20 1 turn CW, return to standard position
Ignition Electrode 1/ year Inspect for corrosion/temperature

U.S. POULTRY EGG ASSOCIATION VII.13
Chart VII.2
FLARE SYSTEM
Decision Chart
Sediment Trap No
Drain Trap
Drained
Yes
No
Clear Restriction or No Pilot Gas Available Pilot Flame
Open Supply Valve Unrestricted Ignite?
Yes
Electrical Components No
Ignition Electrode Yes
Spark Plug or Loose, Damaged Dirty?
Transformer Failure or Frayed? Shut Down
Yes Blower No
Yes Yes Check
Activate?
Clean Electrode Blower Motor
Repair or Replace Tighten, Repair or
Components Replace Components Yes
No
Flame Ignite?
Shut Down and Follow
Manufacturers Guidance
Yes
Continue Routine
Monitoring

VIII. UNIT OPERATIONS – ACTIVATED SLUDGE
This chapter will provide a review of activated sludge systems as they are utilized in a
poultry wastewater full treatment system.
Activated sludge systems are described in terms of

VIII.1. Activated Sludge Systems

The most common form of biological treatment for poultry wastewater
facilities discharging directly to a receiving stream is activated sludge.
This is an aerobic treatment process. Its purpose is two-fold. First, it
completes the required BOD removal initiated by the pretreatment
system. Second and equally critical, is the removal of ammonia, and
organic nitrogen. Many systems are also capable of accomplishing
denitrification. Process microbiology for each of these different
processes occurring within the activated sludge system (i.e.,
carbonaceous BOD removal, nitrification and denitrification) was
described previously in Sections IV.2-IV.4.
VIII.1.A. Activated Sludge System Design Information

Typical design information for activated sludge systems in the poultry
industry are presented in Table VIII.1.
VIII.1.B. Activated Sludge System Operation

The activated sludge system consists of several component parts. The
major components are as follows:
- Aeration Basin
- Aeration Equipment
- Clarifier
- RAS System
- Wasting System
- Alkalinity Control System

U.S. POULTRY & EGG ASSOCIATION VIII.1
Table VIII.1
Typical Design Operating Values
Item
BOD Removal Eff., % 95 +
TKN Removal Eff., % 95 +
O2 Requirement, lbs/lb BOD 1.25 – 1.5
TKN O2 Requirement, lbs/lb TKN 4.6
Temperature, C Ambient
Basin Depth, ft. 10 – 20
Alpha (for use in transfer calcs.) 0.7
Beta (for use in transfer calcs.) 0.95
Theta (for use in transfer calcs.) 1.024
Operating DO, mg/l (with no denitrification) 1–3
Aeration Basin Detention Time, days 1 – 4 days
MLSS, ppm 2000 – 6000
Food/Microorganism Ratio 0.03 – 0.10
Aeration Basin Loading, lb BOD/1000 ft3/day 10 - 20
Clarifier Surface Loading Rate (GPD/ft2) 100 – 200
Sludge Age, days 20 - 50
RAS Capacity, % of Influent Flow 200
Mixing Input, Minimum (HP/1000 ft3) 0.5

These components are shown schematically in Figure VIII.1. Note that
cyclic variations of activated sludge such as Sequencing Batch Reactors
(SBR’s) utilize the same vessel and tank for aeration and clarification, and
require no RAS pumps.
Typical operation for each are reviewed below.
VIII.1.B.1 Aeration Basin:

Aeration basins are the portion of activated sludge systems where biomass
and wastewater are mixed together in the presence of oxygen, allowing the
biomass to consume the pollutants in the wastewater. Although the term
“basin” is utilized herein, note that basin in this context can apply to a
steel or concrete tank, above or in-ground, as well as earthen basins.
Typically, a minimum one day of hydraulic retention time is provided in

the aeration basin, with two to four days hydraulic retention fairly
common. Given that a typical poultry plant uses 1.5 to 2.0 MGD, basin
volumes are fairly large, from 2 – 8 MG being common.
The purpose of the aeration basin, regardless of its material of

construction or its size, is to provide the physical structure for
development and maintenance of bacterial population to aerobically
consume pollutants present in the wastewater. Inputs to an aeration
basin, thus, include the wastewater, active biomass return from the
clarifiers, and oxygen, normally in the form of air. Sufficient mixing,
normally through the aeration system, is provided to keep the biomass
suspended and in contact with the food source present in the wastewater.
Various flow schemes are employed throughout the industry to bring

these three inputs together in the aeration basin. Most activated sludge
systems in the industry are either plug flow, complete mix, step feed or
SBR. The flow arrangements for the first three of these systems are
provided in Figure VIII.2. The operation steps of an SBR are provided
in Figure VIII.3. Regardless of the flow scheme selected at a particular
plant to bring together the three inputs, there is only one desired output:
biomass or mixed liquor. The effluent from the aeration basin should
consist of biomass/water mixture such that when the biomass is settled
from the water in the clarifier, pollutants of concern (i.e., BOD, TSS,
FOG, NH3) have been consumed by the biomass and removed from the
water.

Figure VIII.1
ACTIVATED SLUDGE
BULK
SCHEMATIC ALKALINITY
STORAGE
INFLUENT
WASTEWATER
ALKALINITY
MAKEDOWN
SYSTEM
AERATION BASIN
BLOWERS
AIR HEADER DIFFUSERS
CENTERWELL SKIMMER
EFFLUENT TO
DISINFECTION
RETURN ACTIVATED SLUDGE (RAS)

CLARIFIER
WAS TO SLUDGE
PROCESSING
RAS SLUDGE
RAS WET RAKE
PUMPS BLANKET
WELL ARM

Figure VIII.2
COMMON ACTIVATED
SLUDGE CONFIGURATIONS
Influent
Aeration MLSS
Basin Clarifier
RAS WAS
Complete Mix Activated Sludge (CMAS)
Influent
Aeration
Basin MLSS
Clarifier
RAS WAS
Plug Flow or Conventional Activated Sludge
Influent
Aeration
Basin MLSS
Clarifier
RAS WAS
Step Feed Activated Sludge

U.S. POULTRY & EGG ASSOCIATION VIII. - 5
Figure VIII.3
PHASES OF AN SBR SYSTEM
INFLUENT
FILL/REACT PHASE: Influent

MIXER enteres the reactor. Normally,
aeration and mixing are both
provided.
DIFFUSERS
MIXER
REACT PHASE: Influent flow is

shut off. Aeration may be cycled
during this phase for denitrification.
MIXER
SETTLE PHASE: Aeration and
mixing are halted, allowing the
bacteria to settle from the water.
MIXER
DECANT PHASE: The decant line

is opened, allowing the treated water
to discharge.
IDLE PHASE: Sludge wasting will

occur on decanted solids as needed
MIXER
during this phase.

The main aeration basin operating variables – dissolved oxygen
concentration and mixed liquor suspended solids concentration, basin
pH – actually depend on other components of the activated sludge
system (e.g., aeration equipment, RAS pumps, alkalinity feed system).
As such, these operational characteristics are reviewed in subsequent
section.
Temperature is another important variable, albeit one over which the

operator has limited control. The biomass that develop in a poultry
wastewater activated sludge systems will increase activity as
temperature increase throughout the range normally encountered in the
basin, from 35F to 100F. An operator needs to be aware of the
impact of this varying temperature on the system performance. The
more common impacts are as follows:
1. Freezing ambient temperatures can cause icing on surface

aerators. Further, a “cycling” aerator (one that is turned on and
off throughout the day) is more susceptible to icing. Ice build
up on the aerator feed wires can pull the wires away from the
feed box. Severe ice build up on the aerator itself can cause an
imbalance, damage the aerator and/or causing it to flip over.
If possible, minimize aerator cycling during extremely cold

temperatures, or schedule cycling for warmer daylight hours.
Also, recognize that due to greater oxygen solubility in cold
water, it may be possible to turn some aerators off without
impacting process performance.
2. Because cold temperatures slow biomass activity, a larger

biomass population is desirable during cold months. Many
activated sludge plants maintain a higher mixed liquor (i.e.,
operate at a longer sludge age) during the winter months. The
rationale is that since each individual organism is consuming
less, a greater total number of organisms are required to
maintain the same level of treatment. Increases of 50% for the
targeted winter mixed liquor concentration are not uncommon.
3. Nitrification is particularly prone to failure during cold snaps,

even if a higher mixed liquor is maintained. Minimize aeration
to the extent practical, taking advantage of the greater oxygen
solubility in cold water. In some locations, reliance on surface
aeration alone for nitrification is problematic. Repeated loss of
nitrification during cold weather is an indication that at least a

portion of the aeration equipment should come from diffused
air. Diffused air offers at least two advantages in cold weather
situations. First, as the blower compresses the air; air
temperature is increased; therefore heat is actually supplied to
the basin via the air flow. Second, there is minimal evaporative
cooling occurring, in contrast with a surface aerator splashing
droplets of water into the air.
4. Like most living things, activated sludge is stressed by rapid

changes in their environment. Extreme temperature swings
should be avoided if at all possible, and the operator should
recognize the process disruptiveness of such swings.
VIII.B.1.2. Aeration Equipment

The role of the aeration equipment is to supply oxygen the biomass
requires to consume the pollutants present in wastewater. As was
reviewed in detail in Chapter IV, the consumption of pollutants in
activated sludge can be described in the following equations:
Carbonaceous BOD Removal

BOD + O2  CO2 +H2O + additional biomass
Nitrification
TKN + O2  NO3 + H+ + additional biomass
The oxygen, or O2, represented in these equations is supplied by the

aeration equipment.
The two primary means to provide aeration in the industry are via
surface aerators, or via a blower/diffused air system. Aerators
normally have a lower capital cost, and have the advantage of
portability. Blower/diffuser systems are usually more capital intensive,
but generally are more efficient. Therefore blower operating costs are
less; in some applications this can be a significant savings.
Other types of aeration systems (e.g., jet aeration and brushes) are
utilized as well in the industry at a lower frequency.
Regardless of the type of aeration system, its intent is to deliver oxygen

into the aeration basin for biomass utilization in the consumption of
pollutants. Maintaining a proper oxygen level is crucial to the success
of activated sludge. Generally speaking, it is desirable to maintain a
dissolved oxygen (DO) level of 1.5 – 2.0 mg/l in a significant portion

of the aeration basin (or, in the case of SBR’s, during the aeration
cycle). Continually low DO environments can contribute to
development of filamentous bacteria, which are extremely difficult to
settle from the water phase in the clarifier. In low DO environments,
filamentous bacteria – with long, spiny tentacles – have a competitive
advantage in finding oxygen in the wastewater due to their greater
surface area. However, these same tentacles prevent filamentous
bacteria from settling rapidly in a final clarifier which can ultimately
cause biomass loss over the clarifier wier, and process failure. By
maintaining a minimum DO of 1.5 to 2.0 mg/l in a significant portion
of the aeration basin, floc forming bacteria rather than filamentous
bacteria, have the competitive advantage resulting in a better-settling
biomass.
On the other end of the spectrum, maintaining a DO much above this

range provides little if anything in terms of process performance or
biomass quality. Therefore, operating at significantly higher DO’s (3 or
above) should be avoided to minimize electrical costs.
As activated sludge systems have progressed and waste treatment

technology improved, it has become increasingly common to
incorporate denitrification in the process. As was detailed in Section
IV.4, denitrification is the process whereby bacteria utilize the
elemental oxygen in the nitrate molecule as their oxygen source.
Normally, bacteria must be “forced” to utilize this source of oxygen;
denitrification will not occur where there are significant levels of DO
present. Consequently, in such systems it is necessary to operate a
portion of the aeration basin (or a cycle in a SBR type system) with
essentially no DO. This section of the basin (or cycle) is called the
anoxic zone (or cycle). Since no air is supplied in these sections, it is
often necessary to supply a mixing device to keep the biomass in
suspension as it flows through this section of the basin.
VIII.B.1.3. Clarification
Bacterial mass consumes food, reducing pollutant levels such as BOD
and ammonia and increasing the population of biomass. In order to
separate out the suspended biomass (mixed liquor suspended solids or
MLSS), the process water is clarified. The clarifier is a quiescent tank
that promotes the settling of solids and the overflow of clearwater
effluent.

