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Primary Sedimentation
Jae K. (Jim) Park, Professor Dept. of Civil and Environmental Engineering University of Wisconsin-Madison 1
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Primary Sedimentation
Objective: To remove settleable organic solids in large basins under relatively quiescent conditions Removal efficiency BOD5: 30~40% TSS: 50~70% Settled solids: collected by mechanical scrapers into a hopper, from which they are pumped to a sludge-processing area. Oil, grease, and other floating materials: skimmed from the surface Effluent: discharged over weirs into a collection trough Types of primary sedimentation tanks Horizontal flow Solids contact Inclined surface Stacked or two-tray Proprietary 2
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Horizontal Flow Rectangular Sedimentation Tank
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Primary Sedimentation Tank
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Horizontal Flow Advantages
Occupy less land area when multiple units are used Provide economy by using common walls for multiple units Easier to cover the units for odor control Provide longer travel distance for settling to occur Less short-circuiting Lower inlet-outlet losses Less power consumption for sludge collection and removal mechanisms Disadvantages Possible dead spaces Sensitive to flow surges Restricted in width by collection equipment Require multiple weirs to maintain low weir loading rates High upkeep and maintenance costs of sprockets, chain, and flights used for sludge removal 5
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Primary Sedimentation Tank
V-notched overflow weirs 6
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Primary Sedimentation Tank Manual scum removal system
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Horizontal Flow Rectangular Sedimentation Tank
Longitudinal section with skimmer 8
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Horizontal Flow Rectangular Sedimentation Tank
Cross section 10
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Horizontal Flow Sedimentation Tanks
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Horizontal Flow Rectangular Sedimentation Tank
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Horizontal Flow Rectangular Sedimentation Tank
V-notched overflow weirs 13
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Horizontal Flow - continued
circular clarifier 14
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Primary Sedimentation Basin
Scrubber for Odor Control Odor Control Pipe Covered Overflow Weir Scum Collection Arm Scum Removal Weir 15
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Primary Sedimentation Tank
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Floating Inorganic Materials in Primary Sedimentation Tank
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Primary Sedimentation Tank Cover
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Inside of Covered Primary Sedimentation Tank
Too low Potential maintenance problem during cleaning 19
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Solids Contact Incoming solids rise and come in contact with the solids in the sludge layer. This layer acts as a blanket, and the incoming solids agglomerate and remain enmeshed within this blanket. The liquid rises upward while a distinct interface retains the solids below. Better hydraulic performance and shorter detention time for equivalent solids removal in horizontal flow clarifiers. Either circular or rectangular Not suitable for biological sludges because long sludge-holding times may create undesirable septic conditions. 20
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Solids-Contact Clarifier
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Inclined Surface Utilize inclined trays to divide the depth into shallower sections, which in turn results in significantly short settling time. Frequently used to upgrade the existing overloaded primary and secondary clarifiers. Tube settlers: use thin-wall tubes in circular, square, hexagonal, or any other geometric shape Parallel plate separators: provide a large surface area, thereby reducing the clarifier size. Little wind effect, laminar flow, good for upgrading overloaded horizontal flow clarifiers Disadvantages: septic condition, sludge sloughing off, and clogging of inner tubes and channels. 22
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Inclined Plate Settlers
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Lamella Settlers 24
