6/28/2013

Process Control for

Activated Sludge
June 27th, 2013

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Speaker

Jeanette Brown, Senior Scientist,

University of Connecticut
Department of Chemical,
Materials, and Biomolecular
Engineering

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Activated Sludge

Process Control

Jeanette Brown

Presentation Outline
• Definitions
• Description of the activated sludge
process
• Process Control
• Troubleshooting

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Definitions
• Heterotrophic-derive carbon for cell growth
and energy from organic compounds
• Autotrophic-derive carbon for cell growth
and energy from inorganic compounds
– Nitrification-converting ammonia nitrogen to
nitrate nitrogen

Definitions
• Aerobic-aerated with DO ~ 2mg/L
• SRT-The average time suspended solids
are retained in a biological waste
treatment system
• F:M-the loading rate expressed as pounds
of BOD5 per pound of mixed liquor volatile
suspended solids per day

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Plant Flow Diagram-Liquid

Treatment Processes

Preliminary Primary Biological

SC
Receiving
Secondary Disinfection
Water

Secondary Treatment
• Biological wastewater treatment that
generally removes at least 85% of BOD
and suspended solids.
• <30 mg/L BOD and TSS
• Two types
– Biofilms (Attached Growth) (Fixed Film)
• Trickling filters
• Rotating Biological Contactors
– Suspended Growth
• Activated Sludge

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The Activated Sludge Process

• In 1913, H. W. Clark and S. De M. Gage from
the Lawrence Experiment Station in
Massachusetts, reported in the 45th Annual
Report to the State Board of Health of
Massachusetts, the results of studies on the
purification of sewage using aeration.
• They found that if you aerated sewage you
achieved a clarified sewage and a reduction of
TKN.

The Activated Sludge Process

• In1914, British researchers
Edward Ardern and W.T.
Lockett, added the concept
of recycling sludge and
patented the process.
• The paper they published in Davyhulme Sewage Works,
Manchester, UK, first full-
1914, first used the term scale activated sludge
“Activated Sludge”. plant.

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Classification of Activated
Sludge Processes
• The activated-sludge process is often
classified on the basis of loading rate
– may be expressed as a volumetric loading
rate, SRT, or F:M
• Classified as
– High rate
– Conventional
– Low rate

Conventional Activated Sludge

• Conventional systems
– provide BOD5 removal efficiencies of 85 to
95%
– typically carry MLSS concentrations varying
from 1000 to 3000 mg/L
– typically have an SRT between 3-15 days
– F:M between 0.2 and 0.4 lb/lb.d (kg/kg.d)

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Basic Components
• Single or multiple biological reactors (aeration
tanks).
• Aeration source to provide
– Oxygen
– Mixing
• Clarifier(s)
• Collection and delivery mechanism for RAS
• Means of removing excess solids (WAS)

Basic Activated Sludge Process

O2 + Pollutants + Microorganisms

BOD5

RAS (microorganisms)

WAS

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Biochemical Oxygen Demand

NBOD
BOD, mg/l

TBOD
CBOD

days

Process
• Remove carbonaceous BOD
• Remove carbonaceous BOD and oxidize
ammonia (nitrify)
• Design is based on
– Length of time the solids are kept within the process;
solids retention time (SRT)
– Amount of food provided to the bacteria; food to
microorganism ratio (F/M)
– Hydraulic retention time

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Basic Process
• Organic matter is the carbon and energy
source for cell growth
• Carbon is converted to cell tissue, water,
oxidized products mainly CO2
• Contents of aeration tank is MLSS,
MLVSS

Microbiology and
Biochemistry
• Activated sludge process is a big biochemical
factory
– Bacteria
– Fungi
– Protozoa
– Rotifers
– Nematodes
• Bacteria are the significant organisms for
consuming organic matter

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Microbiology and
Biochemistry
• Predominant species of microorganisms
depends on
– Characteristics of the influent wastewater
– Environmental conditions
– Process design
– Plant operation

Microbiology and
Biochemistry
• A successful plant depends on cultivating
a biological community that will
– remove and consume (assimilate) waste
material,
– Flocculate together
– Settle well to produce a concentrated solids
for recycling
– Produce a clear effluent

