e> Pergamon Wat. ScL Tech. Vol.37. No.9. pp. 41-47.1998.

C 199& IAWQ. Published by Ebevier Science Ltd

PrinledIn Great Britain.
0273-122319& S19'00+ 0-00
PIT: 50273-1223(98)00269-8

UPGRADING OF WASTEWATER
TREATMENT PLANTS FOR NlTROGEN
REMOVAL: INDUSTRIAL APPLICAnON
OF AN AUTOMATED AERATION
MANAGEMENT BASED ON ORP
EVOLUTION ANALYSIS

P. Caulet*, B. Bujon*, J. P. Philippe**, F. Lefevre* and

J. M. Audic*
• CIRSEE. Suez. Lyo1l1Ulue des Eaux. 38. ruedu Pdt. Wilson, 78 230 Le Pecq, France
•• ClTl. Suez. Lyonnaise des Eaux; 59. Avenue E. Thiebault, 78110 Le Visinet,
France

ABSTRACT
Upgrading conventional wastewatct treatment plants for nitrogen removal involves total control of
nitrification. denitrification and carbon removal. On low-load activated sludge processes. a comprehensive
surveyon fast and low kineticbiological reactions has been carriedout. whichdescribes the short-term and
long-term requirements on the aeration sequences in a single tank. Although solubleand adsorbed pollution
have to be treated in routine conditions, soluble pollution treatment becomes a priority during limited
overloads. indicatedby a slow ORP evolution. The treatment of adsorbed material is hencedelayed.In order
to implement the appropriate strategy. an automated aeration management system has been developed. This
systemis based on the analysis of both the real time signaland time evolutionof the Redox potentialsignal.
This information is used for command and controlpurposes. The application of this logic-based approachat
full scale has beenfruitful in evaluating its adaptability to the industrial environment and its potentialresults.
The operation of seven plants under the control of the automated management system has enabled the
nitrogen removalperformance to be increased. Mostof the nitrification and denitrification yieldsreach 90%.
whereas previousresults were far lower and more erratic, In addition. the present work determines limiting
conditions for a guaranteed long-term result and a successful upgrading. C 1998 IAWQ. Published by
ElsevierScienceLtd

KEYWORDS

Aeration; automation; denitrification; reliability; management; nitrification; quality; redox potential;

upgrading.

INTRODUCflON

Wastewatermanagement in Europe faces a major challenge since new European Union regulations require
operations to achievea higher level of results. Mostof the plants now have to combinethe treatmentof both
carbon and nitrogen elements. All collected water must be treated, and outflow standards must be met
41
42 P.CAULETet al.

whatever the weatherconditions. These regulations are stringent and very specific, and deviations from the
expected treatment results may expose the operators to fines and even imprisonment. This helps set a strict
objective in termsof treatment qualityand reliability for the removal of waterpollution.

Most smaIl size plants « 10000 PE) were not originally designed with such an intensive treatment in view.
In many cases, they were expected to treat C pollution only. In addition, small size activated sludge units
account for most WWfP in France. Because of technical and economic considerations, the appropriate
solutions for such plants are limited. Time, expertise and investments are limited, whilethe processhas to be
adapted to the varying and non-controlled conditions of in-flows and loads. Besides, manpower is also
limited on the plants (8 hours on 24 a day, 5 days a week), and a complete process expertise is not always
locally available. Finally,the potential financial investments are generally as low as the scale of the units.

