SEWAGE TREATMENT PLANT

 Sewage Treatment Plant In Malaysia

In Malaysia extensive use has been made of primary treatment systems such as communal
septic tanks and imhoff tanks and unreliable low cost secondary systems such as oxidation
ponds. In addition, large urban areas utilize Individual Septic Tanks (IST). It is estimated that
there are over one million individual septic tanks in Malaysia.
These tanks only partially treat sewage, discharging an effluent still rich in organic
material. This has the potential to create public health and environmental problems, particularly
in urban areas.
Indah Water Konsortium (IWK) is responsible for planning and rationalizing the public
sewerage facilities to reduce the number of treatment plants using the "multipoint concept" or
regionalization. Finally, sewerage pipeline networks will be layed in urban areas currently
serviced by IST to convey the domestic sewage to modern secondary treatment facilities.
In Malaysia, 38% of public sewage treatment plants in the country are mechanical plants.
These plants operate using mechanical equipment that accelerates sewage break down. It is
hoped that in the long-term, Malaysia's sewerage system will be made more efficient through the
standardization of the types of plants used.
These extensive programs are nothing short of a revolution in the management of
domestic sewage in Malaysia. The entire sewerage infrastructure can expect to undergo changes.
Estimates have been made of the number and type of public treatment plants currently in
Malaysia.

No Types of Sewage Treatment Plant As At Oct 2014 Population Equivalent

.
1 Imhoff Tank 679 507,648
2 Oxidation Ponds 403 1,681,176
3 Mechanical Plants 4,902 18,665,408
4 Network Pump Stations 982 4,852,844
TOTAL 6,966 25,707,076
Table: Public Sewage Treatment Plants in Malaysia
Package  Sewage Treatment Plants
Commercially available prefabricated treatment plants known as "package plants" are
often used to serve small communities up to population equivalent (PE) of 5,000. Package plants
require little design work and can be installed quickly although they require the same operational
and maintenance care as conventional treatment plants. Claims that package plants produce no
sludge is incorrect.
Care must be taken in using package plants where large variations in flow (hydraulic
shock are experienced), in addition adequate provision must be made for sludge removal, scum
and grease removal and the proper control of air supply.The most common types of package
plants use Extended Aeration, Contact Stabilisation, Bio-Filter, Sequenced Batch
Reactors and Rotating Biological Contactor processes.

Extended Aeration

Fine Bubble Diffused Air Extended Aeration Systems (FBDAEA) are mechanical
secondary treatment systems. FBDAEA systems are robust and can withstand surges in
hydraulic or organic load.To breakdown the organic material in sewage, bacteria require
oxygen. This may be introduced by agitation (using surface aerators) or by submerged
"diffusers".
As the name implies FBDAEA systems introduce air in the form of fine bubbles through
submerged diffusers. Fine bubbles promote higher oxygen transfer efficiency and are
therefore used in preference to coarse bubbles.
Sewage entering a plant in passed through primary treatment where coarse material and
grit is removed. The sewage then passes to secondary treatment in the form of any
aeration tank where it is injected with fine bubbles of air from submerged diffusers.Solids
 in the sewage are held in suspension by the bubbles and bacteria in the sewage break
down organic materials. Sewage is held in the aeration tank between 18-24 hours.
The effluent with suspended material is then passed into a "clarifier" (sedimentation tank)
where the material settles as a sludge. The sludge is drawn off with some being returned
to the aeration tank to ensure enough bacteria are present in the tank to continue the
process of breaking down newly introduced sewage.The effluent is then polished and/or
discharged to the receiving environment.
Typical values for FBDAEA plants are as follows:
(mg/L) Raw Sewage Effluent DOE Standard B
Biological Oxygen Demand 200-400 10-30 50

Suspended Solids 200-350 15-40 100

FBDAEA systems can consistently produce a high quantity effluent. By monitoring the
influent and effluent, the activity in the aeration tank can be adjusted to cater for
variations in hydraulic or organic load. These plants only require moderate areas of land.
There are currently approximately 60 extended aeration systems in Malaysia and this is
expected to significantly increase to some 200 plants as older systems are phased out.