As with aeration basins, clarifiers come in several different
configurations. The most common in use in the industry is center-
feed, peripheral overflow but other arrangements, such as periphery
feed, center overflow, or a rectangular tank, are not uncommon.
Regardless of the tank configuration, the objective of the clarifier is to

“still” the mixed liquor, such that the biomass solids settle to the tank
bottom, and the clarified effluent can overflow the wiers.
Mixed liquor is introduced into the clarifier normally behind a baffle

wall or skirt, to dissipate energy from the flow of the mixed liquor.
Indeed, many facilities flow by gravity to the clarifier, or utilize slow
turning screw lift pumps to feed the clarifiers, to avoid excessive
biomass “sheer” that would hinder settling.
Once this inlet velocity has been dissipated, a proper settling mixed
liquor will begin “floc” formation. Particle-particle contact of biomass
occurs; floc-forming bacteria excrete a natural exocellular polymer that
allows formation of larger and larger floc. These larger floc settle to
the tank bottom. If necessary, cationic polymers are added to enhance
this process, however, the use of polymer should not be a continual
practice. Over time, of course, a sludge blanket forms in the clarifier
by the accumulated, settled bacteria. The sludge blanket level is
increased, or decreased, by increasing or decreasing the rate of flow on
the return activated sludge pumps.
The clarified effluent should have very low levels of remaining

pollutants. Typically, it will have less than 30 mg/l of BOD and TSS,
and less than 5 mg/l of ammonia and oil and grease.
As was mentioned in the previous section, the presence of filamentous

bacteria can impede proper settling in the clarifier. In the short term,
use of synthetic cationic polymers is usually effective as a settling aid
for filamentous activated sludge (often called “bulked sludge”).
However, it is relatively expensive to continually apply this polymer.
Consequently, the facility should search for the root cause that favors
the formation of filamentous bacteria in the system. As was previously
pointed out, inadequate DO is a common cause. Deficiencies of other
nutrients, such as phosphorus, can similarly lead to a filamentous
bacteria predominating in activated sludge systems. Other potential
causes include wide pH or temperature swings, excessive slug loading,
or the presence of toxic or inhibitory substances.

Other interference can cause settling problems as well. Excessive
levels of surfactants, soaps, etc. can result in poor settling even in a
sludge that does not appear filamentous. Many poultry facilities have
glycol chillers. Spilling or leaking of glycol can have a surfactant-like
effect on sludge settling.
Settled sludge in a clarifier is collected via a scraper or vacuum

mechanisms traversing across the bottom surface of the tank. In a
circular clarifier, a drive, mounted in the center of the clarifier, sweeps
a rake arm around at a very slow rate – on the order of a revolution per
hour. In a rectangular clarifier, a submerged series of paddles on a
chain and sprocket drive pulls the settled sludge back to a hopper;
again it travels slowly so as not to cause turbulence that would re-
suspend the settled solids.
Most clarifiers are also equipped with a scum removal system. This
system is designed to remove floating bacterial scum or film, oil film,
and other floatable trash which invariably makes its way to the clarifier
surface. Scum removal is normally accomplished by a skimmer arm
skimming the clarifier surface, directing floatable materials to a scum
box. Materials collected in a scum box should be removed from the
system via landfilling or other acceptable means. Care should be
exercised to ensure no object is placed in the clarifier that will interfere
with the motion of either the sludge rake or the skimmer mechanism.
Most clarifiers are equipped with a shear pin that will break first if an
obstruction is encountered, however, replacing the shear pin can
require a minimum of several hours or more during which time the
clarifier is out of service.
Similarly, special attention should be given to the skimmer arm in cold

weather conditions. Ice formation on the clarifier surface can bind the
skimmer arm as readily as a piece of angle iron. Break up any large ice
floes that form.
VIII.1.B.4. Return Activated Sludge System

The return of settled activated sludge to the aeration basin is the key to
activated sludge systems (see Section IV.2.). The ability to retain
bacterial solids for many days allows development of a more diverse
microbial population. Nitrifiers, for example, are slower growing
bacteria. Without the ability to age the microbial population via return
activated sludge, or RAS, they would not develop to the point of
allowing significant ammonia removal in the system. Higher life forms
such as protozoa, which provide scavenging of fine floc, also would

not develop without the ability to return sludge to the aeration basin.
In essence, the RAS continually reseeds the aeration basin, ensuring
sufficient bacterial population, and the proper bacterial population, to
sustain the process.
As described in the previous section, settled activated sludge in a

clarifier is normally moved to a center well via a rake arm scraper.
From the well, it normally flows – by gravity or vacuum – to the return
activated sludge pump well. The rate of flow is normally set by raising
or lowering the level of the “draw down” tube. If more recycle is
desired, a hand wheel (or similar device) on the draw down tube is
lowered, allowing the hydraulic head of the clarifier water level to push
more RAS to the RAS wet well. When lower flow rates are desired, the
hand wheel is turned to raise the draw down tube, decreasing the RAS
rate.
Recessed impeller centrifugal pumps, or screw lift pumps, are most

commonly used for RAS pumps. (Note, however, in systems where
mixed liquor is pumped to the clarifier, no pumps at all are utilized, just
gravity flow.) Normally, they are fixed rate pumps operated off float
controls. If the draw down tube is lowered, liquid level in the RAS wet
well rises, to the point an additional pump is activated to maintain the
level.
The rate of recycle return is an important operational variable that is

set by the operator. On the one hand, it is desirable to thicken the
sludge in the clarifier. Normally sludge wasting will occur from this
line, so the thicker the sludge the fewer gallons of wasted sludge the
facility has to process. On the other hand if one leaves sludge in the
clarifier too long in an attempt to thicken it, denitrification will occur in
the clarifier. As was shown in Section IV.4, a by-product of
denitrification is nitrogen gas. Sufficient nitrogen gas can be produced
to float the entire sludge blanket to the tank surface. Few sights in
poultry wastewater treatment are more disheartening than seeing the
sludge blanket on the clarifier surface. This situation can easily lead to
permit non-compliance.
Beyond the thickening versus denitrification balance, one has to ensure

as well that active biomass is being returned to aeration biomass to
sustain the process. In practice, facilities operate in a range of 40% to
140% recycle, with the majority operating in the range of 60% to 100%
recycle. In other words, for every 1 MGD of flow, the RAS rate is 0.4

MGD to 1.4 MGD, with most facilities being in the somewhat tighter
window of 0.6 MGD to 1.0 MGD.
Note that there are times when higher rates are desirable, at least in the
short-term. For example, if a clarifier is beginning to experience
denitrification – as evidenced by clumps of sludge blanket popping to
the tank surface – an immediate increase in RAS return rates to the
maximum pump capacity is clearly advisable.
VIII.1.B.5. Sludge Wasting

The conversion of pollutants into bacterial mass eventually results in
more bacteria being present than necessary. Left unchecked, bacterial
population would increase to the point where a number of undesirable
alternatives could occur. Two examples of this are:
1. Bacterial population could increase to the point where the

additional oxygen demand to simply support the additional
bacteria exceeds the oxygen supplied by aeration system,
resulting in septicity, massive solids loss and system failure.
2. Unchecked biomass buildup could result in insufficient food

(pollutant loss) to support all the bacteria, resulting in biomass
die-off, massive solids loss from the clarifier and system failure.
In order to prevent these and many other undesirable consequences of

unchecked biomass accumulation, a portion of the settled bacteria
from the clarifier is removed from the system. This process is called
"wasting." Biomass so removed is said to be "wasted."
Wasting is accomplished by directing excess solids out of the system to

solids handling system. Normally, this is accomplished by taking a side
stream of the RAS, and directing it to the holding tank or lagoon for
waste activated sludge (WAS).
The key to controlling an activated sludge system is controlling the

inventory and age of bacterial solids or, in other words, controlling
mixed liquor. Again, this is accomplished through wasting.
There are two common methods of determining how much biomass

should be wasted. The first of these is the mean cell residence time
(MCRT) or sludge age. Sludge age is defined as:

Sludge age = Total amount of biomass system
Total amount of biomass removed daily
from system
In other words, sludge age, or MCRT, is the length of time an average

bacterial cell remains in the system. By making some assumptions (see
Section IV.2) this equation can be mathematically reduced to:

FW  RSS
Where
Sludge age = MCRT, average biomass age in days
VAB = Volume, Aeration Basin, in MG
MLSS = Mixed liquor suspended solids level in the
aeration basin (mg/l)
FW = Daily Wasting Rate (MG)
RSS = The Return Activated Solids, suspended solids of
the clarifier return sludge
Aeration basin volume is a fixed, known number. Both MLSS and RSS
can be determined analytically. To solve this equation to determine
how much should be wasted per day, one picks a desired sludge age
(typically 25-50 days). The equation then can be rearranged as follows
using a 30-day sludge age:
FW = VAB  MLSS
30  RSS
FW (in MGD) = VAB  MLSS

30  RSS
Consequently, the amount of material to be wasted each day using the
sludge age method can be determined merely by determining MLSS
and RSS. For example, assume analytical tests indicate MLSS = 3000
mg/l and RSS = 6000 mg/l, for a plant with a 4 MG aeration basin.
FW= VAB (3000/6000) = .0166 VAB mg/l

30
= .066 MG = 66,000 gallons
With this information, an operator can activate the sludge wasting

pumps or open the wasting valve until the calculated gallons have been

wasted. Wasting pumps should be provided with an hour meter or
flow meter. If wasting is done via gravity flow, a flume or similar
device should be utilized to measure the volume wasted.
Waste sludge volumes are provided in Table VIII.2 for typically

employed sludge ages and MLSS/RAS ratios.
The second method of determining the amount of sludge to be wasted

is by using the Food to Mass, or F/M ratio. The F/M ratio is
determined as follows:
F/M = Pollutant load, lb/day

Total biomass in system
This can be mathematically defined as:
F/M = BOD  F
MLSS  VAB
Where
F/M = Food to Mass ratio
BOD = Influent BOD to Aeration Basin, mg/l
F = Influent flow to Aeration Basin, MGD
Other terms = As previously defined
For a typical system with an F/M of 0.04 as a typical value, the desired
MLSS can be determined as follows:
MLSS = (BOD  F) x VAB

(0.04)
Assuming BOD equals roughly 60% of COD, the equation becomes:
MLSS = 0.6/0.04 (COD  F)  VAB
Daily flow is known from the system influent flow meter. COD can
be determined on-site analytically. Consequently, a desired MLSS value
can be calculated. If the actual MLSS is lower than the desired MLSS,
no wasting is necessary. If actual MLSS is greater than desired MLSS,
then wasting is necessary.

Table VIII.2
Sludge Wasting Volumes
(Per MG of Basin Volume)
Sludge Age, Days

25 30 35 40 45 50 55 60
MLSS/RAS
0.400 16000 13333 11428 10000 8889 8000 7272 6666
0.425 17000 14167 12143 10625 9444 8500 7727 7083
0.450 18000 15000 12857 11250 10000 9000 8181 7500
0.475 19000 15833 13571 11875 10555 9500 8636 7916
0.500 20000 16667 14286 12500 11111 10000 9091 8333
0.525 21000 17500 15000 13125 11667 10500 9545 8750
0.550 22000 18333 15714 13750 12222 11000 10000 9166
0.575 23000 19166 16428 14375 12778 11500 10454 9583
0.600 24000 20000 17143 15000 13333 12000 10909 10000
0.625 25000 20833 17857 15625 13889 12500 11363 10416
0.650 26000 21666 18571 16250 14444 13000 11818 10833
0.675 27000 22500 19285 16875 15000 13500 12272 11250
0.700 28000 23333 20000 17500 15555 14000 12727 11666
0.725 29000 24166 20714 18125 16111 14500 13181 12083
0.750 30000 25000 21428 18750 16667 15000 13636 12500
0.775 31000 25833 22143 19375 17222 15500 14090 12916
0.800 32000 26666 22857 20000 17778 16000 14545 13333
0.825 33000 27500 23571 20625 18333 16500 14999 13749
0.850 34000 28333 24285 21250 18889 17000 15454 14166
0.875 35000 29166 25000 21875 19444 17500 15908 14583
0.900 36000 30000 25714 22500 20000 18000 16363 14999
Example: Aeration Basin Volume = 4.5 MG, and desired sludge age = 45 days,
MLSS = 3000 mg/l, and RAS = 5000 MG/l.
Then MLSS/RSS = 3000/5000 = 0.6

Enter charter in left side at MLSS/RAS ratio of 0.6. Proceed right
across the chart until the 45 day column. This yields 13,333 gallons,
which is the volume to be wasted daily per MG of aeration basin
volume. Therefore, total wasting is as follows:
FW = 13,333 gallons/MG of aeration basin X 4.5 MG Aeration Basin

FW = 59,998 gallons

An example will best illustrate how sludge wasting volume is
determined from F/M .
Assume
Actual MLSS = 3000 mg/l,
RSS = 6000 mg/l
Influent Flow = 1.0 MGD,
COD = 470 mg/l
Volume Aeration Basin = VAB = 2.4 MG
Desired MLSS = (6.2)(470)(1) = 2914 mg/l
Excess MLSS = 3000 mg/l - 2914 mg/l = 86 mg/l

Excess lbs MLSS = 86 mg/l  VAB  8.34 = 1721 lbs
It is therefore necessary to waste 1721 lbs of bacterial solids.