Duringthe past few years, a concerted effort has been madeto adaptthe aeration strategyso as to combineC
and N treatments with the available means of the plants. Under the condition of process information
availability, automation enables this demand to be fulfiIled, by a real time adjustment of the appropriate
settings. However, usual strategies were not complete. since their information analysis could not providean
indication of the state and potentiality of the biological population. Moreover, abnormal process behaviors
could not be detect. Both limitations may lead to an ill adapted aeration management system and/or a risky
drift whichcan cause a major malfunctioning of the plant. Basedon the expertise developed at the CIRSEE
(CENTEROP INTERNATIONAL RESEARCH fOR WATER AND ENVIRONMENT - Suez - Lyonnaise des Eaux Group), a
well adapted automated aeration management systemwas elaborated. using the oxide-reduction potential as
a regulator and control signal. This automated strategy was applied on different activated sludge systems.
Although originallydesignedfor the assistance to small wastewater treatment plants, larger plants have also
benefited from this auto-adaptive aeration management. This automated system is actually patented and
named OGAR,for Optimized manaGement of Aeration by Redox.

Firstly,this paper presentsthe above-mentioned complete management strategy, assisted by a regulation and
control logic. In a second part, illustrations of full scale applications are given. Aspects related to plant
upgrading are presented therein in termsof qualityand reliability of the treatment

NEEDFOR RELIABLE NITROGEN REMOVAL

On low load activated sludge process, alternation of aerobic and anoxic phases characterizes nitrogen
removal. On the one hand, both an adequate sludge age and a minimum residence time in an aerobic
environment are necessary for complete nitrification. On the other hand, to carry out denitrification both a
favorable carbon/nitrate ratio and a sufficient residence time in anoxic conditions are needed. In a single
tank, elimination of N speciesresults from a strict control of aeratedand non-aerated sequences (Rittman et
al., 1985). The oxide-reduction potential is often used as an indicator of the reaction progress in the bulk
(Barnes et al., 1985; Mosey, 1985). In activated sludge processes, it has been observed that the range in
which the Redox potential is located gives information on physical or biological events occurring in the
aeration tank (Koch et al., 1985; Heduit et al., 1990). Briefly, re-suspension of the sludge. priority
elimination of the C source, partial and complete nitrification during the aeration period, and total
denitrification during the anoxic period are indeeddirectly linked to specific Redox ranges (see Fig. 1). A
prohibited zone is also specified in which anaerobic conditions will promote the development of non-
expectedmicroorganisms.

This description represents the elimination priorities of the soluble pollution. However, low degradable
carbon elements also compete for oxygen consumption. If an important part of the C source is first
eliminated during the aeration phase at low Redox potential, a remaining fraction is adsorbed on the floes.
The degradation kineticof this fraction is slow, and its removal takes place over many aeration periods. The
fraction of this adsorbed pollution determines the general oxidation slate of the sludge. A too important mass
of non treated adsorbed pollution may lead the biological systemto its limits. At the time of a major backlog
in the overall treatment, the elimination capacity of the biomass can be exceeded. Water pollution removal
 Upgrading of WWTPfor nitrogen removal 43

would then be difficult, and the produced sludge would not be stabilized, with a tendency to uncontrolled
evolution.

Oxido-Reduction Complete Nitrification

Potential Partial Nitrification
Priority C removal PartialDenitrification
(Sludge re-suspension) Total denitrification
Anaerobic conditions

AERAlED SEQUENCE NON-AERAlED SEQUENCE

Figure I. Schematic relations between Redoxrangesand physical and biological phenomena.

Therefore, in activated sludge processes, the instant value of the Redox potential represents the treatment
quality of soluble carbon and nitrogen pollutants. In addition, the general oxidation state of the sludge
determines the treatment reliability. This oxidation statecan be assessed, in addition to the potentiality of the
biological system to face the current load. following the time evolution of the Redox potential. Long term
management requires both quality and reliability of pollution treatment.

In wastewater treatment plants, many strategies of aeration management already exist. However, they are
insufficient when regarding the requirements concerning result reliability (Lefevre et al., 1993). Timer
programming cannot face an unexpected load in the plant and does not offer any control of the process.
Oxygen regulation systemsdo not enabledenitrification to be optimized. Lastly,in ordinary controlsystems,
Redox signal is used for threshold regulation, with a possible combination of time settings, oxygen or
ammonia controllers. Even if adapted to instant conditions, these approaches only guarantee a short term
management of the plant, since no indication and no control on the biological potential of the sludge are
available.

