WATER POLLUTION CONTROL RESEARCH SERIES
12060EHV12/70
Aerobic Secondary Treatment
of
Potato Processing Wastes
ENVIRONMENTAL PROTECTION AGENCY • WATER QUALITY OFFICE
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WATER POLLUTION CONTROL RESEARCH SERIES
The Water Pollution Control Research Series describes the
results and progress in the control and abatement of pollu-
tion of our Nation's waters. They provide a central source
of information on the research, development, and demon-
stration activities of the Water Quality Office, Environ-
mental Protection Agency, through inhouse research and grants
and contracts with Federal, State, and local agencies, re-
search institutions, and industrial organizations.
Inquiries pertaining to the Water Pollution Control Research
Reports should be directed to the Head, Project Reports
System, Office of Research and Development, Water Quality
Office, Environmental Protection Agency, Washington, B.C. 20242.
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Aerobic Secondary Treatment
of
Potato Processing Wastes
by
The R. T. French Company
Shelley, Idaho
for the
ENVIRONMENTAL PROTECTION AGENCY
WATER QUALITY OFFICE
Program 12060 EHV
WPRD 15-01-68
December 1970
For sale by the Superintendent of Documents, U.S. Government Printing Office
Washington, B.C., 20402 - Price $1.50
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EPA Review Notice
This report has been reviewed by the Water Quality Office,
EPA, and approved for publication. Approval does not signi-
fy that the contents necessarily reflect the- views and poli-
cies of the Environmental Protection Agency, nor does mention
of trade names or commercial products constitute endorsement
or recommendation for use.
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ABSTRACT
A new secondary treatment facility at the R. T. French Company, Shelley, Idaho, has
demonstrated the feasibility of a complete mix activated sludge system for secondary
treatment of potato processing wastes. The secondary treatment facility was designed for
an average daily flow of 1.25 million gallons per day and a BOD loading of 14,100
pounds per day. Frequent aerator shutdowns following mechanical problems have limited
oxygen transfer and biological activity in the aeration basins; however, BOD removals of
over 90 percent have been obtained for extended periods of time, demonstrating the
applicability of the activated sludge process for treating the wastes. These removals have
been obtained with: (1) MLSS concentrations between 2,000 mg/1 and 8,000 mg/1, (2)
aeration basin D. O. concentrations between 0.3 mg/1 and 5.2 mg/1, (3) aeration basin
temperatures between 45 degrees F and 67 degrees F, (4) aeration basin pH between 7.1
and 8.4, (5) organic loadings between 10 and 120 Ib BOD/1,000 cu ft/day, (6) hydraulic
detention times of 0.9 to 8.7 days, and (7) BOD/MLVSS ratios of 0.15 to 0.47.
This report was submitted in fulfillment of Grant No. WPRD 15-01-68, Program 12060
EHV, between the Environmental Protection Agency and R. T. French Company.
Key Words: Potato processing wastes, food processing wastes, activated sludge,
secondary treatment, treatment costs.
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TABLE OF CONTENTS
SECTION
PAGE
ABSTRACT '
I SUMMARY '
II RECOMMENDATIONS 3
ill INTRODUCTION 4
IV TREATMENT METHODS
Activated Sludge Process 6
Solids Treatment and Disposal 6
V THEORETICAL CONSIDERATIONS 8
VI PLANT DESCRIPTION
Design Criteria ' 1
Flow Pattern 12
Design Factors 15
Demonstration Procedures 19
VII PLANT INFLUENT CHARACTERISTICS 23
VIII PLANT PERFORMANCE
Activated Sludge System 25
Solids Treatment and Handling 65
IX OPERATING PROBLEMS
Mechanical Problems 70
Process Problems 71
X FINANCIAL CONSIDERATIONS
Constmction Costs 73
Operation and Maintenance Costs 73
Total Annual Costs 74
XI DISCUSSION
Activated Sludge System 76
Solids Treatment and Disposal 105
Xll ACKNOWLEDGMENT 108
XIII REFERENCES 109
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TABLE OF CONTENTS - CONTINUED
SECTION PAGE
XIV APPENDIXES 111
A. Glossary
B. Photographs of Major Components
C. Supplemental Operating Data
D. Sampling Points, Sampling Schedule, and Testing
Equipment
E. Outside Laboratory Testing Reports
F. Construction, Operation, and Maintenance Costs
G. Supplemental Velocity Profiles, Dissolved Oxygen
Profiles, and Oxygen Uptake Data
H. Heat Loss Relationships
in
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LIST OF FIGURES
FIGURE PAGE
1 Aerial View Secondary Waste Treatment Facility 13
2 Flow Diagram Secondary Waste Treatment Facility I4
i ~> "*
j Aeration Basin Operation
4 Average BOD Loading vs. Time
5 Probability of Influent BOD 26
") H
6 Aeration Basin Dissolved Oxygen
^ Q
7 Dissolved Oxygen, Basin 1
OQ
8 Dissolved Oxygen, Basin 2
9 Basin Temp vs. Time
O 1
10 Temperature, Basin 1
11 Temperature, Basin 2 32
12 Basin pH vs. Time 34
13 pH, Basin 1 35
14 pH, Basin 2 36
15 Plant Influent and Effluent pH 37
16 SVI vs. Time 38
17 Influent and Effluent BOD 39
18 Average Organic Removals vs. Time 40
19 Average BOD Removal 41
20 Average BOD Removal vs. Average BOD Loadings 42
21 Average Effluent BOD vs. Average BOD Loading 43
22 Substrate Removal vs. BOD Loading 44
23 Effluent Soluble BOD 45
24 Average BOD Removal vs. Average BOD Loading 47
25 Basin Temperature vs. Coliform Removal 48
26 Average MLSS vs. Average Effluent TSS 49
27 Average Clarifier Loading vs. Average Effluent TSS 50
28 Average Effluent BOD vs. Average Effluent TSS 51
29 Average SVI vs. Average Effluent TSS 52
30 Total Phosphate Removal vs. Time 53
31 Total Nitrogen Removal vs. Time 54
32 Substrate and BOD Removal vs. BOD Loading 55
33 Substrate and BOD Removal vs. BOD Loading 56
34 Velocity Profile, Basin 1, 3 Aerators 58
35 Velocity Profile, Basin 1, 3 Aerators 59
36 Dissolved Oxygen Profile, Basin 2, 6 Aerators 60
IV
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LIST OF FIGURES - CONTINUED
FIGURE PAGE
37 Dissolved Oxygen Profile, Basin 1, 3 Aerators 61
38 Dissolved Oxygen Profile, Basin 1, 9 Aerators 62
39 Dissolved Oxygen Profile, Basin 1, 9 Aerators 63
40 Dissolved Oxygen Profile, Basin 1, 9 Aerators 64
41 Average TSS Removal vs. Time, Clarifier-Thickener 66
42 Average BOD Removal vs. Time, Clarifier-Thickener 67
43 Solids Concentration and Dewatering 68
44 Photomicrographs of Activated Sludge 77
45 Effluent Soluble BOD vs. Substrate Removal 78
46 Effluent Soluble BOD vs. Substrate Removal 79
47 Effluent Soluble BOD vs. Substrate Removal 80
48 Substrate Removal Rate vs. Temperature 81
49 Substrate Removal vs. Sludge Production 83
50 Substrate Removal vs. Sludge Production 84
51 Endogenous Respiration Rate vs. Temperature 85
52 Sludge Age vs. Sludge Production 87
53 Oxygen Uptake Rate vs. Substrate Removal Rate 88
54 Average BOD Removal vs. Average Basin D. O, 89
55 Average BOD Removal vs. Average Basin Temp 91
56 Average BOD Removal vs. Average Basin pH 92
57 Average BOD Removal vs. Average PO4/BOD 93
58 Average BOD Removal vs. Average N/BOD 94
59 Average Substrate Removal vs. Average D. O. 95
60 Average Substrate Removal vs. Average Basin Temp 96
61 Average Substrate Removal vs. Average pH 97
62 Substrate Removal vs. PO4/BOD 98
63 Substrate Removal vs. N/BOD 99
64 Plant Influent and Effluent Temperatures 100
65 Aeration Basin Heat Loss Relationship, 2 to 3.5 Days
Detention Time 102
66 Aeration Basin Heat Loss Relationship, 3.5 to 6.5 Days
Detention Time 103
67 Aeration Basin Heat Loss Coefficient vs. Detention Time 104
68 Secondary Clarifier Loading Factor vs. MLSS 106
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LIST OF TABLES
TABLE PAGE
1 Secondary Treatment Facility Design Criteria 11
2 Secondary Treatment Facility Design Factors 15
3 Major Equipment Manufacturer 18
4 Activated Sludge System Operation Schedule 20
5 Secondary Treatment Costs 74
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SECTION I
SUMMARY
During the 1969-70 potato processing season, aerobic secondary treatment of potato
processing wastewater at R. T. French Company was studied. These studies were partially
supported by an Environmental Protection Agency demonstration grant.
On the basis of the results presented in this report, the following conclusions have been
reached:
1. Treatment of potato processing wastewater by a fully aerobic aeration process,
specifically by the activated sludge process, is feasible.
2. BOD removals of over 90 percent have been obtained for sustained periods of time
while operating the plant as an activated sludge system.
3. BOD removals of between 70 and 80 percent have been obtained while operating as
a flow-through aeration system, without secondary clarification.
4. Coliform removals in excess of 96 percent were obtained in the activated sludge
system.
5. High pH values of influent process wastewater were buffered in the aeration basins
and were not detrimental to treatment efficiencies.
6. Low air temperatures have not caused failure of the activated sludge process. Data
obtained do, however, demonstrate the need to consider temperature loss in system
design.
7. The quantity of excess biological sludge, AXy, was found to be a function of the
BOD removal rate, Sf, and the average MLVSS (mixed liquor volatile suspended
solids), X^.
8. The substrate removal rate coefficient, k, was found to be a function of
temperature, as follows:
k = 0.016 x 1.
9. System oxygen requirements are a function of the BOD removal rate, Sr, and the
average MLVSS, X^, in accordance with the following equation:
02 = 0.48 Sr + 0.03 Xd
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10. Total annual activated sludge treatment costs are estimated to be $0.038 per pound
of BOD applied and $0.021 per pound of COD applied. These costs are for
secondary treatment only and do not include waste activated sludge disposal.
11. The clarifier-thickener approached 100 percent suspended solids removal when
operated as a straight silt removal system.
12. Operation of the clarifier-thickener for dewatering secondary sludge in combination
with silt was not successful.
13. Operation of the clarifier-thickener, vacuum filter, and solids conveying system has
demonstrated the need for special designs for handling silt removed from potatoes.
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SECTION II
RECOMMENDATIONS
It is recommended that future studies be initiated to determine feasible methods to
concentrate, dewater, and dispose of the large quantities of waste activated sludge from a
potato processing waste treatment facility. These studies should be concentrated on
methods which could produce an end product palatable for use as cattle feed.
Development of a system to mix and dewater silt and waste activated sludge effectively
would be beneficial to use as a standby for a cattle feed disposal system. Chemical
additions would probably be required to meet this objective.
Additional studies in the area of sludge bulking control are needed. Development of a
feasible control system would enhance the value of the highly efficient activated sludge
process in treating potato process wastewater and other similar industrial wastes.
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SECTION III
INTRODUCTION
SCOPE
Aerobic secondary treatment systems were studied at the R. T. French Company in
Shelley, Idaho, during the 1969-70 potato processing season to ascertain their efficiency
in treatment of potato processing wastes. These studies were conducted as an
Environmental Protection Agency demonstration grant project.
The objectives of the grant were to:
1. Demonstrate the feasibility of secondary treatment of potato processing wastewater
by a fully aerobic aeration process; specifically by the activated sludge system.
2. Determine the BOD removal efficiency and effluent characteristics when the system
is operated as:
a. An activated sludge system with biological sludge being returned to the
aeration basins to maintain a specific MLSS (mixed liquor suspended solids)
concentration.
b. A flow-through aeration system with biological sludge carry-over into the
effluent.
c. An intermittent aeration system with the clarified upper portion of the
aeration basin contents being discharged directly to the river.
3. Determine the quantity and characteristics of the excess biological sludge which
must be disposed of.
4. Demonstrate the effectiveness of solids removal through the clarifier-thickener and
disc filter handling system when operated:
a. As straight silt removal system.
b. With dewatering of secondary sludge in combination with silt.
c. With dewatering of secondary sludge alone.
5. Demonstrate and establish operating parameters for the systems constructed and
studied, which will include:
'This objective was to be pursued only if time permitted and it could be worked in
conveniently.
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a. Initial and construction costs.
b. Operating costs (power, chemicals, etc.).
c. Operation problems.
d. Treatment efficiency.
e. Maintenance problems and costs.
f. Silt and waste secondary sludge disposal problems and cost.
6. Determine the effect of this treatment on MPN and chlorine requirements of the
final effluent.
7. Establish the influence of: foaming, ice, climatic temperatures, pH, nitrogen,
phosphorus, and periodic flow interruptions and processing plant shutdowns upon
the treatment system.
Operation and cost data included in this report are for the secondary treatment facility
only. Primary treatment of the process wastewater is provided at the processing plant and
has not been evaluated in this study.
The R. T. French Company retained the firm of Cornell, Rowland, Hayes & Merryfield,
Consulting Engineers, to design the facility and to exercise technical supervision over the
research and development program.
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SECTION IV
TREATMENT METHODS
ACTIVATED SLUDGE PROCESS
The activated sludge process is a biological treatment process in which biologically active
growths (activated sludge) are continuously mixed in a basin with the wastewater in the
presence of oxygen. The combination of wastewater and activated sludge is called mixed
liquor. The oxygen is supplied to the mixed liquor from compressed air injected into the
liquid mass in the form of fine bubbles under turbulent conditions, or by mechanical
aeration. The activated sludge is subsequently separated from the mixed liquor by
sedimentation in a clarifier and is then wasted or returned to the aeration basin as
needed. The overflow from the clarifier (treated wastewater) is chlorinated and discharged
to a receiving stream.
There are many variations of the activated sludge process; however, all operate basically
the same. The variations are the result of unit arrangement and methods of introducing
air and wastewater into the aeration basin.
The most recent advances in the activated sludge process utilize a "complete mix"
approach when combining the activated sludge and wastewater. Biological stability and
the subsequent efficiency of the aeration basin is enhanced by the design which maintains
the entire content of the aeration chamber in a "completely mixed" and essentially
homogeneous state during the aeration cycle. Wastewater introduced into the aeration
basin is dispersed rapidly throughout the mass and is subjected to immediate attack by
fully-developed organisms throughout the aeration basin.
Complete-mix activated sludge treatment may or may not be preceded by primary
treatment. In general, large treatment facilities use primary treatment in conjunction with
the activated sludge process, while smaller treatment plants do not.
The R. T. French treatment facility is a complete-mix system, preceded by primary
treatment.
SOLIDS TREATMENT AND DISPOSAL
Unit processes currently employed in treatment and disposal of solids can be divided into
four categories: concentration, stabilization, dewatering, and dehydration disposal. The
R. T. French facility employs concentration, dewatering, and disposal methods as
described below:
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GRAVITY THICKENING-Gravity thickening is a concentration process in which solids
are gently stirred in a sedimentation tank to release entrapped water and gas, allowing
thickened solids to settle to a bottom hopper from which they are later removed.
VACUUM FILTRATION—Vacuum filtration is a dewatering process in which cylindrical
drums or discs, covered with filter media and partially submerged in a container of
sludge, rotate while a vacuum is pulled through the drum or disc surfaces and filter
media. Water is extracted while solids are retained on the filter media to form a cake.
LANDFILL—Landfill is an ultimate process for disposing of dehydrated solids. It is,
however, generally limited to reclaiming waste land.
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SECTION V
THEORETICAL CONSIDERATIONS
BIOLOGICAL CHARACTERISTICS OF ACTIVATED SLUDGE
MICROBIOLOGY-The living organisms of activated sludge can be classified as plants and
animals. The plants consist of bacteria and fungi, while the animals consist primarily of
protozoa, rotifers, and nematodes.
Hawkes [1] stated that bacteria are normally dominant as primary feeders on organic
wastes, with different holozoic protozoa being secondary feeders, and rotifers and
nematodes being at the higher levels in the food chain. Fungi cannot normally compete
with bacteria, but they may predominate as primary feeders if certain conditions exist,
such as: low pH, nitrogen deficiency, or low dissolved oxygen [2]. High-carbohydrate
wastes are also reported to stimulate fungi growth.
The composition of the organic waste determines which bacterial genera will predominate
[1,2]. Protein wastes favor Alcaligenes, Flavobacterium, and Bacillus, while carbohydrate
wastes favors Pseudomonas. A high population of free swimming bacteria will sustain free
swimming ciliata as the predominate protozoa; however, if the free swimming bacterial
population is reduced, stalked ciliJates take over from the free swimming cililates because
the lower food level cannot provide the amount of energy required by the free swimmers
Rotifers thrive in very stable systems and are better indicators of stable conditions than
are the nematodc worms.
Ml TABOLlSM-The metabolic reactions which occur within activated sludge can be
divided into three phases: (1) oxidation, (2) synthesis, and (3) endogenous respiration.