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Design Factors Design Objective: provide sufficient time under quiescent conditions for maximum settling to occur. Conditions causing decrease in solids removal efficiency Eddy currents induced by incoming fluid Surface currents provided by wind action Vertical currents induced by outlet structure Vertical convection currents induced by the temperature difference between the influent and the tank contents Density currents causing cold or heavy water to underrun a basin, and warm or light water to flow across its surface Currents induced due to the sludge scraper and sludge removal system 25
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Stacked or Two-Tray Sedimentation Basin
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Design overflow rates for sedimentation tanks (m3/m2·day)
Condition Range Typical Primary sedimentation prior to secondary treatment Average flow 30~50 40 Peak flow 70~ Primary sedimentation with WAS return Average flow 25~35 30 Peak flow 45~80 60 Detention Times for Various Overflow Rates and Tank Depth Overflow rate Detention period (hrs) (m3/m2·day) 2-m 2.5-m 3-m 3.5-m 4-m 4.5-m depth depth depth depth depth depth Detention time at average design flow Primary sedimentation tanks - 1~2 hrs Secondary clarifiers - 2~4 hrs 1 m3/m2·day = gal/ft2·day 27
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BOD5 and TSS Removal Efficiency with Respect to Overflow Rate and Detention Time
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Design Factors - continued
Weir loading rate (< 370 m3/m2·day) (Ten-States Standards) 124 m3/m2·day for plants designed for average design flow of 44 L/sec* 186 m3/m2·day for plants designed for average design flow of > 44 L/sec* Dimensions Type Range Typical Rectangular Length, m 10~100 25~60 Length-to-width ratio 1~7.5 4 Length-to-depth ratio 4.2~25 7~18 Sidewater depth, m 2.5~5 3.5 Width, m 3~24 6~10 Clarifier Diameter, m 3~60 10~40 Side depth, m 3~6 4 Solids Loading Not an important deciding factor for primary sedimentation tank design Primary sedimentation tanks: 1.5~34 kg/m2·day Secondary clarifiers: 49~98 kg/m2·day * 44 L/sec = 1 MGD 29
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Design Factors - continued
Influent structure Dissipate energy in incoming flow by means of baffles or stilling basin Distribute flow equally along the width Prevent short circuiting by disturbing thermal and density stratification Provide small head loss Provision for flow control, scum removal, and maintenance Velocity at inlet pipe: 0.3 m/sec 30
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Influent Structures 31
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Design Factors - continued
Effluent structure Provide a uniform distribution of flow over a large area Minimize the lifting of the particles and their escape into the effluent Reduce the escape of floating matter to the effluent Weir loading for plants 44 L/sec – 124 m3/m·day > 44 L/sec m3/m·day Straight (1~2 mm head over weirs – capillary clinging effects – slime accumulation or V-notches either one side or both sides of trough Baffle in front of the weir to stop the floating matter from escaping into the effluent Recommended 32
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Design Factors - continued
Sludge collection Bottom slope: to facilitate draining of the tank and to remove the sludge toward the hopper. Rectangular tanks: 1~2%; circular clarifiers: 40~100 mm/m (4~10%) diameter Equipment Rectangular tanks A pair of endless conveyor chains running over sprockets attached to the shafts or moving-bridge sludge collectors having a scraper to push the sludge into the hopper Suction-type arrangement to withdraw the sludge from basins Circular tanks Scraping mechanism with radial arms having plows set at an angle supported on center pier ( 10 m diameter) or on a beam spanning the tank (< 10 m diameter) (flight travel speed ~0.06 revolution/min) Suction-type units for handling light sludge. 33
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Conveyor Chain One endless chain is connected to a shaft and a drive unit. Linear conveyor speed is 0.3~1 m/min for primary and 0.3 m/min for secondary clarifier Cross-wood (flights) (5 cm thick and 15~20 cm deep) are attached to the chain at 3-m intervals and are up to 6 m in length. For tanks greater than 6 m in width, multiple pairs of chains are used. The floating material is pushed in opposite direction of sludge and is collected in a scum collection box. Advantages: simple to install, low power consumption, efficient scum collection, and suitable for heavier sludge Disadvantages: high maintenance cost of chain and flight removal mechanism, dewatering of tanks for gear and chain repair, and potential resuspension of light sludge 34
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Chain-and-Flight Sludge Collector