PRESENTAnON OPTIIE AUfOMATED MANAGEMENT STRATEGY

Considering the presented expertise on the aeration process, a more powerful strategywas elaborated with a
view to associate the reliability to the quality of the treatment (Lefevre et al., 1993; Wouters-Wasiak et al.,
1994). The systematic occurrence of the previously described relations characterizing physicalor biological
events in the oxidation ditch has led the aeration strategy to be based on the location of the Redox signal in
pre-defined ranges.

In addition, the Redox potential value is continuously linked with an analysis of the signal evolution. The
speedof the Redoxsignalincrease conditions the length of the aeration phases.

A rapid ORP increase attests a low level of load and a sufficient oxidation of the organic material
adsorbed on the floes. The biological systemhas a maximal potentiality, and for economic reasons,
the aeration sequences are short(phaseA on figure 2).

An usual ORP increase indicates a regularsoluble pollution load, and the aeration phase has to go to
the indication of the adsorbed pollution oxidation andcomplete nitrification (phaseB on figure2).

Lastly, a slow increase of the Redox signal announces a limitedoverloador a peak period. Soluble
pollutiontreatment then becomes a priority in order to satisfythe outflowstandards on ammoniaand
nitrate, and the treatment of adsorbed elements is delayed. The aeration sequence is long, but limited
44 P.CAULETet al.

in order not to penalize denitrification. It is then accepted not to go to very high values of Redox
potential (phase C on figure 2).

During non-aerated phases, a fast or usual decrease of the Redox signal leads to the startof the nextaeration
sequence when denitrification is completed. At the opposite, a slow decrease will conduce not to wait the
end of denitrification to start again the aeration sequence, in order to equilibrate the ammonia and nitrate
concentration in the outflow.
EH (mV)
450 ; --
A B
400 +

350
!
300 1
I
I
250

200 -

150 I

100i On
I
I I
50 .......1- -I...l-'-l---lI-l---'-..l--I-oI---t'--iJ-l.-l-IL-I-+-'u---L....---'--..l,.-........J-.L....I--t.-I-J Off
00:00 12:00 00:00 12:00 00:00 12:00

Figure2. ORPevolution analysis andconsecutive aeration command on a fuJI-scale application.

The analysis of the Redox signal evolution also allows to detect unusual operating conditions on the plant.
For example, aeration equipment failure, inflow of an longexceeding loadof pollution, and drift of the ORP
signal have to be reported to the operators. Furthermore, a modification of the biological behavior (leaching,
poisoning, ...) must be mentioned, to prevent any long term malfunctioning. These events are mainly
indicated by an abnormal low increase of the ORPsignal, or by the occurrence of consecutive indications of
"limited" overloads.

This behavior analysis then leads to a double function of the automated logic. The first is a regulation
function, with a command of the aeration sequencing periods, in view to adopt a compromise solution
between fast and slow kinetic reaction for carbon elimination, nitrification anddenitrification. The second is
a control function, in view to detect and prevent abnormal conditions in the process. Alarms are activated
when unusual events appear. Thus there are several objectives to such a strategy. It has first to afford an
adapted treatment to the currentconditions encountered in the plant(Treatment Quality). Secondly, it has to
maintain a sufficient general oxidation state of the sludge and to offer a control of the process (Treatment
Reliability). Indeed, plant upgrading for nitrogen removal requires both conditions to be fulfilled. Such an
automated management system is adapted to the context of small wastewater treatment plants. Investment is
reduced to the Redox probe equipment, and does not involve any modification of available facilities.
Existing sensors had been proved to be adapted to wastewater treatment. Finally, human involvement is
limited in time,and an assistance is provided in the process expertise.
 Upgradiniof WWTPfor nitrogen removal 4.5

INDUSTRIAL SCALEAPPUCATIONS ANDCONDmONS FOR A

SUCCESSFUL UPGRADING

The aeration management system presented above was developed and then tested on full scale applications
Over a long period of time. The aim of the study was to evaluate the performances of such a strategy and to
determine its limitingconditions. For these reasons, the automated aeration management strategy was used
in sevenplants with differentconfigurations, capacities, loads,and initialyields (see Table 1).