These three phase reactions can be illustrated with the following general equations, which
have been simplified from those formulated by Weston and Eckenfelder [3]:
(1) Organic Matter Oxidation
CxHyOz + a02 *xC02 + bH2O + Energy
(2) Cell Material Synthesis
CxHyOz + NH3 + cO2 + Energy ^CjH-yNO-, + dCO2 + eH->O
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(3) Cell Material Oxidation
C5H7NO2 + 5O2 *• 5CO2 + 2H2O + NH3 + Energy
In the presence of enzymes, produced by living microorganisms, about one-third of the
organic matter removed is oxidized to carbon dioxide and water to provide energy for
synthesis of the other two-thirds of the organic matter removed to cell material [4]. The
cell material is also oxidized to carbon dioxide, water, etc., by endogenous respiration
(auto-oxidation).
KINETICS—Several authors [5,6,7] have formulated mathematical equations for design
and operation of complete-mix activated sludge plants. Some of these formulations are
more easily used for evaluation of full-sized plant operation than others. Eckenfelder's
equations [6] are of this nature and have been used to evaluate the operation of the new
R. T. French Company waste treatment facility. The basic equations are presented below:
SUBSTRATE UTILIZATION-The Michaelis-Menton relationship was used to define the
microbial growth rate and steady state substrate removal in a completely mixed system,
and a simplified equation for substrate removal was developed:
Sa - Sf Sr
6 Xat Xat
where Sr = BOD removed, Ibs per day
Sa = influent BOD, Ibs per day
Sf = soluble effluent BOD, Ibs per day
Se = soluble effluent BOD, mg/1
Xa = average mixed liquor volatile suspended solids, Ib
t = aeration time, days
k = removal rate coefficient, Ib BOD/day-lb MLVSS-mg/1 BOD
The equation shows that the substrate removal is proportional to the product of the
MLVSS and the aeration time.
SLUDGE YIELD—Excess solids in the activated sludge system will result from the
non-biodegradable suspended solids in the influent and the biological cells synthesized in
the system during BOD removal less the quantity of cell mass synthesized which is
broken down by endogenous respiration. This excess sludge can be expressed with the
following equation, when influent non-volatile suspended solids do not exist or are
ignored:
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AXN = fS0 + aSr bXd
where A\v = net accumulation of volatile suspended solids, Ibs per day
f = fraction of volatile suspended solids present in the influent
which are not degradable
S0 = influent volatile suspended solids, Ibs per day
a = sludge synthesis yield coefficient
Sr = BOD removed, Ibs per day
b = rate of sludge endogenous respiration, per day
X^ = average mixed liquor volatile suspended solids which are
degradable, Ib
Where non-volatile suspended solids exist in the system influent, this quantity can be
added directly to the foregoing excess solids yield, AXy.
OXYGEN REQUIREMENTS-O.xygen is used to provide energy for synthesis of
biological cells and for endogenous respiration of the biological mass. The total oxygen
requirements can be expressed with the following equation:
02 = a' Sr + b' Xd
where O-> = oxygen requirements, Ibs per day
a1 = fraction of BOD removed that is oxidized for energy
Sr = BOD removed, Ibs per day
b - oxygen used for endogenous respiration of the biological mass, per
day
Xd = average mixed liquor volatile suspended solids that are degradable,
Ib
10
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SECTION VI
PLANT DESCRIPTION
Potato processing plant wastewater can be divided into two major streams: (1) silt water
and (2) process water. The silt water originates from raw potato washing and fluming
operations. It contains large amounts of soil removed from the raw potatoes. Process
water flows from potato processing operations, where raw potatoes are processed into
packaged, partially cooked food products. It contains caustic potato peeler and barrel
washer discharges, as well as all other liquid wasted from the processing operations,
including cleanup water.
DESIGN CRITERIA
The criteria used for the final design of the secondary treatment facilities at the R. T.
French Company are listed in Table 1.
TABLE 1
SECONDARY TREATMENT FACILITY DESIGN CRITERIA
AVERAGE DAILY FLOW
Waste Process Water
Waste Silt Water
TOTAL
1.0
0.25
1.25mgd
PEAK HOUR FLOW RATE
Waste Process Water
Waste Silt Water
TOTAL
836
400
1,236 gpm
BOD LOAD
Waste Process Water
Waste Silt Water
TOTAL
13,700
400
14,100 Ib/day
SUSPENDED SOLIDS LOAD
Waste Process Water
Waste Silt Water
TOTAL
5,680
940
6,620 Ib/day
11
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FLOW PATTERN
An aerial photo of the secondary waste treatment facility is shown on Figure 1, and the
treatment facility flow diagram is shown on Figure 2. A general description of the flow
patterns of the plant is given in the following paragraphs.
Primary clarified potato process wastewater flows by gravity to the influent pump pit
where it is combined with clarified silt water. This total plant influent is then pumped to
the aeration basin inlet-outlet structure, where the flow can be divided, as desired,
between the two aeration basins. The incoming wastewater is dispersed throughout each
of the aeration basins by floating mechanical aerators.
Effluent from the aeration basins flows by gravity back through the aeration basin
inlet-outlet structure to the clarifier bypass structure. The flow is normally directed to
the secondary clarifier, but in an emergency may be bypassed at the clarifier bypass
structure for discharge to the Snake River.
Effluent from the secondary clarifier flows to the Snake River.
Lightweight settled sludge flows by gravity from the bottom of the clarifier to the sludge
collection launder. It then flows by gravity from the sludge launder to the sludge
recirculation pump pit. The sludge is then pumped to the recirculated sludge splitter box,
where it can be divided into two portions of desired size and returned to the two
aeration basins.
Dense settled sludge is pumped from the sludge hopper in the bottom of the clarifier to
either the vacuum filter or to the clarifier-thickener. This waste sludge may also be
pumped to the clarifier bypass structure for discharge to the river.
The waste sludge, pumped to the clarifier-thickener, is concentrated along with silt water.
Clarifier-thickener overflow is transferred by gravity to the influent pump pit. The
thickened sludge is pumped from the bottom of the clarifier-thickener to the vacuum
filter, where it is dewatered along with any waste sludge pumped directly to the filter.
Solids discharge from the vacuum filter is conveyed to the silt bunker in a cake form.
This cake is then hauled away by trucks for ultimate disposal as landfill.
12
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FIGURE 1
AERIAL VIEW
SECONDARY WASTE
TREATMENT FACILITY
CLARIFIER-
THICKENER
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FLOW DIAGRAM
SECONDARY WASTE
TREATMENT FACILITY
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DESIGN FACTORS
The design factors used for major equipment selection are shown in Table 2. Photographs
of the major components are located in Appendix B and the major treatment units are
described below. Selected equipment manufacturers are listed in Table 3.
Aeration Basin 1 holds 1.25 million gallons and normally contains three 50-hp foating
mechanical aerators. Aeration Basin 2 holds 2.5 million gallons and normally utilizes six
50-hp floating mechanical aerators. Both basins have a water depth of 16 feet. The design
BOD loading is 28 lb/1,000 cu ft/day when the two aeration basins are operated in
parallel. The aeration basins are constructed of earth and were lined with PVC (polyvinyl
chloride). The bottom of the basins were sloped to prevent forming pockets for
entrapment of water or gas. A sun-resistant Hypalon plastic sheet was placed around the
perimeter of the basins to protect the PVC from exposure to sunlight. The Hypalon was
bonded to the PVC to provide a watertight field weld.
The secondary clarifier is 70 feet in diameter and has a 12-foot side water depth. The
clarifier has a rapid sludge withdrawal mechanism. The hydraulic overflow rate is 325
gal/sq ft/day at the design flow of 1.25 mgd.
The treatment facility control building houses the vacuum filter, sampling and testing
laboratory, and various sludge handling equipment. The vacuum filter is a disc type and
has a surface area of 300 square feet.
The clarifier-thickener is 30 feet in diameter and has a side water depth of 8 feet. The
hydraulic overflow rate at design flow is 860 gal/sq ft/day.
TABLE 2
SECONDARY TREATMENT FACILITY DESIGN FACTORS
INFLUENT PUMPS
Number 2
Type Centrifugal
Capacity
Each 1,300 gpm
Total 2,600 gpm
Total Head 27 feet
Constant Speed 870 rpm
15
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TABLE 2 CONTINUED
SLUDGE RECIRCULATION PUMPS
Number
Type
Capacity
Each
Total
Total Head
Constant Speed
WASTE SLUDGE PUMP
Number
Type
Capacity
Total Head
Speed
Drive
Centrifugal
435 gpm
870 gpm
18 feet
870 rpm
1
Positive displacement
100 gpm
46 feet
550 rpm
Variable - speed
AERATION BASINS
Number
Type
Volume of Basin 1
Volume of Basin 2
Basin Water Depths
Basin Side Slopes
Basin Freeboard
Basin Lining
Number of Aerators, Basin 1
Number of Aerators, Basin 2
Design Organic loading
AERATION EQUIPMENT
Number Aerators in Aeration Basins
Type
2
Earthen
1.25 million gallons
2.5 million gallons
16 feet
2:1
2 feet
PVC with Hypalon cover in
sun-exposed area
3
6
28 Ib BOD/1,000 cu ft/d
Floating pump type mechanical
surface aerators with variable
oxygen transfer-power draw feature
16
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TABLE 2 - CONTINUED
AERATION EQUIPMENT - Continued
Oxygen Transfer Capacity
SECONDARY CLARIFIER
Number
Diameter
Side Water Depth
Mechanism Type
Design Flow
Overflow Rate at Design Flow
Detention Time at Design Flow
CLARIFIER-THICKENER
Number
Diameter
Side Water Depth
Design Flow
Overflow Rate at Design Flow
VACUUM FILTER STATION
Vacuum Filter
Number
Type
Diameter
Number of Discs
Filter Area
Tank Volume
Hydraulic Capacity - Filtrate
Vacuum Pump
Number
Capacity
Speed
Vacuum
75 pounds per hour each in
aeration basins with mixed liquor
suspended solids = 4,000 mg/1,
operating elevation = 4,627 ft. above MSL,
temperature at 20 degrees C.,
Alpha = 0.85, Beta = 0.90, and
operating dissolved oxygen =1.5 mg/1
1
70 feet
12 feet
Multiple port hydraulic suction
1.25 million gallons/day
325 gal/sq ft/day
7.2 hours
1
30 feet
8 feet
425 gpm
860 gal/sq ft/day
1
Disc
6 feet
6
300 square feet
750 gallons
150 gpm
1
900 cfm
2,100 rpm
20 inches Hg
17
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TABLE 2 CONTINUED
VACUUM FILTER STATION - Continued
Filtrate Pump
Number 1
Capacity 150 gpm
Speed l,750rpm
Allowable Head 55 feet
Blower
Number *
Capacity 199 cfm
Speed l,750rpm
Discharge Pressure 5 psi
Screw Conveying System
Size of Screw 9 inches
Length 27 feet
Capacity 200 pounds per hour
Clarifier-Thickener Underflow Pump
Number 1
Type Diaphram
Capacity 50 gpm
Total Head 30 feet
Power Unit Variable drive
TABLE 3
MAJOR EQUIPMENT MANUFACTURER
EQUIPMENT ITEM MANUFACTURER
Influent pumps Cornell Manufacturing Co.
Sludge recirculation pumps Chicago Pump Co.
Waste sludge pumps Moyno Pumps
sample pumps Robbins & Meyers, Inc.
Clarifier-thickener underflow pump Marlow Pumps
Flowmeters Hersey-Sparling Meter Co.
Aerators Welles Products Corp.
Disc filter Eimco Corporation
clarifier-thickener mechanism
Secondary clarifier mechanism Dorr-Oliver, Inc.
18
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DEMONSTRATION PROCEDURES
During the test period, the secondary treatment facility received wastewater flow on a
schedule parallel with the operating schedule of the potato processing plant. The
processing plant operated almost continuously, except for a two-day shutdown on
weekends for cleanup and repairs. Cleaning water flow during processing shutdowns was
directed to the treatment facility.
Primary clarified process wastewater was directed to the secondary treatment facility by
adjusting slide gates in Manhole 1 (see Figure 2). The amount of process water discharged
to the facility was determined by the aeration basin operation. All process water entered
the facility during normal operation. Screened silt water was directed to the
clarifier-thickener by silt water pumps in the storage cellars.
Potato processing seasons are about nine to ten months long in Idaho.
OPERATION SCHEDULE—The secondary waste treatment facility was operated from 3
September 1969 through 6 June 1970. The activated sludge system was operated as
shown in Table 4.
AERATION BASIN STARTUP-Initial startup of the activated sludge system
included: (1) filling aeration basin 2 with wastewater, (2) aerating the wastewater
without additional influent until the D. O. rose above 0.5 mg/1, (3) directing increased
portions of the total plant influent to the aeration basin while maintaining the D. O.
above 0.5 mg/1, and (4) returning all of the secondary clarifier solids to the aeration basin
until the desired MLSS concentration was reached.
After initial plant startup, aeration basins have been restarted by transferring some or all
of the contents of the basin in operation into the basin being started. Influent wastewater
was then directed to the newly started basin in increasing proportions of the total plant
influent while maintaining a residual D. O. concentration over 0.5 mg/1. All of the
secondary clarifier solids were returned until the desired MLSS concentration was
attained.
The startup method used successfully during the latter part of the demonstration period
and during the current processing season includes the following steps:
1. Fill the basin with clean water.
2. Position and start aerators.
19
-------
TABLE 4
ACTIVATED SLUDGE SYSTEM
OPERATION SCHEDULE
OPERATION
PERIOD
SEPT. 3
TO
OCT. 22
OCT. 22
TO
NOV. 10
NOV. 10
TO
DEC. 18
DEC. 18
TO
JAN. 12
JAN. 12
TO
FEB. 12
FEB. 12
TO
APR. 13
APR. 13
TO
MAY 27
MAY 27
1 U
JUNE 6
BASIN
NO.
2
1
2
1
2
1
2
2
1
2
1
2
METHOD
OF
OPERATION
R.S.<2>
R.S.
R.S.
R.S.
R.S.
R.S.
FT. <3>
R.S.
R.S.
R.S.
F.T.
R.S.
% OF
INFLOW
100
20
80
33
67
20
80
100
100
100
22.5
77.5
AVERAGE
FLOW
(MGD)
0.530
0.241
0.967
0.341
0.694
0.207
0.829
0.717
1.144
1.071
0.197
0.681
AVERAGE
DETENTION
TIME (DAYS)
4.71
5.18
2.58
3.66
3.60
6.03
3.01
3.48
1.09
2.33
6.34
3.67
LENGTH
OF
OPERATION
(DAYS)
50
19
36
25
31
60
45
9
MLSS<1>
OPERATING
RANGE (MG/L)
930-3600
66-6280
1830-6130
2350-5140
1830-6450
1430-3360
1350-4050
245-3270
455-9400
1450-7100
450-2750
1100-3600
BASIN TEMP.
OPERATING
RANGE
(°F)
46-67
50-68
55-67
45-63
45-61
42-50
49-58
43-60
45-65
50-70
50-60
60-68
to
O
NOTES:
(11 MIXED LIQUOR SUSPENDED SOLIDS
(2) RETURN SLUDGE AERATION
(3) FLOW THROUGH AERATION
-------
3. Build up a D. O. of about 5 mg/1 in the basin.
4. Start feeding wastewater to the basin at increasing flow rates as the MLSS
concentration increases. Keep the F:M ratio (pounds of BOD per day to the pounds
of mixed liquor volatile suspended solids in the basin) between 0.1 and 0.5 in
accordance with Figure 3.
5. Keep the D. O. level above 1.0 mg/1 at all times, preferably in the range of 1.5 to
3.0 mg/1.
6. Return all secondary clarifier solids to the aeration basin until the desired MLSS
level is reached.
Future processing plant annual startups will be by stages, permitting treatment of the
entire wastewater flow by the secondary treatment facility.
SAMPLING SCHEDULE AND PROCEDURE-Sample points are shown on Figure 2 and
are described in detail in Appendix D. Waste activated sludge and vacuum filter filtrate
analyses were made on grab samples. Samples were collected at all other sample points
with sample pumps and automatically controlled stock samplers to give 24-hour
composite samples, proportional to flow.
The sampling and testing schedule used during the demonstration operation is located in
Appendix D.
ANALYTICAL TECHNIQUES-Analytical tests were performed in accordance with the
twelfth edition (1965) of Standard Methods for the Examination of Water and
Wastewater of the American Public Health Association, with the following exception:
Suspended Solids—Suspended solids tests were performed using GF/C glass-fiber filter
discs instead of asbestos mats. A list of the laboratory equipment used in the analytical
testing is included in Appendix D.
21
-------
I J
I J
4.000
INFLUENT BOD LOAD TO AERATION BASIN 1 (LBS./DAY)
8,000 12,000 16,000 20.000
5.000
o 4,000 .
CO
Q
o
CO
a
LLJ
Q
O_
co
CO
<
_l
o
cr
O
O
3,000 .
2.000
1,000 .
OPERATION NOT
RECOMMENDED
IN THIS RANGE
RECOMMENDED;
OPERATING i
RANGE
8,000
OPERATION NOT
RECOMMENDED
IN THIS RANGE
16,000 24,000 32000 40,000
INFLUENT BOD LOAD TO AERATION BASIN 2 (LBS./DAY)
FIGURE 3
24,000
28.000
48,000
56,000
AERATION BASIN OPERATION
-------
SECTION VII
PLANT INFLUENT CHARACTERISTICS
Total secondary treatment plant influent contains primary clarified process water and
clarified silt water. Characteristics of the total plant influent are described below, and
daily variations and probability plots of the characteristics are located in Appendix C.
