v>EPA United States Environmental Protection Agency V Municipal Environmental Research^' Laboratory Cincinnati OH 45268 Research and Development EPA-600/S2-81-095 July 1981 Project Summary Feasibility Study of Open Tank Oxygen Activated Sludge Wastewater Treatment Kerwm R Rakness The pilot plant for this study con- sisted of one oxygenation basin and two clarif iers capable of treating 151 L/min (40 gpm). The system treated primary effluent from the Englewood, Colorado, municipal wastewater treat- ment facility. The influent flow rate was adjusted to attain average aera- tion reactor detention times ranging from 0.94 to 3.3 hr. The pilot plant operation was conducted in two phases. Treatment performance during both phases was excellent. Final ef- fluent BOD5 concentrations and sec- ondary BOD5 removals averaged less than 20 mg/L and greater than 90 percent, respectively. No degradation in process removal efficiency occurred, even at organic loadings as high as 1.23 kg BOD5 applied/day/kg MLVSS (1.23 Ib BODs applied/day/lb MLVSS) and volumetric loadings as high as 4.07 kg BOD5 applied/day/m3 (254 Ib BOD5 applied/day/1000 ft3) of reactor capacity. Analysis of pilot plant operations indicated that somewhat less sludge was produced with the oxygen system when compared with literature-cited, typical air sludge production. This decreased sludge production occurred and became more pronounced at higher organic loadings. Comparisons were made between literature-cited, typical air-sludge and oxygen-sludge settling characteristics. In all cases, the oxygen-sludge initial settling velocity was greater than typical air sludge at given TSS con- centrations. This Project Summary was devel- oped by EPA's Municipal Environmen- tal Research Laboratory, Cincinnati, OH, to announce key findings of the research project that is fully docu- mented in a separate report of the same title (see Project Report ordering information at back). Introduction The investigation of high purity oxygen for wastewater treatment was originally conducted by Okun in 1948. No signifi- cant further development was conducted until the late 1960's when a "closed tank" oxygenation process was devel- oped. The closed tank process demon- strated that oxygen activated sludge treatment was feasible and economically attractive when compared with a parallel operated air activated sludge system. Two of the reasons for the attractiveness of the closed tank process were (1) its ability to treat wastewater with smaller aeration reactors than required for air systems and (2) its ability to achieve high (90 percent) oxygen utilization efficiencies. There are many reasons why an "open tank" oxygenation system would be attractive: (1) extensive safety pre- cautions are required with the closed tank system, (2) extra expense is involved in covering and sealing an aeration reactor as well as a requirement for 0.9 to 1.5 m (3 to 5 ft) of freeboard, (3) other high purity oxygen activated sludge treatment systems have been shown to be feasible and economically attractive at high oxygen utilization efficiencies, ------- and (4) existing aeration basins may be easily converted to oxygen systems in an open tank concept. To date, there is one known open tank high purity oxygen activated sludge system on the market, MAROX,* mar- keted by Zimpro Inc. The MAROX system was originally developed by FMC Corpo- ration, but Zimpro has subsequently acquired the rights to the technology. The basis for performance of the MAROX system is an ultra fine bubble diffuser that achieves oxygen utilization effi- ciencies comparable with those obtained with closed tank reactor systems. The MAROX system