WASTEWATER TREATMENT FACILITY OFSUGAR INDUSTRY

Extended Aeration Activated Sludge Process

In Partial Fulfillment of the Requirements for the Course

Environmental Engineering for Chemical Engineering

Submitted By:

LEADER: Remigio, Edrickson C.

MEMBERS

Mora, Roxan B.

Tangonan, Visitacion D.

Ventula, Lea B.

Submitted To:

ENGR. CAESAR P. LLAPITAN

DECEMBER 2017
 TABLE OF CONTENTS
I. Introduction .......................................................................................................................... 3

II. Objectives .............................................................................. Error! Bookmark not defined.

III. Extended Activated Sludge................................................. Error! Bookmark not defined.

A. Principles ......................................................................... Error! Bookmark not defined.

1. Process Control Parameter............................................ Error! Bookmark not defined.

2. Substrate Stabilization .................................................. Error! Bookmark not defined.

3. Nutrient Removal ......................................................... Error! Bookmark not defined.

4. Dissolved Oxygen......................................................... Error! Bookmark not defined.

B. Process Flow .................................................................... Error! Bookmark not defined.

C. Disadvantages .................................................................. Error! Bookmark not defined.

D. Advantages ...................................................................... Error! Bookmark not defined.

IV. Design Consideration .......................................................... Error! Bookmark not defined.

V. Design Problem ..................................................................... Error! Bookmark not defined.

A. Material Balance.............................................................. Error! Bookmark not defined.

B. Computational Analysis .................................................. Error! Bookmark not defined.

C. Specifications................................................................... Error! Bookmark not defined.

VI. Conclusion and Recommendation...................................... Error! Bookmark not defined.

VII. References ....................................................................................................................... 23

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NOMENCLATURE

TSS Total Suspended Solids

VSS Volatile Suspended Solids

MLVSS Mixed Liquor Volatile Suspended Solids

MLSS Mixed Liquor Suspended Solids

BOD Biological Oxygen Demand

COD Chemical Oxygen Demand

Kd Decay rate of microorganisms

Q Volumetric flowrate

TDS Total Dissolved Solids

TVS Total Volatile Solids

X Denoted as MLVSS

F/M Food-Microorganism Ratio

S BOD Initial

V Volume

Ks Half Velocity Constant

μm Maximum Growth Rate Constant

Y Yield Velocity

h Effective Depth

SVI Sludge Volume Index

θc Mean Cell Retention Time

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I. INTRODUCTION

The extended aeration process is one modification of the activated sludge process which
provides biological treatment. The process maximizes the stability of the operating
environment and provides high efficiency treatment. The system utilizes a longer sludge age
than other aerobic systems. Sludge age, also known as SRT (Solids Retention Time) or
MCRT (Mean Cell Residence Time), defines the operating characteristics of any aerobic
biological treatment system. A longer sludge age dramatically lowers effluent BOD and
ammonia levels, especially in colder climates. The systems long sludge age process produces
BOD levels of less than 10 mg/L and complete nitrification (less than 1 mg/L ammonia).
Minor modifications to the system will extend its capabilities to denitrification and biological
phosphorus removal. The large quantity of biomass treats widely fluctuating loads with very
few operational changes. Extreme sludge stability allows sludge wasting to non-aerated
sludge ponds or basins and long storage times.

The effluent generated from sugar processing industry has miscellaneous quality because
it contains high BOD and constitutes a number of chemical pollutants, such as oil and grease,
carbonate, bicarbonate, nitrite, phosphate, leading to high COD, in addition to total
suspended solids, dissolved solids, volatiles and scopes of other toxicants. These can harm
the environment if discharged irresponsibly.

This paper will give emphasis on the process of activated sludge using extended retention
of biological solids to create an extremely stable, easily operated system. It will discuss the
advantages of the process as well as the functionality of the treatment process under extended
aeration activated sludge such as aeration and clarification in the wastewater treatment plant.
Moreover, calculations in the process and mechanical designs of this treatment processes
were also included in the plant design.

II. OBJECTIVES

Generally, this section aims to develop a design in the process of an extended aeration to
be used in the secondary treatment of the sugar industry wastewater. Specifically,

1. The process to be used must lower the biodegradable organic matter and suspended
solids to an effluent quality standard of 50 mg/L and 100 mg/L, respectively;

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 2. The equipment to be used must be able to cater the influent flow rate of 750 m3/day;
and,
3. The process and design of conventional activated sludge must be able to achieve the
effluent standards at the most desirable time.