ALKALINITY, pH, AND TEMPERATURE-Total plant influent alkalinity varied from 70
mg/1 to 5,740 mg/1, with an average of 1,640 mg/1, as CaCC^. The pH varied from 6.8 to
11.5, and averaged 9.3. The influent temperature varied from 12 degrees C to 24 degrees
C. The average temperature was 20 degrees C.
BOD AND COD-The BOD of the total plant influent varied from 780 mg/1 to 3,210
mg/1. The average BOD was 1,680 mg/1. Sixty-five to 70 percent of the total influent
BOD was in a soluble form. The total BOD loading varied from 385 Ibs/day to 33,000
Ibs/day, with an average of 14,500 Ibs/day. Figure 4 shows the average weekly BOD load
variation and the general tread of increased load (first order curve, least squares fit) as
the processing season progressed. The COD (chemical oxygen demand) of the influent
varied from 1,330 mg/1 to 7,100 mg/1, with an average of 3,050 mg/1. The average
influent BOD:COD ratio was 0.55.
SUSPENDED SOLIDS-The TSS (total suspended solids) concentration in the total plant
influent varied from 320 mg/1 to 6,460 mg/1. The average TSS was 1,480 rng/1. VSS
(volatile suspended solids) averaged 70 percent of the TSS.
NUTRIENTS-The BOD:nitrogen:phosphate ratio of the plant influent varied from
100:4.4:0.6 to 100:10.1:2.4 and averaged 100:6.2:1.1.
FLOW—The total plant influent flow varied from 0.03 mgd to 1.64 mgd and averaged
0.95 mgd.
23
-------
cc
o
CD
cr
o
CD
UJ
cr
a:
erg
ID
SEPT. 1
OCT. 1
NOV. 1
DEC. 1
JAN. 1
FEB. 1
MAR. 1
1969
TIME
1 1
APRIL 1 MAY 1
1970
I
JUNE 1
JULY 1
FIGURE 4
AVERAGE BOD LOADING VS. TIME
(ALL DATA)
-------
SECTION VIH
PLANT PERFORMANCE
ACTIVATED SLUDGE SYSTEM
SYSTEM OPERATION—Numerous mechanical problems hindered plant performance;
however, four months of effective operation has been achieved. The operating data from
these four months of experience have been analyzed in greater detail than the data for
the other five months of demonstration operation.
Figure 5 is a computer plot of the best fit curve of the frequency distribution of BOD
loading to the activated sludge system on arithmetic-probability paper. The probability
shown on this and following similar figures is the percentage of measurements equal to,
or less than, the stated class mean of the measured item, with all available data being
used. Figure 5 shows that about 45 percent of the time the BOD loading to the activated
sludge system was equal to, or less than, the plant design load of 14,100 Ibs BOD/day or
55 percent of the time, the BOD loading was equal to, or greater than, the design load.
Actual loadings exceed the design criteria because of a delay in the construction of the
facility and an expansion of the processing plant. However, design safety factors permit
the present treatment plant to handle the existing volume of processing wastes; although
further expansion of the processing plant capacity could require expansion of treatment
facilities.
Aeration basin dissolved oxygen levels are shown on Figure 6. Figure 7 shows that about
40 percent of the time the D. O. (dissolved oxygen) in Basin 1 was less than 1.0 mg/1,
which is often thought to be a minimum level to avoid limiting biological activity. Basin
2 operated at a similar level for over 25 percent of the time (Figure 8). Low basin D. O.
levels were associated with mechanical aerator problems. At the top of Figure 6 and
subsequent plots with time functions, R. S. means return sludge operation and F. T.
means flow-through operation. The percentages represent the portion of influent to each
basin.
The temperature variations in the aeration basins are shown on Figure 9, while Figure 10
shows that about 20 percent of the time, Basin 1 temperature was equal to, or below, 50
degrees F (10 degrees C), which is reported to be low enough for filamentous bacteria to
become competitive. Basin 2 had similar low temperatures 10 percent of the time (Figure
11). Low basin temperatures occurred at long aeration times and low air temperatures.
Basin temperatures also dropped during weekend shutdowns when warm process water
discharges to the treatment facility were decreased or discontinued.
25
-------
PROBABILITY (% EQUAL TO OR LESS THAN)
CD
CD
00
f~i
o
OS9S3
csets
SSR83
i.esoe
J CD
-3 . ^pou)*-cno)-ja)(DCD CD •
-------
BASIN 2
R.S. *~
BASIN 1
20%
BASIN 2
80%
3OTH R.S.
BASIN 1-33%
BASIN 2-67%
BOTH R.S.
BASIN 1
20% R.S.
BASIN 2
80% R.S.
BASIN 1
DOWN
* BASIN 2 *"
R.S,
BASIN 1 R.S.
* BASIN 2 DOWN *~
BASIN 1 DOWN
|" BASIN 2 R.S. *~
BASIN 1
F.T.
BASIN 2
DOWN
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM
UPSET
BULKING
DUE TO
LOW D.O.
X
o
o
•5'
o
(O
(O
KEY
BASIN 1 »
BABIH 2 X
S^PT.
OCT. 1 NOV. 1
1969
DEC. 1
JAN. 1 FEB. 1
TIME
MAR. 1
APRIL 1 MAY 1
1970
JUNE 1
JULY 1
FIGURE 6
AERATION BASIN DISSOLVED OXYGEN
(ALL DATA)
-------
99.99
99.9
to
to
ui
DC
o
o
O
LU
m
O
a:
o.
99
95
O.I
0.01
DISSOLVED OXYGEN-BASIN 1 (MG/L)
FIGURE 7
PROBABILITY OF DISSOLVED OXYGEN - BASIN 1
-------
ay .yy
QQ Q
AA
QQ
< on
i
1-
W
_J
DC
O7n
o
H so
3 50
O
m 40
£
x_ qn
> 30
_i
mon
<
CO
0
DC
Q. in
C
¥
ht,
Jt
s
) C
a
i •-
4
X
> •-
? E
X
* »•
• *
i a
4
r
i
/
• i-
- a
•a o
<
I
/
• *.
» •-
i>
^
t X
^"
J ^
Q
J •-
)
X
» ^
i a
Q
>
i
( ^
3 (j
0 i-
n ci
i) C
a
9 (1
^^^i
t t
i a
a -
^^
a <
S J
X)
>. «
i 0
- Cl
x
S )
>• •»
n a
n a
^
0
So
0
X
^^ <
1 Cl
i :
X
q
*'
n a
3 2
X
*
i!
1 0
y iv
c
X
D a
3 Q
n o
x
^
l> Ol
1 U
3 OJ
DISSOLVED OXYGEN - BASIN 2 (MG/L)
FIGURE 8
PROBABILITY OF DISSOLVED OXYGEN - BASIN 2
29
-------
BASIN 2
R.S. "~
BASIN 1
20%
BASIN 2
80%
BOTH R.S.
BASIN 1-33%
BASIN 2-67%
BOTH R.S.
BASIN 1
20% BS.
"* BASIN 2
80% R.S.
BASIN 1
DOWN
~" BASIN 2
R.S,
BASIN 1 R.S.
J BASIN 2 DOWN *
BASIN 1 DOWN
* BASIN 2 R.S.
BASIN 1
FT.
BASIN 2
DOWN
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM
UPSET
BULKING
DUE TO
LOW D.O.
o_
z:
LJ
03
KCT
BASIN 1 »
MtBIN 8 X
S?PT.
OCT. 1
NOV. 1
DEC. 1
1969
JAN. 1 FEB. 1
TIME
MAR. 1
APRIL 1 MAY 1
1970
JUNE 1
JULY 1
FIGURE 9
BASIN TEMP. VS. TIME
(ALL DATA)
-------
yy
In
QO
on
Cfl
A. n
an
on
1U
2
• 1
rti
fv
a
X
> it
> C.
^
) Cl
? r»
xl
i a
> v* o
• jt.
'
» -
n a
s,
1 0
9 »•
jt
/,
3 C
»
^ i
3 J
h V
x
r \
t
t
\
n c
o
J C
/
r ^
\
n a
a i
3 C
S
r «
4
r
n c
^ 0
a c
^
/
; 3
n c
n c
i> t
/
3
r
I I
3 ft
r )
n c.
o c
3 «
J
X^
3 S
n a
X
s ?
a >•
t
, X
Sr
n c
9 (1
- 4
i
*
X
s ?
1. V
^
^
y
! 8
4 e
X
? *
3 U
TEMPERATURE BASIN 1 (°F)
FIGURE 10
PROBABILITY OF TEMPERATURE - BASIN 1
31
-------
»•»»
QQ a
99
96
yu
Cn
A ft
^fi
on
i n
i •
0. I
0.01
0
i r
X
» V
/
/
j a
^
/
> c
X
n o
3 >-
''
! ?
X
1 0
) *
X
1 '
/
'
u °
fl •-
/
J
1 ) T
> U
^
) 1
> a
,>
^1
•> a
i a
X
1 -J
) a
•
X
> a
> (c
O)
-------
Aeration basin pH variations are shown on Figure 12. Figure 13 shows that about 35
percent of the time, the pH of Basin 1 was equal to, or above, 8.0, which is normally
considered the top of the normal operating range for an activated sludge system. This
occurred in Basin 2 about 25 percent of the time (Figure 14), but neither basin appeared
to be directly affected by the high pH.
CC>2 production in the aeration basins during organic material breakdown buffered the
high alkalinity in the influent and resulted in a pH drop. This is illustrated on Figure 15.
The average influent pH was 9.3 and the average effluent pH was 7.8. Many of the high
basin pH levels were associated with low values of organic removal, which were caused by
mechanical aerator problems.
The aeration basin SVI (sludge volume index) variations are shown on Figure 16. SVI
levels above 200 correspond to sludge bulking and corresponding reduced process
efficiencies.
Influent and effluent BOD variations are shown on Figure 17. Figure 18 shows that
weekly average BOD and COD reductions decreased during periods of sludge bulking.
Sludge bulking was associated with mechanical aerator failures, which lowered the
available D. O. in the aeration basins below desirable levels.
Figure 19 shows that the BOD removal was 82 percent, or greater, 50 percent of the
time. The average BOD removal for the entire demonstration period was 80 percent, even
though numerous mechanical problems limited operating efficiency much of the time.
Analysis of three periods of effective operation, two about one month long each, and one
about two months long, with the plant operating as a return sludge activated sludge
system, has provided several operating relationships. These relationships are described
hereinafter and are based on weekly average data unless noted otherwise. The three
periods of optimum operation, analyzed in detail, were: 14 September - 4 October, 23
November - 20 December, and 1 March 22 April. The referenced figures include
least-square curves fitted to the plotted data by computer. Figures without average data
reference are plotted from available daily data.
The effect of average BOD loading (Ib BOD/lb MLVSS/day) on percentage of BOD
removal is shown on Figure 20. Figure 21 shows the effect of this same BOD loading on
effluent BOD concentration. As the BOD loading increased, the effluent BOD appeared
to increase, while the BOD removal remained above 94 percent. Figure 22 shows
substrate removal [(influent BOD-effluent soluble BOD)/influent BOD] versus BOD
loading for all data. Substrate removal was above 90 percent during the entire
demonstration period, including sludge bulking periods, and effluent soluble BOD
remained below 125 mg/1 (Figure 23).
33
-------
BASIN 2
US. *~
BASIN 1
20%
BASIN 2
80%
JOTH H.S.
BASIN 1-33%
BASIN 2-67%
BOTH R.S.
BASIN 1
20% ns.
* BASIN 2
80% R.S.
BASIN 1
DOWN
* BASIN 2 *
RS.
BASIN 1 R.S.
* BASIN 2 DOWN *
BASIN 1 DOWN
"* BASIN 2 R.S. *~
BASIN 1
F.T.
BASIN 2
DOWN
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM
UPSET
BULKING
DUE TO
LOW D.O.
KEY
BASIN 1 *
M81N 8 X
. i
OCT. 1
NOV. 1
DEC. 1
1969
JAN. 1 FEB. 1 MAR. 1
TIME
APRIL 1 MAY 1
1970
JUNE 1
JULY 1
FIGURE 12
BASIN pH VS. TIME
(ALL DATA)
-------
99.9
99
95
^ 90
ui
DC *^0
O
O 60
v >
5S
30
_J 20
m
CQ
g 10
CL
O.t
O.D:
• at 6> o c» to
<7> -J ~J Ut CO 25 <3 a Q •- "'!O IV} Ctf CO «» *- VI
en en
PH BASIN 1
FIGURE 13
PROBABILITY OF pH BASIN 1
35
-------
QO -WW
99
9o
90
OU
>-
*"" sn
i— • Oil
_l
•— • i «=n
m 50
mvn
o
a: 30
Q_ 3°
on
% n
>
)
O.i
0.01
C
^
t
r> G
? *
/
i>
y
^
j
^
X
4
S
J
•
^
J
^^^ ^
^ 4
J
^r \
4
I/
J
y
4
j
/
4
/>
/
4
^
^ ^
4
/
4 0
•
X
1) 0
>/)
8 0
•
•
'
0 0
1
X
a a
•
—
1
i>
h ^
a a
pH - BASIN 2
FIGURE 14
PROBABILITY OF pH BASIN 2
36
-------
BASIN 2
R.S.
BASIN 1
20%
BASIN 2
80%
3OTH R.S.
BASIN 1-33%
BASIN 2-67%
BOTH R.S.
BASIN 1
20% R.S.
BASIN 1
80% R.S.
BASIN 1
DOWN
^ BASIN 2 *"
R.S,
BASIN 1 R.S.
BASIN 2 DOWN *"
BASIN 1 DOWN
BASIN 2 R.S.
BASIN 1
F.T.
BASIN 2
DOWN
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM
UPSET
BULKING
DUE TO
LOW D.O.
KEY
INFLUENT +
EFFLUENT X
SJEPT. 1
OCT. 1 NOV. 1
1969
DEC. 1
JAN. 1 FEB. 1
TIME
MAR. 1
APRIL 1 MAY 1
1970
JUNE 1
JULY 1
FIGURE 15
PLANT INFLUENT AND EFFLUENT PH
(ALL DATA)
-------
BASIN 2
R.S. *"
BASIN 1
20%
BASIN 2
80%
BASIN 1-33%
BASIN 2-67%
BASIN 1
20% R.S.
BASIN 2
80% RS.
BOTH R.S. BOTH R.S.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
BASIN 1
DOWN
"" BASIN 2 *"
R.S.
BASIN 1 R.S.
* BASIN 2 DOWN *
BASIN 1 DOWN
* BASIN 2 R.S.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM
UPSET
BULKING
DUE TO
BASIN 1
F.T.
BASIN 2
DOWN
LOW D.O.
KEY
M8IN 1 »
BASIN 8 X
ui
oo
>o
(Of-
§.
sBr. i
OCT. i
NOV. 1
DEC. 1
1969
JAN. 1 FEB. 1 MAR. 1 APRIL 1 MAY 1 JUNE 1 JULY 1
TIME 1970
FIGURE 16
SVI VS TIME
(ALL DATA)
-------
BASIN 2
R.S. *
BASIN 1
20%
BASIN 2
80%
3OTH R.S.
BASIN 1-33%
BASIN 2-67%
BOTH R.S.
BASIN 1
20% R.S.
BASIN 2
80% R.S.
BASIN 1
DOWN
~" BASIN 2 *~
R.S,
BASIN 1 R.S.
* BASIN 2 DOWN *
BASIN 1 DOWN
* BASIN 2 R.S. *~
BASIN 1
F.T.
BASIN 2
DOWN
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM
UPSET
BULKING
DUE TO
LOW D.O.
vo
HPT. 1
OCT. 1
NOV. 1
DEC. 1
JAN. 1
FEB. 1
MAR. 1
1969
TIME
APRIL 1 MAY 1
1970
JUNE 1
JULY 1
FIGURE 17
INFLUENT AND EFFLUENT BOD
(ALL DATA)
-------
BASIN 2
" R.S. *
BASIN 1
n, *>* ^
BASIN 2
80%
BASIN 1-33%
BASIN 2-67%
BASIN 1
20% R.S.
* BASIN 2
80% R.S.
BASIN 1
DOWN
* BASIN 2 *~
R5,
BASIN 1 R.S.
BASIN 2 DOWN
BASIN 1 DOWN
" BASIN 2 R.S.
BOTH R.S. BOTH R.S.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM
UPSET
BULKING
DUE TO
BASIN 1
FT.
BASIN 2
DOWN
LOW D.O.
CO
_i
0.
UJ
o
UJ
o
cc
QC
UJ
S?PT. 1
OCT. 1
NOV. 1
DEC. 1
1969
JAN. 1 FEB. 1
TIME
MAR. 1
APRIL 1 MAY 1
1970
JUNE 1
JULY 1
FIGURE 18
AVERAGE ORGANIC REMOVALS VS TIME
(ALL DATA)
-------
99.9
99
95
90
80
70
60
50
40
30
20
10
S
1
0.1
3 01
X
_x*
^"
X^
X^
X
p
x^
jXl
x^
x3
1
X
t
X
\^^^^
4
^
»<*
9^
X)
^
J
X
*
x^
"*"** f* * 01 (II C/l 05 0) -3 ^J -J 00 CD CD O> (0 CD U
AVERAGE BOD REMOVAL (%)
FIGURE 19
PROBABILITY OF AVERAGE BOD REMOVAL
41
-------
K)
cr
o
z:
UJ
cc
o
o
m
UJ
cr
O£
3
0.0
°'flVERflGE BOD LOflDINO (LB BOO/LB MLVSS/OflY)
0.8
FIGURE 20
AVERAGE BOD REMOVAL VS. AVERAGE BOD LOADINGS
SELECTED DATA
-------
a
a _
w
a
o
to'
I—
z
UJ
23
_l
u.
u.«
UJc
-------
o
o
/•^ 10
^^
_J
cr
o
UJ
t—
GC
ce
t—
-------
BASIN 2
* R.S. *
BASIN 1
^ 20% f
BASIN 2
80%
BASIN 1-33%
BASIN 2-67%
BASIN 1
20% R.S.