Mathematically, this reduces to (all terms as previously defined):
1721 lbs = Fw  RSS  8.34
FW = 1721 lb
6000  8.34
FW (in MGD) = 0.0344 MGD = 34,400 gallons
As before, the operator obtains an initial sludge wasting flow or hour

meter reading and then activates the sludge wasting pumps, or sets the
wasting valve appropriately. When the flow totalizer indicates
34,000 gallons have been wasted, the pumps are turned off (or valve
closed) and wasting is halted.
Regardless of the method used to determine proper sludge wasting

volumes, there are a few general rules regarding wasting an operator
should adhere to in order to prevent a sudden shift in the bacterial
population, causing an unsettled condition.
1. Wasting must be a regular, consistent occurrence. Ideally, wasting

would occur 7 days per week. From a staffing/manpower
perspective, this is not always possible. As a minimum, wasting
determinations should be made 5 days/week. Further, waste over a
several hour period in a given day; do not waste as fast as possible.
2. Use three-day rolling average for MLSS and RAS values to take out
the day-to-day variations in analytical results.

3. Never waste a volume of more than 15% of influent flow without
engineering consultation.
To close the discussion, remember one wants to undertake only

gradual changes in sludge age or mixed liquor concentrations. The
above suggestions are intended to help insure that. Bacterial
populations do not like rapid change. Forcing rapid changes on sludge
age or mixed liquor concentration often yields unintended and
undesirable consequences.
There are a number of visual observations an operator can make that

help determine the health and viability of an activated sludge system.
Table VIII.3 lists those visual observations and what they are telling
an operator about a system.
VIII.1.B.6 Alkalinity Control System

Alkalinity control is essential to activated sludge treatment in the
poultry processing industry. As discussed in Chapter IV.3, the
nitrification process (the conversion of organic and ammonia nitrogen
to nitrate) produces acid. If this acid is allowed to accumulate in the
system, un-neutralized, aeration basin pH will be depressed to the
point the nitrifying bacteria are inhibited, and nitrification will cease.
This, in turn, will almost certainly result in a permit limit violation.
The primary purpose of alkalinity control systems in poultry activated

sludge systems, then, is to neutralize the acid produced by nitrification.
Sufficient alkalinity must be present to absorb the acid produced by
nitrification, and still maintain aeration basin pH at 6.8 S.U. or above.
For every pound of nitrogen a plant removes, 7.14 lb of alkalinity must
be supplied to neutralize the acid produced by nitrification.
A variety of chemicals are employed in the industry to supply this

alkalinity – in a variety of physical states. Table VIII.4 below lists
those chemicals and their respective states.
The powder and granular products typically are shipped in bulk by either
truck load quantities or in 1000 lb “supersacks”. Smaller 50 lb and 100 lb
bags are also available. Bulk shipments are typically stored in a hopper.
Vibration equipment is installed on bulk storage tanks to minimize
product bridging. Typically an auger is utilized to convey the product to
a slurry tank, where it is mixed (using agitation) with water. Small-
bagged shipments are typically added directly to the slurry tank. In either
case, the slurry is metered out of the tank into the waste stream.

TABLE VIII.3
ACTIVATED SLUDGE VISUAL OBSERVATIONS
OBSERVATION POTENTIAL CAUSES
Basin has "earthy" odor, rich Indicative of properly operated and loaded system
brown color
Basin has "sour mash" odor, Oxygen deficient (septic). Reduce loading or increase
gray, black color aeration
Excessive light brown to Young sludge age (high F/M). Common on start-up
white foam. May overflow basin. and in recovering systems, or slug loadings
Heavy brown to orange foam 1.Old sludge age (low F/M). Increase wasting or
loading.
2. Excessive oil and grease. Review DAF operations.
Ensure no anaerobic short circuiting.
Pin Floc in Effluent Old sludge age (low F/M). Increase wasting or
loading.
Turbid Effluent 1.Young sludge age (high F/M). Common on start-up

or recovering systems
2. Bacterial die-off in aeration basin. If other items
are in order (DO, loading, sludge age, etc.) then
look for toxic constituent
Solids Pop-up In Clarifier Denitrification. Short term: increase recycle rate. Then,
review operations to determine why denitrification is
not being adequately performed in aeration basin.
Filamentous Bacteria Numerous causes including shock loads, septicity,

(Poor Settling) high influent oil and grease, erratic wasting,
phosphorus deficiency, micronutrient deficiency,
toxicant presence. Chlorinating RAS sometimes
helps @ 1-10 lb CL2/1000 lb MLSS. Start low &
build up. Effluent will become turbid. Polymer addition
(cationic) also can help. Best strategy is to employ
careful process control and avoid conditions
favorable to filaments.

Table VIII.4
Alkalinity Control Chemicals
Commonly Used in Poultry Wastewater Treatment Facilities
Chemical Physical State

Quick Lime (CAO) Powder, Slurry
Hydrated Lime (Ca(OH)2) Powder
Soda Ash (Na2CO3) Granular
Magnesium Hydroxide (Mg(OH)2) Slurry
Sodium Hydroxide Liquid
Substances purchased as slurries are normally purchased in bulk. It is

necessary to provide mixing to the bulk storage tank to prevent
deposition. Typically, the slurry is fed to a day tank, when it may be
further diluted with water. From the day tank, the slurry (or diluted
slurry) is metered into the wastewater stream.
Caustic soda – or sodium hydroxide – is normally purchased as a bulk

liquid or in 300 gallon totes, through the use of 55 gallon drums is still
common. The strength of solution is typically either 25% or 50%.
The freezing point of 50% solution is 50 - 55° F; it is therefore
unsuitable for outside storage during winter in most locations; and may
prove problematic even in inside storage in some cases. Caustic soda is
typically fed neat directly to the waste stream. Dilution of caustic soda
– particularly 50% caustic – can release significant quantities of heat,
damaging piping and/or storage systems if they are not designed for
this purpose.
VIII.1.C. Activated Sludge System Instrumentation and Control

An activated sludge system can utilize several instruments and control
devices to aid in its operation. Description and purposes of critical
control devices is as follows:
Influent Flow Meter:

A flow meter is often installed in the influent line into the aeration
basin. If wastewater is pumped to the basin, this is often a magnetic
flow meter. If wastewater flows via gravity, this is often a flume or
wier with a recording meter. These units provide both instantaneous
and totalized flow readings. The flow information is critical in
determining mass loading on the activated sludge system and wasting
rates.

pH Sensor/Controller:
A pH sensor is often installed in the aeration basin. In addition to the
display unit, a controller is often provided to pace alkalinity feed. The
operator should periodically check the pH manually.
Insuring nitrification in the aeration basin requires careful pH control.

Nitrification bacteria are inhibited by pHs below 6.8 s.u., and
nitrification will cease at pHs below the 6-6.5 s.u. range. The pH
sensing/control unit is installed to prevent this occurrence. When
aeration basin pH begins to drop, the controller signals the alkalinity
feed pump to increase output. As aeration basin pH rises, the
controller signals the alkalinity feed pump to reduce output.
Ammonia Analyzer with Pre-Filtration:

Some facilities have extremely stringent ammonia limitations. Virtually
all of the nitrogen removal occurring at the facility must occur in the
aeration basin. Consequently, it is not surprising that an ammonia
analyzer is provided in some systems to control aeration (e.g., turns on
and off blowers). Real-time ammonia sensing requires prefiltration.
A side stream of aeration basin mixed liquor is pumped to the blower

building into the pre-filtration unit. This unit, an ultrafiltration device,
removes solids and large molecules from the mixed liquor, while
allowing smaller dissolved ions, such as ammonia, to pass through the
filter with the water.
Once prefiltered, the water can be introduced into the ammonia

analyzer. The ammonia analyzer unit uses a selective ion electrode
method to determine the concentration of ammonia in the water.
The unit contains a microprocessor which, in addition to controlling

automatic calibration and cleaning of the unit, is also capable of
generating output signals.
The unit can be programmed to begin activating additional blowers

whenever NH3 levels in the sample exceed a pre-set level. Conversely,
the unit will start deactivating blowers whenever sample ammonia
levels drop below a set point. The unit should neither activate nor
deactivates all blowers or aerators at once, but should have a
programmed time delay between each start-up or shut-down.

DO Sensor:
A DO sensor is often provided to control aeration equipment in an
activated sludge system. Typical operating range for DO level is 1 to 2
mg/l, unless denitrification is occurring. Observation and notation of
basin DO levels should be performed each shift. The DO sensor will
activate and deactivate blowers to maintain DO in the desired range.
DO is especially important with respect to nitrogen removal.
Nitrifying bacteria are inhibited without some DO residual; hence a
minimum DO level of 0.5 mg/l is suggested.
VIII.1.D. Activated Sludge System Analytical Sampling

Sampling of the activated sludge system should be in accordance with
company guidelines. A suggested sampling protocol is provided below.
DO AB
BOD I,E
COD I,E
TSS AB, RAS,E I
TKN I,E
NH3 E
P E
Alk I,E
pH AB,I,E
Temp A,B
NO3 E
KEY: I = Aeration Basin Influent

E = Clarifier Effluent
AB = Aeration Basin (MLSS)
RAS = Return Sludge
VIII.1.E. Activated Sludge System Operator Maintenance

Detailed maintenance requirements are provided separately for the
component parts of the activated sludge system. Table VIII.3.
summarizes some of the more common operator maintenance
functions.
VIII.1.F. Activated Sludge System Troubleshooting Flow Sheet

A troubleshooting flow sheet for this system is included as Chart
VIII.1.

VIII.1.G. Activated Sludge System Typical Mathematical Calculations
Example 1: A circular aeration basin has a diameter of 120’ and a
depth of 16 feet. It has a MLSS of 3500 and RAS of 7000. Daily flow
is 1 MGD. 34,000 gallons per day are wasted. What is the retention
time? What is the sludge age? If influent is BOD 300 ppm, what is the
F/M ratio?
1. Retention Time = Volume = π(60)2 (16) (7.48) = 1.35 days

Flow 1,000,000
2. Sludge Age = VAB • MLSS = (1.35 mg) (3500) = 20 days

FW • RAS (0.034 MGD) (7000)
3. F = (1 MGD) (300) = 0.063

M (1.35) (3500)
Example 2: The plant described above has two 60’ diameter clarifiers,
with a depth of 10’. What is the retention time in the clarifier? What is
the surface loading rate? What is the solids loading rate?
1. Retention Time = V ;Volume = 2 x π(30)2 (10’) x 7.48

F = 422,767 gallons
Retention Time = 422,767 gal = 0.423 days = 10.1 hours

1,000,000 gal/day
2. Surface Loading = 1 MGD = 177 gal/day/ft2

2 x π(30) 2
3. Solids Loading = 1MGD x 3500 x 8.34 = 5.2 lb/day/ft2

2 x π(30) 2
Example 3: The plant described above has an influent TKN of 100

mg/l. If the air diffuser system can deliver 2 lb O2/hour HP, what is
the minimum HP required?
Loading BOD = 1 x 300 x 8.34 = 2500 lb/day BOD

lb O2/lb BOD = 1.25
lb O2 for BOD removal = 3125 lb/day
Loading TKN = 1 MGD x 100 x 8.34 = 834 lb/day

lb O2/lb TKN = 4.6

O2 for TKN removal = 834 x 4.6 = 3836 lb/day
Total O2 required = O2 for BOD + O2 for TKN

= 3125 lb/day + 3836 lb/day
= 6961 lb/day
= 290 lb/hr
HP required = 290 lb/hr. = 145 HP
2 lb/hr/HP
(Note: does not account for peak loading, spares, etc.)

