Process and Mass balance analysis

Gyeongsang National University

Department of Biological and chemical Engineering
Environmental Engineering Lab

Ngoc Thuan Le

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Discussions

• Environmental treatment reactors

• Hydraulic Detention time
• Study the hydraulic flow characteristics of reactors
• Mass Balance principles
• Modeling with tracer elements

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Overview

• The constituents in wastewater are removed by physical, chemical,

biological methods. These process occur in a variety of combination
in treatment flow diagram.
• Important factors:
 The type of reactor (container or tank)
 The size of the treatment facilities
 Temperature,
 and others

• The fundamental for the basis analysis of the wastewater treatment is

materials mass balance principle in which an accounting of mass is
made before and after reactions.

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Reactors used for the treatment of wastewater

Batch reactor
Activated sludge biological treatment, Complete-Mix reactor
mixing of concentrated solution Aerated lagoons, aerated sludge digestion

Plug-Flow reactor
Chlorine contact basin, natural treatment systems,
Activated sludge biological treatment…

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Complete Mix reactor in series
Lagoon treatment systems, used to simulate nonideal
flow in plug flow reactor

Packed-bed reactor Packed-bed upflow reactor Fluidized-bed reactor

Trickling filter Anaerobic treatment system Upflow sludge blanket reactors,
air stripping…

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

Detention time

 Detention time is the length of time water is retained in a vessel or basin or the period
from the time the water enters a settling basin until it flows out the other end.
 The theoretical detention time of a container is the same as the amount of time it
would take to fill the container if it were empty.
 Detention times are normally calculated for the following basins or tanks:
 Flash mix chambers (seconds)
 Flocculation basins (minutes)
 Sedimentation tanks or clarifiers (hours)
 Wastewater ponds (days)
 Oxidation ditches (hours). Where:

τ = hydraulic detention time, T

V
τ = V = volume of the reactor, L3
Q
Q = volumetric flow rate, L3T-1

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

Ideal flow in complete-mix and plug-flow reactors

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis
 Ex.

Problem

The reservoir for the community holds 110,000 gallons. The well will produce 60
gpm. What is the detention time in the reservoir in hours?

Solution

110 ,000 gal 1834 min

τ= =1834 min or = 30 .6hrs
60 gal / min 60 min/ hr

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

Nonideal flow in complete-mix and plug-flow reactors

The flow in complete-mix and plug-flow reactors is seldom ideal

a. Temperature differences, a portion of the water can travel to the outlet along
the bottom of or across the top of the reactor without mixing completely.
b. Wind-driven circulation patterns.

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 c. Inadequate mixing, sometimes due to sufficient energy input.
d. Poor design, dead zone may develop within the reactor that will not mix with
the incoming water.
e. Axial dispersion in plug flow reactors

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 The Mass-balance principle

• Mass is neither created nor destroyed, but the form of the mass can be
altered (e.g., liquid to a gas)
• Precisely, the law of the conservation of mass: “What comes in must
equal what goes out.”

• The mass balance analysis define what occurs within treatment

reactors as a function of time.

The two numbers — in (influent) and out (effluent) — must be within 10 to 15% of
each other to be considered acceptable. Larger discrepancies may indicate sampling errors
or increasing solids levels in the unit or undetected solids discharge in the tank effluent.
(Frank R, Spellman)

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Mixer

Accumulation = inflow – outflow + generation (or disappearance) Inflow Outflow

Q, Co Q, C

 One or more of the terms can be equal to zero. V, C

- In a batch reactor in which there is no inflow

or outflow, accumulation will be equal to zero.
- under steady-state condition, the rate of
accumulation is zero
 Generation term:
rc = -kC for a decrease in the reactant or,
rc = +kC for an increase in the reactant.

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Preparation of the Mass Balance

1. Prepare a simplified schematic or flow diagram of the system or

process
2. Draw a system or control volume boundary to define the limit
over which the mass balance is to be applied.
3. List all of the pertinent
4. List all of the rate expressions for the biological or chemical
reactions that occur within the control volume.
5. Select a convenient basis on which the numerical calculations will
be based.