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Microbiology and
Biochemistry
• Two general types of microorganisms
– Floc formers
– Filament formers
• Floc formers
– Clump together
– Form gelatinous floc which is heavy enough to settle
• Filament formers
– Stringy, threadlike structures
– Light-weight, doesn’t settle

Microbiology and
Biochemistry
• Activated sludge process uses
– Heterotrophic bacteria for carbonaceous BOD
removal
• Organisms that use organic carbon for the
formation of cell tissue
• Organic matter + oxygen +nutrients + C2H7O2N
(microorganisms) C2H7O2N (new
microorganisms) + CO2 + H2O

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Aerobic, Heterotrophic Metabolism

Nutrients

C5H7 O2N (New

Synthesis Cells)
Organic ---Bacteria---
Compounds
Energy CO2 + H2 O

O2

Aerobic, Autotrophic Metabolism

Nutrients

CO2 C5H7 O2N (New

Synthesis Cells)
---Bacteria---

NH4-N Energy NO2- + NO3 -

O2

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Solids Separation
• An important feature of the activated-
sludge microbial system is its ability to
separate by gravity under quiescent
conditions.
• This property is achieved by
– selecting the culture that settles,
– recycling the settled sludge, and
– operating the process under loading conditions
that will select for a flocculent culture.

Process Control

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Process Control
• Need to provide sufficient nutrients and food
• Need to keep a balance population of bacteria and
protozoa
• Need to provide sufficient oxygen
• Need to provide mixing

O2 + Pollutants + Microorganisms

RAS (microorganisms)
WAS

Food and Nutrients

• Incoming wastewater
• BOD
• Nitrogen
• Phosphorus
• Trace minerals
• Need 100 parts of BOD, to 5 part of
nitrogen, to 1 part of phosphorus

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Balanced Population
• RAS
– Source of microorganisms to aeration tanks
– Typically 30 to 50% Q
• WAS
– Removal of excess organisms

Oxygen and Mixing

• Need sufficient energy to mix as well as
aerate
• Accomplished by aeration devices
– Mechanical
– Diffused air
• Fine bubble
• Coarse bubble

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Aeration
• Aeration consumes
50%-65% of net
power demand for
treatment
• Important to select
design that meets
mixing and oxygen
requirements at
lowest cost possible

Key Process Control

Parameters
– MLSS and MLVSS
– SRT-solids retention time also called MCRT
(mean cell residence time)
– F/M-food to microorganisms
– SVI-sludge volume index
– RAS rate
– WAS
– Dissolved oxygen

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MLSS
• MLSS-concentration of suspended solids
in activated-sludge mixed liquor,
expressed in milligrams per liter (mg/L)
– Typically 1500 to 3500 mg/L
– Plant specific
– Can be measured in-situ

MLVSS
• MLVSS-the fraction of the suspended
solids in activated-sludge mixed liquor
– that can be driven off by combustion at 550
°C (1022 °F);
– indicates the concentration of microorganisms
available for biological oxidation
• Not an exact measurement because dead cells are
also volatile

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Solids Retention time

• SRT, MCRT, Sludge Age-How long the
solids remain in the system, terms used
interchangeably
– Dependent on growth rate of the organisms
(bacteria).
– Used as a process control and design
parameter.

SRT
• SRT = Solids under aeration divided by
the solids leaving the system.
– For BOD removal, typically 3 to 5 days
– For nitrogen removal, greater than 6 days.

Note: If there is a blanket in the secondary

clarifiers, those solids must also be taken into
account.

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SRT(MCRT)-US Units
Solids Under Aeration = Vaer (million gallons) x 8.34
lbs/million gallons-mg/L x MLSS, mg/L

Solids leaving the system = Qwas million gallons/d x 8.34

lbs/million gallons-mg/L x Cwas, mg/L + Q, million gallons/d
x 8.34 lbs/million gallons-mg/L x TSSeff, mg/L
Therefore;
SRT =(Vaer (MG) x 8.34 lbs/million gallons-mg/L x MLSS,
mg/l)/(Qwas MGD x 8.34 lbs/million gallons-mg/L x Cwas, mg/L) + (
Q, MGD x 8.34 lbs/million gallons-mg/L x TSSeff)

SRT(MCRT)-SI Units

Solids Under Aeration = Vaer (m3/d) x MLSS, g/m3 (mg/L)

x kg/1000 g

Solids leaving the system = [Qwas m3/d x Cwas, g/m3 (mg/L)

x kg/1000 g] + [Q, m3/d x TSSeff, g/m3 (mg/L) x kg/1000 g]

