MUNICIPAL WASTEWATER TREATMENT PLANT (WWTP)

PROCESS DESIGN CALCULATION REPORT

MLE + CAS 10,000 m3/d

Project Information

Item Description

Project Title Municipal Wastewater Treatment Plant (WWTP)

Treatment Technology Anoxic + Aerobic MLE + CAS Process

Design Capacity 10,000 m³/day

Reuse Category Unrestricted Municipal Irrigation

Project Location Kingdom of Saudi Arabia, Eastern province

Project Phase FEED Design

Document Type Process Design Calculation Report

Discipline Process Engineering

Document Number xxxxxx

Revision Rev.0

Status For Design Review

Date June 2026

Prepared By

Process Engineer

Adel Hassan

PMP® | CMRP®

Submitted to

PMC / Client
SECTIONS

Section 01 – Design Basis & Effluent Requirements

Section 02 – Process Selection: MLE-CAS Configuration
Section 03 – Flow Basis & Peaking Factors
Section 04 – Influent Load Calculation
Section 05 – Preliminary Treatment Design
Section 06 – Equalization / Flow Balancing Check
Section 07 – Anoxic Tank Design
Section 08 – Aeration Tank Design
Section 09 – Internal Mixed Liquor Recycle Design
Section 10 – RAS / WAS Design
Section 11 – Secondary Clarifier Design
Section 12 – Blower & Oxygen Demand Calculation
Section 13 – Sludge Production Calculation
Section 14 – Tertiary Filtration Design
Section 15 – Disinfection System Design
Section 16 – Treated Effluent Tank & Reuse Pumping
Section 17 – Sludge Thickening / Dewatering Basis
Section 18 – Hydraulic Profile / HGL Basis
Section 19 – Equipment List
Section 20 – Control Philosophy / Instruments
Section 21 – PMC Verification & Design Summary

SECTION 01
DESIGN BASIS & EFFLUENT REQUIREMENTS

1. DESIGN FLOW BASIS

Parameter Value
Average Daily Flow, Qavg 10,000 m³/d
Average Hourly Flow 416.7 m³/h
Design Peak Factor 2.5
Peak Flow, Qpeak 25,000 m³/d
Peak Hourly Flow 1,041.7 m³/h

2. PROPOSED TRAIN ARRANGEMENT

Item Selection
Number of Biological Trains 2 Duty Trains
Capacity per Train 5,000 m³/d
Average Flow per Train 208.3 m³/h
Peak Flow per Train 520.8 m³/h
Process per Train Anoxic Tank + Aeration Tank + Secondary Clarifier

3. INFLUENT WASTEWATER DESIGN BASIS

Parameter Unit Design Value

BOD₅ mg/L 300
COD mg/L 600
TSS mg/L 300
TKN mg/L 50
NH₄-N mg/L 40
Total Nitrogen, TN mg/L 55
Total Phosphorus, TP mg/L 8
Temperature °C 20–35
Minimum Design Temperature °C 15

4. FINAL EFFLUENT TARGET

Parameter Unit Target Value

BOD₅ mg/L ≤ 10
TSS mg/L ≤ 10
Parameter Unit Target Value
NH₄-N mg/L ≤5
TN mg/L ≤ 15
TP mg/L Project specific
Fecal Coliform CFU/100 mL As reuse standard
Residual Chlorine mg/L ≥ 0.5 at outlet

5. MAIN PROCESS FUNCTIONS

Unit Main Function

Anoxic Tank Denitrification and nitrate removal
Aeration Tank BOD removal and nitrification
Internal Recycle Return nitrate-rich mixed liquor to anoxic tank
Secondary Clarifier Biomass separation
RAS System Return settled activated sludge to biological reactor
WAS System Waste excess sludge
Tertiary Filter Final TSS / turbidity polishing
Disinfection Pathogen reduction

Next section: Section 02 – Process Selection: MLE-CAS Configuration.

SECTION 02
PROCESS SELECTION: MLE-CAS CONFIGURATION
1. PROCESS CONFIGURATION

Preliminary Treatment → Anoxic Tank → Aeration Tank → Secondary Clarifier → Tertiary

Filtration → Disinfection → TSE Tank

With:

Internal Mixed Liquor Recycle from Aerobic Outlet to Anoxic Inlet

And:

RAS Return from Secondary Clarifier to Anoxic Tank

2. MLE-CAS PROCESS FLOW DESCRIPTION

Stream Description
Raw Sewage Enters inlet works and preliminary treatment
Screened / degritted sewage Flows to anoxic tank
RAS Returned from secondary clarifier to anoxic tank
Internal Recycle Nitrate-rich mixed liquor recycled from aerobic tank outlet to anoxic tank
Anoxic Effluent Flows by gravity to aeration tank
Aeration Effluent Flows to secondary clarifier
Clarifier Underflow Split into RAS and WAS
Clarifier Overflow Flows to tertiary treatment

3. PURPOSE OF EACH BIOLOGICAL ZONE

Zone Main Function

Anoxic Tank Denitrification using influent rbCOD as carbon source
Zone Main Function
Aeration Tank Carbon oxidation, nitrification, and biomass growth
Secondary Clarifier Solid-liquid separation and sludge return
Internal Recycle Returns nitrate to anoxic zone for denitrification
RAS Maintains MLSS and active biomass concentration
WAS Controls sludge age / SRT

4. TYPICAL CONTROL TARGETS

Parameter Typical Design / Control Target

Aerobic DO 1.5 – 2.5 mg/L
Anoxic DO < 0.5 mg/L
MLSS 3,000 – 4,500 mg/L
MLVSS / MLSS 0.70 – 0.80
SRT for nitrification 8 – 15 days
Internal Recycle Ratio 200 – 400% of influent flow
RAS Ratio 50 – 100% of influent flow
F/M Ratio 0.05 – 0.15 kg BOD/kg MLSS.d
HRT Biological Reactor 8 – 14 h

5. PRELIMINARY SELECTED DESIGN VALUES

Parameter Selected Value

Number of Biological Trains 2
Flow per Train 5,000 m³/d
Anoxic Zone Provided at head of biological reactor
Aerobic Zone Provided after anoxic zone
Internal Recycle From aerobic outlet to anoxic inlet
RAS Return Point Anoxic inlet
Design MLSS 3,500 mg/L
Design MLVSS/MLSS 0.75
Design SRT 12 days
Design DO in Aeration Tank 2.0 mg/L
Design DO in Anoxic Tank < 0.5 mg/L

6. MLE NITROGEN REMOVAL PRINCIPLE

In MLE-CAS:

Ammonia is oxidized in the aerobic tank:

NH₄-N → NO₂-N → NO₃-N

Then nitrate is recycled to the anoxic tank by internal recycle:

NO₃-N + rbCOD → N₂ Gas

Item Role
Aeration Tank Produces nitrate by nitrification
Internal Recycle Transfers nitrate to anoxic tank
Anoxic Tank Converts nitrate to nitrogen gas
Influent rbCOD Provides carbon for denitrification

7. INITIAL INTERNAL RECYCLE SELECTION

Parameter Value
Internal Recycle Ratio, IR 300% of Qavg
Plant Qavg 10,000 m³/d
Internal Recycle Flow 30,000 m³/d
Internal Recycle per Train 15,000 m³/d

Theoretical nitrate recycle removal fraction = IR / (1 + IR)

IR = 3:

Removal fraction = 3 / (1 + 3) = 0.75

Theoretical maximum nitrate return removal ≈ 75%

Next Section: Section 03 – Flow Basis & Peaking Factors.

SECTION 03
FLOW BASIS & PEAKING FACTORS

1. DESIGN FLOW BASIS

Parameter Symbol Value

Average Daily Flow Qavg 10,000 m³/d
Parameter Symbol Value
Average Hourly Flow Qavg,h 416.7 m³/h
Number of Biological Trains N 2
Average Flow per Train Qavg,train 5,000 m³/d
Average Hourly Flow per Train Qavg,h,train 208.3 m³/h

2. PEAKING FACTOR SELECTION

Flow Condition Peaking Factor Basis

Average Flow 1.0 × Qavg Normal process design
Maximum Daily Flow 1.5 × Qavg Hydraulic / process check
Peak Hourly Flow 2.5 × Qavg Hydraulic peak check
Minimum Flow 0.4 × Qavg Low-flow operation check

3. PLANT FLOW CALCULATION

Flow Condition Formula Flow

Average Daily Flow 10,000 × 1.0 10,000 m³/d
Maximum Daily Flow 10,000 × 1.5 15,000 m³/d
Peak Hourly Flow as Daily Equivalent 10,000 × 2.5 25,000 m³/d
Minimum Daily Flow 10,000 × 0.4 4,000 m³/d

4. PLANT HOURLY FLOW CALCULATION

Flow Condition Formula Flow

Average Hourly Flow 10,000 / 24 416.7 m³/h
Maximum Daily Hourly Flow 15,000 / 24 625.0 m³/h
Peak Hourly Flow 25,000 / 24 1,041.7 m³/h
Minimum Hourly Flow 4,000 / 24 166.7 m³/h