Table I. Characteristics of the plantsfor projectvalidation, and level of Nitrogen treatmentencountered with
timer programming, beforethe application of the presented aeration management system
M~ ABC D E F G
Capacity (PE) 3 000 I 500 3 000 3 000 17 500 40000 26000
Equipment available(.) 2T+IM 15+IM IT+IM 3T 2T 4B+4M 35
Aeration power lllcW 3.5 kW 25 kW 5.5 kW 18.5 iw 55kW
Yields (%) Nitrification 31 28 89 43 67 75
(BEFORE) Denitrification 0 0 ? 68 34 86
• T for Turbine; S for Screw;B for Blower(fine bubblemembranes); M for Mixingdevice.

The rangeof chosen WWTP is rather wide,and representative of most mediumand small size units actually
operating. Different shapes of single aeration basins are involved. from rectangular, cylindrical tanks, to
annular channels. In term of N pollution treatment, it is interesting to compare the plant performances
withoutand with the use of the automated aeration management. Initially, erratic performances characterized
mainly ammonia treatment on the plants. Plants A, B, and E were not constrained to any nitrogen removal
Obligation. Nitrification occuredoccasionally and partly during the summer period. Outflow standardsfixed
the total nitrogen species concentration (NOL) below 20 mg/l for plants D, F and G. Nitrification was
mainly incomplete excepted during the summer period. Denitrification was never achieved, inducing
frequent malfunctioning in the secondary settlers. Plant C was newly built, and directly operated with the
automated management system. That explainswhy no valueswere initiallypresent.

Table 2. Nitrogen removal performances with the use of automated aeration management

Plant A B· C DU E••• F G
Yields (%) Nitrification 90 SO 95 93 84 93 88
(AFTER) Denitrification 90 88 93 91 89 92 90
Meanoutflow N-NH4 (mg/l) 8 10 5 7 6 5 6
concentration N-N03 (mg/l) 5 5 5 5 8 5 5
Satisfying balancesheets # 516 4n 515 3/5 4/6 14/15 21/22
Conformity to EU norms yes no yes no no yes yes
• Secondary settlertroubles(sludgelosses)and powerlessaeration.
•• Hydraulicby-pass in the aeration basin.
• U Uncoupled mixing and aeration devices.
# The total balancesheetsnumberis relativeto the unit size and to the
respective study period, in agreement with European regulations.
With the use of automated aeration management, as presented in Table 2, most of the nitrification and
denitrification yields reach 90%. Outflow concentration in ammonia and nitrate are low, and the mean
concentration of rejected nitrogen elements on the whole is generally below the standards' values.
Comparing results from Tables J and 2, it is clear that automated management enhanced the plants'
performances, in terms of quality of treatment. The treatmentreliability can be evaluated both by the daily
experience of the system use and by the maintenance of the elimination performances over time. Over the
study period of S to 7 months dependingof the site, the automate proved to be well adapted in the case of
 46 P.CAULETet al.

small units. Probe maintenance was limited at a weekly frequency; robustness of the logic was sufficient to
face usual conditions (pollution overloading, storm weather). Finally, when necessary, alarm functions
secured the aeration process during the occurrence of critical events (sensor clogging, aeration equipment
failure or exceeded capacities).

Thus, plant upgrading was successfully achieved with no modification of the existing facilities for plants A,
C, F and G. These units met European Union standards. Adaptation of the treatment to the encountered
loads, maintenance of a sufficient oxidation state of the sludge and process control together led to the long-
term stability of the treatment.