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Application of the Mass Balance analysis

• In a complete-mix reactor, it will be assumed that:

1. The vol. flowrate into and out of the control volume is constant.
2. The liquid within the control volume is not subject to evaporation
(constant vol.)
3. The liquid within the control volume is mixed completely.
4. A chemical reaction involving a reactant A is occurring within the
reactor.
5. The rate of change in the concentration of the reactant A that is
occurring within the control volume is governed by a first-order
reaction (rc = -kC)

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Accumulation = inflow – outflow + generation

dC dC
V = QC o − QC + rcV or V = QC o − QC + (−kC )V
dt dt

Steady state simplification

Q
rc = ( Co − C )
Where:
V
dC/dt = rate of change of reactant concentration within the control volume, ML-3 T-1
V = volume contained within control vol., L3
Q = volumetric flow rate into and out of control volume, L3T-1
Co = conc. of reactant entering the control vol, ML-3
C = conc. of reactant leaving the control vol., ML-3
rc = first –order reaction (-kC), ML-3 T-1
k = first-order reaction rate coefficient, T-1cc
MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis
 Modeling ideal flow in reactors

Ideal flow in complete-mix reactor

Simplified word statement:

Accumulation = inflow – outflow

dC
V = QC o − QC
dt
Simplifying by noting that Co = 0 yields Where:
C= conc. of the tracer in the reactor at time t, ML-3
dC Q Co = initial conc. of the tracer in the reactor, ML-3
V =− C
dt V t = time, T
c t V = reactor volume, L3
dC Q
∫c C = − ∫
V 0
dt Q = volumetric flow rate, L3T-1
τ = theoretical detention time, V/Q, T
o
θ = normalized detention time t/τ, unitless
The resulting expression after integration is

C = Co e −t ( Q / V ) = Co e −t /τ = Co e −θ

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Modeling ideal flow in reactors

Ideal flow in plug flow reactor

Simplified word statement:

Accumulation = inflow – outflow

∂C
∆V = QC x −QC x + ∆x
∂t

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Modeling ideal flow in reactors

∂C  ∆C 
∆V = QC − Q C + ∆x 
∂t  ∆x 
A∆x = ∆V, A is the cross sectional area in the x direction

∂C ∆C ∂C Q ∆C
A∆x = −Q ∆x =−
∂t ∆x ∂t A ∆x
Taking the limit as ∆x approaches zero yields

∂C Q ∂C ∂C
=− = −v Where, v =velocity of flow, LT-1 (m/s)
∂t A ∂x ∂x
Where:
∂C/∂t = constituent concentration, ML-3 (g/m3)
∆V = differential volume element, L3 (m3)
t = time T (s)
Q = volumetric flowrate, L3T-1 (m3/s)
x = some point along the reactor length L, (m)
∆x = differential distance L (m)

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Analysis of nonideal flow in reactors using tracers

Need for tracer analysis

• The use of dyes and tracers for measuring the residence time
distribution curves is one of the simplest and most successful
methods

• Now, to assess the hydraulic performance of full scale reactors

a. The assessment of short circuiting in sedimentation tanks and

biological reactors

b. The assessment of contact time in chlorine contact basins

c. The assessment of the hydraulic approach condition in UV

reactors

d. The assessment of flow patterns in constructed wetlands and

other natural treatment systems

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Properties of tracers

a. The tracer should not affect the flow.

b. The tracer should be conservative.
c. It must be possible to inject the tracer over a short time period.
d. Be able to be analyzed conveniently.
e. The molecular diffusivity of the tracer should be low.
f. Not be absorbed on or react with the exposed reactor surfaces.
g. Not be absorbed on or react with the particles in the wastewater.
Success in tracer studies: congo red, fluorescein (C20 H12 O5), fluorosilicic acid
(H2SiF6), hexafluoride gas (HF6), lithium chloride (LiCl), potassium
permanganate (KMnO4)….