5. PER TRAIN FLOW CALCULATION

Flow Condition Formula Flow per Train

Average Flow 10,000 / 2 5,000 m³/d
Maximum Daily Flow 15,000 / 2 7,500 m³/d
Peak Hourly Flow Equivalent 25,000 / 2 12,500 m³/d
Minimum Flow 4,000 / 2 2,000 m³/d

6. PER TRAIN HOURLY FLOW CALCULATION

Flow Condition Formula Flow per Train
Average Hourly Flow 5,000 / 24 208.3 m³/h
Maximum Daily Hourly Flow 7,500 / 24 312.5 m³/h
Peak Hourly Flow 12,500 / 24 520.8 m³/h
Minimum Hourly Flow 2,000 / 24 83.3 m³/h

7. HYDRAULIC DESIGN FLOW APPLICATION

Unit / System Design Flow to be Used

Inlet works Peak hourly flow
Screens Peak hourly flow
Grit removal Peak hourly flow
Influent pumping Peak hourly flow
Equalization inlet Peak hourly flow
Biological reactors Average flow + recycle flows
Internal recycle pumps Average flow basis, checked at maximum daily
RAS pumps Average / maximum biological flow
Secondary clarifiers Average, maximum daily, and peak hydraulic checks
Tertiary filters Average / maximum daily flow
Chlorination system Maximum daily flow
TSE pumps Project reuse demand / peak discharge flow

8. BIOLOGICAL PROCESS DESIGN FLOW APPLICATION

For MLE-CAS process sizing:

Design Item Flow Basis

Organic loading Qavg
Nitrogen loading Qavg
Aeration tank volume Qavg
Anoxic tank volume Qavg
SRT calculation Qavg
F/M calculation Qavg
Oxygen demand Qavg and checked at maximum daily
Internal recycle Qavg
Design Item Flow Basis
RAS flow Qavg
Clarifier hydraulic loading Qavg, maximum daily, and peak hourly

9. SELECTED DESIGN FLOW SUMMARY

Item Value
Design Average Flow 10,000 m³/d
Maximum Daily Flow 15,000 m³/d
Peak Hourly Flow 1,041.7 m³/h
Minimum Flow 4,000 m³/d
Number of Trains 2
Average Flow per Train 5,000 m³/d
Peak Hourly Flow per Train 520.8 m³/h

Next Section: Section 04 – Influent Load Calculation.

SECTION 04
INFLUENT LOAD CALCULATION

1. DESIGN FLOW BASIS

Parameter Value

Average Daily Flow, Qavg 10,000 m³/d

Average Hourly Flow 416.7 m³/h

Number of Biological Trains 2

Parameter Value

Average Flow per Train 5,000 m³/d

Average Hourly Flow per Train 208.3 m³/h

2. DESIGN INFLUENT QUALITY

Parameter Symbol Design Value

Biochemical Oxygen Demand BOD₅ 300 mg/L

Chemical Oxygen Demand COD 600 mg/L

Total Suspended Solids TSS 300 mg/L

Ammonia Nitrogen NH₄-N 40 mg/L

Total Kjeldahl Nitrogen TKN 50 mg/L

Total Nitrogen TN 55 mg/L

Total Phosphorus TP 8 mg/L

3. LOAD CALCULATION FORMULA

Load, kg/d = Flow, m³/d × Concentration, mg/L / 1,000

4. PLANT INFLUENT LOADS

Parameter Formula Load

BOD₅ Load 10,000 × 300 / 1,000 3,000 kg/d

COD Load 10,000 × 600 / 1,000 6,000 kg/d

TSS Load 10,000 × 300 / 1,000 3,000 kg/d

Parameter Formula Load

NH₄-N Load 10,000 × 40 / 1,000 400 kg/d

TKN Load 10,000 × 50 / 1,000 500 kg/d

TN Load 10,000 × 55 / 1,000 550 kg/d

TP Load 10,000 × 8 / 1,000 80 kg/d

5. PER TRAIN INFLUENT LOADS

Parameter Formula Load per Train

BOD₅ Load 5,000 × 300 / 1,000 1,500 kg/d

COD Load 5,000 × 600 / 1,000 3,000 kg/d

TSS Load 5,000 × 300 / 1,000 1,500 kg/d

NH₄-N Load 5,000 × 40 / 1,000 200 kg/d

TKN Load 5,000 × 50 / 1,000 250 kg/d

TN Load 5,000 × 55 / 1,000 275 kg/d

TP Load 5,000 × 8 / 1,000 40 kg/d

6. BIOLOGICAL LOAD BASIS

Design Item Basis

3,000 kg
Organic Loading for Aeration Design
BOD₅/d

COD Loading for Carbon Balance 6,000 kg COD/d

Ammonia Loading for Nitrification 400 kg NH₄-N/d

TKN Loading for Sludge / Nitrogen Balance 500 kg TKN/d

TN Loading for Denitrification Design 550 kg TN/d

Design Item Basis

TP Loading for Chemical Phosphorus Review 80 kg TP/d

7. REQUIRED REMOVAL LOADS

7.1 BOD₅ Removal

Item Value

Influent BOD₅ 300 mg/L

Effluent BOD₅ Target 10 mg/L

BOD₅ to be Removed 290 mg/L

BOD₅ Removal Load 10,000 × 290 / 1,000 = 2,900 kg/d

7.2 TSS Removal

Item Value

Influent TSS 300 mg/L

Effluent TSS Target 10 mg/L

TSS to be Removed 290 mg/L

TSS Removal Load 10,000 × 290 / 1,000 = 2,900 kg/d

7.3 Ammonia Removal

Item Value

Influent NH₄-N 40 mg/L

Effluent NH₄-N Target 5 mg/L

NH₄-N to be Nitrified 35 mg/L

NH₄-N Nitrification Load 10,000 × 35 / 1,000 = 350 kg/d

7.4 Total Nitrogen Removal

Item Value

Influent TN 55 mg/L

Effluent TN Target 15 mg/L

TN to be Removed 40 mg/L

TN Removal Load 10,000 × 40 / 1,000 = 400 kg/d

7.5 Total Phosphorus Removal

Item Value

Influent TP 8 mg/L

Effluent TP Target Project specific

TP Load 80 kg/d

8. INITIAL DENITRIFICATION CARBON CHECK

COD required ≈ 2.86 kg COD/kg NO₃-N removed

TN removed = 400 kg/d

COD required = 400 × 2.86 = 1,144 kg COD/d

Total COD load = 10,000 × 600 / 1,000 = 6,000 kg COD/d

Available rbCOD = Total COD load × rbCOD fraction

Available rbCOD = 6,000 × 0.20 = 1,200 kg COD/d

Item Value

Available rbCOD 1,200 kg/d

Required COD for Denitrification 1,144 kg/d

Preliminary Surplus 56 kg COD/d

Next Section: Section 05 – Preliminary Treatment Design.

SECTION 05
PRELIMINARY TREATMENT DESIGN

1. PURPOSE OF PRELIMINARY TREATMENT

Preliminary treatment is provided upstream of the biological process to remove coarse solids,
plastics, rags, grit, sand, and floating materials.

The preliminary treatment stage protects:

2. SELECTED PRELIMINARY TREATMENT UNITS

Step Unit

1 Inlet chamber

2 Coarse screen

3 Fine screen

4 Screenings washing / compacting

5 Grit removal chamber

6 Grit classifier / washer

7 Flow measurement channel

8 Distribution to downstream process

3. DESIGN FLOW BASIS

Parameter Value

Average Flow 10,000 m³/d

Average Hourly Flow 416.7 m³/h

Peak Factor 2.5

Peak Flow 25,000 m³/d

Peak Hourly Flow 1,041.7 m³/h

Peak Flow 0.289 m³/s

 Parameter Value

4. SCREENING SYSTEM DESIGN

4.1 Selected Arrangement

Item Selection

Coarse Screens 2 channels: 1 duty + 1 standby

Fine Screens 2 channels: 1 duty + 1 standby

Screen Type Mechanical inclined / step screen

Bypass Screen Manual bar screen

Coarse Screen Opening 25–40 mm

Fine Screen Opening 3–6 mm

Screen Design Flow Peak hourly flow

Channel Isolation Stop logs / penstocks

5. SCREEN CHANNEL DESIGN

5.1 Design Criteria

Parameter Typical EPC Value

Approach Velocity at Average Flow 0.3 – 0.6 m/s Metcalf &Eddy

Approach Velocity at Peak Flow 0.6 – 1.0 m/s Metcalf &Eddy

Velocity Through Screen at Peak 0.8 – 1.2 m/s Metcalf &Eddy

Maximum Allowable Headloss, Clean 50 – 100 mm Huber , Parkson

Parameter Typical EPC Value

Maximum Allowable Headloss, Dirty 150 – 300 mm Huber , Parkson

5.2 Channel Sizing

Qavg,h =10,000 / 24 = 416.7 m3/h

Qpeak = 416.7 × 2.5 = 1,041.7 m3/h
Qpeak = 1041.7 / 3600 = 0.289 m³/s

Parameter Value

Peak Flow 0.289 m³/s

Selected Approach Velocity 0.80 m/s

Required Wet Area 0.289 / 0.80 = 0.361 m²

flow depth at peak:

Parameter Value

Selected Flow Depth 0.70 m

Required Channel Width 0.361 / 0.70 = 0.516 m

Verification

Item Selected Value

Screen Channel Width 600 mm

Operating Flow Depth at Peak 0.70 m

Actual Approach Area 0.60 × 0.70 = 0.42 m²

Actual Approach Velocity 0.289 / 0.42 = 0.69 m/s

Item Selected Value

6. SCREENING SYSTEM SELECTION

Item Selected Value

Number of Coarse Screen Channels 2

Duty / Standby 1D + 1S

Number of Fine Screen Channels 2

Duty / Standby 1D + 1S

Channel Width 600 mm

Peak Flow per Duty Channel 1,041.7 m³/h

Coarse Screen Opening 25–40 mm

Fine Screen Opening 3–6 mm

Screen Inclination Vendor standard

Screen Material SS316 / Duplex as project requirement

7. GRIT REMOVAL DESIGN

7.1 Selected Arrangement

Item Selection

Grit Removal Type Vortex / aerated grit chamber

Number of Units 2
Item Selection

Duty / Standby 1D + 1S

Design Flow Peak hourly flow

Target Grit Size Removal ≥ 0.20 mm

Grit Handling Grit classifier / washer

8. GRIT CHAMBER DESIGN CRITERIA

Parameter Typical EPC Value

Hydraulic Retention Time at Peak 2 – 5 min

Horizontal Velocity 0.25 – 0.35 m/s

Target Grit Particle ≥ 0.20 mm

Organic Content in Washed Grit As vendor standard

Freeboard ≥ 0.30 m

9. GRIT CHAMBER VOLUME

HRT = 3 minutes at peak flow.

Parameter Value

Peak Flow 0.289 m³/s

Selected HRT 3 min = 180 s

Required Grit Volume 0.289 × 180 = 52.0 m³

Parameter Value

Flow per Unit at Peak 0.289 / 2 = 0.1445 m³/s

Volume per Unit 52.0 / 2 = 26.0 m³

Item Selected Value

Parameter Value

Volume per Unit 30 m³ (adopted)

Number of Units 2

Total Installed Volume 60 m³ (adopted)

HRT at Peak, 2 Units Operating 60 / 0.289 = 208 s = 3.47 min

HRT at Average, 1 Unit Operating 30 / 0.116 = 259 s = 4.31 min

10. FLOW MEASUREMENT

Item Selection

Flow Meter Type Magnetic flow meter or ultrasonic open channel flow meter

Location Downstream of preliminary treatment

Design Range Minimum to peak flow

Signal 4–20 mA to PLC/SCADA

Function Flow monitoring, process control, reporting

11. PRELIMINARY TREATMENT EQUIPMENT SUMMARY

Equipment Quantity Duty Design Capacity

Coarse Mechanical Screen 2 1D + 1S 1,041.7 m³/h each

Manual Bypass Screen 1 Emergency Peak flow

Fine Mechanical Screen 2 1D + 1S 1,041.7 m³/h each

Equipment Quantity Duty Design Capacity

Screenings Compactor 1 Duty Vendor design

Grit Chamber 2 2 operating at peak 30 m³ each

Grit Classifier / Washer 1 Duty Vendor design

Inlet Flow Meter 1 Duty 0–1,200 m³/h

Next Section: Section 06 – Equalization / Flow Balancing Check.

SECTION 06
EQUALIZATION / FLOW BALANCING CHECK
1. PURPOSE OF EQUALIZATION

Equalization is provided to reduce hydraulic and organic shock loading to the downstream
biological treatment system.

For MLE-CAS, equalization improves:

Item Benefit
Biological stability Reduces flow/load fluctuation
Anoxic performance Improves denitrification stability
Aeration control Reduces DO swings
Clarifier performance Reduces hydraulic peak loading
Tertiary filtration Provides steadier feed flow

2. DESIGN BASIS

Parameter Value
Average Daily Flow 10,000 m³/d
Average Hourly Flow 416.7 m³/h
Peak Hourly Flow 1,041.7 m³/h
Biological Feed Flow Target 416.7 m³/h
Number of Biological Trains 2
Flow per Train after EQ 208.3 m³/h

3. SELECTED EQ HRT

Item Selected Value

EQ HRT at Average Flow 6h
Design Flow 10,000 m³/d
Average Hourly Flow 416.7 m³/h

4. EQ VOLUME CALCULATION

EQ Volume = Qavg,h × HRT

Parameter Formula Value

Average Hourly Flow 10,000 / 24 416.7 m³/h
Selected HRT — 6h
Required EQ Volume 416.7 × 6 2,500 m³
Item Value
Total Working EQ Volume 2,500 m³
Number of EQ Tanks 2
Working Volume per Tank 1,250 m³

5. EQ TANK DIMENSIONING

Parameter Per Tank Value

Working Volume 1,250 m³
Selected Water Depth 5.0 m
Required Surface Area 1,250 / 5.0 = 250 m²

Dimension Value
Length 25 m
Width 10 m
Water Depth 5.0 m
Working Volume 25 × 10 × 5 = 1,250 m³
Freeboard 0.5 m
Total Wall Depth 5.5 m

6. EQ MIXING REQUIREMENT

Equalization tanks shall be mixed to avoid solids settlement and septic conditions.

Parameter Typical Value

Mixing Intensity 5 – 10 W/m³
Selected Mixing Intensity 6 W/m³
Total EQ Volume 2,500 m³

Mixer Power = Volume × Mixing Intensity

Item Formula Value
Total Mixer Power 2,500 × 6 15,000 W
Total Mixer Power — 15 kW

Item Selected Value

Mixers per Tank 2
Mixer Rating 4 kW each
Total Installed Mixing Power 2 × 2 × 4 = 16 kW ( adopted)

7. EQ AERATION / ODOUR CONTROL CHECK

For municipal wastewater, EQ tanks may require air mixing or mechanical mixing with odour
extraction depending on retention time and site requirements.

Item Selection
Mixing Type Submersible mechanical mixers
Odour Control Recommended for covered EQ tank
Septicity Control Required if long retention or warm climate
Tank Cover Project / authority requirement

8. EQ TRANSFER PUMP DESIGN

EQ transfer pumps shall feed the biological trains at controlled flow.

Parameter Value
Total Biological Feed Flow 416.7 m³/h
Flow per Train 208.3 m³/h
Selected Pump Arrangement 2 Duty + 1 Standby
Flow per Duty Pump 208.3 m³/h

Adopt:
Item Selected Value
EQ Transfer Pumps 3
Duty / Standby 2D + 1S
Capacity per Pump 210 m³/h
Control VFD
Discharge Destination Biological inlet distribution chamber

9. EQ CONTROL PHILOSOPHY

Control Item Description

Influent to EQ From preliminary treatment
EQ Level Control Ultrasonic / radar level transmitter
Transfer Pump Control VFD flow control
Flow Split Equal distribution to 2 biological trains
Low Level Protection Pump trip on low-low level
High Level Alarm High level alarm to SCADA
Mixer Operation Continuous or level-based
Odour Fan Operation Continuous when tank covered

10. EQ DESIGN SUMMARY

Item Selected Design

Total EQ Working Volume 2,500 m³
Number of Tanks 2
Volume per Tank 1,250 m³
Tank Dimensions per Tank 25 m × 10 m × 5 m SWD
Freeboard 0.5 m
Total Wall Depth 5.5 m
Mixers 4 total
Mixer Rating 4 kW each
EQ Transfer Pumps 2D + 1S
Pump Capacity 210 m³/h each
Control VFD flow control
Next Section: Section 07 – Anoxic Tank Design.

SECTION 07
ANOXIC TANK DESIGN

1. PURPOSE OF ANOXIC TANK

The anoxic tank is provided for biological denitrification.

In the anoxic zone:

NO₃-N is converted to N₂ gas

2. DESIGN FLOW BASIS

Parameter Value
Plant Average Flow 10,000 m³/d
Number of Biological Trains 2
Flow per Train 5,000 m³/d
Flow per Train 208.3 m³/h
Influent TN 55 mg/L
Effluent TN Target ≤ 15 mg/L
TN to be Removed 40 mg/L
TN Removal Load 400 kg/d
TN Removal per Train 200 kg/d

3. INTERNAL RECYCLE BASIS

For MLE-CAS preliminary design:

Parameter Value
Internal Recycle Ratio 300% of influent flow
IR Ratio 3Q
Plant Internal Recycle Flow 30,000 m³/d
Internal Recycle per Train 15,000 m³/d
Internal Recycle per Train 625 m³/h
4. RAS RETURN BASIS
Parameter Value
RAS Ratio 75% of influent flow
RAS Ratio 0.75Q
Plant RAS Flow 7,500 m³/d
Parameter Value
RAS Flow per Train 3,750 m³/d
RAS Flow per Train 156.3 m³/h
5. TOTAL HYDRAULIC FLOW ENTERING ANOXIC TANK

Qtotal,anoxic = Q + IR + RAS

Flow Component Value

Influent Flow to Train 208.3 m³/h
Internal Recycle Flow 625.0 m³/h
RAS Flow 156.3 m³/h
Total Hydraulic Flow through Anoxic Tank 989.6 m³/h