Chart VIII.1
Is Influent pH > 7.0 & No
ACTIVATED SLUDGE SYSTEM Increase Alkalinity
Alkalinity > 300 mg/l Feed Rate
Decision Chart
Yes
Reduce Influent Flow or Begin Is Influent COD

OK No
DAF Chemical Pretreatment
Within Design Specs
or Increase Aeration
Not OK
Yes
Turn on Standby Aeration
Sludge Age or F/M
No Sludge Age Too Low?
No
In Proper Range
Decrease Wasting
Sludge Age Too High?
Yes
Increase Wasting
Absence of Foaming No
No Dark Brown/Orange
Excessive Whitish Foam? Problems Foam? Increase Wasting
Decrease or Stop Wasting
Yes
DO > 0.5 mg/l and No No

Reduce Influent Flow
< 2.0 mg/l Inbound Loading OK?
or Begin DAF
Yes Chemical Pretreatment
Yes
Check Meter OK
No No Turn on Standby
Increase Alkalinity Feed Basin Alkalinity >100 mg/l Is Basin Ammonia
Aeration
Within Discharge Limits
Yes
Increase Air or Decrease Yes
Loading Not BOD/TKN >3/1
Is Effluent Nitrate No Operate at Lower DO OK
< 60 mg/l No
(Denitrification Only) OK Increase BOD/TKN

Yes
No Yes Decrease Sludge Age. Add

Is Effluent Sus. Solids Pin Floc?
Polymer @ Clarifier
< 20 mg/l No
High Turbidity or Yes Increase Sludge Ag. Add

Yes
Dispersed Floc Polymer @ Clarifier
Continue Routine No
Yes
WASTEWATER TREATMENT MANUAL Monitoring Large Clumps of Restore Denitrification. Add
POULTRY PROCESSING FACILITIES Floating Solids? Polymer @ Clarifier
TABLE VIII.5
TYPICAL ACTIVATED SLUDGE MAINTENANCE SCHEDULE
COMPONENT INSPECTION MAINTENANCE

INTERVAL ACTION REQUIRED
Aeration Bridge 1/ day Visually inspect daily for irregularities
Drive Units 1/ day Visually inspect daily for irregularities
Clarifier Bridge 1/ day Visually inspect daily for irregularities
Blower Pressure 1/week Record Weekly. If 0.5psi increase is

noted, raise & inspect diffusers
pH Probe 1/week Inspect and clean electrode, calibrate
DO Probe 1/week Inspect and clean electrode, calibrate
Track/Drive Wheels 1/ 6 months Inspect for wear and alignment.

Repair or replace when needed.

IX. TERTIARY FILTRATION
This chapter will provide a review of three tertiary filters often employed in the poultry
industry today. Each of these filters is described in terms of

IX.1. Shallow Bed Granular Filters (Travelling Bridge Filters)

The purpose of shallow bed granular filters is to reduce the level of
suspended solids (and hence, BOD, TKN and total P) in the clarifier
effluent. Most commonly in poultry wastewater treatment facilities,
these are travelling bridge filters, with sand as the media. Many
facilities have BOD and TSS limits of less than 20 mg/l. Without
reduction of clarifier suspended solids – which do contribute to BOD,
TKN and total P – the facility may not be achieving consistent
compliance with the NPDES permit. Hence, travelling bridge filters
can be employed to polish the effluent and enhance system compliance
reliability.
IX.1.A. Filter Design

Travelling bridges are high rate filters most commonly utilizing sand
media, but occasionally employing anthracite or a sand/anthracite
combination. A sectional view of a typical sand shallow bed filter is
provided in Figure IX.1.
Provided in the table below are typical design ranges for a sand or
anthracite travelling bridge filter.
Design Parameter Sand Media Anthracite Media
Bed Depth, Inches 10 – 12 12 – 20

Particle Effective Size, mm 0.35 – 0.6 0.8 – 1.5
Particle Uniformity Co-efficient 1.2 - 1.6 1.3 – 1.8
Hydraulic Loading (GPM/ft2) 2–5 2-6
Solids Loading (lb/ft2/day) 1.2 1.4
Pressure Drop (in) 8 – 24” 8 – 24”
A travelling bridge, shallow bed granular filter uses gravity flow of
secondary effluent through the media bed – most commonly sand –

U.S. POULTRY & EGG ASSOCIATION IX.1
Figure IX.1
SHALLOW BED SAND FILTER
Control Panel
Traveling Bridge
Backwash
Discharge Bridge Pond
Channel Support
Effluent
Channel
Backwash Hood
Influent
Channel
Sand Media
Backwash Pump
Backwash Underdrain
Channel Control Panel
Backwash Hood
Cell Dividers
Sand Media
Backwash
Channels

Underdrains
U.S. POULTRY & EGG ASSOCIATION XI.2
to strain out suspended solids remaining in the clarifier effluent. (See
Figure IX.1) Note the sand is contained in “cells”, individual sections
of the filter. These sections are backwashed independently, allowing
the filter to stay in service during cleaning.
Secondary effluent enters a distribution channel, then normally flows
through ports into the filtration section. The filtration section consists
of approximately 12 inches of sand (anthracite is typically deeper).
Water passes through the sand, leaving the suspended solids entrapped
in the sand media. Ports allow the filtered effluent to enter the
discharge channel, from whence it exits the filter.
As solids accumulate in the filter bed, the filtration rate slows. At a
timed interval, or based on an increase in head pressure (i.e., water level
in the tank), the filter is backwashed to remove the accumulated solids.
The backwash is accomplished through the use of a backwash pump
located on the traveling bridge. As the bridge traverses the filter, the
pump picks up clean water from the effluent channel and pumps this
clear liquid through a filter cell, removing the accumulated solids from
this cell. When complete, the bridge moves to the adjacent cell, and
performs the same function. Backwash water is returned to the
aeration basin, or to the anaerobic lagoon, or similar preceding
treatment unit.
IX.1.B. Shallow Bed Granular Filters Instrumentation and Control
The most common instrumentation provided on this type of filter is a
liquid level sensor or static head pressure device. Either of these units
will sense when head loss through the filter has reached a point at
which backwash should occur. Typically, this measurement is set at 12
– 15 inches above the filter bed.
IX.1.C. Shallow Bed Granular Filters Analytical Testing
The analytical process data control testing requirements for the shallow
bed granular filter should be conducted per company policy. A
suggested sampling protocol is provided below.
Parameter 1/Shift 1/Day 1/Week 1 Month
TSS 1
NH3 1
COD 1
BOD 1
TKN 1
P 1
pH 1

All samples should be obtained at the filter effluent. Influent
information is provided by the clarifier effluent data.
IX.1.D. Shallow Bed Granular Filter Maintenance

The operator should perform the following maintenance functions:
 Visually inspect the filter daily to ensure traveling bridge is free and
clear of obstructions.
 Inspect pump discharge on a periodic basis to ensure backwash is
properly occurring.
 Follow manufacturer’s recommendations on lubrication of
backwash pump, bridge rollers, rails, etc.
 Visually inspect filter surface each day and remove any debris from
filter bed.
 Periodically replenish sand as needed in individual cells.
 Replace sand at manufacturer recommended intervals (24 – 36 mo.)
IX.1.E. Shallow Bed Granular Filter Troubleshooting Chart

A flow chart for the shallow bed granular filter is included as Chart
IX.1.
IX.2. Upflow Filter

The purpose of an upflow filter is to reduce the level of suspended
solids (and hence, BOD, TKN and total P) in the clarifier effluent.
Many facilities have BOD and TSS limits of less than 20 mg/l.
Without reduction of clarifier suspended solids – which do contribute
to BOD (and TKN and total P) – the facility may not be achieving
consistent compliance with the NPDES permit. Hence, an upflow
filter can be employed to polish the effluent and enhance system
compliance reliability.
IX.2.A. Upflow Filter Design

Typical design parameters for upflow filters are as follows:
Loading Rate = 30 gpm/ft2

Depth = 4 – 8 ft. (synthetic media, anthracite)
= 6 – 10 ft. (sand)
Solids Loading = 10 – 15 lb/day/ft2
Pressure Drop = 6” – 24”
The component parts of the filter are:

1. Filter vessel, with upper and lower perforated plates, and filter
media
Chart IX.1
SHALLOW BED GRANULAR
FILTER SYSTEMS
Decision Chart
Yes Is Backwash Pump No

Is Filter Tank Turn on Pump(s)
Overflowing? On?
Yes
No Yes
Media Surface Seating Reduce Polymer Dose
Reduce Influent TSS Yes Excessive Influent No
Is Backwash No
or FOG or Flow Algaes TSS or
or Control Algae FOG or Flow? Frequency Normal? Yes Reduce Influent TSS
Excessive Influent
No TSS or FOG or Flow or FOG or Flow
Adjust Backwash No Backwash Hood No
Hood Properly Seated? Backwash Hood No
Adjust Backwash Hood
Yes Yes Properly Seated?
Chlorinate @ 10 ppm Yes Slime Growth Yes
for 30 Minutes In Media? Slime Growth Yes Chlorinate @ 10 ppm
In Media? for 30 Minutes
Effluent Quality
Getting
Progressively Worse?
Level Controls No Lower Control
Yes
No Properly Set? (More Backwashes)
Yes
Water Bypassing
No Springs Properly Media in Yes Broken Underdrain
Backwash Shoe?
Adjust Springs Effluent Chamber Plate Repair
Adjusted?
Yes No
Replace Strip No Continue Routine
Wear Strip OK?
if Needed Monitoring

2. Wash blowers and diffusers
3. Control PLC and components
Upflow filters are high rate filters utilizing anthracite, sand or fiber
spheres as the media to remove suspended solids in the clarifier
effluent. The fiber sphere media consists of synthetic fiber balls
normally 3 – 4 cm in diameter, which are slightly heavier than water.
The filter bed is defined by a fixed upper plate at the top of the filter
vessel and an adjustable (motor driven by a non-rising stem) lower
plate (see Figure IX.2). The filter operates in three cycles – the
filtration cycle, the backwash cycle and the rinse cycle.
IX.2.B. Upflow Filter Operations

Water enters the filter via a feed line from the clarifier. During the
filtration cycle, the upward flow of the clarifier effluent through the
filter compresses the media against the top fixed plate. Filter effluent
water passes through the perforated fixed plate and discharges by
gravity to disinfection. Solids are captured in the media. As operations
continue, more solids are captured which leads to a pressure build-up
in the filter chamber. At an operator determined pressure set point,
the pressure sensor located beneath the lower plate signals the filter's
PLC unit to initiate the backwash cycle.
When the backwash cycle starts, the effluent valve closes. Water level
in the unit will rise until it reaches the wash water outlet, which
typically discharges to the plant’s headworks. The lower plate is
automatically lowered, relieving the pressure build-up. At this point,
the PLC initiates the wash blowers which introduce air into the bottom
of the vessel. The combination of water flowing upwards through the
filter, and air rising from the diffusers results in a scouring action on
the filter media. The accumulated solids released are carried out
through the backwash water discharge to the plant’s headworks.
The scouring phase will repeat based on operator input into the PLC.
When the pre-selected number of scours has been completed, the
lower plate is raised, again compressing the media. Incoming water
continues to pass through the media, rinsing remaining suspended
solids into the backwash water discharge. This is known as the rinse
cycle.
At an operator selected time interval, the effluent valve will

automatically open, ending the rinse cycle and returning to the filtration
cycle with discharge to disinfection.

IX.2.C. Upflow Filter Instrumentation and Control
As was described in the preceding section, the PLC and pressure
sensor are an integral part of the process and control the different
cycles employed by the filter. Specific manufacturer manuals should be
reviewed regarding PLC inputs, pressure switches, etc.

