S o  S

Si 
1

6.11 Common Variations of Activated Sludge Process

To improve the organics removal efficacy, the plug flow and completely mixed systems had been
modified over the past years. Such modification was primarily based on F/M ratio, BOD5 loading
and hydraulic retention time (HRT). The modified processes include step aeration, tapered
aeration, contact stabilization, pure oxygen activated sludge system, Kraus process, two sludge
system, extended aeration and sequential batch reactors. This section provides a brief operational
description of such modified processes.

Step aeration. The step aeration process distributes waste flow to a number of points along the
basin (Figure 6.16), thus avoiding locally high O2 demand; the return activated sludge (RAS) is
introduced at the aeration tank head. The flow distribution lessens the effect of peak hydraulic and
organic loads, and may provide sufficient dilution to protect bacteria against toxic materials. Step
aeration follows plug flow regime.

Figure 6.16 Step aeration process.

Tapered aeration. This process attempts to match O2 supply to demand (through plug flow
regime) by introducing more air at the head end (Figure 6.17). In this process, the diffusers are
spaced close together (at the influent section) to achieve a high oxygenation rate. The intensive air
supply at the head end promotes higher organic degradation. As the mixed liquor traverses the
aeration tank, synthesis of new cells occurs, increasing the number of microorganisms and
decreasing available food concentration. Such inverse correlation is associated with lower food to
microorganism ratio and lower of oxygen demand at the outlet section (Figure 6.17). The spacing
of diffusers is therefore increased toward the tank outlet, to match the lower oxygen demand. A
disadvantage of the process can be attributed to its vulnerability towards shock loading, or toxic
materials.

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Figure 6.17 Tapered aeration process.

Contact Stabilization. According to this process, returned sludge (containing adsorbed organics)
from the secondary clarifier is being transferred to a stabilization tank, where it is aerated for 3-6h
(Figure 6.18), and is mixed again with influent wastewater for 20-40 min. Such stabilized sludge
promotes the adsorption of suspended and colloidal solids (from influent wastewater), but cannot
adsorb dissolved organic matter. After the contact period, the activated sludge is separated from
mixed liquor in the secondary clarifier. Contact stabilization is a plug flow process with shorter
retention time, which enhances the vulnerability of the system to organic and hydraulic loading
variations.

Figure 6.18 Contact stabilization activated sludge process.

Pure oxygen activated sludge system. In this process, the aeration basin is divided into several
compartments by baffle walls; each compartment includes an agitator. The incoming wastewater is
mixed with high purity oxygen in the first compartment. Wastewater flows from one compartment
to other through baffle walls, following plug flow regime. Exhausted gas, mixture of nitrogen,
carbon dioxide and 10% of supplied oxygen emits from the last compartment. The mixed liquor is
then transferred to the following secondary clarifier. The settled activated sludge (in secondary

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clarifier) is again recirculated to the aeration tank, and a portion of the settled sludge is wasted.
The mixed liquor of this system has dissolved oxygen concentration varying between 4-10 mg/L.
Figure 6.19 provides an operational diagram of pure oxygen activated sludge system.

The advantages of this system include higher transfer of oxygen, small reaction chambers, peak
loading tolerance, higher efficiency in terms of treating soluble wastewater, reduction of sludge
bulking, and effective odor control.

Figure 6.19 Pure oxygen activated sludge process.

Kraus process. This process is effective for the treatment of nitrogen deficient wastewater. The
digester supernatant (source of food) is added with a portion of the return sludge, and transferred
to the aeration tank for nitrification. The resulting mixed liquor is then transferred to the main plug
flow aeration tank. Figure 6.20 provides a schematic diagram of the Kraus process.

Figure 6.20 Schematic flow diagram of Kraus process.

Two sludge system. This system is divided into two stages; the first stage removes BOD, whereas
the second stage removes ammoniacal nitrogen (NH4-N) at longer sludge age (Figure 6.21). BOD
removal in the first stage promotes treatment of toxic substances, thereby protecting more
sensitive nitrifying bacteria in the second stage. A portion of the influent wastewater (of the first

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stage) can be by passed around the nitrifying stage, to enhance organics and solids availability for
nitrification.

Figure 6.21 Two sludge process.

Extended aeration. The extended aeration process is operated under longer hydraulic retention
time and sludge age. The system is also subjected to longer aeration time, resulting higher MLSS
concentration, higher RAS pumping rate, and substantial endogenous decay of sludge mass. Such
prolonged endogenous phase allows equal proportion of cell mass production and decay, resulting
in no net mass production, thereby minimizing sludge production and wastage.

