&EPA
            United States
            Environmental Protection
            Agencv
           Municipal Environmental Research
           Laboratory
           Cincinnati OH 45268
EPA-6QO/2-78-158
September 1978
            Research and Development
Advanced Waste
Treatment for Housing
and Community
Developments

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                 RESEARCH REPORTING  SERIES

 Research reports of the Office of Research and Development. U 3 Environmental
 Protection Agency, have been grouped into nine series. These nine broad cate-
 gories were established to facilitate further development and application of en-
 vironmental technology Elimination of traditional  grouping was consciously
 planned to foster technology transfer and a maximum interface in  related fields
 The nine series are

      1   Environmental Health  Effects Research
      2   Environmental Protection  Technology
      3   Ecological Research
      4.   Environmental Monitoring
      5.   Socioeconomic Environmental Studies
      6   Scientific  and Technical Assessment Reports (STAR)
      7.   Interagency Energy-Environment Research and Development
      8   "Special'  Reports
      9.   Miscellaneous Reports

 This report has been assigned to the ENVIRONMENTAL PROTECTION TECH-
 NOLOGY series. This series describes research performed to develop and dem-
 onstrate  instrumentation, equipment, and methodology to  repair or prevent en-
 vironmental degradation from point and non-point sources of pollution This work
 provides the new or improved technology required for the control  and treatment
 of pollution sources to meet environmental quality standards
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia  22161.

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                                   EPA-600/2-78-168
                                   September  1978
         ADVANCED  WASTE  TREATMENT
                    FOR
    HOUSING AND COMMUNITY  DEVELOPMENTS
                    by

              Russell  Bodwell
       Levitt arid Sons,  Incorporated
       Greenwich, Connecticut   06830
          Contract No.  68-01-0077
              Project Officer

             Irwin J. Kugelman
       Wastewater Research Division
Municipal  Environmental  Research Laboratory
          Cincinnati, Ohio  45268
MUNICIPAL ENVIRONMENTAL RESEARCH LABORATORY
    OFFICE OF RESEARCH AND DEVELOPMENT
   U.S. ENVIRONMENTAL PROTECTION AGENCY
          CINCINNATI, OHIO  45268

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                           DISCLAIMER
     This report has been reviewed by the Municipal  Environmental
Research Laboratory, U.S. Environmental  Protection Agency, and
approved for publication.  Approval does not signify that the
contents necessarily reflect the views and policies  of the U.S.
Environmental Protection Agency, nor does mention of trade names
or commercial products constitute endorsement or recommendation
for use.

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                                  FOREWORD


     The Environmental  Protection Agency was created because  of increasing
public and government concern about the dangers of pollution  to the  health
and welfare of the American people.  Noxious air,  foul  water, and spoiled
land are tragic testimony to the deterioration of  our natural environment.
The complexity of that environment and the interplay between  its components
require a concentrated and integrated attack on the problem.

     Research and development is that necessary first step in problem solution
and it involves defining the problem, measuring its impact, and searching  for
solutions.  The Municipal Environmental Research Laboratory develops new and
improved technology and systems for the hazardous  water pollutant discharges
from municipal and community sources, for the preservation and treatment of
public drinking water supplies, and to minimize the adverse economic, social,
health, and aesthetic effects of pollution.  This  publication is one of the
products of that research; a most vital communications link between  the
researcher and the user community.

     Provision of sewerage facilities for a dispersed population living in
semi-isolated subdivisions is a significant problem.  Either the subdivision
must be connected to a central treatment plant, or a small scale plant must
be provided for treatment of the community wastewater.  The  former procedure
is often expensive because a long sewer run is required to serve only a few
homes.  Small scale biological treatment plants are also relatively expen-
sive and exhibit poor performance when subjected to the wide fluctuations
of loading inherent in a small flow situation.  In this study a treatment
plant for isolated subdivision wastes using wholly physical  chemical treat-
ment technology was evaluated.  Physical chemical  treatment  systems are
superior under fluctuatory loads, and are small enough to be placed in a
shell of a typical suburban house, thus reducing land costs.
                                         Francis  T.  Mayo,  Director
                                         Municipal  Environmental  Research
                                          Laboratory
                                       m

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                           CONTENTS
                                                           Page
Foreword                                                    iii
ListofFigures                                              V1-
List of Tables                                               ix
Abbreviations                                                xi
Acknowledgments                                             x-j-j
I       Introduction                                           1
II     Conclusions                                            4
III    Recommendations                                        7
IV     Phase 1:  Preconstruction Study
                 and Engineering Design                       9
V       Phase 2:  Construction                                36
VI     Phase 3:  Operation and Evaluation                    44
       A.   Liquid Handling Process                           44
           1.  Plant Startup and Break-In                    44
               October 1972 - June 1973
           2.  Steady State Operations                       57
               a. Normal  Evaluation                          65
               b. Intensive Evaluation I                     97
               c. Intensive Evaluation II                   102
       B.SolidsDisposal                                  114
       C.   Plant Modifications                              124
VII    Financial Considerations                             126
VIII   Appendixes
       A.   Laboratory Procedures                            132
       B.   Photographs                                      136
       C.   Conversion Table                                 140

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                         LIST OF FIGURES


Number                                               Page

  1.   West Goshen Pa.,  Waste Treatment Plant
        Flow Data for Fifty Day Period	      10

  2.   West Goshen Pilot Plant Operation  Schematic
        Flow Diagram	      11

  3.   Assumed Raw Sewage Flow Characteristics  For
        Surge Tank Design	      16

  4.   Freehold Treatment Plant Furnace Sludge
        Incineration Mode	      23

  5.   Freehold Treatment Plant Furance Carbon
        Regeneration Mode	      24

  6.   Freehold Treatment Plant Regenerating Sludge
        Dewatering Sand Filter	      26

  7.   Sludge Dewatering Filter and Furnace Feed
        Screw Chamber	      27

  8.   Furnace Feed Screw Location in Sludge
        Dewatering Filter	      28

  9.   Vicinity Map Freehold Treatment Plant	      37

 10.   Site Plan Freehold Treatment Plant	      38

 11.   Equipment Layout, Main Floor Plan	      40

 12.   Equipment Layout, Basement Plan	      41

 13.   Plant Exterior	      42

 14.   Process Flow Diagram	      45

 15.   Flow and Occupancy During the Plant
        Start-Up and Break-In Period	      59

 16.   Monthly Variation of BOD of Sewage During
        Break-In Period	      63

                            vi

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                          LIST OF FIGURES
                            (continued)

Number                                                Page

  17.  Suspended Solids Variation During Break-In
         Period ...................................     64

  18   Weekly Analysis Report .....................     68

  19.  Average Monthly Flow During Original
         Occupancy ...............................      70

  20.  Daily Effluent Flow July 1973-March 1974
         Frequency Distribution ..................      71

  21.  Freehold Treatment Plant Dirunal  Flow
         Profile .................................      73

  22.  Suspended Solids Frequency Distribution
         In Raw Sewage and the Surge Tank ........      75

  23.  Biochemical Oxygen Demand Frequency
         Distribution In Raw  Sewage and the Surge
         Tank ....................................      76

  24.  Total Hydrolyzable Phosphorus Frequency
         Distribution In Raw  Sewage and the Surge
         Tank ....................................      77

  25.  Removal of Pollutants  Along the Flow Sheet
         of the Freehold Treatment Plant .........      82

  26.  Suspended Solids Weekly Averages ..........      84

  27.  Total Hydrolyzable Phosphorus Monthly
         Average .................................      85

  28.  Biochemical Oxygen Demand Monthly
         Averages ................................      86

  29.  Kjeldahl Nitrogen Monthly Averages ........      87

  30.  Ammonia  Nitrogen Monthly Averages .........      88

  31.  Suspended Solids Frequency Distribution
         Clarified and Filtered Effluent .........      89

  32.  Suspended Solids Frequency Distribution
         Plant  Effluent ..........................      90

  33.  Biochemical Oxygen Demand Frequency
         Distribution Ferrofilter Effluent ......       92
                            vi i

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                         LIST OF FIGURES
                            (conti nued)
Number
  34.   Biochemical  Oxygen  Demand  Frequency
         Distribution Plant Effluent .............       93

  35.   Intensive Analysis  II
         Daily Variation Suspended Solids 10 Day
         Average, 2 Hour Frequency January 17, 1974-
         April 7, 1974 ...........................      104

  36.  Intensive Analysis  II
         Daily Variation Biological Oxygen Demand
         10 Day Average, 2  Hour Frequency
         January 17,  1974-April 7, 1974 ..........     105

   37.  Intensive Analysis  II
         Daily  Variation  in Total  Organic Carbon
         10 Day  Average,  2 Hour  Frequency
         January  17,  1974-April  7, 1974 ..........      106

   38.   Intensive Analysis  II
          Daily  Variation  in Total  Oxygen Demand
          10  Day Average,  2 Hour  Frequency
          January 17, 1974-April  7, 1974 ..........      107

   39.   Intenstive Analysis II
          Daily Variation  in Total Kjeldahl  Nitrogen
          10 Day Average,  2 Hour Frequency
          January 17, 1974-April  7, 1974 ..........      108

   40.  Intensive Analysis  II
          Daily Variation  in  Phosphorus  10 Day
          Average, 2  Hour  Frequency January  17, 1974-
          April  7, 1974 ...........................     109

   41.  Intensive Analysis  II
          Daily  Variation  in  Ammonia-Nitrogen
          10  Day Average,  2 Hour  Frequency
          January  17, 1974-April  7, 1974 ..........     HO

   42.   Intensive  Analysis II
          Daily  Variation  in  pH  10 Day Average,
          2 Hour Frequency January 17, 1974-
          April  7,  1974 ...........................      '"'

    43.   Estimated  Operating Cost vs.  Plant  Size...      130
                             vn i

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                       LIST OF TABLES
Number                                                  Page
  1.   West Goshen Pilot Plant  Operation
        Operating Conditions	    13
  2.   West Goshen Pilot Plant  Operation
        Operating Results	    14
  3.   Incinerator Design Parameters	    31
  4.   Occupancy and Flow	    58
  5.   Raw Sewage Characteristics	    60
  6.   Surge Tank Characteristics	    61
  7.   Plant Effluent Characteristics	    62
  8.   Analytical & Sampling  Schedule
        During  Normal  Evaluation	    66
  9.   Analytical & Sampling  Schedule  in  Addition
        to Normal Evaluation During  Intensive
        Evaluation	    67
 10.   Occupancy and Flow	    69
 11.   Liquid Treatment Performance Average  Values	    78
 12.   Liquid Treatment Performance Average  Analysis	    80
 13.   Liquid Treatment Performance Efficiencies	    81
 14.   Chemical  Consumption	    94
 15.   Intensive Evaluation  I
        Average Values	    99
 16.   Intensive Evaluation  II
        Average Values	   103
 17.   Intensive Evaluation  II
        Three Period Average	   112
                             ix

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                        LIST  OF  TABLES
                         (conti nued)

 Number                                                  Page

  18.   Freehold  Sludge  Characteristics	  116

  19.   Intensive Evaluation  -  Sludge  Samples	  118

  20.   Hydrasieve  Solids  Collected	  119

  21.   Incinerator Operating  Data	  123

*• 22.   Operating Costs	  128

  23.   Projected Operating  Costs	  131

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                        ABBREVIATIONS
AC          -  Alternating Current
ALK         _  Alkalinity
B°D         _  Biochemical Oxygen Demand (Five-Day)
CFM         -  Cubic Feed Per Minute
COD         _  Chemical Oxygen Demand
Col         _  Coliform
DC          _  Direct Current
D!A.        -  Diameter
00          -  Dissolved Oxygen
FTU         _  Formazin Turbidity Unit
GAL.        -  Gallon (United States Measure)
            _  Gallons Per Hour
            _  Gallons Per Minute
HP          -  Horsepower
Hr.         .  Hour
ID          -  Interval Diameter
JJU         -  Jackson Turbidity Unit (1FTU a 1JTU)
mg/1        -  Milligrams Per Liter
MGD         _  Million Gallons Per Day
NH3-N       -  Ammonia Nitrogen
P           -  Hydrolyzable Phosphorus
PSIG        -  Pounds Per Square Inch - Gauge
Res. C12    _  Residual Chlorine
RPM         _  Revolutions Per Minute
SCFM        _  Standard Cubic Feed Per Minute
SS          _  Suspended Solids
TDH         _  Total  Discharge Head
TDS         _  Total  Dissolved Solids
TKN         .  Total  Kjeldahl Nitrogen
TOD         _  Total  Oxygen Demand
TS          _  Total  Solids
                         xi

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                         ACKNOWLEDGMENTS
     The authors  wish to acknowledge  the  contributions  of  several
persons and organizations whose efforts  were  instrumental  in
developing and completing this project.

     Mr. Wallace  B.  Johnson of AWT Systems,  Inc.  for  his  efforts
and contributions in process research and development on  this
plant and for preparing the greatest  portion  of this  report.

     Mr. Russell  S.  Bodwell, Vice President-Engineering,  Levitt
and Sons, Inc., and  the Engineering Department of Levitt  and
Sons, Inc. for their interest and efforts in  advancing the state-
of-the-art of waste  water treatment plants relative to optimizing
effluent quality  standards and incorporating  treatment plants  in
total compact community planning.

     AWT Systems, Inc., for their efforts in  research and design
of the treatment  system and interest  and contributions in the
construction and  evaluation of the plant.

     Appreciation is also expressed to Mr. Carl Birkhimer and  Mr.
Henry J. Greenemeir  of Winslow Sanitary Company.   Both were plant
operators during  the stead-state operation phase and whose
efforts in the collection of samples, smooth  plant operations,
and general cooperation and assistance were invaluable.

     Acknowledgment must also be made to Henderson and Bodwell
for modifications to the system, greatly instrumental in reducing
operating costs and  increasing plant reliability; modifications
were largely implemented by Mr.  Birkhimer.  They also prepared
portions of the final draft and  documents included herein.
                              xi

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                            SECTION I

                           INTRODUCTION
GENERAL
     The home and community building industry,  in order to meet
the housing requirements of today,  has developed a concept of
total  community planning.   Such community planning includes
single-multi family housing, shopping centers,  sites  for industry,
schools, churches, etc.   Consequently the building industry is
faced  with a unique waste water disposal  problem in that the
industry, not the municipality, is  generally required to provide
adequate disposal facilities for new community  developments.
This trend toward total  community planning, in  which  domestic and
industrial wastes must be handled over a  wide range of flow rates
and waste characteristics, requires that  building firms in this
country have access to treatment facilities of  types  heretofore
seldom utilized.

     A national commitment to manage water quality has been mani-
fested in the past decade in response to  continual degradation  of
water  supplies for beneficial uses.  Technical, legislative, and
financial moves have begun to zero  in on  the environmental prob-
lems.   One of the first and most important needs in our national
priorities to meet existing water management goals is to develop
the minimum cost technology for removing  contaminants from water
and permanently disposing of them in order to alleviate water
pollution problems.  A further objective  is to  renovate waste
waters for agricultural, industrial, recreational, or even poten-
tially potable purposes.  New advanced systems  are now being
designed to meet the new objectives of total pollution control,
namely, the capability of treatment to extremely high levels of
quali ty.

     Advanced waste treatment has made great progress in supply-
ing many tools to water resource management.  Traditionally,
small  scale treatment plants have had to  be installed where
existing sewer lines were not available for hookup, or where
barriers existed making hookup impractical.  Suburban developments
had to make use of so-called "package plants" to treat their
waste  water flows.  These plants are usually adaptations of the
conventional activated sludge process designed  to meet special-
ized problems encountered in situations where flow is highly
variable.

                                 1

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     Two commonly used modifications are extended aeration and
contact stabilization.  Contact stabilization aerates waste water
mixed with highly concentrated activated sludge to adsorb colloi-
dal organics.  Sludge from a clarifier is then aerated to stabil-
ize the organic matter and renew the sludge surface for more
adsorption.  Extended aeration handles waste without primary
settling.  The aeration tank acts as an equalization basin to
smooth out variations in load and to dilute slugs of concentrated
or toxic impurities.

     The most serious problems encountered with these package
plant units are related to the highly varying natures of waste
water flow together with waste strength or concentration.  For
example, it is common to see flow patterns where peak flows of
2.5 to 3 times the average occur during the day and zero flow
occurs during hours of the night.  Such flow and strength charac-
teristics are ill suited to the capabilities of secondary bio-
logical processes.  Coupling these shock loadings with substandard
operation, maintenance, and reliability, it is not surprising that
these plants cannot be expected to achieve, on a consistent basis,
existing and projected water quality effluent requirements.

     Physical-chemical treatment represents the first major inno-
vation in sewage treatment in several decades.  Such systems,
while increasing the capability for handling a wide range of con-
tinuous and intermittent flow rates, offer added advantage in the
ability to handle toxic industrial wastes and to remove components
which cannot be treated biologically.

     Advantages of a physical-chemical system include:

     1.  Smaller land area required (less than 1/2) of the
         conventional biological plant.
     2.  Higher degrees of treatment efficiency than conventional
         biological processes.
     3.  Lesser sensitivity to unusual loadings.
     4.  Lesser sensitivity to daily flow variations.
     5.  Greater design flexibility.
     6.  Greater operational flexibility and control.

Because these features make it possible to meet stringent effluent
criteria in remote sites,  physical-chemical treatment technology
was chosen for a plant in  a community in northern New Jersey.  The
basic concept was to place the treatment plant within the frame of
a standard house on a standard lot in a subdivision.  This pro-
cedure provides more land  for ultimate development because a
buffer zone need not be established around the treatment plant as
it must if more conventional technology is used.

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LOCATION

     An advanced waste treatment system based on physical-chemical
treatment technology was designed to serve approximately 127
single-family dwelling units, and a demonstration plant was  con-
structed in a residential subdivision in Freehold Township,  Mon-
mouth County, known as Woodgate Farms.   The nominal  average  design
flow was 50,000 GPD.

PLANT DESCRIPTION

     The plant design chosen provided for screening, flow equal-
ization, chemical coagulation, sedimentation, filtration, carbon
adsorbtion, and disinfection with chlorine.  Sludge  was to be de-
watered on site and incinerated on site in a fluidized  bed furnace.

OBJECTIVE

     The specific objective of this project was to demonstrate
the performance, economics, and applicability of a physical-
chemical domestic wastewater treatment  system designed  to provide
varying high quality discharges for isolated or developing com-
munities having an average wastewater flow in the 25,000 to
500,000 GPD range.

APPROACH

     The total project was conducted in the following three  phases

     Phase I - Preconstruction Study and Engineering, during which
all necessary preliminary studies, subsystem designs, and engineer-
ing plans were completed.

     Phase II - Construction, including purchase of  all equipment,
subcontract work, construction of the building, and  assembly of
the complete system.

     Phase III - Operation and Evaluation, including a  start-up
and break-in period while houses in the development  were being
built and occupied (October 1972 through June 1973), and a period
of operation under steady state conditions (July 1973 through
March 1974) to obtain data on all aspects of plant performance.

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                           SECTION  II

                           CONCLUSIONS


      1)  The physical-chemical wastewater treatment system provided
 a  high-quality discharge while processing all the sewage from an
 isolated community of 127 single-family dwelling units over a
 period of  18 months.

      2)  Average treatment performance showed removals of 99%
 BODs, suspended solids and phosphorus; 37% Kjeldahl nitrogen.
 The use of the ferric chloride coagulant caused reduction of 46%
 alkalinity and a threefold increase in chlorides.

      3)  Unit operations performance shows:

         a.  Primary screen removed approximately 1/4 of the BOD,
 suspended solids and phosphorus.

         b.  Chemical treatment and clarification removed approx-
 imately 2/3 of the 8005, suspended solids and phosphorus.

         c.  Carbon adsorption removed about 16% of the BOD and
 25% of the TKN.

         d.  Filtration was relatively ineffective.

      4)  Characteristics of raw sewage from the totally domestic
 source were:

         Flow     -    206 gpd/unit
         BOD      -    207 mg/1
         SS       -    242 mg/1
         TS       -    628 mg/1
         P        -    10.8 mg/1
         TKN      -    44.7 mg/1
         Coliforn -    1.1  x  106 MPN/100 ml

     5)   Twenty-four hour raw sewage profiles on flow and eight
analytical  parameters showed  substantial  variation.   For example:
Hourly peak flow (180%  of average) occurred at 11  a.m.-noon,  with
secondary peaks at 8 p.m. and 11:30 p.m.   Minimum flow was  reg-
istered  between 4 and 5 a.m.  at 14% of average.   Analytical  para-
meters showed similar variation but with peak and minimum concen-
trations  occurring at different hours.