uses a unique bubble shear method for dissolution of pure oxygen to the mixed liquor. The fixed active diffuser hardware used in this project has two gas bars adjacent to each slot that emitted oxygen through very small capillaries where a high velocity mixed liquor stream sheared the bubbles on formation into 50/u- to 100/u-diameter gas bubbles. Testing was completed using a pilot plant facility capable of treating sec- ondary influent (primary effluent) flow- rates up to 151 L/min (40 gpm). Sec- onday influent (SI) to the pilot plant was obtained from the primary treatment process of the Englew^ood facility. During the testing period, "one oxygenation basin and either one or two clanfiers were in service. The program plan with both constant flow and the maximum- minimum diurnal flow conditions are shown in Table 1. Diurnalflow variations were selected based on the historical raw wastewater flow at the Englewood facility. The program was divided into two phases with the latter phase using a broader range of operational controls and monitoring. Further information concerning open tank oxygen activated systems can be found in the EPA project report "Full- Scale Demonstration of Open Tank Oxygen Activated Sludge Treatment" (EPA-600/2-79-012). The follow-on, full-scale demonstration project used a rotating active diffuser, which in general required less power than the fixed active diffuser used in this project. The rotating active diffuser has supplanted the fixed active diffuser as the standard oxygen transfer device in the MAROX open tank oxygen system. •Mention of trade names or commercial products does not constitute endorsement or recommenda- tion for use. Results and Conclusions The MAROX oxygen pilot plant pro- vided data that led to the following conclusions: 1. Final effluent (FE) BOD5 concen- trations averaged less than 20 mg/L, even at average volumetric loadings as high as 4.07 kg BOD5 apphed/day/m3 (254 Ib BOD5 applied/day/1000 ft3) of oxygen- ation basin capacity and maximum organic loadings of 1.23 mass BOD5 applied/day/mass mixed liquor volatile suspended solids (MLVSS). 2. Better effluent quality was attained by operating at return flow/influent flow (R/Q) ratios between 50 and 60 percent as opposed to R/Q between 30 and 40 percent. 3. No significant nitrification occurred during the test program; oxygen- ation basin detention times ranged from 0.94 to 3.3 hr. 4. Excellent oxygen feed control re- sponse was achieved using a dis- solved oxygen (D.O.) monitoring and control system to vary oxygen supply rate. 5. Oxygen utilization efficiencies averaged 91.5 and 92.5 percent during two separate oxygenation basin "off-gas" tests. 6. Oxygen-sludge mixed liquor sus- pended solids (MLSS) initial settling velocities were greater than liter- ature-cited, air-sludge settling velocities at specific total sus- pended solids (TSS) concentrations. 7. Oxygen-sludge production values were somewhat lower than most literature-cited, air-sludge produc- tion values. Recommendations The following recommendations are made from the results of the MAROX pilot plant operation. For oxygen utiliza- tion efficiency verification in an "open" oxygenation basin, the following ap- proach is recommended for activated sludge systems. (1) Compare the ratio of mass of oxygen supplied per mass of BOD5 removed with expected ratios. If the calculated ratio is equal to or less than the expected ratio, then the oxygen utilization efficiency is acceptable. If the calculated ratio is greater than the expected ratio, then the oxygen utiliza- tion efficiency may not be acceptable and further verification testing is re- quired. (2) An accurate oxygen