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Journal of Chemical Technology and Biotechnology J Chem Technol Biotechnol 83:109–114 (2008)

Technical Note
Effect of sludge retention time in sludge
holding tank on excess sludge production in
the oxic-settling-anoxic (OSA) activated sludge
process
Fen-Xia Ye,∗ Rui-Fen Zhu and Ying Li
Institute of Chemical Engineering, Ningbo University of Technology, 20 Houhe Lane, WenHua Road, Ningbo 315016, China

Abstract
The activated sludge process is a core technology in wastewater treatment plants. Excess sludge produced in
the process must be treated and disposed of properly and may account for up to 60% of total plant operating
cost. Therefore, it is necessary to develop new biological concepts to minimize excess sludge production. The
oxic-settling-anoxic process (OSA process), a modified activated sludge process, may produce less excess sludge
than the conventional activated sludge process. The effect of sludge retention time in the sludge holding tank of the
OSA process on excess sludge yield has been studied. Four pilot-scale activated sludge systems were employed,
one of which was a conventional activated sludge process, and was used as the control system. The other three
were OSA systems operated with different sludge retention times (5.5 h, 7.6 h, and 11.5 h) in the sludge holding
tank. All systems were operated with synthetic wastewater for 7 months. Results showed that the three OSA
processes with 5.5 h, 7.6 h, and 11.5 h sludge retention time reduced the excess sludge by 33%, 23% and 14%,
respectively. Compared to the control process, chemical oxygen demand (COD) removal efficiency and effluent
NH3 –N concentration were not significantly influenced, but total nitrogen (TN) removal efficiency decreased by
0–9%. Total phosphorus (TP) removal efficiency of OSA processes with 7.6 h and 11.5 h sludge retention time
increased by 19%. Sludge settleability was excellent in the three OSA processes. No distinct shift in the diversity
of the predominant species was found in microbial populations. We conclude that the OSA system could reduce
excess sludge production. Results suggest 6–7 h sludge retention time would be optimal.
 2007 Society of Chemical Industry

Keywords: activated sludge process; excess sludge reduction; sludge yield; oxic-settling-anoxic (OSA) process

INTRODUCTION Dissipating the energy intended for anabolism of cell


Biological treatment, generally the activated sludge mass without reducing the rate of removal of organics
process, has become the major technology treating from aqueous waste provides a direct mechanism for
both municipal and industrial wastewaters worldwide. reducing sludge yeild. Oxidation of the substrate still
However, the recent rising cost of treatment and occurs, but the phosphorylation of adenosine diphos-
especially disposal of excess sludge produced by the phate (ADP) to ATP is reduced and consequently
activated sludge operation, and increasingly restrictive there is less energy available for the formation of
legislation have reinforced the need for minimization biomass. Uncoupled metabolism promoted by abnor-
of waste sludge. mal circumstances, such as oxic and anoxic (or anaer-
Catabolism is a reaction that reduces the com- obic) cycling, the presence of a chemical uncoupler,
plexity of organic compounds and produces free changing process temperature and limiting nutrients,
energy. Anabolism involves the use of free energy has been applied to the activated sludge process to
to build the molecules required by cells. Energy reduce sludge production, but the three latter meth-
transfer is in the form of adenosine triphos- ods either increased operating costs or are not practical
phate (ATP). Bacterial anabolism is coupled to environmentally.4 The metabolic uncouplers reduce
the catabolism of substrate through rate limiting the production of excess sludge yield, some of which
respiration. However, the chemiosmotic mechanism of has no toxicity, but they are xenobiotic and their use
oxidative phosphorylation, by which ATP is produced requires great care.
during catabolism, can be uncoupled under some con- Chudoba et al. pointed out that anaerobic condi-
ditions, therefore part of the ATP is dissipated.1 – 3 tions induced exhaustion of the intracellular stock


Correspondence to: Fen-Xia Ye, Institute of Chemical Engineering, Ningbo University of Technology, 20 Houhe Lane, WenHua Road, Ningbo 315016, China
E-mail: yefenxia@hotmail.com
(Received 21 March 2007; revised version received 23 July 2007; accepted 23 July 2007)
Published online 15 October 2007; DOI: 10.1002/jctb.1781