Figure IX.2
UPFLOW FILTER CYCLES
ACTUATOR FOR ACTUATOR FOR ACTUATOR FOR

LOWER PLATE LOWER PLATE LOWER PLATE
BACKWASH LINE BACKWASH LINE BACKWASH LINE
(EMPTY) TO BW CHAMBER TO BW CHAMBER
FIXED PLATE FIXED PLATE

FIXED PLATE
EFFLUENT EFFLUENT EFFLUENT
FILTER MEDIA FILTER MEDIA
(CLOSED) (CLOSED)
(compressed)
FILTER MEDIA
LOWER PLATE (uncompressed) LOWER PLATE
LOWER PLATE
INFLUENT INFLUENT INFLUENT

(WASH WATER)
WASHING AIR WASHING AIR WASHING AIR
LINE (EMPTY) LINE (EMPTY)
FILTRATION CYCLE BACKWASH CYCLE RINSE CYCLE

IX.2.D. Upflow Filter Analytical Sampling
The analytical process data control testing for the upflow filter should
be conducted in accordance with company policy. A suggested
sampling protocol is as provided below:
Parameter 1/Shift 1/Day 1/Week
TSS 1
NH3 1
COD 1
BOD 1
TKN 1
P 1
pH 1

IX.2.E. Upflow Filter Operator Maintenance

 Traveling plate machine screw should be checked for lubricant level

once per 30 days and filled as needed.
 Check belt tensioning on blower units once/month and tighten as

needed. Follow manufacturers recommended maintenance
guidelines on blowers.
 Traveling plate and seal should be inspected every 90 days and

repairs made as needed (detailed procedure provided in
manufacturer’s literature).
 Check plate position level during filtration cycle.
IX.2.F. Upflow Filter Troubleshooting Chart

A troubleshooting flow chart for Upflow Filters is provided as Chart
IX.2.
IX.3. Disk Filters

A relatively recent addition to filtration of secondary effluents from
poultry wastewater facilities is the use of disk filters. Disk filters utilize
a cloth media attached to a hollow plastic cylinder. As with other
filters utilized in the industry, the purpose of the filters is to polish
remaining TSS, BOD, total P and TKN from the filter.
Chart IX.2
UPFLOW FILTER SYSTEMS
Decision Chart
Yes
Backwash Frequency Blowers and Valves No Repair Blower/
Excessive Properly Operating? Valves
No Yes
Correct PLC No Reset
Repair Blower/ No Blowers and Valves Yes
Properly Operating? Effluent Quality Sequence Timer? Sequence Timers
Valves
Getting Progressively Yes
Yes Worse
No Travelling No Reset
Reset Correct PLC
Sequence Timers Sequence Timer? Plate Limits OK? Plate Limits
Yes Yes
No No Yes Reduce Clarifier
Reset Travelling High Influent TSS?
Plate Limits Plate Limits OK? TSS or Algae
Yes
Reduce Clarifier TSS Yes High Influent TSS Yes Yes
Water Backing Up Reduce Clarifier
or Control Algae or Algae in Clarifier? High Influent TSS
TSS or Algae
No No
Influent Line Yes
Remove Blockage
Repair Travelling No Travelling Plate Yes Reduced Effluent Blockage?
Plate Properly Functioning? Flow?
No
Yes
No Air Pocket in Yes Bleed Air
Repair Discharge No Discharge Valve Influent Line From Pipeline
Valve Properly Operating Continue Routine
Yes Monitoring
No
Remove Influent Line
Blockage Blockage

IX.3.A. Filter Design
Typical design criteria for sizing disk filters is as follows:
Average Peak
Hydraulic Load (GPM/ft2) 3 6

Solids Load (lb/d/ft2) 1.9 -
Pressure Drop (ft) 6” – 24” -
There are several types of cloth media available. Each facility should
have the various cloths evaluated by the manufacturer for their specific
effluent characteristics.
IX.3.B. Filter Operation

A sectional view of the filter is provided in Figure IX.3.
A description of each of the major components, and their intended

function, is as follows:
Tank – The tank is either a steel vessel supplied by the filter

manufacturer or a poured-in-place concrete vessel built to the
specifications of the filter manufacturer. Influent and effluent
connections, as well as support members for other components, are all
provided in the tank design.
Filter disk – The filter disk can be further subdivided into two
components – the filter cloth and the polypropylene support frames.
Each disk has multiple pie shaped segments, these segments connect to
each other and to the center tube. (See Figure IX.3).
Center tube with Drive – The center tube is essentially a hexagonal

piece of pipe to which the disks are attached. The center tube is the
effluent pipe, filtered water passing through the filter disk flows to the
center tube and is discharged. The center tube is on a drive so it can
be slowly turned during backwash or cleaning.
Backwash System – The backwash system consists of two manifolds

for each disk (one on each side of the disk) and a backwash pump.
When the backwash pump is activated, a vacuum is created in the
manifold, removing accumulated solids on the filter cloth. The
backwash water is normally pumped to the aeration basin, anaerobic
lagoon or other previous treatment unit.

Figure IX.3
DISK FILTER OPERATION
Filter Disks
1. Normal Operation
Effluent During normal operation, the
disks are not rotating. Influent
flows through the filter cloth,
Influent leaving the solids in the cloth.
Filtered water is collected in
the center tube and discharged
by gravity. Settled solids are
periodically purged.
Settled Solids Purge
Center Tube
Filter “Pie” Section
2. Backwash Cycle
A level sensor or timer
initiates the backwash cycle
when head loss reaches an
operator-set point. The
backwash pump is activated,
and the center tube begins a
slow rotation. Clean water is
pulled back through the filter
Backwash cloth into the backwash
vacuum head. Note, typically
Backwash only two disks at a time are
Center Tube
Vacuum Head backwashed.
Hi-Pressure
Nozzles 3. Hi-Pressure Wash
At an operator set interval, flow
to the unit ceases and is allowed
to drain out. Then, the high
pressure pump is activated,
scouring the cloth surface with
225 psi spray. This washwater
flow to the facility headworks.
Wash Water
Discharge

High Pressure Spray System – The high pressure spray system consists
of two sets of nozzle manifolds for each disk (one on each side of the
disk), and a high pressure pump. The intake source for the high
pressure pump is usually filtered effluent. When the pump is activated,
filtered water is pressurized to approximately 200 psi and released
through the nozzles onto the filter cloth surface, to dislodge any
embedded solids on the cloth.
Control System – The capability of the control system, normally a PLC

panel, will vary from facility to facility. Typically, such systems control
high pressure washes, backwashes, and various alarm functions.
Washes may be controlled by a head loss measurement, or by elapsed
time; further flexibility is provided in the duration of the wash.
During routine operation, the disks on the filter are not turning.
Secondary effluent enters the tank, and flows through the filter cloth
media, leaving solids behind in the media. The filtered water flows
through the open polypropylene support structure of the disk to the
center tube. The center tube, sealed on one end and open on the
remaining end, collects the filtered water from all the disks, and
conveys it from the tank to subsequent treatment or discharge.
When a backwash cycle is initiated (either by a timer, head-loss sensor

or manually), the backwash pump is activated, as is the drive that
slowly turns the center tube and hence, the disks. Filtered effluent is
pulled back through the filter cloth, into the manifolds on either side of
the disk. The reversal of flow through the filter cloth results in solids
being flushed out of the cloth, into the manifold and pumped back to
the aeration basin or other previous treatment unit. Normally, the PLC
opens and closes valves such that only one or two disks are
backwashed at a time. The operator can control, through the PLC
interface the length of time a backwash occurs.
IX.3.C. Disk Filter Instrumentation and Control

A PLC is normally employed to control the operation of the filter. A
liquid level sensor or pressure measuring device is provided so that the
backwash cycle will initiate whenever head loss reaches a
predetermined setting. The operator, through the PLC entry screen,
can manipulate the length of time backwashing occurs, or sometimes
the head pressure setpoint at which backwash is initiated.
The frequency and duration of a high pressure wash is also operator

controlled via the PLC interface. Many operators set the high pressure

wash frequency as a multiple of the backwash frequency; e.g., after
every ten backwash cycles a high pressure wash is initiated.
The PLC also provides totalized information reporting the total

number of backwashes and high pressure cleanings. An operator
should track this information; such data can be an indicator when
cloths need to be chemically cleaned or replaced.
IX.3.D. Disk Filter Analytical Testing
Analytical testing of the disk filter should be conducted according to

company policy. A suggested sampling protocol is as provided below:
TSS 1
NH3 1
COD 1
BOD 1
TKN 1
P 1
pH 1

IX.3.E. Disk Filter Maintenance Checklist

Cloths: It is periodically advisable to clean disks with chemical agents,
particularly if a facility is using polymers in the filter to aid in solids or
phosphorus removal. In situ cleaning is normally accomplished with
bleach or dishwashing detergent (low sudsing).
Some facilities choose to purchase an extra set (or two) of filter cloths.
Then, on a periodic basis, the spare set is used when the cloths are
removed from one or two disks and sent to a commercial laundry.
Check for rips/tears in cloth periodically. Replace/repair as needed.

Ensure cloths are properly attached to support plates.
Backwash Pump: Lubricate as directed by manufacturer. Check

pressure/vacuum gauges regularly to monitor for a loss of
performance. Tighten belts as needed.

High Pressure Pump: Lubricate as directed by manufacturer. Check
pump discharge pressure to monitor a loss of performance.
NEVER RUN THIS PUMP DRY
Center Tube Drive: Lubricate as directed by manufacturer. Check and

replace seals on shaft as necessary.
IX.3.F. Disk Filter Troubleshooting Chart

A troubleshooting chart for the disk filter is provided in Chart IX.3.

Chart IX.3
DISK FILTER SYSTEM
Decision Chart
Too Is Filter Yes Repair or

Yes Too Low High
Clear Obstruction Is Pump Obstructed? Backwash Vacuum Cloth Torn? Replace
9 – 11 Inches Hg? No
No Cloths Properly No
Attach Cloths
Follow Manuf. Check Pump Manuf. Attached to Support Properly
Recommendation Maintenance Manual Yes
Yes
Check for Pipe Not
Fix Leaks
Yes No Line Leaks OK
Clear Obstruction Is Pump Obstructed? Does Hi Pressure Pump
Deliver > 200 psi? Check Pump Follow Pump
No Manuf. Manual Manuf. Guidance
Follow Manuf. Check Pump Manuf. Yes
Recommendation Maintenance Manual
No Excessive TSS or Yes Reduce Influent
Backwash Frequency Algae in Influent? Algae, TSS or Flow
Normal? No
No Yes Excessive Yes Reduce Polymer
PLC Setting No
Adjust PLC Polymer Dose? or Alum Feed
Correct Hi Pressure Wash
Frequency Normal? No
Yes
Perform In Situ OK
Reduce Influent Yes Yes Cleaning
Excessive TSS
TSS or Flow In Influent? Not OK
Continue Routine
No Monitoring Remove & Clean
Reduce Polymer Yes Excessive or Replace Cloths
or Alum Feed Polymer Dose?
No
OK Perform In Situ
Cleaning
Not OK
Remove & Clean
or Replace Cloths

X. DISINFECTION SYSTEMS
This chapter provides a review of the two major disinfection processes utilized in
poultry wastewater treatment: chlorination/dechlorination and ultraviolet light
systems. Each of these is described in terms of

X.1. Chlorination/Dechlorination System
CAUTION: BOTH CHLORINE AND SULFUR DIOXIDE ARE TOXIC GASES. EXERCISE EXTREME
CAUTION WHEN WORKING AROUND THE GAS CYLINDERS AND HANDLING EQUIPMENT.
NEVER ENTER A BUILDING WHERE YOU SUSPECT A GAS LEAK MIGHT HAVE OCCURRED.
EVACUATE THE IMMEDIATE AREA UNTIL THE GAS HAS DISSIPATED.
NOTE: CHLORINE AND SULFUR DIOXIDE ARE REGULATED UNDER CERCLA. RELEASES IN
EXCESS OF THEIR RESPECTIVE REPORTABLE QUANTITIES (RQ) MUST BE REPORTED TO THE
NATIONAL RESPONSE CENTER AND THE APPROPRIATE STATE AGENCY.
To insure effluent from the facility contains no pathogenic bacteria, it

must be disinfected prior to discharge. The most common method of
disinfection in poultry wastewater treatment facilities is chlorination.
Further, because of concern regarding the toxicity of chlorine itself, the
effluent is also dechlorinated using sulfur dioxide gas which removes
the chlorine from solution.
X.1.A. Chlorination/Dechlorination System Design Information