BASIN 2
80% R.S.
BASIN 1
DOWN
** BASIN' 2 *
R.S,
BASIN 1 R.S.
* BASIN 2 DOWN *
BASIN 1 DOWN
BASIN 2 R.S.
BASIN 1
FT.
BASIN 2
DOWN
BOTH R.S. BOTH R.S,
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM
UPSET
BULKING
DUE TO
LOW D.O.
o
8
00
UJ
_I
00
tn-
S?PT. 1
OCT. 1 NOV. 1
1969
DEC. 1
JAN. 1 FEB. 1
TIME
MAR. 1
APRIL 1 MAY 1
1970
JUNE 1
JULY 1
FIGURE 23
EFFLUENT SOLUBLE BOD
(ALL DATA)
-------
Figure 24 shows the effect of BOD loading as Ib BOD/1,000 cu ft/day on BOD removal.
As the BOD loading increased, the BOD removal appeared to decrease slightly. MLVSS
concentrations are not considered in this relationship.
Increased coliform bacteria reduction was achieved through the activated sludge system
with increased basin liquor temperature (Figure 25). Results show that the system is
capable of significant coliform count reduction. Effluent coliform concentrations averaged
3.9 x 107 per ml.
Figures 26 and 27 are related to secondary clarifier operation. Increased MLSS levels,
with corresponding higher solids loading to the secondary clarifier, normally resulted in
increased effluent suspended solids levels. Both figures have second-order curves.
Figure 28 shows that better secondary clarification would have reduced the effluent
BOD. During periods of effective operation, SVI variations between 100 and 200 did not
affect the effluent suspended solids (Figure 29).
Total phosphate and total nitrogen removal variations with time are shown on Figures 30
and 31. Decreased removal efficiencies coincide with periods of sludge bulking and loss of
bacterial cells in the secondary clarifier effluent.
Figures 32 and 33 show BOD removal and substrate removal (soluable BOD) versus BOD
loadings while Basin 1 was operated as a flow-through aeration basin without secondary
clarification. The difference in the two removal curves on each figure represents the BOD
of the suspended solids in the basin effluent.
Limited chlorine breakpoint testing of the plant effluent provided a breakpoint range
from 14 to 18 mg/1 and an average of 15 mg/1.
The average effluent characteristics during effective activated sludge treatment are listed
below:
pH = 8.0
Temperature = 16.4 degrees C.
Suspended Solids = 160 mg/1
COD = 380 mg/1
BOD = 85 mg/1
Soluble BOD = 40 mg/1
Chlorine Breakpoint = 15 mg/1
Additional effluent relationships are located in Appendix C.
46
-------
2=
LU
o
o
CD
LU
o
a:
a:
S
20 40 60 80
flVERfl&E BOD LORDING (LB/1000 CF/DflY)
too
120
FIGURE 24
AVERAGE &UU REMOVAL VS AVERAGE BOD LOADING
SELECTED DATA
-------
o
o
to
to
—'10
CC w
cc
n
oc
CM
a
x x
64
56
59
60 62 64
BflSIH TEflPERflTURE (F)
66
FIGURE 25
BASIN TEMPERATURE VS COLIFORM REMOVAL
(ALL DATA)
-------
o
p.,
O
r:
UJ
Ci>
C£
o:
UJ
CM
50
100 150 200
RVERfl&E EFFLUENT TSS
250
300
350
400
FIGURE 26
AVERAGE MLSS VS AVERAGE EFFLUENT TSS
SELECTED DATA
-------
T
50
100 150 200
AVERAGE EFFLUENT TSS I1&/L)
250
300
360
FIGURE 27
AVERAGE CLARIFIER LOADING VS. AVERAGE EFFLUENT TSS
(SELECTED DATA)
-------
o
o
CM
O
«D
CD
Z
UJ
UJ
o
a:
a:
UJ
50
100 150 200 250
flVERfl&E EFFLUENT TS3 (M&/U
300
350
400
FIGURE 28
AVERAGE EFFLUENT BOD VS. AVERAGE EFFLUENT TSS
(SELECTED DATA)
-------
o
o
o
u>
CM
O
a
CM
CO
a:
oz.
HJ
>
CL
o
o
o
in
—i—
50
—i 1 1 1
100 150 200 250
HVERH&E EFFLUENT TSS IM&/LJ
300
350
400
FIGURE 29
AVERAGE SVI VS. AVERAGE EFFLUENT TSS
(SELECTED DATA)
-------
BASIN 2
R.S. *"
BASIN 1
20%
B
ASIN 2
80%
BASIN 1-33%
BASIN 2-67%
BASIN 1
20% R.S.
BASIN 2
80% R.S.
BASIN 1
DOWN
"" BASIN 2 *"
R.S,
BASIN 1 R.S.
* BASIN 2 DOWN *~
BASIN 1 DOWN
BASIN 2 R.S.
BASIN 1
FT.
BASIN 2
DOWN
BOTH R.S. BOTH R.S.
SYSTEM
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
UPSET
BULKING
DUE TO
LOW D.O.
<
O
S?PT. 1
OCT. 1 NOV. 1
1969
DEC. 1
JAN. 1 FEB. 1
TIME
MAR. 1
APRIL 1 MAY 1
1970
JUNE 1
JULY 1
FIGURE 30
TOTAL PHOSPHATE REMOVAL VS. TIME
(ALL DATA)
-------
BASIN 2
R.S
BASIN 1
-. 20% .
BASIN 2
80%
BASIN 1-33%
BASIN 2-67%
BASIN 1
20% R.S.
BASIN 2
80% R.S.
BOTH R.S. BOTH R.S.
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
BASIN 1
DOWN
"* BASIN 2 ""*
R.S,
BASIN 1 R.S.
"* BASIN 2 DOWN *
SYSTEM UPSET
BULKING DUE
TO LOW D.O.
BASIN 1 DOWN
BASIN 2 R.S.
SYSTEM
UPSET
BULKING
DUE TO
BASIN 1
F T
BASIN 2
DOWN
LOW D.O.
o
IE
LLJ_
OS
o
oc
o
•-s
NO DATA COLLECTED DURING THIS PERIOD OF TIME
S?PT.
OCT. 1 NOV. 1
1969
DEC. 1
JAN. 1 FEB. 1
TIME
MAR. 1
APRIL 1
MAY 1
JUNE 1
JULY 1
1970
FIGURE 31
NITROGEN REMOVAL VS. TIME
(ALL DATA)
-------
SUBSTRATE
g-
Oo,
Q
O
CO
cc
CO
CO
Z>
CO
BOD
o
10
3.000
0.090 3.150 0.240 0.920 0.400
BOO LOflDINO (LB BOO/LB MLVSS/OflY)
0.480
FIGURE 32
SUBSTRATE AND BOD REMOVAL VS. BOD LOADING
FLOW-THROUGH DATA
-------
o _
o
at
Q
O
CO
Q
2
< ?
LU
CO
D
CO o
to
a
10
SUBSTRATE
•BOD
49 12 16 20
BOO LOflOINO (LB BOO/1000 C.F./OflY)
24
FIGURE 33
SUBSTRATE AND BOD REMOVAL VS. BOD LOADING
(FLOW - THROUGH DATA)
-------
VELOCITY PROFILES-Velocity measurements were made in the aeration basins with
three different aerator arrangements. An example of velocity profiles obtained is shown
in plan view on Figure 34 and in section on Figure 35. Additional velocity profile plots
are located in Appendix G.
Measurements were made from a raft with a propeller type current meter and counter
made by A. Ott. The velocity profile is meaningful for evaluating possible minimum or
maximum velocities in the given areas of the basins during operation. Each of the
aerators has a nameplate horsepower of 50 and an impeller pumping rate of 23,500
gallons per minute at a power draw of 67 amperes. The aerator power use during the
testing is provided on the figures. Some minor scour was noted in the high velocity and
turbulence areas at the ends and sides of Aeration Basin 1 after about two months of
operation without a plastic liner. The scour was 6 to 8 inches deep and was located
primarily in the wave action zone.
DISSOLVED OXYGEN PROFILES-Dissolved oxygen measurements were taken in the
aeration basins at various depths with four different aerator location configurations. The
dissolved oxygen readings were obtained with a YSI field probe and meter from a raft.
Figures 36 through 39 show dissolved oxygen profiles for the basins with power loadings
from about 90 to 245 hp per million gallons of aeration basin mixed liquor. Dissolved
oxygen profiles, at 2-foot and 6-foot depths of Basin 1 with 9 aerators, are shown on
Figures 38 and 39, respectively. A section profile taken through these plan profiles is
included as Figure 40. Other dissolved oxygen profiles are located in Appendix G. The
power use for each aerator is given on the figures.
The dissolved oxygen distribution shown on Figures 38 through 40 was fairly uniform.
Having one of nine aerators out of operation does not appear to have affected the
dissolved oxygen distribution in the basin at the time of the measurements. If the aerator
out of operation had been at the end of the basin, the effect might have been more
noticeable.
OXYGEN UPTAKE RATES—Oxygen uptake studies were conducted on grab samples of
aeration basin mixed liquor. The oxygen uptake tests were conducted by placing the
sample in a BOD bottle, mixing with a magnetic stirrer, and using a YSI BOD bottle
probe. Dissolved oxygen values obtained during the first 60 seconds and below 1.0 mg/1
were discounted in determing the slope of the oxygen uptake plot. Plots of dissolved
oxygen depletion with time are included in Appendix G. The oxygen uptake rates varied
from 0.06 to 0.26 mg ©2 per day per mg MLVSS with corresponding temperatures of
11.3 and 15.5 degrees C. These uptake rates are described in more detail in Section 11.
57
-------
4 JUNE 1970
x VELOCITY READINGS
IN FEET PER SECOND
AERATOR NOT IN OPERATION
PROFILE AT 3 FOOT DEPTH
POWER = 66 HP/MILLION GALLONS
AERATOR WITH OPERATING
HORSEPOWER DURING TEST
FIGURE 34
THE R. T. FRENCH COMPANY
SHELLEY,IDAHO
VELOCITY PROFILE
BASIN 1
3 AERATORS
-------
4 JUNE 1970
SECTION A-A
VELOCITY READINGS IN
x FEET PER SECOND
FIGURE 35
THE R. T. FRENCH COMPANY
SHELLEY, IDAHO
VELOCITY PROFILE
BASIN 1
3 AERATORS
-------
30 MAY 1970
POWER - 94 HP/MILLION GALLONS
25
SCALE IN FEET
s~*\
50
25 50
I
AERATOR WITH OPERATING
HORSEPOWER DURING TEST
PROFILE AT 2 FOOT DEPTH
X DISSOLVED OXYGEN
READINGS IN MG/L
FIGURE 36
THE R. T. F-HtNI-n UWrrrrrMM T
SHELLEY,IDAHO
DISSOLVED OXYGEN PROFILE
BASIN 2
6 AERATORS
-------
30 MAY 1970
PROFILE AT 2 FOOT DEPTH
AERATOR WITH OPERATING
HORSEPOWER DURING TEST
DISSOLVED OXYGEN
READINGS IN MG/L
= 91 HP/MILLION GALLONS
FIGURE 37
THE R. T. FRENCH COMPANY
SHELLEY, IDAHO
DISSOLVED OXYGEN PROFILE
BASIN 1
3 AERATORS
-------
30 MARCH 1970
X DISSOLVED OXYGEN READINGS
IN MG/L
AERATOR NOT IN OPERATION
OXYGEN UPTAKE = 0.06 MG 02/DAY-MG MLVSS
POWER
243 HP/MILLION GALLONS
50 ) AERATOR WITH OPERATING
HORSEPOWER DURING TEST
FIGURE 38
THE R. T. FRENCH COMPANY
SHELLEY,IDAHO
DISSOLVED OXYGEN PROFILE
BASIN 1
9 AERATORS
-------
30 MARCH 1970
X DISSOLVED OXYGEN READINGS
IN MG/L
AERATOR NOT IN OPERATION
AERATOR WITH OPERATING
HORSEPOWER DURING TEST
PROFILE AT 6 FOOT DEPTH
FIGURE 39
25
25
50
SCALE IN FEET
THE R. T. FRENCH COMPANY
SHELLEY, IDAHO
DISSOLVED OXYGEN PROFILE
BASIN 1
9 AERATORS
-------
30 MARCH 1970
SECTION B-B
DISSOLVED OXYGEN
X READINGS IN MG/L
FIGURE 40
THE R. T. FRENCH COMPANY
SHELLEY,IDAHO
DISSOLVED OXYGEN PROFILE
BASIN 1
9 AERATORS
-------
SOLIDS TREATMENT AND HANDLING
CLARIFIER-THICKENER-The clarifier-thickener was used to clarify silt water and a
mixture of silt water and waste activated sludge. The primary function of the
clarifier-thickener is to remove most of the abrasive silt from the silt water. Influent silt
water suspended solids varied from 1,050 mg/1 to 72,640 mg/1 and averaged 13,240 mg/1.
Suspended solids removal from the silt water is shown on Figure 41. Influent silt water
BOD varied from 75 mg/1 to 2,730 mg/1 and averaged 770 mg/1. BOD removal is a side
benefit and is shown on Figure 42.
Total suspended solids removals have approached 100 percent with silt water alone
flowing through the clarifier-thickener. The average suspended solids removal was 72
percent. COD and BOD removals approached 80 percent. The noticeable variations in
suspended solids removal and BOD removal are primarily the result of poor underflow
pump performance which prevented frequent solids withdrawal. Waste activated sludge
discharge to the clarifier-thickener also hindered silt settling and reduced removal
efficiencies. Preliminary coagulation studies were conducted on clarification of silt water
alone, and on a combination of silt water and waste activated sludge. Anionic polymers
improved clarification of silt water alone, and cationic polymers improved the
settleability of a mixture of silt water and waste activated sludge during bench scale
testing; however, limited full-scale testing has not been very successful to date. Further
testing is presently being conducted to optimize waste activated sludge-silt water mixing
and polymer dispersion. Waste activated sludge was normally bypassed to the river.
The thickening capability of the clarifier-thickener is shown on Figure 43. The underflow
solids level reached about 48 percent before being transferred to the vacuum filter for
dewatering. Polymer additions increased the thickened solids concentrations.
VACUUM FILTRATION-The solids concentration of the clarifier-thickener underflow
averaged about 48 percent and the vacuum filter cake averaged 62 percent solids without
coagulants (Figure 43). When an anionic polymer was added to the silt water entering the
clarifier-thickener, the underflow solids increased to about 53 percent and the filter cake
solids increased to about 72 percent. The addition of waste activated sludge directly to
the vacuum filter, while attempting to use the silt as a filter precoat, was not successful
because the waste activated sludge only tended to wash off part of the silt cake, resulting
in overall thinner sludge cakes. Spraying waste activated sludge on a preformed silt cake
also resulted in thinner cakes.
The dewatered solids cake became more concentrated with more dilute clarifier-thickener
underflow solids concentrations; however, the dewatered cake was thinner, resulting in
lower filter loading rates.
65
-------
o
o _
> s
O
LU
DC
OC
LLJ
O .
«
SEPT. 1
OCT. 1
NOV. 1
DEC. 1
JAN. 1
FEB. 1
MAR. 1
1
APRIL 1
MAY 1
JUNE 1
JULY 1
1969
TIME
1970
FIGURE 41
AVERAGE TSS REMOVAL VS. TIME
(CLARIFIER - THICKNER)
-------
WASTE ACTIVATED SLUDGE ADDED •
§
o\
-a
DC
Q
O
CO
3°
LU
O
CM
EPT. 1
OCT. 1
NOV. 1
DEC. 1
JAN. 1
FEB. 1
MAR. 1
1969
APRIL 1
TIME
1970
MAY 1
JUNE 1
JULY 1
FIGURE 42
AVERAGE BOD REMOVAL VS. TIME
(CLARIFIER - THICKNER)
-------
g
ON
00
z
UJ
CD
o
og-
o
-------
DEWATERED SOLIDS HANDLING-The dewatered silt solids were very acceptable as
landfill. During the 1969-70 processing season, most of the waste silt solids were used to
fill in low areas around the plant site. Excess waste silt solids were hauled to a local
sanitary landfill. This practice has been continued during the 1970-71 processing season.
69
-------
SECTION IX
OPERATING PROBLEMS
MECHANICAL PROBLEMS
Numerous mechanical problems were encountered at the secondary waste treatment
facility, and as a result, problems developed within the biological and physical treatment
processes. Some of the major mechanical problems are discussed below, along with
attempted solutions to these problems.
AERATION BASINS-The following listed problems were encountered with equipment
and materials used with the aeration basin:
1. The Hypalon basin-top Lining would not stay below the water surface and, as a
result, it caught in the wind and tore in several places. Pieces of the lining caught in
the aerators. The problem was solved by removing the remaining lining and replacing
it with a rock surface.