III. EXTENDED ACTIVATED SLUDGE

A. PRINCIPLE

1. Process Control Parameter

The overall control of an extended aeration process depends on biomass
control and control over dissolved oxygen levels. Biomass control may be obtained in
a number of ways. The most common ways of achieved this is to control by
maintenance of a constant mixed liquor volatile suspended solids (MLVSS), control
by maintenance of a constant food-to-micro-organism (F/M) ratio, and control by
maintenance of a constant, mean cell residence time (MCRT). The parameters may be
adjusted as required to meet changes in wastewater characteristics or1 temperature.
(Blevins, 2017)

a. Constant Mixed Liquor Volatile Suspended Solids

This method, has a constant mass of microorganisms is maintained to make
use of the incoming food supply. If a certain concentration of MLVSS is found, to
work effectively at a given plant then this level of concentration will be maintained.
If the MLVSS concentration happens to increase above this optimum level, some
solids should be wasted. Till the concentration falls down to the optimum
concentration level. If the MLVSS drops below the optimum, less solids should be
wasted to allow the MLVSS concentration to increase.
This system of solids control is simple to understand and manage, involves a
minimum amount of laboratory work, and can produce good results if the incoming
wastewater strength is stable. However, this method has a rather severe limitation in
that the important F/M ratio is ignored. If the BOD load of the incoming wastewater is
increased over a substantial period of time, the increased solids production from the
high loading would be wasted to maintain the constant MLVSS. The result of this
action, however, is that the F/M ratio is higher than the previously maintained ratio.
The resulting high F/M ratio easily could lead to process inefficiency or failure.

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 b. Constant Food to Microorganism
This method, the MLVSS concentration is increased or decreased to match an
increase or decrease in the BOD entering a plant, so as to maintain a certain desired
F/M ratio. The use of this method presupposes the knowledge of the organic (BOD)
load present and the MLVSS concentration. While the latter parameter could be
measured readily at any time, real-time data regarding the former parameter are not
available (BOD7 analysis takes 7 days). This organic load can sometimes be
approximated by making use of chemical oxygen demand (COD) or total organic
carbon (TOC) measurements combined with BOD/COD or BOD/TOC correlations.
As can be imagined this method requires a large amount of laboratory work. An
additional disadvantage of this method is that the MLVSS is not an accurate measure
of active mass of microorganisms, among other' things, dead cells (unlysed once) are
registered in volatile solids test. As a result, even with a constant BOD7/MLVSS ratio,
there is no assurance that the F/M ratio is constant.

c. Constant Mean Residence Time

The mean cell residence time (MCRT) is the most logical parameter on which
to base the operation of an activated sludge plant. The control of an activated sludge
plant through MCRT has been practiced since the inception of the treatment process.
Activated sludge is wasted from the return sludge flow to maintain a desired
concentration of mixed liquor suspended solids (MLVSS). If, by this wasting
operation, the MLVSS concentration is kept constant, then the weight of waste sludge
solids represents the net sludge growth in the system. Sometimes, a certain MCRT
that is required to produce a desired degree of treatment is set (beforehand) and the
maintenance of a solids wasting rate that would produce this MCRT is calculated. In
doing this there are two obstacles to over-come. The first is that solids are wasted
unintentionally in the effluent and secondly, the relationship between MLVSS and
return sludge solids is not constant and cannot always be controlled closely by the rate
of return sludge pumping since settle ability of the activated sludge influences the
ratio of MLVSS to return sludge volatile suspended solids (RSVSS). Hence a return
sludge wasting rate, established to produce a given MCRT at a low sludge volume
index (SVI), will not be great enough to maintain this same MCRT if the SVI
increases significantly. The SVI increase would cause the return sludge solids
concentration eventually to decrease. A measurement of RSVSS on a composite

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sample easily can establish the desired waste flow rate to be used to accomplish the
wasting of a certain quantity of sludge solids.
Another way of control of a plant through MCRT is by wasting sludge direct
from the aeration tank. This process of wasting mixed liquor rather than return sludge
is called hydraulic control of the activated sludge system.
This control method is easier yet than the previous one. If a steady state is
achieved i.e. solids produced equal those wasted both intentionally and
unintentionally, control through MCRT could be achieved by simply wasting a
constant percentage of the mixed liquor in the aeration tank (reactor) each day.
The hydraulic control system is self-regulating. As the concentration of the
MLSS increases, the mass of solids wasted also increases, lowering the MLVSS
concentration over a period of time. If the MLSS concentration decreases below the
level dictated by the selected MCRT, the mass of solids wasted decreases, raising the
MLVSS concentration over time. The hydraulic control system lends itself to
automation readily and is the simplest system to control. This method of controlling a
treatment process results in stable operation of the process because there will be less
variation in the F/M ratio and MCRT than the other control methods.