The following summarize components of a
chlorination/dechlorination system:
Chlorinator
Sulfanator
Chlorine and sulfur dioxide cylinders
Chemical water supply pumps
Chlorine contact chamber; minimum 15 minute retention
time and length/width ratio of 10/1 or greater
U.S. POULTRY & EGG ASSOCIATION X.1
X.1.B. Chlorination/Dechlorination System Operation
Effluent enters the chlorination channel and (See Figure X.1) a
chlorine solution is injected simultaneously at this point. The effluent
then travels through remaining channels. The purpose of both the 15
minute retention time and 10/1 channel length/width ratio is to ensure
effective contact with the chlorine, ensuring effective pathogen kill. At
the end of the final chlorination channel, the water flows into the
dechlorination channel. Immediately upon entering into this channel, a
sulfur dioxide solution is injected to remove chlorine. The sulfur
dioxide solution causes the chlorine to be stripped from the effluent.
Following dechlorination, the water is discharged to flow monitoring
and re-aeration.
Both the chlorine and sulfur dioxide solutions are derived by mixing
clarifier effluent with the appropriate gas. A booster pump draws
clarified or filtered effluent and pressurizes this water to approximately
60 psi (See Figure X.1). This pressurized water is pumped through an
ejector nozzle. Passing through the nozzle causes a vortex and vacuum
to be created. The ejector also has a gas induction line which is
connected to the cylinder mounted chlorinator (or sulfanator; both
systems operate identically). The vacuum created by the water passing
through the injector then draws chlorine gas through the gas induction
line into the injector. The rate at which gas is drawn from the gas
cylinder can be regulated by the valve and sight glass gauge on the
bottle mounted chlorinator. The chlorine gas and water then mix and
are piped into the chamber.
X.1.C. Chlorination/Dechlorination System Instrumentation and Control

Both gas systems are normally equipped with automatic switchover
equipment. These units sense pressure in the gas bottle. When the
bottle is almost empty, pressure falls and the switchover unit
automatically begins withdrawing gas from a second gas bottle.
X.1.D. Chlorination/Dechlorination System Operator Maintenance

 Keep chamber clear of blown-in debris such as sticks, leaves,

trash, etc. daily.
 Chlorine and sulfur dioxide feed system should be inspected

routinely for signs of stress and fatigue that could lead to a gas
release.

FIGURE X.1
Discharge
CHLORINATION/
DECHLORINATION
SYSTEM
Dechlorination Sulfur Dioxide
Chamber Solution
Gas
Sulfur Dioxide
Gas Injector Gas Injector
Supply Pumps
Chlorination
Chamber
Chlorine
Gas Injector
Chlorine
From Filter Solution
or Clarifier
Effluent Line

 The booster pumps should be serviced in accordance with
manufacturer’s recommendations.
 Contact basin should be cleaned as needed.
X.1.E. Chlorination/Dechlorination System Analytical Testing

Analytical testing should be conducted in accordance with company
policy. A suggested sampling protocol is presented below:
1/day
pH X
Cl2 X
X.1.F. Chlorination/Dechlorination System Troubleshooting Flow Sheet

A troubleshooting flow sheet is included for this system as Chart X.1.
X.2. UV Disinfection
CAUTION: OVEREXPOSURE TO UV LIGHT CAN BURN SKIN AND
EYES. NEVER RUN UV LAMPS IN OPEN AIR. DO NOT LOOK AT OR
EXPOSE SKIN DIRECTLY TO UV LIGHT.
Ultraviolet (UV) light is utilized as an alternative to

chlorination/dechlorination to disinfect effluent from poultry
wastewater treatment facilities. UV disinfection does not require
storage and handling of hazardous chemicals; further it leaves no
residual. As noted above, however, it does require its own precautions.
The principal means of UV disinfection at present is through the use of

low pressure mercury arc lamps in quartz enclosures. An electric arc is
passed through the mercury vapor in the lamp. The excitation of the
vapor results in emission of UV light at a wavelength at 253.7 nm.
This wavelength in the optimal range for germicidal effects on micro-
organisms. The absorption of this UV light by the DNA and RNA on
micro-organisms either kills the organisms outright, or prevents them
from replicating. In either mechanism, the desired disinfection effect is
achieved.
X.2.A. UV Disinfection Design

UV disinfection systems are purchased as a packaged commercial unit
from the manufacturer. A typical unit is shown in Figure X.2.
Essential elements of the package include the following components:

Chart X.1
CHLORINATION/
DECHLORINATION
SYSTEM
Decision Chart
Are Pumps No No
Operating at Proper Pressure Is Pump On? Turn On
Yes
Is There Pump No
Yes
Pipe Restriction? Replace Gauge
Yes
No No Is Chlorine Feed
Gas in Bottle? Not Consult Pump
Replace Bottle Clear Obstruction
Approx. 20 lb/MGD OK OK Manual
Yes
Take Unit Offline Not
Adjust Rate Yes
Switch Bottles OK
Yes
Is Sulfer Dioxide Feed No
No
Approx. 25 lb/MGD Gas In Bottle? Replace Bottle
Yes Yes
Yes
Not Take Unit Offline
Adjust Rate OK
No Chlorine Non- Switch Bottles
Increase Sulfer Detectable in OK
Dioxide Feed Discharge
Yes
Continue Routine
Monitoring

Figure X.2
TWO-BANK UV DISINFECTION SYSTEM
PLC
Influent Distribution Interface
Baffle
Plan
View
Influent Effluent
Line Line
UV Channel UV Bank
Power
Distribution
Center Flow Control
PLC Valve
UV Module Interface
Sectional
View
Influent
Line
Influent Distribution UV Lamp in Effluent

Baffle Quartz Tube UV Sensor Line

UV Channel: The flow trough in which disinfection occurs. Steel
channels can be purchased as part of the system, however, it is
common to utilize poured-in-place concrete channels. Note failure to
precisely follow the dimensional data given by the UV system
manufacturer can affect performance and void any process warranties.
UV Light: The individual mercury vapor arc lamps, generally from

have a guaranteed life of one year, a two-year life is fairly typical.
Quartz Sleeve: These sleeves encase the individual UV lights in a

watertight enclosure. Quartz is utilized because of its relatively high
transmittance of UV light; new quartz sleeves will allow transmission
over 85% of the UV light generated by the lamp.
UV Module: A horizontal or vertical rack of UV lights.
UV Bank: Multiple rows of UV modules. Again, the individual lights

are wrapped in a horizontal or vertical configuration, depending upon
the manufacturer.
UV Sensor: A control device included to ensure the output of light for

the UV lamps maintains minimum acceptance levels.
Power Distribution Unit: The device, mounted on or adjacent to the

UV bank, that provides power and control information to the UV
lights.
PLC Interface: Unit utilized to control, and provide an operator

interface with, the UV system.
Flow Control Valve: This unit, which is on most systems in excess of

1 MGD, ensures that the proper liquid level is maintained in the
channel.
The efficacy of UV disinfection is proportional to the “dose” of UV

light, where dose is defined as:
Dose = Intensity X Retention Time
(microwatts – sec)=(microwatts) (seconds)

cm2 cm2

X.2.B. UV Disinfection System Operation
On the one hand, operation of a UV system is extremely simple.
Following initial start-up and calibration – almost always done by the
manufacturer – the operation needs to ensure flow is unobstructed and
power is supplied to the UV lamps. Over time though, failure to
routinely monitor indicators of process performance, and take the
appropriate corrective action, will lead to process failure. The
operator, therefore, should routinely check the following items.
Lamp Efficiency: Most manufacturers base their design calculations on

the UV radiation emitted by a one year old lamp – about 2/3 as much
as a new lamp. Although lamp life can be two years or more, lamp
radiation continues to decline over the actual life of the light. Careful
attention should be paid to UV measuring sensors, and an accurate
record of lamp life should be maintained. Replace lamps if the sensor
indicates an unacceptable fall off in transmission, or, at a preset interval
that facility experience indicates is necessary to maintain compliance.
Sleeve Fouling: The most common cause of failure of UV system to

achieve the desired disinfection level is fouling of the quartz tubes.
Over time, debris, bacteria and algae/slimes, precipitate solids, etc.,
form a film on the quartz sleeves, obstructing and reducing UV
radiation into the effluent.
Again, the UV sensor can be utilized as a guide, but maintaining facility

records to track performance is the best method of determining an
appropriate time interval for removing the racks for cleaning.
Suspended Solids: UV systems are designed at an assumed level of

suspended solids – normally 30 mg/l or less. Process changes or
upsets that increase suspended solids beyond the level considered in
the design can result in process failure. Like fouling, excess suspended
solids can obstruct the UV radiation from reaching the targeted micro-
organisms. Appropriate steps must be taken to maintain suspended
solids at or below the design level.
Dissolved Organics: Some organic compounds can absorb UV

radiation, rendering it unavailable for disinfection purposes. Note
facility changes, and changes in chemicals utilized on site, and be aware
of the potential impacts on UV disinfection.

Dissolved Solids Levels: Increased levels of dissolved solids – such as
calcium carbonate – can result in more rapid coating of the sleeves.
Again, the facility should note changes in chemicals utilized, and
dosage rates. If adverse impact is noted, the cleaning frequency may
need to be increased.
Flow Rate: Flow rate impacts retention time on the system; the lower
the retention time, the lower the dosage will be (and lower kill efficacy).
If facility operations change such that even relatively minor, yet
consistent, increases in flow are noted, the situation should be reviewed
with the manufacturer.
Note substantially lower flows can also adversely affect performance.

UV systems are based on turbulent flow through the channel. If flow
is reduced sufficiently to change to a laminar flow regime, performance
can suffer.
Finally, it is important to note these impacts can be synergistic. For

example, the contamination of an 18 month old bulb, combined with
suspended solid levels at the design limit, combined with a cleaning
frequency determined when the bulb was new, can cumulatively result
in process failure. Hence, the operator should be aware of these
cumulative effects, and make the appropriate changes to ensure
continuous compliance.
X.2.C. UV Disinfection Instrumentation and Control

UV systems are supplied with a programmable logic controller (PLC)
with an operator interface. The units offer display, warning and alarms
on light intensity, totalizer timers, water level, light failure, power
failure, etc.
Individual manufacturer instruction manuals should be reviewed to

determine the specific capabilities of the facility’s PLC.
X.2.D. UV Disinfection Analytical Sampling

Analytical testing of the UV disinfection system should be conducted
in accordance with company policy. A suggested sampling protocol is
provided below:
Dissolved Solids 1/week

Suspended Solids 1/week
Fecal Coliform per permit

X.2.E. UV Disinfection System Maintenance
The operator should perform the following maintenance functions.
 Ensure flow control valve is free of obstruction and fully

operational on a daily basis.
 Clean tubes on a frequency necessary to maintain effective

treatment. Note frequency may increase with age.
 Replace lamps as needed. Maintain accurate logs on lamp age.

Maintain 5% lamp inventory on site.
 Replace quartz sleeves as needed. Maintain accurate logs of sleeve

age. Maintain 5% sleeve inventory on-site.
X.2.E. UV Disinfection System Troubleshooting Chart

A troubleshooting chart for the UV disinfection system is attached as
Chart X.2.

