SLUDGE MANAGEMENT

TREATMENT AND DISPOSAL OF SLUDGE

• The conventional wastewater treatment process although efficient in
removing organics generates a large amount of excess sludge.
• The constituents removed in wastewater treatment plants include
screenings, grit, scum, and sludge.

• These wastes that are

generated from
wastewater treatment
operations are usually
in the form of liquid or
semi-solid typically
containing 0.25 to 12
% solids by weight.
• Sewage sludge refers to the residual semi-solid material that is
produced as a settled by-product during sewage treatment of industrial
or municipal wastewater.

• Of all the constituents removed in the treatment process, the disposal

and processing of sludge are the most complex because of their
offensive character.

• Here, we are going to describe the operations and processing that can
reduce the water and organic content of the sludge and make it
suitable for disposal.

• The main process used for sludge disposal includes thickening

(concentration), conditioning, dewatering, and drying for the removal
of moisture and digestion, composting, incineration, wet air oxidation,
etc. for stabilizing the organic matter in the sludge.
SOLIDS AND SLUDGE SOURCES
• Primary sludge is typically composed of settable solids which are removed
from raw wastewater in the primary treatment facilities.

• Generally, the sedimentation and at times grit chamber are also considered,
but the grits are mostly inert material. So, they are not normally processed
with sedimentation sludge or the primary sludge. They can be disposed of in a
landfill.

• Typically primary sludge is generated in the range of 110 to 170 kg per million
liters from municipal wastewaters.

• Secondary sludge is produced from the biological processes and mostly from
the aerobic biological processes because anaerobic biological processes sludge
production is very low.
 CHARACTERISTICS OF SLUDGE
• The characteristics depend on the origin of the solids and sludge, the
amount of aging that has taken place, and the type of processing they
have been subjected to.

• Knowledge of chemical composition including nutrients is important in

considering the ultimate disposal of the processed sludge.

• Measurement of pH, alkalinity, and organic acid content is important for

the process control of anaerobic digestion.

• The content of heavy metals, pesticides, and hydrocarbons has to be

determined when incineration and land application methods are
considered.
• The energy content of sludge is important when the thermal reduction
process is considered.

• Characteristics of sludge that affects its suitability for land application and
beneficial use include organic content, nutrients, pathogens, metals, and
toxic organics.

• The fertilizer value of sludge which should be evaluated where the sludge is
to be used as a soil conditioner, is based primarily on the organic content of
nitrogen, phosphorus, and potassium (potash).

• The quantity of solids entering the wastewater treatment plant fluctuates in

a wide range. To ensure the capacity to handle this waste, the designer
should consider the average and maximum rates of sludge production and
the potential storage capacity.
Characteristics of solids and sludge produced during wastewater treatment
Solids or Sludge Description

Screening Screenings include all types of organic and inorganic materials large enough to be
removed on bar racks.
Grit Grit is usually made of the heavier inorganic solids that settle with high velocities.

Scum/ Grease Scum consist of floatable materials skimmed from the surface of primary and
secondary settling tanks. This may contain grease, oils, fats, waxes, soaps, fruit
wastes, vegetables and fruit skins, paper and similar materials.

Primary Sludge Sludge from primary settling tanks is usually grey and slimy, and has an offensive
odour.
Sludge from chemical Sludge from chemical precipitation with metal salts is usually dark in colour, reddish if
precipitation iron is present in high amount. Lime sludge is greyish brown. The odour can be
objectionable but not as offensive as primary sludge. Generally it is slimy. Hydrates of
iron and aluminium can make the sludge gelatinous.

Activated Sludge Activated sludge generally has a brownish, flocculent appearance. Sludge in a good
condition has an offensive earthy odour.
Solids/ Sludge Description
Trickling filter sludge Humus sludge from trickling filters is brownish and relatively
inoffensive when fresh. It undergoes decomposition more slowly
than other undigested sludge.
Digested Sludge Aerobically digested sludge is brown to dark brown and has a
(aerobic) flocculated appearance. The odour of digested sludge is not
offensive and is said to be musty.
Digested sludge Anaerobically digested sludge is brown to black and contains large
(anaerobic) amount of gas. The smell is not offensive if thoroughly digested and
smell like hot tar, burnt rubber, or sealing wax.
Composted Sludge Composted sludge is usually dark brown to black, but the colour may
vary if bulking agents like recycled compost or wood chips have been
used in the composting system.
Septage Sludge from septic tanks is black. Unless the sludge is well digested
by long storage, it is offensive because of the hydrogen sulphide and
other gases that it gives off.
 VOLUME WEIGHT RELATIONSHIP
• The volume of sludge mainly depends on its water content and very
slightly on the character of the solid matter.
• If the solid matter is composed of fixed (mineral) solids and volatile
(organic) solids, the specific gravity of all the solid matter can be
computed using the equation 1:
• The volume of the sludge can be computed with the following equation 2

• For approximate calculation for a given solid content, volume varies inversely
with the percent of solid matter
Question: Determine the liquid volume before and after digestion and the
percent reduction for 1000 lb (dry basis) for primary sludge with the
following Characteristics