Contact Stabilisation

The activated sludge system is a suspended-growth aerobic process which uses the
metabolic reactions of microorganisms to convert biodegradable organic wastewater
constituents and certain inorganic fractions into new cell mass and byproducts. This
process has been widely applied for the treatment of domestic and industrial wastewater,
due to the high efficiency obtained, operational flexibility, and possibility of nutrient
removal [1-3].
Contact stabilization, as an activated sludge process modification, comprises two aerated
reactors (the contact reactor [CR], and the stabilization reactor [SR]) separated by a
sedimentation tank [3-7]. The CR receives the influent flow and the biomass in a starved
condition so that soluble material is readily adsorbed and absorbed by the starved
biomass.
The mixed liquor leaving the CR is settled and the biomass is concentrated. Then, the
biomass is sent to SR, where colloidal material removed from the wastewater in the CR is
stabilized. Stabilized biomass is returned to the CR by a biomass recycle flow [8].
The main design and operating parameters of activated sludge systems include the
hydraulic retention time (HRT), the sludge recycle rate (r), the sludge retention time
(SRT), mixed liquor volatile suspended solids (MLVSS), the volumetric organic load
(VOL), the food microorganism relation (F/M), the sludge settling properties (sludge
volumetric index [SVI]), the characteristics of floc, and the concentration of dissolved
oxygen (DO) [6, 9, 10].

The HRT is one of the main parameters in the activated sludge system as it is implicitly
associated with the organic load applied and the reactor volume. The HRT affects the
costs of implementation, operation, and maintenance [11]. For CR, the HRT varies
between 0.5 and 1.5 h. For SR, the HRT is determined by the recycle rate (flow
recirculation) and can vary between 2 and 6 h [9].
The VOL and F/M represent the organic load applied to the system in terms of the reactor
volume and the active biomass, respectively [9, 10]. The F/M can create conditions that
favor the predominance of filamentous organisms that affect the settling properties of the
sludge, causing brown foam in the aeration tank and deterioration in effluent quality [12,
13].
The SRT, used for the design and operation of the system, is the most important
parameter in maintaining the MLVSS concentration, as it influences the evolution of the
biochemical transformation processes and is related to the rate of growth of
microorganisms, because only the microorganisms capable of breeding in this time can
survive and enrich the system [6, 14]. According to Liao et al. [15, 16], Liss et al. [17],
and Wilen et al. [18], the SRT can affect the floc structure and the settling properties of
the sludge.
The MLVSS represents the amount of biomass in the system. The typical values for
activated sludge systems vary between 500 and 5000 mg.L-1 and the recommended
concentrations for the contact stabilization process are between 1000 and 3000 mg.L-1
for CR, and between 4000 and 10000 mg.L-1 for SR [6, 9, 19].
The fraction of biomass in CR is called the sludge distribution fraction (a factor), and
values recommended are between 0.1 and 0.3 [4, 8]. The SVI indicates the separation
efficiency of the biomass of the mixed liquor. According to Withey et al. [20], the settling
properties of sludge formed during the activated sludge process are essential for the
clarification of the effluent. Jenkins et al. [12] indicated that high values of SVI are
associated with sludge bulking and foam problems that affect the effluent quality.