6. ANOXIC TANK HRT SELECTION

For MLE-CAS municipal design:

Parameter Typical Range

Anoxic HRT based on influent flow only 1.5 – 3.0 h
Anoxic HRT including recycle flows 0.4 – 1.0 h

Selected design basis:

Parameter Selected Value

Anoxic HRT based on influent flow 2.0 h

7. ANOXIC VOLUME CALCULATION

Anoxic Volume per Train = Qtrain × HRT

Parameter Formula Value

Flow per Train 208.3 m³/h 208.3 m³/h
Selected HRT 2.0 h 2.0 h
Required Anoxic Volume per Train 208.3 × 2.0 416.6 m³

Adopt:

Item Value
Anoxic Volume per Train 420 m³ “ adopted”
Number of Trains 2
Total Anoxic Volume 840 m³

8. HRT CHECK INCLUDING RECYCLE FLOWS

Parameter Value
Adopted Anoxic Volume per Train 420 m³
Total Flow through Anoxic Tank 989.6 m³/h

Actual HRT including recycle = 420 / 989.6 = 0.424 h

Item Result
HRT including recycle 0.424 h
HRT including recycle 0.424 x 60 = 25.4 min

9. THEORETICAL TN REMOVAL CHECK BY INTERNAL RECYCLE

For MLE:

Theoretical NO₃-N removal fraction = IR / (1 + IR)

Where:

IR = Qinternal recycle / Qinfluent

IR = 3:

Removal fraction = 3 / (1 + 3) = 0.75

Parameter Value
Influent TN 55 mg/L
Maximum Theoretical TN Removal 55 × 0.75 = 41.25 mg/L
Theoretical Effluent TN 55 − 41.25 = 13.75 mg/L

10. DENITRIFICATION CARBON CHECK

From Section 04:

Item Value
TN Removal Required 400 kg/d
COD Required for Denitrification 400 × 2.86
COD Required 1,144 kg COD/d
Available rbCOD 1,200 kg COD/d
Item Value

rbCOD Surplus 1,200 − 1,144 = 56 kg COD/d

11. ANOXIC MIXER DESIGN

Anoxic tanks shall be mechanically mixed without aeration.

Parameter Typical Value

Mixing Intensity 5 – 10 W/m³
Selected Mixing Intensity 8 W/m³
Volume per Train 420 m³

Mixer Power per Train = 420 × 8 = 3,360 W

Item Value
Mixers per Anoxic Tank 2
Mixer Rating 2.2 kW each
Installed Mixer Power per Train 4.4 kW
Total Installed Mixer Power 8.8 kW

12. ANOXIC TANK DIMENSIONS

rectangular reinforced concrete tank.

Parameter Value
Adopted Volume per Train 420 m³
Selected SWD 5.0 m
Required Plan Area 420 / 5.0 = 84 m²

Adopt per train:

Dimension Value
Length 14 m
Width 6m
SWD 5.0 m
Working Volume 14 × 6 × 5 = 420 m³
Freeboard 0.5 m
Total Wall Depth 5.5 m

13. DO CONTROL REQUIREMENT

Parameter Required Condition
Anoxic DO < 0.5 mg/L
Preferred DO 0.1 – 0.3 mg/L
Aeration Not allowed
Mixing Required
Nitrate Monitoring Recommended for large plants

14. ANOXIC TANK EQUIPMENT SUMMARY

Equipment Quantity Duty Capacity / Rating

Anoxic Tank 2 Duty 420 m³ each
Submersible Mixer 4 Duty 2.2 kW each
DO Analyzer 2 Duty 0–5 mg/L
Nitrate Analyzer 1–2 Optional / recommended Vendor standard
External Carbon Dosing Point 2 Duty At anoxic inlet

Next Section: Section 08 – Aeration Tank Design.

SECTION 08
AERATION TANK DESIGN

1. PURPOSE OF AERATION TANK

The aeration tank is provided for:

Function Description
Carbon oxidation Removal of soluble and biodegradable BOD
Nitrification Conversion of NH₄-N to NO₃-N
Biomass growth Maintaining active MLSS concentration
Final polishing Stabilization before secondary clarification

2. DESIGN FLOW AND LOAD BASIS

Parameter Plant Value Per Train Value

Average Flow 10,000 m³/d 5,000 m³/d
Average Flow 416.7 m³/h 208.3 m³/h
Influent BOD₅ 300 mg/L 300 mg/L
BOD₅ Load 3,000 kg/d 1,500 kg/d
BOD₅ Removed 2,900 kg/d 1,450 kg/d
Influent NH₄-N 40 mg/L 40 mg/L
NH₄-N to be Nitrified 350 kg/d 175 kg/d
Parameter Plant Value Per Train Value
Effluent NH₄-N Target ≤ 5 mg/L ≤ 5 mg/L

3. SELECTED MLSS AND SRT BASIS

Parameter Selected Value

MLSS 3,500 mg/L
MLVSS / MLSS Ratio 0.75
MLVSS 2,625 mg/L
Design SRT 12 days
Aerobic DO 2.0 mg/L
Minimum Wastewater Temperature 15°C

4. AERATION TANK HRT SELECTION

Item Typical Range

Aeration HRT 6 – 10 h
Total biological HRT 8 – 14 h

Selected:

Item Value
Aeration HRT 8h
Anoxic HRT 2h
Total Biological HRT 10 h
5. AERATION TANK VOLUME CALCULATION

Aeration Volume per Train = Qtrain × HRT

Parameter Formula Value

Flow per Train 5,000 / 24 208.3 m³/h
Selected Aeration HRT — 8h
Aeration Volume per Train 208.3 × 8 1,666.4 m³

Adopt:

Item Value
Aeration Volume per Train 1,670 m³
Number of Trains 2
Total Aeration Volume 3,340 m³
6. TOTAL BIOLOGICAL VOLUME CHECK

Item Per Train Plant Total

Anoxic Volume 420 m³ 840 m³
Aeration Volume 1,670 m³ 3,340 m³
Total Biological Volume 2,090 m³ 4,180 m³
Parameter Value

Total Biological HRT per Train 2,090 / 208.3

Total Biological HRT 10.0 h

7. F/M RATIO CHECK

F/M = BOD Load / MLSS Mass

MLSS Mass = Aeration Volume × MLSS / 1,000

Per train:

Parameter Value
Aeration Volume 1,670 m³
MLSS 3,500 mg/L = 3.5 kg/m³
MLSS Mass 1,670 × 3.5 = 5,845 kg
BOD Load per Train 1,500 kg/d

F/M = 1,500 / 5,845 = 0.257 kg BOD/kg MLSS.d

Using total biological reactor MLSS mass:

Parameter Value
Total Biological Volume per Train 2,090 m³
MLSS Mass 2,090 × 3.5 = 7,315 kg
F/M 1,500 / 7,315 = 0.205 kg BOD/kg MLSS.d

Comment:
For complete nitrification CAS, F/M should preferably be lower. Therefore, volume shall be
increased or MLSS increased.

8. F/M CORRECTION

To achieve conservative nitrifying CAS operation:

Selected design target:

Parameter Value
Target F/M based on total biological MLSS ≤ 0.15 kg BOD/kg MLSS.d
MLSS 3,500 mg/L
BOD Load per Train 1,500 kg/d

Required total biological volume:

V = BOD Load / (F/M × MLSS)

Parameter Formula Value

Required Volume 1,500 / (0.15 × 3.5) 2,857 m³

Existing anoxic volume:

Item Value
Anoxic Volume per Train 420 m³

Required aeration volume:

Aeration Volume = 2,857 − 420 = 2,437 m³

Adopt:

Item Value
Corrected Aeration Volume per Train 2,450 m³
Corrected Total Biological Volume per Train 2,870 m³
Number of Trains 2
Total Aeration Volume 4,900 m³
Total Biological Volume 5,740 m³

9. CORRECTED HRT CHECK

Item Value
Corrected Aeration Volume per Train 2,450 m³
Flow per Train 208.3 m³/h
Corrected Aeration HRT 2,450 / 208.3 = 11.76 h
Anoxic HRT 420 / 208.3 = 2.02 h
Total Biological HRT 2,870 / 208.3 = 13.78 h
10. CORRECTED F/M CHECK

Parameter Value
Total Biological Volume per Train 2,870 m³
MLSS 3.5 kg/m³
MLSS Mass 2,870 × 3.5 = 10,045 kg
BOD Load per Train 1,500 kg/d

F/M = 1,500 / 10,045 = 0.149 kg BOD/kg MLSS.d

11. AERATION TANK DIMENSIONING

rectangular tank.