Primary Digested
Solids % 5 10
Volatile matter % 60 60 (destroyed)
Specific gravity of fixed solids 2.5 2.5
Specific gravity of volatile Approx. 1 Approx. 1
solids
 Sludge Treatment and Flow diagrams
• A generalized flow diagram incorporating the unit operations and processes is
presented ahead
• In practice, the most commonly used process flow diagram (Fig 3) for sludge
treatment can be divided into two categories, depending on whether or not
biological treatment is involved.
• A typical flow diagram incorporating biological processes is represented ahead
(Fig 4).
• Depending upon the sludge source, thickeners may be used contingent upon the
method of sludge stabilization, dewatering, and disposal.
• Following biological digestion, any of the following methods may be used to
dewater the sludge, the choice influenced by economic evaluations and local
conditions.
• The presence of industrial and other toxic wastes also presents a problem in
biological digesters, hence, a number of plants have been designed with other
means of sludge treatment (Fig 5).
Primary Operations Thickening Stabilization

Chlorine oxidation
Rotary drum Conditioning
Sludge grinding
thickening Disinfection
Lime Stabilization
Gravity Thickening Chemical Conditioning
Sludge handling Heat Treatment Pasteurization
Floatation Thickening Elutriation
Anaerobic Digestion Long term storage
Sludge storage
Centrifugation Heat Treatment
Aerobic digestion
Sludge degritting
Gravity thickening Composting

Fig 3: Generalized sludge processing and disposal flow diagram

 Dewatering Drying Thermal reduction Ultimate disposal

Vacuum filter Multiple hearth incineration

Multiple effect evaporator
Landfill
Pressure filter Fluidized bed incineration
Flash Drying
Horizontal belt filter Flash Combustion Land application
Spray drying
Centrifuge Co incineration with solid wastes
Reclamation
Rotary drying
Drying bed Vertical deep well reactor
Multiple hearth dryer reuse
Lagoon Wet air oxidation

Fig 3 continued : Generalized sludge processing and disposal flow diagram

 a)

b)

c)

Fig 4 Typical sludge treatment flow diagram with biological digestion and three different sludge dewatering process: a)
belt filter process b) centrifugation c) drying beds
 Fig 5 Typical non biological sludge treatment diagrams: a) heat treatment with
vacuum filter dewatering b) multiple hearth incineration c) fluidized belt incineration
Preliminary Operations of
Sludge Management
 Sludge and Scum Pumping
• Sludge produced in wastewater treatment plants must be conveyed from
one plant point to another in conditions ranging from a watery sludge or
scum to a thick sludge.
• Sludge may also be pumped offsite for long distances for treatment and
disposal. A different type of pump may be needed for different type of
sludge pumping application.
• Pumps: Pumps used most frequently to convey sludge include plunger,
progressive cavity, centrifugal, torque flow, diaphragm, high piston, and
rotary lobe types.
• Diaphragm and centrifugal pumps also are used extensively for pumping
scum.
 Sludge Grinding
• Sludge grinding is a process in which large and stringy materials
contained in sludge are cut or sheared into small particles to prevent
the clogging of or wrapping around rotating equipment.

• Grinders historically have required high maintenance, but new

designs of slow-speed grinders have been more durable and reliable.

• These designs include improved bearings and seals, hardened steel

cutters, overload sensors, and mechanisms that reverse the cutter
rotation to clear obstructions or shut down the unit if the
obstruction cannot be cleared.
 Sludge Degritting
• In some plants where separate grit removal facilities are not used ahead of primary
sedimentation tanks or where the grit removal facilities are not adequate to handle the peak
flow and peak grit load, it may be necessary to remove the grit before further processing of
sludge.
• Where further thickening of the primary sludge is desired a practical consideration is sludge
degritting.
• The most effective method of degritting sludge is through the application of centrifugal forces in
a flowing system to achieve the separation of the grit particles from the organic sludge.
• Such separation is achieved through the use of cyclone degritters. The sludge is applied
tangentially to a cylindrical feed section, thus imparting a centrifugal force.
• The heavier grit particles move to the outside of the cylinder and are discharged through a
conical feed section. The organic section is discharged through a separate outlet.
• The efficiency of cyclone degritter is affected by pressure and by the concentration of the
organics in the sludge.
• To obtain effective grit separation, the sludge must be diluted. As the concentration increases
the particle size that can be removed decreases.
 Sludge Blending
• Sludge is generated in primary, secondary, and wastewater treatment
processes. Primary sludge consists of settleable solids carried in raw
wastewater. Secondary sludge consists of biological solids as well as
additional settleable solids. Sludge produced in advanced wastewater
treatment consists of biological and chemical solids.