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      6)   The  surge  tank,  provided  to  level out raw sewage varia-
 tion,  was  very  effective.   It  allowed constant flow rate process-
 ing  through the plant with  only periodic adjustment.  Also varia-
 tions  in  the  concentration  of major constituents were smoothed
out and reduced to about half that in the instantaneous  flow.

     7)  Chemical consumptions were higher than anticipated,  aver-
aging 267 mg/1 for FeCls;  154 mg/1  for NaOH;  2.6  mg/1  for poly-
electrolyte; and 26.4 mg/1 for chlorine.  They have been reduced
with plant modifications which include more automation,  pH  control
of FeCls, and  greater mixing effectiveness  and detention times.

     8)  Operating costs were higher than anticipated  because:

         a.  Labor costs were excessive due to the experimental
nature of much of the equipment, due to the high  level  of analyt-
ical work carried out, and because more manual control  was  required
than anticipated.

         b.  Chemical, fuel  and utility costs escalated  signifi-
cantly during  the trial  period.

     9)  Soli ds disposal.

         a.  Sludge discharged from the clarifier averaged  6.8%
soli ds .
17%
     b.
soli ds.
             Sludge discharged from the primary screen averaged
         c.  An experimental continuously regenerating filter did
not perform satisfactorily for dewatering of the sludges.

         d.  Direct incineration of clarifier sludge was success-
fully conducted for short periods, but required significant
quanti ties of fuel .

         e.  Particulate emission was 0.011 grains/cu. ft. from
the incineration.
failure
use was
costs.
     f.  The incinerator was plagued with problems such as
    of the distributor plate and hot spots in the shell.   Its
    discontinued due to above problems coupled with high  fuel
    10)  An automated sludge removal system using an optical  den-
sity probe has worked exceptionally well, and is a recommended
feature for future design considerations.

    11)  The magnetic filter used here has limited potential  for
use if applied after a clarification process which functions
properly.

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     12)  The turbidimeter used to signal for recycle of poor
quality effluent to the head of the plant during periods of non-
operator attendance proved highly satisfactory.   If possible,
however, the turbidimeter should have a continuously adjustable
set point in order to be used to full advantage  by the operator.

     13)  The plant had an attractive appearance with no odors
or problems with close neighboring houses in four years of opera-
tion .

     14)  Liquid handling, chemical feed, mixing, and control
thereof, can be highly automated to minimize manpower require-
ments .

     15)  Disadvantages of this type of treatment plant are:

          a.  High electric and energy cost
          b.  Sludge disposal problem
          c.  Deficiency in nitrogen removal
          d.  Pumps and equipment are more prone to maintenance
problems than in large plants.
          e.  High cost of chemicals.

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                           SECTION III

                         RECOMMENDATIONS


     Based on the experience gained from research,  development,
construction and evaluation of this physical-chemical  waste  water
treatment plant, several  positive steps are recommended to  increase
plant efficiency and reduce operating costs.

     Plant Efficiency:   Positive head pumps in the  lift station
would provide more dependable operation; solids cutting capability
in raw sewage pumps would improve settling process  in  the clari-
fier; air mixing provisions in surge tank would produce a better
mixture and a larger surge tank storage capacity would enhance
equalization of BOD loading.

     Operational Cost Reduction:  Manpower requirement can  be min-
imized by highly automating liquid handling,  chemical  feed,  and
mixing.  Bulk storage provisions for chemicals would reduce  chem-
ical  costs significantly.  In addition, spray washing  the screens
with  plant effluent would minimize water consumption costs.

     Within the carbon  column, biological regeneration of carbon
seemed to be evident.  Investigation into this phenomenon could
result in development of a system which does  not require thermal
regeneration of activated carbon.  It is also recommended that the
volume of the carbon quench tank and the carbon spent  tank  be
enlarged to the equivalent volume of carbon within  the column.
These tanks could then  serve as carbon storage tanks when, the col-
umn must be emptied.

     Carbon columns are in need of sophisticated design considera-
tions not previously highlighted in the literature.  .Among  these
are:

     a.  Adequacy of backwash
     b.  Proper distribution of support mechanisms
     c.  Proper design  of take-off
     d.  Properly designed screens (stainless steel in screens
and support mechanisms  may have limited life).

     Sludge disposal methods specifically applicable to plants of
this  type and size range are needed:

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     a.  Land fill facilities in the nearby vicinity is the most
logical and probably economical solution.
     b.  A large treatment plant nearby normally handling scaven-
ger and industrial wastes would be a good alternative.
     c.  Dewatering and land disposal is a current possibility
but has an uncertain future.
     d.  Dewatering and incineration is not economical unless the
plant is in the 500,000 gpd range.
         Any dewatering system must recognize the difficulties of
accomplishing this on ferric sludges.  The system tried at Free-
hold consisting of the coil vacuum filter had limited success pro-
bably due to lack of adequate pre-treatment and high chemical
levels at the time of experimentation.

     The concept of putting a treatment facility in the shell of
a home in a subdivision should be tried again with a different
design in another location.  Special attention should be given to
the physical  arrangement in the shell,  the need to use equipment
and construction features different from those in standard home
construction, and the method of sludge  disposal.  Treatment pro-
cesses which  have not been proven at the scale to be used should
not be included.  Special attention should be given to the pro-
blems which may result from the use of  small  site lines and small
capacity pumps.
                               8

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                           SECTION IV

       PHASE 1.   PRECONSTRUCTION STUDY AND ENGINEERING  DESIGN


A.  LIQUID HANDLING PROCESS

     Predesign studies on all  liquid process unit operation  were
conducted in a transportable pilot plant,  which for these studies
was installed at the Township  of West Goshen, Pa., Sewage Treat-
ment Plant.   The West Goshen treatment plant is a nominal 3  MGD
trickling filter plant, treating sewage from the bedroom commu-
nity of West Goshen along with a small percentage of commercial
wastes.

     The sewage entering this  plant is characterized as weak,  with
BOD and suspended solids averaging about 100 mg/1.  Infiltration
of ground water into the collection system is estimated to be  50-
60% of the total flow.  The typical diurnal flow pattern entering
the plant is shown in Figure 1.

     The transportable pilot plant contained the following unit
process equipment:

     1 .  Primary Screen
     2.  Surge Tank
     3.  Chemical Addition System
     4.  Magnetic Filter
     5.  Carbon Adsorption System

     Figure 2 is a schematic drawing of the arrangement of these
components in the process excluding the carbon adsorp.tion system
which followed the magnetic filter.

     The primary screen was a  Bauer Hydrasieve.  It was operated
with a number of different screen openings ranging from 10 to  40
mils.  A 20 mil opening was found to be optimum to give acceptable
solids removal with a minimum of blinding.

     The liquid from the screen flowed by gravity into the surge
tank which was a portable 4,000 gallon vinyl-lined swimming pool.

     The screened sewage was pumped through a flow control valve
and flow meter into the treatment system where inorganic floccu-
lant was added continuously.  Previous work had established ferric
chloride as the most cost effective inorganic flocculant.  Kenics

-------
                         FIGURE I
                     WESTGOSHEN.PA.
                 WASTE TREATMENT PLANT
                        FLOW DATA
                 FOR FIFTY DAY PERIOD
                                      AVERAGE FLOW
                                      10 MAXIMUM DAYS
                                 50 DAY COMPOSITE
                             \MEAN FLOW
                               10 NORMAL DAYS
50 DAY PERIOD
  MEAN FLOW
  s 1,800 MOD
                        NAVERAGE FLOW
                          10 MINIMUM DAYS
12  I  2  3  4  5  6  7  8  9 10  II  I2W I  2  3 4  5  6  7  8  9 10  II  C
                         TIME OF DAY
                            10

-------
            FIGURE 2
WEST GOSHEN PILOT PLANT OPERATION
     SCHEMATIC FLOW DIAGRAM
Raw Sewage^ ^ J^
A S A ^ A
*l Pump ) *l Hydrasievel • "\ burge lany n Hump J
_i
_i
\
Slu
NaOH
r
dge
FeCl3
f Static A^ v r RetentionV. C Static A- ir f Flow A^

V Mixer J' \^ Loop J^ V Mixer y" ^Control ^/"
Polyelectrolyte
^Rptpntinn A ir ^ <;ta

Fe 0 M
3 * Turbidimeter
u
tip A *T .. ... A v /" MaanPticA
'V LOOD J X Mixer J V,ar,.,e»V V Filter J „*
                       T
                    Siudge
Sludge

-------
 Corporation  Static  Mixers  were  used  to  achieve  satisfactory mixing
 with minimum  energy,  followed by  a variable retention loop to
 attain  optimum  contact  time  for ferric  phosphate precipitation and
 hydroxide  floe  formation.  Study  of  flocculation process estab-
 lished  the desirability  of controlling  the pH of the stream after
 primary  coagulation,  and a pH control section was added to the
 system.

     Following  primary  floe  formation and pH control a polyelec-
 trolyte  was added,  and  the stream flowed through another Static
 Mixer and  retention loop into the clarifier.  The clarifier was
 constructed of  plexiglass  sheet to enable visual observation of
 the effects of  chemical  and  flow  variations on  the clarification
 process.   The action  of  the  sludge blanket under varying operat-
 ing conditions  was  also  observed.

     The filtration device was a magnetic filter, "Ferrofi1ter",
 supplied by the S.  G. Frantz Co.  Its use required the addition
 of finely  divided magnetic iron oxide to the clarified stream.
 Contact  with the magnetic  field in the  filter removed these iron
 oxide particles as  well  as occluded residual suspended solids
 from the clarification step.   Several variables were studied with
 this device:

     1 .   Field  Strength
     2.   Amount and type of  iron oxide
     3.   Through-put
     4.   Filter loading
     5.   Backwash mode and cycle time

 Effluent turbidity  from the magnetic filter was continuously re-
 corded.

     Following  filtration  a portion of  the clarified stream was
 contacted with  granular activated carbon in 2-inch ID adsorption
 columns.  An  upflow expanded  bed mode of operation was utilized.
 Carbon  capacity, shape of  the column exhaustion curve, and  op-
 timum contact time were studied in these columns.

     Table 1  summarizes the range of operating conditions  used in
 the West Goshen pilot plant to obtain design information for the
 Freehold plant.  Table 2 presents a summary of typical  operating
 results  from  the pilot plant.

B.    DESIGN PARAMETERS AND EQUIPMENT SELECTION

     Following the pre-design research at the West Goshen  plant,
the following design parameters  were selected for the plant at
Freehold, based on anticipated population,  State regulations  and
pilot plant analytical data.

    !•   Design Capacity - 50,000 GPD (35 gom)


                                12

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                           TABLE  1

              WEST GOSHEN  PILOT  PLANT  OPERATION
                    OPERATING CONDITIONS
                                     Range           Typical



Flow Rate from Surge Tank,  gpm       10-27             20


Fe111  Addition, mg/1                 19-71             45



Polyelectrolyte Addition,  mg/1     0.75-2.0            1.0



Fe-jO,  Addition, mg/1                  5-28             10


                                p
Carbon Column Feed Rate,  gpm/ft.       3-9              5



Carbon Contact Time, min.             20-60             40



Hydrasieve Screen Opening,  mils     10 to 40          20
                              13

-------
                                         TABLE 2
Analysis, mg/1




Surge Tank




Clarifier Effluent




Magnetic Filter Effluent




Carbon Column Effluent
Clarifier
Filter
Carbon Columns
WEST GOSHEN PILOT
OPERATING

Suspended
Solids
98
14. 9
7. 5
3. 2
PER CENT
85
92
97
PLANT OPERATION
RESULTS
Soluble
Ortho-
Phosphate
18. 5
1. 0
0. 8
0. 5
REMOVAL
94
96
97
Total
Organic
Carbon
44
18. 1
16.3
1. 5
59
63
97
Biochemical
Oxygen
Demand
95
-
23.4
4.6

75
95

-------
     2.  Lift Station

         Dual pump system with automatic level controls.   A
vacuum-primed unit was selected with dual centrifugal pumps,
each with capacity of 75 gpm.

     3.  Primary Screen

         Bauer Hydrasieye - 36" wide x .020" openings.   Since it
was possible for both lift station pumps to operate simultane-
ously, the Hydrasieve was sized for a flow of 150 gpm.   In order
to avoid corrosion problems, the screen was constructed of 316
stainless steel  and the frame of fiberglass reinforced  polyester.

     4.  Hydrasieve Enclosure

         Because of the possibility of generating odors around
the Hydrasieve and the necessity for frequent cleaning  in  the
area it was decided to enclose this unit.  A room was built with
Transite paneling around the Hydrasieve on three sides  and a 6
ft. glass sliding door on one side.  This enclosed area was ven-
tilated by a small exhaust fan (1/8 HP, 195 CFM) discharging to
the atmosphere.

     5.  Surge Tank

         15,680  gallons, reinforced concrete, 13.5' x 13.5' x
11.5'  deep.  The design capacity of the surge tank was  11,500
gallons.  This was based on operation at constant withdrawal of
36 gpm with the  flow profile as shown by Figure 3.  This  profile
was derived from flow data of a Levitt and Sons' Stony  Brook,
Long Island, New York, treatment plant processing domestic sewage
which  contained  essentially no infiltration.  Under these  con-
ditions maximum  calculated accumulation is 11,500 gallons.  Thus,
the surge tank has excess capacity of 4,180 gallons or  36% of
normal requirements.

     6.  Surge Tank Agitator

         The agitator was selected to provide sufficient agitation
to suspend any particles passing through the Hydrasieve screen.
The agitator selected was a 2 HP unit.  The impeller operates at
68 RPM with a four blade single agitator 36" in diameter with
stabilizer fins  on a 24" diameter.  The center of the agitator
paddle is 24" from the bottom of the tank.

     7.  Primary Feed Pumps

         50 gpm  at 120 ft. TDH, 3 HP, 2450 rpm.  The design
throughput of the plant is 35 gpm.  To provide for overload con-
ditions and recycle water the pumps were specified at 50 gpm.
                                15

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                                     FIGURE  3
  200
        ASSUMED  RAW SEWAGE FLOW CHARACTERISTICS FOR SURGE
                                TANK  DESIGN
      \
       \

LJ
tr
LJ
LJ
O

tr.
LJ
Q_


O
LJ

_l
U_


100
     12
 100
                                                                           o
                                                                           §
                                                                           Z>

                                                                           Z>
                                                                           o
                                                                           3
                                                                           X
 50
                                                          INFLUENT
                                                                           >
                                                                           LU
                                                                           *


                                                                           I

                                                                           LJ

                                                                           tE
                                                                           13
                                                                           cn
                                                	SURGE TANK
                                   12 NOON
                                    TIME
12

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Although the head requirement for the primary feed pumps  was
approximately 50 TDK, the pumps were specified to have a  120  ft.
TDH so that they would be interchangeable with the adsorber  feed
pumps.

     8.  Chemical Treatment System

         Chemical preparation and pumping equipment, mixers,  and
retention loop.   This system included dual 50 gallon polyethylene
tanks for FeCla  and polyelectrolyte and one tank each for NaOH
and magnetic iron oxide.  Each tank was provided with an  agitator.
Chemical feed pumps were electronic drive diaphragm pumps by
Precision Chemical Pump Company.  Electronic controllers  were
provided for the FeCls and  NaOH pumps.  Kenics Corporation Static
Mixers, PVC-2" pipe size by 8 elements, were installed after  each
chemical injection point.  The retention loop was designed for
one minute detention at design flow, and consisted of 55  feet of
4" PVC pipe mounted horizontally.

         Calculation of loop length:

         1 min.  x 35 gallons/minute = 35 gallons = 4.68 ft.3
         Retention pipe loop at 0.085 ft.* for 4 in.
         PVC pipe = 4.68 ft.3 * 0.085 ft.2 = 55 ft. long

     9.  Chemical Requirements

         Based on raw sewage composition at design flow:  based on
selected design  criteria agreed upon by all agencies in the
approval process
                                         mg/1
         BODs                             275
         Suspended Solids                 275
         Phosphorus                        12

         FeCls:   two mole ratio to phosphorus
            2 x  12 x 162/31 = 125 mg/1 FeCl3 = 48 Ibs./day

         NaOH:  to neutralize half of FeC^

            FeCl3 + 3 NaOh + 3 Nad + Fe  (OH)3
            125/2 x 3(40)/162= 46 mg/1 NaOH = 19 Ibs./day

         Hercofloc:  1  to 2 mg/1
            1 to 2 x 10-6 x 0.050 x 106 x 8.35 = 0.42 to 0.83 Ibs./day

         Chlorine:  10  mg/1
            10  x 10-6 x 0.050 x 106 x 8.35 = 4.2 Ibs./day
                               17

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                 10 mg/1

            10 x 10'6 x 0.050 x 106 x 8.35 = 4.2 Ibs./day
    10
         C 1 a r i f i e r
         1.5 gpm/ft.   upflow rate and 30 minutes  retention  time
at design flow rate.   Actual fabrication:
                                            1 '6"  dia. center well
                                            =  26.5  ft.2
         6' dia. x 6' side -wall depth wit!
         Upflow area = 28.3 ft.2 - 1.8 ft.'
         Volume = 1270 gallons
         Upflow Rate = 1-32 gpm/ft.2
         Retention Time = 36 minutes

         Several commercially available clarifiers were investi-
gated for utilization in the Freehold plant.  The size required
was below the normal size of most clarifier manufacturers and
consequently the cost of commercial units was very high.   It was
then decided that it was more economical  to design a special
clarifier for this plant and have it fabricated.  As originally
designed the clarifier had a conical  bottom sloping down  to the
center line.  Equipment arrangement studies showed, however, that
there was not enough elevation to locate the clarifier above the
control panel  and still  have access room to the rake drive.  The
slope of the bottom was, therefore, changed to the outside
instead of to the center line.  This  change allowed the control
panel equipment to fit beneath the clarifier.  Because of the
limited ability to lift tanks in the  building the clarifier was
made in two sections and the center seam welded in the field.
The main tank was fabricated from steel.   The inlet well  and
overflow weir were constructed of 304 stainless steel.

    11.  Clarifier Rake

         Tip speed:   1.1  in./sec.  The clarifier rake was driven
by a gear reducer with an output of 0.67  rpm.  The rake was con-
structed of steel  pipe and angle iron.  Because of the limited
headroom, it was necessary to use a gear  drive with as low a pro-
file as possible.

    12.   Sludge Level  Controller

         Ultrasonic  sensors  with adjustable depth.  During the
development stages at the West Goshen pilot plant the sludge
level was normally controlled manually.   An ultrasonic level
detector was tested  for  use  on the sludge level  control mecha-
nism, and this  equipment was installed at Freehold.
                              18

-------
    13.   Sludge Pumps

         Jabsco positive displacement pumps  had  been  used  success-
fully at West Goshen for handling sludge  from the  clarifier.  These
same pumps were utilized in the design of the Freehold  plant.

    14.   Magnetic Filter

         Upflow rate 50 gpm/ft.2 at design flow.   Flush Cycle:
Adjustable with timer  control.   Typical  operating  cycle:  1  hr.
interval; 20 sec. flush; 20 sec. rinse.   A Model  473  Ferrofilter
(S.G.  Frantz Company)  with 12"  ID was used for this  application.


    15.   Adsorber Feed Tank

         7 ft. dia.  x  7 ft. deep; operating  capacity  1800  gal.
This tank was constructed of carbon steel.

    16 .   Adsorber Feed Pumps

         Identical to  Item 7.

    17.   Carbon Adsorption System

         After considering various proposals by potential  suppliers,
it was decided to purchase a carbon adsorption system from Chemec
Process  Systems Inc.  This unit consisted of the carbon adsorber,
the quench tank, the blow case, interconnecting piping, pneumat-
ically operated control valves, and a panel  for activating the
control  valves.  In order to avoid corrosion from the activated
carbon,  all piping was made of type 304 stainless steel.

    18.   Activated Carbon Adsorption Column

         Empty bed contact time: 40 minutes; Upflow rate:  2.2 gpm/
ft.2; Actual fabrication: 4.5 ft. dia. x  14 ft. straight side x
90° top cone x 60° bottom cone.  Total volume 253 ft.3 = 1890 gal-
lons; contact time = 1890/35 = 54 minutes.

         The original  adsorption system concept consisted of three
downflow pressure columns in series.  A study of other systems,
coupled with theoretical considerations and physical  constraints,
indicated  that a single upflow  packed-bed column using pulse trans-
fer would  have several  advantages.  These included more efficient
overall  operation, substantially less space requirements, a simpler
piping system, and significantly lower total cost.  Off-setting
these advantages were concern about suspended solids penetration
into  the column, the risks involved with  only a single contact unit,
and difficulties experienced with upflow  packed-bed operation at
other locations.