 2007 Society of Chemical Industry. J Chem Technol Biotechnol 0268–2575/2007/$30.00


F-X Ye, R-F Zhu, Y Li

of ATP (anaerobic starvation). Its resynthesis under MATERIALS AND METHOD


aerobic conditions was accompanied by reduction in Sludge cultivation
excess sludge production.5 The oxic-settling-anoxic Four identical glass cylindrical (aeration tank) and
(OSA) activated sludge process is an activated sludge four identical plastic conical vessels (settling tank)
system based on oxic and anoxic cycling. In the OSA were used to construct four parallel bench-scale,
process activated sludge is exposed to an anoxic or completely mixed activated sludge processes that were
anaerobic zone under no food and low oxidation- fed synthetic wastewater (Table 1). The volumes of
reduction potential (ORP) conditions, alternately.2,5 – 8 the aeration tank and settling tank were 12.6 L
and 1.2 L, respectively. To start the cultivation,
It is a modification of the conventional activated sludge
sludge taken from a local sewage treatment plant
system, made by inserting a sludge holding tank in the
was seeded to all four experimental setups (Fig. 1).
sludge return line between the aeration tank and the
After 2 months of cultivation, sludge production and
secondary clarifier. It is believed that the settler can process performance of these four processes became
minimize both substrate residues in the liquid and food stable. Three of them were modified to OSA processes
storage in the sludge, which induces sludge starvation by inserting a sludge holding tank with a volume of
under anaerobic conditions. It should be pointed out 2.2 L, capped to keep oxygen out. A conventional
that the OSA process is different from the conven- activated sludge process served as a control. The
tional biological nitrogen removal process in which sludge retention times in the sludge holding tank in
an anaerobic tank contains adequate amounts of sub- the three OSA systems were 5.5 h, 7.6 h and 11.5 h,
strate to promote denitrification or phosphorus release. respectively. A diagram of the systems is shown in
Re-circulation of activated sludge among an oxic (aer- Fig. 1. Excess sludge withdrawal did not start until
ation tank), starvation (settling tank), and anoxic(or the mixed liquor suspended solids (MLSS) level in
anaerobic) environment (sludge holding tank), can the aeration tank exceeded 4500 mg L−1 . The MLSS
reduce excess sludge by 40–50% according to Chu- level was then maintained at this level throughout
doba et al.6 – 8 In their study, sludge is retained in the the remaining test period. Sludge cultivation and
anaerobic tank for 3 h. Different from their OSA sys- subsequent experiments were all conducted at a room
temperature of 25 ± 1 ◦ C.
tem, Saby et al.8 evaluated a modified OSA process,
using a membrane module submerged in the aeration
Analytical procedure
tank, and investigated the effect of ORP in the anaer-
Chemical analysis
obic tank on sludge reduction. Their results showed
MLSS, COD, NH3 -N, total nitrogen (TN), total
that the OSA process could result in a significant phosphorous (TP) and sludge volume index (SVI)
decrease in excess sludge production, and chemical (mixed liquor was diluted to about 2 g L−1 before the
oxygen demand (COD) removal and sludge settleabil- SVI test) were determined according to the Standard
ity could also be improved. Sludge reduction in the Methods.9 MLSS and SVI were measured every day,
OSA system can be explained by sludge decay, which is but the other parameters were measured every 3 or
accelerated effectively under low ORP in the anaerobic 4 days.
tank. It is certain that low ORP caused by a long reten-
tion time in the sludge holding tank induced sludge Sludge microbial population analysis
decay and endogenous metabolism. Their results sug- Uncoupled metabolism may affect growth rates of
gest that a short retention time in the anoxic tank and individual species in the sludge population differently.
subsequently return to the aeration tank stimulates Therefore sludge population dynamics may change,
uncoupled metabolism. In addition, a long retention which may, in turn, alter sludge settleability. A diverse
time in the sludge holding tank increases the cost of microbial population is required to effectively remove
building the sludge tank. nutrients and achieve sludge flocculation. Metabolic
In order to maximize excess sludge reduction in uncoupling in a mixed population may shift the
the OSA system cost-effectively, coupled with less
Table 1. Components and concentrations of synthetic municipal
adverse effects on process performance and sludge
wastewater∗
characteristics, an appropriate sludge retention time
in the sludge holding tank should be identified. Thus, Concentration Concentration
we have investigated the effect of sludge retention Components (mg L−1 ) Components (mg L−1 )
time in the anoxic (or anaerobic) holding tank on the starch 268 MgSO4 66
excess sludge production of an OSA process. Four glucose 200 CaCl2 6
pilot-scale activated sludge systems, a conventional peptone 132 KH2 PO4 28.8
activated sludge system and three OSA systems, were yeast extract 68 (NH4 )2 SO4 112
employed. It is hoped that the results generated from urea 8 FeSO4 0.3
NaHCO3 80 MnSO4 6
this investigation may provide useful information for
future research on the feasibility of the OSA approach ∗ Mean influent quality: COD = 550 mg L−1 , TN = 100 mg L−1 , NH -N =
3
for the reduction of excess sludge. 50 mg L−1 , TP = 6.0 mg L−1 .