• Sludge is blended to produce a uniform mixture for downstream

operations. Uniform mixtures are important in short detention time
systems such as sludge dewatering, heat treatment, and incineration
and also influence plant operability and performance.
# Sludge from primary, secondary, and advanced wastewater treatment processes
can be blended in several ways.
1. In primary settling tanks: Secondary or advanced wastewater treatment
sludge can be returned to the primary settling tanks and mix with the
primary sludge.
2. In pipes: This process required careful control of the sludge feed to ensure
proper blend.
3. In sludge processing facilities and long detention times: Aerobic and
anaerobic sludge digesters can blend the sludge uniformly.
4. In a separate blending tank
• In a treatment plant with less than 1Mgal/d (0.044 m3/s) capacity, blending is
usually accomplished in the primary settling tanks.
• Blending tanks are usually equipped with mechanical mixers and baffles to
ensure good mixing.
 Sludge Storage
• Sludge storage must be provided to smooth out fluctuations in the rate of sludge
production and to allow sludge to accumulate during periods when subsequent sludge
processing facilities are not operating (night shifts, weekends, etc.)
• Sludge storage is particularly important in providing a uniform feed rate ahead of the
following process: lime stabilization, heat treatment, mechanical dewatering, drying,
and thermal reduction.
• Short-term sludge storage can be accomplished in wastewater-settling tanks or sludge
thickening tanks. Long-term sludge storage may be accomplished in the sludge
stabilization process with long detention times or in specially designed separate tanks
and digesters.
• Sludge is often aerated to prevent septicity and to promote mixing. Mechanical mixing
may be necessary to assure the complete blending of sludge.
• Chlorine and hydrogen peroxide have been used with limited success to arrest septicity
and to control the odors from sludge storage and blending tanks. Sodium hydroxide or
lime may also be used for odor control by raising the pH and keeping the hydrogen
sulfide in the solution.
 Thickening (Concentration)
• The solid content of primary, activated, trickling filter or mixed sludge (i.e.
primary plus activated) varies considerably, depending on the
characteristics of the sludge, the sludge removal and pumping facilities, and
the method of operation.
• Thickening is a procedure to increase the solids content of sludge by
removing a portion of the liquid fraction.
• Thickening is generally accomplished by physical means including gravity
settling, floatation, centrifugation, and gravity belts.
• For example, if a sludge with 0.8 percent solids can be thickened to a
content of 4%, then a five-fold decrease in sludge volume is achieved.
• The volume reduction obtained by sludge concentration is beneficial to
the subsequent treatment process such as dewatering, drying, and
combustion, from the following standpoints:
1. The capacity of tanks and equipment required
2. Quantity of chemicals required for sludge conditioning
3. Amount of heat required by digesters
• On a large project where sludge is required to be transported to a
significant distance, a reduction in sludge may result in a reduction of pipe
size and pumping cost.
• On small projects, the requirement of a minimum practicable pipe size
and minimum velocity may necessitate the pumping of significant volumes
of wastewater in addition to sludge, thereby diminishing the value of
reduction.
 Gravity Thickening

• This is accomplished in a tank similar in design to a conventional

sedimentation tank. Normally, a circular tank is used.
• The feed sludge is allowed to settle and compact, and the thickened
sludge is withdrawn from the bottom of the tank.
• The thickened sludge that collects on the bottom of the tank is
pumped to the digesters or dewatering equipment as required.
• Gravity thickening is most effective on primary sludge.
Gravity thickener a) plan
Gravity thickener b) cross section
 Floatation Thickening
• There are three basic mechanism of the floatation thickening: dissolved air
floatation, Vacuum floatation and dispersed air floatation. Dissolved air
floatation is mostly used for thickening purpose.
• In dissolved air floatation, air is introduced into a solution that is being held
at an elevated pressure. When the solution is depressurized, the dissolved
air is released as finely divided bubbles carrying the sludge to the top,
where it is removed.
• Floatation thickening is used most efficiently for waste sludge from
suspended growth biological treatment process, such as the activated
sludge process or the suspended growth nitrification process.
• The float solids concentration that can be obtained by floatation thickening
of waste activated sludge is influenced primarily by air to solids ratio,
sludge characteristics, solids loading rate, and polymer application.
• The air to solids ratio is
probably the most important
factor affecting the
performance of the floatation
thickener and is defined as the
weight ratio of air available for
floatation to the solids to be
floated in the feed stream.
• SVI is also important because
better thickening has been
reported when the SVI is less
than 200 using nominal
polymer dosage. At high SVI,
the float concentration
deteriorates and high polymer
dosage is required.
Dissolved air floatation unit used for thickening waste activated sludge
 Centrifugal Thickening

• Centrifugal thickening are used for both thickening and to dewater sludge.
• Their application in thickening is limited normally to waste activated sludge.
• Thickening by centrifugation involves the settling of sludge particles under
the influence of centrifugal forces.
• The two basic types of centrifuges currently used for thickening are solid
bowl and imperforate basket centrifuge.
• Under normal conditions, thickening can be accomplished by centrifugal
thickening even without polymer addition. Maintenance and power cost can
be substantial, hence, this process is attractive at facility larger than 5Mga/d
where space is limited and skilled opertors are available.
• The solid bowl centrifuge consists of a long bowl,
normally mounted horizontally and tapered at
one end.

