Sludge Minimization - Home - Ohio Water Environment ... Flow CH2M HILL Confidential and Proprietary...
Transcript of Sludge Minimization - Home - Ohio Water Environment ... Flow CH2M HILL Confidential and Proprietary...
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Sludge MinimizationA Paradigm Shift in Sludge Management
Sam Jeyanayagam, PhD, PE, BCEE
Vice President/Senior Principal TechnologistCH2M Hill
OWEABiosolids Specialty Workshop
December 9, 2010
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Our Profession Will Continue to be Fueled by Paradigm Shifts
Dr. John Snow
Broad Street Pump
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Broad Street Pump Today
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Presentation Outline
• Key Drivers• Background• Sludge Minimization at the Source• Sludge Minimization ‘After the Fact’• Sustainability Perspective• Summary
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Presentation Outline
•Key Drivers• Background• Sludge Minimization at the Source• Sludge Minimization ‘After the Fact’• Sustainability Perspective• Summary
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Key Drivers for Sludge Minimization
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2
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1 2 3 4
Year
Mill
ion
Dry
Tons
6.9 7.17.6
8.2
EPA (2000)
1998 2000 2005 2010
• Steadily increasing sludge production (500-800 lb dry weight per million gallons treated)
• Sludge operations represent >50% of a plant’s O&M cost
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Key Drivers for Sludge Minimization
• Three primary disposal alternatives– Land application (51%)– Landfilling (38%)– Incineration (11%)
• All three face varying degrees of pressures– Land application costs are escalating– Landfill availability is rapidly declining– Regulatory controls are increasing– Closer public scrutiny (NIMBY)
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It is clear that we cannot keep doing the same thing and expect a different answer.
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Benefits of Sludge Reduction
• Reduce costs (capital and O&M) in sludge processing and ultimate disposal/reuse.
• Optimize energy use• Reduce carbon footprint
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Presentation Outline
• Key Drivers
•Background• Sludge Minimization at the Source• Sludge Minimization ‘After the Fact’• Sustainability Perspective• Summary
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Sources of Sludge
Waste Activated Sludge (WAS)
Return Activated Sludge (RAS)
Biological Reactor
Primary Sludge
Primary ClarifierFinal Clarifier
Handling and
Processing
Disposal
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What’s in Your WAS?
MLSS/WAS
Organic Solids (VSS)
Inorganic Solids
ActiveBiomass(Bugs)
Organic Cell Debris
Non-Biodegradable Influent VSS
Influent Inert
Solids
Chemical Solids
Inorganic Cell
Debris
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Sludge is the ‘Undesired’ End Product of the Biological Process
Soluble Substrate
Biomass Growth (Y)
Net Growth (Ynet)
EnergyOxygen, Nitrate
CO2, H2O
Maintenance
ATPADP
DebrisBiodegradable Substrate
Decay, Predation, Lysis
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Net or Observed Growth (Yield)(Sludge Production)
Ynet =Y
Kd*SRT
Actual growth
Endogenous Decay Coefficient
Solids Retention Time
+ (Cell Debris) + (Inert solids) + …..