A. Chain B. Sprockets C. Shear pin D. Chain tightener brackets E. Wall bearings P. Gear box Q. Baffles R. Flights (fiberglass or wood) S. Weirs T. Scum pipe F. Pillow block bearings G. Sewage take-up bearing H. Set collars I. Screw conveyer J. Shafting K. Return rail system L. Floor rail wear strip M. Couplings N. Wear shoes O. Filler blocks 35
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Bridge Drive Scraper Standard traveling beam bridges for spans up to 13 m (40 ft) and truss bridge for spans over 13 span are used. Bridge travel is accomplished by the use of a gear motor. The wheels run on rails which are attached to the footing wall along each side wall of the basin. Mechanical scrapers or rakes are hung from the top carriage that push the sludge to the hopper. Separate blades are provided on top to move the scum. Advantages: all moving mechanisms above water, scraper repair or replacement without dewatering tanks, no width restrictions, longer operation life, and lower maintenance cost in low-span bridges. Disadvantages: high power requirement, not suitable for cold weather (ice formation in tanks), and frequent break-down due to wheel climbing over rails in long-span bridges. 36
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Traveling Bridge Sludge Collector
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Bridge Drive Sludge Suction
The bridge design is similar to the bridge drive scraper. The sludge removal mechanisms are attached to the bridge and provide continuous removal of sludge along the length of travel. Pump, siphon, or airlift arrangements are used to suck and remove the sludge. Advantages: Better pickup of light sludge, all moving mechanisms above water, scraper repair or replacement without dewatering tanks, no width restrictions, longer operation life, and lower maintenance cost in low-span bridges, and suitable for biological and chemical sludges. Disadvantages: high power requirement, not suitable for cold weather (ice formation in tanks), and frequent break-down due to wheel climbing over rails in long-span bridges, and not used in primary sedimentation tanks. 38
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Vacuum Sludge Removal Rectangular sedimentation basins
Southern States and warm climate areas None freezing environments Surface ice is difficult to design for. 39
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Vacuum Sludge Removal 40
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Design Factors - continued
Sludge Removal Removed by means of a pump. Design considerations Provision of continuous sludge pumping is desirable. Each sludge hopper should have individual sludge withdrawal line at least 15 cm in diameter. In rectangular tanks, cross-collectors are preferred over multiple hoppers. Screw conveyors for sludge removal are also used. An automatic control of sludge pump or siphon pipes using a photocell-type or sonic-type sludge blanket detector is desirable, especially for secondary clarifiers. The sludge pump used are self-priming centrifugal and normally discharge into a common manifold. One sludge pumping station can serve two rectangular sedimentation tanks. The circular clarifiers are normally arranged in groups of two or four. 41
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Design Factors - continued
Scum removal Generally pushed off the surface to a collection sump. In rectangular tanks, the scum is normally pushed in the opposite direction by the flights of the sludge mechanism in its return travel. In circular clarifiers, the scum is removed by a radial arm which rotates on the surface with the sludge removal equipment. Sometimes, removed by water sprays. Scraped manually or mechanically up an inclined apron. All effluent weirs have baffles to stop the loss of scum into the effluent. The scum has a specific gravity of Solids content may vary from 25 to 60%. The quantity of scum varies from 2 to 13 kg/103 m3 (17~110 lb/million gallon). Pipings are often glass-lined and kept reasonably warm to minimize blockage. Scum has been digested in aerobic and anaerobic digesters. 42
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Scum Collection and Removal Arrangements
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Information Checklist
Average and peak design flows including the returned flows from other treatment units All sidestreams from thickener, digester, and dewatering facility Treatment plant design criteria prepared by the concerned regulatory agencies Equipment manufacturers and equipment selection guide Information on the existing facility if the plant is being expanded Available space and topographic map of the plant site Shape of the tank (rectangular, square, or circular) Influent pipe data, to include diameter, flow characteristics, and approximate water surface elevation or hydraulic grade line Headloss constrains for sedimentation facility 44