110 J Chem Technol Biotechnol 83:109–114 (2008)


DOI: 10.1002/jctb
Effect of sludge retention time on excess sludge in OSA process

(a) Settling tank conducted to detect any changes in the microbial


Aeration tank
population of the process caused by uncoupled
Effluent
metabolism.
For molecular analysis, samples (2 mL) were
Influent removed from the culture and frozen in liquid
nitrogen for 15 s and stored at −70 ◦ C for subsequent
analysis. Cells were disrupted and total DNA was
Excess sludge
extracted using a FastDNA SPIN Kit foe Soil (Jingmei
Biotechnology Company, Shanghai Branch, China).
Recycled sludge
PCR amplification was performed with F357 GC and
Conventional activated sludge process R518 primers. The sequences of F357 GC and R518
(b) Settling tank
primers were (5 -CGC CCG CCG CGC GCG GCG
Aeration tank GGC GGG GCG GGG GCA CGG GGG GCC
Effluent TAC GGG AGG CAG CAG-3 ) and (5 -ATT ACC
GCG GCT GCT GG-3 ) respectively. The final
concentrations of the different components in the
Influent
mastermix were 25 pmol of each primer, 5 ml of
10× PCR reaction buffer (with MgCl2 ), 200 µmol L−1
Excess sludge
deoxynucleoside triphosphates, 2.5 U of Taq DNA
polymerase (Jingmei Biotechnology Company). DNA
amplification was performed using a Mastercycle
Recycled sludge
gradient thermal cycler (Eppendorf, Germany) with
Sludge anoxic tank
the following program: 94 ◦ C for 5 min; 35 cycles of
OSA process 94 ◦ C for 1 min, 50 ◦ C for 50 s and 72 ◦ C for 50 s;
and 72 ◦ C for 7 min. Amplified DNA was verified by
Figure 1. Diagram of the four systems.
electrophoresis aliquots of PCR reaction (5 mL) in
1.0% agarose 1× TAE buffer. The product of PCR
sludge population dynamics. Traditional methods of amplification was about 200 bp.
studying sludge population dynamics often involve DGGE was performed using the Bio-Rad Dcode
enumeration and morphologically based identification (Bio-Rad, Hercucles, CA, USA). The PCR products
using microscopy in conjunction with biological strains were loaded onto 10% (w/v) polyacrylamide gels in
and selective isolation procedures. 1× TAE (20 mmol L−1 Tris, 10 mmol L−1 acetate,
Bacterial ribosome ribonucleic acid (rRNA) genes 0.5 mmol L−1 EDTA, pH 8.0). The polyacrylamide
are amplified from a deoxyribonucleic acid (DNA) gels were made with denaturing gradient ranging from
extract obtained from the environmental sample. 35–60% (where 100% denaturant contains 7 mol
These products are of mixed sequence composition. L−1 urea and 40% formamide). Gels were poly-
Exploitation of DNA sequence differences from a merized with ammonia persulphate and N,N,N ,N -
mixed population would provide a fingerprint of tetramethylethylenediamine (TEMED) according to
the microbial community composition contained manufacturer’s instructions. The electrophoresis was
within an environmental sample. This may be run for 6 h at constant 160 V at 60 ◦ C. Gels were silver
achieved by denaturing gradient gel electrophoresis stained after being fixed.
(DGGE). DNA fragments from polymerase chain
reaction (PCR) products are electrophoresced through
a polyacrylamide gel that contains an increasing 550
concentration gradient of a denaturant, usually urea. 500 control (y=2.39)
At a certain denaturant concentration the fragment 5.5h (y=1.84)
450
unzips or becomes denatured and electrophoretic 7.6h (y=1.60)
Cumulative excess sludg