utiliza- tion efficiency can be determined by using a cap or cover on all or a portion of the surface area of the oxygenation basin and conducting an off-gas analysis. Other indirect methods for obtaining mass of oxygen used are not acceptable alternatives Discussion of Results Phase I The Phase I experimental program consisted of the first three test condi- tions identified in Table 1. Monitoring and operating results obtained during Phase I are shown in Tables 2 and 3, respectively. Most data listed in Table 2 are self-explanatory. Raw wastewater BOD5 and TSS concentration values are Englewood laboratory results for the raw wastewater entering the treatment facility. Phase I process removal efficiencies were satisfactory despite limited opera- tional controls and low primary clanfier TSS removal efficiencies. MAROX sec- ondary BOD5 removal efficiencies ranged from 89.8 to 94.3 percent with TSS removal efficiencies from 78 8 to 87.7 percent. Primary treatment BOD5 removal efficiencies were in an expected { range of 21.8 to 40 percent. Primary treatment TSS removal efficiencies were much lower than expected, ranging from a negative 17 percent to a positive 21 percent. The low primary TSS re- moval efficiencies may be attributed to higher than desired TSS concentrations of various Englewood inplant recycle flows, namely anaerobic digester super- natant, and may have adversely affected the final effluent quality. Final effluent during Phase I had BOD5 concentrations less than 17 mg/L and TSS concentrations less than 27 mg/L. The slightly higher TSS values apparently were composed of inert suspended solids not captured in the final clarifier. The final effluent probably contained more inert suspended solids than normal because of (1)a long sludge detention time in the clarifier (2.0to 3.9 hr), which contributed to degradation of mixed liquor quality and (2) a high con- centration of anaerobic digester super- natant solids in the SI flow Degradation of mixed liquor quality was demon- strated by its poorer ability to capture solids in the clarifier. The long sludge detention time in the clarifier was caused by a lower return sludge flow rate than was established in Phase II. The excellent settling characteristics of | the mixed liquor (SVI ranged from 65.9 to 81.5 ml/g) did not result in a clean- ------- Table 1. Program Plan Operating Conditions Test No. 1 2 3 4 5 6 7 A verage Daily Flow (L/minf 37.8 378 56.7 75.8 94.5 113.5 132.5 Flow Condition Constant Diurnal Constant Diurnal Constant Dirunal Constant Maximum Daily Flow (L/min) 47.3 102.0 133.5 Minimum Daily Flow (L/min) 22.7 45.5 75.8 Reactor* Detention (hr) 3.30 330 2.20 1.65 1.32 1.10 094 Clar. No. 1 1 1 1 2 2 2 Clarified Overflow Rate (m3/day/m2)e 15.2 15.2 22.9 30.5 19.1 22.9 26.7 Clarified Overflow Rate (m3/day/m2) 16.7 16.7 25.1 33.5 21.0 25.1 293 8'Based on average daily SI flow. ^Includes clanfier centerwell. ^Excludes clarifier centerwell. *L/min x 0.264 - gpm em3/day/mz * 24.5 = gpd/ft2 Table 2. Monitoring Results - Phase I Parameters Run 1 Run 2 Run 3 Operating conditions A verage SI flo w, L /min 37.8 37.8 56.7 (gpm) (W) (10) (15) Flow pattern Constant Diurnal Constant Run length, days 47 25 54 Wastewater temperature, °C 22 20 13 BODs data Raw wastewater, mg/L 183 179 245 SI, mg/L 131 140 147 Primary removal. % 18.4 21.8 40.0 FE, mg/L 10 8 16 Secondary removal, % 92.4 94.3 89.8 Primary plus secondary removal, % 94.5 95.5 93.5 Oxygen supplied, mass 02/mass BOD* 2.30 2.60 1.17 TSS data Raw wastewater, mg/L SI, mg/L Primary removal, % FE. mg/L Secondary removal, % Primary plus secondary removal, % 197 187 5.1 19 84.4 90.4 153 179 17* 21 87.7 86.3 157 124 