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Design Calculations Design criteria
1. Two rectangular units shall be designed for independent operation. Allow for a bypass to secondary treatment process when one unit is out of service. 2. Overflow rate and detention times shall be based on an average design flow of 0.44 m3/sec (10 MGD). 3. The overflow rate shall be < 36 m3/m2·day at average design flow. 4. The detention time shall be > 1.5 hrs at average design flow. 5. The influent structure shall be designed to prevent short circuiting and reduce turbulence. The influent channel shall have a velocity < 0.35 m/sec at design peak flow (0.661 m3/sec through each basin). 6. All sidestreams shall be returned to aeration basins. 7. The weir loading shall be < 186 m3/m·day at average design flow and < 372 m3/m·day at design peak flow. 8. The launder and outlet channels shall be designed at the peak design flow of m3/sec (0.661 m3/sec through each basin). 9. The average liquid depth in the basin shall be > 3 m. 10. The slope of the tank bottom shall be 1.35% (1~2% in slide #33). 45
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Design Calculations - continued
Basin dimensions 1. Select basin geometry and provide two rectangular basins with common wall Average design flow through each basin = 0.44/2 = 0.22 m3/sec Overflow rate at average design flow = 36 m3/m2·day Surface area = 0.22 m3/sec × 86,400 sec/day 36 m3/m2·day = 528 m2 Use length-to-width ratio (L:W) = 4:1 ~ OK 4W × W = 528 m2; W = 11.5 m; use W = m (38 ft) due to ft increments for sludge collectors. Thus, length = m (152 ft). Depth at mid-length of the tank = 4 m (13.1 ft) Length-to-depth ratio = m/4 m = 11.6 ~ OK Freeboard = 0.6 m (2 ft) Average depth of the basin = 4.6 m (15 ft) 46
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Design Calculations - continued
2. Check overflow rate Overflow rate at average design flow = 0.22 m3/sec × 86,400 sec/day (11.58 m × m) = 35.4 m3/m2·day Overflow rate at peak design flow = m3/sec × 86,400 sec/day (11.58 m × m) = m3/m2·day 3. Check detention time Average volume of the basin = 4 m × m × m = 2,146.0 m3 Detention time at average design flow = 2,146.0 m3 (0.22 m3/sec × 3,600 sec/hr) = 2.7 hrs ⇒ > 1.5 hrs ~ OK Detention time at peak design flow = 2,146.0 m3 (0.661 m3/sec × 3,600 sec/hr) = 0.9 hr Influent structure 1. Select the arrangement of the influent structure The influent structure includes a 1-m wide influent channel that runs across the width of the tank. Eight submerged orifices 34 cm square each, are provided in the inside wall of the channel. 47
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Design Calculations - continued
A submerged influent baffle is provided 0.8 m in front, 1 m deep, and 5 cm below the liquid surface. Why? Potential constructability issue To prevent settling 48
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Design Calculations - continued
2. Compute the headloss in the influent pipe connecting the junction box located downstream of the grit chamber and the influent structure of the sedimentation basin The elevation of the water surface in the influent channel of the basin is lower than that in the junction box downstream from the grit chamber. H is the sum of the headloss in the connecting pipe due to the entrance, friction, bends, and fittings and exit loss into the influent channel of the sedimentation basin. 49
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Design Calculations - continued
3. Compute the headloss at the influent structure The horizontal velocity in the sedimentation basin (v2) is small and is ignored. The average velocity in the influent channel (v1) is calculated at peak design flow. Half of the flow divides on each side of the basin. The depth of water into the influent channel is fixed by the designer. Assume the depth of water at the entrance of the influent channel is 1 m and the width of the influent channel is 1 m. z = hL; Q = CdA < 0.35 m/sec ~ OK See slide #48 See slide #48 50
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Design Calculations - continued
Effluent structure 1. Select the arrangement of the effluent structure The effluent structure consists of weirs, launder, an outlet box, and an outlet pipe. Use V-notched weir. 2. Compute the length of the weir Weir loading = 372 m3/m·day at peak design flow Peak design flow per basin = m3/sec × 86,400 sec/day = 57,110 m3/day Weir length = 57,110 m3/day 372 m3/m·day = m Provide weir notches on both sides of the launder. Thus, Total length of the weir plate = 2( ) m + 2( ) m - 1 m = m Actual weir loading = 57,110 m3/day m = m3/m·day ≈ 372 m3/m·day at peak flow → OK 3. Compute the number of V-notches Provide 90° standard V-notches at a rate of 20 cm center to center on both sides of the launders. 51