Therefore;
SRT =[Vaer (m3/d) x MLSS, g/m3 (mg/L) x kg/1000 g]/[Qwas m3/d x Cwas,
g/m3 (mg/L) x kg/1000 g] + [Q, m3/d x TSSeff, g/m3 (mg/L) x kg/1000 g]

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Example
• Given:
– Vaer = 1.4 million gallons (5,300 m3)
– Q = 3.1 MGD (11,735 m3/d)
– MLSS = 2650 mg/L
– Qwas = 70,000 gpd (265 m3/d)
– TSSeff = 20 mg/L
– WAS =RAS = 5960 mg/L

Example-US Units
• Solids under aeration = (1.4 million gallons x
8.34 lbs/million gallons-mg/L x 2650 mg/L) =
30,941 lbs
• Solids leaving system = (0.07 million gallons x
8.34 lbs/million gallons-mg/L x 5960 mg/L) + (3.1
million gallons/d x 8.34 lbs/million gallons-mg/L x
20 mg/L) = 3997 lbs/day

• SRT = 30,941 lbs = 7.7 days

3997 lbs/d

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Example-SI Units
• Solids under aeration = (5300 m3 x 2650 g/m3 x
kg/1000 g = 14,045 kg
• Solids leaving system = [(265 m3/d x 5960 g/m3
x kg/1000 g)] + [(11,735 m3/d x 20 g/m3) x
kg/1000 g] = 1814 kg/day

• SRT = 14,045 kg = 7.7 days

1814 kg/d

Process Control
Calculations
• F/M Ratio
– Food to microorganism ratio
– Mass of food entering biological reactors, lbs
(kg) BOD
– Mass of microorganisms in the biological
reactors, lbs (kg) MLVSS
– MLVSS typically is 80% of the MLSS

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F/M Ratio-US Units

• F/M Ratio
• Food = Q, MGD x 8.34 lbs/MG-mg/L x BOD,
mg/L
• Microorganisms = Vbio, MG x 8.34 lbs/MG-mg/L x
MLVSS, mg/L
F/M = (Q, MGD x 8.34 lbs/MG-mg/L x BOD5,mg/L)
(Vbio x 8.34 lbs/MG-mg/L x MLVSS, mg/L)

F/M Ratio-US Units

Example: MLSS=3000 mg/L; 82% volatile; Q = 16.5 MGD; V =
7.5 MG; PE BOD = 135 mg/L
F/M = (Q, million gallons/d x 8.34 lbs/million gallons-mg/L x
BOD, mg/L)/(Vaer x 8.34 lbs/million gallons-mg/L x MLVSS,
mg/L)

F/M = (16.5 MGD) * 8.34 lbs/ MG-mg/L * 135 mg/L

(7.5 MG) * 8.34 lbs/MG-mg/L * (3000*0.82) mg/L

F/M = 2228 = 0.12

18450

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F/M Ratio-SI Units

• F/M Ratio
• Food = Q, m3/d x BOD5, g/m3 x kg/1000 g
• Microorganisms = Vbio, m3 x MLVSS, g/m3 x
kg/1000 g

F/M = [(Q, m3/d x BOD5, g/m3 x kg/1000 g ]

[(Vbio, m3 x MLVSS, g/m3 x kg/1000 g)]

F/M Ratio-SI Units

Example: MLSS=3000 g/m3 ; 82% volatile; Q = 62,460 m3/d ; V =
7.5 MG; PE BOD = 135 g/m3
F/M = (Q, million gallons/d x 8.34 lbs/million gallons-mg/L x
BOD, g/m3)/(Vaer x 8.34 lbs/million gallons-mg/L x MLVSS,
g/m3)

F/M = (62,460 m3/d) * 135 g/m3 * kg/1000 g

(28,391 m3) * (3000*0.82) g/m3* kg/1000 g

F/M = 8432 = 0.12

69842

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Sludge Volume Index

• SVI= a measurement of the ability of the
floc to settle
• Typically 80 to 150

210 ml
• SVI = ml/MLSS,g
• SVI = 210 ml/2.2 g = 95
(2200 mg = 2.2 g)

WAS and RAS Rates

• RAS is the source of microorganisms
• Microorganisms use the food (BOD) to make
new cells. For every pound of BOD used, there
are about 0.5 to 0.6 pounds of new cells
produced. This is known as Cell Yield.
• WAS is used to remove excess cells (solids)
from the process.