2. The PVC basin linings failed and pieces of the linings caught in the aerators. The
linings were replaced and covered with rock on the basin bottom and on the side
slopes in the wave action area. Basin 1 lining failed again near the beginning of the
1970-71 processing season, but the extent of the failure will not be assessed until
the processing plant shuts down in June.
3. The floating mechanical aerators frequently: (1) overdrew amperage and shut off,
(2) had bearing failures, and (3) developed loose hardware. The aerator
manufacturer determined that these problems were the result of high velocity axial
flow entering the aerator intake. The manufacturer recently installed an intake cone
with a baffle plate in the center of the intake on each of the aerators, which
appears to have solved the problems.
SECONDARY CLARIFIER WASTE SOLIDS PUMP-The sludge withdrawal mechanism
rotation was jerky until the seals were adjusted and additional structural bracing was
installed.
The waste sludge pump became inoperable when the waste sludge line had become filled
with sand from grout on the clarifier bottom. The problem was solved by replacing the
pump stator and cleaning the waste sludge line.
70
-------
CLARIFIER-THICKENER-Frequent clarifier-thickener underflow pump breakdowns
resulted in excessive silt concentration in the bottom cone, and hardened silt prevented
rotation of the rake mechanism. A silt recycle system was installed to allow frequent silt
removal and rubber scrapers were installed on the rakes to limit the reoccurrence of this
problem. The underflow pump manufacturer provided air chambers for the suction and
discharge sides of the pump to relieve excessive pump strain; however, breakdowns still
occur, and additional analysis is planned to eliminate this problem.
VACUUM FILTER—Several problems encountered with the vacuum disc filter are listed
below:
1. The rubber scrapers did not remove the solids cake from the cloth media. Stainless
steel media with plastic scrapers were installed to remedy this problem. This has
proven successful.
2. Limited funds required housing the vacuum filter in the control building. This has
resulted in a noisy control building and laboratory. Placing the exhaust muffler
underground relieved the external noise and resident complaints. Internal noise will
be reduced to an acceptable level with insulation.
3. Dewatered silt and sludge conveying was hampered by excessive wear of the screw
conveyor hanger bearing and stub shaft. A new belt conveyor was installed to
replace the screw conveyor.
PROCESS PROBLEMS
Problems encountered in the activated sludge process have been primarily associated with
sludge bulking. This has occurred several times and appears to be related to frequent
aerator problems, with accompanying large fluctuations in D. O. levels. Recycling of
waste activated sludge through the clarifier-thickener, where removal efficiencies were
poor, resulted in increased aeration basin suspended solids levels and reduced D. O. levels.
Increased D. O. levels and reduced influent BOD to basin MLVSS ratios have been
successfully used to eliminate the bulking sludge when it appeared; however, the last
occurrence of bulking sludge (last part of April) was not controlled by these methods. At
the close of the processing season, a sludge sample was sent to nearby Ricks College and
was reported to contain a filamentous fungus (Appendix E). Subsequent pilot plant
studies indicated that the fungus can be controlled with a fungicide, potassium sorbate,
and that it can be eliminated by starvation (continuous aeration without food) in less
than two weeks.
71
-------
Foaming has occurred on the aeration basins at low MLSS levels, but has not been a
problem at MLSS levels above 2,000 mg/1 and a D. O. above 1.5 mg/1.
Addition of an anionic polymer to the silt water, ahead of the clarifier-tlu'ckener, has
improved the silt removal efficiency. Polymers have not been found effective on
full-scale, combined waste activated sludge-silt water clarification and thickening in the
clarifier-thickener. Preliminary laboratory testing with cationic polymers has, however,
looked promising. Additional coagulation testing is being conducted at this time under
the sponsorship of the Potato Processors of Idaho Association.
12
-------
SECTION X
FINANCIAL CONSIDERATIONS
CONSTRUCTION COSTS
The total capital cost for construction of the secondary wastewater treatment facility was
$598,105. A detailed cost breakdown is presented in Appendix F. About 28 percent, or
$167,000, of this cost is estimated to be attributable to providing additional facility
capabilities to carry out the demonstration project.
OPERATION AND MAINTENANCE COSTS
The first season's operation and maintenance costs for the secondary wastewater
treatment facility were $93,212. A detailed cost breakdown is provided in Appendix F.
Approximately 22 percent ($20,950) of the total operation and maintenance costs are
estimated to be the result of the first-year demonstration project, which required
additional sampling, testing, supervision, and data analysis.
Reported solids disposal costs were low during the 1969-70 processing season because
most of the waste silt solids were used to fill in low areas around the plant site and waste
activated sludge was discharged to the river. Waste silt solids are being hauled to a local
sanitary landfill this year for a cost of $1,000 per month or about $3.30 per cubic yard.
Disposing of the waste activated sludge and all of the silt by this method during the
1969-70 season would have cost about $14,000 more than the reported costs. This would
have resulted in a total operating and maintenance cost of about $86,300, excluding the
first-year demonstration costs.
Michael [8] reported annual operation and maintenance costs for activated sludge plants
(secondary treatment only) sized for a population equivalent of 85,300 people (14,500
pounds of BOD per day) to range from $80,000 to $400,000 per year. The average
reported cost was $180,000 per year. On the basis of a season lasting about 9 months,
these reported figures would range from $60,000 to $300,000, with an average of
$135,000. These costs were reported for 1965-67 and should be increased by at least 15
percent to arrive at comparable 1969-70 costs. The updated cost range would be from
$69,000 to $345,000, with an average of $155,000 per season. The operation and
maintenance costs at R. T. French during the 1969-70 processing season, excluding the
demonstration expenses, were about $72,300 (Appendix F), which is on the low end of
the range reported for municipal activated sludge plants.
73
-------
TOTAL ANNUAL COSTS
Total annual treatment costs can be shown to be equal to the sum of: (1) annual capital
amortization costs (7 percent interest for 20 years), (2) annual operation and
maintenance costs, and (3) equipment replacement and depreciation costs (5 percent ot
equipment capital cost). Table 5 contains treatment cost estimates for the demonstration
year (1969-70 season) with and without the demonstration costs. On the basis of these
elements, the unit treatment costs of the demonstration year were about $0.049 per
pound of BOD applied, or $0.027 per pound of COD applied. The estimated costs,
excluding demonstration costs, are $0.038 per pound of BOD applied, or $0.021 per
pound of COD applied. Both season's unit cost estimates are based on the waste load
during the 1969-70 season, or 3,335,000 pounds of BOD and 6,064,000 pounds of COD.
TABLE 5
SECONDARY TREATMENT COSTS
ESTIMATED
TOTAL 1969-70
1969-70 SEASON WITHOUT
ITEM SEASON DEMONSTRATION
Construction Cost $598,105 $431,379
Amortized Capital Cost
(7% - 20 years) 56,500 40,700
Annual Operation & Maintenance Cost 93,200 72,300
Estimated Equipment Replacement &
Depreciation (5% of Equipment Cost) 15,000 15,000
Total Annual Cost $164,700 $128,000
Estimated Cost of Treatment
(3,335,000 Ib BOD/year) $0.049/lb BOD Applied $0.038/lb BOD Applied
(6,064,000 lb COD/year) $0.027/lb COD Applied $0.021/lb COD Applied
These total annual cost estimates are lower than costs reported for activated sludge
treatment of fruit processing wastes [9]. Activated sludge treatment of fruit wastes were
estimated to be $0.061 per pound of BOD removed or $0.048 per pound of COD
removal. Assuming 95 percent BOD removal and 90 percent COD removal, the reported
costs would be S0.058 per pound of BOD applied or $0.043 per pound of COD applied.
74
-------
The lower unit cost at R. T. French is probably due to the greater annual organic load
experienced. Lower unit treatment costs are frequently associated with systems receiving
larger waste loads.
Adding extra sludge disposal costs ($14,000) to the estimated 1969-70 total annual
costs at R. T. French, without demonstration costs, would result in unit treatment costs
of $0.043 per pound of BOD applied and $0.023 per pound of COD applied.
75
-------
SECTION XI
DISCUSSION
ACTIVATED SLUDGE SYSTEM
MICROBIOLOGY—Treatment system operation was the most efficient when the activated
sludge contained a high population of stalked ciliates and a moderate population of
free-swimming ciliates. Some filamentous growth was usually present in the sludge;
however, during periods of efficient operation, it was present only in limited quantities.
These findings are in agreement with the findings of many other researchers [1,2,10,11].
Photomicrographs of the activated sludge during normal operation and during periods of
sludge bulking are shown on Figure 44.
Ciliates which were identified in the activated sludge include Vorticella microstoma,
Vorticella campanula, Lionotus species, and Paramecium. The best effluent was produced
when Vorticella campanula was the predominant Vorticella.
During extended periods of low dissolved oxygen, filamentous growth, either bacteria or
fungi, seemed to dominate the activated sludge as shown in the left-hand
photomicrograph of Figure 44.
SUBSTRATE REMOVAL-The substrate utilization equation presented in Section V is
shown below:
If the total weight of BOD removed per day per unit weight of MLVSS is plotted against
the effluent soluble BOD, the slope of the first order curve passing through (0,0) will be
equal to the BOD removal rate coefficient, k. Figures 45, 46, and 47 are plots of BOD
removal versus effluent soluble BOD at the three temperature ranges in which the system
operated when working efficiently. The lines were passed through (0,0) and the mean
coordinates. Figure 46 has considerable scatter, which is not unusual for field data.
Figure 48 is a semi-logarithmic plot of the BOD removal rate coefficient, k, versus the
average basin temperatures obtained from the figures described above. The equation of
the straight line can be used to determine BOD removal rate coefficients at various
temperatures. The equation is:
k - 0.016 x 1.1
76
-------
\*t*£?t''Z&i£*ftt
W.>$$^ 1
fc-^>*-.-^.- '-2
ir
*-*,' • ^•
&(' •-••. •.;.?:•
FILAMENTOUS ACTIVATED SLUDGE
(100X)
IB4435.3
t-f ~~-
i* •-
.
H '
^ &^:
A^cy*!* \;«.
NORMAL ACTIVATED SLUDGE
(100X)
FIGURE 44
PHOTOMICROGRAPHS OF ACTIVATED SLUDGE
-------
o
o
«•—» •
CO-
CO
CD
Q
\
UJ
oo
CO"?
ODO
CO
CD
_J
ujS
cc.
>
o
Zio
UjW
0:0
UJ
I—
cc
a:
>—
co_
QQ§
S-.
0.0048
40 60 80 100
EFFLUENT SOLUBLE BOD WG/L)
120
140
FIGURE 45
EFFLUENT SOLUBLE BOD VS. SUBSTRATE REMOVAL
TEMPERATURE EQUALS 50 TO 56 °F
(SELECTED DATA)
-------
co
<0
DO
o
\
IU
I—
oc
ce
CQO
ID
CO
03
-o
ceo
UJ
t—
a:
cc
0.0082
40 eo so too
EFFLUENT SOLUBLE B3D (flQ/LJ
ISO
140
FIGURE 46
EFFLUENT SOLUBLE BOD VS. SUBSTRATE REMOVAL
TEMPERATURE EQUALS 58 TO 60 °F
(SELECTED DATA)
-------
OC
o
co
40 50 80 100
EFFLUENT SOLUBLE BOD (fIG/L)
120
FIGURE 47
EFFLUENT SOLUBLE BOD VS. SUBSTRATE REMOVAL
TEMPERATURE EQUALS 61 TO 63 °F
(SELECTED DATA)
-------
0.020
UJ
a:
0.010
0.009
0.008
0.007
0.006
0.005
0.004
DC
I-
£ 0.003
D
C/3
0.001
ky = 0.016 x 1.17 (T'20>
0.016
LOG " 0.0189 = 1.17
5 10 15
BASIN TEMPERATURE (°C)
20
FIGURE 48
SUBSTRATE REMOVAL RATE VS. TEMPERATURE
81
-------
SLUDGE YIELD-An equation expressing net sludge yield in a completely mixed
activated sludge system was presented in Section V and is repeated below:
AXV = fSQ + aSr bXd
This equation shows that the net change in average MLVSS concentrations should be
equal to the sum of the non-biodegradable volatile suspended solids in the influent plus
the volatile fraction of biological cells produced while removing BOD from the waste
material, minus the volatile fraction of the biological cells used in endogenous respiration.
The fraction of volatile suspended solids in plant influent, which is not degradable, has
been assumed to be negligible, resulting in the following equation:
AXv = aSr bXd
A plot of net volatile suspended solids produced per day, AXy, per unit weight of
MLVSS versus the quantity of BOD removed per day, Sp per unit weight of MLVSS was
made for each of two temperature ranges with enough data to plot a first-order curve
(Figures 49 and 50). Even then, the field data included sufficient scatter to require prior
knowledge of the direction that the straight line should be plotted. Both sets of
temperature data represented about the same sludge age range, and as a result, straight
lines with the same slope, a, seemed to fit both sets of data. The sludge synthesis yield
coefficient, a, is shown as 0.88. The Y-axis intercept, which is equal to net sludge growth
at zero BOD removal or the rate of endogenous respiration (auto-oxidation) per day, b,
was different in each case.
Figure 51 is a semi-logarithmic plot of the endogenous respiration rate, b, versus average
basin temperature. The data for the two points shown on Figures 49 and 50, and the
semi-logarithmic plot was chosen because of the tendency of the BOD removal rate
coefficient versus temperature plot to vary in a semi-logarithmic order, and because of
other reported experience [9] in evaluating b. The equation of the straight line plot can
be used to determine the endogenous respiration rate, b, at various temperatures;
however, it should be understood that the variability of field data and the narrow range
of aeration basin operating temperatures did not allow verification of this equation over a
wide range of temperatures. The equation is:
bT = 0.19 x 1.3l(T-2°)
The sludge synthesis yield coefficient, a, presented above is slightly above other published
data [6,9,11], which indicates the presence of non-biodegradable volatile suspended solids
in the influent. The rate of endogenous respiration, b, corresponds to other published
82
-------
o
ID
to.
d
O
oo
OJ
0°
CC
Q_
UJ
O
O
0.05 —
0.88
.00
0.10 0.20 0.30 0.40 0.50 O.SO
SUBSTRRTE REflOVRL RRTE (LB SUBSTRRTE/DRY/LB MLV5S)
FIGURE 49
0.10
0.80
SUBSTRATE REMOVAL VS. SLUDGE PRODUCTION
TEMPERATURE EQUALS 58 TO 60 F
SELECTED DATA
-------
oo
o
11}
CO
CO
to
CO
>
CO
CJ
ZJ
o
o
cc:
o
:D
_i
CO
o
o
0.09-
.00
0.88
r0.lO 0.20 0.^0 0.40 O.SO 0.60
SUBSTRflTE REflOVflL RRTE (LB SUBSTRRTE/DRY/LB fILVSS)
FIGURE 50
SUBSTRATE REMOVAL VS. SLUDGE PRODUCTION
TEMPERATURE EQUALS 61 TO 65 F
SELECTED DATA
0.70
0.80
-------
Q.3 -
-Q
LU
I-
cc
z
o
I-
cc
ol
CO
LJJ
QC
CO
o
o
Q
0.2 -
0.1
0.09
0.08
0.07
0.06
0.05
0.04
0.03 -
0.02 -
0.01
0.19
bT = 0.19x1.31 (T'20)
LOG "1 0.116= 1.31
5 10 15
BASIN TEMPERATURE (°C)
20
FIGURE 51
ENDOGENOUS RESPIRATION RATE VS. TEMPERATURE
85
-------
data [6,9.11]. but the correlation between b and basin temperature appears high. This is
probably because the narrow aeration basin temperature range limited the number of
points for Figure 51.
Figure 52 shows that net sludge production decreases with sludge age; therefore, systems
operating with a longer sludge age will have less waste sludge for disposal. This is a
general plot and does not include the temperature variations described above. The net
sludge production rates include influent volatile suspended solids and are in agreement
with other data published [6,9,11] on treatment of wastewaters with influent volatile
suspended solids.
OXYGEN REQUIREMENTS-The equation presented in Section V for oxygen
requirements is:
O2 = a1 Sr + b Xd
System oxygen uptake rate data is included in Appendix G. Plotting the oxygen uptake
rate (weight of O2 used per day per unit weight of MLVSS) versus the BOD removal rate
(weight of BOD removal per day per unit weight of MLVSS) provided a first-order
least-square curve (Figure 53). The equation of the curve is equal to the total oxygen use,
the slope of the line is equal to a' and the Y-axis intercept is equal to b , the oxygen
utilization rate when BOD removal is equal to zero. The coefficient a1 is equal to 0.48
and the coefficient b' is equal to 0.03. This plot is for temperatures between 52 and 60
degrees F.
The oxygen requirement equation, with the determined coefficient values, becomes:
O2 = 0.48 Sr + 0.03 Xd
The determined value of a1 compares favorably with published data [9,11]. The
determined value of b is slightly below the same published data because of the low basin
temperature range.
BOD AND SUBSTRATE REMOVAL RELATIONSHIPS-Data obtained during periods of
efficient operation have been analyzed to determine the effect that certain operating
parameters had on BOD and substrate removal. The curves are least-square fits of weekly
average data by computer. Each of the curves takes into consideration only the
referenced variables.
Figure 54 shows that BOD removal increased slightly with higher average aeration basin
dissolved oxygen levels, while operating between the range of 0.6 to 2.8 mg/1 dissolved
oxygen.
86
-------
CO
Q
00
Q
Q
UJ
cc.