21 26 78.8 83.4 T/7/s indicates an increase of 17%. sweeping sludge. If the R/Q ratio had been increased, the lower sludge deten- tion time in the clarifier might have improved the mixed liquor quality. During all periods of Phase I operation, manual D.O control was provided. The average D.O. concentration of the mixed liquor in each pass of the oxygenation basin was higher than desired during the first two Phase I tests During the last part of Phase I, the average D.O. concentration of the mixed liquor was in the desired range. In parts of Phase I operation, the mass of oxygen supplied per mass of BOD5 removed was larger than expected because of higher than desired mixed liquor D.O. concentra- tions. Phase I pilot plant operation demon- strated that the MAROX system can be satisfactorily operated at high MLVSS concentrations, high return sludge TSS concentrations, and long mean cell residence times (Table 3). Phase II The experimental program for Phase II included the last four test conditions cited in Table 1 plus reruns of test conditions Nos. 1 and 3. Monitoring and operating results obtained during Phase II are presented in Tables 4 and 5, respectively. All six periods of operation during Phase II demonstrated excellent BOD5 and TSS removals. Final effluent BODs and TSS concentrations ranged from 14 to 18 mg/L and from 11 to 15 mg/L, respectively. Primary treatment BOD5 and TSS removal efficiencies were acceptable, ranging from 13.1 to 39.7 percent and from 16 to 63.5 percent, respectively. The low primary TSS removal efficiency of 16 percent is attributed to anaerobic digester supernatant recycle flow The final effluent TSS concentration, how- ever, was much improved over the Phase I overall final effluent TSS con- centration Two reasons contributed to the better effluent quality during this period (1) operation at higher R/Q ratios and (2) lower sludge detention time in the clarifter. The R/Q ratio and clarifier sludge detention time were 50 percent and 1 hr, respectively During Phase I, these same parameters were approximately 40 percent and 3 hr. During the 95-L/min (25-gpm) flow condition, the secondary influent TSS concentration was lower than the over- all values for Phase I. The lower second- ary influent TSS concentration may have contributed to the final effluent TSS concentration of 13 mg/L. In all but two periods of Phase II (37.8 L/min (10 gpm) and 56 7 L/mm (15 gpm)), the sludge detention time in the clanfier was less than 1.4 hr. In these two periods, however, the sludge detention time in the clarifier was 3.3 and 2.5 hr, with SVI values of 204 ml/g and 184 ml, respectively Although the settling characteristics were poorer than de- sired, the final effluent quality did not deteriorate (12 and 14 mg/L TSS, respectively). Sludge in these two peri- ods was clean-sweeping, even though ------- Table 3. Operating Results - Phase I Parameters Run 1 Run 2 Run 3 Operating conditions Average SI flow, L/min Igpm) Flow pattern Run length, days Volumetric loading, kg BOD$/m3/day (Ib BODS/ 1000 ft3 /day) Aerator detention time (0.1 hr Sludge detention time-aerator (Q+R), hr RAS* flow, L/min Igprn) R/Q ratio, % Sludge detention time-clarifier (Q+R), hr Clarifier mass loading, kg TSS/day/m3 (Ib TSS/day/ft3) Overflow rate0, m3/day/m2 (gpd/ff) Overflow ratec, m3/day/m2 (gpd/ft2) Sludge aged, days Mean cell residence time, days Sludge synthesis, mass excess VSS/ mass BODs removed F/M ratio, mass BOD5/mass MLSS/day Oxygen data Pass A mixed liquor DO, mg/L Pass B mixed liquor DO, mg/L Pass C mixed liquor DO, mg/L Final effluent DO, mg/L So/ids data MLSS, mg/L MLVSS, mg/L MLVSS/ MLSS ratio, % RAS TSS. mg/L RAS VSS. mg/L RASVSS/RASTSS ratio, % SVI. ml/gm aRAS = return activated sludge ^Includes clarifier centerwell. cExcludes clarifier centerwell. dBased on TSS in secondary influent. 