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WAS and RAS Rates

• How do I know how much to waste or return?
– Based on mixed liquor concentration
– Based on F/M ratio
– Based on SRT (MCRT)
• Depends on what you are trying to achieve.

WAS and RAS Rates

• Typically, RAS is 30-50% influent Q, but can be
higher. Designers generally give capability of
returning 100%, but high rates can negatively
impact clarifier performance.
• Calculate WAS by rearranging the SRT formula
solving for WAS.

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WAS Rate
SRT = lbs (kg) of solids biological system
WAS, lbs/d (kg/d) + TSSEff, lbs/d (kg/d)

WAS = Solids biological system- TSSEff

SRT

WAS Rate

WAS, lbs/d (kg/d)= Solids biological- TSSEff

SRT
WAS, MGD = (WAS, lbs/d)/(8.34 MG-mg/L x WAS,mg/L)

WAS, m3/d = (WAS, kg/d)/( WAS,g/m3 x kg/1000 g )

Waste time, minutes = (WAS, gal (m3)/Pump rate,

gpm (m3/min)

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WAS Rate Example-US Units

WAS = 6774 lbs/d

WAS, MGD = 6774 lbs/d / (8.34 lbs/MG-mg/Lx 8600 mg/L)
WAS = 0.094 MGD =94,000 gpd
Pump rate = 250 gpm
Pump time = 94,000 gal/250 gpm = 376 min = 6.2 hrs.

WAS Rate Example-US Units

• SRT = 10 days
• MLSS = 3100 mg/L, Vbio =3.1 MG
• TSSEff = 8 mg/l, WAS = 8600 mg/l
• Q = 18.6 MGD
Sbio = 3100 mg/L x 8.34 lbs/million gallons/d-mg/L x 3.1
million gallons= 80147 lbs/d
TSSeff, lbs/d = (8 mg/L x 8.34 lbs/million gallons/d-mg/L x
18.6 million gallons/d) =1241 lbs/d
WAS, lbs/day = 80147 lbs/d–1241 lbs/d
10
WAS = 6774 lbs/d

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WAS Rate Example-SI Units

WAS = 3073 kg/d

WAS, MGD = 3073 kg/d / (8600 g/m3 x kg/1000 g)
WAS = 357 m3/d
Pump rate = 0.95 m3/min

Pump time = 357 m3 =376 min = 6.2 hrs

0.95 m3/min

Process Control-Microbiology
• Indicator microorganism
– Amoeba
– Flagellates
– Motile ciliates
– Stalked ciliates
– Rotifers
– Nematodes

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Free Swimming and Crawling

Ciliates

Stalked Ciliates

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Stalked Ciliates

Rotifers

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Filamentous

Nematodes/Worms

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Water Bears

Control Strategies
• Operators have a preferred method for
calculating the amount of solids to waste
to maintain an optimum solids inventory.
– What is right for one plant may not be right for
another
– Strategies include F:M, constant MLSS or
SRT

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Control Strategies
• F:M Control
– Wasting rates determined by F:M will depend
on the variations of influent BOD,
• Constant MLSS
– wasting rates determined for a constant
MLSS will depend on changes in activated-
sludge growth rate (resulting from influent
variations). Easiest control strategy for small
treatment plants

Control Strategies
• SRT control is most often the method
chosen for municipal WWTPs.
– For a given target SRT, the same portion of
activated-sludge inventory is wasted every
day regardless of the variations occurring in
the influent wastewater.
– For example, if you set a target SRT of 10
days, you will waste 10% of the MLSS every
day.