400
migration ceases. The point of denaturation is 11.5h (y=2.06)
production (g SS)

350
dependent upon the DNA sequence, which is a
300
function of the bacterial species. Mixed populations
that contain a mixed number of DNA types will 250
produce a ‘ladder’. However, these DNA analysis 200
techniques do not distinguish active cells from those 150
that are dead or dormant. Analysis of small molecular 100
weight rRNA directly has been used to determine the 50
active population of bacteria. 0
1 21 41 61 81 101 121 141 161 181 201
The aim of population investigation is to discern
Time (days)
whether a population shift occurs and identify any
resulting loss in the efficacy of the process. Therefore Figure 2. Cumulative excess sludge production in the control system
microscopic and molecular analysis of sludge was and three OSA systems during 7-month continuous operation.

J Chem Technol Biotechnol 83:109–114 (2008) 111


DOI: 10.1002/jctb
F-X Ye, R-F Zhu, Y Li

RESULTS AND DISCUSSION 55


Effect of sludge retention time in holding tank on control (Cm=34 mg/L)

Effluent NH3 -N concentration (mg L-1)


50 5.5h (Cm=32 mg/L)
sludge yield 7.6h (Cm=34 mg/L)
Figure 2 shows the accumulated amount of excess 11.5h (Cm=32 mg/L)
45
sludge during the 7-month operation experiment in
the four processes (one was the control). The effluent 40
suspended solids in the four systems were so low that
the accumulated excess sludge did not include it. In the 35
control process, the excess sludge production rate was
2.392 g SS d−1 , while in the three OSA processes, 30
which retained sludge for 5.5 h, 7.6 h and 11.5 h,
25
respectively in the holding tank, the rates dropped to
1.842, 1.597, 2.062 SS d−1 (i.e. reduced by 23%, 33% 20
and 14%, respectively). The 7-month operation data 5 31 55 84 108 136 166 180 206
further confirmed that the OSA process can effectively Time (days)
reduce excess sludge production, and 7.6 h appears to Figure 4. Variations of effluent NH3 -N concentrations in the control
be the best sludge retention time in the sludge holding system and three OSA systems during 7-month continuous operation.
tank. Sludge retention times in the sludge holding
tank here were longer than those reported by Chudoba Effect of OSA system on process performance
et al.,6 – 8 who found that the OSA process can reduce Figure 3 shows the COD removal rates in the four
excess sludge by 40–50% when sludge is retained in continuous operation activated sludge cultures. The
the anaerobic tank for 3 h. Saby et al.,8 who reported a mean COD removal efficiency in the control unit
modified OSA process, incorporating a membrane was 93%. In the OSA systems with sludge retained
module submerged in the aeration tank, obtained for 5.5 h, 7.6 h and 11.5 h, respectively, in the sludge
23%–58% sludge reduction efficiency when the ORP holding tank, the efficiencies were 91%, 91%, and
in the sludge holding tank decreased from +100 to 90%, respectively. The substrate removal capacity
−250 mV. COD removal and sludge settleability were decreased with increasing sludge retention time in
also improved. A 10.4 h retention time was used to the anoxic holding tank, which may contribute to
facilitate effective maintenance of the ORP level at sludge decay caused by a longer sludge retention time
−250 mV. This 10.4 h retention time is longer than in the sludge holding tank. Cell decomposition was
the sludge retention time here. Because of the limited the food source of the organisms in the aeration tank,
literature on the OSA system, it is difficult to compare i.e. the external bacteria load in the aeration tank. It
results obtained in this study with those of previous was fortunate that the substrate removal efficiencies
relevant studies. The OSA process was investigated in these OSA processes were not affected significantly
again with 7 h sludge retention time in the sludge by the insertion of the sludge anoxic tank. The results
holding tank for 2 months. Results were similar to demonstrated in these experiments were not consistent
those of the previous investigation (data not shown with those reported by Saby et al., who reported that
here). However, the cause of sludge reduction by the OSA process is able to improve COD removal
increasing or decreasing sludge retention time under efficiency. In their study, a sludge retention time of
anoxic (or anaerobic) conditions needs to be further 10.6 h in the anoxic holding tank was employed.8 It is
investigated. thus apparent that the mechanism of sludge reduction
in the OSA system should be investigated thoroughly.
100
Figures 4 and 5 summarize the variations of the
effluent NH3 -N concentrations and TN removal rates
in the four processes. The mean effluent NH3 -N
95 concentration in the control unit was 33.97 mg L−1 .
COD removal rate (%)