Chart X.2
UV DISINFECTION SYSTEM
Decision Chart
No No
Turn On Is Unit On?
Blue/Green Glow
Visible in Channel?
Yes
No PLC
Activate PLC Yes
Operational?
No Quartz Tubes Need Yes
Yes Cleaned? Clean Tubes
UV Sensor Above
Activate No Minimum? No
Power Supply OK?
Power Supply
TSS Level Yes
Yes >30 mgll? Reduce TSS
Check with Yes No
Manufacturer
TDS Level Yes
Elevated Reduce TDS
Is Flow
No No Unobstructed No
Repair Flow Flow Control through Channel?
Control Valve Value Properly Dissolved Organics Yes Reduce
Functioning? Yes Level Elevated Dissolved
Organics
Yes No
Deactivate Unit Yes Continue Routine
and Debris in Bulbs Need
Channel? Monitoring
Remove Debris Replacement

XI. FINAL FLOW MEASUREMENT
Prior to discharge to a receiving stream, it is normally necessary to record discharge

flow. With this flow data, and the analytical concentration data for a particular
pollutant, the daily discharge mass loading can be calculated as follows:
Mass Loading = Flow x Concentration x 8.34

Where
Mass Loading = Calculated daily discharge of a
pollutant, in lb/day
Flow = Daily flow result, in million
gallons per day, or MGD
Concentration = Laboratory analytical result, in units
of mg/l or parts per million (ppm)
8.34 = Conversion factor
Discharge flow measurement depends upon two distinct units. First is the open
channel flow device, such as a flume or weir. The head, the difference in elevation
between the base of the flume or weir, and the actual water level, is directly
proportional to the flow through the device.
The second unit necessary is the flow recording and totalizing device. These units
simply measure the head present in the flume or weir, and convert that head level to
instantaneous and (if so equipped) totalized daily flow.
X1.A. Final Flow Measurement Design

The selection of the appropriate weir or flume is generally dictated by
flow, i.e., the greater the flow, the larger the flume or weir. The flow of
water through a flume or weir can be written in equation form as:
Q = KWHn
Q = flow rate
K = constant factor, dependent upon weir or flume type
W = width
H = head
n = an exponent dependent upon the weir or flume type
From this equation it is apparent that, for a given flume of a given

width, as the flow rate (Q) increases, H must also increase. At some
point, it becomes desirable to have a larger W, so the head loss through
the flume does not become excessive. An example would be if flow,
Q, were to increase sufficiently such that the resulting Head, H, caused
a manhole to overflow. In such a case, a wider flume or weir would
clearly be desirable. On the other extreme, an extremely low flow
results in a small H, which can increase the likelihood and impact of
measurement error. So, the designer wants to ensure that, over the
flow range for a given plant, the flume or weir is sized appropriately to
avoid either of these extremes.
The most commonly used weirs and flumes in poultry wastewater

treatment facilities are:
60° V Notch Weirs

90° V Notch Weirs
Rectangular Weirs
6” Parshall Flumes
12” Palmer-Bowlus
15” Palmer-Bowlus
18” Palmer-Bowlus
A typical V Notch Weir is presented in Figure X1.1. Flow charts for

60° and 90° V Notch Weirs are presented in Table X1.1.
A typical Rectangular Weir is presented in Figure XI.2. A flow chart

for a rectangular weir is presented in Table XI.2.
A typical Parshall Flume is presented in Figure XI.3. Flow charts for

6”, 9”, and 12” flumes are provided in Tables XI.3.
A typical Palmer-Bowcus Flume is presented in Figure XI.4. Flow

charts for 12”, 15” and 18” flumes are provided in Table XI.4.
The choice of a flow measurement and recording device is normally

the preference of the designer or operator. Three basic types enjoy
widespread use in poultry processing wastewater facilities.
 Ultrasonic
 Bubbler
 Mechanical Float
Each of these is capable of measuring the head level created by flow. All
are accurate enough for the purpose intended.

Figure XI.1
TYPICAL V-NOTCH WEIR
Front View
Flow H
Side View

TABLE XI.1
Discharge Rate for

V-Notch Weirs
H Q Q Q
(Inch) (gpm) (MGD) (gpm) Q (MGD)
60o Weir 90o Weir

1 1.27 0.002 2.19 0.003
2 7.16 0.010 12.41 0.018
3 19.74 0.028 34.19 0.049
4 40.53 0.058 70.19 0.101
5 70.80 0.102 122.62 0.177
6 111.68 0.161 193.43 0.279
7 164.18 0.236 284.38 0.410
8 229.25 0.330 397.08 0.572
9 307.74 0.443 533.04 0.768
10 400.48 0.577 693.67 0.999
11 508.23 0.732 880.30 1.268
12 631.73 0.910 1094.22 1.576
13 771.68 1.111 1336.63 1.925
14 928.75 1.337 1608.69 2.317
15 1103.59 1.589 1911.52 2.753
16 1296.82 1.867 2246.21 3.235
17 1509.04 2.173 2613.81 3.764
18 1740.85 2.507 3015.31 4.342

Figure XI.2
TYPICAL RECTANGULAR WIER
Front View
Flow H
Side View

TABLE XI.2
Discharge Flows for
Rectangular Weirs
H
Head Flow, Weir = 1 ft Flow, Weir = 2 ft Flow, Weir = 3 ft Flow, Each add'l Foot
(inch) GPM MGD GPM MGD GPM MGD GPM MGD
1 35.35 0.05 71.31 0.10 107.26 0.15 35.95 0.05

2 98.30 0.14 199.99 0.29 301.67 0.43 101.69 0.15
3 177.47 0.26 364.29 0.52 551.10 0.79 186.81 0.27
4 268.44 0.39 556.06 0.80 843.68 1.21 287.62 0.41
5 368.46 0.53 770.42 1.11 1172.38 1.69 401.96 0.58
6 475.55 0.68 1003.94 1.45 1532.32 2.21 528.39 0.76
7 588.16 0.85 1254.01 1.81 1919.85 2.76 665.84 0.96
8 705.04 1.02 1518.54 2.19 2332.05 3.36 813.50 1.17
9 825.10 1.19 1795.81 2.59 2766.52 3.98 970.71 1.40
10 947.42 1.36 2084.33 3.00 3221.24 4.64 1136.91 1.64
11 1071.17 1.54 2382.81 3.43 3694.45 5.32 1311.64 1.89
12 1195.60 1.72 2690.11 3.87 4184.61 6.03 1494.50 2.15
13 1320.04 1.90 3005.20 4.33 4690.35 6.75 1685.16 2.43
14 1443.86 2.08 3327.15 4.79 5210.44 7.50 1883.29 2.71
15 1566.47 2.26 3655.11 5.26 5743.74 8.27 2088.63 3.01
16 1687.36 2.43 3988.30 5.74 6289.23 9.06 2300.94 3.31
17 1805.99 2.60 4325.98 6.23 6845.97 9.86 2519.99 3.63
18 1921.91 2.77 4667.48 6.72 7413.06 10.67 2745.58 3.95

Figure XI.3
TYPICAL PARSHALL FLUME
Point of H
Measurement
Flow
W
Q
Plan View
Flow
H
Q
Elevation View

TABLE XI.3
Parshall Flume
Flow Rates
H Inch 6 in Parshall 9 in Parshall 12 in Parshall

GPM MGD GPM MGD GPM MGD
1 21 0.03 30 0.04 38 0.06

2 52 0.08 88 0.13 121 0.17
3 103 0.15 166 0.24 207 0.30
4 165 0.24 256 0.37 328 0.47
5 230 0.33 355 0.51 557 0.80
6 310 0.45 475 0.68 605 0.87
7 394 0.57 603 0.87 769 1.11
8 489 0.70 736 1.06 946 1.36
9 588 0.85 889 1.28 1135 1.63
10 691 1.00 1049 1.51 1336 1.92
11 800 1.15 1206 1.74 1550 2.23
12 925 1.33 1378 1.98 1773 2.55
13 1047 1.51 1555 2.24 2007 2.89
14 1179 1.70 1743 2.51 2251 3.24
15 1315 1.89 1939 2.79 2505 3.61
16 1413 2.03 2139 3.08 2779 4.00
17 1558 2.24 2347 3.38 3042 4.38
18 1691 2.44 2563 3.69 3323 4.79

Figure IX.4
TYPICAL PALMER-BOWLUS FLUME
Point of H
Measurement
Flow
Q
W
Plan View
End View
Flow
Q
H
Elevation View

TABLE XI.4
Palmer-Bowlus Flume
Flow Rates
H Inch 6 in Palmer-Bowlus 9 in Palmer-Bowlus 18 in Palmer-Bowlus

GPM MGD GPM MGD GPM MGD
3 105 0.15
4 181 0.26 211 0.30 235 0.34
5 279 0.40 318 0.46 353 0.51
6 396 0.57 451 0.65 501 0.72
7 532 0.77 606 0.87 673 0.97
8 687 0.99 781 1.12 869 1.25
9 840 1.21 980 1.41 1090 1.57
10 1199 1.73 1334 1.92
11 1440 2.07 1599 2.30
12 1892 2.72
13 2006 2.89

Flumes and weirs should be kept free and clear of branches, sticks, debris, algae
or foam that can cause interference with proper measurement and recording of
flow. Note both influent and effluent channels need to be maintained in this
manner. An obstruction downstream of the flume or weir can “back-up” water
into the flume, invalidating measurement.
Special attention is necessary in winter months, when icing may interfere with
normal channel flow, or the free movement of a mechanical float recording
device.
Measurement and recording device information is manufacturer specific. The

operator should refer to the manufacturer’s manual for particular device
operating instructions.
XI.C. Final Flow Measurement Instrumentation and Control

Instrumentation and control are an integral part of the design and operation of
a flow measurement device. A general description has been provided above;
particular unit instrumentation and control should be reviewed in the
manufacturer’s manual. Flow measurement and recording devices should be
calibrated at the frequency directed by the manufacturer. Calibration should be
spot checked (i.e., compare instantaneous head reading versus instantaneous
flow rate) daily.
Please note that flow measurement and recording devices are factory calibrated
for a particular size flume or weir. Therefore, it cannot, without proper
reconditioning, be adapted to another size flume or weir.
XI.D. Final Flow Measurement Analytical Testing

Analytical testing performed at the final flow measurement device is normally
dictated by the facility’s discharge permit.
XI.E. Final Flow Measurement Maintenance Checklists

As applicable to a particular facility, the following preventive maintenance
checks should be performed.
With mechanical float devices, ensure the float is free to travel and not binding.
Lubricate as needed.
If a stilling well is utilized, routinely check for, and remove, any accumulated
debris. Clean algae/slime growths from flume or weirs routinely.
Inspect air bubbler line monthly for leaks. Replace as needed.

XII. PROCESS DATA COLLECTION
Process data collection is fundamentally essential to the successful treatment of

poultry processing wastewater. Throughout this manual, suggested process control
tests, and the frequency of testing, have been provided. Individual facilities can
decide to do more or fewer tests, and perform the tests more or less frequently, as
specific site circumstances dictate.
Provided in Table XII.1 is the recommended sample type, sample container and
recommended preservation techniques for common poultry wastewater analyses.
Provided as Table XII.2 following are summary process log sheets that a facility can
use directly, or modify to suit their needs. Please note no data sheet has been
provided for the final effluent. Samples collected at the final discharge monitoring
location are controlled and regulated by the permit. Final effluent samples should be
collected and analyzed in accordance with permit terms and conditions and company
policy.

U.S. POULTRY & EGG ASSOCIATION XII.1
TABLE XII.1 SUMMARY OF SAMPLING HANDLING REQUIREMENTS
Minimum Maximum
Sample Storage
Size Sample Recommended/
Determination Container † m/ L Type‡ Preservation§ Regulatory║
Alkalinity P,G 200 g Refrigerate 24 h/14 d

BOD P,G 1000 g Refrigerate 6 h/48h
COD P,G 100 g,c Analyze as soon as possible, or add H2SO4 7 d/28 d
to pH<2; refrigerate
Chlorine, residual P,G 500 g Analyze immediately 0.5 h/stat
Conductivity P,G 500 g,c Refrigerate 28 d/28 d
Hardness P,G 100 g,c Add HNO3 to pH<2 6 months/6 months
Metals, general P(A), G(A) 500 g For dissolved metals filter immediately, add 6 months/6 months
HNO3 to pH <2
Ammonia, Nitrogen P,G 500 g,c Analyze as soon as possible, or add H2SO4 7 d/28 d
to pH<2, refrigerate
Nitrate, Nitrogen P,G 100 g,c Analyze as soon as possible or refrigerate 48 h/48 h (28 d for
chlorinated samples)
Nitrate + Nitrite, Nitrogen P,G 200 g,c Add H2SO4 to pH<2, refrigerate none/28 d
Nitrite, Nitrogen P,G 100 g,c Analyze as soon as possible or refrigerate none/48 h
Organic, Kjeldahl, Nitrogen* P,G 500 g,c Refrigerate; add H2SO4 to pH<2 7 d/28 d
Oil and grease G, wide-mouth 1000 g,c Add HC1 to pH<2, refrigerate 28 d/28 d
calibrated
Oxygen, dissolved, Electrode G, BOD bottle 300 g Analyze immediately 0.5 h/stat
pH P,G 50 g Analyze immediately 2 h/stat
Phosphate G(A) 100 g For dissolved phosphate filter immediately; 48 h/N.S.
refrigerate
Salinity G, wax seal 240 g Analyze immediately or use wax seal 6 months/N.S.