The solids concentration in the secondary settler affect the solids concentration in the
recirculation sludge, although if the sludge is concentrated, the recycle rate requirements
will be lower in order to guaranteed the MLSSV in the SR, which is also affected by the
SRT [6, 9].
The DO concentration is important in the development of processes that occur in the
activated sludge systems. The main oxygen requirements are determined by oxidation of
organic matter and ammonium through heterotrophic and autotrophic microorganisms
respectively [21]. Low levels of DO can affect the sludge settling properties and the
metabolic activity of microorganisms, generating an incomplete removal of substrate,
which is reflected in the poor effluent quality [22].
Since 1972, studies have been conducted on this process. Between 1975 and 1980 Gujer
and Jenkins [5, 7] and Alexander et al. [8] proposed the kinetic models for carbon
removal and nitrification, and found that this system can be highly efficient in organic
matter removal with efficiencies around 80%. They established that the most relevant
operating parameters for this process are the HRT, SRT, r, and  factor. Sarioğlu et al.
[4] applied the contact stabilization process to the domestic wastewater of Istanbul.
The experimental results showed that the treatment efficiency increases when the
particulate COD fraction of an influent domestic wastewater increases. Efficiencies
observed during the study were around 82%.
Sequenced Batch Reactors

Sequencing Batch Reactor (SBR) system is a variation of the activated-sludge process for
treatment of waste water. SBR reactors treat wastewater such as sewage or output from
anaerobic digesters or mechanical biological treatment facilities in batches. Oxygen is
bubbled through the mixture of wastewater and activated sludge to reduce the organic
matter (measured as biochemical oxygen demand (BOD) and chemical oxygen demand
(COD). The treated effluent may be suitable for discharge to surface waters or possibly
for use on land.
It differs from activated-sludge plants because the SBR combines all of the treatment
steps and processes into a single tank, thus reducing the footprint, whereas conventional
facilities rely on multiple basins.
SBR helps introduce various process flexibilities and alternatives in process controls and
design so as to better achieve the latest effluent discharge standards. With its design
flexibility and better process control the SBR process has been widely used not only to
treat domestic wastewater, but also for biological treatment of industrial wastewater
containing difficult-to-treat organic chemicals.
Improvements in equipment and technology, like aeration devices, piping design and
computer control system, have made SBR an efficient solution over the conventional
activated-sludge system. The system is very practical for a number of reasons:
 Required low area as well as man power operation
 With effective automated system, it will save more than 60% of the operating
expenses than a conventional activated sludge process.
 Able to achieve high effluent quality in a very short aeration time.
 Biochemical oxygen demand (BOD) levels of less than 5 mg/L can be achieved
consistently.
 Minimizing sludge handling requirements downstream of SBR
Rotating Biological Contactor 

Water is the most important natural gift for human being and aquatic life. Due to
continuous technological growth and industrialization, the water has been fully polluted
and categorized as water pollution. The outlet water of industries and human which
accedes the limit of organic and inorganic components in the water is called wastewater
(polluted water).
Rotating Biological contractor is one type of treatment system. Treatment system with
RBC can be designed to provide to provide secondary or advanced level of treatment.
Effluent BOD characteristics for secondary treatment are comparable to well – operated
ASP. Where a nitrified effluent is required, RBC can be used to provide combined
treatment for BOD and ammonia nitrogen, or to provide separate nitrification of
secondary effluent.
The RBC process applicable typically consists of a number of units operated in series.
The number of stage depends on the treatment goal, with two to four stages of BOD
removal and six or more stages for nitrification. Stages can be accomplished by using
baffles in a single tank or by use of separate tanks in series. The suppliers of RBC
equipment differ in there disc designs, shaft, and packing support, and configuration
designs. The principal elements of a RBC system design are the shaft, disk materials and
configuration, drive system, enclosures and settling tanks.
 The performance of package plants can be improved by sizing the components
conservatively. In general, the careful selection of the right process should lead to an adequate
plant for small isolated communities requiring sewage treatment. A plant such as the one using
an "Extended Aeration Activated Sludge" process should produce a good effluent quality, have
low sludge yield and be easy to operate.
There are now a large number of package plants in the market using a variety of
equipment. Uncontrolled selection of plants can lead to problems with operational knowledge
and supply of spare parts. Hence, some form of regulation for the use of these plants will be
employed to ensure overall industry efficiency.
Further, market forces have driven the manufactures to make optimistic claims for the
treatment capacity of small package plants, leading to plants designed in the high rate activated
sludge mode in order to reduce the capital cost of construction. This often leads to high
operational, maintenance and operator costs due to the need for high operator involvement to
keep the plants running within the design parameters.