         A compromise solution  was  reached  retaining the single

                                 19

-------
 column  concept  but  increasing  the straight side of the column
 from  12  to  14 feet  to  allow operation in an upflow expanded-bed
 mode  if  desired.

          The column was constructed of steel, lined with Plasite
 No. 7155  with a minimum dry thickness of 8 to 10 mils.  The bottom
 cone  included a Neva-Clog underdrain constructed of stainless
 steel.   Design  pressure was 50 psig.

    19.   Spent  Carbon  Blow Case

          30 ft.3 to contain approximately 5% of carbon column
 charge per  transfer (assuming  blow case to be half full of carbon).
 Actual fabrication: 3'-6" dia. x 3' straight side, dished heads;
 Total volume-36 ft.3.  The blow case was constructed of steel with
 Plasite  No. 7155 lining.  Design pressure was 50 psig.

    20.   Carbon Quench Tank

          5  ft. dia. x  5 ft. x  60° cone bottom; volume-930 gallons.
 The quench  tank was constructed of type 304 stainless steel  with
 an internal launder at the top to allow backwashing of the carbon.

    21 .   Spent Carbon  Tank

          4.5 ft. dia.   x 6 ft.  x 60° cone bottom; volume-850 gal-
 lons.   The  spent tank  was built of carbon steel  and lined in the
 field with  two coats of Ceilcote Flakeline No. 252 and a top coat
 of clear  resin.   It was also equipped with an internal launder at
 the top to allow for excess water overflow and for backwashing of
 the carbon.

    22.   Sludge Holding Tank

          Capacity for approximately 2 days sludge storage at 3%
 solids.   5 ft.  dia. x 8 ft.=1150 gallons.   The sludge hold tank
 was designed to have a working capacity of 1100  gallons and con-
 structed  of carbon steel.   The original  concept  was to sluice the
 sludge out of the bottom of the sludge hold tank.   A special
 bottom was therefore designed  with a water inlet and sludge outlet
 nozzle 180° apart.   This concept was later abandoned but the tank
 specifications had already been prepared and  since the additional
 nozzle was not detrimental, it was left in.

    23.    Chlorine Feeder

          In order to avoid having chlorine under pressure in the
 building, a Wallace and Tiernan chlorine injection system was used
The driving force for  the  injection  unit was  a 10  gpm rotary pump.*
The chlorine cylinders, chlorine scales,  and  feed  rotometers were"
 located in a separate  room in  the building as  required by New
Jersey law.  This room was located behind  the  laboratory and office
 space  so  that the operator could observe the  consumption of  chlo-
 rine,  as  shown on the  scales,  through a  window.

                               20

-------
    2 4 .   Chlorine Contact Tank

         30 minutes at design rate =30x3b=  1050  gallons.   Actual
Fabrication:  5 ft.  dia.  x 9.5 ft.=1200 gallons.   In  order  to
encourage plug flow the tank was baffled, with  flow  entering  the
top of the tank on  one side of  the baffle,  then  down under the
baffle,  up, and out the overflow nozzle.   It was constructed  of
carbon steel.   There was some concern about overchlorinating  in
case the flow  stopped.  Consequently, a weir was put in  the over-
flow nozzle so that when the flow stopped  the level  in  the weir
would drop.  This in turn would close a switch  which would shut
off the  circulating water pump  and thus stop the input  of  chlo-
rine into the  chlorine contact  tank.

    25.   Instrumentation

         Economical operation of the  plant  required  that operator
attention be at a minimum.  Consequently,  the extensive  intrumen-
tation supplied was approximately 12% of capital cost.   The major
instrument systems  for the liquid handling  process were  as follows:

         a.  Level  alarm showing high level in the wet  well
         b.  Level  recorder alarm on  the surge tank
         c.  Process flow recorder controller alarm
         d.  pH recorder controller alarm for NaOH addition ahead
of the clarifier.
         e.  Level  alarm showing high level in the sump
         f.  Level  controller adding  make-up water to the adsorber
feed tank.
         g.  Turbidity recorder controller alarm, setting the
ferric chloride flow as determined by the turbidity  leaving the
clarifier, and also diverting flow from the clarifier to  the  surge
tank in case of high turbidity.
         h.  Timers on the magnetic filter to set the time and
frequency of backwash.
         i.  Effluent flow recorder and totalizer.
         j.  Sludge level controller in the clarifier to  automati-
cally control  discharge of sludge to the holding tank.
         k.  Telephone connection to transmit any alarm condition
to a remote location.

B.  SOLIDS DISPOSAL

     The solids disposal  segment of  the process was  in a  consider-
ably less advanced state  than  the liquid handling process.  It was
based upon concepts developed  by Procedyne Corporation, New Bruns-
wick, New Jersey.  This  concept was  based upon  the  use of a fluid-
ized bed reactor in both  incineration  and carbon regeneration modes
In addition,  the raw  sludge  would be mixed with sand from  the fluid
bed  reactor and  the mixture  dewatered  in a continuous sludge de-
watering filter of novel  design.  After dewatering  the mixture of
sand and sludge would be  fed to the  incinerator.  The combustible

                                 21

-------
 portion of the sludge  would  be  burned  off  and  the  sand  recycled  to
 the filter.   This  process  is shown  schematically  in  Figure 4.  The
 Carbon  Regeneration  mode  of  operation  is shown  schematically  in
 Figure  5.

      The sludge  dewatering concept  shown in  Figure 4 consisted of
 continuously  pumping sludge  from  the Sludge  Holding  Tank into the
 top of  a filter  (6)  where  the sludge would mix  with  hot sand  re-
 cycling from  the  Incinerator.   Make-up  sand  could  be added as re-
 quired  from a  bin  (8).  The  sand-sludge mixture would move down
 the filter screen  where the  liquid  would be  removed  under vacuum
 to  a  filtrate  receiver  (9) by a vacuum  pump  (11) and returned to
 the head of the  plant  by a transfer pump (10).  The  dewatered sand-
 sludge  mixture would be discharged  to  a feed screw (7) which would
 convey  it  into the fluid bed of the Incinerator (1).  Fluidizing
 and combustion air would be  supplied by a  blower (5).  Fuel oil
 would be injected  automatically via gun burners as required to hoi
-------
                                                                                     GAS DISCHARGE
ro
CO
                TO
             TREATMENT
               PLANT
                             SLUDGE  FEED
                                                                    
-------
                REGENERATED  CARBON
                16
16
                rr  rr
                                    ,SPENT
                                    I CARBON
                                                                           —M	
                                                      «.
                                                    V
                                                             GAS DISCHARGE
                                                                  t
     TO THE
TREATMENT PLANT
EQUIPMENT  LIST:

13.  After  Burner
14.  Start-Up  Burner
15.  Plenum Burner  System
16.  Carbon Bins  (Mobile)
                                                    FIGURE  5
                                           FREEHOLD TREATMENT  PLANT FURNACE
                                             CARBON  REGENERATION   MODE

-------
         a.   Vacuum is a more effective driving  force than  exter-
nal  pressure in the filtration of these slurries.
                                                         p
         b.   Filtration rates average between 0.2  gpm/ft.   and  0.6
gpm/ft.2.

         c.   The filtration device should be constructed to provide
a contact and mixing section, a filtration section,  and  a  cake
removal  section.

         d.   The filtration section should be truncated  in  shape
for smooth and continuous downward motion of the slurry.  The angle
of truncation should be 65°-750 to prevent bridging  of the  wet sand/
sludge mixture.

         e.   A multi-screw live bottom should be provided  for dry
cake removal.

         These considerations in combination with  material  and  heat
balance  calculations involved in the dewatering  process  led to  the
design and specifications shown in Figure 6 and  as described herein,
In this  design, evaporation occurs in the mixing zone above the
distribution screw.  Filtration takes place through  the  inner sides
of the unit.  This false side is constructed of  stainless  steel
wedgewire screen with 10 mil  openings.  Compression  dewatering
occurs beneath the three feed screws through a false bottom screw
which is also constructed of 10 mil wedgewire.

         Initial demonstration tests with this concept showed that
the volume of dewatered sand-sludge mixture was  too  small  for con-
trollable discharge with the three-screw live-bottom-bin configura-
tion.  This  led to a further refinement in the design.  The three
removal  screws were replaced by a single screw placed in a  drop
section  in the bottom of the unit.  This was fed by  two  counter
rotating paddles to prevent bridging of the wet  sand.  This modi-
fication is  shown in Figures 7 and 8.  The unit  was  built in this
manner.   Prior to installation of the filter at  the  Freehold Plant,
the unit was subjected to intensive testing.  Several mechanical
and operational problems were encountered and corrected:

         a.   Sand Sludge Distribution

             Tests on the filter as originally delivered showed
that sand-sludge distribution into the top of the filter was not
uniform  and  resulted in piling up of the sand toward one end of
the filter.   This problem was resolved by replacing  the  top ribbon
distributor  with a variable pitch paddle arrangement.  The  lower
paddles  were also replaced with an adjustable unit so that  the
proper arrangement could be determined experimentally.

         b.   Sand Leakage

             In the original experiments sand leaked past the

                                25

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 PARTS  IDENTIFICATION:
 1 .   Screens
 2.   Filtrate Collector
 3.   Filtrate Outlet Nozzle
 4.   Short Pitch Screw  (Feed Screw)
 5.   Distribution Screw
 6.   Sand  Inlet Nozzle
 7.   Sludge Inlet Nozzle
 8.   Vent  & Insp. Nozzles
 9 .   SIudge Mixing Zone
10.   Paddle Screws
    DIMENSIONS:
     A   Screen  Width		-	-18
     B   Screen  Height	12
     C   Mixing  Zone Height	-	9
r\i    D   Bed Leveling Zone	 6
     E   Trough  Diameter	 4
     F   Filter  Width---		21
     G   Filter  Depth	-	13
     H   Mixing  Zone Depth			4"
     I   Short Pitch Screw Size	 3"
     J   Sand Inlet Nozzle Dia.	 3"
     K   Sludge  Inlet Nozzle Dia.	 1"
     L   Vent Size	 2"
     M   Bottom  Screen Size		18"xl2"
     N   Filtrate  Outlet Nozzle Dia	 2"
     0   Feed Length	To Be Spec
     AREAS:
     Total  Filtration Area Provided - 5 Sq.Ft.
ified
                                                                                 DROCEDYNE CORPORATION
                                                                                   NEW BRUNSWICK. NEW JERSEY
                                                                            joe NQ 1431  - FIGURE  6
                                                                            FREEHOLD  TREATMENT  PLANT
                                                                              REGENERATING  SLUDGE
                                                                            DE WATERING  SAND  FILTER
                                                                           DATE
                                                                             -2-71
                                    DRAWING No
                                       B-05552

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           SLUDGE
           SAND
                                   SLUDGE 8 SAND
                                       INTO
                                  MIXING CHAMBER
FEED AND MIXING
SCREWS ON BULKHEAD
ATTACHED HERE
                                       TO REACTOR
                                        SPRAY NOZZLE
                                         TO CLEAN
                                      •WATER DRAIN
                           SCREENS
VACUUM DEWATERING SPACE
                           FIGURE   7
                   SLUDGE   DEWATERING
        FILTER 6  FURNACE  FEED  SCREW  CHAMBER
                  FREEHOLD TREATMENT  PLANT
                          27

-------
 MIXING CHAMBER-
                        SAND 8  SLUDGE
    SCREENS
OUTER SHELL
                                SAND a SLUDGE
                                DISTRIBUTION
                                SCREW
                                    PADDLE SCREW
                                   REACTOR
                                   FEED SCREW
                       FIGURE  8
             FURNACE FEED  SCREW  LOCATION
              IN  SLUDGE  DEWATERING  FILTER

                           FREEHOLD TREATMENT PLANT
                       28

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screen in considerable quantity into the  filtrate  area.   Dis-
mantling of the filter showed that the  gasket has  been  improperly
piaced.

         c •   Drive Chain S1 •[ pj) a g e

             In early tests  considerable  difficulty was  encoun-
tered with the drive chain jumping or slipping on  some  of the
sprockets.  This was attributed to the  excessive loads  caused
largely  by piling up of sand because of the improper arrangement
of the mixing paddles.  This condition  was  corrected by  the  adjust-
able paddle arrangement and  also by installing larger sprockets on
the lower mixing paddles, allowing operation at slower  speeds  with
a greater wrap of chain around the sprockets.

         d.   SIudge Bypass ing

             In early tests  considerable  solids werefound in the
filtrate from the sand filter.  This was  believed  to be  caused by
sludge bypassing sand at the top of the filter.  In order to mini-
mize this problem part of the filter screen was temporarily  blanked
off by tape in approximately the top six  inches of filter area.
Tests showed that it might be desirable to  blank off the entire
side area section of the screens.  The  unit was subsequently modi-
fied with an adjustable gasket arrangement  so that any  portion of
the side screen could be blanked off.

             These mechanical modifications consumed much of the
time available for testing.   Consequently,  only very limited per-
formance data was developed.  Two primary observations  evolved:

             (1)  Filtrate quality was  very poor with suspended
solids in the range of 0.3 to 1.5% when feeding sludge  at concen-
trations of 1.2 to 3.0% solids.

             (2)  At high sludge feed concentrations, an almost
impervious layer of sand and dewatered  sludge mixture tended to
built up against the side screens, preventing further filtration
and also inhibiting downward movement of  sand within the filter.
This eventually caused a cavity to develop  in the  center of  the
filter,  followed by discontinuation of  discharge from the dis-
charge screw, bridging above the screens, and inability to con-
tinue feed of sand and sludge to the top  of the filter.

             These difficulties were felt to be due to  a combina-
tion of the mechanical problems outlined  above and limited facil-
ities at the test location.  The unit was, therefore, installed at
the Freehold Plant.  It was  believed that the modifications  out-
lined above would permit satisfactory mechanical operation of the
unit, and that more appropriate testing could be accomplished
where the complete facilities and components of the filtration
concept were available.
                                29

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     2.  Incinerator

         Early discussions on incinerator design revolved around
the relative merits of insultated high temperature alloy construc-
tion versus refractory lined steel.  It was decided that the most
conservative design would be with refractory lining, and this ap-
proach was chosen.  This choice dictated that the inside diameter
of the unit be no less than two feet in order to allow access for
a bricklayer into the unit.

         The incinerator was designed with a superficial vapor
velocity of approximately 2 ft./sec.  For this velocity, the de-
sired disengaging height is 8 ft.  Because of space limitations
the disengaging space provided was only 7 ft. above the expanded
bed height of 4.9 ft.  This causes a slightly greater loss of sand
because of sand being carried over in the exit gas.  The inciner-
ator design was completed after the building and most of the equip.
ment had been designed and laid out.  It was therefore necessary
to make much of the incinerator equipment fit the available space
and to provide the capability of placing the reactor in the field,
moving it around equipment already in place.  This limitation dic-
tated that the reactor be built and installed in three flanged
sections.  Installation of the incinerator required that the top
section be suspended in place prior to setting and refractory
lining the base and middle sections.  This added to the reactor
design, fabrication and installation time and cost.

         Basic performance parameters for sludge incineration are
shown in Table 3.

     3.   FJuidizing Blowe^

         The blower to feed the incinerator was  designed for 150
scfm with a discharge pressure of 10 psig.

     4.   Cyclone

         The cyclone for  separating solids  from  the incinerator
offgas  was  specially designed for this  service.   It was fabricated
of high  temperature resistant alloy (RA 330).   The design specifi-
cations  were:

         Incoming  gas flow:
             Rate  -  Max.  250  scfm
             Temperature  - 1600°F.
             Pressure -  Approx.  6"  Water
             Pressure Drop -  5"  to  8" Water
             Collection  Efficiency  - 99% above 5 micron
                                30

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                          TABLE 3
               Incinerator Design Parameters
      Parameters





Bone Dry Sludge





Water




Ash





Air




Fuel Oil




Operating Temp,  (exit gas)




Diameter





Static Bed Height





Expanded Bed Height




Sand Loss





Maximum Flue Gas Generation




Minimum Fluidization Velocity
Quantity




13.65 #/hr.




62.2 #/hr.




4.78 #/hr.




77.6 scfm




2. 36 gal/hr.




160QOF.




2'




3.5'




4.9'




ca. 1 #/hr.




110 scfm




0. 255 ft. /sec.
                                          FREEHOLD  TREATMENT PLANT
                               31

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             Dimensions:
                  Diameter - 22"
                  Height of Straight Side - 33"
                  Height of Conical Side - 55"
                  Nozzles:  Gas Inlet 11" x 4.4"
                            Gas Outlet 11" dia.
                            Solids Outlet 6" dia.

     5.   Scrubber

         The scrubber was designed to handle a maximum of 400 scfm
of gases at 400°F.  A Crol1-Reynolds No. 8x8 Fume Scrubber with
24" Circulation Tank and Pump was selected.

     6.   Suction Blower

         Incorporation of the Continuously Rengenerating Filter in
the solids handling design required a suction blower to overcome
the pressure drop from the incinerator through the cyclone and
scrubber system in order to create a slightly negative pressure at
the inlet to the filter.  The blower was designed for 300-500 scfm
at 3" mercury.

     7.   Carbon Rengeneration

         The carbon regeneration concept in the overall design was
based on interruption of the sludge incineration mode in the fluid-
ized bed reactor for a period of about two days once each thirty
days.  During this two-day period, the accumulated spent carbon
would be regenerated.  The regeneration system was designed to
interface with  the treatment system on the following basis:

                                             mg/1       Ib./day
         BOD to Carbon Adsorber               40         16.7
         BOD Residual                          5          2.1
         BOD Removed                          35         14.6
         Carbon Exhausted                                29.2

29.2 Ib/day x 30 days * 48 hr.  regeneration cycle = 18.25 Ib/hr.

         Preliminary carbon regeneration work was carried out using
a 6" diameter laboratory fluidized bed reactor.  General observa-
tions made as a result of this  work are as follows:

         a.   Carbon recovery during steady state operations ranged
from 85% to 100%.

         b.   Regenerated carbon quality as determined by relative
capacity and iodine value was equivalent to virgin carbon.

         c.   The ratio of carbon to sand in the bed overflow in-
creased  with time.

                                32

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         d.   For a given  fluidization  velocity,  low  initial  static
sand bed height reduced the  percentage of sand  in  the  overflow.

         Initial design specifications for the  carbon  regeneration
process were:

             Carbon                       18.25  #/hr.
             Volatiles                    9.125  #/hr.
             Water                        18.25  #/hr.
             Fuel                         3.05  gph
             Air                          64.6  scfm
             Flue Gas                     115.9  scfm
             Temperature  in  Reactor       1400°F.

Later work showed that the water to carbon ratio in  the spent  car-
bon would be nearer 1.5:1  rather than  the 1:1  originally assumed.
This condition required more heat during the regeneration cycle
than had been previously  calculated; requiring  several  design
changes.

         a.   The plenum temperature capability  was increased from
1600°F. to 2000°F. to effect greater heat utilization.

         b.   The incinerator would be  operated  with  limited air  and
with fuel injected directly into the bed.

         c.   A carbon feed screw was designed with a special drain-
age section  to try to bring  the water  in the carbon  feed to as low
a value as possible.

     8.  Instrumentation

         Major instrumentation in the  fluidized bed  reactor system
included the following:

         a.   Plenum temperature recorder controller

         b.   Bed temperature recorder  with high-low  shut-off and
alarm.

         c.   Upper bed temperature indicator.

         d.   Freeboard temperature indicator with high temperature
shut-off and alarm.

         e.   Off gas temperature indicator with high temperature
shut-off and alarm.

         f.   Scrubber inlet gas temperature indicator alarm.

         g.   Scrubber water temperature  indicator alarm.

         h.   Scrubber water level control alarm.

                                33

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C.  AUXILIARY FACILITIES

     Certain facilities in the plant were common to both the
liquid handling and solids disposal processes.

     1 .  Oil Tank

         2,000 gallon capacity, steel:  Fuel  was needed for three
purposes:  incinerator, emergency generator, and space heaters.  It
was originally thought that natural gas could be used for the space
heater and the emergency generator, but it developed that no natu-
ral gas would be available in the community.  Since fuel oil was to
be used for the fluid bed incinerator, the generator and heater  were
changed to fuel oil.  A 2,000-gallon tank size was selected.  This
was located outside, underground with a level indicator showing
inside the building.

     2.  Oil Pump

         A gear pump with a capacity of 0.23 gpm against a  head  of
276 ft. of fluid was selected.

     3.  Air Compressor and Receiver

         10.8 cfm,  100 psig,  3 HP;  with 240  gallon receiver.  The
air compressor was  sized  to handle  instrument and other require-
ments, with the largest instantaneous  use being  flushing of the
magnetic filter.   The  oversize receiver was  specified to handle
this large but infrequent load.