In OSA systems with sludge retained for 5.5 h, 7.6 h


90
and 11.5 h in the anoxic holding tank, the mean
effluent NH3 -N concentrations were 32.35, 33.79 and
31.97 mg L−1 , respectively. The mean TN removal
85 efficiency in the control process was 30%. In the OSA
control (Rm=93%) systems with sludge retained for 5.5 h, 7.6 h and 11.5 h
5.5h (Rm=91%) in the anoxic holding tank, the mean TN removal
80
7.6h (Rm=91%) efficiencies were 28%, 30%, and 30%, respectively.
11.5h (Rm=90%) Figures 4 and 5 demonstrate that effluent NH3 -N
75 concentrations and TN removal efficiencies were not
3 27 59 87 118 148 180 210
affected by insertion of the sludge holding tank, which
Time (days)
was possibly due to the oxic-anoxic recycling of sludge,
Figure 3. Variations of COD removal efficiencies in the control causing a nitrification–denitrification effect. This
system and three OSA systems during 7-month continuous operation. suggests that longer sludge retention time in anoxic

112 J Chem Technol Biotechnol 83:109–114 (2008)


DOI: 10.1002/jctb
Effect of sludge retention time on excess sludge in OSA process

50 the OSA process (higher sludge SVI values) and


control (Rm=30%)
more phosphorus being absorbed. In addition, the
45 5.5h (Rm=28%)
results obtained by Chudoba et al.6 revealed that the
Total nitrogen removal rate (%)

7.6h (Rm=30%)
40 OSA biomass contained about 60% of polyphosphate
11.5h (Rm=30%)
accumulating bacteria (poly-P), in contrast to 10%
35 in the conventional activated sludge system. It is
30 concluded that the anaerobically or anoxically treated
microorganisms are subjected to a physiological shock
25 created by a lack of oxygen and food. Under the above
20
conditions, they use ATP and polyphosphates as a
source of energy. When they are returned to aerobiosis
15 and supplied with exogenous substrate, they rebuild
their energy reserves at the expense of growth. An
10
1 28 49 76 96 118 136 160 180 200 important part of the substrate is oxidized in order
Time (days) to provide the energy accumulated in the cells and
utilized later under anaerobic conditions. It seems that
Figure 5. Variations of effluent TN removal efficiencies in the control
the bacteria selected by these oxic/anoxic conditions
system and three OSA systems during 7-month continuous operation.
possess a certain kind of memory that enables them to
regulate an overaccumulation of energy. This energy
100 is thus stored by means of the intracellular ATP
control (Rm=49%) pool and the surplus is transferred in polyphosphates
90 5.5h (Rm=48%)
accumulated by poly-P bacteria. Consequently, this
Total phosphate removal rate (%)