Mechanical Plant
The trend will be moving towards "mechanical plants" such as
 Extended Aeration (EA)
 Oxidation Ditch (OD)
 Rotating Biological Contactors (RBC)
 Sequence Batch Reactors (SBR)
 Trickling Filters
Oxidation Ditch (OD)

The Oxidation Ditch (OD) is a modified form of the activated sludge system. Oxidation
ditches are mechanical secondary treatment systems which are tolerant of variations in hydraulic
and organic loads.
The OD consists of a "ring or oval shaped channel" equipped with mechanical aeration
devices. Screened wastewater, which enters the ditch is aerated and circulated. ODs typically
have long detention times and are capable of removing between 75% and 95% of the Biological
Oxygen Demand (BOD).
The proprietary "Orbal System" uses three channels or ditches concentrically placed.
Each channel is independently aerated and can be configured to act in parallel or series with the
other channels, depending upon the degree of treatment required.
 After screening and grit removal, sewage enters the outer channel where most of the
biological reaction takes place. The second channel is held at a slightly higher dissolved oxygen
content for further BOD and nutrient reduction. The innermost channel is used for polishing the
effluent before it passes to a clarifier.
Typical figures for ODs are as follows:
(mg/L) Raw Sewage Effluent DOE Standard B
Biological Oxygen Demand 200-400 10-30 50
Suspended Solids 200-350 15-40 100

The ODs can be easily adjusted to meet most combinations of incoming sewage and
effluent standards. This system achieves both high BOD reduction and some nutrient removal.
ODs require more land than other processes but can be cheaper to construct and operate.
There are currently approximately 30 ODs in Malaysia. The new modified ODs in Malaysia are
located in Sg. Besi - Kuala Lumpur, Bayan Baru - Penang and Cyberjaya.

Rotating Biological Contractors (RBC)

Rotating Biological Contactors (RBCs) are mechanical secondary treatment systems,

which are robust and capable of withstanding surges in organic load. RBC's were first installed
in Germany in 1960 and have since been developed and refined into a reliable operating unit.
Sewage entering a plant is passed through primary treatment where coarse material and
grit is removed. The sewage then passes through one or more RBC units, which have historically
been built in a variety of configurations.
An RBC unit comprises a series of closely spaced "circular disks" normally made from a
plastic material. The disks are partially submerged in the sewage and are slowly rotated through
it.
 The rotating disks support the growth of bacteria and micro-organisms present in the
sewage, which breakdown and stabilise organic pollutants. To be successful, micro-organisms
need both oxygen to live and food grow. Oxygen is obtained from the atmosphere as the disks
rotate. As the micro-organisms grow, they build up on the media until they are sloughed off due
to shear forces provided by the rotating discs in the sewage.
Effluent from the RBC is then passed through final clarifiers where the micro-organisms
in suspension settle as a sludge. The sludge is withdrawn from the clarifier for further treatment.
The Submerged Biological Contactor (SBC) is the modified version of the conventional
RBC where the disks are 80% -100% submerged and forced air is introduced.
Typical values for RBC's are as follows:
(mg/L) Raw Sewage Effluent DOE Standard B
Biological Oxygen Demand 200-400 10-30 50
Suspended Solids 200-350 15-40 100

RBC units are suitable where land is restricted. They are quite and consistently produce a
high quality effluent. Because they are modular they are also suitable for a staged development.
Operations and maintenance costs are lower than for other forms of mechanical treatment.
There are currently approximately 40 RBC plants in Malaysia.