     4.  Emergency  Generator

         A 50 kilowatt emergency generator was selected. This
would  supply power  to  the liquid handling equipment in the  plant
in case of any loss  of  power.   Because  of the large size of  the
blower motors on  the incinerator,  and  because sludge storage
capacity was provided, it was  decided  that it was not economical
to supply emergency power for  the  incinerator section.   In  order
to avoid overloading the  emergency  generator by  the high starting
current on motors,  a timer was installed to  sequence the startup
of some motors.

     5.  Instrument Air Drier

         A refrigeration  type  air drier was  provided to insure a
source of dry air  for  instrumentation.

         Inlet  Flow:         25 scfm
         Inlet  Pressure:     100  psig
         Outlet Moisture:   -IQOF. dewpoint at atmospheric prssure
                                34

-------
     6 .   Sump _P um£

         One-half HP open impeller,  with  pressure  switch  actua-
tion;  50 gpm at 20 ft.  head.
                                35

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                             SECTION V

                       PHASE 2.  CONSTRUCTION


A.  INTRODUCTION

     One objective of this project was to locate the treatment
plant within the housing development subdivision which  it would
serve.  Since a portion of the development plot bordered on  the
Manasquan River the plant site was selected for convenient dis-
charge into this receiving stream.  Figure 9 is a vicinity map
showing the location of the treatment plant within the  subdivision.
A more detailed view of the plant site is depicted in Figure 10,
showing the adjacent playground  area, location of the lift station
which delivers raw sewage to the plant,  and the point of effluent
discharge into the Manasquan River.

     Construction of the treatment plant was carried out under a
number of contracts and subcontracts for equipment and  construction
services.  Coordination of this  phase with other aspects of  the
total project was essential in order to  meet the schedule objectives
As a result some overlap of work was necessary, leading to a few
problems and inefficiencies which would  not have been encountered
otherwise.

     For example, the treatment  plant was scheduled to  be the only
route for disposing of sewage from the housing development.   It was
necessary,  therefore, that the plant be  operational, at least in
the liquid  handling process, before the  first house in  the develop-
ment was completed and occupied.  This requirement in turn dictated
early completion of construction design  before part of  the process
engineering design was completed.

     A critical path schedule was developed for Phase 1 and  2 of
the project as a guide to the most efficient route to completion.
In general, the construction phase was carried out with no major
insurmountable problems although some annoyances and delays  did
develop.

B.  CONSTRUCTION DETAILS, PROBLEMS AND SOLUTIONS

     The balance of this section deals principally with difficul-
ties which  were encountered during construction, solutions to these
problems, and recommendations, where appropriate, for avoiding
similar pitfalls in other projects of this type.


                                36

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            FIGURE  9
            VICINITY MAP
    FREEHOLD TREATMENT PLANT
   TOWNSHIP OF FREEHOLD,MONMOUTH CO..N.J.
37

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MtOFOK)   OWO
                                  FIGURE 10
                                  SITE PLAN
                          FREEHOLD TREATMENT PLANT
                          TOWNSHIP OF FREEHOLD, MONMOUTH CO..N.J.
                      38

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     1•   Building  Selection

         It was originally  planned  to  enclose  the  treatment  plant
in one  of the four housing  models  offered  in  the development.   The
first choice was a so-called  high  ranch  style,  a two-story house,
chosen  primarily because  it  offered the  largest envelop.   It was
later decided,  however,  to  change  to a single-story  Cape  Cod style,
the Phoenix, for a lower  profile and to  blend  into the  neighborhood.
This house had  external  dimensions  of  24'8"  x  50'.  In  order to
utilize the Phoenix house a  basement 13  feet  deep  had  to  be  incor-
porated in the  design.   Since economics  dictated that  no  rock  exca-
vation  would be done,  the floor of  the basement was  built on bed
rock.  This put the ground  floor of the  house  several  feet above
the existing grade, thereby  requiring  extensive grading around the
house.

         Although  the  building selection proved generally satisfac-
tory some improvements  in cost and  equipment  arrangement would
likely  have resulted from a  slightly larger  (10-20%) envelop and
construction on a  single  floor layout.

     2.  Arrangement and  Layout

         As noted  above,  it was necessary to  proceed with the  build-
ing design and  construction while development work and equipment
engineering design were still in progress.  As a  result, the size
and optimum arrangement of several  major pieces of equipment,
primarily in the sludge dewatering and incineration sections,  had
not been established when the final building configuration was
selected.  This situation,  compounded by space limitations,  made
the physical dimensions of equipment a very  important consideration.
In several cases extensive engineering effort was  expended to
satisfy the simultaneous  requirements of field installation, access-
ability for operation  and future maintenance, relationship to  other
equipment, and available space.  The principal problems involved
carbon transfer piping layout, clarifier location  and design,  carbon
configuration and arrangement, and provision for  a small office-
laboratory space.

         Final  arrangement of major equipment in   the plant is  shown
in Figures 11 and 12.   Figure 13 is a photograph  of the completed
building.

     3.  Access and Services

         The treatment plant was the  first structure to be built in
the  development,  and initial construction work preceded the building
of  the permanent  road to the plant.  A  temporary  acess from a  nearby
road was bulldozed  to the plant site.   This was not an all-weather-
road, however, and  there were many  days during the  Winter and  Spring
when access was very difficult or  impossible,  particularly  for large
trucks and  cranes,  needed for placing heavy equipment.  An  unusually
mild winter contributed  to the difficulty, as  the ground did  not

                                39

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D
012  345
                  o
                  o
                       outfit
                        MM*
                         TANK-
                        fllUWOfc
                         TtolKft
                                            •
                                                    \
                                                       (/^\
                                                                      00 1
                                                                    WOIA


                              MAIN FLOOR PLAN
                K)
                                                                           }\
                                                        FIGURE  II
                                                      EQUIPMENT  LAYOUT

                                                 FREEHOLD TREATMENT PLANT
                                                   TOWNSHIP OF FREEHOLO,MONMOUTHCa,N.J.

-------
                       Ooo
 FWM^g-V
FLED
 CD
FULL OIL
 RJMP
                               BASEMENT PLAN
O I 2 3 4
                                               FIGURE 12
                                            EQUIPMENT LAYOUT

                                        FREEHOLD TREATMENT PLANT
                                         TOWNSHIP OF FREEHOLD,MONMOUTH Co.,N.J.

-------
                                                      FIGURE  13
                                                   PLANT EXTERIOR
r
                                                                           FREEHOLD

-------
freeze in the area.   This  problem  was  finally  solved  by  hauling  in
sufficient rock  to  stabilize  the  access  road.

         No permanent electric  service was  provided  during  the  con-
struction phase,  and  a portable  generator  was  required  to  furnish
power for hand tools  and  other  equipment.

         The driveway to  the  treatment pi ant, completed  in  the  latter
stage of the development,  was of  the  same  type as  in  the adjacent
home construction.   It was not  heavy  enough  for the  large  trucks
delivering equipment  and  materials to  the  plant.   In  addition,  the
driveway was designed with an "S"  curve which  made it very  diffi-
cult for a truck  to back  into the  area.   The net result  was  con-
siderable damage  to the lawn  area  and  driveway.  The  driveway  was
ultimately straightened and strengthened.

     4.   Mi seel 1aneous

         The surge  tank was constructed of reinforced concrete.
Leaks were encountered when the tank  was initially filled  with
water for testing.   Two patching  attempts,  requiring  draining  and
refilling the tank, were  needed to completely  eliminate  the  leaks.

         The building contractor  misplaced the Hydrasieve  dis-
charge opening in the poured  concrete  floor.  It was  then  necessary
to cut out and repour part of the floor.

         During the electrical  check  out phase  an  electrician
inadvertently connected 100 volt  AC power to the low voltage DC
circuits in the instrument panel.   This accident damaged a number
of alarm systems  which had to be  replaced.

         Several  delays caused a  number of problems in other phases
of the construction.   The most serious of these were:
         a.  The access problem referred to above.
         b.  Overlap of development and design of the solids dis-
             posal  system with plant  design and construction as
             discussed earlier.
         c.  Slow completion of the building,   requiring double
             handling of delivered equipment.
         d.  Late delivery of the carbon adsorption system,  inter-
             fering with the scheduling of piping and electrical
             work .
                                 43

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                            SECTION VI

                PHASE 3.  OPERATION  AND  EVALUATION


 A.  LIQUID  HANDLING  PROCESS

     1.   Plant  Startup  and  Break-In:  October  1972-June 1973

         a •   General  Description

             The  Woodgate Farms  wastewater treatment plant uses
 physical-chemical technology, patterned after the pilot system de
 scribed  in  Section  IV.                                           ""

             Large solids are  removed by screening; fine suspended
 solids and  some  dissolved solids are removed by chemical floccu-
 lation,  settling, and  filtration;  and  dissolved organic matter 1S
 removed  by  adsorption  on granular  activated  carbon.  The effluent
 is  disinfected and  discharged to the river.  The settled sludges
 are  converted  to an  inert ash by incineration in a fluidized bed
 reactor.  The  plant  is automated for operation with minimum
 attention.   A  schematic Process Flow Diagram is shown in Figure IA

         b•   Process  Description

             (1)  Lift  Station

                 Gravity mains  in  the community deliver raw do-
 mestic sewage to the lift station which is near the treatment
 plant.   This station is a vacuum lift type unit with two centri-
 fugal sewage pumps,  check valves, a vacuum chamber and pump, level
 control  floats, and  electric starters and controls.   The vacuum
 pump and chamber keep the centrifugal pumps primed by not  allowlno
 sewage to drain back to the well when a pump shuts down.  The
 electrical  switching gear alternates pump operation,  thus  equally
 ing wear. The pumps  can be  operated automatically  or  manually.
 The station is equipped with an  automatic temperature-controlled
 heater to prevent freezing  during cold  weather.

                 When the sewage level  in the wet  well  rises to a
 predetermined point  set by  float No. 1, one of the lift  pumps will
 start and run until  the level  is pumped down to  the  low  set  point
of the float, then  it will  shut  off.  If for some  reason,  such  as
a very high inflow  or a defective pump, the  level  continues  to  in-
crease, float control No. 2  will start  the second  pump.   If  the

                                44

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              HYDRASEIVE
en
                                 SURGE
                                 TANK
          i
          T
         COARSE SOL'CS
          TC  DISPOSAL
         T
                     CARBON
                     COLUMN
                              CLARIFIER
                                                            MIXING
                                                                            	  J
                                                       SLUDGE
                                                       HOLDING
                                                         TANK
EFFLUENT
  TO
 STREAM
FERRO
FILTER















ii



\ Pv^^^










                                                                                                 - SEWAGE
                                                                                                 - SLUDGE

                                                                                                  CARBON
                                         CHLORINE
                                          CONTACT
                                           TANK
                                    SPENT
                                    CARBON
                                   ! TANK
                             FIGURE 14

                       PROCESS  FLOW DIAGRAM
                     FREEHOLD TREATMENT PLANT
                     TOWNSHIP OF FREEHOLD, VONMOUTH CO..N.J.
CAR30N
COLUMN
 FEED
 TANK

-------
 level increases above this point,  float No.  3  will  activate  a
 "High Wet Well  Level" light on the process  control  panel  and an
 alarmwill  sound.

              (2)   Pr i m a r y S cr e e_n_ i ni £

                   Raw sewage from  the  lift  station  is  pumped to  the
 distribution box  of a Bauer "Hydrasieve", a  3  ft. wide  sloping
 wedge wire  screen  with 0.020 inch  openings  between  the  wedge wires
 As  the sewage flows down the screen,  solids  greater  than  0.020
 inches in size  are separated from  the  liquid and slide  into  a col-
 lection  hopper  for further processing.  The  liquid  flows  through
 the  screen  to a collection pan and then by  gravity  to  the Surge
 Tank.   The  screen  can handle flows of  150 GPM.

              (3)   Surge  Storage

                   The Surge  Tank serves as  a storage and  equalizing
 vessel  between  the highly  variable raw  sewage  influent  flow  and  the
 subsequent  operations which  are  carried out at a constant rate.
 The  capacity  of the tank  is  15,680 gallons.  It is constructed'of
 reinforced  concrete and  is  equipped with an agitator.

              (4)   Process  Flow Control

                   The  screened liquid from the Surge Tank is pumped
 through  a chemical  mixing-retention loop to the clarifier by one
 of two Process  Feed  Pumps  rated  at 50 GPM each.  The flow rate is
 controlled  by an automatic valve in the process line actuated by
 the  Process  Flow Recorder-Controller on the control  panel.   This
 instrument  will automatically  maintain a present flow when the
 switch on the front  of the controller case is in "Auto" position,
 and  the  switch  on  the  side is  in the "Local" position.   It will
 increase  the  flow  as  the surge level increases and decreases the
 flow as  the surge  level descreases when the switch on the side is
 moved  to  the  "Remote"  position; however, this method of control
 was not  used.

              (5)   Chemical Treatment

                  As  the screened  liquid is  pumped through the
 mixing loop  enroute  to the Clarifier, three  chemicals are added
 continuously.

                   (a)  Ferric Chloride is  added to react with the
 phosphorus to form insoluble ferric phosphate.   It also forms
 ferric hydroxide,  a gel-like material  which  acts  as  a coagulant.
The ferric chloride is continuously injected into  the process line
downstream of the  process flow control  valve at a  tee by an  elec-
 tronically operated chemical metering pump.   This  pump  can be
 controlled automatically by a turbidity sensor, or it can be con-
trolled manually.   Ferric chloride  is  received  in  50 gallon  drums


                                46

-------
as a 40% solution by weight of FeCl3 in  water.   When  it  is  trans-
ferred to the feed tank,  one gallon  of 40% ferric  chloride  is
diluted with one gallon of water for greater  accuracy of metering
into the system.

                   (b)   Sodium Hydroxide,  added  for  pH control,  is
continuously injected into the process stream halfway through  the
retention loop, at a 180  bend, by an electronically  controlled
chemical metering pump  similar to the ferric  chloride pump.   The
pump is regulated by a  pH Recorder-Controller which  is set  to  con-
trol the pH of the process stream at the desired value;  usually
about 7.0.   Sodium Hydroxide (caustic soda)  is  received  in  50  gal-
lon drums as a 50% solution by weight.  When  it  is transferred to
the feed tank, one gallon of 50% caustic is  diluted  with one  gallon
of water.

                   (r)   Flocculant is added  downstream from the
caustic addition point  at the end of the retention loop.  A 0.2%
solution of Hercofloc 836.2, a polyelectrolyte,  is used.  It  in-
duces efficient f1occulation, incorporating  the  suspended sewage
solids and  ferric precipitates into  large, rapidly settling floes.
The flocculant is injected by a chemical metering  pump,  manually
controlled  but otherwise  similar to  the  ferric  pump.   Hercofloc
836.2 is received in 50 Ib. bags as  a white  powder.   The 0.2%
solution is prepared by dissolving the calculated  amount of powder
in hot water using an eductor and agitator.

                        Kenics mixers were originally installed
in the pipelines downstream of each  chemical  feed  point but were
later removed because of excessive plugging.

              (6)  Clarification

                   The  flocculated sewage enters the clarifier via
a central downflow feed well, then flows up  through a sludge blan-
ket.  The clarified liquid leaves the clarifier peripherally
through "V  notch slots  to a collection trough.   A continuous slip
stream of the clarifier effluent runs through a turbidity meter.
The results are continuously recorded as JTU by the Turbidity
Recorder on the control panel.  If the turbidity rises above a pre-
set level (8.4 JTU) the clarifier effluent is automatically re-
cycled to the Surge Tank and the High Turbidity alarm sounds.

                   Sludge discharge  is assisted by a slow moving
rake  (0.3RPM).  Ultrasonic type fixed probe sludge level detectors
monitor the sludge level  and automatically start or stop the Clari-
fier Sludge Pump, as required to maintain the predetermined sludge
level desired in the clarifier.  The  sludge is pumped to the
Sludge Holding  Tank.
                                47

-------
               (7)   Fi1tratlon

                    The  Clarifier  effluent flows  by  gravity
 through  a  magnetic  filter to  the  Carbon  Adsorber Feed  Tank.
 Magnetic iron  oxide slurry is injected  into  the  effluent  stream
 enroute  to the filter.   The magnetic  iron oxide  is  received  in
 50  Ib.  bags.   It  is slurried  in water at a concentration  of  0.5%
 by  weight  and  pumped by a chemical  feed  pump  similar to the
 flocculant pump.

                    The  magnetic filter  (Ferrofi1ter) consists
 essentially of a water  cooled shell with copper  coils  which,
 when  electrically energized,  produce  a  strong magnetic field.
 The  center of  the shell  through which the liquid  flows is pack-
 ed  with  iron grids.   The  iron oxide added to  the  clarifier
 effluent stream attaches  to or associates with any  floe particles
 leaving  the clarifier,  then is trapped and holds  the floe in the
 magnetic field of the filter.  The magnetic field is turned  off,
 and  the  filter washed via  an  automatic valve  arrangement  to
 the  Surge  Tank at regular  intervals as determined by timers  in
 the  control panel.   These  timers  can  be  set to obtain  the
 desired  frequency as well  as  duration of air  scour  and wash.

                (8)   Carbon  Adsorptjon

                     The  Ferrofilter effluent  flows  by gravity
 to  the Carbon  Adsorber  Feed Tank  which has a  capacity of 2,000
 gallons.   The  tank  is normally nearly full, the  level controlled
 by  a  float operated  valve,  because water from this  tank is used
 tccool the Ferrofilter  jacket  and as  the  supply  for the incinera-
 tor off  gas spray nozzles  and  scrubber.   Should  the level  in the
 Feed  Tank  get  too high  it  will overflow  to the basement sump and
 be  pumped  to the Wet Well.  Should the level drop too low, a
 pressure switch opens an automatic valve  to add city water.   An
 approved backflow preventer valve was in  the water  line.

                     The Adsorber  Feed Pumps, rated  at 50 GPM
 each, pump effluent  from the  Feed Tank through the  Carbon  Ad-
 sorber to  the  Chlorine  Contact Tank.  The  float operated valve,
 described  under Item 8, in  the discharge  line from  the Adsorber
 will  open or close as required to maintain the proper level  in
 the Feed Tank.

                     The Carbon Adsorber  utilizes granular
 activated carbon to  adsorb  the dissolved  organic material  in
 the effluent stream.  The water enters the bottom through  a
 screen,  moves   up through the carbon and  leaves at the top  via
 four Johnson well  point wedge wire screens.  Part of the  water
 returns  to the  Feed Tank as required to maintain the proper
 level.  The remainder passes through a flow meter and enters
 the Chlorine Contact Tank.  Periodically, a small amount  of  car-
bon is removed  from the base of the column.  The carbon in the

                                48

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column is washed with water and an air scour,  and then  the car-
bon is put back into the top of the column.

               C9)   Disi nfection

                    The effluent stream is  disinfected  with
chlorine in the Chlorine Contact Tank.  The  chlorine is supplied
from a cylinder in  the Chlorine Room and is  added via an eductor
driven by a circulating pump.   The chlorinated effluent is dis-
charged to the Manasquan River.

               (10) Sludge Storage

                    As described in the Clarification section,
sludge is pumped from the Clarifier and stored in the Sludge
Holding Tank.   The  sludge pump is controlled by the sludge level
detectors in the Clarifier which are set to  turn the pump on  at
a predetermined upper level and turn it off  at a lower  level  so
as to maintain a sludge blanket.  This is designed to produce a
sludge ranging from 5 to 8% total solids.  The speed of the pump
can be manually changed to vary the pumping  rate as may be
requi red.

                    The sludge is pumped to  the Sludge  Holding
Tank where it  is stored.  Hydrasieve solids  are also pumped to
this tank from the  Hydrasieve  Hopper via the grinder pump.  This
is a manual operation performed daily.  The  sludge in the Hold-
ing Tank thickens by settling.  Periodically,  clear liquid can
be decanted from the tank via  the decant nozzles.  The  original
design provided for sludge to  go through the sand filter into
the Incinerator.

                    Sludge is  pumped to the  Incinerator by the
Incinerator Sludge  Feed Pump.   This pump is  controlled  by an  in-
dicator-controller  on the Incinerator panel  which shuts the
pump off if the bed temperature drops below  the set point and
restarts the pump when the temperature rises above the  set point
provided the pump switch is on "Auto".