The other objectives of these full scale applications was to give clearer information on the conditions of a
successful upgrading. Indeed, if the single use of a control logic enhances plant performance, total
conformity of the outflows cannot be guaranteed when strong limitations already exist. Logically, ammonia
removal cannot be met during daily peaks of load when aeration capacity is insufficient, as illustrated for
Plant B. In that case, the addition of design effects in the secondary settler led to frequent breaches of EU
standards. Mixing conditions and bulk homogeneity also condition the treatment quality. Hydraulic by-pass
in the aeration tank limits the representativeness of the sensor signal, and thus, treatment in Plant D was not
optimized. Uncoupled mixing and aeration devices were known to limit the plant performances, mainly in
denitrification sequences (Roustan et al., 1993). Experience on plant E illustrates this limitation, where
nitrate concentration is often higher than in other applications. Due to the limitations presented, standards
were not met for plants B, D and E.

CONCLUSION

The automated aeration management system presented has been shown to be well adapted to medium and
small size units of urban wastewater treatment. A Redox signal is used as an indicator of processing
biological reaction. The analysis of its behavior over time enhances its information capacity, with a view to
favoring the treatment reliability. The developed management logic is based on this expertise, in order to
action the aeration equipment for nitrification and denitrification alternation sequences. A control function
has been associated to secure the aeration process.

The application of this aeration strategy enables plants to be upgraded, with no modification of the existing
facilities. Conformity to standards in terms of nitrogen removal is ensured by the quality and the reliability
of the treatment. However, conditions exist for a successful upgrading:

aeration capacity has to be sufficient enough to allow peak pollution treatment;

bulk homogeneity has to be provided during both nitrification and denitrification sequences;
non existence of uncontrolled anaerobic zones in other basins Qfthe plant has also to be mentioned -
filamentous microorganism development would then induce a major malfunctioning in the plant.
lastly, regular maintenance of the Redox probe is a prerequisite for appropriate information reading.

Under these conditions, existing plants may perform their conversion to nitrogen removal by process control
only, with no modification of the Civil Engineering. The results presented showed that performance on
treatment reliability can be considered as excellent when no design effect is present in the plant. The
automated strategy allows the existing sites to reach the level of treatment required by European Union
regulations. New sites may also benefit from this optimized and reliable aeration management to guarantee
the control of their process.

REFERENCES

Barnes, D., Fitzgerald, P. A., McFarland, R., Swan, H and Schulz, T. (1985). Redox potential. Basis of measurement and
application. EjJlllent & Water Treatment 1.,1uly85.
H~uit, A., Duchene, P. and Sintes, L. (1990). Optimization of nitrogen removal in smallactivated sludge plants. Waf. Sci. Tech.,
22(3/4),123-130.
 Upgrading of WWI'P for nitrogen removal 47

Koch. F. A. and Oldman. W. K. (1985). ORP a tool for monitoring control and optimization of biological nutrient removal
systems. War. Sci. Tech., 17(11/12), 259-28J.
Lefevre. P.• Audic, 1. M. and Bujon, B. (1993). Automatic regulation of activated sludge aeration - Single-tank nitrification-
denitrification. War. Sci. Tech.. 28(10).289-298.
Mosey. F. (1985). Redox potentials in wastewater treatment Chemical Engineer. May 85. 21-24.
Rittman, B. E. and Langeland. W. E. (1985). Simultaneous denitrification with nitrification in single-ehannel oxidation ditches.
JWPCF. 57(4).300-308.
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in oxidation ditches: Application to the denitrification by activated sludge. Environmental Tech. , 14(9).841-849.
Wouters-Wasiak, K.• Heduit, A.• Audic, 1. M. and Lefevre. P. (1994). Real-lime control of nitrogen removal at full-scale using
oxidation reduction potential. War. Sci. Tech., 30(4). 207-210.