d. Dissolved Oxygen Control

The other major control parameter mostly applicable to oxidation ditch plants
is the dissolved oxygen concentration in the reactor. Almost all oxidation ditch plants
are designed to allow some control over oxygen input.
This may be accomplished with variable submergence or speed on mechanical
aerators and blower turndown when jet aerators are used. In plants designed for BOD
removal and/or nitrification, control is utilized to maintain a dissolved oxygen level
greater than or equal to 2 mg/L. Considerable cost savings through reduced aeration
power requirements may be obtained through control to prevent unnecessarily high
dissolved oxygen levels.

e. Sludge Recycle Ratio

The required rate of recycle of sludge from the settling tank to the reactor is
related to the sludge volume index (SVI) and MLSS concentration of the mixed liquor
in the reactor. In return the SVI limits the reactor MLSS concentration that can be
achieved because it controls the settling tank underflow concentration.

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According to McCarty and Brodersen, the sludge recycle rate may be formulated as
follows:
R V

R  1 1000
Where; f.

R = ratio of sludge recycle rate to influent flow

V= the volume of concentrated sludge in ml after half an hour- settling of
mixed liquor in a 1--1 graduated cylinder.
Sludge recycles rates of 1:1 or 2:1 are desirable and adequate for most plants. This
range of recycle rate gives reasonable flexibility to adjust the MLSS to the desired
concentration. However, the ability of a plant to retain a maximum concentration of
MLSS depends not only on the recycle rate, but also on the ability of the settling tank
to efficiently settle and retain the solids. Because of this, the efficiency of an extended
aeration activated sludge plant depends to a large degree on the proper design of the
settling tank, which must not only provide for proper settling at average flows, but
also must provide for efficient operation in the presence of any surge flows chat might
come into the plant. It is often due to such surge flows that large quantities of solids
are discharged to the effluent.

2. Substrate Stabilization
The biological removal and stabilization of organic wastes in an activated sludge
process is shown in Figure III.1, this conversion of organic wastes into end-products
can be thought to take place in two different stages, which occur simultaneously in the
same tank.

CO2 +H2O
+

Degradable Energy
Organic Waste
New Bacterial
Cells Inert Organic
Residue

Figure III.2: Substrate Stabilization

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 First the degradable organic wastes are metabolized and partially used for
energy and partially synthesized into new microbial cells. With continued aeration, in
the second stage, the microbial cells formed (their protoplasm) are metabolized for
further energy (this so-called endogenous phase takes place when substrate
concentration is at a minimum). The active biological solids utilize oxygen while
undergoing endogenous respiration to oxidize the degradable portion of their cells to
carbon dioxide and water with a resulting decrease in sludge mass. Ideally, with
extended aeration this sludge mass would continue to oxidize itself to carbon dioxide
and water so that no net sludge accumulation would occur in the system. However, it
has been found out that some of the biological solids produced are relatively inert to
biological oxidation and so accumulate in the system. As a result, with continuous
operation and no sludge wasting intentional or unintentional (controlled sludge
wastage or loss of biological solids to the effluent), from an extended aeration system
an increase in mixed liquor volatile solids (MLVSS) will result.
The total accumulation of sludge in the system will be equal to the
accumulation of biological solids plus the accumulation of biologically degradable
suspended solids which were originally present in the influent waste.
In extended aeration plants where controlled sludge wasting is not practiced,
the solids will increase until the system capacity to settle and retain the solids is
exceeded. The excess solids produced will then be discharged to the effluent, resulting
in an increase in effluent BOD and as a consequence a decrease in overall efficiency.

3. Nutrient Removal

a. Nutrient Requirements
Domestic wastewater contains more than a sufficient amount of nitrogen and
phosphorus, compared with carbon, for the correct balance of nutrients required for
bacterial growth. The question of nitrogen and phosphorus utilization must be
considered from two viewpoints; the minimal requirement and the extent of removal
in biological treatment.
To ensure maximum removal of carbon (and therefore BOD) from a given
substrate, carbon must be made the limiting nutrient, while nitrogen and phosphorus
(and other nutrients also) must be present in at least the minimum required proportion
for cell growth.