Biomass or Bugs
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Sludge Reduction TechnologiesMarketplace is actively responding to the paradigm shift. Available technologies can be classified based on:• Location
– At the source– After the fact– Enhanced digestion
• Process mechanism– Biological– Chemical– Physical
15
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Based on Location
PS WAS
Primary Treatment
Activated Sludge
Plant Effluent
Secondary TreatmentHeadworks
Plant Influent
Anaerobic Digester
Dewatering/ Disposal
At the SourceAfter the Fact
Enhanced Digestion
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Presentation Outline
• Key Drivers• Background
•Sludge Minimization at the Source
• Sludge Minimization ‘After the Fact’• Sustainability Perspective• Summary
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Sludge Reduction at the Source
WAS
RAS
BiologicalReactorPrimary Clarifier
Final Clarifier
Sludge Minimization Technology
• Extended Aeration• Cannibal• Ozonation
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Extended Aeration
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1.0
1.2
1.4
0 10 20 30 40
Ynet =Y
Kd * SRT
SRT, d
Net
Yie
ld, l
b VS
S/lb
CO
D
OxidationDitches
PlugFlow
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CH2M HILL Confidential and Proprietary Disclosure
CannibalTM Process
• Been in operation since 1998• Siemens licensed the technology in 2003• In operation: 10 plants. Largest: 16 mgd• Entails 2 mechanisms:
• Physical separation of inert materials and grit • Biological process
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Typical Cannibal™ Process Flow Scheme
Aeration Basin
Final Clarifier
RAS
Influent Effluent
PeriodicPurge
0.1 lb TSS/lb BOD
SRT = 8-15 days
• 0.2 to 0.3 lb TSS/lb BOD•Dewaters to 30 – 40% solids• 90% VSS
Trash, grit and inerts to landfil
Fine Screen (250 micron) and
Hydrocyclone
Interchange Reactor
• SRT = 10-12 days• MLSS = 10,000 mg/L• Low/no DO conditions
WAS
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Cannibal Process – Biological Step
• Builds on the extended aeration concept• Interchange Reactor operated on the
cusp of anaerobic/anoxic conditions• Several biological processes act in combination
to reduce sludge production– Cycling between aerobic & low/no DO conditions selects
organisms with low yield– Long SRT– Predation– Decay and lysis
Interchange Reactor
Ynet =Y
Kd*SRT
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Cannibal Process – Biological Step(Chudoba et al. 1992)
• Anabolism and catabolism are closely coupled during aerobic metabolism
• Low/no DO interchange tank acts like a ‘speed bump’– Shock and starvation conditions – no oxygen, no substrate– ATP (energy reserve) consumed – Catabolism and anabolism are uncoupled
• In the aeration tank, substrate used to restock ATP and less used for growth
CELL
Anabolism( Cell Growth)
Catabolism (Energy Production)
Substrate
50 - 60%
40 - 50%
ATPADP
AerobicBasin
No DOIR
Low DO - High DO sequencing selects organisms with low yield
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Cannibal System
• Proven technology-several full scale applications• Relatively large interchange tank needed – may not be
cost effective for large facilities• Issues with phosphorus mass balance remain
unresolved• May not be compatible with biological phosphorus
removal
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Ozonation
• Mechanisms involved – Solubilization of sludge solids and cell lysis cause an
increase in the rate of degradation– Renders the non-degradable organic fraction
degradable, thereby increasing the extent of degradation
• Solids that would otherwise contribute to sludge production are degraded resulting in sludge reduction
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Cell Lysis Caused by Ozonation
Bacterial cell to be ozonated
Ozone penetrates cell wall
Weakened cell wall ruptures in aeration basin
Cell with lysis ‘pockets’ after contact with ozone
Ozone contacts cell wall
Ozone oxidizes cell wall causing lysis
Praxair Technology
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Ozonation
WAS
RAS
Biological Reactor
Final Clarifier
RASOzoneContactor
• Contact time = 15 min • Solids inventory cycled through the contactor every
3-4 days• Ozone dose: 0.05 – 0.4 g O3/g TS red
Ozone Generator
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Ozonation
• Solids reduction reported: 30-70%• Side benefits
– Filament control - avoid bulking and foaming – Lower SVIs - improved settleability
• Higher oxygen demand in aeration basin• Require on-site ozone generation • May not be compatible with biological
phosphorus removal
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Presentation Outline
• Key Drivers• Background• Sludge Minimization at the Source
•Sludge Minimization ‘After the Fact’
• Sustainability Perspective• Summary
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‘After the Fact’ Approaches
WAS
RAS
Biological Reactor
Primary Sludge
Primary ClarifierFinal Clarifier
Dewatering and Offsite Disposal
Thickening ThickeningSludgeMinimization
Anaerobic Digester • Thermal hydrolysis
• Ultrasound• MicroSludge• Pulsed Electric Field
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The Goal is to Increase WAS Biodegradability
• WAS is slowly biodegradable during anaerobic digestion – Cell wall is like a walnut shell– The initial hydrolysis process (shell rupture) is rate limiting
• WAS biodegradability can be increased by pretreating digester feed
• Increased biodegradability means:– Increased VSS reduction– Increased methane production– Reduced biosolids to offsite disposal
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Thermal Hydrolysis (Cambi)
DEWATERINGSTEAMINJECTION
REACTOR
HIGHPRESSURE
PUMP
FEED SLUDGE15-20% TS
PULPERFLASHTANK
HOTWATER
40 C
DIGESTER
• 170-180 C; 120 psi; 20 min• Organics solubilized
• Rapid decrease in pressure (60 psi)• Flashing ruptures cells
• 90 C; 45 psi• Sludge preheatedand homogenized
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Thermal Hydrolysis (Cambi)
• Several full scale operations in Europe • Blue Plains, Wash DC – First US installation,
largest in the world. Operational in 2012.• Smaller digester volume:
– Homogenized feed - lower viscosity. Higher solids concentration in digester (15%).