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Treatment processes involving mass transfer

Table 4-9
Principal applications of mass transfer operations and processes in wastewater treatment
Type of reactor Phase equilibria Application
Absorption Gas ---> liquid Addition of gases to water (e.g., O2, O3, CO2, Cl2, SO2), NH3
scrubbing in acid
Adsorption Gas ---> solid Removal of organics with activated carbon
Liquid ---> solid Removal of organics with activated carbon, dechlorination
Desorption Solid ---> liquid Sediment scrubbing
Solid ---> gas Reactivation of spent activated carbon
Drying (evaporation) Liquid ---> gas Drying of sludge
Gas stripping (also known Liquid ---> gas Removal of gases (e.g.,O2,CO2, H2S, NH3, volatile organic
as desorption) compounds, NH3 from digester supernatant)
Ion exchange Liquid ---> solid Selective removal of chemical constituents, demineralization

Adapted from Crittenten (1999), McCabe and Smith (1976) and Montgomery (1985)

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

MASS BALANCE USING BOD REMOVAL

From: Mathematics Manual for water and wastewater treatment plant operators

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 • Step 1: BODin = influent BOD x flow x 8.34 1g/m3 = 8.34 lb/Mgal

• Step 2: BODout = effluent BOD x flow x 8.34

• Step 3: BOD pounds removed = BODin – BOD out
• Step 4: Solids generated (lb) = BOD removed (lb x factor)
• Step 5: Solids removed = sludge pumped (gpd) x % solids x 8.34
• Step 6: Effluent solids (mg/L) x flow (MGD) x 8.34

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

Example

Problem
A conventional activated biosolids system with primary treatment is operating at the levels
listed below. Does the mass balance for the activated biosolids system indicate a problem?

Solution
• BODin = 166 mg/L x 11.40 MGD x 8.34 = 15,783 lb/day
• BODout = 25 mg/L x 11.40 MGD x 8.34 = 2377 lb/day
• BOD removed = 15,783 lb/d – 2377 lb/d = 13,406 lb/day
• Solids produced = 13,406 lb/day x 0.7 lb solids/lb BOD = 9384 lb solids/day
• Solids removed = 6795 mg/L x 0.15 MGD x 8.34 = 8501 lb/day
• Difference = 9384 lb/day – 8501 lb/day = 883 lb/day, or 9.4% of solids produced.
These results are within the acceptable range.

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

MASS BALANCE FOR SETTLING TANKS

• Step 1: Solids in = pounds of influent suspended solids

• Step 2: Pounds of effluent suspended solids
• Step 3: Biosolids solids out = pounds of biosolids solids pumped per day
• Step 4: Solids in — (solids out effluent + biosolids solids pumped)

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Ex,
Problem
A settling tank receives a daily flow of 4.20 MGD. The influent contains 252 mg/L
suspended solids, and the unit effluent contains 140 mg/L suspended solids. The biosolids
pump operates 10 min/h and removes biosolids at the rate of 40 gpm. The biosolids
content is 4.2% solids. Determine if the mass balance for solids removal is within the
acceptable 10 to 15% range.

Solution
• Step 1: Solids in = 252 mg/L x 4.20 MGD x 8.34 = 8827 lb/d
• Step 2: Solids out = 140 mg/L x 4.20 MGD x 8.34 = 4904 lb/d
• Step 3: Biosolids solids = 10 min/hr x 24 hr/day x 40 gpm x 8.34 x 0.042 = 3363 lb/d
• Step 4: Balance = 8827 lb/day – (4904 lb/day + 3363 lb/day) = 560 lb, or 6.3%

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis

 Thank you for your attention!

Settled sludge volume (ml/l) *1000

%h =
suspended solids (mg/l)

MECALF & EDDY|Wastewater Engineering-treatment and reuse Chap.4|Introduction to Process analysis