Sequence Batch Reactors (SBR)

Sequencing Batch Reactor (SBR) is a typical suspended growth aerobic biological
treatment. In most SBR systems, the plant has two or more identical treatment tanks. The
treatment for a particular batch of sewage is done sequentially in the same tank. To achieve the
controlled and evenly distributed sewage across the tank, the entire mass of sewage inside the
tank is churned and mixed thoroughly with aeration devices. The activated sludge already
present in the tank provides the micro-organisms for the biological treatment of the sewage. The
new batch of raw sewage is subjected to this biological treatment. Aeration Devices provide air
for the growth and multiplying of bacteria inside the Reactor Tank. This helps to maintain the
Dissolved Oxygen inside the tank within the required limits
Trickling Filter

The first trickling filter was brought into operation in England in 1893.
The modern trickling filter comprises a bed of highly permeable medium to which micro-
organisms are attached. Sewage is percolated or trickled through this media which is made from
rocks (2cm to 10cm in size) or specially designed plastic.
Rock beds are typically 2 meters deep and are circular. A revolving arm is used to distribute the
sewage over the media. Plastic media varies in design with depths ranging from 4 to 12 meters
depending upon the organic load.
Filters under the media drain the effluent and biological solids, which have become detached
from the media. Air is circulated back through the drainage system to the media. The effluent
from the drain is settled before discharge to the receiving environment.
Some effluent from the drain is recycled to dilute the strength of the incoming sewage and to
ensure the media remain moist.
As the effluent passes through the media organic material is absorbed onto the biological film or
slime layer covering the media. Here is it degraded by aerobic micro-organisms. As the slime
layer grows an anaerobic environment is created near the media interface. Eventually the micro-
organisms at the media interface loose their ability to cling to the media and the slime is washed
off. A slime layer begins to grow again and the cycle is repeated.
Filters are classified by hydraulic or organic loading rates. Classifications are low rate,
intermediate rate, high rate, super high rate and roughing. Re-circulation of filter effluent permits
higher organic loadings in high rate filters.
High rate trickling filters remove between 65% to 85% of the organic load. They are used where
there is sufficient land available and where a quiet operation is required. They can sustain some
variation is hydraulic or organic load.
Pros:
 Removes 97% of suspended soil
 Capable of biological nitrification without using chemicals
 Maintenance-free plant operation
 Highly efficient
 Includes oxidation and nitration
 Eliminates organics
 Separates solids and liquids automatically
 Affordable
 Easy to operate, install
 Require low maintenance
 Self sustaining system
 Helps in saving the environment
Cons:
 Causes hassle in cleaning
 Most of the plant require three tanks to treat the water
 Tanks gets easily affected by the change in temperature
Combined Process
Recent developments in sewage treatment technology include the combination of various aerobic
treatment processes to obtain the best performance and most economical treatment of sewage.
Combining the various aerobic processes available can derive a large number of treatment
systems. The main reason for combining these processes is that they provide the stability and
resistance to shock loads of attached growth processes and the high-quality effluent of suspended
growth systems.
Various standard combinations exist such:
 Activated Bio-Filter Process
 Roughing - Filter Activated Sludge Process
 Bio-Filter Activated Sludge Process
 Series Trickling Filter Activated Sludge Process
In particular, the combination of a trickling filter and solids-contact process produces a high
quality effluent with complete reliability. The trickling-filter solids-contact (TF/SC) process
consists of a trickling filter, an aerobic contact tank, and a final clarifier. Modifications to this
system include a return-sludge aeration tank and flocculating center-well clarifiers.
The trickling filters are sized to remove the major portion of the BOD, typically 60 to 85 percent.
The biological solids formed on the trickling filter are sloughed off and concentrated through
sludge recirculation in the contact tank. In the contact tank, the suspended growth is aerated for
less than one hour, causing the flocculation of the suspended solids and further removal of
soluble BOD. When short solids contact times are used, a sludge re-aeration tank is usually
required. Because of the high level of dispersed solids in contact tank effluent, flocculating
center-well clarifiers have been found to be effective in maximising solids capture.
Combined Processes can be used to upgrade both existing trickling filter or extended aeration
plants. It is particularly suitable where there are problems of high suspended solids in the final
effluent. This can occur where solids in the effluent do not settle out sufficiently in the final
clarifier