QQ
o
is
oc°
Q.
CO
CO
I-
UJ_
nit
AERATION BASIN TEMPERATURE RANGE = 52-65°F
SLUDGE ROE (DRY3)
FIGURE 52
SLUDGE AGE VS. SLUDGE PRODUCTION
(SELECTED DATA)
-------
o
10
10
GO
00
CO
_l
UJ
t—o
OCQ
UJ
en
i—
a.
x
o
0.48
AERATION BASIN TEMPERATURE RANGE = 52-6Q°F
0.03
0.00
0-05
0.10 0.15 O.£0 0.15 0.33 0.95
SUBSTRflTE REflOVRL RfiTE (LB SUBSTRflTE/OflY/LB HLVS3)
Q.40
0.45
0.50
FIGURE 53
OXYGEN UPTAKE RATE VS. BOD REMOVAL
-------
oo
(X
ISM
LU
o:
o
o
CD
0.00
X X
0.40
0.90 1.20 1.60
BflSIN 0.0. (HG/L)
2.00
2.40
2.80
FIGURE 54
AVERAGE BOD REMOVAL VS. AVERAGE BASIN D.O.
(SELECTED DATA)
-------
The average aeration basin temperature did not appear to affect BOD removal between
52 and 66 degrees F. (Figure 55).
The BOD removal seemed to increase with higher pH levels while operating within the
range of 7.4 and 8.2 as shown on Figure 56. This may have been a coincidence.
Figures 57 and 58 show that BOD removal increased only a slight amount with increases
in influent total phosphate to BOD and total Kjeldahl nitrogen to BOD ratios. This
indicates that the treatment system was not significantly deficient in nutrients.
The average substrate removal did not appear to be affected by dissolved oxygen over a
wide range of 0.7 to 5.1 mg/1 (Figure 59). Higher BOD removals with higher dissolved
oxygen levels (Figure 54), while substrate removal stayed about the same, suggest the
formation of a better settling sludge at higher dissolved oxygen levels and subsequent
better final clarification.
Average basin temperature did not measurably affect the substrate removal (Figure 60);
however, substrate removal did increase slightly with pH (Figure 61) as did the BOD
removal shown on Figure 56.
The influent total phosphate to BOD ratio and total Kjeldahl nitrogen to BOD ratio did
not affect the substrate removal (Figures 62 and 63), indicating that sufficient nitrogen
and phosphates were available. These two plots are based on available daily data.
The average BOD:N:PO4 ratio of the plant influent was 100:6.2:1.1. This ratio is
generally considered adequate.
HEAT LOSS RELATIONSHIPS-Figure 64 shows plant influent and effluent
temperatures. The difference in the two plots is the heat loss throughout the plant. This
net heat loss can be analyzed by plotting the heat lost from the aeration basins versus the
heat added to the aeration basins. The heat lost from the basins has been reported [13]
to be related to the surface area of the basins and to the temperature differential
between the basin contents and the surrounding air. This relationship can be expressed by
the following equation:
HL - hL(TW-TA)A
where: H^ = heat lost from aeration basins
!IL - heat loss coefficient
Tyy = temperature of aeration basin liquor, degrees F
TA = air temperature, degrees F
A = aeration basin surface area, square feet
90
-------
a
a _
to
at
s
CO
IA
CD
X X
X
X X
X
X
1 1 1 1 1—
50 53 56 59 62 65
BRSIN TEMP (F)
FIGURE 55
AVERAGE BOD REMOVAL VS. AVERAGE BASIN TEMP.
(SELECTED DATA)
-------
g
U> .
a>
cn
l§
LU
Ct
O
o
CO
o .
CD
7.3
7.4
7.5
7.6
7.7 7.8
BflSIN PH
7.iJ
S-0
R.I
FIGURE 56
AVERAGE BOD REMOVAL VS. AVERAGE BASIN pH
-------
UJ
cc
o
o
oo
«0
0.000 0.100 0.200 0.900 0.400 0.500 0.600 0.700 0.800 0.900
P/BOO *lCr
FIGURE 57
AVERAGE BOD REMOVAL VS. AVERAGE POd/BOD
(SELECTED DATA)
-------
0 _
LU
o:
a
o
CD
0.04
O.OS
O.OB
0.07
N/BOO
0.08
0.08
0.10
FIGURE 58
AVERAGE BOD REMOVAL VS. AVERAGE N/BOD
(SELECTED DATA)
-------
o
o
tug
a:
tu
K-
cr
oc:
to
cc
a:
UJ
XXX XX
XX
XX
flVERROE RERfiTION BflSIN 0. 0. (J1G/L)
FIGURE 59
AVERAGE SUBSTRATE REMOVAL VS. AVERAGE D.O.
(ALL DATA)
-------
O
O
o\
CL
O
z:
ce
LU(
i—
cc
t—
CD
23
t
IU
cn
a:
LU
to
«o
50
flVERfl&E BflSIN TEMP (F)'
FIGURE 60
AVERAGE SUBSTRATE REMOVAL VS. AVERAGE BASIN TEMP.
(ALL DATA)
-------
UJ
I—
A
7.3
7.4
7.6
7.6 7.7 7.8
RVERflGE BflSIN PH
7.9
9.0
8.1
FIGURE 61
AVERAGE SUBSTRATE REMOVAL VS. AVERAGE pH
(ALL DATA)
-------
g
00
o
z:
UJ
a:
GC
te.
i—
(O
CD
23
(O
8
X X X
•0.000
o.oso
0.100
0.150
0.200
P04/BOD
FIGURE 62
.250
0.900
0.360
0.400
0.450
SUBSTRATE REMOVAL VS. PO4/BOD
-------
o _
O
z:
LU
cc
ct:
OO
3
to
1C
0.00
0.02
0.04
0.06
N/BOD
0.08
0.10
0.12
FIGURE 63
SUBSTRATE REMOVAL VS. N/BOD
(ALL DATA)
-------
o
o
CL
a:
UJ
INFLUENT
EFFLUENT
JUNE 1
. 1
OCT. 1
NOV. 1
DEC. 1
1969
JAN. 1 FEB. 1
TIME
MAR. 1
APRIL 1
MAY 1
JULY 1
1970
FIGURE 64
PLANT INFLUENT AND EFFLUENT TEMPERATURES
(ALL DATA)
-------
The heat added to the aeration basins has been reported [13] to be related to the
influent flow volume and to the temperature differential between the influent flow and
the basin contents. This relationship can be expressed with the equation:
where: Hj = heat added to aeration basins
hj = heat addition coefficient
Tj = temperature of aeration basin influent, degrees F
T^- = temperature of aeration basin liquor, degrees F
Q = aeration basin influent flow, mgd
Assuming that the heat lost from the basins is equal to the heat added to them, the
following equations result:
hL (TrTw)Q
h=~h7 = (Tw-TA) A
The heat loss coefficient, h, is directly related to the heat added to the aeration basins
and inversely related to the heat lost from the basins. Therefore, as the heat loss increases
(with other variables remaining the same), the heat loss coefficient decreases.
Plotting (T-yy - TA) A versus (Tj - T^y) Q will provide a straight line with a slope equal to
h. Figures 65 and 66 are similar plots in accordance with the above discussion for two
detention times at one hp per million gallon ratio. The lines were passed through (0,0)
and the mean coordinates of daily data. The effect of detention time is shown by the
lower heat loss coefficient, h, and higher aeration basin heat loss with a longer detention
time. Similar plots at higher hp per million gallon ratios are located in Appendix H. The
water surface areas of Basin 1 and Basin 2 are 17,850 square feet and 30,370 square feet,
respectively, at design water level. The air temperatures used are averages of the
maximum and minimum daily temperatures and the influent and basin temperatures are
actual average temperatures.
The slopes of the straight lines shown on the figures mentioned above are plotted versus
average aeration basin detention times on Figure 67. The hp per million gallon ratios are
shown for each point. A general curve is shown passing through the data points and is
assumed to be asymptotic at each axis, h is shown to decrease with longer detention
101
-------
O
K)
cv
Q
O
2.32 X 10"'
44 TO 84 HP/MILLION GALLONS
AVERAGE AIR TEMP. RANGE = 24 TO 62°F
fl(TH-Tfi)
(100.000 SO FT-FJ
18
FIGURE 65
AERATION BASIN HEAT LOSS RELATIONSHIP
2 TO 3.5 DAYS DETENTION TIME
-------
Q
(D
o
(Jj
1.64 X 10"'
44 TO 84 HP/MILLION GALLONS
AVERAGE AIR TEMP. RANGE = 15 TO 57°F
R(TW-Tfl)
(100,000 SO FT-F)
18
FIGURE 66
AERATION BASIN HEAT LOSS RELATIONSHIP
3.5 TO 6.5 DAYS DETENTION TIME
-------
10 •
. 8-
O
CO
8
O
o"
O
Q
6-
103-185 HP/MG X
O 4-
211-243 HP/MG x
X103-185 HP/MG
UJ
O
O
CO
CO
O
2-
uu
I
44-84 HP/MG *
44_84 HP/MG
3 4
DETENTION TIME (DAYS)
FIGURE 67
AERATION BASIN HEAT LOSS COEFFICIENT VS. DETENTION TIME
-------
times. The temperature differential between the basin liquor and the air appears to have a
stronger effect on h than the hp per million gallon ratio. This is shown by the lower
values of h at 44 to 84 hp per million gallons (with high temperature differentials) than
at 103 to 185 hp per million gallons with low temperature differentials.
Figure 67 can be used for design purposes to determine approximate h values for design
detention times. The equation for h, which was presented above, can then be solved for
the basin liquor temperature, T^. Additional work should be performed to obtain a
clearer understanding of the effects of hp per million gallon ratios and other variables not
considered during this project, including the effect of heat loss through the sides and
bottom of a basin, the effect of wind velocity, and the effect of solar radiation.
SECONDARY CLARIFIER LOAD ING-Section VII includes secondary clarifier
operational data, which show that effluent suspended solids and BOD values are
somewhat related to clarifier loading, which, in turn, is dependent upon the MLSS and
the flow rate to the clarifier. The ability of the clarifier to settle and compact the solids
applied to it is a function of the SVI of the MLSS, as well as the solids loading. The
higher the SVI value is, the lower the settleability of the mixed liquor. When the SVI
increases to a point of clarifier overload, the MLSS load must be decreased in
compensation, by increasing the rate of sludge wasting.
Figure 68 is a plot of MLSS versus (Q + ROJSVI, using different symbols for good and
poor operation. Q represents total plant influent and R is the quantity of return sludge as
a fraction of total plant influent. A straight line is drawn between the good data and
poor data. Good secondary clarification can be predicted by operating the system so that
the coordinates of (Q + ROJSVI and MLSS fall below the line. Acceptable operation
allows lower (Q + ROJSVI values for increased MLSS levels.
SOLIDS TREATMENT AND DISPOSAL
WASTE ACTIVATED SLUDGE CHARACTERISTICS-A sample of waste activated
sludge was concentrated, analyzed, and found to contain and exhibit the following listed
materials and characteristics:
pH 6.6
Moisture 94.5%
Protein 1.9%
Fat 0.02%
Fiber 0.16%
Ash 1-64%
NFE (Nitrogen Free Extract) 1.78%
TON (Total Digestible Nutrients) 2.7%
105
-------
o
o
C3o
-2
* OBOO 8PCBATIOM
+ POOH OPtRATtOM
A *
10
20
40 50 SO
MLSS (M&/L) »10*
80
90
100
FIGURE 68
SECONDARY CLARIFIER LOADING FACTOR VS. MLSS
(ALL DATA)
-------
Calcium 0.25%
Phosphorus 0.051%
Iron 0.0028%
Sodium 0.099%
Pesticides None Detected
A laboratory report on this analysis is located in Appendix F.
The protein content of the waste activated sludge amounted to 34.5 percent of the total
solids, indicating that it may have a nutrition value high enough to allow use in animal
feed.
The heat value, or calorific value, of the waste activated sludge was found to be 5,200
Btu per pound of total solids or 9,020 Btu per pound of volatile solids. The volatile
solids value is about 10 percent below values reported for dairy waste sludge, pulp and
paper waste sludge, and domestic sewage activated sludge [12].
TREATMENT SYSTEM SOLIDS-The variation of the average VSS to TSS ratio through
the treatment system is listed below:
Location VSS/TSS
Plant Influent 0.70
Aeration Basins 0.70
Final Effluent 0.52
Return Sludge 0.74
Waste Sludge 0.74
The BOD to VSS ratio of the plant influent solids was 0.49, while the same ratio for the
plant effluent solids was 0.55 and did not appear to be dependent on sludge age.
107
-------
SECTION XII
ACKNOWLEDGMENT
This project was supported in part by Research and Development Grant WPRD 15-01-68,
Program 12060 EHV, from the Environmental Protection Agency.
108
-------
SECTION XIII
REFERENCES
1. Hawkes, H. A., Ecology of Waste Water Treatment, Pergamon Press, New York,
N. Y. (1963).
2. McKinney, R. E., Microbiology for Sanitary Engineers, McGraw-Hill Book Co., New
York, N. Y. (1962).
3. Weston, R. F., and Eckenfelder, W. W., "Application of Biological Treatment to
Industrial Wastes, I. Kinetics and Equilibria of Oxidative Treatment." Sewage and
Industrial Wastes, 27, 802 (1955).
4. McKinney, R. E., "Biological Design of Waste Treatment Plants." Presented at
Kansas City Section of ASCE Seminar, Kansas City, Mo. (1961).
5. McKinney, R. E., "Mathematics of Complete Mixing Activated Sludge." Jour. San.
Engr. Div., Proc. Amer. Soc. Civil Engr., 88, SA3, 87 (May 1962).
6. Eckenfelder, W. W., "Comparative Biological Waste Treatment Design." Jour. San.
Engr. Div., Proc. Amer. Soc. Civil Engr., 93, SA6, 157 (December 1967).
7. Lawrence, A. W., and McCarty, P. L., "Unified Basis for Biological Treatment
Design and Operation." Jour. San. Engr. Div., Proc. Amer. Soc. Civil Engr., 96, SA3,
757 (June 1970).
8. Michel, R. L., "Costs and Manpower for Municipal Wastewater Treatment Plant
Operation and Maintenance, 1965-68." Jour. Water Poll. Control Fed., 42, 1883
(1970).
9. Snowkist Growers, Inc., "Aerobic Treatment of Fruit Processing Wastes." Report
No. DAST-8, U. S. Dept. Interior, Fed. Water Quality Admin. (1969).
10. Sawyer, C. N., "Bulking of Activated Sludge and Related Problems." Proceedings of
Seminar at the University of Michigan, 185 (February 1966).
11. Eckenfelder, W. W., "A Theory of Activated Sludge Design for Sewage." Proceedings
of Seminar at the University of Michigan, 72 (February 1966).
109
-------
12. Eckenfelder. W. W._. and O'Connor, D. J., Biological Waste Treatment, Pergamon
Press, New York. N. Y. (1961).
13. Eckenfelder, W. W., "Design and Performance of Aerated Lagoons for Pulp and
Paper Waste Treatment." Proc. 16th Ind. Waste Conf., Purdue Univ., Ext. Ser. 109,
115 (1962).
110
-------
SECTION XIV
APPENDIXES
111
-------
APPENDIX A
-------
APPENDIX A
GLOSSARY
Some of the various terms frequently used in conjunction with wastewater systems and
referred to throughout this report are defined as follows:
ACCLIMATION—Period during which the microorganisms become accustomed to then-
new environment and substrate.
ACTIVATED SLUDGE—A biological mass produced in wastewater by the growth of
bacteria and other microorganisms in the presence of dissolved oxygen, and accumulated
in sufficient concentration by returning floe previously formed.
ACTIVATED SLUDGE PROCESS-A method of secondary wastewater treatment in
which a mixture of wastewater and activated sludge is agitated and aerated. The activated
sludge is subsequently separated from the treated wastewater (mixed liquor) by
sedimentation, and wasted or returned to the process as needed.
AERATION—The bringing about of intimate contact between air and liquid by one of
the following methods: spraying the liquid in the air, bubbling air through the liquid, or
agitation of the liquid to promote surface absorption of air.
AERATOR—A device which agitates the liquid and brings fresh surfaces of liquid into
contact with the atmosphere, thereby introducing atmospheric oxygen into the liquid by
mechanical means.
AEROBIC TREATMENT—A biological treatment process in which bacteria stabilize
organic matter in the presence of dissolved oxygen.
ANAEROBIC TREATMENT-A biological treatment process in which bacteria stabilize
organic matter in the absence of dissolved oxygen.
AVERAGE DAILY FLOW-The average quantity of wastewater reaching a given point in
a 24-hour period.
BIOCHEMICAL OXYGEN DEMAND (BOD)-A measure of the oxygen necessary to
satisfy the requirements for the aerobic decomposition of the decomposable organic
matter in a liquid by bacteria. The standard (BOD 5) is five days at 20 degrees C.
A-l
-------
BIOLOGICAL SEED-Sludge that has undergone decomposition which is mixed with
undecomposed wastewater for the purpose of introducing favorable organisms, thereby
accelerating the initial stages of decomposition.
BUFFER—The action of certain solutions in opposing a change of composition, especially
of pH.
CHEMICAL OXYGEN DEMAND (COD)-A measure of the oxygen required to approach
total oxidation of the organic matter in the waste.
CLARIFIER-A tank or basin, in which wastewater is retained for a sufficient time, and
in which the velocity of flow is sufficiently low to remove by gravity a part of the
suspended matter.