– Higher volumetric loading rate
• VS reduction: 55 – 65%• Class A biosolids• Dewatered cake: 30 – 35% TS
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Ultrasound
• Sound frequency: 20 – 40 kHz• Human threshold: 18 kHz• Mechanism:
– Formation, growth and collapse of microbubbles
• Hot spots created• 4,7000C; 7,250 psi• Jet stream velocities of 250 mph.
– Causes cell rupture
Bubble size, um
Time, ms
Formation
Growth
Collapse
“Hot Spot”
4000
150
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Ultrasound – How it works
Refraction forms cavitation bubbles
Compression
Bulk Sludge
Sonic Wave
Adapted from Tiehm, et al.
Bubbles implode creating ‘hot spots’
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Ultrasound
Sonico Ultrasound Horn
Small footprint Sludge reduction claimed: 20-50% Filament control achieved Improved SVI and settleability Improved dewaterability
Reactor Digester
TransducerHigh Voltage
Ultrasound Waves
WAS
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MicroSludge Process
Chemical/Physical Treatment
• pH: 9-10
• Weaken cell wall
• Mechanical sheer
High PressureHomogenizer
•12,000 psi
• Cell rupture
MicroSludge Process
DigesterWAS
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Impact of MicroSludge Pretreatment
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Pulsed Electric Field
• Sludge is exposed to electric pulses: • High voltage and high frequency microbursts of
conditioned electricity• Application of electrical energy results in
breaching of the cell membrane leading to: • Cell inactivation• Cell lysis• Release of intracellular material
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Pulsed Electric Field – How it Works
OpenCEL
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Full-Scale Installation at Mesa, AZ
Performance data:• Greater than 10% increase in VS reduction• Increase in methane by 55-60%• Sludge treated with pulsed electric field is a
potential carbon source for denitrification
Mesa anaerobic digestersOperating data:• Plant flow: 10-12 MGD• Thickened PS/WAs mixture
50,000 - 60,000 gpd• Solids content: 4 - 6%• In operation since Sept. 2007
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Enhanced Digestion
42
• Thermophilic• Acid/Gas Phase • Anaerobic-Aerobic
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Presentation Outline
• Key Drivers• Background• Sludge Minimization at the Source• Sludge Minimization ‘After the Fact’
•Sustainability Perspective•Summary
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Ener
gy a
nd M
ater
ials
Wastes and Em
issions
No Sludge Reduction
Larger Sludge Quantity
Life Cycle AnalysisHolistic Approach to Achieve Net Environmental Benefit
With Sludge Reduction
Reduced Sludge Quantity
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Summary
• Sludge minimization provides O&M cost savings and net environmental benefit.
• WAS provides the greatest opportunity to implement sludge minimization.
• A wide range of technologies both emerging & proven are available.
• Process selection should be based on a Triple Bottom Line analysis
• Water Environment Research Foundation study outlines a methodology for evaluating candidate technologies
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Questions?