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 Nutrient requirements in the conventional activated sludge process are higher
than those of the extended aeration process since, in the latter, there is more recycling
and less sludge withdrawal. It is suggested that the ratio of BOD7: N: P should be
about 100:5:1.

b. Phosphorus Removal
Phosphorus removal in biological treatment is due mainly to the removal of
microbial solids from the system. At steady state, the surplus microbial solids
removed equal those produced per unit time. Thus, it is necessary to estimate the net
volatile solids produced, and to know the phosphorus content of the solids.
Phosphorus removal from a given wastewater is a function of the MCRT of
the system. As MCRT increases, the phosphorus removal rate decreases since less
surplus sludge is removed from such a system. Thus, due to a higher MCRT, an
extended aeration process should give less phosphorus removal than conventional
activated sludge. Conversely when treating phosphorus-deficient wastewater, the
extended aeration process should require less artificial phosphorus addition than the
activated sludge process.
Generally, chemical precipitation is found to be a more efficient method of
phosphorus removal than biological treatment.

c. Nitrification
Most of the nitrogen in treated wastewater is in the form of ammonia.
Consequently, when wastewater containing ammonia is discharged to the
environment, depletion of recipient-water oxygen can occur as the ammonia is
oxidized to nitrate. This depletion of oxygen can be avoided if the ammonia is first
oxidized to nitrate before it is discharged Nitrification, which is the bio-oxidation of
ammonia to nitrate, is the process used to accomplish this objective. This conversion
of ammonia to nitrate is performed by nitrifying micro-organisms (either
heterotrophic or autotrophic) which are present in almost all aerobic biological
treatment processes, but usually their numbers are limited. In spite of the fact that
over one hundred species have been cited as forming nitrite (NO2-) from ammonia, it
is doubtful that significant quantities of nitrate are generated heterotrophically in
natural systems. Consequently, most research into nitrification in waste-water
treatment systems has concentrated on the autotrophic micro-organisms.

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 The major nitrifying bacteria are thought genera Nitrosomonas and
Nitrobacter. These organisms obtain their cell carbon from carbon dioxide and energy
from the oxidation of inorganic compounds ammonia and nitrite/. Nitrosomonas
oxidizes ammonia nitrogen (NH4+-N) to nitrite (NO2- -N) through complex pathway
which is not yet completely understood, and remains largely speculative. Nitrobacter
oxidizes NO2- -N to nitrate nitrogen (NO3--N) in a single step. The theoretical
stoichiometric equations for the growth of Nitrosomonas and Nitrobacter are:
For Nitrosomous:
55 NH 4  76O2  109 HCO3  C 5 H 7 O2 N  54 NO2  57 H 2 O  104 H 2 CO3

For Nitrobacter:
400 NO2  NH 4  4 H 2 CO3  HCO3  195O2  C 5 H 7 O2 N  3H 2 O  400 NO3

These equations are important for two reasons. First, they tell us that a large
amount of alkalinity(HCO3-) will be utilized during the oxidation of NH4+-N: 8.64 mg
HCO3-/mg oidized NH4+-N. A small part of this will be incorporated into the cell
material, but the majority will be used to neutralize the hydrogen ions (pH) released
during the oxidation. If the water contains insufficient alkalinity, nitrification will be
retarded because of the unavailability of a needed reactant and the deleterious effect
of the resulting low pH. Efficient nitrification usually consumes alkalinity and
consequently causes pH depression. Secondly, they tell us that approximately 3.22 mg
O2 will be required for each mg oxidized NH4+-N to NO2- -N, and 1.11 mg O2 will be
needed for each mg NO2- -N of oxidized to NO3--N for a total of 4.33 mg 0 2 per mg
of oxidized NH4+-N all the way to NO3--N.
The nitrifying organisms are sensitive to their environment, and even under
favorable conditions they are slower growing than the usual BOD-removing micro-
organisms (heterotrophs). The former has a doubling time of 1 - 2 days while the
latter have typical doubling time of 0.25 - 1.5 hours 12.21. Since the growth rate of
Nitrosomonas is lower than that of Nitrobacter, it is the one that determines the rate of
nitrification.
It has been found out that the following factors have a significant effect on the
nitrification process: ammonia concentration, BOD/Total Kjeldahl Nitrogen (TKN)
ratio TKN  NH 4  N  N organic dissolved oxygen concentration, pH, temperature and

MCRT.

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 Ammonia concentration in a reactor affects the growth rate of the nitrifying
organisms. It has been found out that the reaction that determines the growth of the
organisms proceeds at a constant rate (zero-order reaction) till the concentration of
ammonia reduces to about 1.5 to 2 mg/liter, below which the nitrification rate is
reported to drop off rapidly. When the wastewater to be treated contains a very high
concentration of NH4+-N, the concentrations of NO2- -N and NO3--N formed are likely
to be high enough to inhibit the organisms so that complete nitrification cannot occur,
even at very long MCRT’s. Jenkins and Garrison report that previous work has shown
that the rate of NH4+-N oxidation by Nitrosomonas is not limited by NH4+-N
concentration above 1 to 3 mg/L, the exact value depending on the temperature.
The choice of MCRT for an activated sludge treatment plant must take into
account the actual growth rate of nitrifiers at field conditions. Unless the MCRT is
somewhat greater than the cell doubling time, cell washout would occur.
1
MCRT 