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Weir Arrangement 52
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Design Calculations - continued
Total number of notches = 5 notches per m × m = 769 In order to leave sufficient space on the ends of the weir plate, provide a total of 765 notches. 53
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Design Calculations - continued
4. Compute the head over the V-notches at the average design flow The average discharge per notch at average design flow = 0.22 m3/sec 765 notches = 2.88 × 10-4 m3/sec per notch The discharge through a V-notch is calculated using the eq. below. Q = 8/15 Cd 2g ·tan(/2) H5/2 where Cd = 0.6, H = head over notch, m, and = angle of the V- notch = 90°. 2.88 × 10-4 m3/sec = 8/15 × 0.6 × 2 ×9.81 m/sec2·tan (90/2) H5/2 H = 0.03 m = 3 cm 5. Compute head over V-notches at peak design flow Discharge per notch at peak design flow = m3/sec 765 notches = 8.64 × 10-4 m3/sec per notch 8.64 × 10-4 m3/sec = 8/15 × × 2 ×9.81 m/sec2·tan (90/2) H5/2 H = 0.05 m = 5 cm 6. Check the depth of the notch The total depth of the notch is 8 cm. Max. liquid head over the notch at peak design flow is 5 cm (safe allowance of 3 cm). 54
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Design Calculations - continued
7. Compute the dimensions of the effluent launder Width of the launder, b = 0.6 m Width of the effluent box = 1.0 m Diameter of the outlet pipe = 0.92 m The depth of water in the effluent box = 1.0 m (fixed by designer) Provide the invert of the effluent launder 0.46 m above the invert of the effluent box Depth of water in the effluent launder at exit point y2 = 1.0 m m = 0.54 m Critical depth of flow in the launder Since 0.54 m > 0.5 m, the outfall is submerged. Half of the flow divides on each side of the launder Flow on each side of the launder = m3/sec 2 = 0.33 m3/sec 55
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Weir Trough (Launder) Values given by designer Section AA
In slide #53, cm - 5 cm = 3 cm Thus, 1.45 m m = 1.48 m Section CC 56
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Effluent Launder Water Surface Profile
Δz=hL = 1.45 m m = 0.91 m (10.38 m – 1 m)/2 = 4.69 m Section BB 57
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Outlet Channel 4.02 m – 0.91 m – 0.54 m = = 4.02 m – 0.91 m 58
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Design Calculations - continued
Q’ = m3/s 2 = 0.33 m Generally, an allowance for losses due to friction, turbulence, and bends is 10~30%. In this case, provide a 25% allowance, and add 0.6 m for freefall. Water depth at the far end of trough = 0.64 m × 1.25 = 0.80 m Total depth of the effluent launder = 0.80 m m = 1.40 m Headloss through sedimentation basin Headloss at the influent structure (calculated) = 0.07 m Headloss at the effluent structure (calculated) = 0.91 m Headloss in the basin (small - ignored) Headloss at the influent and effluent baffles (small - ignored). 59
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Design Calculations - continued
Hydraulic profile through the basin A total headloss of 0.98 m (3.25 ft) (= 4.09 m m) at the peak design flow. = 2.57 m m 60
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Design Calculations - continued
Sludge Quantities 1. Establish sludge characteristics Primary sludge: specific gravity of 1.03 and a solids content of 3~6%. Assume a typical solids content of 4.5%. 2. Compute average quantity of sludge produced per day Amount of solids produced per basin per day at a removal rate of 63% = 260 g/m3 × 0.63 × 0.22 m3/sec ×86,400 sec/day × kg/1,000 g = 3,113.5 kg/day Average quantity of sludge produced per day from both basins = 2 × 3,113.5 kg/day = 6,227 kg/day 3. Compute the volume of sludge produced per minute per basin Volume of sludge at specific gravity of 1.03 and 4.5% solids = 3,113.5 kg/day (1.03 × 1 g/m3 × 1 kg/1,000 g × × 106 cm3/m3 × 1,440 min/day) = m3/min per basin 4. Determine sludge pump size and pumping cycle Provide separate sludge pumps for each basin. Arrange such that each pump will serve both basins in case one pump is out of service. 61
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Design Calculations - continued
Operate each pump on a time cycle, at 16.5-min intervals with a 1.5-min pumping cycle per basin (total time 18 min per cycle) The desired pumping capacity of the pump = ( m3/min per basin × 18 min per cycle) 1.5 min pumping per cycle = 0.56 m3/min per basin (150 gpm) When one pump is used to remove the sludge from two basins, the cycle time will be reduced. Cycle interval in min for two basins = ( ) min 2 = 9 min per cycle Effluent quality from primary sedimentation basin 1. Establish BOD5 and TSS removal At overflow rate of 35.4 m3/m2·day, BOD5 removal = 34% SS removal = 63% 62