COAGULANT—A chemical, which, when added to water or wastewater, furnishes ionic
charges opposite to those of the colloidal turbidity particles in the water or wastewater,
allowing the colloidal particles to come together in the form of a flocculant precipitate.
COAGULATION-The agglomeration of colloidal or finely divided suspended matter in
water or wastewater by the addition of an appropriate coagulant.
COMPLETELY MIXED ACTIVATED SLUDGE-Treatment system in which the
untreated wastewater is instantly mixed throughout the entire aeration basin.
COMPOSITE SAMPLE—Integrated sample collected by taking a portion at regular time
intervals, with sample size varying with flow; or taking uniform portions on a time
schedule varying with the total flow.
DETENTION TIME—Period of time required for a liquid to flow through a tank or unit.
DISSOLVED OXYGEN (DO)-Free or uncombined oxygen in a liquid.
EFFLUENT—Liquid flowing out of a basin or treatment plant.
FLOC—Small gelatinous masses, formed in water or wastewater by the addition of
coagulants, through biochemcial processes, or by agglomeration.
FLOCCULATION—The bringing together of flocculating particles by hydraulic or
mechanical means.
A-2
-------
INDUSTRIAL WASTEWATER—Flow of waste liquids from industries using large volumes
of water from processing industrial products, such as food processing plants.
INFLUENT—Liquid flowing into a basin or treatment plant.
MILLIGRAMS PER LITER (mg/l)-The weight of material in one liter of liquid.
MIXED LIQUOR (ML)-A mixture of sludge and wastewater in a biological reaction tank
undergoing biological degradation in an activated sludge system.
NITRIFICATION—A biological process in which certain groups of bacteria, when in the
presence of dissolved oxygen, convert ammonia nitrogen first to nitrites and then to
nitrates.
NUTRIENT—Any substance absorbed by organisms which promotes growth and
replacement of cellular parts.
OXYGEN UPTAKE RATE—Oxygen utilization rate or rate at which oxygen is used by
bacteria in the decomposition of organic matter.
PEAK FLOW—The highest average daily flow occurring throughout a period of time.
pH—The logarithm of the reciprocal of the hydrogen ion concentration. It is used to
express the intensity of the acid or alkaline condition of a solution.
POLYELECTROLYTES-High molecular weight water soluble polymers that contain
groups capable of undergoing electrolytic dissociation to give highly charged, large
molecular weight ions. Polymers whose functional groups in water solution give positively
charged ions are cationic, while polymers that dissociate to form negatively charged ions
are called anionic. Polymers which dissociate to yield both large positive and large
negative ions are referred to as nonionic.
PRIMARY TREATMENT—A wastewater treatment process that utilizes sedimentation
and/or flotation to remove a substantial portion of the settleable or flotable solids and
accompanying BOD of untreated wastewater.
RETURN SLUDGE—Sludge which has settled in the final clarifier and is returned to the
biological reaction tank in an activated sludge system.
SECONDARY TREATMENT-A wastewater treatment process that utilizes
microorganisms to reduce the oxygen demand and pollutional load of primary treated
wastewater and to remove the solids resulting from the process.
A-3
-------
SETTLEABLE SOLIDS-Suspended solids which will settle in sedimentation basins
(clarifiers) in normal detention times.
SLUDGE—The accumulated settled solids separated from wastewater in clarifiers, and
containing more or less water to form a semi-liquid mass.
SLUDGE AGE-The average total time of detention of a suspended solids particle in a
system. It is defined as the total weight of suspended solids in the aeration basin divided
by the total weight of suspended solids in the effluent and otherwise wasted per day.
SLUDGE DENSITY INDEX (SDI)-The reciprocal of the sludge volume index (SVI)
multiplied by 100.
SLUDGE VOLUME INDEX (SVI)-The volume of sludge occupied by one gram of
activated sludge after 30 minutes of quiescent settling in a 1,000 ml graduated cylinder.
SUBSTRATE—Raw waste feed on which a microorganism grows or is placed to grow by
decomposing the waste material.
SUBSTRATE REMOVAL-The total BOD in plant influent, minus the soluble BOD in
plant effluent, divided by the total influent BOD.
SUPERNATANT LIQUOR-The liquid overlying settled solids.
SUSPENDED SOLIDS (SS or TSS)-The quantity of material deposited when a quantity
of wastewater is filtered through an asbestos mat in a Gooch crucible, or equal method.
TOTAL SOLIDS (TS)—The solids in the wastewater, both suspended and dissolved.
VOLATILE SUSPENDED SOLIDS (VSS)-The quantity of suspended solids in
wastewater that are lost on ignition of the total suspended solids.
WASTE SLUDGE—Sludge which is no longer needed in the treatment system and
therefore is disposed of.
-------
APPENDIX B
-------
FIGURE B-1
THE R.T. FRENCH COMPANY
SHELLY, IDAHO
AERATION BASIN 1
-------
FIGURE B-2
THE R.T. FRENCH COMPANY
SHELLEY, IDAHO
AERATION BASIN 2
-------
FIGURE B-3
THE R.T. FRENCH COMPANY
SHELLEY, IDAHO
SECONDARY CLARIFIER
-------
FIGURE B-4
THE R.T. FRENCH COMPANY
SHELLEY, IDAHO
CONTROL BUILDING
-------
FIGURE B-5
THE R.T. FRENCH COMPANY
SHELLEY, IDAHO
CLARIFIER - THICKENER
-------
APPENDIX C
-------
o
o
Si
1 OCT. 1 NOV. 1
1969
DEC. 1
JAN. 1 FEB. 1 MAR. 1
TIME
APRIL 1 MAY 1
1970
JUNE 1
JULY 1
FIGURE C-1
INFLUENT ALKALINITY VS. TIME
-------
99.09
99.9
99
95
90
80
70
60
50
40
30
20
10
0.1
0.01
INFLUENT ALKALINITY (MG/L CaCo3)
FIGURE C-2
PROBABILITY OF INFLUENT ALKALINITY
02
-------
99. £
99.9
2
<
I
W
(/)
oc
o
<
O
01
99
98
90
80
60
40
30
20
10
0-1
0.01
CO
03(0<0(£{O'"'''p-IH-*-H->-'
0)
to
o o» «n
(a (d O)
J» O
Q O)
en
o
vj
CD
o w — u>
o> •- en o>
INFLUENT pH
FIGURE C-3
PROBABILITY OF INFLUENT pH
C-3
-------
98.99
99.9
99
95
90
80
70
SO
50
40
30
20
10
5
>:
/
o.i
0.01
•\>
u) *-
o o
en
o
CO
en o *o *j QB oo
>••••«
C0 C/1 •*" ^ O) CQ
a o a o o a
INFLUENT TEMPERATURE (°C)
8
•o
a
c/i •-
o o
r ? ?
a a a
O)
a
FIGURE C-4
PROBABILITY OF INFLUENT TEMPERATURE
C-4
-------
99.99
99.3
go
95
on
fin
7n
en
^n
A n
Ofl
1U
5'
• 1
Oni
a
4
*
,
D C
». c
•• ^
/
t
tf c
3 <
x
' '
1
3 N
! I
X
§ a
n *
^
X
! 1
t
j ^^^
X
>• c
k >.
D <
^
t
/
/
n c
J U
3 •-
«
t
V
^
s s
. c
4
/
3 ^
3 "
1 -
n
)
X
3 C
f
* t
4 6
J
3 0
3 4
0 <<
0 C
5
/
2 £
3 4
3 A.
X
3 I1
n c
>. c
3 C
X
3 (N
n
n <
o c
3 £
5 £
x
«
3 £
ii S
i
S S
3 *
D (C
INFLUENT BOD (MG/L)
FIGURE C-5
PROBABILITY OF INFLUENT BOD
C-5
-------
iw.wa
99.9
99
95
90
80
70
60
SO
40
30
20
10
5
1
I3
0.1
0.01
X
t
\
/
\
X
i
X
x1
)
/
^
>
t
V
>
f
t
x
>
/
>
t
/
t
'
\
x
X
X
X
X
1 <
8
2
INFLUENT COD (MG/L)
FIGURE C-6
PROBABILITY OF INFLUENT COD
C-6
-------
99.99
99.9
0-01
0.1
w
vi en o en
INFLUENT SUSPENDED SOLIDS (MG/L)
FIGURE C-7
PROBABILITY OF INFLUENT SUSPENDED SOLIDS
C-7
-------
3
_J
U-
o
SEPT. 1
OCT. 1 NOV. 1
1969
DEC. 1
JAN. 1 FEB. 1 MAR. 1
TIME
APRIL 1 MAY 1
1970
JUNE 1
JULY 1
FIGURE C-8
INFLUENT FLOW VS. TIME
-------
99.99
99.9
99
95
90
33
70
SO
50
43
30
20
10
X
X
);
;;
O.I
0.01
o —
TOTAL INFLUENT FLOW
FIGURE C-9
PROBABILITY OF TOTAL INFLUENT FLOW
C-9
-------
g
g
a
o
o
S
S
a
g
400
800
1200
1600 2000
BOD IMO/L)
2400
2800
3200
9600
4000
FIGURE C-10
INFLUENT BOD VS. COD
(ALL DATA)
-------
n
a
o
to
UJ
-Jo
03 g
=3*
_J
«D
(O
g
400
800
1200 1600 2000
TOTflL BOO U1G/U
2400
2800
3200
3600
FIGURE C-11
INFLUENT TOTAL BOD VS. SOLUBLE BOD
(ALL DATA)
-------
U3
2
io
§
•00
1200
1800
2400 9000
S3 (MO/L)
9600
4200
4800
5400
6000
FIGURE C-12
INFLUENT SS VS. VSS
(ALL DATA)
-------
o
a
Si
ta
CO
n
20
30
40 50 60
S3 (M&/L) »10*
70
80
90
100
FIGURE C-13
BASIN SS VS. VSS
(ALL DATA)
-------
99.(
99.9
99
96
90
80
70
60
50
40
30
^ 20
10
J
5
x
X
0.1
o.oi
oo
EFFLUENT BOD (MG/L)
FIGURE C-14
PROBABILITY OF EFFLUENT BOD
C-14
-------
99.99
99.9
0.1
0.01
EFFLUENT SOLUBLE BOD (MG/L)
FIGURE C-15
PROBABILITY OF EFFLUENT SOLUBLE BOD
C-15
-------
Sj
10 H
§
a
o ,
100
230
1.00
403 533 600
BOD K1&/L)
700
930
000
1000
FIGURE C-16
EFFLUENT BOD VS. COD
(ALL DATA)
-------
12
18
24 30 36
SS (MO/L) »10*
42
48
54
£-0
FIGURE C-17
EFFLUENT SS VS. VSS
(ALL DATA)
-------
APPENDIX D
-------
APPENDIX D
SAMPLING POINTS, SAMPLING SCHEDULE, AND TESTING EQUIPMENT
SAMPLING POINTS
1. TOTAL PLANT INFLUENT-The sample was taken from the influent pump
discharge line, downstream from the influent pump pit, and pumped to the stock
samplers in the control building. The sample point is shown as S-l on Figure 2. The
pump is located in the control building.
2. SILT WATER—The sample was taken from the silt water line to the
clarifier-thickener, just inside the control building wall adjacent to the
clarifier-thickener. It flows by pressure to the stock sampler adjacent to the sample
point. The sample point is shown as S-2 on Figure 2. No pump was used to collect
this sample.
3. CLARIFIED SILT WATER-The sample was taken from the bottom of the
clarifier-thickener effluent launder and pumped to the stock samplers located in the
control building. The sample point is shown as S-3 on Figure 2. The sample pump is
located in the control building.
4. AERATION BASIN NO. 2 EFFLUENT-The sample was taken from the aeration
basin inlet-outlet structure, near the bottom of the box just upstream from
discharge Weir W-3, and pumped to the stock samplers in the control building. The
sample point is shown as S-4 on Figure 2. The sample pump is located in the
control building.
5. RETURN SLUDGE—The sample was taken from the recirculation sludge line,
downstream from the valve and meter pit, and pumped to the stock samplers in the
control building. The sample point is shown as S-5 on Figure 2. The sample pump is
located in the control building.
6. WASTE SLUDGE—A grab sample was taken from the waste sludge line by opening
Valve V-13, shown on Figure 2. The sample point is shown as S-6 on Figure 2.
7. FINAL PLANT EFFLUENT-The sample was taken from the secondary clarifier
effluent line, just downstream from the secondary clarifier, and pumped to the
stock samplers in the control building. The sample point is shown as S-7 on Figure
2. The sample pump is located in the control building.
D-l
-------
8. PRIMARY TREATED PROCESS WATER-The sample was taken from the treated
process water line at the meter manhole just upstream from the influent pump pit,
and pumped to the stock samplers in the control building. The sample point is
shown as S-8 on Figure 2, and the sample pump is located in the control building.
9. AERATION BASIN NO. 1 EFFLUENT-The sample was taken from the aeration
basin inlet-outlet structure, near the bottom of the box upstream from discharge
Weir W-2, and pumped to the stock samplers in the control building. The sample
point is shown as S-9 on Figure 2. The sample pump is located in the control
building.
10. FILTRATE—A grab sample was taken from the filtrate discharge line by opening
Valve V-19, shown on Figure 2. The sample point is shown as S-10 on Figure 2.
D-2
-------
TABLE D-1
SAMPLING AND TESTING SCHEDULE
NUMBER OF TESTS PER WEEK
SAMPLE
POINT
1
9
»
5
7
2
3
10
8
6
TOTAL
PLANT
INFLUENT
AERATION POND
NO. 1
EFFLUENT
AERATION POND
NO. 2
EFFLUENT
RETURN
SLUDGE
FINAL PLANT
EFFLUENT
SILT
WATER
CLARIFIED
SILT
WATER
FILTRATE
PRIMARY
TREATED
PROCESS WATER
WASTE
SLUDGE
o
o
5
5
5
1
5
2
5
1
5
-
CJ
o
CO
2
2
2
-
2
1
2
1
2
-
SUSPENDED SOLIDS
o
5
5
OR
MORE
5
OR
MORE
5
5
3
3
5
5
5
UJ
K
_l
o
1
2
2
5
1
1
1
1
1
-
SETTLEABLE
5
5
5
-
5
3
1
1
5
-
TEMPERATURE
5
CONT.
CONT.
1
5
1
1
1
5
-
o.
CONT.
5
5
1
1
1
1
1
5
-
DISSOLVED
OXYGEN
-
10
10
-
5
-
-
-
-
-
CO
O£.
O
u.
o
o
1
-
-
-
1
1
1
-
1
-
NITROGEN
i—
o
1
1
-
-
1
-
1
-
1
-
CO
0
1
1
-
-
1
-
1
-
1
-
PHOSPHOROUS
1
1
-
-
1
-
1
-
1
-
UJ UJ
o :E x
0 =» LU
=> _l 0
— 1 O Z
CO =*• —
-
5
5
-
-
-
-
-
-
-
i—
0.
CM UJ
O OQ
1
-
1
-
1
-
-
-
1
-
1
en >-
gt
UJ OQ
0 -t
-
-
-
1
-
1
-
-
-
-
MICROSCOPIC
EXAMINATION
-
1
1
-
-
-
-
-
-
-
I
1
1
1
-
-
-
1
-
1
-
Z UJ
UJ *£
O < UJ
X O-
-------
TABLE D-2
TESTING EQUIPMENT
ITEM
1. INCUBATOR
CABINET
TEMPERATURE
CONTROL
MANUFACTURER
GENERAL ELECTRIC
N-CON, INC.
MODEL
OPERATING
RANGE ACCURACY
20° C
±1°C
2. REFRIGERATOR
3. pH METER
4. ANALYTICAL
BALANCE
GENERAL ELECTRIC
SARGANT
METTLER
54
H 10TW
35° C
0-14
0-160g
±2°C
±0.05
± 0.0001 g
5. MUFFLE
FURNANCE
THERMOLYNE
F-D1525M
550° C
±10° C
6 DRYING OVEN
NATIONAL
APPLIANCE CO.
420
103°C
±1°C
7. VACUUM PUMP
8. ION EXCHANGE
COLUMN
GELMAN
BARNSTEAD
13400
20" HG
± 0.5 "HG
9. DISSOLVED OXYGEN
PROBE
FIELD PROBE
BOD BOTTLE PROBE
YELLOW SPRINGS
INSTRUMENT CO.
54
0-10
MG/L
±0.1 MG/L
10. SPECTROPHOTOMETER
BAUSCH & LOMB
SPEC.-20
11. PHOTO BINOCULAR
MICROSCOPE
BAUSCH & LOMB
PG252
12. CURRENT METER
A. OFF
C1
D-4
-------
APPENDIX E
-------
.icks Coll
Ricks College
REXBURG. IDAHO 83440
>. Q.UJ
JOHN I. CLARKE,
BIOLOGICAL SCIENCES
June 13, 1970
Mr. lynne Sirrins
The R.T.French Company
P.O.Box Drawer AA
Shelley, Idaho
Dear
This is a report on our findings of the waste disposal sample which we re-
ceived from you the week of June 8th. Our examination of the organism
you designated has been, a preliminary examination only.
Our results show that the orgaism is not a bacterium; it is likely a fungus.
¥e do not have a ugrcologist on our staff, for this reason we;1 were unable
to identify the organism for you»
The bacteria found, which were long filamentous rods, belonged to the genus
Bacillus. No other long filamentous bacteria were observed.