               (11)  Inci nerati on

                     The sludge is destroyed by fluid bed in-
cineration at  1400-1500 F. which produces a  sterile ash and odor-
less flu gases.  The details of the operation  of the fluid bed
reactor system are  contained in the Solids  Disposal section.

           c.   Problems, Solutions, Modifications

                (1)  Equipment Checkout

                     During August and September, 1972, as plant
construction was nearly complete and prior to  start up, the pipe


                                49

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 lines  were flushed out and checked  for  leaks,  all  electric
 motors tested  for proper  rotation,  and  the  tanks  and  vessels
 washed out and calibrated.   The  reinforced  concrete Surge Tank
 leaks  were repaired.

                 The  four  chemical feed  pumps were  tested and
 calibrated with  water.  The  control  instruments were  tested and
 adjusted.   The Clarifier  effluent turbidity meter  was calibrated
 and  the  recorder-controller  set  point set to divert the effluent
 flow back  to the  Surge  Tank  when the turbidity exceeded 8.4 JTU.

                 The  Clarifier weir  was  leveled while  the unit
 was  full of water so as to obtain a  uniform overflow  distribu-
 tion.  The Carbon Adsorber was loaded with  granular activated
 carbon by  preparing  a  carbon-water  slurry in the Quench Tank and
 educting it to the Adsorber.

                 The  laboratory was  cleaned.  Major laboratory
 equipment  was  installed and  calibrated  as needed.   Analytical
 procedures  were  checked using blanks and known standards.

            (2)   Startup Activi ties

                On September 27, 1972,  sewage from an adjacent
 community  was  pumped to the  Lift Station via a force main  connec-
 tion.  The  Lift Station automatically pumped this   sewage to the
 Surge  Tank  and treatment was begun.   During the first three
 months sewage  from this force main was  admitted as needed  to
 maintain plant operations for tests  and adjustments.   The  use of
 force main  sewage was discontinued in December 1972.   At a later
 date the valve in the connecting line was removed  and the  line
 was  plugged.

                From the initial  startup until  late December
 1972, the  plant was operated intermittently as  required to treat
 the  effluent sewage.  Starting in late  December,  the  flow  in-
 creased so that continuous, around-the-clock operations could
 be sustained.   Initially,  the plant  was checked several times
 during the night.  As start-up problems described  in  the follow-
 ing  sections were solved,  the frequency of operator attendance
 was  reduced.   By  the latter part of  the start-up  period, the
 plant was  running unattended about sixteen hours  a day during
 the week and about twenty-one hours  a day during  weekends  and
 hoiidays.

           (3)   Problems

                The problems  encountered during the start-up
period, together with changes in  equipment or procedures to
solve the problems, are described according  to  the unit opera-
tions involved  and not  chronologically.
                                50

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               (a )   Li ft Station

                    The lift station  failed  at irregular  inter-
vals during the start-up period.   The cause  of the  failures  and
the solutions were  as follows:

                    [1]  The level  control  float  would  swing over
and hang up on carbon and other solids accumulated  at  one side
of the wet well,  allowing the liquid  to be  pumped down  to the
level  of the priming tank suction  pipe.  Air would  enter  the pipe
and the priming tank thus would lose  the vacuum lift which keeps
the sewage pumps  primed.  The surge of air  into the vacuum prim-
ing tank would jam  the  vacuum pump  surge float closed  so  the
vacuum could not  evacuate air from  the priming tank to  return
the vacuum lift to  normal operation.

                         The carbon and other solids were removed
from the wet well and the floats  and  float  guides readjusted.
In addition, screen baskets were  installed  on the carbon  column
and Quench Tank drains  to catch any carbon  so it  can  be reused.
A longer surge chamber  supplied by  the manufacturer was install-
ed on  the vacuum  pump.

                    [2]  After about  six months of  operation,
the high humidity of the lift station caused corrosion  of the
switching gear contacts so that arcing occurred and the pumps
would  sometimes fail to start.   The contacts were cleaned and a
regular maintenance and inspection  procedure was  initiated.

                    [3]  Small  sticks, rags, and  similar  objects
hung in the check valves, preventing  them from closing  when the
pumps  stopped.  Thus, air flows back  through the  line  and the
pump prime was lost.  Changing the  check valve spring  tension
did not solve the problem.  Submersible pumps were  installed at
a later date which  solved the problem.

               (b)   Hydrasieve

                    The initial openings between  the wedge wires
were 0.020 inches.   The screen had to be cleaned several  times
a day  because of blinding with grease.  The screen  was  exchanged
for one with 0.040  inch openings.   Performance of this  screen
was better, but it  still blinded during the unattended periods,
especially during late evening hours.  A hot water  spray wash
was installed complete with timers  to control the duration and
frequency of the wash.   Experience has proven that  satisfactory
operation is obtained with a spray frequency of 1 1/2  to 2 hours
and a  spray duration of 2 minutes.    In addition,  the Hydrasieve
is manually cleaned with a brush and cleanser each  morning.
This hot spray wash and cleaning procedure has resulted in good
Hydrasieve performance.
                                51

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                (c)   Surge  Tank

                     The  Surge  Tank  is  vented  to  the  Hydrasieve
 enclosure  via  the  influent line  from  the  Hydrasieve  and  to  the
 Chlorine  Contact  Tank  via  the  emergency overflow  line  from  the
 Surge  Tank.  There  is  also an  access  manhole  from the  Storage
 Room above  the  tank.   The  tank  is agitated, but  not  aerated.
 Odor has  never  been  a  problem.

                     Periodically, during  the  nine-month  starting
 period, problems were  encountered with floe floating in  the
 Clarifier.  After considerable  study,  it  was  noted that  this
 problem occurred when  the  Surge  Tank  level was below the 21%
 mark.  It was determined that at levels below about  21%  the agi-
 tation was  such that air became  entrained and dissolved  in  the
 liquid, which was then pumped through  the chemical treatment
 loop to the Clarifier.   The air, disengaging  in the  Clarifier,
 caused some flocculated  solids  to float instead of settling.

                    The  Surge Tank  Level  sensing  system was
 modified to control the  agitator.   When the Surge Tank level
 drops to 25%, the controller stops  the agitator.  When the  level
 increases to 30%, the controller restarts the agitator.  This
 procedure solved the problems of air entrained floating solids
 in the Clarifier.  No problem was encountered with solids that
 settle in the Surge Tank during periods when the  agitator is off.

                (d)  Chemical Treatment

                    The ferric chloride, sodium hydroxide,
 flocculant, and magnetic iron oxide were each added to the
 process flow stream by Precision Control Products electronic
 pulser, diaphragm type, chemical metering pumps.   Just down-
 stream from each injection point, two-inch diameter Kenics static
 mixers  were used to rapidly and completely mix each chemical with
 the process stream.   To avoid a pulsed flow of chemical,  small
 diameter tubing and an accumulator were installed between each
 pump and the process line.   Early in the start-up period, fifty
 foot lengths of capiliary tubing were inserted between the
 accumulators and the injection points.  This resulted in  a
 fairly  uniform flow of chemical.

                    The static mixers seemed to be very effec-
 tive in mixing the chemicals with the process  stream; however,
 plugging of the elements with fiberous material  from the  process
 sewage  stream was a serious problem.  Once a week the plant had
 to be shut down to remove and clean  the three  mixers (ferric
 chloride,  sodium hydroxide, and flocculant)  upstream from the
 Clarifier.   This required three to  four hours  of operator time.
A strainer was  installed upstream from the mixers.  The mixer
cleaning  frequency was  reduced from  once a week to once every
two weeks;  however,  the strainer had to be cleaned daily, a


                                52

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simple task requiring  about ten  minutes  of  operator  time.   The
two-week cleaning frequency was  unacceptable;  therefore,  the
static mixers were removed  and  the  chemicals  introduced  at  tees
in the process line.   Clarification and  effluent  quality  were
satisfactory, but chemical  consumption  increased.

                    The original  ferric  chloride,  flocculation
and magnetic iron oxide feed tank agitators were  stainless  steel
powered by 1/20 HP motors.   They were  used  to  dilute and  mix  the
chemicals.  These agitators were too small  and lacked sufficient
power to adequately mix the chemicals  in a  reasonable time.   The
ferric chloride agitators were  removed.   An air sparge was  used
to mix the 40% as received  solution with water prior to  feeding
to the process stream.   A portable  1/4  HP mixer was  used  to pre-
pare the flocculant solution.   An air  sparge  was  installed  and
ran continuously to improve the  agitation of  the  magnetic iron
oxide slurry to keep it in  suspension.

               (e)  Clarifier

                    The original  design  of  the Clarifier pro-
vided for the process  flow  to enter the  center well  in a down-
ward direction parallel to  the  rake shaft,  and to discharge
laterally against the  inside wall of the center well through  a
tee installed at the end of the  inlet  pipe  about one foot below
the surface.  During the initial  start-up period, it was found
that at flows of about 20 GPM and higher the Clarifier was  plagu-
ed with erratic operation and periods  of high clarifier  effluent
turbitidy.  This problem appeared to be  aggrevated by operation
of the clarifier rake, which had a  speed of 0.67 rpm.  It was
soon discovered that the tee had not been installed  on the  inlet
line, and that the influent flow was producing a jet-like dis-
turbance of the sludge blanket.   Installation of the tee and re-
duction of the rake speed to 0.3 rpm eliminated this type of
clarifier sludge problem.

                    In the fabrication of the clarifier  a conical
wooden block was installed at the bottom just below  the  rake hub.
Its purpose was to minimize the accumulation of sludge in what
might be a dead spot.   This cone began to disintegrate after
about six months of operation,  and pieces of wood occasionally
plugged the sludge discharge nozzle.  The remains of the cone
were finally removed.   Sludge accumulation, if it occurs, on the
flat center section under the rake hub has not been  determined
to be a problem.

                    The  Clarifier effluent leaves via a  circular
V-notch weir and collection trough to a float chamber and from
there by  gravity through the Magnetic Filter to the  Adsorber
Feed Tank.  A slipstream of about two liters per minute flows by
gravity from the float chamber to a continuous turbidity meter.
                               53

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 The turbidity controller is normally set to divert  the  flow h*r^
 to the Surge Tank if the Clarifier effluent is  higher  than  8 4
 JTU.   The float was designed to regulate a  valve  down-streamof
 the magnetic filter so as to maintain a constant  level  in  the
 float chamber,  thus assuring a  representative  slipsteam flow tn
 the turbidimeter.   Despite frequent adjustments  to  the  float
 control  system, the water level fluctuated  to  the extent that
 periodically air bubbles would  be  drawn into  the  turbidimeter
 slipstream giving  erroneous readings and control.   The  float
 control  system  was  removed and  a short  standpipe  inserted  in the
 discharge line.   This  eliminated the air bubbles, yet provided
 a  slipstream typical  of the Clarifier effluent.

                .     Erratic sludge level  control was a  reoccurr-
 ing problem during  the first six months of  operation.   Frequent
 ly, the  ultrasonic  sludge level  controller  would fail to start
 or stop  the sludge  pump as required to  control  the  sludqe  level
 in the  Clarifier.   Thus, the sludge level would get too hiqh
 resulting in solids carryover;  or  too low,  resulting in loss of
 the sludge  blanket  leading to less efficient clarification  and
 low sludge  solids  in  the sludge hold tank.  Representatives  of
 the manufacturer, working with  plant operating  personnel  de-
 termined  that the erratic operation was caused  by misalignment
 of the  Sensall  probes,  which had been supplied on an adjustable
 mount during the development phase.   Factory aligned probes  in
 rigid assembly  were then installed and  the  controls adjusted
 Sludge  level  control  has been good since  this change was made
               ' • i V> I  ts I  iiui.*/  fc* %, *» iI  ^ v V* V*  <^iii\*x»


               (f)   Clarifier  Sludqe Pump


                     Tl-*^i r*lav»-i-P-iAw* c* "I i i /"I /i « r
                    The Clarifier sludge pump was originally
 located on the basement floor under the Sludge Tank.  The pump
 was a positive displacement type with an eccentric rotor and a
 rubbecrlined stator.  This pump soon failed because of wear be-
 tween the sides of the rotor and the stator.  It was replaced
 with a stainless pump with a flexible gear-like rotor made of
 rubber.  The rubber rotor failed after a few weeks of service
 A Moyno, type FS, progressing cavity pump with a chrome plated
 stainless rotor and synthetic rubber stator was installed.  The
 high head, about 23 feet, on the suction caused frequent col-
 lapse of the synthetic rubber stator.  The pump was moved to the
 Hydrasieve room reducing the suction head to about 7 feet.  The
 operation and maintenance history of this pump has been good
 The stator needs to be replaced at three-month intervals.  The
 rotor lasts about nine months.

                    Considerable difficulty was encountered in
 handling sludge containing five to eight weight percent solids
 in small diameter lines, i.e.  lines less than 1.0" diameter
 Steel  pipe was replaced with reinforced synthetic rubber hose
 using the minimum number of valves and fittings to avoid points
where plugging might occur.   In addition, a procedure was estab-
 lished to flush the sludge line with water each day.   These

                               54

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changes reduced plugging  problems  to  infrequent  intervals.

               (g)   Carbon  Adsorption System

                    In the  initial  loading  operation  of  the  car-
bon adsorption column, some difficulty was  experienced  in  moving
the carbon slurry from the  quench  tank into the  carbon  transfer
line.   This condition  also  occurred periodically during  the  sub-
sequent plant evaluation.   This  condition  was  inevitably traced
to the presence of  some foreign  material  in the  quench  tank,
causing blockage  of the quench tank discharge  line,  the  lower
valve, or the transfer line eductor.   It  was  necessary  on  several
occasions to drain  water  from the  tank, remove the  lower toot-
tings, and clean  out the  problem material.   The  foreign  material
ranged from 1" diameter rubber balls, which entered  with the
granular carbon,  to pieces  of paper,  plastic,  wrenches,  pens,
bolts, and nuts.   This problem was  caused primarily  by  the open
top quench tank being  located below an opening in the floor.

                    The original design of the Carbon Adsorber
provided for about  five percent  of  the carbon  to be  removed  each
week from the bottom of the Adsorber  and  stored  in  the  Spent
Tank.   Regenerated, or fresh carbon,  from the  Quench  Tank was  to
be added to the top of the  Adsorber.   Approximately  once a month
the spent carbon  was to be  thermally  regenerated in  the  fluid
bed reactor then  stored in  the Quench Tank until needed  to refill
the Adsorber.  Several problems  developed during the  start-up
period which led  to changes in the  design operation.

                    [1]  The four effluent screens  at the top
of the Adsorber each consisted of a cylindrical  backing  screen
covered with a 60 mesh twill woven  wire screen.   They were
flanged on one end  and inserted  into  the  Adsorber via four
nozzles.  These screens gradually plugged with carbon fines  and
biogrowth, and had  to  be cleaned every two weeks, a  four-hour
job.  To facilitate cleaning, the rigid pipe on the discharge
manifold was replaced  with  pressure hose with quick  disconnects
mating with quick disconnects welded to the flanged end of the
screens. «This reduced cleaning time to about one hour.   Finally,
the screens were replaced with wedge wire well points with 0.010
inch openings.  These  screens require cleaning every four to six
months.

                    [2]  In April of 1973, after approximately
six months of operation, pressure drop began to be evident
throughout the entire column rather than only across the effluent
screens.  High levels  of iron and turbidity in the plant effluent
were also observed periodically, in addition to the presence of
hydrogen sulfide in the carbon  column effluent.  These  symptoms
appeared to  result from bacteriological growth and anaerobic
activity within the carbon column.  The first attempt to correct
this problem was to employ recirculation through the column back


                                55

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 to  the  adsorber  feed  tank.   This  tended  to  reduce, but not elim-
 inate,  the  anaerobic  frequency;  however,  the  pressure drop in-
 creased.   The  addition  of  chlorine  at  a  rate  of 8 to 14 mg/1
 to  the  Adsorber  Feed  Tank  was  then  initiated.  This reduced the
 rate  at which  the  pressure  drop  increased,  especially the pres-
 sure  differential  across the  lower  third  of the Adsorber.  The
 dissolved  oxygen content of adsorber effluent was still very low,
 at  0  to 3  mg/1,  and the presence  of H2S  in  the adsorber effluent"
 persisted.  A  compressed air  line and  rotometer were installed,
 and air was introduced  into the Adsorber  with the feed water at
 a rate  of  about  1.5 SCFM.   The dissolved  oxygen content of the
 adsorber effluent  increased to about 8 to 10 mg/1 and the
 anaerobic  condition was eliminated.

                         The  Standard  Operating Procedure was
 modified to require continuous addition of  chlorine at about 8
 to  14 mg/1  to  the  Adsorber  Feed Tank,  and air at a rate of about
 2 SCFM  to  the  base of the Adsorber.  In addition, once a week
 about half  a blow  case of carbon was moved  from the Adsorber to
 the Spent Tank,  the Adsorber  flushed for  two hours with water
 and an  air  scour,  then reloaded with carbon which had been pre-
 viously washed in  the Quench  Tank.  This  procedure has produced
 good Adsorber  operation.  The  BOD of the  plant effluent has con-
 sistently averaged less than  5 mg/1 each  month; thus  it has not
 been necessary to  thermally regenerate the carbon.

               (h)  Chlorination

                    It was noted near the end of the  start-up
 period  that sludge was accumulating in the bottom of  the Chlorine
 Contact Tank.  Two nozzles 180° apart were welded on  the side of
 the tank, flush with the bottom, and equipped with valves so the
 tank could  be washed as needed.  The chlorinated water circu-
 lating  pump used to educt chlorine into the water failed.  A new
 pump was supplied by the manufacturer.   During the interval  when
 the pump was out of service city water was used as the motive
 force to educt the chlorine.

               (i )  Emergency Generator

                    Power failures occurred frequently during
 the last four months of the start-up period.  On each failure
 the emergency generator started and supplied power to continue
 wastewater  treatment operations automatically without requiring
 operator attention.  This  generator starts fifteen seconds after
 a power failure.   All  wastewater processing equipment and con-
 trollers then start in sequence.   The generator continues to
 operate until  the power has been restored then shuts  down auto-
mati cally.

                    The Incinerator and related equipment do not
 restart automatically  after a power failure, manual  restart  was
 used to assure safety.

                               56

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               (j)   Mi seel 1aneous

                    The temperature in  the  building  would  fre-
quently exceed 38°  C on warm days  in  the early  summer.   A  two-
speed ventilating fan was installed in  the  roof above  the
Incinerator.   This  reduced  the building temperature  to  accept-
able levels.

                    The original  sump pump  in  the basement had
inadequate capacity, and frequently plugged with fibrous and
solid materials.  A higher  capacity open impeller submersible
type pump was installed which performed satisfactorily.

                    The magnetic  filter would  start  its  pro-
grammed air and water wash  cycle  before the relatively  slow mov-
ing automatic valve in  the  effluent line to the Adsorber Feed
Tank had fully closed.   This would send a slug  of dirty  water  to
the feed tank, and  the  force of the air caused  splashing.   A
limit switch  was installed  on the  automatic effluent valve to
delay the wash until the valve was fully closed.  The  air-water
wash also caused a  surge of water  to  flow back  up the  line to  the
Clarifier.  A fast-action check valve was installed  in  the line
to stop this  backflow.

           d.  Wastewater Characteristics
               (1)  The occupancy rate and flow data  are contain-
ed in Table 4 and are plotted in Figure 15.   The high average
daily flows per house for October and November 1972 were due
partly to use of sewage from the force main  and partly to infil-
tration.  The flows from December 1972 through May 1973 show a
steadily decreasing infiltration rate as the result of intensive
efforts by the developer to locate and repair breaks  in the
sewerage system.  The flow per house for the final seven months
of 1973 was 216 gallons per day.

               (2)  Raw sewage, surge tank,  and plant effluent
analysis are contained in Tables 5, 6 and 7  respectively.  The
BODc and suspended solids values are plotted in Figures 16 and 17
The influent, typical of domestic sewage, became stronger as the
infiltration decreased and the occupancy rate increased.  Despite
various start-up problems, the quality of plant effluent was con-
sistently high, with all parameters well below design limits.
These data are the average of daily composites.