Parameter Value
Aeration Volume per Train 2,450 m³
Selected SWD 5.0 m
Required Plan Area 2,450 / 5.0 = 490 m²

Adopt per train:

Dimension Value
Length 49 m
Width 10 m
SWD 5.0 m
Working Volume 49 × 10 × 5 = 2,450 m³
Freeboard 0.5 m
Total Wall Depth 5.5 m

12. NITRIFICATION SRT CHECK

For municipal CAS nitrification at minimum temperature of 15°C:

Item Selected Value
Design SRT 12 days
Typical Required SRT at 15°C 8 – 12 days

13. MLSS MASS SUMMARY

Item Per Train Plant Total

Anoxic Volume 420 m³ 840 m³
Aeration Volume 2,450 m³ 4,900 m³
Total Biological Volume 2,870 m³ 5,740 m³
MLSS 3.5 kg/m³ 3.5 kg/m³
MLSS Mass 10,045 kg 20,090 kg
MLVSS Mass 7,534 kg 15,068 kg

14. PROCESS DESIGN SUMMARY

Item Selected Value

Number of Biological Trains 2
Anoxic Volume per Train 420 m³
Aeration Volume per Train 2,450 m³
Total Biological Volume per Train 2,870 m³
Aeration Tank Dimensions per Train 49 m × 10 m × 5 m SWD
MLSS 3,500 mg/L
MLVSS 2,625 mg/L
SRT 12 days
F/M Ratio 0.149 kg BOD/kg MLSS.d
Aeration HRT 11.76 h
Total Biological HRT 13.78 h
Aerobic DO 2.0 mg/L

Next Section: Section 09 – Internal Mixed Liquor Recycle Design.

SECTION 09
INTERNAL MIXED LIQUOR RECYCLE DESIGN

1. PURPOSE OF INTERNAL RECYCLE

Internal mixed liquor recycle is required in MLE-CAS to return nitrate-rich mixed liquor
from the aerobic zone outlet back to the anoxic zone inlet.

Function:

Aerobic Tank produces NO₃-N → Internal Recycle returns NO₃-N to Anoxic Tank →
Anoxic Tank converts NO₃-N to N₂ gas

2. DESIGN FLOW BASIS

Parameter Value

Average Plant Flow, Qavg 10,000 m³/d

Number of Biological Trains 2

Flow per Train 5,000 m³/d

Flow per Train 208.3 m³/h

Influent TN 55 mg/L

Effluent TN Target ≤ 15 mg/L

3. INTERNAL RECYCLE RATIO SELECTION

MLE-CAS:

Parameter Typical Range

Internal Recycle Ratio 200 – 400% of Q

Selected Internal Recycle Ratio 300% of Q

Selected IR Ratio 3Q

4. INTERNAL RECYCLE FLOW CALCULATION

4.1 Plant Internal Recycle Flow

QIR = 3 × Qavg

Item Formula Value

Plant Qavg — 10,000 m³/d

IR Ratio — 3Q

Plant Internal Recycle Flow 3 × 10,000 30,000 m³/d

Plant Internal Recycle Flow 30,000 / 24 1,250 m³/h

4.2 Per Train Internal Recycle Flow

Item Formula Value

Flow per Train — 5,000 m³/d

IR Ratio — 3Q

Internal Recycle per Train 3 × 5,000 15,000 m³/d

Internal Recycle per Train 15,000 / 24 625 m³/h

5. THEORETICAL TN REMOVAL CHECK

For MLE process:

Maximum theoretical nitrate removal fraction = R / (1 + R)

R = Internal recycle ratio = QIR / Q

R=3

NO₃-N removal fraction = 3 / (1 + 3) = 0.75

Item Value

Influent TN 55 mg/L

Theoretical Removal Fraction 75%

Theoretical TN Removed 55 × 0.75 = 41.25 mg/L

Theoretical Effluent TN 55 − 41.25 = 13.75 mg/L

6. SELECTED DESIGN CAPACITY WITH FLEXIBILITY

Item Normal Design Maximum Design

IR Ratio 300% Q 400% Q

Plant IR Flow 30,000 m³/d 40,000 m³/d

Plant IR Flow 1,250 m³/h 1,667 m³/h

IR Flow per Train 15,000 m³/d 20,000 m³/d

IR Flow per Train 625 m³/h 833 m³/h

7. INTERNAL RECYCLE PUMP ARRANGEMENT

Item Selection

Pump Type Submersible mixed liquor recycle pump / axial flow pump

Pump Location Aerobic tank outlet zone

Discharge Location Anoxic tank inlet zone

Number of Pumps per Train 2

Duty / Standby per Train 1D + 1S

Control VFD

Normal Flow per Duty Pump 625 m³/h

Maximum Flow per Duty Pump 833 m³/h

9. INTERNAL RECYCLE PUMP CAPACITY

Item Value

Number of Trains 2

Pumps per Train 2

Total Pumps 4

Duty Pumps 2

Standby Pumps 2

Normal Capacity per Duty Pump 625 m³/h

Maximum Capacity per Duty Pump 833 m³/h

Selected Pump Capacity 835 m³/h each

Control VFD

10. INTERNAL RECYCLE HYDRAULIC CHECK

Internal recycle normally has low static head because it transfers mixed liquor from the
aerobic zone to the anoxic zone within the biological reactor.
Component Typical Allowance

Static / level difference 0.3 – 0.8 m

Pipe / channel losses 0.5 – 1.5 m

Fittings / valves losses 0.5 – 1.0 m

Discharge turbulence allowance 0.5 m

Total Design Head 2.0 – 4.0 m

Item Selected Value

Design Pump Head 4.0 m

Pump Capacity 835 m³/h

Pump Control VFD

11. INTERNAL RECYCLE POWER ESTIMATION

Hydraulic Power = ρ × g × Q × H / 1000

Parameter Value

Flow, Q 835 m³/h = 0.232 m³/s

Head, H 4.0 m

Density 1,000 kg/m³

Pump Efficiency 65%

Hydraulic Power = 1000 × 9.81 × 0.232 × 4 / 1000 = 9.1 kW

Shaft Power = 9.1 / 0.65 = 14.0 kW

Adopt:

Item Selected Value

Motor Rating 18.5 kW

Quantity 4 pumps

Duty 1D + 1S per train

Item Selected Value

12. INTERNAL RECYCLE PIPE SIZING

mixed liquor recycle piping:

Parameter Typical Range

Velocity 1.0 – 2.0 m/s

Selected Velocity 1.5 m/s

At maximum pump flow:

Item Value

Flow per Pump 835 m³/h

Flow per Pump 0.232 m³/s

Selected Velocity 1.5 m/s

Required Area 0.232 / 1.5 = 0.155 m²

Equivalent Diameter √(4 × 0.155 / 3.1416) = 0.444 m

Adopt:

Item Selected Value

Internal Recycle Pipe Diameter DN450

Velocity at 835 m³/h 1.46 m/s

13. CONTROL PHILOSOPHY

Control Item Description

Normal Operation IR pump operates continuously with VFD

Control Item Description

Flow Control Based on influent flow ratio

Normal Setpoint 300% of influent flow

Maximum Setpoint 400% of influent flow

Low Flow Operation Reduce IR to avoid excessive DO carryover

High TN Condition Increase IR if carbon and anoxic capacity are available

DO Carryover Control Avoid excessive aerobic DO return to anoxic zone

Pump Trip Alarm and standby pump start

Flow Measurement Magnetic flow meter recommended on IR line

14. INTERNAL RECYCLE DESIGN SUMMARY

Item Selected Value

Normal IR Ratio 300% Q

Item Selected Value

Maximum IR Ratio 400% Q

Normal IR Flow per Train 625 m³/h

Maximum IR Flow per Train 833 m³/h

Selected Pump Capacity 835 m³/h

Pump Head 4.0 m

Pump Motor 18.5 kW

Arrangement 1D + 1S per train

Total Pumps 4

Pipe Size DN450

Control VFD, flow-paced

Discharge Location Anoxic inlet

Suction Location Aerobic tank outlet

Next Section: Section 10 – RAS / WAS Design.

SECTION 11
SECONDARY CLARIFIER DESIGN
1. PURPOSE OF SECONDARY CLARIFIER

Secondary clarifiers are provided to separate activated sludge solids from treated mixed
liquor.

Function Description

Solid-liquid separation Settles MLSS from aeration tank effluent

Clarified effluent production Provides overflow to tertiary treatment

RAS production Returns settled sludge to anoxic tank

WAS source Provides excess sludge withdrawal

Sludge blanket control Maintains stable solids inventory

2. DESIGN BASIS

Parameter Value

Plant Average Flow 10,000 m³/d

Maximum Daily Flow 15,000 m³/d

Peak Hourly Flow 25,000 m³/d equivalent

Number of Biological Trains 2

Flow per Train 5,000 m³/d

MLSS 3,500 mg/L

RAS Ratio Normal 75%

RAS Ratio Maximum 100%

Clarifier Type Circular secondary clarifier

3. CLARIFIER ARRANGEMENT

Item Selection

Number of Clarifiers 2

Arrangement 1 clarifier per biological train

Duty Both operating

Item Selection

Design Flow per Clarifier 5,000 m³/d average

Peak Flow per Clarifier 12,500 m³/d equivalent

RAS Withdrawal From clarifier sludge hopper / scraper pit

Overflow To tertiary filtration

4. SURFACE OVERFLOW RATE DESIGN CRITERIA

Flow Condition Typical EPC Criteria

Average SOR 16 – 24 m³/m².d

Maximum Daily SOR 24 – 32 m³/m².d

Peak Hourly SOR 40 – 50 m³/m².d

Selected design criteria:

Flow Condition Selected Limit

Average SOR ≤ 20 m³/m².d

Maximum Daily SOR ≤ 30 m³/m².d

Peak Hourly SOR ≤ 50 m³/m².d

5. REQUIRED SURFACE AREA

5.1 Area Based on Average Flow

Item Formula Value

Average Flow per Clarifier — 5,000 m³/d

Selected Average SOR — 20 m³/m².d

Required Area 5,000 / 20 250 m²

Item Formula Value

5.2 Area Based on Maximum Daily Flow

Item Formula Value

Maximum Daily Flow per Clarifier 7,500 m³/d 7,500 m³/d

Selected Max Daily SOR — 30 m³/m².d

Required Area 7,500 / 30 250 m²

5.3 Area Based on Peak Hourly Flow

Item Formula Value

Peak Flow per Clarifier 12,500 m³/d 12,500 m³/d

Selected Peak SOR — 50 m³/m².d

Required Area 12,500 / 50 250 m²

6. SELECTED CLARIFIER DIAMETER

Required area = 250 m².