Where: µ is the growth rate for Nitrosomonas at the worst operating temperature and
other conditions.
Activated sludge plants in cold climates designed for MCRT less than 10 days
may show relatively poorer nitrification in winter. Extended aeration plants generally
designed for MCRT greater than 10 days may show nitrification uniformly over all
seasons. Even activated sludge plants in warm climates may show nitrification
uniformly, provided sufficient aeration capacity is available to meet the total oxygen
demand and maintain required high dissolved oxygen levels in mixed liquors.
Contact time between incoming ammonia and micro-organisms in the mixed
liquor must also be sufficient, besides appropriate MCRT, for successful nitrification.
Nitrifying bacteria are very sensitive to pH. The effects of pH on nitrifiers in
mixed cultures, such as activated sludge, are not quite as severe. A wide range of pH
optima have been reported, but most researchers agree that as the pH moves to the
acid range the rate of ammonia oxidation declines. pH ranges of 7.8 to 9.2 and 8.5 to
9.2 are thought to be optimum for Nitrosomonas and Nitrobacter respectively.
Temperature has a strong influence on the nitrification process. It affects the
growth rate of nitrifying bacteria just as it does heterotrophs.
Dissolved oxygen concentration (DO) in a reactor is one of the parameters that
could determine the extent of nitrification. Jenkins and Garrison reported that work by

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Garret and a group at the British Water Pollution Research Laboratory showed that
the rate of NH4+-N oxidation by Nitrosomonas was dependent on the DO below levels
of about 3.0 mg/L. It is assumed that a DO concentration greater or equal to 1 - 2 mg
O2/1 is required for the nitrification process.
It should be mentioned here that nitrification could be a major problem in
extended aeration plants. Due to the large excess of air and low organic loadings
normally used in extended aeration plants, the condition becomes favorable for. The
growth of nitrifying bacteria pH depression (mentioned earlier) in aeration tanks and
rising sludge in settling tanks are frequent problems.
Another problem of importance is the effect of nitrification on measurement of
effluent BOD and evaluation of efficiency of operation. Effluent samples taken from
highly nitrifying activated sludge plants exhibit higher BOD values than would be
caused by the carbonaceous demand alone. This has been shown to be due to the
nitrifying organisms present in these effluents, which caused nitrification to take place
immediately in the BOD test.

4. Dissolved Oxygen

a. Dissolved Oxygen Concentration

In the activated sludge treatment process, oxygen is used in those reactions
required to degrade the substrate to produce the high energy compounds required for
cell synthesis and for respiration. For long MCRT systems, as in the extended aeration
process, the oxygen needed for cell maintenance can be of the same order of
magnitude as substrate metabolism. Usually a minimum residual Dissolved oxygen
(DO) is maintained in a reactor basin to prevent oxygen deficiencies from limiting the
rate of substrate removal. In the literature different values are given for the minimum
DO concentration, ranging from 0.5 to 2 mg/L. However, it must be recognized that
high DO concentrations could allow deeper and more rapid penetration of oxygen into
floes, thereby removing an oxygen limitation on the inner cells.
Since DO concentration and mixing energy can affect the apparent kinetic
characteristics of the sludge, careful consideration should be given to them. If this is
not done the resulting parameters will not adequately reflect the true nature of the
system.
Several “rules of thumb” for determining oxygen requirements have been
developed over the years. For diffused air aeration plants, 3.7 to 15 m3

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 air/m3wastewater was considered adequate, but later, 30 to 55m3 air/kg BOD5 was
used. Values ranging from 43 to 123 m3 of air/kg of BOD5 treated have been used. For
extended aeration systems, the air supplied may range up to 125 m 3/kg BOD5
removed in those cases where the effects of endogenous respiration and nitrification
are significant. It should be noted that these “rules of thumb” are generally
conservative in that they include the air needed for mixing as well as for biological
needs and presume a fixed transfer efficiency of the aeration device.

b. Oxygen Transfer Aeration Systems

Oxygen transfer to the activated sludge floe is usually accomplished by
oxygen absorbed from diffused bubbles of air entrained in the mixed liquor by
subsurface injection and mechanical or- natural surface agitation in which oxygen is
absorbed from the air above the reactor-surface.
The rate of oxygen transfer for a given aeration system depends largely on the
contact time between the bubble and the liquid, the size of the bubble, and the
turbulence in the liquid. Good transfer efficiencies will result if the contact time is as
long as possible, the bubble size is maintained as small as possible and the turbulence
is such that the bubble is held in the liquid as long as possible before reaching the
surface.
The two most common types of aeration systems are subsurface diffusion and
mechanical aeration. In the diffused air system, compressed air is introduced at the
bottom of the reactor near' one side (see Figure III.3). This causes the reactor's
contents to be circulated by the air-lift effect. Many different patterns of diffuser
placement are being used. Systems that allow longer and more complete contact
between the air and the liquid are preferred. Coarse bubble diffusion devices produce
larger bubbles than do fine bubble diffusors.
Since oxygen-transfer is a function of mass transfer across a gas-liquid
interface, an increase in bubble size will decrease the amount of surface area in the
gas-liquid interface. Essentially, if bubble size is doubled then the gas-liquid
interfacial area is halved. However, fine bubble diffusers are easily clogged resulting
in injection inefficiency.
There are several types of mechanical aeration devices. The floating or fixed
bridge aerators are quite common. Some use a blade to agitate the surface of the
reactor and dispense air- bubbles into the mixed liquor. Others circulate the mixed