7.6h (Rm=59%)
80 phenomenon may be explained by the presence of
11.5h (Rm=58%)
70 uncoupling of catabolism and anabolism, resulting in
decreased sludge production.
60

50

40 290 control (SVIm=61)


260 5.5h (SVIm=65)
30
7.6h (SVIm=65)
230
20 11.5h (SVIm=90)
200
10
SVI

2 35 62 95 124 150 180 212 170


Time (days) 140

Figure 6. Variations of effluent TP removal efficiencies in the control 110


system and three OSA systems during 7-month continuous operation. 80
50
or anaerobic conditions favours nitrogen removal. The 20
1 21 41 61 81 101 121 141 161 181 201
results were not consistent with the views of Low et al.,
Time (days)
who thought effluent nitrogen concentration would
increase during uncoupled metabolism, although in Figure 7. Variations of the SVI in the control system and three OSA
their investigation with uncoupler pNP, they did systems duringr 7-month continuous operation.
not test the effluent nitrogen content.10 – 12 However,
until now there have been no reports on the effect
of the OSA system or uncoupling metabolism on 1 2 3 4 5 6 7 8
effluent nitrogen concentrations. Owing to the limited
literature on uncoupled metabolism, it is difficult Lanes 1-4—at the beginning,
to compare the results obtained from this study
Lanes 5-8—at the end,
with those of previous relevant studies. Detailed
investigations should be carried out in the future. Lane 1 and 5—control unit,
Effluent TP removal rates in the four processes Lane 2 and 6—sludge retained 5.5 h,
are shown in Fig. 6. The mean TP removal rate in Lane 3 and 7—sludge retained 7.6 h,
the control unit was 48.90%. In the OSA systems
Lane 4 and 8—sludge retained 11.5 h.
with sludge retained for 5.5 h, 7.6 h and 11.5 h in
the anoxic holding tank, the mean TP removal
efficiencies were 48%, 59% and 58%, respectively.
The introduction of the sludge anoxic tank decreased
the effluent TP concentration, which possibly resulted Figure 8. PCR-DGGE profiles of activated sludge samples from the
from the higher organic substrate in the sludge from four systems at the beginning and end of the experiment.

J Chem Technol Biotechnol 83:109–114 (2008) 113


DOI: 10.1002/jctb
F-X Ye, R-F Zhu, Y Li

Effect of OSA system on sludge characteristics by the oxic/anoxic cycling in the OSA process. TP
Figure 7 shows that SVI values remained below 100 removal rate increased.
throughout the entire 7-month OSA process, which (3) Sludge settleability was comparable with that of
was consistent with the results of Saby et al.8 This may the sludge from the control system, but the SVI
be attributed to the release of intracellular polymers value for the OSA system with 11.5 h sludge reten-
under anaerobic condition since they can act as floc tion time increased sharply due to the failure of a
bridging agents to improve sludge settleability. SVI temperature controller. Microscopic examination
values in the OSA process with a sludge retention and PCR-DGGE technique identified no distinct
time of 11.5 h were higher than those in the control shift in the predominant microbial species after
unit and the other two OSA systems, which was due uncoupled metabolism for 210 days. The reduced
to the failure of the temperature controller on day capital and operating costs of the OSA process
192, when the temperature decreased sharply. After with a sludge retention time of 6–7 h make it a
1 week, the same fault occurred in the OSA system novel method to reduce excess sludge production,
with a sludge retention time of 7.6 h. Afterwards, the well worth further investigation.
SVI value of the sludge in the control system increased
and process performance decreased. The OSA system
with a sludge retention time of 7.6 h operated well all ACKNOWLEDGEMENTS
the time. This implies that an OSA system with sludge The author would like to express her thanks to NSFC
retention time of 6–7 h in the sludge holding tank is a (The National Natural Science Foundation of China)
feasible approach from the viewpoint of both cost and for financial support under No.50478043.
process performance.
Microscopic examination showed that after 210 days
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114 J Chem Technol Biotechnol 83:109–114 (2008)


DOI: 10.1002/jctb

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