For circular clarifier:

Area = π × D² / 4
D = √(4 × Area / π)

Item Formula Value

Required Diameter √(4 × 250 / 3.1416) 17.84 m

Adopt:

Item Selected Value

Clarifier Diameter 18.0 m

Surface Area π × 18² / 4 = 254.5 m²

7. SURFACE OVERFLOW RATE CHECK

Flow Condition Flow per Clarifier Area Actual SOR

Average Flow 5,000 m³/d 254.5 m² 19.6 m³/m².d

Maximum Daily Flow 7,500 m³/d 254.5 m² 29.5 m³/m².d

Peak Hourly Flow 12,500 m³/d 254.5 m² 49.1 m³/m².d

8. SOLIDS LOADING RATE CHECK

For secondary clarifier solids loading, the influent solids flow to clarifier includes mixed
liquor flow from aeration tank.

For conservative check:

Solids Load = Q × MLSS

8.1 Average Solids Loading

Item Value

Flow per Clarifier 5,000 m³/d

MLSS 3.5 kg/m³

Solids Load 5,000 × 3.5 = 17,500 kg/d

Clarifier Area 254.5 m²

SLR 17,500 / 254.5 = 68.8 kg/m².d

8.2 Peak Hydraulic Solids Loading Check

Item Value

Peak Flow per Clarifier 12,500 m³/d

MLSS 3.5 kg/m³

Solids Load at Peak 12,500 × 3.5 = 43,750 kg/d

Clarifier Area 254.5 m²

SLR at Peak 43,750 / 254.5 = 171.9 kg/m².d

9. CLARIFIER WITH EQ OPERATIONAL CHECK

Item Value

Controlled Biological Flow per Train 5,000 m³/d

Normal RAS Flow per Train 3,750 m³/d

Maximum RAS Flow per Train 5,000 m³/d

Item Value

MLSS Flow to Clarifier 5,000 m³/d

MLSS Concentration 3.5 kg/m³

Solids Load 17,500 kg/d

Area 254.5 m²

SLR 68.8 kg/m².d

10. WEIR LOADING RATE CHECK

peripheral weir.

Weir Length = π × D

Item Formula Value

Clarifier Diameter — 18 m

Weir Length π × 18 56.5 m

10.1 Average Weir Loading

Item Formula Value

Average Flow — 5,000 m³/d

Weir Length — 56.5 m

WLR 5,000 / 56.5 88.5 m³/m.d

10.2 Peak Weir Loading

Item Formula

Peak Flow —

Weir Length —

WLR 12,500 / 56.5

Condition Result

Average WLR 88.5 m³/m.d

Item Formula

Peak WLR 221.2 m³/m.d

11. SIDE WATER DEPTH AND VOLUME

Parameter Selected Value

Clarifier Diameter 18 m

Surface Area 254.5 m²

Side Water Depth 4.0 m

Working Volume 254.5 × 4.0 = 1,018 m³

Hydraulic detention time at average flow:

Item Formula Value

Volume — 1,018 m³

Average Flow 5,000 / 24 208.3 m³/h

HRT 1,018 / 208.3 4.89 h

12. CLARIFIER MECHANICAL DESIGN BASIS

Item Selected Design

Clarifier Type Circular center-feed clarifier

Sludge Collection Rotating scraper mechanism

Scum Removal Surface skimmer and scum box

Inlet Arrangement Center feed well

Effluent Collection Peripheral V-notch weir

Sludge Withdrawal Central sludge hopper

Item Selected Design

Bridge Half bridge or full bridge, vendor design

Drive Low-speed clarifier drive with torque protection

13. SLUDGE BLANKET CONTROL

Item Requirement

Sludge Blanket Depth Monitored during operation

Normal Blanket As low as practical

High Blanket Alarm Recommended

RAS Adjustment Based on blanket level and MLSS

WAS Adjustment Based on SRT / MLSS

Online Sludge Blanket Meter Recommended for PMC / large plant

14. SECONDARY CLARIFIER DESIGN SUMMARY

Item Selected Value

Number of Clarifiers 2

Clarifier per Train 1

Clarifier Type Circular

Diameter 18 m

Surface Area 254.5 m² each

Item Selected Value

Side Water Depth 4.0 m

Volume 1,018 m³ each

Average SOR 19.6 m³/m².d

Maximum Daily SOR 29.5 m³/m².d

Peak SOR 49.1 m³/m².d

Normal SLR 68.8 kg/m².d

Peripheral Weir Length 56.5 m

Average WLR 88.5 m³/m.d

Peak WLR 221.2 m³/m.d

Next Section: Section 12 – Blower & Oxygen Demand Calculation.

SECTION 11A
SECONDARY CLARIFIER SRT / RAS / WAS / SOLIDS BALANCE VERIFICATION

1. OBJECTIVE

Item Selected Value

MLSS 3,500 mg/L

Item Selected Value

SRT 12 d

Total Biological Volume 5,740 m³

Biological Trains 2

Clarifiers 2

Clarifier Diameter 18 m each

2. BIOLOGICAL SOLIDS INVENTORY

Item Formula Value

Total Biological Volume — 5,740 m³

MLSS — 3.5 kg/m³

Total MLSS Inventory 5,740 × 3.5 20,090 kg MLSS

Per train:

Item Formula Value

Biological Volume per Train — 2,870 m³

MLSS — 3.5 kg/m³

MLSS Inventory per Train 2,870 × 3.5 10,045 kg MLSS

3. SRT EQUATION

SRT = Solids inventory / Solids leaving system per day

Solids leaving system = WAS solids + effluent solids loss

SRT = V × X / (QW × XW + QE × XE)

4. EFFLUENT SOLIDS LOSS

Assume final secondary clarifier effluent TSS before tertiary filtration:

Item Value

Clarifier Effluent TSS, XE 15 mg/L

XE 0.015 kg/m³

Plant Flow, QE 10,000 m³/d

Item Formula Value

Effluent Solids Loss 10,000 × 0.015 150 kg/d

5. REQUIRED TOTAL SOLIDS WASTING FOR 12-DAY SRT

Item Formula Value

MLSS Inventory — 20,090 kg

Required Solids Leaving System 20,090 / 12 1,674 kg/d

Effluent Solids Loss — 150 kg/d

Required WAS Solids 1,674 − 150 1,524 kg/d

Per train:

Item Formula Value

Required WAS Solids per Train 1,524 / 2 762 kg/d

6. WAS FLOW VERIFICATION

Assume WAS is withdrawn from RAS line.

Item Value

Assumed WAS Concentration, XW 8,000 mg/L

XW 8 kg/m³

Required WAS Solids 1,524 kg/d

Item Formula Value

Required WAS Flow 1,524 / 8 190.5 m³/d

Required WAS Flow 190.5 / 24 7.94 m³/h

Per train:

Item Formula Value

WAS Flow per Train 190.5 / 2 95.3 m³/d

WAS Flow per Train 95.3 / 24 4.0 m³/h

Selected WAS Pump: 10 m³/h duty pump

7. RAS CONCENTRATION VERIFICATION

RAS concentration depends on sludge settling and clarifier thickening.