13
liquor by an updraft or downdraft pump or turbine (see Figure III.4). This action
produces surface and subsurface turbulence, at the same time diffusing air through the
liquid mass.
Rotating brushes or blades partially submerged are used in oxidation ditch
plants (see Figure III.5). The turbulence produced entrains the air bubbles and keeps
the mixed liquor in motion.
Turbulence of the mixed liquor, as mentioned above, is one of the main factors
that determine the transfer of oxygen in the aforementioned aeration systems.
However, excessive turbulence (mixing of the mixed liquor) can damage the floe
particles of the mixed liquor, causing poor sedimentation and loss of solids in the
effluent.

Figure III.6: Diffused Aeration System

Figure III.7: Surface Aerator

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 Figure III.8: Brush Aerator

B. Process Flow

Influent and
Infiltration Effluent

Return Sludge

Flow Chlorine
Aeration Basin Clarifier Dechlorination
Equalization Contact Tank

Figure III.9: Extended Aeration Process Flow Diagram

The activated sludge system is embodied in the aeration chambers and clarifiers. The
preliminarily treated wastewater is pumped to the activated sludge system by the lift station.
Flow is normally split to the 2 chambers according to the position of the baffle plate in the
flow splitter box at the influent end of the unit. An equal division of flow to the 2 chambers is
achieved when the baffle plate is oriented perpendicular to the adjacent wall of the aeration
chambers.
Within each aeration chamber the incoming wastewater is intimately mixed with the
active biological mass and provided with the necessary dissolved oxygen by the action of the
air bubbles released from the diffusers. These diffusers are located at the centre (toward the
centre wall) and cause a spiralling flow pattern to develop which rolls the chamber contents
from the influent to effluent end. Each chamber ought to be sized to produce 24 hours of
aeration detention at the design flow.

At the end of the aeration period the wastewater biological mass mixture (mixed
liquor) reaches the effluent end of the chamber and flows in a trough to the clarifier. Here the
suspended solids (MLSS) and liquid are separated by gravity. The separated solids are
returned to the aeration compartment as return sludge while the liquid flows over weirs into
the chlorine contact tank for disinfection. Foam control sprays are provided to control
frothing in the aeration chamber and skimmers are provided to remove floating material from
the surface of the clarifiers.

The settled sludge and scum are returned to the aeration chambers by air lifts. The
extended aeration system is quite simple in concept. The maintenance of a favourable

15
environment for the activated sludge (oxygen and complete mixing) and good solids
separation (clarifier) are readily accomplished. The MLSS is a well operating system and
should have a brown colour and settle well, and have an earthy odour.

C. Disadvantages
1. Extended aeration plants do not achieve denitrification or phosphorus removal
without additional unit processes because of flexibility is limited to adapt to the
changing effluent requirements resulting from regulatory changes.
2. The longer aeration period requires more energy therefore; systems require a
larger amount of space and tankage then other “higher rate” processes, which have
shorter aeration detention times.

D. Advantages
1. Extended aeration process is often better at handling organic loading and flow
fluctuations, as there is greater detention time for the nutrients to be assimilated by
microbes.
2. This plant is easy to operate and systems are easy to install as they are shipped inn
one or two pieces and then mounted on an onsite concrete pad, above or below
grade.
3. The systems are odor free, can be installed in most locations, have a relatively
small footprint, and can be landscaped to match the surrounding area.

IV. DESIGN CONSIDERATION

Design an extended aeration activated sludge process given the pre-treated wastewater
treatment characteristics.

Based upon flow and organic loading the design factors determining the size and
volume of an activated sludge unit are the aeration volume, the total mixed liquor volume
necessary to handle the biological load, and the clarification area required to obtain solids
separation.
Since this unit is an extended aeration system, its BOD5/MLSS (F/M) loading is in the
range of 0.042 to 0.153. Under normal conditions an average range of 0.042 to 0.096 should
be used. The optimum ratio of F/M for the system must be determined by direct operation of
the unit and evaluation of the results. This F/M ratio establishes the MLSS concentration in
the range of 2,500 to approximately 6,000 mg/L.