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Control Strategies
• SRT Control-
– Easier for operators to maintain a constant
SRT than a constant F:M or MLSS.
– Gives operators more control and the process
more stability when the SRT method is used.
– Choose the one that is easiest for you and
gives the best performance, but be open to
changes

Solids Separation
• Clarifiers are part of the activated sludge
process
• Need to understand and manage clarifier
performance to ensure permit compliance
• Need to understand relationship of RAS
flow to clarifiers performance

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Solids Separation
• There are five parameters that will have
the most influence over the performance
of a well-designed secondary clarifier:
– 1) MLSS concentration in the flow to the
clarifier,
– 2) wastewater flow,
– 3) RAS flow,
– 4) surface area of the clarifier, and
– 5) settleability of the activated sludge

Secondary Clarifiers
• Typically circular
• Have lower detention times
than primary because
solids are biological-1 to 2
hours
• Overflow rates at ADF =
800 gpd/ft2
• With BNR =600 gpd/ft2
• SLR = 30 lbs/d/ft2
• With BNR =20 lbs/d/ft2

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Surface Overflow Rates (SOR)

• Used to design and process control
• SOR, gal/ft2.day =Q,gpd/A,ft2
• SOR,m3/m2.day = Q, m3/d / A, m2

• Example:
A = 7,000 ft2 (650 m2) (Per unit)
Q=5,500,000 gal/d (20,820m3.d) ((Per unit)
SOR = (5,500,000 gal.d)/ 7,000 ft2 = 785 gal/ft2.day
SOR = (20,820 m3d)/ 650 m2 = 32 m3/m2.day

Solids Loading Rate

SLR = (Q,MGD + R, MGD) x MLSS, mg/L x 8.34
lbs/million gallons-mg/L/ A, ft2
SLR = Solids loading rate (lbs/d-ft2 )
SLR = (Q,m3.d + R, m3.d) x MLSS, g/m3 x kg/1000 g
A, m2
SLR = Solids loading rate (kg/d.m2)
Q = Plant flow, MGD (m3.d)
R = RAS flow rate, MGD (m3.d)
MLSS = Mixed liquor suspended solids, mg/L (g/m3)
A = Clarifier surface area, ft2 (m2)

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SLR Example
• Q = 18.2 MGD (68894 m3.d)
• R = 7.7 MGD (29148 m3.d)
• MLSS = 3350 mg/L, (g/m3)
• A = 39,978 ft2 ( 3714 m2)

SLR = (18.2 + 7.7)million gallons/d x 8.34 lbs/million

gallons-mg/L x 3350, mg/L / 39,978 ft2
SLR = 18 lbs/d-ft2

SLR = (68894+29148)m3.d x (3350, g/m3 x kg/1000 g)

39,978 m2
SLR =8.2 kg.d/m2

Process Control Tools

• Four steps are essential to manage any
process:
– gather information,
– evaluate the data,
– develop and implement a proper response,
– reevaluate.

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Process Control Tools

• First, information is collected in the form of
analytical data, hour meters, visual
observations, and other miscellaneous
facts.
– Information is only as good as the device
used for the analysis.
– Reliable instrumentation carefully selected
and properly maintained provides the best
information

Process Control Tools

• Most data numerical
• Use graphs, mass balance analysis, and basic statistics

190.0

180.0

170.0
Average Monthly
Influent BOD5
mg/L

160.0 (mg/l)
Average Monthly
150.0 Influent TSS
(mg/l)

140.0

130.0
October-06 February-08 July-09 November-10
Time

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Troubleshooting

Gathering Information
• Gathering information is a basic
troubleshooting task that requires
knowledge of
– the specific plant,
– waste constituents received, and
– specific processes.

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Gathering Information
• The following guidelines will assist in
gathering information:
– Determine whether a problem exists or the
test results are in error.
– Find out when the problem was first observed
and what was done about it.
– Examine the biomass with a microscope to
evaluate the state of the microorganisms,their
diversity, motility, and numbers.

Gathering Information
– Determine whether the operation of the plant
contributes to the problem. Check the
upstream unit for contributory problems,
including the sewer system and recycle
streams.
– Complete flow and mass-balance analysis.
Check each unit process separately because
one weak process can overload the whole
plant.

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Gathering Information
– Use a quality assurance program to improve
the accuracy of test results.
– Check for pipeline leaks that can divert flows,
including chemicals.
– Check for changes in treatment chemicals.
– Ensure that air-delivery systems work.
– Determine whether mechanical or electrical
failures are causing problems

Gathering Information
– Check for such failures when problems occur.
• A brief power outage can stop equipment,
requiring manual restart.
– Separate the symptoms from the problem.
• Listen to everyone’s observations but mistrust
everyone’s interpretation.
• Identify the root cause, not the symptom.
• Things are not always as they first appear; do not
be too quick to jump to conclusions.