For preliminary EPC design, use solids balance across aeration tank / clarifier:

XR = X × (Q + QRAS) / QRAS

Symbol Description

X MLSS in aeration tank

Q Influent flow

QRAS RAS flow

XR RAS concentration

For normal RAS ratio:

Item Value

Q per train 5,000 m³/d

QRAS per train 3,750 m³/d

MLSS, X 3.5 kg/m³

Item Formula Value

XR 3.5 × (5,000 + 3,750) / 3,750 8.17 kg/m³

RAS concentration = 8,170 mg/L

8. RAS CONCENTRATION CHECK AT MAXIMUM RAS

At maximum RAS ratio = 100%:

Item Value

Q per train 5,000 m³/d

QRAS per train 5,000 m³/d

MLSS, X 3.5 kg/m³

Item Formula Value

XR 3.5 × (5,000 + 5,000) / 5,000 7.0 kg/m³

RAS concentration = 7,000 mg/L

9. RAS CONCENTRATION ACCEPTANCE

Condition Calculated XR

RAS = 75% Q 8,170 mg/L

RAS = 100% Q 7,000 mg/L

Typical Municipal RAS Range 7,000 – 12,000 mg/L

Selcected >> RAS = 75 % Q

10. COMPLETE SOLIDS BALANCE PER TRAIN

10.1 Clarifier Influent Solids

Item Formula Value

Clarifier Influent Flow Q + IR? Not applicable

Mixed Liquor Flow to Clarifier Q + IR? No

Correct Clarifier Feed Flow Q 5,000 m³/d

MLSS X 3.5 kg/m³

Solids to Clarifier 5,000 × 3.5 17,500 kg/d

10.2 Clarifier Solids Leaving

Stream Flow Solids Conc. Solids Load

RAS 3,750 m³/d 8.17 kg/m³ 30,638 kg/d

Stream Flow Solids Conc. Solids Load

WAS 95.3 m³/d 8.17 kg/m³ 779 kg/d

Effluent 5,000 m³/d 0.015 kg/m³ 75 kg/d

11. SRT RE-CHECK USING VERIFIED WAS FLOW

Item Formula Value

Plant MLSS Inventory — 20,090 kg

WAS Flow — 190.5 m³/d

WAS Concentration — 8 kg/m³

WAS Solids 190.5 × 8 1,524 kg/d

Effluent Solids Loss 10,000 × 0.015 150 kg/d

Total Solids Leaving 1,524 + 150 1,674 kg/d

Verified SRT 20,090 / 1,674 12.0 d

12. CORRECTED SOLIDS LOADING RATE CHECK

SLR = Q × MLSS / Clarifier Area

Per clarifier:

Item Value

Clarifier Feed Flow 5,000 m³/d

MLSS 3.5 kg/m³

Solids Load 17,500 kg/d

Clarifier Area 254.5 m²

Item Formula Value

SLR 17,500 / 254.5 68.8 kg/m².d

Item Value

Typical Normal SLR 50 – 100 kg/m².d

Actual SLR 68.8 kg/m².d

13. SOLIDS FLUX CHECK

13.1 Applied Solids Flux

Item Value

MLSS 3.5 kg/m³

Clarifier Feed Flow 5,000 m³/d

Area 254.5 m²

Applied Flux 68.8 kg/m².d

14. SLUDGE BLANKET CHECK

Item Selected / Required

Clarifier SWD 4.0 m

Normal Sludge Blanket 0.5 – 1.0 m

High Blanket Alarm 1.5 m

Maximum Operating Blanket 2.0 m

Clear Water Zone at Maximum Blanket 4.0 − 2.0 = 2.0 m

15. CLARIFIER SIZE CONFIRMATION

Check Result

Average SOR 19.6 m³/m².d

Max Daily SOR 29.5 m³/m².d

Peak SOR 49.1 m³/m².d

Average WLR 88.5 m³/m.d

Check Result

Peak WLR 221.2 m³/m.d

Normal SLR 68.8 kg/m².d

Verified SRT 12.0 d

RAS Concentration 8,170 mg/L

WAS Flow 190.5 m³/d

16. UPDATED RAS / WAS SETTINGS

Item Normal Setting

RAS Ratio 75% of Q

RAS Flow per Train 3,750 m³/d

RAS Flow per Train 156.3 m³/h

RAS Concentration 8,170 mg/L

WAS Flow per Train 95.3 m³/d

WAS Flow per Train 4.0 m³/h

Total WAS Flow 190.5 m³/d

Total WAS Flow 7.94 m³/h

WAS Solids 1,524 kg/d

Effluent Solids Loss 150 kg/d

Verified SRT 12 d
Next Section: Section 12 – Blower & Oxygen Demand Calculation.

SECTION 12
BLOWER & OXYGEN DEMAND CALCULATION

1. DESIGN OBJECTIVE

This section calculates the required aeration air flow and blower capacity for the MLE-CAS
aerobic tanks based on:

Item Purpose

Carbon oxidation Oxygen for BOD removal

Nitrification Oxygen for NH₄-N oxidation

Field correction Conversion from standard to actual site conditions

Blower sizing Required Nm³/h and installed capacity

2. DESIGN BASIS

Parameter Value

Plant Flow 10,000 m³/d

Parameter Value

Number of Biological Trains 2

Flow per Train 5,000 m³/d

BOD Removed 2,900 kg/d

NH₄-N Nitrified 350 kg/d

Aeration Volume per Train 2,450 m³

Total Aeration Volume 4,900 m³

Aerobic DO, C_L 2.0 mg/L

Design Temperature 35°C

Minimum Temperature Check 15°C

3. ACTUAL OXYGEN REQUIREMENT, AOR

3.1 Oxygen for Carbon Oxidation

O₂ for BOD removal = 1.10 × BOD removed

Item Formula Value

BOD Removed — 2,900 kg/d

O₂ for Carbon Oxidation 1.10 × 2,900 3,190 kg O₂/d

3.2 Oxygen for Nitrification

Oxygen required for nitrification:

O₂ = 4.57 kg O₂ / kg NH₄-N oxidized

Item Formula Value

NH₄-N Nitrified — 350 kg/d

O₂ for Nitrification 4.57 × 350 1,599.5 kg O₂/d

3.3 Denitrification Oxygen Credit

O₂ credit = 2.86 kg O₂ / kg NO₃-N denitrified

Assume TN removed biologically:

Item Value

TN Removed 400 kg/d

Oxygen Credit 2.86 × 400 = 1,144 kg O₂/d

3.4 Net AOR

Item Value

O₂ for Carbon Oxidation 3,190 kg/d

O₂ for Nitrification 1,599.5 kg/d

Subtotal 4,789.5 kg/d

Less Denitrification Credit 1,144 kg/d

3,645.5 kg
Net AOR
O₂/d

Add design margin:

Item Value

Design Margin 15%

Design AOR 3,645.5 × 1.15 = 4,192 kg O₂/d

Item Value

Design AOR 4,192 kg O₂/d

4,192 / 24 = 174.7 kg
Design AOR
O₂/h

Design AOR per Train 87.4 kg O₂/h

4. FIELD OXYGEN TRANSFER EFFICIENCY EQUATION

FOTE = SOTE × α × β × F_f × ((C_s(T) − C_L) / C_s,20) × θ^(T − 20)

Q_air = AOR / (0.279 × FOTE)

Symbol Description

FOTE Field Oxygen Transfer Efficiency

SOTE Standard Oxygen Transfer Efficiency

α Alpha factor

β Beta factor

F_f Fouling factor

C_s(T) Oxygen saturation at design temperature

C_L Operating DO

C_s,20 Oxygen saturation at 20°C

θ Temperature correction factor

T Wastewater temperature

0.279 kg O₂ per Nm³ air

5. SELECTED OXYGEN TRANSFER PARAMETERS

Parameter Selected Value

SOTE 25% = 0.25

Alpha factor, α 0.60

Beta factor, β 0.95

Fouling factor, F_f 0.85

Aerobic DO, C_L 2.0 mg/L

C_s,20 9.08 mg/L

C_s at 35°C 7.00 mg/L

θ 1.024

Temperature, T 35°C

6. FOTE CALCULATION AT 35°C

FOTE = 0.25 × 0.60 × 0.95 × 0.85 × ((7.00 − 2.00) / 9.08) × 1.024^(35 − 20)

Item Value

SOTE 0.25

α 0.60
Item Value

β 0.95

F_f 0.85

DO correction (7.00 − 2.00) / 9.08 = 0.551

Temperature correction 1.024^15 = 1.428

FOTE = 0.25 × 0.60 × 0.95 × 0.85 × 0.551 × 1.428

FOTE = 0.0955

Item Value

FOTE 0.0955

FOTE 9.55%

7. AIR FLOW CALCULATION

Q_air = AOR / (0.279 × FOTE)

Item Formula Value

174.7 kg
AOR —
O₂/h

FOTE — 0.0955

Air Flow 174.7 / (0.279 × 0.0955) 6,559 Nm³/h

Adopt:

Item Value

Required Air Flow 6,559 Nm³/h

Selected Design Air Flow 6,600 Nm³/h

Item Value

Per train:

Item Value

Air Flow per Train 3,300 Nm³/h

8. CHECK AT 15°C

At lower temperature:

Parameter Value

C_s at 15°C 10.07 mg/L

C_L 2.0 mg/L

C_s,20 9.08 mg/L

θ 1.024

T 15°C

FOTE = 0.25 × 0.60 × 0.95 × 0.85 × ((10.07 − 2.00) / 9.08) × 1.024^(15 − 20)

Item Value

DO correction 8.07 / 9.08 = 0.889

Temperature correction 1.024^-5 = 0.888

FOTE 0.0956

FOTE 9.56%
*FOTE at 15°C is approximately similar to 35°C due to opposite effects of oxygen solubility
and temperature correction.