• Sludge is introduced into the unit continuously

and the solids concentrate on the periphery. A
helical scroll, spinning at a slightly different speed
moves the accumulated sludge towards the
tapered end where additional solids
concentration occurs. The sludge is then
discharged.

• The imperforate basket centrifuge operates on a

batch basis. The liquid sludge is introduced into a
vertically mounted spinning bowl. The solids
accumulate against the wall of the bowl and the
centrate is decanted. When the solid holding
capacity of the machine has been achieved, the
bowl decelerates and a scraper is positioned in Centrifuges used for the thickening of sludge:
the bowl to help remove the accumulated solids. a) solid bowl
b) imperforate basket
 Gravity belt thickening
• This system uses a belt press for sludge dewatering.
• In this, particularly for sludge with solids concentration less than 2%
effective thickening occurs in the gravity drainage section of the
press.
• The gravity belt thickener has been used for thickening raw and
digested sludge; polymer addition is required.
Gravity belt thickening
 Rotary Drum Thickening
• Rotary media-covered drums are also
used to thicken sludge. It consists of a
waste-activated sludge conditioning
system and a rotating cylindrical
screen. Polymer is mixed with thin
sludge in the mixing and conditioning
drum. The conditioned sludge is then
passed to rotating screen drums,
which separate the flocculated solids
from the water. Thickened sludge
comes out of the end of the drum,
while separate water decants through
the screen.
• The advantages of rotary drum
thickeners are low maintenance, low
energy use, and small space
requirement.
 Stabilization
• Sludge is stabilized to reduce pathogens, eliminate offensive odors, and
inhibit, reduce, or eliminate the potential for putrefaction.
• Survival of pathogens, the release of odors, and putrefaction occur when
microorganisms are allowed to flourish in the organic fraction of the sludge.
• The means to eliminate these nuisance conditions through stabilization are
1. The biological reduction of volatile content
2. The chemical oxidation of volatile matter
3. The addition of chemicals to the sludge renders it unsuitable for the survival of
microorganisms.
4. The application of heat to disinfect or sterilize the sludge
• If sludge is to be applied on land, pathogen reduction by various
methods of sludge stabilization is important.
 The technologies for sludge stabilization include
1. Lime stabilization; 2. Heat treatment; 3. Anaerobic digestion;
4. Aerobic digestion; 5. Composting
Lime Stabilization:
Lime is added to untreated sludge in sufficient quantity to raise pH to 12 or higher.
High pH creates an environment that is not suitable for the survival of
microorganisms. Consequently, the sludge will not putrefy, create odors, or pose a
health hazard, so long as the pH is maintained.
Two systems can be adopted for adding the lime, one is the addition of lime prior
to the dewatering, termed “lime pre-treatment” and the addition of lime after the
dewatering termed “lime post-treatment”.
Either hydrated lime Ca(OH)2 or quick lime CaO, may be used for stabilization.
Fly ash, cement kiln and carbide lime can also be used as a substitute in some cases.
Lime pre-treatment of liquid sludge requires more lime per unit weight of
sludge processed than that necessary for dewatering.
Higher lime and sufficient contact time are needed to attain a higher pH and
ensure a high level of pathogen killing.
Recommended design value is to maintain the pH above 12 for about 2 hours.
In Lime post-treatment of dewatered wastewater hydrated lime or quicklime is
mixed with dewatered sludge in a pugmill, paddle mixer, or screw conveyor to
raise the pH of the mixture. Quicklime is preferred because the exothermic
reaction of quicklime and water can raise the temperature of the mixture above
50 C sufficient for inactivating the worm eggs.
Post-lime stabilization has several significant advantages when compared to
pre-lime stabilization:
1) dry lime can be used hence no extra water is added to the dewatered sludge
2) No special requirement for dewatering
3) Scaling problems and associated maintenance problems can be eliminated.
 Heat Treatment
It is a continuous process in which sludge is heated in pressure vessel
temperatures up to 500 F at a pressure of 2760kN/m2 for a short period of
time (approx. 30 min).

It serves both as a stabilization process as well as a conditioning process.

Heat treatment conditions the sludge by rendering the solids capable of

being dewatered without the use of chemicals.

When the sludge is subjected to high temperature and pressure, the

thermal activity releases bound water and results in the coagulation of
solids.
 Anaerobic Sludge digestion
Anaerobic digestion is the biological degradation of organic matter
usually performed in a biodigester in absence of oxygen.

Much of the organic matter is converted to biogas (methane and CO2).

The process can be either thermophilic digestion, in which sludge is

fermented at 55C or mesophilic, at a temperature of around 36C.

The operations and physical facilities for anaerobic systems are discussed
ahead.
 Stages in sludge digestion process
Acid fermentation:

In this first stage of sludge digestion, the sludge begins to be acted upon by
anaerobic and facultative bacteria, called acid formers.
They solubilize the organic solids through hydrolysis.
The soluble products are then fermented to volatile acids and organic
alcohols of low molecular weight like propionic acid, acetic acid, etc.
Intensive acid production makes the sludge acidic, and putrefaction odors
are evolved lasting upto 15 days.
 Acid regression:
 IN this intermediate stage, the compounds formed in the first stage are
attacked by bacteria to form acid carbonates and ammonia compounds.
 The decomposed sludge gives a very offensive odor and the pH rises a little.
 The decomposed sludge, also, entraps, the gases of decomposition, acts
foamy and rises to the surface to form scum.