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Effective Troubleshooting
• To troubleshoot effectively,
– operators must determine the probable cause
of a problem and
– select one or more corrective measures to
restore the process to full efficiency with the
least adverse effect on the final effluent
quality and at the lowest cost.

Effective Troubleshooting
• An operator needs
– thorough knowledge of the plant’s activated-
sludge process
– familiarity with influent wastewater
characteristics, plant flow rates and patterns,
– design and actual loading parameters,
– performance of the overall plant and individual
processes, and
– current maintenance procedures

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Effective Troubleshooting
• When a problem or situation arises, first
evaluate the problem and determine if it
fits into one or a combination of the
following areas:
– Hydraulic,
– Mechanical, and/or
– Process.

Hydraulic
• Hydraulic problems are easy to detect
because of solids washout at the
secondary clarifiers. These problems can
be the result of several conditions.
– rainstorms. This is especially true if the
treatment facility is served from combined
sewers.
– not enough tanks in service because of
maintenance or repairs.

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Mechanical
• Mechanical problems can result in an
effluent violation if it is not corrected or
noticed immediately.
• Problems may include failure of:
– clarifier collector mechanism,
– return activated-sludge (RAS) pump,
– blower, or mechanical aerator

Process
• Process problems are typically the most
difficult to identify and correct.
• It is important to maintain good records.
– can see warning signs of an impending
problem
– change in influent characteristics could result
in a change in settling characteristics.

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Process
– In-plant sidestream changes,
– differences in dissolved oxygen
concentrations, and other parameters and
– plant conditions are important aspects that an
operator must know to effectively troubleshoot
a treatment facility.
• Good plant records will help to determine
and correct the problem.

Microscopy
• Another excellent process troubleshooting
mechanism is microscopic examination
– can determine the condition of the activated-
sludge process by knowing and determining
the predominance of various microorganisms.
– microscopic examination of the mixed liquor
will help identify the presence and type of
filamentous organisms present in the facility,
which in turn will help determine the best
course of action to correct a process problem

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Troubleshooting Skills
• Troubleshooting requires several skills,
including
– investigative thinking and
– logical use of all tools available to help solve a
problem.
• It is important when troubleshooting not to
make more than one change at a time.

Troubleshooting Skills
• If multiple changes are made at once, it is
difficult, if not impossible, to identify which
process change was the most effective.
• Always remember that the activated-
sludge system is a biological process so
most responses will not be noticed
immediately. It may take days or weeks
before a process improvement can be
seen.

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Keys to Successful
Troubleshooting
• The following seven areas are critical for
narrowing the search for solutions to most
problems:
– Thorough knowledge of the process being
evaluated.
– Thorough knowledge of all plant flow patterns,
including sidestreams.
– Thorough knowledge of the plant’s design
parameters and how actual loadings compare
to design values.

Keys to Successful
Troubleshooting
– Thorough knowledge of all maintenance
procedures, including equipment maintenance
considerations and staff responsibilities.
– Thorough knowledge of how to recognize an
abnormal condition.
– Thorough knowledge of what alternatives are
available when trouble develops.
– Thorough knowledge of the amounts and
characteristics of any industrial waste that
may be discharged to the plant.

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Laboratory Testing
• Several simple laboratory tests that can
help solve or troubleshoot operational
problems include
– the mixed liquor settleability test,
– sludge volume index (SVI),
– mixed liquor respiration rate,
– dissolved oxygen (DO) measurement, and
– sludge blanket level

Settleability Test

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Operational Problems
• The following are some common
operational problems:
– Foaming in bioreactors
– Solids Washout
• Hydraulics
• Solids loading
– Bulking

Foaming
• Stiff white billowing foam, indicating a
young sludge (low SRT) is found in either
new or underloaded plants.
– MLSS concentration is too low and the F:M is
too high.
• The foam may consist of detergents or
proteins that cannot be converted to food
by bacteria that grow in the mixed liquor at
a high F:M.

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Causes-white foam
• Causes include:
– Problem with RAS flow
– Low MLSS resulting from process startup or
excessive sludge wasting
– presence of a toxic or inhibiting material,
– abnormally low or high pHs or insufficient DO
– nutrient deficiencies,
– activated-sludge biomass in the secondary
clarifier effluent

Potential Corrective Measures

• The following measures can be tried when
applicable to correct the foaming problem:
– Verify that return sludge is flowing to the
biological reactor. Maintain sufficient return
rates to keep the sludge blanket in the lower
quarter of the clarifier, preferably between 0.3
and 0.9 m (1 and 3 ft) from the bottom.
– Stop the sludge wasting for a few days to
increase the MLSS concentration and SRT to
target values.