37.8 110) Constant 47 0.96 160) 3.3 2.4 14.8 (3.9) 39.4 2.0 161 (33.0) 15.2 (374) 16.7 (411) 13.9 25.6 0.44 0.18 9.3 9.5 8.0 4.1 7,488 5,390 72.0 26,755 19,325 72.2 65.9 37.8 (10) Diurnal 25 1.03 (64) 3.3 2.3 16.7 (4.4) 43.6 3.9 220 (45.0) 15.2 (374) 16.7 (411) 13.0 27.8 0.57 0.15 9.1 10.1 10.5 5.7 10.206 7,111 69.7 24,448 17,234 70.5 67.7 56.7 (15) Constant 54 1.71 (107) 2.2 1.6 20.8 (5.5) 36.4 2.8 152 (31.2) 22.7 (561) 25.1 (617) 3.3 7.1 0.77 0.46 3.7 3.6 4.3 1.8 4,877 3,870 79.4 14,139 10,951 77.5 81.5 its settling rate was not as good. The sludge settling characteristics of the other four periods were excellent with SVI's ranging from 67.8 to 74.5 ml/g. During Phase II, the automatic oxygen controller was in operation and per- formed very effectively. The D.O. con- centration of the mixed liquor in each pass was within the satisfactory range of 1 to 4 mg/L. The mass of oxygen supplied per mass of BODs removed varied from 0.92 to 1.49. Results of the total nitrogen series analyses indicate that no significant nitrification occurred during Phase II. Limited TKN and NH3-N removals were observed. Results of organic analyses indicated that the relationship of final effluent COD to final effluent BOD5 was very erratic. The final effluent COD concentration ranged from 48 to 94 mg/L, whereas the final effluent BOD5 concentration ranged from 14 to 18 mg/L. The final effluent turbidity test results were low and consistently ranged from 4.4 to 6.3 JTU. No significant decrease in pH occurred between the SI and FE during Phase II. It is apparent that most of the C02 pro- duced during the biological reaction was removed from the system in a manner that did not significantly de- crease the pH of the final effluent. System Evaluation The average final effluent BOD5 con- centration for each test condition never exceeded 20 mg/L. Primary treatment removals showed wide variations; how- ever, primary plus secondary BODs removals always exceeded 90 percent. The TSS concentration of the FE never exceeded 30 mg/L during Phase I, nor 20 mg/L during Phase II. Primary re- moval efficiencies exhibited wide varia- ------- Table 4. Monitoring Results - Phase II Parameters Run 1 Run 2 Run 3 Run 4 Run 5 Run 6 Operating conditions Average SI flow, L/min (gpm) Flow pattern Run length, days Wastewater temperature, °C SI pH FE pH FE turbidity, JTU BOD5 and COD data Raw wastewater BOD5, mg/L Sl BOD5, mg/L Primary BODs removal, % FE BOD*, mg/L Secondary BODS removal, % Primary plus secondary BOD5 removal, % Oxygen supplied, mass Oz/mass BODn SI COD, mg/L FE COD, mg/L COD removal, % TSS data Raw wastewater, mg/L SI, mg/L Primary removal, % FE. mg/L Secondary removal, % Primary plus secondary removal, % Nitrogen data SI TKN. mg/L FE TKN, mg/L TKN removal, % SI NHyN, mg/L FE NHyN. mg/L NH3-N removal, % SI NOZ-N + NO3-N, mg/L FE NOz-N + N03-N, mg/L 37.8 (10) Constant 30 18.1 6.8 6.7 4.7 282 212 24. 8 15 92.9 9.47 1.49 396 48 87.9 205 134 34.6 12 91.4 94.1 31 20 34.2 18 16 10.6 0.25 0.25 56.7 (15) Constant 31 19.5 6.9 6.9 4.6 292 210 28.1 16 92.4 94.5 1.32 345 48 85.5 202 119 41.1 14 86.7 93. J 27 13 51.9 19 16 15.8 0.1 0.15 75.8 (20) Diurnal 31 21.5 6.9 6.9 5.1 289 208 17.6 16 92.3 94.5 1.08 321 61 80.1 175 115 34.3 15 85.6 91.4 27 12 55.6 18 15 16.7 0.1 0.15 94.5 (25) Constant 23 14.6 7.0 6.9 5.6 191 166 13. 