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Design Calculations - continued
2. Compute BOD5 and TSS in the effluent Assume the sidestreams from the thickeners, digesters, and dewatering facilities are returned to the aeration basin. BOD5 in the primary effluent = 250 g/m3 × ( ) × 0.44 m3/sec × 86,400 sec/day × kg/1,000 g = 6,273 kg/day TSS in the primary effluent = 260 g/m3 × ( ) × 0.44 m3/sec × 86,400 sec/day × kg/1,000 g = 3,657 kg/day Volume of primary effluent = Average flow to primary - Sludge withdrawal = 0.44 m3/sec × 86,400 sec/day - (6,227 kg/day × 1,000 g/kg) (0.045 g/g × 1.03 × g/cm3 × 106 cm3/m3) = 38,016 m3/day m3/day = 37,882 m3/day BOD5 conc. in effluent = 6,273 kg/day 37,882 m3/day × 1,000 g/kg = g/m3 = mg/L TSS conc. in effluent = 3,657 kg/day 37,882 m3/day × 1,000 g/kg = g/m3 = 96.5 mg/L Scum quantity: ave. quantity of scum (S.G.=0.95) = 8 kg/1,000 m3 × 38,016 m3/day = 304 kg/day = 0.32 m3/day 63
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Layout of the Primary Sedimentation Basins
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Common Operating Problems
1. Black and odorous septic wastewater due to decomposing wastewater in the collection system, recycle of excessively strong digester supernatant, or inadequate pretreatment of organic discharges from the industries preaeration, chlorination, or hydrogen peroxide/ potassium permanganate oxidation, control of digester supernatant, and strict enforcement of industrial pretreatment regulations 2. Scum overflow due to inadequate frequency of scum removal, excessive industrial contribution, worn or damaged scum wiper blades, or improper alignment of the skimmer 3. Sludge that is hard to remove from the sludge hopper due to excessive grit accumulation check the grit removal facility 4. Low solids in the sludge due to excessive sludge withdrawal, short circuiting, or surging flow 5. Excessive corrosion of metals due to H2S gas 6. Frequent broken scraper chain and shear pin failures due to improper shear pin sizing and flight alignment, ice formation, or excessive loading on the sludge scraper 7. A noise chain drive or a loose or stiff chain due to misalignment 66
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Operation and Maintenance
1. Remove accumulations from the influent baffles, effluent weirs, scum baffles, and scum box each day. 2. Inspect all mechanical equipment at least once each shift. 3. Hose down and remove wastewater sludge and spills ASAP. 4. Determine sludge level and underflow concentration, and adjust primary sludge pumping rate accordingly. 4. Observe operation of scum pump and provide hosing as necessary. 5. Check daily electrical motors for overall operation, bearing temperature, and overload detector. 6. Check oil levels in gear reducers and bearings on a regular basis. 7. Drain each primary basin annually and inspect the underwater portion of the concrete structure and all mechanical parts. 8. Inspect all mechanical parts for wear, corrosion, and set proper clearance for flights at tank walls. 9. Clean and paint the exposed metal surfaces as necessary. 67
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Specifications General
Include a complete assembly of a sludge collector mechanism with drive and collector chains with flights, access bridge and walkway, influent and effluent structures, pumping facilities, and overload alarm system. Dimensions: # of basins (identical basins with common wall), Length, width, side wall depth (SWD) at effluent end, influent end, and mid length, bottom slope, free board, etc. 68
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Specifications - continued
Materials and Fabrication Conform to proper ASTM standards. The min. thickness of all submerged metal shall not be < 0.64 mm (1/5 in) and of all-above water metal 4.8 mm (3/16 in). Conform to all American Institute of Steel Construction (AISC) standards for structural steel buildings. Collectors Provide two longitudinal collectors and one cross-collector in each basin Dimensions, numbers, and materials of flights, sprocket wheels, scrapers, chains, etc. 69
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Specifications - continued
Drive Unit Consists of a gear motor, gear reducer, drive base, shear pin coupling, overload alarm device, and drive sprocket and chain Motor and gear – detailed specifications Sludge Pump Self-priming, centrifugal, and nonclogging, pumping rate, etc. Effluent Weir V-notch weir and effluent box dimensions, scum removal, etc. Skimmer Hand-operated adjustable scum trough Painting Primed and painted with approved paint or epoxy 70
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