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CE 333: ENVIRONMENTAL ENGINEERING II

Lecture-06: SLUDGE TREATMENT AND DISPOSAL

What is Sludge?
Sludge is the solids derived from preliminary, primary and secondary sedimentation tank. Preliminary
and primary sludge is largely organic containing fecal matter, food scrap etc. has a strong odor and is
unstable. Secondary sludge is usually finely divided and dispersed particles. It is difficult to dewater
and is generally odor free. Treated sludge is often referred to as Bio solids.

Significance of Sludge Treatment

Sludge has three characteristics that make such a simple solution unlikely:
i. they are aesthetically displeasing,
ii. they are potentially harmful, and
iii. they have too much water
The main component of all sludge is water. Prior to treatment, most sludge contain 95 to >99% water.
This high water content makes sludge handling and processing extremely costly in terms of both
money and time. Sludge handling may represent up to 40% of the capital cost and 50% of the
operation cost of a treatment plant

Sludge Characteristics
The composition and characteristics of sewage sludge vary widely and can change considerably with
time. However, the basic components of wastewater sludge remain the same. The only variations
occur in quantity of the various components as the type of sludge and the process from which it
originated changes.

The water content of the sludge is present in a number of different forms. Some forms can be removed
by several sludge treatment processes, allowing the same flexibility in choosing the optimum sludge
treatment and disposal method. The forms of water associated with sludge are:
i. Free water
Water that is not attached to sludge solids in any way. This can be removed by simple gravitational
settling.
ii. Floc water
Water that is trapped within the floc and travels with them. This part of sludge water removal is
possible by mechanical dewatering.
iii. Capillary water
Water that adheres to the individual particles and can be squeezed out of shape and compacted.
iv. Surface absorbed water
Water that is chemically bound to the individual particles by adhesive force
v. Inter cellular water
Water that exists in individual sludge molecules.

Sludge Treatment
Release of wastewater solids without proper treatment could result in severe damage to the
environment. As sludge contain potentially harmful contaminants and huge amount of water – both
removal of water and stabilization of solid wastes are required. Treatment of sludge may include a
combination of the following treatment processes:
1. Sludge thickening
2. Sludge stabilization
3. Sludge conditioning
CE-333 : Lecture-06: Sludge Treatment and Disposal /Prepared by: Snigdha Afsana, Assist Prof, Dept. of Civil Engineering, BUET
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4. Sludge dewatering
5. Ultimate disposal

Figure-2: Sludge handling and disposal option for hazardous & non-hazardous sludge

Sludge Thickening
Thickening is the first step for reducing the sludge volume by removal of free sludge water. The main
objective is to increase the efficiency and financial optimization of subsequent processes. By sludge
thickening a reduction in volume by a factor of 2 to 3 can be achieved. The main thickening processes
for sludge treatment are based on the following:

a. Gravity thickening:
Gravity thickening is the simplest and least expensive process for consolidating waste sludge. Gravity
thickening is most effective on primary sludge that decant well by gravity. Biological sludge decants
slowly. In operation, solids are withdrawn from primary treatment and pumped to the thickener. The
solids buildup in the thickener forms a solids blanket on the bottom. The supernatant (clear water) that
rises to the surface is returned to the wastewater flow for treatment. Performance of gravity thickeners
(i.e., the solids concentrations achieved) typically results in producing 8 to 10% solids from primary
underflow.

a) Gravity thickening b) Floatation

b. Flotation:
This type of system is useful for thickening biological sludge due to its low sedimentation capacity.
Recycled water from the flotation thickener is aerated under pressure. Air bubbles become attached to
the solids and lift them toward the surface. The accumulation of solids on the surface is called the float
cake. The solids are then moved up an inclined plane by a scraper and discharged. The supernatant
leaves the tank below the surface of the float solids and is recycled or returned to the waste stream for
treatment. Flotation thickener performance is typically 3 to 5% solids for WAS

CE-333 : Lecture-06: Sludge Treatment and Disposal /Prepared by: Snigdha Afsana, Assist Prof, Dept. of Civil Engineering, BUET
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c. Centrifugation:
Centrifugal force is used to separate mainly biological sludge. The equipment is often expensive and
requires adequate maintenance.

c) Centrifugation d) Rotary drum

d. Rotary drum:
Separation is by filtration through the rotary drum, and this is used for biological sludge. Operational
costs are not high, little space is required and unpleasant odors are not produced.

e. Gravity belt filter:

The separation occurs by draining the water through a moving
porous horizontal belt. This is suitable for active or digested sludge,
but not for primary sludge.

Sludge Stabilization
Stabilization is a process that stops the natural fermentation of the sludge. Sludge stabilization –
a. Reduce pathogens
b. Eliminate odors
c. Reduce or eliminate the rotting capacity of organic material.
The equipment required for stabilization depends on the specific process used. Depending on that
sludge stabilization methods can be divided as -
1. Biological stabilization
2. Chemical stabilization

1. Biological Stabilization
This further classified as –
i. Aerobic digestion
ii. Anaerobic digestion
iii. Composting

i. Aerobic Digestion
Equipment used for aerobic digestion consists of an aeration tank (digester) which is similar in design
to the aeration tank used for the activated sludge process. Aeration is periodically stopped and the
solids are allowed to settle. Generally, aeration continues for approximately 20 d retention time. When
no additional volume is available, mixing is stopped for 12 to 24 h before solids are withdrawn for
disposal.

ii. Anaerobic Digestion

Anaerobic digestion is the traditional method of sludge stabilization. The advantage of anaerobic
digestion is that only a small percentage of the wastes are converted into new bacterial cells. Most of
the organics are converted into carbon dioxide and methane gas.