       2 .  Steady State Operations

           By June, 1973, most of the houses in the development
were occupied, influent sewage flow had stabilized at about
26,000  GPD, and a number of problems in the liquid handling
process had been encountered and corrected.   A 36-week period of
"steady-state" operation was designated to begin on July 1, 1973.
                                57

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                                         TABLE 4
OCCUPANCY AND FLOW
WOODGATE FARMS - FREEHOLD, N. J.
October '72
November '72
December '72
January '73
February '73
March '73
April '73
May '73
June '73
July '73
August '73
*
September '73
October '73
November '73
December '73
Average
Daily
Flow
Gallons
6,928^)
21,503^)
18, 192'1)
16, 331
24, 307
24,615
26,836
27,429
26, 168
25,344
25,917

26,816
24, 324
26,702
26,053
Titles
Issued
During
Month
14
12
21
10
10
11
8
14
13
7
1

3
0
0
2
Cumulative
Titles
Issued
14
26
47
57
67
78
86
100
113
120
121

124
124
124
126
Average
Monthly
Occupancy
7
20
37
52
62
73
82
93
107
117
121

123
124
124
125
Avg. Flow
Per House
Gal. /Dav
990(1>
I.OTSW
492
-------
tn
UD
     0
       ID
       O
     I
        o
     UJ
                          1972
                                                  FIGURE 15
                                               FLOW & OCCUPANCY
                                           DURING THE PLANT START UP
                                             AND BREAK-IN PERIOD
                                                          #OF HOJSES OCCUP
                                                                    FLOW
                                                     Of
                                                     UJ
                                                     li-
                            UJ

                            -3
1973
                                    DATE
                                                                           FREEHOLD TREATMENT PLANT

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                                                 TABLE 5

                                       RAW SEWAGE CHARACTERISTICS
Month


October '72


November '72


December '72


January '73


February '73


March  '73


April  '73


May  '73


June '73
                       SS  TOC  BOD,  COD  TOD
                                	*j  	  	
7.0  266   14   36    93


6.9  119              -    -


7.2  185   -    -    152   -


7.5  147   -    52   162


7.3  212   46   -    242  272


7.3  165   -   165   356


7.0  280   -   132   345


7.5  208   -   186   333


7.6  191   -    83   403
TKN   NH.3iN.
4.3  25.6   28.8


6.4  35.7   28.0
                                                 6.5


                                                 4.8


                                                 6.3
                     N07
                      + ^
                     Ni3  Acidity  Alk.


                            28      34
                                                                      4.5
                                                                                 Total
                                                                         Total   Solids
                                                                         Solids  % Ash
                                                                             12
                      48
                              21
                                    504      34


                                    434      52


                                    493      43
NOTE:  All units mg/1 except as noted.
                                                                        FREEHOLD TREATMENT PLANT

-------
                                                TABLE  6
Month
October  '72
November  '72
December  '72
January  '73
February  '73
March  '73
April  '73
May  '73
June '73
SURGE TANK CHARACTERISTICS
RH
7.3
-
7.2
7.5
7.2
7.1
7.0
7.5
7.5
SS
123
140
120
147
153
181
240
200
230
TOC
17
-
-
40
38
40
39
38
53
BODC
22
-
-
86
98
195
143
154
77
COD TOD
80
-
151
299
216 284
252 185
276 324
332 283
391 354

1
1
4
2
1
3
3
4
7
P
.04
.37
.44
.55
.53
.03
.43
.57
.01
TKN
14.6
17.7
24.2
29.4
38.5
19.0
47.0
50.0
55.0
NH.-N
10.0
14.8
14.8
16.5
16.5
12.4
25.5
22.2
27.2
NO-
+ ^
NO,
0.21
2.1
11 .4
6.3
2.1
0.6
1 .7
2.8
2.6
Acidity Alk.
21.6 93
17.3 106
-
49.7 173
43.2 165
-
175
150
158
Total
Total Solids
Solids % Ash
-
-
-
-
-
-
816 46
442 51
489 41
NOTE:  All units mg/1 except as noted.
                                                                         FREEHOLD TREATMENT PLANT

-------
                                                     TABLE 7
ro
Month
Oct. '72  6
Nov. '72  6
Dec. '72  6
Jan. '73  7
Feb. '73  7
Mar. '73  6
Apr. '73  6
May  '73   7
June '73  7
.8
.6
.6
.1
.2
.9
.7
.0
PLANT EFFLUENT CHARACTERISTICS
Fe
-
-
-
3.2
0.7
1 .4
1 .4
1.4
0.9
Free
Res.
C12
0.4
0.5
0.9
0.9
1.6
0.9
0.7
2.2
1.5
SS
3.2
1.8
1.3
6.1
2.4
4.1
4.1
4.7
4.0
TOC
4
-
-
11
7
7
6
5
6
BOD
1
3
-
1
5
1
1
4
1
COD
9
1
12
15
44
17
20
26
33
TOD
-
-
-
52
33
22
49
53
49
P
.26
-
.17
.95
.19
.65
.46
.26
.23
TKN
7.9
-
17.0
20.4
20.9
19.0
18.5
40.0
38.0
NH^-
3.
-
12.
11 .
12.
i 10.
15.
16.
21 .
N
9

4
1
2
8
8
5
4
N02
N03
.0:
-
8.1
2.5
1 .0
0.5
0.9
1 .7
1 .6
                                                                                    Total           Avg. Daily
                                                                             Total  Solids            Flow
                                                                             Solids %Ash   Alk. Col.  Gal.
335
381
348
24
43
30
 41
 42

 97
134

 91
 96
117
0
1
0
0
0
 6,928
21,503
18,192
16,331
24,307
24,615
26,836
27,429
26,168
     NOTE:  All units mg/1 except as noted.
                                                                               FREEHOLD  TREATMENT  PLANT

-------
CT>
CO
                                  MONTHLY VARIATION OF BODOF
                                SEWAGE DURING BREAK-IN PERIOD  '
                      SLRGETANKS:WAGE
                                                    R4 ¥ SEWAGE
                                                             PLuNTEFFLUEJIT
                         1972
                                     TIME
1973
                                                                      FREEHOLD TREATMENT PLANT

-------
                        FIGURE 17   ;.:
                SUSPENDED SOLIDS VARIATION
                ."  DURING BREAK-IN PERIOD
1972
          TIME
1973
                                               FREEHOLD TREATMENT PLANT

-------
A schedule of normal sampling and analysis was established in
accordance with Table 8.  A schedule of intensive evaluation was
also specified as shown in Table 9.  The intensive tests were to
be conducted during eight one-week periods, in addition to the
normal evaluation.

       Several changes in these schedules were made during the
course of the test period.  Some tests were added or increased
in frequency, while others were dropped, based on evaluation of
the results collected.

          a.   Normal Evaluation

              The analytical  schedule for the normal  evaluation
included (1)  a rather complete set of samples and analyses for
one day each  week, (2) somewhat reduced coverage for two addi-
tional days,  and (3) minimal  analyses on the remaining four days.
A rotating sampling plan was  used in order to cover all days of
the week during the 36-week duration of the evaluation.  Results
were reported weekly, using the analysis report form typified by
Figure 18.  Analytical and operating data were also summarized
and reported  on a monthly basis.

              (1 )  Raw Sewage Characteri sti cs

                   (a)  Flow

                        As noted above, the variable and abnor-
mally high average raw sewage flow experienced during the start-
up and break-in period had diminished by June, 1973.   This
stabilization in influent flow was due primarily to correction
of the infiltration problems  encountered during construction of
the houses in the development.  Occupancy and flow data for the
steady-state  period are shown in Table 10; the daily flow per
home during this nine-month period averaged 207 gallons, and
ranged from 173 to 226 on a monthly basis.  These data are shown
graphically in Figure 19, including the latter six months of the
break-in period from January  through June, 1973.

                        A frequency distribution of the 274 daily
effluent flows occurring during the steady state phase is shown
in Figure 20.  These flows are the daily differences read from
the plant effluent totalizing meter at 8:00 a.m. each day.
Approximately 90% of the values fell within the range of 18,000
to 33,000 gallons per day.  It should be noted, however, that
these flows are not corrected for changes in surge tank level,
nor do they reflect the effect of the frequent failure and
erratic operation of the lift station.  Limited study of these
factors showed that the extremes in effluent flow, both high
and low, were always related  either to a lift station failure
or to some other condition causing a substantial change in surge
tank level.  These changes in turn required frequent adjustment


                                65

-------
                           TABLE 8

   ANALYTICAL & SAMPLING SCHEDULE DURING NORMAL EVALUATION
Sample Point

Hydra Sieve Feed
   (Raw Sewage)
                              Analyses & Frequency

                              pH, Alkalinity,  Suspended  Solids,
                              BOD, TOC or COD,  Total  P,  Total
                              Nitrogen, Ammonia Nitrogen,
                              Coliform

                              3 times per week  on  24-hour
                              composi tes
Hydra Sieve Effluent
   (Holding Tank)
                              Same as above + Soluble  TOC  or
                              COD + Soluble P

                              Once per week on 24-hour composite
                              pH, Suspended Solids, Total P,
                              Coli form

                              Once per week on 24-hour composite
Clarifier Effluent
Ferrofilter Effluent
                              pH,  Alkalinity,  Suspended  Solids,
                              Total  COD or  TOC,  Soluble  TOC  or
                              COD, Total  P,  Soluble  P, Total  N,
                              Ammonia  N,  Coliform

                              Once per week  on 24-hour composite

                              Dissolved Q£  once  per  day  (grab
                              sample)
Carbon Column Effluent
                              pH,  Total  &  Soluble  TOC  or  COD,
                              Fe

                              Once per  week  on  24-hour composite
                              D.O. once  per  day  (grab  sample)
Plant Effluent
                              Same  as  Hydra  Sieve  Effluent  +  Fe
                              +  Cl2  residual

                              3  times  per  week  on  24-hour
                              composite
hydra Sieve Solids
Clarifier Sludge
Dewatered Sludge
                              Total  Solids,  Volatile  Solids
                              Once  per  week
GENERAL:
          ALL  DATA  ON
          CONSUMPTION
          REQUIREMENT
 LIQUID AND  SLUDGE  FLOW, FUEL
,  ELECTRICITY  USE AND MANPOWER
 TO  ALLOW  FOR  ECONOMIC ANALYSIS.
                                     FREEHOLD TREATMENT PLANT
                               66

-------
                                                    TABLE 9
                                 ANALYTICAL & SAMPLING SCHEDULE IN ADDITION TO
                                NORMAL EVALUATION DURING INTENSIVE EVALUATION
         Sample Point

         Hydra Sieve Feed
         Hydra Sieve Effluent
Frequency

2 days/week
                    Analyses

pH, Alkalinity, Suspended Solids,  BOD,  TOG or COD,
Total P, Total N, Ammonia N, Coliform.

Each on 2-6 hour and one 12-hour composite
2 days/week
Same as above +  Soluble TOC or COD and Soluble P.

Each on 2-6 hour composites and one 12-hour composite
cr>
         Clarifier Effluent
2 days/week
pH, Suspended Solids, Total P,  Coliform

Each  on 2-6 hour composites, and one 12 hour composite
         Ferrofilter Effluent
2 days/week
pH, Alkalinity, Suspended Solids,  Total & Soluble COD
or TOC, Total P,  Soluble P, Total N, Ammonia N,
Coliform

Each on 2-6 hour composites and one 12-hour composite
         Carbon Column Effluent    2 days/week
                      pH,  Total & Soluble TOC or COD, Fe

                      Each on 2-6 hour composites and one 12-hour composite
         Plant Effluent
2 days/week
Same as Hydra Sieve Effluent -*- Fe -t- Cl2 residual
Each on 2-6 hour composites and one 12-hour composite
         Solids Handling Loop
Total week
Complete Solids Balance & Sludge Volume Accounting
                                                                                   FREEHOLD  TREATMENT PLANT

-------
                                                                     FIGURE  18
                                                                          FREEHOLD
                                                                   WEEKLY ANALYSIS REPORT
                                                                                                   12/14/73
                                                                                                 Total Solids %
                                                                                                 Volatile Solids %
Hydraaieve Clarifier  Hold Tank
   17.4       4.7
   94. 1      48.0
 4.4
48. 6


R
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Dec. cf
11 FFE
CCE
24. 504 Eal."
R
WED. ST
Dec. «
12 '"
CCE
17. 776 gal. "
R
THURS. ST
Dec. «
13 f«
CCE
23.499 eal. PE
R
FRI. ST
Dec. «
14 '"
CCE
24, S51 eal. "
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8. 7




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8. 2
7. 7
7. 1
7. 1
6.7
6.8
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6.9






6.9
7.0
7. 2
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i 7.0
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600

126

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158
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-------
                           TABLE  10

                      OCCUPANCY  AND  FLOW
Month


1973

July

August

September

October

November

December
 Average
Daily Flow
 Gal Ions
  25,344

  25,917

  26,816

  24,324

  26,702

  26,053
Cumulative
  Titles
  Issued
   120

   121

   124

   124

   124

   126
 Average
 Monthly
Occupancy
   117

   121

   123

   124

   124

   125
Average Flow
 Per House
Gallons/Day
    217

    214

    218

    196

    215

    208
1974
January
February
March

28,490
24,134
21 ,737

126
126
126

126
126
126

226
192
173
                                     FREEHOLD TREATMENT PLANT
                               69

-------
                                           FIGURE 19
400
300
100
                                  AVERAGE MONTHLY FLOW
                                 DURING ORIGINAL OCCUPANCY
200
               Jan   Feb   Mar Apr  May Jun July Aug  Sept  Oct  Ncyir  Dec  Jan   Feb  Mar Apr  May June

                                             1973          FREEHOLD  TREATMENT PLANT     1974

-------
                                                              FIGURE 20
                                            DAILY EFFLUENT FLOW JULY 1973-MARCH 1974

                                                      FREQUENCY DISTRIBUTION
  33


  32


  31


  30


  29
 S27
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  22
  21
  20
  19
  18
  17
  16
  15
      0.01
             0.05 0.1  0.2
                        0.5
                                                 20   30   40   50   60   70   80      90


                                                  PER CENT LESS THAN VALUE
                                                                                      95
  98   99      99.8 99.9       99.99


FREEHOLD  TREATMENT PLANT

-------
 in  the  process  flow  to  maintain  continuous  operation without a
 surge  tank  overflow.  The  most  frequent  normal operating condi-
 tion  affecting  surge  tank  level  was  the  weekly transfer of carbon
 from  the  carbon  column  followed  by  carbon column backwash and
 reloading.   This  sequence  required  the internal use of substan-
 tial  process  water with accompanying  adjustments in operating
 flows  to  compensate  for the  abnormal  volume of recycle water.

                         Correction  of the  recorded effluent
 flows  for these  effects, to  obtain  daily influent flow, would
 undoubtedly  have  produced  a  narrower  range  of values.  This
 correction was not made for  the  entire period, but study of
 several minimum  and maximum  values  indicated that true influent
 flow ranged  from  approximately  17,000 to 34,000 gallons per day
 or  roughly plus  or minus one third  of the mean daily flow of    '
 25,315  gal Ions .

                         A 24-hour  influent flow profile for the
 plant was developed by  averaging 10  selected days of surge tank
 level and effluent flow data.  The  smoothed curve is shown in
 Fi gure  21.

                    (b)  Raw and Surge Tank Sewage Quality

                         Raw sewage and surge tank averages for
 four major parameters determined during this period are shown
 below:

                                   Raw           Surge Tank

 Suspended Solids                   242               182
 BOD                                207               153
 Total Hydrolyzable Phosphorus      10.8              8.3
 Total Kjeldahl Nitrogen             44.7              53.1

                         Raw sewage sampling was  subject to the
 usual difficulties in obtaining representative composites,  and
 was discontinued in December, 1973, with  a  corresponding increase
 in the number of Surge  Tank samples.  The two sets  of determina-
 tions are, therefore, not strictly suited for direct comparison,
 although average values  for suspended solids,  BOD,  and phosphorus
 did show similar reductions (25, 21 and 23%  respectively)  from
 the raw to surge tank samples.   The suspended solids reduction
 is in agreement with  calculated removals, based on  the weight of
 primary screen solids collected during a  period of  several  days.
 The same pattern was  not evident, however,  in  other  parameters
where comparable reductions might have been  expected.   The  ab-
sence of other correlations is  undoubtedly  due to  a  combination
of the limited number of analyses performed, sample  variability,
and analytical precision.


                                72

-------
CO
        200
         180
FIGURE 21
                FREEHOLD  TREATMENT  PLANT
                   DIURNAL FLOW  PROFILE
            12   1
                                            TIME OF DAY

-------
                          Frequency  distributions of raw sewage
 and  surge  tank  analyses  for  suspended  solids, BOD, and phosphorus
 are  shown  in  Figures  22,23 and  24.   As  seen from these graphs the
 median  values and  80% occurence  for  these properties in the raw
 sewage  were approximately:

                                  Median          80% Range
 Suspended  Solids                     200            120-400

 BOD                                  190            100-350
 Phosphorus                           11              4-18

                          Nitrogen determinations showed low
 levels  of  nitrites  plus  nitrates in  the raw sewage, averaging
 less  than  2 mg/1 .   Ammonia nitrogen  averaged somewhat less than
 50%  of  the total Kjeldahl nitrogen.  These results are not un-
 expected,  in view  of  the  close proximity of the treatment plant
 to the  sewage source.  There is  some evidence of increased NH-,
 nitrogen in the surge  tank as would  be expected with the 8 to
 12 hour detention  normally experienced in this vessel.

                          Other properties of the raw sewage
 appeared to be within  normal expected ranges for wastewater from
 a purely domestic  source.

               (2)  Liquid Treatment Performance

                    Average values for all  analytical  determina-
 tions made during  this period are shown in  Table 11.   Sampling
 points were at the  effluent of each  vessel  or location listed
 with  the exception  of  raw sewage, which was  taken at the primary
 acreen head box.   Samples were generally 24  hour composites,
 although grab composites were occasionally  necessary when samp-
 ling  pumps or lines became plugged.

                    As previously indicated, some changes were
 made  in the sampling schedule during the course of the steady
 state period of evaluation.   These changes  were made to ease the
 analytical load in  areas where differences  between two sampling
 points were small  or where continued determinations were not
 felt  to be of sufficient value.   For example:  nitrite-nitrate
 analyses were discontinued because values were always  very low;
 raw sewage samples were discontinued in December, 1973 because
 the surge tank sample was felt to be more representative of the
 loading on the treatment processes.   Ferrofilter effluent samples
 were  no longer meaningful when the filter was  taken out of ser-
 vice  in January 1974.   Because of these changes  certain analyses
 have  been combined  in evaluating plant performance in  order to
 increase the number of determinations available  and thus mini-
mize the effect of sampling  and  analytical  variability.   Although
approximately 3,300 major analyses (excluding  pH, dissolved
oxygen, iron and residual chlorine)  were performed during the
                                74

-------
                                                                  FIGURE 22





«9.9  99.8           99     98       95       90        80      70     60    50    40     30     20         10       5        2      1     0.5     0.2   0.1  O.OS       0.01
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400
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a Than Value FREEHOLD TREATMENT PLANT

-------
                                                                    FIGURE 23




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-------
                                                            FIGURE 24
 99.99        99.9 99.8       99    9»      95     90      10   70   60   50   40   30    20      10      5      2    1   0.5    0.2 0.1 0.05     0.01
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041      0.05 0.1  0.2   0.5   1    2       5     10      20    30   40   50   60   70    80       90     95     98   99        99.8 99.9        99.99
                                             Per Cent  Less  Than Value                 FREEHOLD  TREATMENT  PLANT

-------
                                          TABLE 11
                                LIQUID TREATMENT PERFORMANCE
                                       AVERAGE VALUES
O>

Analysis, mg/1
Suspended Solids
BOD
TOC
Soluble TOC
TOD
COD
TKN
N0? + NO^-Nitrogen
NH3-N1tr5gen
Phosphorus
Soluble Phosphorus
A 1 k a 1 i n i ty
Chlori de
Total Solids
Volatile Solids
Total Coliform
(MPN per 100 ml )
Iron
pH (units)
Dissolved Oxygen
Free Residual Chlorine
Total Residual Chlorine
Raw
Sewage
242
207
72
_
460
540
44.7
1.8
19.3
10.8
-
202
78
628
324
/»
I.lxl0b
-
7.5
-
-
-
Surge
Tank
182
163
74
27
433
463
53.1
-
28.0
8.3
5.6
205
105
614
314

2.2xl06
-
7.4
-
-
-

C 1 a r i f i e r
12.2
-
_
_
_
_
-
-
-
0.38
-
-
-
_
_

1.4xl05
_
7.1
-
-
_

Ferrof i 1 ter
10.0
35.1
20.1
10.3
143
103
40.2
1.4
24.3
0.31
0.26
151
_
_
_

e.ixio4
_
7.0
8
-
_
                                                                       Carbon
                                                                       Column
                                                                        5.7
                                                                        4.9
                                                                        0.9
                                                                        6.9
                                                                         8
 Plant
Effluent
  2.9
  1.4
  5.6
  4.1
   72
   25
 28.8
  1.4
 17.3
 0.16
 0.19
  110
  233
  482
  111

 <3.5
  0.7
  6.9
   9
  1.1
  3.4
                                                                 FREEHOLD TREATMENT PLANT

-------
nine month period,  an  even  greater  number  of  determinations  would
have added to the confidence level  in  evaluating  overall  perform-
ance and unit operation efficiencies.