U.S. POULTRY EGG ASSOCIATION XII - 2
Minimum Maximum
Sample Storage
Size Sample Recommended/
Determination Container † m/ L Type‡ Preservation§ Regulatory║
Solids P,G 200 g,c Refrigerate 7 d/2-7 d; see cited

reference
Sulfate P,G 100 g,c Refrigerate 28 d/28 d
Sulfide P,G 100 g,c Refrigerate; add 4 drops 2N zinc acetate/100 28 d 7/d
mL; add NaOH to pH>9
Temperature P,G -- g Analyze immediately stat/stat
Turbidity P,G 100 g,c Analyze same day; store in dark up to 24 h, 24 h/48 h
refrigerate
† P = plastic (polyethylene or equivalent); G = glass; G(A) or P(A) = rinsed with 1 + HNO3.

‡ g = grab; c = composite.
§ Refrigerate = storage at 4°C, in the dark.
║ Environmental Protection Agency, Rules and Regulations, 40 CFR Parts 100-149, July 1, 1992. See this citation for possible differences regarding container and
preservation requirements. N.S. = not stated in cited reference; stat = no storage allowed; analyze immediately.
Adapted from Standard Methods for the Examination of Water & Wastewater, 19th Edition, 1995, APHA, AWWA, WEF.

U.S. POULTRY EGG ASSOCIATION XII.3
TABLE XII.2 XYZ POULTRY COMPANY
Month____ Year _____
WASTEWATER PROCESS CONTROL DATA
SCREENED WASTEWATER - CONCENTRATION
INIT TOTALIZER END TOTALIZER FLOW BOD COD ALKALINI TSS TKN PHOS
READING READING (MGD) pH (SU) (MG/L) (MG/L) TY(MG/L) (MG/L) (MG/L) (MG/L)
Suggested Frequency 1/day 1/day 1/day 1/shift 1/week 1/day 1/day 1/week 1/week 1/month
DATE TIME
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
AVG
MAX
MIN

U.S. POULTRY EGG ASSOCIATION XII. - 4
SCREENED WASTEWATER - LOADING
BOD COD ALKALINI TSS TKN PHOS
(LB/D) (LB/D) TY(LB/D) (LB/D) (LB/D) (LB/D)
1/week 1/day 1/day 1/week 1/week 1/month
DATE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
AVG
MAX
MIN

DAF EFFLUENT - CONCENTRATION DAF EFFLUENT - LOADING
BOD COD ALKALINI TSS TKN PHOS BOD COD TSS TKN PHOS
pH (SU) (MG/L) (MG/L) TY(MG/L) (MG/L) (MG/L) (MG/L) (LB/D) (LB/D) (LB/D) (LB/D) (LB/D)
1/shift 1/week 1/day 1/day 1/week 1/week 1/month 1/week 1/day 1/week 1/week 1/month
DATE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
AVG
MAX
MIN

ANAEROBIC EFFLUENT - CONCENTRATION ANAEROBIC EFFLUENT - LOADING
pH BOD COD ALK. FOG TSS NH3 TKN BOD COD FOG TSS NH3 TKN
(SU) (MG/L) (MG/L) IA/PA (MG/L) (MG/L) (MG/L) (MG/L) (MG/L) (LB/D) (LB/D) (LB/D) (LB/D) (LB/D) (LB/D)
1/DAY 1/week 1/day 1/day 1/day 1/week 1/week 1/day 1/week 1/week 1/day 1/week 1/week 1/day 1/week
DATE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
AVG
MAX
MIN

AERATION BASIN
FILT.NH3 FILT.NO3 ALKALINI MLSS MLVSS RSS TEMP. SLUDGE F/M
DO (mg/l) (MG/L) (MG/L) TY(MG/L) (MG/L) (MG/L) (MG/L) (oC) AGE RATIO
1/day 1/day 1/day 1/day 3/week 3/week 3/week 1/day
DATE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
AVG
MAX
MIN

CLARIFIER EFFLUENT - CONCENTRATION CLARIFIER EFFLUENT - LOADING
BOD COD ALK. TSS NH3 NO3 TKN BOD COD TSS NH3 NO3 TKN
pH (SU) (MG/L) (MG/L) (MG/L) (MG/L) (MG/L) (MG/L) (MG/L) (LB/D) (LB/D) (LB/D) (LB/D) (LB/D) (LB/D)
1/DAY 1/week 1/day 1/day 1/week 1/day 1/day 1/week 1/week 1/day 1/week 1/day 1/day 1/week
DATE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
AVG
MAX
MIN

FILTER EFFLUENT - CONCENTRATION FILTER EFFLUENT - LOADING
BOD COD ALK. TSS NH3 NO3 TKN BOD COD TSS NH3 NO3 TKN
pH (SU) (MG/L) (MG/L) (MG/L) (MG/L) (MG/L) (MG/L) (MG/L) (LB/D) (LB/D) (LB/D) (LB/D) (LB/D) (LB/D)
1/DAY 1/week 1/day 1/day 1/week 1/day 1/day 1/week 1/week 1/day 1/week 1/day 1/day 1/week
DATE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
AVG
MAX
MIN

XIII. FACILITY DESIGN DATA
The following form is for facility use in identifying and maintaining facility design data in a
single location. By completing the applicable sections of this form, the facility can conveniently
respond to questions and inquiries regarding the treatment system and its capacity.
XIII.1. Offal Screening System
XIII.1.A. Primary Screens
Number _______
Type:
External Fed Rotary Dia. ___ ft. Lgth ___ ft. Mesh ___ Opening Size ___mm
Internal Fed Rotary Dia. ___ ft. Lgth ___ ft. Mesh ___ Opening Size ___mm
Shaker Dia. ___ ft. Lgth ___ ft. Mesh ___ Opening Size ___mm
Other Name _________________ Dimensions __________________
Vendors ______________________________________
XIII.1.B. Secondary Screen

Type:
Shaker Dia. ___ ft. Lgth ___ ft. Mesh ___ Opening Size ___mm
Vendors ______________________________________
XIII.1.C. Tertiary Screening

Type:
Vendors ______________________________________

U.S. POULTRY & EGG ASSOCIATION XIII.1
XIII.2. DAF
XIII.2.A. DAF Manufacturer and Model # ___________________________________
Contact Phone #: __________________
Type: Full Flow

Recycle Pressurization
Plate Packs? Yes No
Circular Dia. = ____ft. H = ___ft. Vol. = ___ gal.
Rectangular L = ____ft. W = ___ft. H = ___ft. Vol. = ___ gal.
Retention Time = Avg. Flow Rate (GPM) = ________ minutes

Volume (gal.)
Pressure Pump Model #_______ Pump HP _____ # of pumps ______

Pump Capacity = _______ GPM @ ____ TDH
Pump Vendor Phone # __________________
XIII.2.C. Polymer System

Type of Polymer System:
Ferric/Anionic Alum/Anionic Acidulation
Modified Acidulation 3-Polymer Other (none) ________
Polymer Feed Systems:

Commercial Makedown Systems
Manufacturer ____________________________
Contact Number _________________
Day Tanks and Pumps:

Sizes: Tank #1 ____ gal. Tank #2 ____ gal. Tank #3 ___ gal.
Product: Tank #1 ___ gal. Tank #2 ____ gal. Tank #3 ___ gal.
Pump Capacity: Pump #1 __ gph Pump #2 __ gph Pump #3 __gph
Pump Model: Pump #1 __ gph Pump #2 __ gph Pump #3 __gph
Pump Contact #: Pump #1 __ gph Pump #2 __ gph Pump #3 __gph

XIII.3. Anaerobic Lagoon
Construction: Earthen Lined Concrete Covered

Dimension: L = ___ ft, W = ___ ft. Depth = ___ ft. WL = ___ ft.
Side Slope: :1 ratio
Volume: _______ MG
Retention Time = V (MG) = _________days
Flow (MGD)
Loading = lb/day/BOD = ___ lb/day/1000 ft.3
Vol. (1000 ft.3)
XIII.4. Activated Sludge System
XIII.A. Aeration Basin

Construction: Earthen Lined Concrete Steel
Dimensional Data:
Rectangular Basin: L = ____ft. W = ____ft. D = ____ft.
Slide Slope = ____:1 Ratio Vol. = ____MG
Circular Basin: Dia. = ____ft. Depth = ____ft.
Retention Time = Basin Volume = _____MG = _____days

Daily Flow _____MGD
XIII.4.B. Aeration System
Blowers # = _____ List HP’s _____ Total HP _____

Vendor Phone #___________________
Aerators # = _____ List HP’s _____ Total HP _____
Vendor Phone #___________________
Other (describe) _______ #_____ List HP’s _____ Total HP_____
Vendor Phone #___________________
Total Aeration HP Available _______HP
Diffusers
Coarse # = ______ Vendor Phone #________________________
Fine Bubble # = ______ Vendor Phone #_____________________
Mixers # = ______ Vendor Phone #_________________________
Other (describe ) ______ # = _____ Vendor Phone #____________
Down Draft Mixers #_____ List HP_____ Total HP_____

Vendor Phone #____________________________

XIII.4.C. Clarifier
Construction: Earthen Lined Concrete Steel Other

Dimensional Data:
Rectangular: L = ____ft. W = ____ft. D = ____ft.
Circular: Dia. = ____ft. Depth = ____ft.
Center Feed Peripheral Feed
Retention Time = Clarifier Flow = _____MG = _____days
Daily Flow MGD
= _____hours
Total Weir Length = _______ft.
Weir Loading = Daily Flow(GPD) = _______

Total Weir Length (ft.)


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WASTEWATER TREATMENT MANUAL

FOR POULTRY PROCESSING FACILITIES

In the Spring of 2001, USPOULTRY’s Environmental Impact Committee strongly

Gary Wolfe, Tyson Allen Youngblade, ConAgra

Art Riddick, Reid Engineering Joel Pounders, Gold Kist

The final, and most important acknowledgement, is to the many dedicated

John E. Starkey, P.E.

Second Edition, Eighth Printing, April 2012

I. Introduction to Poultry Processing Water Treatment

II. Process Overview

II.1. Wastewater Generation

III. Overview of Regulatory Requirements

IV. Applied Microbiology

IV.1. Anaerobic Lagoon Treatment

V. Applied Chemistry and Math

V.1. Chemical Glossary

VI. Dissolved Air Flotation (DAF) and Chemical Addition Systems

VI.1. Full Flow Pressurization Dissolved Air Flotation System

VII. Anaerobic Lagoons and Waste Gas Burner Systems

WASTEWATER TREATMENT MANUAL

VII.1. Anaerobic Lagoon

VII.2. Waste Gas Burner System

VIII. Unit Operations – Activated Sludge

IX. Tertiary Filtration

IX.1. Sand Filtration

XI. Final Flow Measurement

XII. Process Data Collection

XIII. Facility Design Data

WASTEWATER TREATMENT MANUAL

Figure II.1 Typical Water Use Schematic for Broilers

WASTEWATER TREATMENT MANUAL

Chart VI.1 Full Flow Pressurization DAF System

WASTEWATER TREATMENT MANUAL

Table II.1 Typical Poultry Plant – Unit Operation Performance

WASTEWATER TREATMENT MANUAL

Poultry processing facilities are subject to these permitting requirements. A particular

The intent of this manual is to provide operators of poultry processing wastewater

WASTEWATER TREATMENT MANUAL

WASTEWATER TREATMENT MANUAL

Provided below is a description of the processes generating wastewater in a poultry

II.1. Wastewater Generation

Water used in processing operations is collected and routed to the

II.2. Wastewater Treatment Components

II.3. Pretreatment System

WASTEWATER TREATMENT MANUAL

0.35 GPB TO WASTE TREAMENT

II.4. Dissolved Air Flotation

In a pressurized recycle system, the entire plant flow is no longer

WASTEWATER TREATMENT MANUAL

Regardless of the type of DAF a facility has, the DAF is designed to

II.5. Anaerobic Lagoon

II.6. Aeration Basin

WASTEWATER TREATMENT MANUAL

II.8. Final Filtration

II.10. Flow Measurement/Re-aeration

WASTEWATER TREATMENT MANUAL

WASTEWATER TREATMENT MANUAL

BOD 3000 1800 350 200 20 10

TSS 2000 900 250 200 30 10

TKN 150 130 100 100 8 4

NH3 50 40 30 90 <5 1.0

FOG 500 200 30 20 7 3

WASTEWATER TREATMENT MANUAL