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 Aeration compartment volume has been established to provide a detention period of
24 hours at design flow. This volume, in turn, determines the BOD5 loading to the plant at 15
lbs. BOD5/day1,[Link]. This loading is within the normal range for extended aeration
plants.

The clarifiers have been sized to produce solids separation under all hydraulic loading
conditions. A good overflow rate is 520 GPD/sq ft at design [Link] is supplied to the
diffusers by positive displacement blowers. These blowers were designed to provide
sufficient air to ensure that the dissolved oxygen content of the aeration chambers can always
be maintained within of 1.0 to 2.0 mg/L.

V. DESIGN PROBLEM

Design the aeration tank and secondary clarifier to be used in an extended aeration
activated sludge process given the pre-treated wastewater characteristics and effluent
characteristics tabulated in Table V.1.

Table V.2: Characteristics of Wastewater from a Sugar Plant

Parameter Concentration

BOD 300 mg/L

COD 1000 mg/L
Temperature 25°C
Total Suspended Solids 600 mg/L
Total Dissolved 2000 mg/L
Total Volatile Solids 1300 mg/L
Nitrogen 10 g/L

A. Material Balance

BOD= 300 mg/L BOD= 50 mg/L

TSS= 600 mg/L TSS= 100 mg/L
Aeration Tank Clarifier
COD= 1000 mg/L COD= 100 mg/L

Figure V.1: Material Balance Analysis of Extended Aeration

Activated Sludge Process
17
B. Computational Analysis
Step 1: Design of an aeration tank.
Efficiency of BOD Removal
The efficiency of removing the BOD of the process is computed as the ratio of
the removed BOD with respect to the initial concentration
mg mg mg
BOD removed in Activated Plant  300  50  250
L L L
mg
250
Efficiency  L  83%
mg
300
L
For efficiency of 95 - 99% use F/M as 0.18 – 0.1 and MLSS between
3000 to 5000
As a rule of thumb, the mixed liquor volatile suspended solids (MLVSS) is
taken as 70% to 80% of the mixed liquor suspended solids (MLSS).
MLVSS
 0.8 to 0.7 ( Rule of Thumb)
MLSS
Taking the values of F/M and MLSS as the mean and the MLVSS as 80% of
the MLSS

F/M = 0.14

MLSS = 5000 mg/L

mg
MLVSS  0.5  5000  4000
L

Solving for the volume

F QSo

M V X
EQ.1

V  401.78  402m3
Solving for the Mean Cell Retention Time θc

YQ S0  S  C
VX  EQ.2
1  kd C
18
 Table V.3: Table of Values for Domestic Wastewater Values are for 20°C

Value
Parameter Basis
Range Typical
Ks mg/l BOD5 25-100 60
kd d-1 0-030 0.10
µm d-1 1-8 3
Y mg VSS/mg BOD5 0.4-0.8 0.6

Sources: Metcalf & Eddy, 2003; and Shahriar et al., 2006

From Table V.4, the values of Y, kd, are taken as the average of their range. The
values, Y=0.6 and kd= 0.03, are substituted to equation to solve for the value of θc.
(0.6)(750)300  30 C
(402)( 4000) 
1  0.03C
 C  21.95  22days
Solving for the Volumetric Loading
Q( S )
 Volumetric Loading
V
750 m3 day300 mg L 1g 1000mg 1g 1000 g 
Volumetricloading 
402m3
kgBOD kg
0.56 0.3  0.7 3
Volumetric loading m3day within the range of m day

Return Sludge Rate:

 mg 
MLSS   100
 L 
% return sludge =
1000000
 MLSS
SVI
Assumed SVI=50 mg/L since the value should be in the range of 50-150
5000 100
% return sludge=  33.3% (within the range of 25%-50%)
1000000
 5000
50
Tank Dimensions
Adopt aeration tank of depth 3 m and width 4.5 m

19
 Volume
L
Area
402
L  29.78 m or 30 m
4 .5  3
Providing continuous chambers with 3 aeration chambers each length is 10 m.