                    Average results for  the  four  Tnajor  parameters
are summarized in Table 12  where  Raw Sewage  and  Surge  Tank  values
have been combined  for Kjeldahl  nitrogen,  and Clarifier Effluent
and Ferrofilter Effluent have been  combined  for  BOD and Kjeldahl
nitrogen.  These averages were used in calculating  the  efficien-
cies shown in Table 13.  Three sets of efficiency values  are
shown :

                    (a)  The individual  major process  step  unit
efficiency, that is:  the percentage of  pollutant removed in each
step as related to  the input to  that operation.

                    (b)  The cumulative  removal  at  each process
step as related to  the raw  sewage (or  raw  sewage-surge  tank
average in the case of Kjeldahl  nitrogen).   These data  are  also
shown graphically in Figure 25.

                    (c)  The contribution  of  each process step in
removing a pollutant,  expressed  as  percent of the raw  influent.

                    Several conclusions  are  evident from  examina-
tion of these results:

                         (1)  Clarification  (which  includes
chemical treatment) was the most  effective step  in  the  removal
of suspended solids, phosphorus,  and BOD,  accounting for  70, 73
and 62% respectively of these pollutants entering with  the  raw
sewage.  Twelve percent of the Kjeldahl  nitrogen was also re-
moved by this step.

                         (2)  Primary screening  removed about a
quarter of the suspended solids,  phosphorus,  and BOD.

                         (3)  Carbon adsorption, although
accounting for removal of only 16% of the  original  BOD, and 2
and 3% of phosphorus and suspended solids, was quite effective
as a unit operation with efficiencies of 96,  46  and 71% respec-
tively.  Twenty-five percent of Kjeldahl nitrogen was  also  re-
moved by this operation.

                         (4)  Filtration was a relatively in-
effective operation, removing only one percent of the  suspended
solids and phosphorus, with unit efficiency of 18%.

                         (5)  Overall  removals for the total sys-
tem were 99% for suspended solids, phosphorus, and BOD.  Kjeldahl
nitrogen was reduced by 37%.
                                79

-------
                         TABLE 12
            LIQUID TREATMENT PERFORMANCE
                 AVERAGE ANALYSES, mg/1

                      Suspended
                       Solids     Phosphorus     BOD
Raw Sewage

Surge Tank

Clarifier Effluent

Ferrofilter Effluent

Plant Effluent
242

182

12.2

10.0

 2.9
10.8

 8.3

.380

.313

0. 161
207

163


35.1


 1.4
                               Kjeldahl
                               Nitrogen
\
/
45.9
   40.2
   28.8
                                         FREEHOLD  TREATMENT  PLANT
                              80

-------
                                TABLE 13

                  LIQUID TREATMENT PERFORMANCE
                  	EFFICIENCIES,  %
                                  Suspended
                                    Solids

1.   Unit Efficiency as Per Cent of Unit Input
Primary Screening
Clarification
Filtration
Carbon Adsorption

Cumulative Removal

Primary Screening
Clarification
Filtration
Carbon Adsorption
                                    25
                                    93
                                    18
                                    71
                                    25
                                    95
                                    96
                                    99
3.   Unit Efficiency as  Per Cent of Raw Influent
    Primary Screening
    Clarification
    Filtration
    Carbon Adsorption
    Residual
                                    25
                                    70
                                     1
                                     3
                                     1
Phosphorus    BOD
                                                   23
                                                   96
                                                   97
                                                   99
              21
              99
                                                                      Kjeldahl
                                                                      Nitrogen
23
95
18
46
21
>s
96
_
12
28
12
37
23
73
1
2
1
21

62
16
1
-

12
25
63
                                                FREEHOLD TREATMENT  PLANT
                                      81

-------
 100
  90
  80
 70
a

-------
                    Other interesting observations  of the average
results show the following:

                         (6)   A threefold increase  in chloride
content, as a result of the  Fed., addition.

                         (7)   Reduction  of alkalinity by 46%.

                         (8)   Reduction  of total  solids  by 23%
despite the increase in chlorides.

                         (9)   Ninety-four percent reduction of
coliform bacteria through the filtration step.   Interestingly,
the unit efficiency of the filter for coliform  removal  was 56%
compared to only 18% for suspended  solids and phosphorus.

                    Figures  26, 27, 28,  29 and  30 show suspended
solids, total phosphorus, BOD, Kjeldahl  nitrogen, and NH,-
nitrogen plotted on time scales.   Suspended  solids  is shown on a
weekly basis.  For this graph, raw  sewage results were averaged
with surge tank data, the latter  increased by 25% to correct
for solids removed by the primary screen.  Clarifier effluent
and Ferrofilter effluent data were  also  combined  since differ-
ences between these sample points were small.  The  other para-
meters are plotted from monthly averages, again combining certain
data where appropriate.

                    Frequency distributions  for Clarifier, Ferro-
filter, and plant effluent suspended solids  are shown in Figure
31 and 32.  The Clarifier-Ferrofi1ter distributions clearly show
the small difference between  these  sample points  as indicated
previously by the average data.  A  rather sharp change in slope
of the clarifier suspended solids distribution  curve is  evident
at about the 12 to 15 mg/1 suspended solids  level.   This break
is indicative of the nature  of clarification performance follow-
ing chemical treatment and flocculation.  The flat  portion of  the
curve represents normal operation with a high level of suspended
solids removal  efficiency.  The steep section shows evidence of
some upset condition with sharply reduced separation efficiency.
The Ferrofilter effluent show substantially  lower suspended
solids in this  region of the  frequency distribution.  This
difference is due primarily  to the  effectiveness  of the  turbidi-
metric control  system following the clarification step which
automatically recycled unacceptable effluent rather than to any
increased Ferrofilter performance at high suspended solids levels

                    The plant effluent suspended solids  distribu-
tion shows a median value of 1.9  mg/1 with 90% of the determina-
tion less than  6 mg/1 and 96% less  than  9 mg/1.  This reflects
the filtration  achieved on the carbon column as the clarifier
effluent median was 9 rag/1.
                                83

-------
      500
                                                        FIGURE 26
00
                                                     SUSPENDED SOLIDS
                                                     WEEKLY AVERAGES
                                     Raw k 1.25 x Surge Tank
                                            Clarifier &
                                            Ferrofliter Effluent
                                              Plant
                                              Effluent
                              8    10    12
                                                                                                                     10
Week 246
   July 1973
24262830   32   34    35    38   40
     FREEHOLD TREATMENT  PLANT    March 1974

-------
      15
                                                     FIGURE 27
oo
en
                                                                          TOTAL HYDROLYZABLE PHOSPHORUS

                                                                                 MONTHLY AVERAGES
      10
                                                                                                  Mr

                                                                                     FREEHOLD TREATMENT PLANT

-------
         300
                                                      FIGURE 28
00
                                                                                    BIOCHEMICAL OXYGEN DEMAND
                                                                                        MONTHLY AVERAGES
                      July
Aug       Sept
      1973
Oct
Nov
Dec
Jan
Mar
                                                                                       FREEHOLD TREATMENT PLANT

-------
                                                    FIGURE  29
                           |       1 1   1 4  1-  1 1  1 1 1  II
                              MONTHLY AVERAGES
                     D
                                                                               /


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                                                                                                            -
      21
                              t  t t
                 July       Aug       Sept


                                1973
                                           Oct
Nov
Dec       Jan        Feb       Mar


                 FREEHOLD TREATMENT  PLANT

-------
                                                     FIGURE 30
oo
00
                                AMMONIA NITROGEN
                               MONTHLY AVERAGES
                                                                                          Feb       Mar
                                                                                       FREEHOLD TREATMENT PLANT

-------
 M.M
            M.9 99.8
                         99    M
                                    9S
                                           90
 FIGURE 31
SO    70   60   50   40   30
                                                                              20
                                                                                     10
                                                                                                       1    O.S    0.2  0.1 O.OS
                                                                                                                             0.01
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-1 — i iiiiin iiiiiiin i 1 1 1 1 1 1 1 in 1 1 ii -
SUSPENDED SOLIDS
QUENCY DISTRIBUTION \\
[ED & FILTERED EFFLUENT -
Clarifier Effluent : :
Ferrofilter Effluent
EEEEEi I! JIJI! i ! !
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0.01
       O.OS 0.1  0.2
                                          10      20    30   40   50   60   70    M      90
                                           Per Cent Equal to or Less  than Value
                                        95     «8    M       99J 99.9        99.99
                                            FREEHOLD TREATMENT  PLANT

-------
    MJ9
                                                  FIGURE 32
              ».« M.8
                                              10
                                                       60504030
                                                                      20
                                                                             10
                                                                                               0.5   0.2 0.1  0.05
                                                                                                               0.01
                                                             MIIMIII11 I "
  8
           SUSPENDED SOLIDS
      FREQUENCY DISTRIBUTION

           PLANT EFFLUENT
uo
B
CO

1
I*
09
CO
           OM 0.1 03
5    10     JO    10  W  tO   W   70   90     W

  Per Cent Equal to or Lets Than Value
M     M   W      MJ 9M       MM

FREEHOLD TREATMENT  PLANT

-------
               Ferrofilter effluent BOD CFigure 33)  follows  a
normal frequency distribution,  with a median  of 30 to 35  mg/1
and 95% of the values less than 65 mg/1.

               The distribution for plant effluent BOD (Figure
34) is highly skewed, with 62%  of the values  reported as  zero,
90% less than 4, and 99% at 8 mg/1 or less.   BOD determination
in this range are subject to substantial  error.  The zero values
were reported when the seed-corrected oxygen  depletion was zero
or a negative number.  The minimum detectabi1ity possible with
the method and dilutions used was 0.3 mg/1.

          (3)  Chemical Consumptions

               Chemical consumptions in mg/1 (Table 14) were
calculated on a monthly basis from raw material receipts,
inventory changes, and total effluent flow from the plant.
Consumptions during the period  of steady state operation  were
substantially higher than anticipated from previous pilot work
and from raw sewage analyses and bench scale  tests at the plant.
Several factors contributed to  these high values:

               (a)  The turbidimetric system  designed to  control
ferric chloride addition was ineffective because of excessive
delay in signal response at the flow rates encountered and also
because of background interferences within the flocculation  and
clarification system.  This method of control  was abandoned early
in the operation and replaced with manual adjustment by the
operator.

               (b)  As reported previously, the static mixers
in the chemical addition system were removed because of frequent
fouling.  Although chemical mixing and flocculation appeared  to
be satisfactory without the mixers,  it seems  highly likely that
their absence contributed to increased requirements of both ferric
chloride  (with resulting higher NaOH usage) and polyelectrolyte.

               (c)  Manual  control of ferric chloride addition
undoubtedly accounted for a large  portion of the  excess usage
of both ferric chloride and sodium hydroxide.  Operator surveil-
lance was generally  limited to normal daylight hours, the period
of maximum ferric  chloride  demand.   A satisfactory  rate of ferric
chloride  addition  during  these hours was  higher than  needed for
the later evening  and early morning  hours when phosphate  and  sus-
pended solids levels were at a minimum.   The operator's reluctance
to risk an underdose was  normal,  particularly  in  view of  the
emphasis  which was  placed on obtaining good operation of  the
liquid handling process.

                (d)   Frequent failure of  the lift  station  caused
excess consumption  of  all chemicals.   This condition  resulted in
                                91

-------
ro
      a
      4)
      nl
      u
      •<4

      e
      4)
      ji
      u

      .2
           19.99
          70
      "g
      I   60
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          50
40
          30
          20
          10
                     99.9 99.S
                                 99
                                                 90
                                                        80
                                                   FIGURE 33


                                                   70    60   SO  40
                                                                              30
                                                                                  20
                                                                                         10
                                                                                                                  0.2  0.1 0.05
                                                                                                                               0.01
                                        BIOCHEMICAL, OXYGEN DEMAND

                                           FREQUENCY DISTRIBUTION

                                            FERROFILTER EFFLUENT
                  OM 04 &2   U
                                  t     U     20   30  40  SO  U   70   tO     99

                                      Per Cent Equal to or Leea than Value
W     W  W       WJ 9M        99.99

   FREEHOLD  TREATMENT PUNT

-------
00
                                                      FIGURE 34
                                                        TO   W   50  40
                                                                                                         0.2  0.1 0.06    OJtt
S    10     20    30  40  SO   ef  70   M     90
   Per Cent Equal to or Lean Than Value
                                                                                            MM
                                                                                                        MJ MJ
                                                                                                                   MM
                                                                                           FREEHOLD TREATMENT PLANT

-------
                             TABLE 14
Month




July




Aug.




Sept.




Oct.




Nov.




Dec.




Jan.




Feb.




Mar.







Avg.
325




180




279




269




280




223




252




276




232







267
CHEMICAL CONSUMPTION

NaOH
201
178
102
174
178
168
134
81
166
mg/1
Hercofloc ]
2.6
2.9
3.6
2.9
1. 5
1.9
2.7
2. 0
3. 1

re3o4
4. 5
4. 0
6. 1
3.6
5. 1
8. 3
0.4
-
_
                        154
2.6
5. 3
                                                    (a)
Chlorine




 24. 1




 28. 4




 18.6




 22. 3




 14. 2




 20.6




 31.8




 34.4




 43.4







  26.4
(a)
  Six Months - July through December
                                              FREEHOLD TREATMENT PLANT
                                   94

-------
a low surge tank level,  with automatic recycle of clarifier
effluent to the surge tank in order to maintain an operating
liquid level.   Lift station failure during the day could  be
corrected by manually operating the lift pumps, but malfunction
at other times caused repeat addition of chemicals to the re-
cycling sewage.

               (e)  On the average the liquid handling system
produced a high quality  effluent with relatively little dif-
ficulty.  The  need to optimize chemical  consumptions, however,
was overshadowed by preoccupation with the solids disposal  opera-
tion which posed a number of difficult problems, as will  be  dis-
cussed 1ater.

               (f)  High chlorine consumption was due in  part
to its use to  control blockage in the carbon column.  Also,  the
degree of chlorination applied to the plant effluent was  probably
in excess of that required to meet state standards.  As with  the
other chemical additions the philosophy was generally "better  to
be safe with a bit too much than not enough."

               In summary, chemical consumptions could undoubted-
ly have been reduced with more work and greater surveillance.   A
detailed analysis would  be required to determine the optimum
economic balance among costs of chemicals, plant size, automation
and instrumentation to optimize consumptions, and operating  and
maintenance labor.

               Activated carbon usage could not be properly
evaluated during this study.  Although no thermal carbon  regenera-
tion was performed it was necessary, during the course of the
evaluation, to transfer  carbon from the column for washing,
followed by column backwash and reloading.  Some carbon was  lost
physically during these  operations (described elsewhere in the
report), and was replaced by virgin carbon.  Several samples  of
"spent" carbon taken during these transfers were analyzed.  None
showed evidence of impending exhaustion.  Most exhibited  capa-
cities  (to adsorb sewage TOC and BOD) of 60 to 80% relative  to
virgin carbon.

          (4)   Operation & Maintenance

               During the "steady state" mode, one operator  was
normally assigned to the plant for eight hours a day, Monday
through Friday.  In addition to making the required operating
adjustments, this operator handled the routine maintenance,  con-
ducted the analyses necessary to monitor the performance of the
plant, and did the housekeeping to keep the building and grounds
neat and clean.  Weekend coverage was usually limited to the time
required to check the operation, collect samples, and run the
minimum analyses.
                                95

-------
               The vacuum lift station continued to fail  at
irregular intervals due to objects hanging in the check  valves
and preventing them from closing when the pumps  stopped.   The
liquid would then drain from the lines and the pump prime would
be lost.  This problem was not solved during the report  period;
however, at a later date, submersible pumps were installed in
place of the vacuum lift pumps.

               Periodically during unattended operation  when  the
lift station failed or when the  sewage flow was  appreciably  less
than expected, the surge tank would go empty.  When this  happened
the process sewage flow would drop to zero and ferric chloride
would back up into the steel process line resulting in severe
corrosion.  When flow resumed, it was often irregular for a  time
and the clarifier operation would be upset.  A relay was  install-
ed on the surge tank level recorded which, when  the level dropped
to 13% would activate the existing automatic valve in the clari-
fier effluent line to recycle the flow to the surge tank, and
when the surge tank level increased to 22% would reset the re-
cycle valve for normal operation.  The system then operated
smoothly in the event of lift station failure or low influent
sewage flow, however, chemical consumption was increased.

               As explained elsewhere, manual control of  ferric
chloride addition accounted for  a large portion  of the excess
use of chemicals.  It was observed that good flocculation was
consistantly obtained when sufficient ferric chloride was added
to depress the pH to about 5.9 to 6.3.  A pH detector-controller
was installed and connected so as to regulate ferric chloride
addition to maintain the set pH  of about 6.1.  Operation  was
satisfactory, however, the instrument failed after ten days  opera-
tion due to a defective seal.  It was returned to the manufac-
turer and not reinstalled during the report period.

               The clarifier rake drive bearings failed  on July
8, and were replaced on July 10.  An inspection  revealed  that
one of the original bearings supplied in the gear box was defec-
tive.  Clarifier effluent turbidity was normal at 3 to 6  JTU
during the two-day period without rake operation, however, the
sludge pumped to the hold tank was very thin, less than  21
total solids.

               The Ferrofilter was a major power consumer yet
its efficiency in removing suspended solids was  low.  In  November
the unit was opened and the grids were removed,  cleaned,  and
replaced.  It was estimated that they were 70 to 80% plugged.
There was little improvement so  on January 17, use of the unit
was discontinued.

               The four woven wire effluent screens at the top
of the adsorber required cleaning every two weeks.  During
October, they were replaced with wedge-wire well point screens.
These worked very well.  The cleaning frequency  was reduced  to

                                96

-------
once per month.   Screen boxes were fabricated and installed on
both the adsorber and quench tank drain lines to catch any carbon
that might be lost when backwashing or draining these units.

               An occasional problem with poor flocculation in
the clarifier and high Hercofloc consumption was believed to be
caused by non-uniform Hercofloc solutions.   The mixing of polymer
and water by the original  small agitators was inadequate.  Double
bladed agitator shafts driven by 1/4 H.P. motors were provided
in January, 1974.  The hercofloc solution and flocculation seemed
to be improved.

               Plant operation during the "steady state"  period
was generally good and effluent quality was consistantly  high.
Only two major deviations  from the design concept were made.
First, the Ferrofilter was removed from operation as described
earlier due to poor efficiency and high power consumption.
Second, the carbon was not thermally regenerated because  by the
end of the report period,  it still had a capacity to adsorb BOD
of at least 60% relative to virgin carbon.

        b.  Intensive Evaluation I
            Sampling for intensive evaluation was conducted under
two different plans.  The first, which was shown in Table 9
(Normal Evaluation Section), specified three sets of samples for
each of two days per week for eight weeks.  The three samples
consisted of composites taken during the following periods:

            Period            Hours

               1              0800 - 1400
               2              1400 - 2000
               3              2000 - 0800

            The following six locations were selected with the
primary objective of determining parameter variations during
the three sampling periods:

            Raw   -   Lift Station Discharge to Hydrasieve Box

            ST    -   Discharge from Surge Tank

            CE    -   Clarifier Effluent

            FFE   -   FerroFilter Effluent

            CCE   -   Carbon Column Effluent

            PE    -   Plant  Effluent
                                97

-------
            uenerally, eleven separate parameters were analyzed
with emphasis stressed primarily on the Raw, Surge Tank,  and
Plant Effluent locations.

            The above evaluation was terminated at the end of
the fifth week instead of the scheduled eighth week.   It  was felt
at that point that the trend of the data gathered did not and
would not show the kind of changes which were expected to occur
during the various times of a typical  diurnal cycle.   Since most
of the other data gathered at this plant showed that  there are
indeed variations in the measured parameters during the course
of the day, it can only be postulated  that the time periods
chosen were most likely not the best and/or that the  number of
periods were too few to show any variation.

            At the end of the fifth week, approximately 1400
data  points had been determined.  The data are summarized in
Table 15.  The value given for each time period is an arithmetic
mean of approximately ten determinations.  A few values were
missing and several  were discarded as  being extremely outside the
normal population.  The unused and missing numbers comprised
slightly over 1% of the total number of determinations.

Observation

            As previously stated, the  data accumulated did not
follow the trend expected and must therefore be carefully
scrutinized in order to extract any meaningful conclusions.  It
was expected that a  significant drop in the absolute  values of
the parameters would be observed during the second and third
periods; similar to  that displayed by  a characteristic diurnal
flow pattern.