Kindest personal regards,
Lyle J. Lovder
E-Ji
-------
*3ta*^t-
f^4-sO*K~'C<^T^
FROM
THE R. T. FRENCH CO.
SHELLEY, IDAHO
0
fi/^
*x_^>' AS , it -70
MEUACE:
^
^__.CL<
-------
LABORATORY REPORT
LAB. NUMBER 5513 July 21, 1970
DATE RECEIVED July 2 , 1970
Sample, potato waste: as received basis
pH 6.6
Moisture 94.5 $
Protein 1.9 ^
Pat .02 £
Fiber .16 f
Ash 1.64 %
NPE 1.78 %
TISS 2.7 i°
Calcium 0.25 %
Phosphorous 0.051
Iron 0.0028
Sodium 0.099
Pesticide residue report will follow.
r n
PHONE 343-783O
R. T. French Co. U
p. 0. Drawer AA ijIBaS
Shelley, Idaho 83274 JABORATORKS
|_ ATTN: Mr. K. L. Sirrjne"' 2808 CASSIA BOISE'IDAHO e3705
E-3
-------
LABORATORY REPORT
LAB. NUMBER 5513 Feb. 7, 1971
DATE RECEIVED Sept. 23, 1970
Waste: Activated sludge sample from R.I.French, Shelley, Idaho:
Pesticide residue by G.L.C. electron-capture.
Results: nil
Pesticides: Detection limit
Standards used ppm
Lindane .005
Aldrin .01
Heptachlor epoxide .01
Dieldrin .05
Endrin .05
DDE .05
DDD .1
DDT -1
Me thoxychlor. .2
r n
Cornell Howaand Hayes & Merryfield ij PHONE 343-7MO
1600 Western Bird. til BBS
Corrallis, Oregon JABORATOiHCS
I ATTH: HZ*. Glen RiChter. i Af aaoe CASSIA BOISE. IDAHO M706
&4
-------
APPENDIX F
-------
TABLE F-l
THE R. T. FRENCH COMPANY
Shelley, Idaho
SECONDARY WASTE TREATMENT FACILITY
CONSTRUCTION COSTS
TOTAL
ITEM COSTS
Control Building
Building, Complete $ 33,884.56
Influent Pumps 12,768.40
Influent Pump Wet Well 8,163.61
Sludge Pumps 9,788.25
Sample Pumps and Samples 17,470.80
Continuous Temperature Recording 4,705.72
Laboratory Equipment and Supplies 6,389.19
Flow Metering Equipment 11,842.85
Aeration Equipment 87,123.85
Secondary Clarifier and Sludge
Recirculation Station 51,811.94
Aeration Basin and Miscellaneous
Earthwork
Earthwork 18,809.93
Plastic Sheet Liner 18,825.00
Influent Splitter Boxes 2,322.10
Outlet Boxes 3,953.11
Inlet Header Piping 6,808.50
Outlet Piping to Clarifier 6,146.55
Miscellaneous Outside Piping and
Plumbing
Sample Lines, Washwater Lines,
and Hydrants 5,167.02
Water Source 2,312.46
Sludge Piping 6,731.04
Pipe from Waste Solids System 650.00
Gravity Influent from Processing Plant 14,628.45
Gravity Outfall to Existing Storm Sewer
in Fir Street 13,418.71
ESTIMATED
TOTAL COSTS LESS
DEMONSTRATION COSTS
$ 20,000
12,768
8,164
9,788
11,843
50,000
40,000
12,000
8,000
6,500
6,000
2,312
6,000
650
14,628
13,419
F-l
-------
TABLE F-l - CONTINUED
Waste Solids System
Filter $ 30,810.68
Intercept Silt Water, Screen, Pump,
and Pipe to Waste Solids System 54,971.38
Clarifier-Thickener 29,254.66
Solids Pump 1,823.85
Solids Bunker 3,419.26
Electrical
Primary Transformer and Meter 6,499.78
In-Plant Electrical 28,693.72
Electrical Building 2,464.00
Painting 830.70
Gravel Roadway and Parking 2,491.02
Fence 4,404.00
Cleanup and Miscellaneous 650.00
Move-in and Temporary Facilities 2,300.00
Bond and Insurance 2,530.00
Design, Engineering, Inspection and
Supervision 78,135.69
Legal and Administrative 4,987.60
TOTAL $598,104.94
$ 30,811
54,971
29,255
1,824
3,419
6,500
28,500
2,464
500
2,491
4,404
650
2,000
2,530
34,000
4,988
$431,379
F-2
-------
TABLE F-2
THE R. T. FRENCH COMPANY
Shelley, Idaho
SECONDARY WASTE TREATMENT FACILITY
OPERATION AND MAINTENANCE COSTS
ITEM
Operating Staff
Laboratory Technician
Clerk-Typist
Chemist-Operator
Professional Staff
Power
Maintenance
Labor
Parts
Improvements and Spreading on Site
Solids Disposal
Laboratory Supplies
Operating Supplies
Outside Laboratory Testing
Preparation of Project Reports
Transportation
On-Site Living Expense
Telephone
TOTAL
TOTAL
COSTS
$ 4,685.14
3,702.51
9,718.83
19,441.53
23,498.90
7,647.65
5,824.17
6,973.64
1,,777.69
5,391.73
2,227.82
82.90
751.59
556.35
150.40
781.61
$93,212.46
ESTIMATED
TOTAL COSTS LESS
DEMONSTRATION COSTS
$ 4,685.14
3,702.51
9,718.83
23,498.90
7,647.65
5,824.17
6,973.64
1,777.69
5,391.73
2,227.82
82.90
730.60
$72,261.58
F-3
-------
APPENDIX G
-------
3 JUNE 1970
POWER = 167 HP PER
MILLION GALLONS
o
^^— 0,5O
/^ ^ 0.46
,0.80
PROFILE AT 3 FOOT DEPTH
SCALE IN FEET
AERATOR WITH OPERATING
HORSEPOWER DURING TEST
X VELOCITY READINGS
IN FT. PER SECOND
FIGURE G-1
THE R. T. FRENCH COMPANY
SHELLEY,IDAHO
VELOCITY PROFILE
BASIN 2
9 AERATORS
-------
3 JUNE 1970
9
to
SECTION C-C
VELOCITY READINGS
IN FT. PER SECOND
20
20
40
SCALE IN FEET
FIGURE G-2
THE R. T. FRENCH COMPANY
SHELLEY, IDAHO
VELOCITY PROFILE
BASIN 2
9 AERATORS
-------
4 MAY 1970
POWER = 167 HP PER
MILLION GALLONS
PROFILE AT 1 FOOT DEPTH
AERATOR WITH OPERATING
HORSEPOWER DURING TEST
X DISSOLVED OXYGEN
READINGS IN MG/L
FIGURE G-3
THE R. T. FRENCH COMPANY
SHELLEY,IDAHO
DISSOLVED OXYGEN PROFILE
BASIN 2
9 AERATORS
-------
4 MAY 1970
DISSOLVED OXYGEN
READINGS IN MG/L
PROFILE AT 6 FOOT DEPTH
AERATOR WITH OPERATING
HORSEPOWER DURING TEST
IGURE G-4
THE R. T. FRENCH COMPANY
SHELLEY, IDAHO
DISSOLVED OXYGEN PROFILE
BASIN 2
9 AERATORS
-------
4 MAY 1970
SECTION D-D
10 o 10
EEC
SCALE IN FEET
X DISSOLVED OXYGEN
READINGS IN MG/L
20
FIGURE G-5
THE R. T. FRENCH COMPANY
SHELLEY, IDAHO
DISSOLVED OXYGEN PROFILE
BASIN 2
9 AERATORS
-------
O
_J
o
2
z
LU
X
o
Q
LU
_J
O
CO
CO
Q
_
_l
O
5
Z
LU
O
X
o
Q
LU
_l
s
5
-
-
3 -
-
-
~
7 '.
_
-
_
_
1 -
"
-
-
0 "
C
-
-
3 -
-
-
—
2 -
1 -
-
_
0
(
MAR 4 - BASIN NO. 1
ao
0 — — = 64.0 MG/L/HR.
dt
° VSS = 6,470 MG/L
0 02 UPTAKE = 0.24 MG O2/DAY/MG ML VSS
« TEMP = 15.7° C
>Q
^W
^^^
>w
e 0
o
e o
) 100 200
TIME (SEC.)
MAR 9 - BASIN NO. 1
e do
-ft- - 24 MG/UHR.
0 VSS = 2,325 MG/L
° 0_ UPTAKE = 0.25 MG O0/DAY/MG ML VSS
0 4 z
0 TEMP. = 15.0° C
e
0
a>v^
^^"^>te^
0*^5^^^
^^0
o
) 100 200
TIME (SEC.)
J
a
5
Z
LU
0
X
o
Q
LU
_J
O
co
CO
Q
~
Z
LU
CO
X
o
Q
LU
_J
0
8
Q
-
-
3-
-
-
~
2 -
_
-
_
_
1 -
"
-
-
0
C
-
-
3 -
-
-
—
2 .
-
1 -
-
-
0~
MAR 6 - BASIN NO. 1
e do
= 48 MG/L/HR.
e dt
0 VSS= 5,100 MG/L
0 0, UPTAKE - 0.23 MG 02/DAY/MG ML VSS
X' - 15.8° C
O
O
o
100 200
TIME (SEC.)
0 MAR 11 - BASIN NO. 1
do
0 -ft- = 36 MG/L/HR.
VSS = 5,950 MG/L
0 02 UPTAKE = 0.15 MG 02/DAY/MG ML VSS
0 TEMP. = 15.0° C
O
N^
^TQL^
^N^k
^^*O
0
'1'IIIITIIII
3 100 200
TIME (SEC.)
OXYGEN UPTAKE DATA
FIGURE G-6
-------
MAR 16 - BASIN NO. 1
MAR 18 - BASIN NO. 1
O
-
-
3 3-
2 •
Z
LU
C3 2-
X "
o -
Q "
LU
j 1 -
O -
(/)
Q -
0_
do
a — = 17 MG/L/HR.
& Qt
VSS = 4,950 MG/L
° 02 UPTAKE = 0.08 MG 02/DAY/MG ML VSS
° TEMP. = 12.4° C
e
*"S^Jk
^'•••^^^^
° ^^*^^&"^*^
^9**^*^,,..
^^^""•"•••P
0 100 20
TIME (SEC.)
MAR 19 - BASIN NO. 1
—
—
3 3-
5 -
•
LU •
O 2™
>-
x •
o -
Q •
LU .
_l 1-
O -
c/? —
Q -
o
e do
, = 30.8 MG/L/HR.
dt
0 VSS = 6,300 MG/L
0- UPTAKE = 0.12 MG 0-/DAY/MQ ML VSS
e
e TEMP. = 14.2 C
e
'S^
^^^xc_
^^•^et
^^ 0
o
o
Mlllllllll'l
0 100 20
TIME (SEC.)
^
a
2
Z
LU
X
O
o
LU
^
0
t/5
Q
_
-
3-
-
-
-
2-
-
™
-
—
1-
-
-
-
0_
do
lit"
0 VSS =
38.4 MG/L/HR.
6,450 MG/L
0 02 UPTAKE = 0.14 MG 02/DAY/MG ML VSS
e TEMP.
e
e^
^^^.
^^i^W
o^»
^V^
0 100
TIME (SEC.)
= 13.2° C
&•
&
6 e
i i i i i
200
_, ° MAR 28 - BASIN NO. 1
<«K.
O
2
UJ
O
X.
0
Q
LU
>
o
V)
V)
Q
—
^
3-
-
•
-
2—
:
-
-
_
.
-
0_
do
© — — =
QT
o
o vss =
25.0 MG/L/HR.
4,600 MG/L
0 Q2 UPTAKE = 0.13 MG 02/DAY/MG ML VSS
^a>^
^^>,^ TEMP. =
^">X^
^°^
• 1 1 1 I 1 1 1
0 100
TIME (SEC.)
ft
= 14.9° C
"^^
^^^
^0
1 1 1 1 1
200
OXYGEN UPTAKE DATA
FIGURE G-7
-------
O
do
3 -
LU
O
>• 2^
X
O
Q
LU
I n
dt
MAR 30 - BASIN NO. 1
= 14.0 MG/L/HR.
VSS - 5,600 MG/L
02 UPTAKE
0.06 MG 02/DAY/MG ML VSS
100
TIME (SEC.)
200
z
LU
O
>-
X
O
O
co
CO
3-
2-
1-
APRIL 1 - BASIN NO. 1
do
-fa = 30.0 MG/L/HR.
VSS = 5,180 MG/L
02 UPTAKE = 0.14 MG 02/DAY/MG ML VSS
TEMP. * 14.3° C
100
TIME (SEC.)
200
5
Z
3H
2-
X
O
O
LU
>
=f 1-
APRIL 8 - BASIN NO. 1
— " 38.4 MG/L/HR.
dt
VSS - 3,560 MG/L
02 UPTAKE « 0.26 MG 02/DAY/MG ML VSS
[EMP.
15.5° C
100
TIME (SEC.)
200
3-
> 2-|
X
a
LU
O
to
to
1-
APRIL 20 - BASIN NO. 2
do
dt
VSS
= 28.8 MG/L/HR.
2,840 MG/L
02 UPTAKE = 0.24 MG 02/DAY/MG ML VSS
TEMP. = 15.0° C
100
TIME (SEC.)
200
OXYGEN UPTAKE DATA
FIGURE G-8
-------
APRIL 27 - BASIN NO. 2
APRIL 28 - BASIN NO. 2
o
vb
_l
c5
6.O-
5:0-
4-°
LU
a
X 3.0
Q
LU
O
% 2.0
Q
1.0-
0.0
do
IT
19.0 MG/L/HR.
do
VSS = 2,650 MG/L
02 UPTAKE = 0.17 MG 02/DAY/MG ML VSS
TEMP.
15° C
i i \ i
too
TIME (SEC.)
200
6.0
5.0 < ^
4.0-
LU
o
X 3.0-1
Q
LU
| 2'«H
Q
1.6-
0.0
26.4 MG/L/HR.
2,800 MG/L
VSS
02 UPTAKE = 0.23 MG 02/DAY/MG VSS
TEMP.
15.0° C
100
TIME (SEC.)
200
OXYGEN UPTAKE DATA
FIGURE G-9
-------
APPENDIX H
-------
u_
I
Q
(D
6.75 X 10"'
103 TO 185 HP/MILLION GALLONS
AVERAGE AIR TEMP. RANGE = 37 TO 57°F
R(TU-TR)
(100.000 SO FT-F)
FIGURE H-1
AERATION BASIN HEAT LOSS RELATIONSHIP
1.0 - 2.0 DAYS DETENTION TIME
(ALL DATA)
H-1
-------
5.16 X 10"'
103 TO 185 HP/MILLION GALLONS
AVERAGE AIR TEMP. RANGE = 42 TO 60° F
fl(TW-Tfl)
(100.000 SO FT-F)
FIGURE H-2
AERATION BASIN HEAT LOSS RELATIONSHIP
2.0 - 3.5 DAYS DETENTION TIME
(ALL DATA)
H-2
-------
4.07 X 1
-------
1
5
Accession Number
n Subject Field &, Group
05D
SELECTED WATER RESOURCES ABSTRACTS
INPUT TRANSACTION FORM
Organization
French Co., The R. T., Shelley, Idaho
Title
AEROBIC SECONDARY TREATMENT OF POTATO PROCESSING WASTES
Authors)
French Co., The R. T.
16
Project Designation
ftVPRD 15-01-68) 12060 EHV
21
Note
22
Citation
23
Descriptors (Starred First)
*Waste treatment, *Secondary treatment, *Industrial wastes, Activated sludge,
Aeration, Treatment facilities
25
Identifiers (Starred First)
*Potato processing wastes, Food processing wastes, Waste treatment costs
27
Abstract
A new secondary treatment facility at the R. T. French Company, Shelley, Idaho, has demonstrated the
feasibility of a complete mix activated sludge system for secondary treatment of potato processing
wastes. The secondary treatment facility was designed for an average daily flow of 1.25 million gallons
per day and a BOD loading of 14,100 pounds per day. Frequent aerator shutdowns following
mechanical problems have limited oxygen transfer and biological activity in the aeration basins; however,
BOD removals of over 90 percent have been obtained for extended periods of time, demonstrating the
applicability of the activated sludge process for treating the wastes. These removals have been obtained
with: (1) MLSS concentrations between 2,000 mg/1 and 8,000 mg/1, (2) aeration basin D. O.
concentrations between 0.3 mg/1 and 5.2 mg/1, (3) aeration basin temperatures between 45 degrees F
and 67 degrees F, (4) aeration basin pH between 7.1 and 8.4, (5) organic loadings between 10 and 120
Ib BOD/1,000 cu ft/day, (6) hydraulic detention times of 0.9 to 8.7 days, and (7) BOD/MLVSS ratios
of 0.15 to 0.47.
This report was submitted in fulfillment of Grant No. WPRD 15-01-68, Program 12060 EHV, between
the Environmental Protection Agency and R. T. French Company.
Abstractor Glenn Richter
institution Cornell, Rowland, Hayes & Merryfield, Corvallis, Oregon
WR:<02 (REV. JULY 1969)
WRSIC
SEND TO: WATER RESOURCES SCIENTIFIC INFORMATION CENTER
U.S. DEPARTMENT OF THE INTERIOR
WASHINGTON. D. C. 20240
* GPO: 1969-359-339
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