This operation can occur in a single tank (single stage) or in two tanks (two stages). In a single-stage
system, supernatant and digested solids must be removed whenever flow is added. In a two-stage
operation, solids and liquids from the first stage flow into the second stage each time fresh solids are
added.

CE-333 : Lecture-06: Sludge Treatment and Disposal /Prepared by: Snigdha Afsana, Assist Prof, Dept. of Civil Engineering, BUET
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Single stage anaerobic digester Two- stage anaerobic digester

iii. Composting
The purpose of composting sludge is to aerobically stabilize the organic matter, reduce volume, and
eliminate pathogenic organisms. In composting, aerobic microorganisms convert much of the organic
matter into carbon dioxide leaving a relatively stable odor free substance which has some value as a
fertilizer. Both percent volatile matter reduction and percent moisture reduction ranges from > 40 to
60%.

2. Chemical stabilization
This is an alternative to biological stabilization, whose purpose is to reduce or minimize pathogens and
substantially reduce odor-producing microorganisms. The most common chemical stabilization is lime
stabilization.

Lime stabilization
Mainly lime is added to the sludge at the appropriate dosage to maintain
the pH at 12 for a sufficient time (minimum 2 hours) to eliminate or
reduce pathogenic microorganisms and those responsible for odor. The
treated solids can then be dewatered for disposal or directly land applied.
The problem using this method is scale formation on tanks, pipes and
other equipment, and disposal of the large quantity of lime sludge
produced.

Thermal / Heat Treatment

Thermal treatment subjects sludge to high temperature and pressure in a
closed reactor vessel. The high temperature and pressure rupture the cell
walls of any microorganism causes chemical oxidation of the organic
matter. This process substantially improves dewatering and reduces the
volume of material for disposal.

Sludge Conditioning
Sludge conditioning is a process whereby sludge solids are treated with chemicals or various other
means to prepare the sludge for dewatering processes. The two most applied conditioning methods
are the addition of chemicals and heat treatment. Other conditioning processes include freezing,
irradiation and elutriation. Chemical conditioning can reduce the 90 - 99% incoming moisture content to
65 - 85%.

Sludge Dewatering
Digested sludge removed from the digester is still mostly liquid. Sludge dewatering is used to reduce
volume (15-60% solids) by removing the water to permit easy handling and economical reuse or
disposal.

CE-333 : Lecture-06: Sludge Treatment and Disposal /Prepared by: Snigdha Afsana, Assist Prof, Dept. of Civil Engineering, BUET
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Dewatering processes include -
- sludge drying beds,
- rotary vacuum filters,
- filter presses (belt and plate) etc.

i. Sludge drying beds

Stabilized /conditioned solids are pumped to the sand + gravel bed and allowed to dry by first draining
off excess water through the bed and then by evaporation. This is the simplest and cheapest method
for dewatering sludge. Drying beds require a great deal of manpower to clean beds. They also may
create odor and insect
problems.

ii. Rotary vacuum filters

In rotary vacuum filter stabilized solids are pumped to a vat or tank
in which a rotating drum is submerged. As the drum rotates, a
vacuum is applied to the drum. Solids collect on the media and
are held there by the vacuum as the drum rotates out of the tank.
The vacuum removes additional water from the captured solids.
When solids reach the discharge zone, the vacuum is released
and the dewatered solids are discharged onto a conveyor belt for
disposal.

iii. Filter presses (belt and plate)

Pressure filtration differs from vacuum filtration in that the liquid is forced through the filter media by a
positive pressure instead of a vacuum. Dewatering occurs by a combination of gravity drainage,
pressure filtration and shear.

a) Belt type filter press b) Plate type filter press

The belt filter includes two or more porous belts, rollers, and related handling systems. In the plate
filter, solids are pumped (sandwiched) between plates. Pressure (200 to 250 psi) is applied to the
plates and water is squeezed from the solids. At the end of the cycle, the pressure is released and as
the plates separate the solids drop out onto a conveyor belt for transport to storage or disposal.

Final Disposal of Treated Sludge

Sludge Incineration
Incinerators produce the maximum solids and moisture reductions. Solids are pumped to the
incinerator. The solids are dried and ignited (burned). As they burn the organic matter is converted to
carbon dioxide and water vapor and the inorganic matter is left behind as ash or fixed solids. The ash
is then collected for disposal.

CE-333 : Lecture-06: Sludge Treatment and Disposal /Prepared by: Snigdha Afsana, Assist Prof, Dept. of Civil Engineering, BUET
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Land Application of Biosolids
The purpose of land application of biosolids is to dispose of the treated
biosolids in an environmentally sound manner by recycling nutrients
and soil conditioners. Biosolids must not contain materials that are
dangerous to human health (i.e., toxicity, pathogenic organisms, etc.)
or dangerous to the environment (i.e., toxicity, pesticides, heavy
metals, etc.). Treated biosolids are land applied by either direct
injection or application and plowing in

CE-333 : Lecture-06: Sludge Treatment and Disposal /Prepared by: Snigdha Afsana, Assist Prof, Dept. of Civil Engineering, BUET