 Alkaline fermentation:
 In this final stage, more resistant materials like protein and organic acids are
attacked and broken up by anaerobic bacteria, called methane formers, into
simpler substances like ammonia, organic acids, and gases.
 During this stage, the liquid is separated from solids and digested sludge is
formed.
 This is granular and does not give an offensive odor. pH value rises above 7.
 A large amount of methane and CO2 is evolved during this stage
Standard Rate Digestion

Standard rate sludge digestion is carried out as a single-stage process. The

functions of digestion, sludge thickening, and supernatant formation are
carried out simultaneously.
In a single-stage process, untreated sludge is added to the zone where the
sludge is actively digesting and the gas is released. The sludge is being
heated by means of an external heat exchanger. As the gas rises to the
surface, it lifts sludge particles and other materials ultimately giving rise to
the formation of a scum layer.
As a result of digestion, the sludge stratifies by forming a supernatant layer
above the digesting sludge and becomes more mineralized.
As a result of stratification and the lack of intimate mixing, not more than
50% of the volume of a standard-rate single-stage digester is used. Because
of this limitation, the standard rate process is used principally for small
installations.
Single Stage High rate Sludge digestion

Single stage high rate sludge digestion differs from the standard rate sludge
digestion in the solid loading rate which is much higher in the high rate
digestion.
The high rate sludge digestion process shown is a single stage sludge digestion
process in which the incoming sludge continuously displaces the digested sludge
and hence there is no separation of the supernatant in the tank.
The sludge is mixed intimately by gas recirculation, mechanical mixers, pumping,
or draft tube mixers, and sludge is heated to achieve optimum digestion rates.
Sludge should be pumped to the digester continuously to maintain constant
conditions in the reactor.
There is no supernatant separation in the high rate digester and the total solids
are reduced by 45 to 50 percent and given off as gas.
Two-stage digestion

Frequently, high-rate digestion is coupled in series with a second digestion tank.

The first tank is used for digestion and is heated and equipped with mixing facilities.
The second tank is used for the storage and concentration of digested sludge and
for the formation of a relatively clear supernatant.
Most wastewater treatment plants employing anaerobic digestion use common
tanks for the digestion of a mixture of primary and biological sludge.
The solid liquid separation of digested sludge, however, is downgraded even by
small additions of biological sludge, particularly activated sludge. Rate of anaerobic
reaction is also slowed slightly.
Some recent designs have separated the digestion of primary and biological sludge,
in some cases biological sludge is digested aerobically.
Reasons for separate digestion include:
1) excellent dewatering characteristics of the digested primary sludge
2) Optimum process control can be maintained.
 Process Design
The design of anaerobic sludge digestion is based on the fundamental
principles of biochemistry and microbiology.
Here we are discussing the methods that have been used to design
digesters in terms of size.
The design is based on
1) Concept of mean cell residence time
2) Use of volumetric loading factors
3) Observed volume reduction
4) Loading factors based on population
Mean cell residence time: Digester design based on mean cell residence time
involves the application of the principles of the volume of gas generated. The
respiration and oxidation end products of anaerobic digestion are methane and
carbon dioxide.
The quantity of methane gas produced can be calculated using the equation:
VCH4= (5.62)[9So – S)(Q)(8.34) – 1.42Px]
VCH4 = Volume of methane produced at standard conditions (32 F and 1 atm) ft3/d
5.62 = theoretical conversion factor for the amount of methane produced from the
complete conversion of one pound of BODL to methane and carbon dioxide. ft3
CH4/lb
Q= flowrate Mgal/d
So = ultimate BODL in influent mg/l
S= ultimate BODL in effluent, mg/l
8.34= conversion factor lb/ Mgal*(mg/l)
Px= net mass of cell tissue produced per day, lb/d
The typical reduction in volatile solids
achieved in anaerobic digestion for mixed
sludge varies from 45 to 60%
For a complete mix high-rate digester
without recycle, the mass of biological
solids synthesized daily, Px can be
estimated using equation:
Q: Estimate the size of digester required to treat the sludge from a primary
treatment plant designed to treat 10Mgal/d (37,800 m3/d). Check the
volumetric loading and estimate the percent stabilization and the amount
of gas produced per capita per day. For the wastewater to be treated, it has
been found that the number of dry solids and BODL removed is 1200lb
/Mgal (approx. 0.15kg/m3) and 1150Mgal (approx. o.14kg/m3),
respectively. Assume that the sludge contains about 95 % moisture and has
a specific gravity of 1.02. Other pertinent design assumptions are as follows
• The hydraulic regime of the reactor is complete mix.
• Θc = 10 days at 35◦C
• Efficiency of waste utilization E=0.60.
• The sludge contains adequate nitrogen and phosphorus for biological
growth
• ϒ = 0.05 lb cells/lb BODL utilized and kd = 0.03/d
• Constants are for a temperature of 35°C
VCH4= (5.62)[9So – S)(Q)(8.34) – 1.42Px]
Loading Factor:
One of the most common methods used to size digesters is to size digesters on the basis of a loading
factor.
Two factors favoured for the design include:
1) the weight of volatile solids added per day per unit volume of digester capacity
2) the weight of volatile solids added per day per unit weight of volatile solids in the digester.