Total width of the tank including 2 baffles each of 0.25 m thickness

 (4  4.5)  (2  0.25)  18.5 m or 19 m

Total depth provided including the free board

 0.6  3  3.6 m or 4m
Overall dimensions of aeration tank  10m 19m  4m

Step 2: Design of Clarifier

Flow rate = 750 m3/day

Provide 2 tanks

Qave = 375 m3/day

Potential Period = 3 hours

3
V (volume of tan k )  375   47 m 3
24

Assume surface overflow rate of 20 m3/m2

750
Surface area   25 m 2
30
47m 3
Effective Depth   1.88 m
25m 2

V 4 47  4
Diameter    5.64 m
h 1.88

20
C. Specifications

Figure V.2: Dimensions of Aeration Tank

Table V.5: Aeration Tank Design Summary

Parameters Calculated Values

Number of Aeration Chambers 3
Length 10 m
Breadth 19 m
Depth 4m
BOD effluent 50 mg/L
BOD removal efficiency 83%
Return Sludge Percentage 33.3%

21
 Figure V.3: Dimensions of Secondary Clarifier

Table V.6: Design Specifications of Secondary Clarifier

Parameters Calculated Values

Diameter 5.64m
Depth 2.5m

VI. CONCLUSION AND RECOMMENDATION

The integration of extended aeration activated sludge process to the treatment of

wastewater from sugar industry makes it possible to lower the concentration of BOD
desired concentration of the effluent water given the efficiency of 83% and return sludge
percentage of 30. The designed dimensions were computed based from the volumetric
flow rate and the detention time in the aerator and in the clarifier.

The design of this wastewater treatment is locally available, thus, can be adopted and
constructed at the local sugar industry. However, further studies are required to test the
effectiveness of the developed treatment method along with costing reports and selection
of materials to be used for each unit. It is also important to consider that the processes in a

22
 sugar industry are seasonal, making the characteristics as well as the quantity and quality
of the proposed design are needed.

The treatment method is also suitable for other types of wastewater which has a high
predominantly organic pollutant load that is biodegradable but short study is required to
determine the bio-reaction and contact times for each step.

VII. References

(n.d.).

Blevins, J. (2017, December 18). Activated Sludge Process-6, Extended Aeration Activated
Sludge. Retrieved from [Link]: [Link]

Davis, M. L. (2010). Water and Wastewater Engineering Design Principles and Practice.
New York: The McGraw-Hill Companies, Inc.

Karthikeyan M., C. B. (Director). (2014). Structural Design of Extended Aeration Treatment

Plant [Motion Picture].

Lin, S. D. (2007). Water and Wastewater Calculations Manual. New York: The McGraw-
Hill Companies, Inc.

Rasu, H. (1984, february). Temperature Effects on Extended Aeration Activated Process.

Tampere, Finland. Retrieved from [Link]

23
 TECHNICAL REPORT ASSESSMENT RUBRIC

In

Environmental Engineering

Name of Student: ______________________________________________________________

Title of Report: __________________________________________________________

Topic Unacceptable Marginal Acceptable Exceptional Points

(Weight) (0) (1) (2) (3)
Organization Sequence of information is Work is hard to follow as Information is presented in Information is presented in
& difficult to follow. No there is very little a logical manner, which is a logical, interesting way,
Style apparent structure or continuity. easily followed. which is easy to follow.
continuity.
Purpose of work is stated, Purpose of work is clearly Purpose is clearly stated
Weight: 8 Purpose of work is not but does not assist in stated and assists the and explains the structure
clearly stated. following work. structure of work. of work.
Content No grasp of information. Uncomfortable with At ease with content and Demonstration of full

22
 & Clearly no knowledge of content. able to elaborate and knowledge of the subject
Knowledge subject matter. explain to some degree. with explanations and
Only basic concepts are elaboration.
No questions are answered. demonstrated and
Weight: 10 No interpretation made. interpreted.
Figures, Work is illegible, format Mostly consistent format. Format is generally Format is consistent
Tables and changes throughout, e.g. consistent including throughout including
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legible, but not convincing. captions. captions.
Figures and tables are
Weight: 8 sloppy and fail to provide Figures and tables are Figures and tables are
intended information. neatly done and provide presented logically and
intended information. reinforce the text.

Equations Work fails to follow Many departures from Minor departures from Departmental format is
required format. Failed to required format. Many required format or observed in all equations.
use MS Equation Editor. problems with citation of inconsistencies between Citations consistent with
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Weight: 2 symbols. not properly defined. with citation of equations.
Some symbols not properly
defined.

23
 Spelling Numerous spelling and Several spelling and Minor misspellings and/or Negligible misspellings
& grammatical errors. grammatical errors. grammatical errors. and/or grammatical errors.
Grammar

Weight: 5
Readability Report plagued with Many instances of “noise.” Some instances of “noise.” Report was free of “noise
distractions and ‘noise.” issues.”
Weight: 4
No referencing system Inadequate list of Minor inadequacies in Reference section
References used. references or references in references. complete and
text. comprehensive.
Consistent referencing
Weight: 3 Inconsistent or illogical system. Consistent and logical
referencing system. referencing system.
TOTAL

Instructor/Rater: Engr. Engr. CAESAR P. LLAPITAN

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