The oxidation ditch (modification of conventional plug flow process- Figure 6.22) is an example
of extended aeration for the treatment of wastewater. It comprises of a single or closed loop
elongated oval channel (Figure 6.22); the liquid depth in the channel is maintained within 1.2-1.8
m, with 45 degree sloping sidewalls. The wastewater usually receives preliminary treatment prior
to the entrance into oxidation ditch. The wastewater in the channel is aerated with mechanical
aerators (i.e. Kessener brush), operating at 60-110 rev/min which allows liquid motion within
0.24-0.37 m/s. Such velocity is maintained to prevent solids deposition; it also allows the
wastewater to complete a tank circulation within 5-15 min. The DO concentration profile of
wastewater increases near the aerators, and falls when it transverses the circuit.

The oxidation ditch usually exhibits higher BOD5 removal efficacy. Nitrification also occurs in the
system due to longer hydraulic and solids retention time. This system is popular for wastewater
treatment generated by small communities, depending on larger land availability. However, in
colder periods, surface aerators may be iced, which can be mitigated by installing electrical
heating.

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Figure 6.22 Oxidation ditch process.

Sequential batch reactors (SBR). These systems consist of a single reactor, for aeration of
wastewater and sludge settling. The wastewater is applied in a batch mode, resulting four
operational phases such as: fill, react, settle and discharge phase (Figure 6.23). During the fill
phase, wastewater is applied (in batch mode) to the reactor, which have sludge mass. The aerator
may or may not be switched on in this phase. In the react phase, the aerator is turned on to provide
treatment of organics and solids, present in wastewater. The settling phase includes settling of
sludge in the reactor, while the aerator is turned off. The discharge phase allows withdrawal of the
clarified effluent from the reactor, along with excess sludge. The main advantage of SBR can be
attributed to simultaneous achievement of equalization, primary clarification, biological treatment
and secondary clarification. However, higher maintenance costs, substantial sludge production and
greater sludge volume index (SVI) are the major disadvantages of SBR systems.

Figure 6.23 Cyclic operations of a sequential batch reactor.

Typical operational parameters, for the design of some of the above described activated sludge
processes have been illustrated in Table 6.7.

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Table 6.7 Typical operational parameters of activated sludge processes.
Operational parameters
MLSS Sludge
BOD5 BOD5 removal
concentration, HRT age, F/M ratio
loading efficiency
3
kg/(m .d)
X hrs  c d-1
%
mg/L d
Step aeration 0.6-1 2000-3500 3-5 5-15 0.2-0.4 85-95%
Contact
1-1.2 80-90%
stabilization
Pure oxygen 1.6-3.2 3000-8000 1-3 8-20 0.25-1 85-95%
Kraus process 0.6-1.6 2000-3000 4-8 0.3-0.8
Oxidation ditch 0.08-0.48 1500-5000 0.05-0.3 85-95%

Example 6.4. Estimate the volume of the aeration tank of high purity oxygen activated sludge
system for municipal wastewater treatment employing the following data set, and check with
design parameters. Also find out the expected effluent BOD5 concentration of the system.

Parameter Value
Design avaerage flow, Q 4000 m3/d
Influent BOD 300 mg/L
Influent TSS 150 mg/L
F/M 0.6 lb BOD applied/lb MLVSS.d
MLSS 7000 mg/L
VSS/TSS 0.8
Maximum volumetric BOD load 4 kg/(m3.d)
Minimum aeration time 2h
Minimum cell residence time 4d
KS 60 mg/L of BOD
kd 0.06/d
Y 0.6VSS/mg BOD
k 6d-1

Solution

1. Calculation of tank volume

MLVSS , X  MLSS  0.8  7000  0.8  5600mg / L

Employing Equation (6.40):

S QS 0
F/M  0 
X VX

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 4000 m 3 / d  300 mg / L
V  357 m 3
1
0.6 d  ( 7000  0.8 )mg / L
2. Check BOD load

4000 m3 / d  300 mg / L
BODload   3.2kg /( m3 .d )  4 kg /( m3 .d )
357 m3
(Lin, 2007)

3. Check aeration time

V 357 m 3
HRT    2.1h  2h( OK ) (Lin, 2007)
Q 4000 m 3 / d

4. Check mean cell residence time (sludge age)

Influent VSS, X i  150  0.8  120mg / L

VX
Sludge age, c 
QX i

357 m 3  5600 mg / L
  4.4 d  4 d ( OK ) (Lin, 2007)
4000 m 3 / d  120 mg / L

5. Estimate effluent BOD5 concentration

Effluent BOD5 concentration (S) can be computed employing Equation (6.33):

K s ( 1  c kd )
S
 c ( Yk  k d )  1

60 mg / L( 1  4.4 d  0.06 d 1 )
  5.2mg / L
4.4 d ( 0.6  6 d 1  0.06 d 1 )  1

6.12 Attached Growth Process: Trickling Filters

Attached culture systems are characterized by the adhesion of bacteria to a solid media.
Wastewater passes through this attached film (and porous spaces of media) in thin sheets, allowing
the attached microorganisms for adsorbing soluble and colloidal organic matter (from wastewater).
The required oxygen for such biodegradation is being supplied by incoming wastewater and
atmospheric air. Waste products (from metabolic process) are diffused outwards and carried away

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