Another factor that should also be checked is the hydraulic detention time because of its
relationship to organism growth and washout and to the type of digester used.
Ideally, the conventional single-stage digestion tank is stratified into three layers with the
supernatant on the top, the active digestion zone in the middle, and the thickened sludge at the
bottom.
Because of the storage requirement for the digested sludge and the supernatant and the excess
capacity provided for daily fluctuation in sludge loading, the volumetric loading for standard rate
digesters is low.
Detention time varies from 30d to 90d for this type of tank.
The recommended solid loading for standard rate digesters are from 0.03 to 0.10 lb/ft3.d (0.5 to
0.16 kg/m3) of volatile solids.
For high-rate digesters, loading rates of 0.10 to 0.30 lb/ft3.d (1.6 to 4.8 kg/m3.d) of volatile solids is
practicable.
Effect of sludge concentration and hydraulic detention time on
volatile solids loading factor
Determination of volatile solids reduction
From the following analysis of untreated and digested sludge, determine the
total volatile solids reduction achieved during digestion. It is assumed that 1)
the weight of fixed solids in the digested sludge equals the weight of fixed
solids in the untreated sludge and 2) the volatile solids are the only
constituents of the untreated sludge lost during digestion.
Volume Reduction
• It has been observed that as digestion proceeds, if the supernatant is
withdrawn and returned to the head end of the treatment plant, the
volume of the remaining sludge decreases approximately exponentially. If
the plot is prepared of the remaining volume vs time, the required volume
of the digester is represented by the area under the curve and can be
computed using equation
Population Basis :

Digestion tanks are also designed on a volumetric basis by allowing

a certain number of cubic feet per capita.
Detention times range from 10 to 20d for high rate digesters and
30 to 60d for standard rate digesters.
These detention times are recommended for design based on total
tank volume plus additional storage volume, if sludge is dried on
beds and weekly sludge drawings are curtailed because of
inclement weather.
Typical design criteria for anaerobic digesters has been shown in
table. These requirements are for heated tanks (mesophilic range).
For unheated tanks capacities must be increased, depending on local
climatic conditions and the storage volume required
 Tank Design
Anaerobic digestion tanks are seldom less than 20ft (6m) or more than 125ft
(38m) in diameter. They should have a water depth of not less than 25ft (7.5m)
and can be as deep as 45 ft (14m).
The floor of the digester is usually conical with the bottom sloping to the sludge
drawn off in the center( minimum slope 1V to 4H).
Alternative bottom designs using a waffle shape have been employed to
minimize grit accumulation and reduce the need for digester cleaning.
The purpose of the egg-shaped design is to eliminate the need for cleaning.
Other advantages include better mixing, better control of the scum layer, and
the smaller land area requirement.
Gas from anaerobic digestion contains about 65 to 70 % CH4 by volume, 25 to
30% CO2, and a small amount of N2, H2, H2S, water vapor, and other gases.
Digester gas has a specific gravity of approx. 0.86.
Since the production of gas is the best measure of the progress of digestion and
also, digestion gas can be used as a fuel, the designer should be familiar with its
production, collection, and use.
Gas Production:
The volume of gas produced during the digestion can be calculated using the
equation discussed before.
Total gas production is estimated usually from the percentage of volatile solids
reduction. Typical values vary from 12 to 18ft3/lb (0.75 to 1.12 m3/kg) of
volatile solids destroyed
Gas Collection:
Digester gas is collected under the cover of the digester. The cover can be of the
floating type or fixed type.
Floating covers fit on the surface of the digester contents and allow the volume
of the digester to change without allowing air to enter. Gas and air should not
be allowed to mix otherwise explosions can occur.
Fixed covers provide a free space between the roof of the digester and the free
liquid surface.
Gas storage is provided so that 1) when the liquid volume is changed, gas, not
air, will be drawn into the digester, and 2) gas will not be lost by displacement.
Uses of digester gas:
Methane at standard temperature and pressure has a net heating value
of 960 Btu/ft3. Gas has approx. 65% methane hence, the heating value
can be obtained around 600Btu/ft3.
In large plants, digester gas may be used as fuel for boiler and internal
combustion engines, which are in turn used for pumping wastewater,
operating blowers, and generating electricity.
Digester Mixing: Various systems for mixing the contents of the digester
have been employed. The most common type involves the use of 1) gas
injection, 2) mechanical stirring, and 3) mechanical pumping.
Digester heating:

The heat requirement of the digester consists of the amount needed

1) to raise the incoming sludge to digestion tank temperature,
2) to compensate for the heat losses through the walls, floors, and roof of
the digester, and
3) to make up the losses that might occur in the piping between the source
of heat and the tank.
The sludge in the digestion tank is heated by pumping the sludge and
supernatant through external heat exchangers.
 Aerobic Sludge Digestion
 Aerobic digestion is the degradation of the organic sludge solids in the presence of oxygen.
 The oxygen is introduced as fine bubbles of air into the reactor.
 The micro-organisms in the sludge convert the organic material to carbon dioxide and
water, and the ammonia and amino species to nitrate.
Advantages claimed for aerobic digestion as compared to anaerobic digestion are as follows:
1) Volatile solids reduction is approx. equal to that obtained anaerobically
2) lower BOD concentrations in supernatant liquor
3) production of an odorless, humus-like biologically stable end product
4) recovery of more of the basic fertilizer values in the sludge
5) operation is easier
6) lower capital cost.
The major disadvantages are
1) high power cost is associated with supplying the required oxygen
2) digested sludge is produced with lower dewatering capacity
3) the process is significantly affected by temperature, location, and type of tank
material
4) useful byproducts are not recovered.
Process Description:
Aerobic digestion is similar to the activated sludge process. As the supply
of available food is depleted, the microorganisms begin to consume their
own protoplasm to obtain energy for cell maintenance reactions
(endogenous phase).
Cell tissue is oxidized aerobically to carbon dioxide, water, and ammonia.
Approx. 75 to 80 % of the cell tissue is oxidized the remaining is
composed of inert components and organic material that are non-
biodegradable. The ammonia is further oxidized to nitrate as the
digestion proceeds. pH drop can occur when ammonia is oxidized to
nitrate if the alkalinity of the wastewater is insufficient to buffer the
solution.
The resulting overall reaction is given by the following equation:
C5H7NO2 + 7O2 → 5CO2 + NO3- + 3H2O + H+
Conventional Aerobic Digestion
Factors that must be considered in designing aerobic digesters include
temperature, solids reduction, tank volume (hydraulic retention time),
oxygen requirements, energy requirements for mixing, and process
operation.
Temperature:
Because the majority of aerobic digesters are open tanks, digester liquid
temperature can fluctuate extensively.
Lower temperature retards the process, whereas higher temperature
accelerates it.
Heat loss should be minimized by using concrete instead of steel tanks,
placing tanks below grade, or providing insulation.
Solids Reduction:
A major objective of aerobic digestion is to reduce the mass of the solids
for disposal.
The change in biodegradable volatile solids can be represented by a first
order biochemical reaction.
𝑑𝑀
= −𝐾𝑑 𝑀
𝑑𝑡
• dM/dt = rate of change of biodegradable volatile solids per unit of time
• Kd = reaction rate constant
• M= concentration of biodegradable volatile solids remaining at time t in
the aerobic digester
Tank Volume: The digester tank volume can be calculated by equation
Oxygen Requirement:
The oxygen requirements that must be satisfied during the digestion
process are those of cell tissue and, with mixed sludge, the BOD in
the primary sludge.
The oxygen requirement for complete digestion of BOD varies from
1.6 to 1.9 lb/lb destroyed.
Process Operation:
Depending on the buffering capacity of the system, the pH may drop
to a low value, because of the nitrate ions in the solution.
Filamentous growth may develop at low pH values. Hence, pH values
must be checked periodically and adjusted if required.
Sludge Digestion Tanks:
A typical sludge digestion tank consist of a circular RCC tank with
hoppered bottom, and having a floating type of roof over its type.
The raw sludge is pumped into the tank, and when the tank is first put into
operation, it is seeded with the digested sludge from another tank.
The gases of decomposition are collected in a gas dome or separately in a
gas holder for subsequent use.
The digested sludge which settles down to the hoppered bottom of the
tank is removed under hydrostatic pressure, periodically.
The supernatant which lies between the sludge and the scum is removed
at suitable elevations, through withdrawl pipes.
The scum formed at the top surface of the supernatant liquor is broken by
the recirculating flow or through the mechanical rakers.
Design Considerations:
Diameter of the tank: 3 to 12m
Slope of the bottom hoppered floor of the tank: 1:1 to 1:3
Depth: 6m and so.
The capacity of the digestion tank is a function of sludge production,
digestion period, degree of digestion, loss of moisture, and
conversion of organic matter.
When the daily digested sludge could not be removed due to the
factors like, monsoon season, winter season, etc. then separate
capacity for its storage is provided in the tank which is V2T where T is
the no of days for which digested sludge is stored, and is called
monsoon storage.
𝑉1 + 𝑉2
𝑉= 𝑡 + 𝑉2𝑇
2
When the change during digestion is assumed to be parabolic, rather
than linear, the required capacity will be given as:
2
𝑉 = 𝑉1 − 𝑉1 − 𝑉2 𝑡 + 𝑉2𝑇
3
Q: Design a digestion tank for the primary sludge with the help of following
data:
Average flow= 20Mld
TSS in raw sewage= 300mg/l
Moisture Content= 85%
Assume other data required
Estimated gas production
Following approx. values can be used as a basis for estimating the
amount of gas produced by digestion:
About 60% of suspended solids are removed by sedimentation; 75% by
chemical coagulation and settling; and 90% by complete treatment.
About 70% of the SS in the sewage is volatile, and the reduction of
volatile matter in sludge is about 65%.
In digestion, the amount of gas produced is 0.6 cum per kg of volatile
matter present in the sludge or 0.9 cum per kg of volatile matter reduced.
The gas produced contains 65% methane, 30% carbon dioxide, and a
trace amount of other gases.
The heat content of methane is approx. 36000 kJ/m3.
Example: A sewage containing 200mg/l of suspended solids is passed through primary
settling tank. The solids from the primary settling tank are digested to recover the gas.
Find the likely volumes of methane and carbon dioxide produced in the digestion of
the sludge from 10,000m3 of sewage. Calculate the fuel value of the gas produced.
State clearly the assumptions made.
Solution:
Two-stage digestion
While treating sewage on a large scale, two-stage digestion of sludge
is generally adopted instead of a single stage in which two digestion
tanks, one primary and the other secondary are used.
Sludge is first admitted to the primary digestion tank and is kept for 7
to 10 days.
The partly digested sludge and supernatant liquor the transferred to
the secondary digestion tank where it is kept for 20 days.
The digested sludge and supernatant liquor from the secondary
digester is finally removed and disposed off.
Advantages of two-stage digestion:

Two-stage digestion is effective in preventing any tendency of short-

circuiting.
Only the primary digester is provided with heating, stirring, gas collection
arrangements; while the second unit acts as a closed settling tank.
Two-stage digestion offers freedom from large scum formations in any of
the digestion tanks.
Total cost may be lower than two tanks operated in parallel.
 Land application of sludge
Land application of stabilized municipal wastewater sludge is defined as
the spreading of sludge or on just below the soil surface.
It is the most widely used sludge disposal option.
Sludge may be applied to agricultural land, forest land, disturbed land,
and dedicated land disposal sites.
Further, after this land application, sunlight, soil microorganisms, and
desiccation can destroy pathogens and many toxic substances found in
the sludge.
Trace materials are trapped in the soil matrix and nutrients are used up
by plants.
Sludge Characteristics affecting land application

The main factors that affect the suitability for land application include
organic content, nutrients, pathogens, metals, and toxic organics.
Degradable organics in unstabilized sludge can lead to odor problems
and attract vectors like mosquitos, rodents etc.
Pathogens in sludge can spread diseases if there is human exposure
to the sludge.
Major plant nutrients- N, P, and K are not removed substantially
during sludge processing but are taken up by vegetation after sludge
has been applied to the land. Nitrogen uptake is of main concern
because of the potential for nitrate contamination of the
groundwater.
Metal and Organics:
Wastewater sludge contain trace metals and organic compounds that
are retained in the soil and pose a potential toxic risk to plants, animals,
and humans.
Waste water contain organic compounds, primarily hydrocarbons such
as PCBs, which are slow to degrade in the soil profile.
The main concern is the direct ingestion by animals, particularly dairy
cattle grazing on the sludge treated grasses.
Site selection
Physical characteristics needed for site selection for land disposal include
topography, soil permeability, site drainage, depth to ground water,
subsurface geology, proximity to critical areas, and accessibility.
Topography influences the potential for erosion and runoff of applied
sludge for equipment operability.
Soil desirable for this purpose should have moderately slow permeability,
are well drained, are alkaline or neutral, deep and relatively fine textured
for high moisture and nutrient holding capacity.
Sludge application should not pose a threat to ground water. Greater the
depth of groundwater, more desirable is the site for sludge application.
Isolated sites are preferred for disposal as it will be nuisance for the
people.
Application methods:
The method of sludge application depends upon the physical
characteristics of the sludge, site topography and the type of
vegetation present.
Application of sludge in the liquid state is attractive because of its
simplicity. Dewatering process is not required, and the sludge can be
transferred by pumping.
Typical solids concentration of sludge applied on land varies from 1 to
10%.
Liquid sludge can be applied to land by vehicle or by irrigation
methods similar to those used for wastewater distribution.
Application of dewatered sludge to the land is similar to application
of semisolid animal manure. Solids concentration in this process lies
between 15 to 30%.
Other beneficial uses:
Distribution and marketing: Sludge that is
distributed and marketed is used as a
substitute for topsoil and peat on lawns, golf
courses, and parks etc.
Chemical fixation: The chemical
fixation/Solidification process is done for the
industrial sludge and hazardous waste to
immobilize the undesirable constituents.
Chemical fixation process consists of mixing
untreated or treated liquid or dewatered
sludge with stabilizing agents such as cement,
pozzolan, and lime so as to chemically react
with or encapsulate the sludge.
 Final Sludge and solids conveyance, storage, and disposal.
Conveyance Methods: Sludge may be transported long distance by
pipeline, truck, rail, etc.
Liquid Sludge should be transported in closed vessel in order to prevent
spills, odor, and dissemination of pathogens to the air.
Stabilized sludge can be transported in open vessels.

Final Disposal:
Methods of sludge disposal include landfilling, lagooning, etc.