9. BLOWER CAPACITY SELECTION

Item Value

Total Required Air Flow 6,600 Nm³/h

Number of Aeration Trains 2

Air Flow per Train 3,300 Nm³/h

Selected Blower Arrangement 3 blowers

Duty / Standby 2D + 1S

Capacity per Blower 3,300 Nm³/h

Total Duty Capacity 6,600 Nm³/h

Standby Capacity 3,300 Nm³/h

10. BLOWER DISCHARGE PRESSURE

10.1 Pressure Components

Component Value

Aeration Tank SWD 5.0 m

Component Value

Static Pressure 50 kPa

Diffuser Loss 5 kPa

Pipe / Valve Loss 10 kPa

Filter / Silencer Loss 3 kPa

Control Valve Allowance 5 kPa

Fouling / Future Allowance 7 kPa

Item Value

Total Blower Discharge Pressure 80 kPa

Total Blower Discharge Pressure 0.80 bar

Adopt:

Item Selected Value

Blower Discharge Pressure 80 kPa

11. BLOWER POWER ESTIMATION

Blower Power ≈ 0.035 to 0.045 kW per Nm³/h at 0.8 bar

Parameter Value

Specific Power 0.040 kW per Nm³/h

Blower Flow 3,300 Nm³/h

Item Formula Value

Estimated Power per Blower 3,300 × 0.040 132 kW

Adopt:

Item Selected Value

Motor Rating per Blower 160 kW

Blower Quantity 3
Item Selected Value

Duty / Standby 2D + 1S

Control VFD

12. DIFFUSER DESIGN

12.1 Air Flow per Aeration Tank

Item Value

Air Flow per Train 3,300 Nm³/h

Aeration Tank per Train 1

Air Flow per Tank 3,300 Nm³/h

12.2 Diffuser Capacity

fine bubble disc diffusers.

Parameter Selected Value

Air Flow per Diffuser 8 Nm³/[Link]

Item Formula Value

Diffusers per Train 3,300 / 8 412.5

Adopt:

Item Selected Value

Diffusers per Train 420

Item Selected Value

Total Diffusers 840

13. DIFFUSER DENSITY CHECK

Item Value

Aeration Tank Plan Area per Train 49 m × 10 m = 490 m²

Diffusers per Train 420

Item Formula Value

Diffuser Density 420 / 490 0.86 diffuser/m²

14. AIR HEADER SUMMARY

Item Selected Value

Total Air Flow 6,600 Nm³/h

Blowers 3 × 3,300 Nm³/h

Main Air Header To be sized for 6,600 Nm³/h

Branch Air Header per Train To be sized for 3,300 Nm³/h

Control per Train Air flow control valve + DO control

Diffuser Type Fine bubble disc diffuser

Item Selected Value

Diffusers per Train 420

Total Diffusers 840

15. CONTROL PHILOSOPHY

Item Control Requirement

Blower Control VFD based on header pressure and DO demand

Aeration Tank DO 2.0 mg/L normal setpoint

DO Control Range 1.5 – 2.5 mg/L

Air Flow Control Flow control valve to each aeration tank

Low DO Alarm Required

High DO Alarm Required

Blower Duty Rotation Automatic

Standby Start Automatic on duty blower trip or low pressure

High Pressure Trip Required

Surge Protection Required for turbo / centrifugal blower

Diffuser Isolation Required per grid

17. FINAL SECTION 12 DESIGN SUMMARY

Item Selected Design

Total AOR 4,192 kg O₂/d

Total AOR 174.7 kg O₂/h

FOTE 9.55%

Required Air Flow 6,559 Nm³/h

Selected Air Flow 6,600 Nm³/h

Air Flow per Train 3,300 Nm³/h

Blower Quantity 3

Blower Duty 2D + 1S

Blower Capacity 3,300 Nm³/h each

Blower Discharge Pressure 80 kPa

Blower Motor Rating 160 kW each

Diffuser Type Fine bubble disc diffuser

Diffusers per Train 420

Total Diffusers 840

Next Section: Section 13 – Sludge Production Calculation.

SECTION 13
SLUDGE PRODUCTION CALCULATION

1. DESIGN OBJECTIVE

This section calculates the estimated biological sludge production from the MLE-CAS
system and verifies consistency with the WAS flow calculated from the selected SRT.

2. DESIGN BASIS

Parameter Value

Average Flow 10,000 m³/d

Influent BOD₅ 300 mg/L

Effluent BOD₅ 10 mg/L

BOD₅ Removed 2,900 kg/d

Influent TSS 300 mg/L

Effluent TSS 10 mg/L

MLSS 3,500 mg/L

Parameter Value

MLVSS / MLSS 0.75

Design SRT 12 d

Total Biological Volume 5,740 m³

3. PRELIMINARY BIOLOGICAL SLUDGE PRODUCTION

Biological sludge production = Yield × BOD removed

Parameter Value

Observed Yield, Yobs 0.50 kg VSS/kg BOD removed

Item Formula Value

Biological VSS Production 0.50 × 2,900 1,450 kg VSS/d

4. CONVERSION FROM VSS TO TSS

Parameter Value

VSS / TSS Ratio 0.75

TSS sludge = VSS / 0.75

Item Formula Value

Biological TSS Production 1,450 / 0.75 1,933 kg DS/d

5. EFFLUENT SOLIDS LOSS

Parameter Value

Clarifier Effluent TSS before tertiary filtration 15 mg/L

Plant Flow 10,000 m³/d

Item Formula Value

Effluent Solids Loss 10,000 × 15 / 1,000 150 kg DS/d

6. NET SLUDGE TO BE WASTED

Item Formula Value

Biological TSS Production — 1,933 kg DS/d

Effluent Solids Loss — 150 kg DS/d

Net WAS Solids 1,933 − 150 1,783 kg DS/d

7. COMPARISON WITH SRT-BASED WAS

From Section 11A:

Item Value

SRT-based WAS Solids 1,524 kg DS/d

Effluent Solids Loss 150 kg DS/d

Total Solids Leaving for 12-d SRT 1,674 kg DS/d

Comparison:

Item Value

Yield-based Net WAS 1,783 kg DS/d

SRT-based WAS 1,524 kg DS/d

Item Value

Difference 259 kg DS/d

8. SELECTED DESIGN SLUDGE PRODUCTION

Item Value

Selected Dry Solids Production 1,800 kg DS/d

Design Margin 15%

Design Sludge Production 1,800 × 1.15 = 2,070 kg DS/d

Adopt:

Item Selected Value

Design Sludge Production 2,100 kg DS/d

9. PER TRAIN SLUDGE PRODUCTION

Item Formula Value

Design Sludge Production — 2,100 kg DS/d

Number of Trains — 2

Sludge Production per Train 2,100 / 2 1,050 kg DS/d

10. WAS FLOW BASED ON DESIGN SLUDGE PRODUCTION

WAS concentration from RAS line:

Parameter Value

WAS Concentration 8,000 mg/L

WAS Concentration 8 kg/m³

Design Sludge Production 2,100 kg DS/d

Item Formula Value

Design WAS Flow 2,100 / 8 262.5 m³/d

Design WAS Flow 262.5 / 24 10.9 m³/h

Per train:

Item Formula Value

WAS Flow per Train 262.5 / 2 131.3 m³/d

WAS Flow per Train 131.3 / 24 5.5 m³/h

11. WAS PUMP VERIFICATION

selected WAS pumps:

Item Selected Value

WAS Pumps 1D + 1S

Capacity per Pump 10 m³/h

Check:

Item Value

Required Design WAS Flow 10.9 m³/h

Selected WAS Pump Capacity 10 m³/h

12. SLUDGE HOLDING TANK DESIGN BASIS

Assume WAS is transferred to sludge holding / thickening tank.

Parameter Value

Design Sludge Production 2,100 kg DS/d

WAS Concentration 0.8% DS

WAS Flow 262.5 m³/d

Storage HRT 1 day

Adopt:

Item Selected Value

Sludge Holding Tank Volume 300 m³

Number of Tanks 1 or 2

Mixing Required

Decanting Optional

Odour Control Recommended

13. SLUDGE THICKENING CHECK

If WAS is thickened to 3% DS:

Item Formula Value

Thickened Sludge Flow 2,100 / 30 70 m³/d

If thickened to 4% DS:

Item Formula Value

Thickened Sludge Flow 2,100 / 40 52.5 m³/d

14. DEWATERING CHECK

dewatered cake at 20% DS:

Item Formula Value

Cake Flow / Mass 2,100 / 0.20 10,500 kg wet cake/d

Item Selected Value

Dewatered Cake Production 10.5 ton/d

Dewatered Cake DS 20%

Polymer Dosing Required

Cake Conveyor / Skip Required

15. SLUDGE PRODUCTION SUMMARY

Item Value

BOD Removed 2,900 kg/d

Biological VSS Production 1,450 kg VSS/d

Biological TSS Production 1,933 kg DS/d

Effluent Solids Loss 150 kg DS/d

Net WAS Solids 1,783 kg DS/d

Selected Design Sludge Production 2,100 kg DS/d

WAS Concentration 8 kg/m³

Design WAS Flow 262.5 m³/d

Item Value

Design WAS Flow 10.9 m³/h

Recommended WAS Pump Capacity 15 m³/h

Sludge Holding Tank 300 m³

Thickened Sludge at 3% DS 70 m³/d

Dewatered Cake at 20% DS 10.5 ton/d

Next Section: Section 14 – Tertiary Filtration Design.