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Brown Foam
• Greasy dark-tan
foam typically
caused by
Nocardia.
• Can be caused by
operating at a
high SRT
• Trapped surfaces
and recycle add
to the problem

Nocardia Foam
• Once established, Nocardia foaming can
be extremely difficult to eliminate because
– Foam is difficult to break with water sprays.
– Foam typically does not respond to chemical
antifoamants.

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Nocardia Foam
– Chlorinating RAS, although often helpful,
does not eliminate Nocardia because most of
it is in the floc and not exposed to chlorine.
– Increased wasting has its limitations because
Foam is not wasted with the WAS.
– Even if foam and scum are removed from the
process, they can cause problems in
downstream units such as digesters and also
can be recycled with decant or supernatant to
the activated-sludge process.

Potential Corrective Action

• The following measures can be tried when
applicable to correct the foaming
problems:
– If possible, gradually increase the wasting
rate to decrease the SRT.
– If filaments appear, try to identify the cause
– If the foam contains filaments, remove it from
the surface of the water and send it to the
solids-disposal facilities. Ensure that the foam
is not recycled back to the treatment plant

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Clarifier Effluent Solids

• Washout due to
– Hydraulic overload
• Know design surface overflow rate (SOR)
• Rainfall
• Unequal flow distribution
• Ensure weirs are level
– Solids Overload
• Know your design solids loading rate (SLR)
• Problem with return rate
• Increase in MLSS without consideration of SLR

Filamentous Bulking
• Filamentous Bulking can be caused by:
– Low-DO concentrations in biological reactors,
– Insufficient nutrients,
– Improper pH—either too low or widely
varying,
– Warm wastewater temperature,
– Widely varying organic loading,
– Industrial wastes with high BOD and low
nutrients (N and P)

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Filamentous Bulking
– High influent sulfide concentrations that cause
the filamentous microorganism Thiothrix to
grow
– Very low F:M, allowing Nocardia
predominance,
– Massive amounts of filaments present in
influent wastewater or recycle streams

Potential Corrective Action

• Chlorination
– Location of the chlorine application point is
critical.
– The point should be located where there is
excellent mixing, where the sludge is
concentrated, and where the wastewater
concentration is at a minimum

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Potential Corrective Action

• The three common application points are
– in the RAS stream,
– directly in the biological reactor at each
aerator, and
– in an installed side stream that recirculates
mixed liquor within the biological reactor.
• Chlorine dose and the frequency at which
organisms are exposed to chlorine are the
two most important parameters.

Potential Corrective Action

• The dose is adjusted so that concentrations
are lethal at the floc surface but not within the
floc.
• The chlorine dose should be based on the
solids inventory in the process (biological
reactors plus clarifiers)
• effective dosages are in the range of 1 to 10
g/kgd MLVSS (1 to 10 lb chlorine/d/1000 lb
MLVSS).

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Non-filamentous Bulking
• Non-filamentous bulking may be caused
by:
– Improper organic loading—either too high or
too low F:M,
– Over aeration, and
– Toxics.

Potential Corrective Action

• If few or no filamentous microorganisms
are present,
– check the F:M to determine if in target range.
– small, dispersed floc characteristic of an
increased F:M.
– If the F:M is higher than normal by 10% or
more, the wasting rate should be decreased.
– decrease in F:M should be reflected by the
disappearance of the dispersed floc over a
period of two to three SRTs

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Potential Corrective Action

– turbulence and DO in the biological reactor is
also important.
– DO concentrations >4.0 mg/L indicate that
excess air, reduce DO concentrations to 1.5-
to 3-mg/L range
– Excessive turbulence (overaeration) may
hinder MLSS floc formation and result in
pinpoint floc
– Toxics such as industrial wastes may also
cause dispersed-growth buildup.

Summary
• Need to understand the activated sludge
process and how it works at your plant
• Good process control requires good
laboratory data and instrumentation
• Troubleshooting is a complex process
especially with process problems
• More detailed information in MOP-11

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Questions?

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