1 14 91.6 92.7 1.17 332 95 70.9 131 110 16.0 13 87.7 90.1 36 28 27.8 29 22 24.1 0.1 0.15 113.5 (30) Diurnal 30 19.0 6.9 6.9 4.4 297 179 39.7 16 91.1 94.6 0.92 259 57 77.6 233 85 63.5 11 85.8 95.3 29 23 20.7 21 19 9.5 0.5 1.3 132.5 (35) Constant 31 16.8 7.0 6.9 6.3 262 159 39.3 18 88.7 93.1 1.08 305 74 75.7 200 85 57.5 15 81.4 92.5 26 21 19.2 18 15 16.7 0.1 0.16 tions, even including a negative TSS re- moval. Primary plus secondary TSS removal efficiencies were greater than 80 percent during Phase I and greater than 90 percent during Phase II. During the study, the pilot facility was operated under a wide range of loading conditions. The BOD5substrate removal rate related to the F/M ratio for both phases is depicted in Figure 1. The graph was developed using weekly average test results for all test condi- tions. The straight-line relationship of the graph illustrates that no degradation in process BOD5 removal efficiency existed even at the higher F/M ratios. The slope of the line indicated that on he average for all tests, 90.2 percent of the BOD5 applied to the system was removed. ------- Table 5. Operating Results - Phase II Parameters Run 1 Run 2 Run 3 Run 4 Run 5 aRAS = return activated sludge ^Includes clarifier centerwell. ^Excludes clarifier centerwell. "Based on TSS in secondary influent. Run 6 Operating conditions Average SI flow, L/min (gpm) Flow pattern Run length, days Volumetric loading, kg BODs/m3/day (Ib BODs/1000 ft3 /day) Aerator detention time (Q), hr Sludge detention time-aerator (Q+R), hr RASB flow, L/min (gpm) R/Q ratio, % Sludge detention time-clarifier (Q+R), hr Clarifier mass loading, kg TSS/day/m3 (Ib TSS/day/ft3) Overflow rate", m3/day/m2 (gpd/ft2) Overflow rate0, m /day/m2 (gpd/ft2) Sludge aged, days Mean cell residence time, days Sludge synthesis, mass excess VSS/ mass BODs removed F/M ratio, mass BODs/mass MLSS/day Oxygen data Pass A mixed liquor DO, mg/L Pass B mixed liquor DO, mg/L Pass C mixed liquor DO, mg/L Final effluent DO, mg/L Solids data MLSS, mg/L MLVSS, mg/L MLVSS/MLSS ratio, % RAS TSS, mg/L RAS VSS, mg/L RASVSS/RASTSS ratio, % SVI, ml/gm 37.8 (W) Constant 30 1.54 (96) 3.3 2.12 20.6 (5.45) 54.5 3.3 112 (23) 15.2 (374) 16.7 (411) 4.5 11.2 0.61 0.39 3.0 2.7 3.1 1.2 4.750 3,952 83.2 13,103 10,842 82.7 204 56.7 (15) Constant 31 2.31 (144) 2.2 1.40 30.2 (8.0) 53.3 2.5 181 (37) 22.9 (56 1) 25.1 (617) 3.2 8.3 0.60 0.57 3.5 4.2 4.5 1.2 5,089 4.044 79.5 13,131 10,390 79.1 184 75.8 (20) Diurnal 31 3.04 (190) 1.6 1.10 37.8 (10.0) 50.1 1.4 181 (37) 30.5 (748) 33.5 (822) 2.6 5.8 0.46 0.95 1.7 2.3 3.9 1.0 3,962 3,361 84.8 10.850 9,080 83.7 74.5 94.5 (25) Constant 23 3.03 (189) 1.3 0.83 56.7 (15.0) 60.0 1.0 156 (32) 19.1 (468) 20.9 (514) 2.0 4.1 0.74 0.77 3.8 4.0 4.8 0.6 5.122 4,008 78.4 1 1,583 9,078 78.4 71.5 113.5 (30) Diurnal 30 3.91 (244) 1.1 0.70 64.6 (17.1) 57.0 1.4 171 (35) 15.2 (561) 25.1 (617) 2.2 6.2 0.50 1.02 3.7 5.2 4.4 1.3 4.743 3.886 81.9 12,221 9.820 80.4 67.8 132.5 (35) Constant 31 4.07 (254) 0.94 0.62 69.2 (18.3) 52.3 1.5 161 (33) 26.7 (655) 29.3 (720) 1.5 4.9 0.61 1.23 4.4 4.5 6.1 1.3 4.028 3.436 85.3 10,487 8,695 82.9 72.4 ------- QJ -J • CO CQ •» I 1.4 1 3 1 2 1 1 1.0 0 9 0.8 07 0.6 0.5 04 0 3 02 0 1 0 Equation of Line Y = 0.902X + 0.006 0 0.1 0.2 0.3 0.4 05 0.6 0.7 08 0.9 1.0 1 1 12 1.3 14 F/M Ralio, mass BOD5 applied'/day/mass MLVSS Figure 1. BOD substrate removal rate versus F/M ratio. Kerwin R Rakness, at the time of this project, was with FMC Corporation, Engle- wood, CO 8O1 W; he is now with M&l Consulting Engineers, Fort Collins, CO 80525 Richard C. Brenner is the EPA Project Officer (see below) The complete report, entitled "Feasibility Study of Open Tank Oxygen-Activated Sludge Wastewater Treatment," (Order No. PB 81-213 274; Cost: $8.00, subject to change) will be available only from. 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