            Generally, the pollutant parameters measured  in the
Raw Sewage and Surge Tank did show a slight drop in the para-
meters for the third period with the exception of alkalinity,
TKN, and NhU-N which were appreciably  higher than in  the  other
two periods.  This sequence, however,  does not extend to  all
the locations sampled.  For example, all three periods of the
plant effluent showed a random trend with the exception of the
TOC, Alkalinity, TKN, and NHg-N which  displayed a significant
downward trend.

            Another observation, for which there is no apparent
explanation, is the large values of total phosphorus  in the raw
sewage and surge tank.  For the most part, the values are three
times the expected normal and the tendency would be to assume
that the concentrations were expressed as P04 and not P.   However,
all laboratory reports indicate that this is not the  case.  The
soluble phosphorus levels obtained during all three periods do
fall within the expected values.
                                98

-------
TABLE 15


Total Phosphorus
Peri od
1
2
3
Average
I


Raw
29.1
26.5
26.3
27.3
n tensive Evaluation I
Average Values, mg/1

ST CE
26.4 1.6
23.7 1.6
18.8 1.7
23.1 1.7
Sol uble Phosphorus
1
2
3
Average
A 1 k a 1 i n i ty
1
2
3
Average
Coliform (MPN -
1 7
2 7
3 6
Average 7





218
202
269
230
Geome
.0x10
.7x10
.5x10
.1 xin
8.7
9.6
6.4
8.4

237
225
246
236
trie Mean)
5 5.1xl05 2.7x10
5 1.2xl06 3.1x10
5 7.2xl05 1.6x10'
5 5
7. 7x1(1 ? 4vin
                     FEE
                     2.4
                     3.2
                     2.1
                     2.5
                     0.83
                     0.92
                     0.84
                     0.86
                     179
                     168
                     164
                     170
                    2.8x10'
                    2.5xlo'
                    1.5x10'
                    2.0xl(/
 PE
0.70
0.74
0.66
0.70
0.43
0.39
0.48
0.43
147
143
130
140
2.4
^1
3.0
2.0
               FREEHOLD  TREATMENT PLANT
    99

-------
TABLE 15 (cont.)
SS
Period Raw
1 261
2 267
3 276
Average 268
TOC
1 132
2 123
3 116
Average 124
SOC
1
2
3
Average
BOD
1 198
2 233
3 200
Average 210
ST CE
304 21.4
298 18.9
207 15.3
272 18.4

117
115
99
114

32.8
31.9
29.4
31 .4

185
172
146
169
FEE CCE
17.4 3.9
18.8 4.1
21.2 4.6
19.2 4.2

26.0 8.5
25.2 8.5
23.7 8.9
25.0 8.6

19.8 6.3
18.4 6.4
18.2 6.0
18.8 6.2





PE
3.5
4.7
3.1
3.7

8.8
8.2
7.6
8.2

7.1
6.8
7.4
7.1

5.7
5.7
5.9
5.8
                                        FREEHOLD TREATMENT PLANT
                              100

-------
TABLE 15 Ccont.)
TKN
Period
1
2
3
Average
N00+N00-N
L. 
-------
            Of interest is the significant increase  in  the  amount
of N0? + NO--N in the plant effluent as compared  to  pre-carbon
column values.  These results would indicate a  substantial  amount
of nitri-nitrafication occuring in the carbon column.   Such re-
sults are not totally unexpected considering the  significant
amount of bio-activity which is present in the  carbon  column,
and which is also responsible for extending the observed  carbon
life.

       c.   Intensive Evaluation, II

            The second intensive evaluation was performed from
January 17, 1974, to April 7, 1974.  In this study,  raw sewage
and surge tank samples were taken every two hours (with the ex-
ception of 3 a.m.) for ten separate 24-hour days.  The  evalua-
tion's main objective was to generate a 24-hour profile of  the
raw sewage and surge tank.  Each sample taken was analyzed  for
eight parameters  consisting of BOD, SS, Total P,  TOC,  TOD,  TKN,
pH, and NH3-N.

            Approximately 1824 determinations were  scheduled
during the evaluation period.  Of this number,  140 determinations
(8% of total) were not performed because of missed samples, and
17 (1%) were discarded as being extremely incongruous  with  the
normal population.

Observations

            A summary of the data obtained is presented on  Table
16 and graphically represented on Figures 35 thru 42.

            In general, the data indicate concentration profiles
similar to the characteristic diurnal flow pattern as  shown in
Figure 21 (Normal Evaluation section).  The data  demonstrate
quite vividly the importance of the surge tank  and its  function
in accepting the  highly variable concentrations in the  raw  in-
fluent and dampening them into more easily handled fluctuations.
It is also interesting to note that the dampening ability of the
surge tank is much more pronounced during periods of high flow
and high concentration as opposed to lower flow and  lower con-
centration of the raw influent.  One of the reasons  for such a
difference is that lower flows are experienced  during  the late
evening and early morning hours which are also  the hours  of
minimum surge tank level and, therefore, minimum  dampening
abi1i ty .

            In Intensive Evaluation I, it was stated that the
three time periods chosen may not have been the best to produce
the results expected.  As an approximate check  of this  statement,
the data summarized in Table 16 was regrouped as  shown  in Table
17.  The numbers  were obtained by averaging the hourly  samples
of Table 16 during the following periods:


                                102

-------
TABLE 16
INTENSIVE
AVERAGE
AM

RAW
S.T
RAW
S.T
RAW
S.T
^ RAW
o S.T
co
RAW
S.T
RAW
S^
.T
RAW
S.T
RAW
S-^
.T

BOD
. BOD
P
. P
SS
. SS
TOC
. TOC
TOD
. TOD
PH
i |
. pH
TKN
. TKN
NH3-N
• NH3-N
1
137
163
5.90
6.98
122
128
47
50
182
211
7.1
6.9
42.8
38.0
25.9
23.5
3 5
79
94
4.60
6.03
107
89
46
36
229
186
7.2
6.8
48.8
43.1
31 .9
21.8
7
139
101
5.87
6.04
256
107
54
40
245
175
7.7
7.1
62.8
47.1
41 .1
25.8
9
169
127
8.40
7.14
177
121
72
47
324
220
7.8
7.3
68.8
56.6
45.1
34.6
EVALUAT
VALUES,
r
11
246
172
10.51
8.20
187
150
117
53
397
248
7.1
7.2
47.8
59.2
33.4
30.0
ION, II
M6/L
1
1
185
181
8.68
8.51
124
189
83
60
319
249
7.0
7.0
38.2
43.4
25.8
29.0
PM
3
146
159
8.26
8.45
183
216
73
62
310
267
7.0
6.9
35.2
35.3
26.5
26.0
5
154
159
7.38
7.37
139
235
65
58
225
235
7.1
6.9
36.2
33.9
22.6
22.1
7
216
158
7
6
173
173
77
56
299
223
6
6
37
35
26
24
9
244
179
.53 6.54
.97 7.38
192
156
65
54
277
221
.9 6.8
.9 6.8
.5 38.1
.4 38.8
.3 22.0
.0 23.0
11
152
190
6.80
7.06
133
179
66
53
251
221
7.0
6.8
35.2
32.9
24.6
20.1
                       FREEHOLD TREATMENT PLANT

-------
o
-p.
     o
     Q
     UJ
     Q
                                                       FIGURE 35
                                                  INTENSIVE ANALYSIS H
                                                                                      RAW INFLUENT
                                                                                —o—SURGE TANK
                                                                          DAILY VARIATION SUSPENDED SOLIDS
                                                                          10 DAY AVERAGE 2 HOUR FREQUENCY
                                                                            JANUARY 17.1974-APRIL 7,1974
                                                                           45678   9   10   II   IE
                                                                               FREEHOLD TREATMENT PLANT

-------
CD
tn
                                                       FIGURE 36
                                                 INTENSIVE ANALYSIS H
                                                                                    RAW INFLUENT
                                                                                    SURGE TANK
                                                                    DAILY VARIATION BIOLOGICAL OXYGEN DEMAND
                                                                       10 DAY AVERAGE,2 HOUR FREQUENCY
                                                                          JANUARY 17,1974-APRIL 7,1974
                                                                               5    6    7    8    9   tO   II   12

                                                                               FREEHOLD TREATMENT PLANT

-------
o
en
      20
                                                                       45678   910   II

                                                                         FREEHOLD TREATMENT PLANT

-------
             FIGURE 38
       INTENSIVE ANALYSIS E
                                  	•	RAW INFLUENT
                                  	o	SURGE TANK
                           DAILY VARIATION IN TOTAL OXYGEN DEMAND
                             10 DAY AVERAGE,2 HOUR FREQUENCY
                                JANUARY 17,1974 -APRIL 7,1974
8   9   10   II   12   I
IZ
                                4   5   6   7    8    9    10   II    12
                                  FREEHOLD TREATMENT PLAN T

-------
      ao
                                                  FIGURE 39
                                            INTENSIVE ANALYSIS H
       ro
    UJ
    O

    g
       90
o
00
    UJ 4O

    t.
      20
K>
                                                                             RAW INFLUENT
                                                                   j	o	SURGE TANK


                                                       DAILY VARIATION IN TOTAL KJELDAHL NITROGEN
                                                            10 DAY AVERAGE, 2 HOUR FREQUENCY
                                                              JANUARY 17,1974-APRIL 7,1974
        12  I
                                            K)   II   12   I
                                                            45678   9   10   II   12

                                                              FREEHOLD TREATMENT fLAMT

-------
o
vo
                                                    FIGURE 40
                                               INTENSIVE ANALYSIS H
                                                          -S-X   o
                                                                                RAW INFLUENT
                                                                                SURGE TANK
                                                                     DAILY VARIATION IN PHOSPHORUS
                                                                   10 DAY AVERAGE, 2 HOUR FREQUENCY
                                                                     JANUARY I7.I974-APRIL7.I974
       12
23458789

  FREEHOLD TREATMENT PLANT

-------
                                              FIGURE 41
                                        INTENSIVE ANALYSIS H
                                                                               RAW INFLUENT
                                                                             -SURGE TANK
                                                                 DAILY VARIATION IN AMMONIA-NITROGEN
                                                                  10 DAY AVERAGE 2 HOUR FREQUENCY
                                                                   JANUARY 17,1974 - APRIL 7,1974
12
6   7   8   9   10    II   18   I    2
                       NOON
45678910   II

   FREEHOLD TREATMENT PLANT

-------
    I	o	SURGE TANK  j    ;

       DAILY VARIATION IN PH
10 DAY AVER AGE 2 HOUR FREQUENCY
 JANUARY 17,1974 -APRIL7.I974

        I    i	  i	i	i	!
   567    8   9   10   II

   FREEHOLD TREATMENT PLANT

-------
         TABLE 17
 INTENSIVE EVALUATION, II
THREE-PERIOD AVERAGE (MG/L)
       Raw Influent
Period
1
2
3
BOD
255
204
108
P
8.18
6.96
5.25
SS
171
166
115
TOC
77.3
69.3
46.5
TOD
304
276
206
TKN
48.2
36.9
45.8
NH3-N
40
24.3
28.9
        Surge Tank
1
2
3
150
176
129
7.62
7.14
6.51
170
169
109
53.3
54.4
43.0
232
222
176
46.0
35.7
40.0
27.8
22.4
22.7
                     FREEHOLD TREATMENT PLANT
           112

-------
           P eri od                Hours

              1                  6  a.m.  -  6  p.m.
              2                  6  p.m.  -  12 midnight
              3                  12 midnight -6  a.m.

This regrouped data indicates  a  substantial drop in all  the
parameters during  the  second and third  periods of operation  with
the exception  of TKN and NH3-N.   Both  of  these parameters,
however, did  experience  a substantial  drop  during the  second
period.   Evaluation of concentration changes  occuring  during
the day  is important in  evaluating chemical usage, particularly
when chemicals are being added manually.   For example, Figure
40 shows significantly less phosphorus  in the late evening  and
early morning  periods  than during  the  6 a.m.  to  6 p.m. period;
however, the rate of FeClo use,  which  is  directly related to
the phosphorus content,  is normally  controlled at an  amount  which
corresponds to that required during  the late morning-early
afternoon periods.  This action, by  the operator, of  not reset-
ting his chemicals for the late evening-early morning  period is
understandable since he  does not wish  to  experience a  possible
upset in the early evening when he has  left.

           Since the treatment plant's  sewage collection system
is a relatively tight one, it would  be reasonable to  propose
the following periods of concentration variations:

           Five Peaks

                -Early morning shower, breakfast, and grooming
                -Middle morning cleaning and cloth washing
                -Lunch
                -Supper
                -Retiring

This, of course, did not occur during the  intensive evaluation
period.

           Observation of  Figures 35 thru  42 do  show, however,
that each  parameter experiences at  least one major peak  (with
the exception of  BOD  in which the raw experiences two major
peaks)  and a  few minor  peaks.

           The major  peak  appears to begin at approximately  5 a.m
and continues until the middle  afternoon.  The  first  minor  peaks
occur from 5  to 9  p.m., with  the  last peak beginning  at  9 a.m.
and lasting only  until  11  p.m.  at which  time all  the  parameters
begin their downward  plunge.  It  seems that  of  the five  peaks
proposed,  the first three  overlap to such  an extent that they
appear  to  be  one.

            It is  interesting  to note that  all parameters did


                                113

-------
not experience similar peaks during the day.  For example, TOD,
TOC, SS, pH, and BOD experienced more than one significant peak
while TKN, P, and NH3-N did not.  The significance of this is
not quite understood at present.

           There is also some doubt as to the correctness of the
suspended solids curve (Figure 35).  The time interval  between
the raw and surge tank peaks seem rather long.  The rapid in-
crease and decrease in the raw should have produced a similar
narrow peak in the surge tank curve.  The surge tank curve did
not display this peak.  It also showed very little dampening
ability.


B.  SOLIDS DISPOSAL

    1 .  Sludge Characteristics

        During the first six months of start-up and break-in
operation (October 1972-March 1973) the total solids content of
the clarifier sludge ranged from about two to four percent with
three percent being a typical value.  The reason, as described
previously was due to erratic operation of the sludge level
controller which frequently allowed very thin sludge to be pumped
to the Sludge Hold Tank.   It was observed that sludge in the hold
tank would settle leaving a relatively clear layer of water  on
top.  Five nozzles were welded on the hold tank,  equally spaced
from the bottom to the top, and drain valves installed  so that
the clear water could be decanted.   A schedule of regularly  de-
canting the tank was established.  The solids content of sludge
from the holding tank was increased to about seven percent.

        After the problems with the clarifier sludge level con-
troller described in Section  VIA1  were corrected the sludge
from the clarifier averaged about seven percent solids.  Little
improvement was then obtained by decanting the holding  tank.

       Considerable difficulty was  encountered in reliably pump-
ing the seven percent solids sludge from the hold tank  to the
inc nerator.   Plugging problem, similar to those  described in
Section  VIA  1  under Clarifier Sludge Pump, occurred frequently.
The steel  pipe and ninety degree elbows were replaced with 2.54
cm. (1  inch)  I.D. reinforced synthetic rubber hose, the gear
pump was replaced with a  variable speed drive progressing cavity
pump complete with bridge breaker,  and a procedure was  establish-
ed to flush the lines daily.  Plugging was reduced to infrequent
intervals.

       Samples  of Hydrasieve solids taken over a  nine month
period of steady state operation, July 1973 - March 1974, aver-
aged seventeen  percent total solids.  The solids  composition was
about 72% volatile compared to about forty-eight  volatile solids
                                114

-------
in the sludge.   The  clarifier  sludge  averaged  6.8%  total  solids
and the hold tank sludge 6.7%.   These data  are  contained  in  Table
18.  The analyses of intensive  evaluation  samples performed  by
an independent  laboratory contained  in Table  19 are in  agreement.

       The wet  weight of Hydrasieve  solids  collected during  one
week in April,  1973, averaged  18.2 kilograms  (40.2  Ibs).   Average
occupancy was eighty-two houses and  average sewage  flow was
102.66 cu. meters (27,122 gal.) per  day.   These data are  contain-
ed in Table 20.

    2. Dewatering

       The original  concept of solids dewatering and disposal   as
described in detail  in Section IV-B-1, Continuously Regenerating
Filter, was for the Hydrasieve solids to drop from  the screen
through a hopper to a belt conveyer  which  fed a sand filter  de-
veloped and built by the Procedyne Corporation.  These solids
together with sludge from the  holding tank were to  be mixed  with
hot recycle sand from the incinerator, dewatered in the filter to
about eighteen  percent solids  via evaporation, vacuum filtration,
and compression, then fed with a screw conveyor into the fluid
bed of the incinerator.

       Several  problems  developed:

       a.  The  belt conveyor required frequent cleaning.  Solids
would accumulate on the drive  and guide rolls resulting in poor
tracking.  Solids frequently would stick to the belt.

       b.  The overflow rate of sand  from the incinerator to the
filter was erratic, thus the mixing of hot sand, Hydrasieve
solids, and sludge was not uniform.    It was necessary to get good
uniform mixing to cool the sand and evaporate part  of the water
content of the solids.

       c.  The filter operation was  unsatisfactory.  The sand-
sludge mixture did not dewater and move through the filter as
designed.  The layer along the wedge  wire screen would dewater
and stay  in place, blinding the screen, then dewatering would
cease.  Sometimes, when  the sludge concentration was high, the
sand-sludge mixture would form balls.
       d.  The  feed
 being discharged to
frequently carbonized on the screw before
thefluidized bed thus plugging the screw.
        It became apparent that further development work was re-
 quired.  In addition, as the Clarifier operation was improved
 and  the  sludge consistency approached seven percent solids, the
 economics of operating  the sand filter became marginal due to the
 cost  of  power to run the filter and vacuum pump, and the  cost of
 oil  required to reheat  the recycle sand from ambiant to 816°C
 (1500  F).  The sand filter was removed.
                                115

-------
                         TABLE 18



              FREEHOLD SLUDGE CHARACTERISTICS
Hydrasieve Solids
Clarifier Sludge
Hold Tank Sludge
DATE
1973-74
July 31
Aug 6
Aug 16
Aug 21
Aug 26
Sept 5
Sept 10
Sept 20
Sept 25
Sept 30
Oct 10
Oct 15
Oct 25
Oct 30
% Total
Solids
14.2
11 .3
12.9
16.7
12.6
16.4
27.7
23.4
16.2
16.1
16.4
13.4
31 .9
23.6
% Volatile
Solids
71 .5
92.6
77.9
68.5
67.7
85.6
40.3
49.4
86.5
71 .0
67.6
81 .6
34.9
59.6
% Total
Sol ids
5.5
5.9
8.3
7.5
10.6
5.8
8.4
9.1
7.0
9.1
9.0
3.6
8.5
2.9
% Volatile
Solids
43.4
48.7
48.6
50.3
73.0
53.6
46.5
49.4
44.1
53.1
40.7
43.1
46.2
50.7
% Total
Solids
6.8
5.5
6.1
9.8
4.0
-
9.8
-
5.2
8.5
6.8
8.6
10.2
3.4
% Volatile
Solids
46.8
41.5
52.6
58.8
52.1
-
46.3
-
53.9
53.0
44.7
41.7
41 .0
47.7

-------
TABLE 18 (Cont'd)
              Hydrasieve Solids	Clarifier Sludge	Hold  Tank  Sludge
DATE
1973-74
Nov 8
Nov 14
Nov 19
Nov 27
Dec 5
Dec 14
Dec 21
Dec 26
Jan 21
% Total
Solids
13.2
14.3
11 .9
14.0
15.7
17.4
25.2
11 .2
16.2
% Vol
Sol
84
90
70
71
80
94
44
82
86
a tile
ids
.0
.0
.8
.2
.5
.1
.0
.5
.7
% Total
Solids
7
4

6
6
4
9
5
6
.5
.8
-
.3
.3
.7
.5
.5
.2
% Vol
Sol
44
41
-
49
45
48
41
48
56
a t i 1 e
ids
.0
.5

.1
.5
.0
.0
.1
.2
% Total
Sol ids
7
5

5
7
4
8
9
6
.0
.8
-
.6
.8
.4
.3
.4
.1
% Vol
Sol
44
45
-
48
45
48
49
46
56
atile
ids
.7
.0

.5
.4
.6
.6
.9
.2
                                                         FREEHOLD  TREATMENT  PLANT

-------
                                             TABLE 19
                               INTENSIVE EVALUATION - SLUDGE SAMPLES
CO
     AVERAGE
                   Hydrasieve Solids
                          Clarifier Sludge
                                      Hold Tank Sludge
DATE
1973
Sept 27
Oct 23
Nov 12
Nov 15
Dec 10
Dec 17
% Total
Solids
14.0
18.2
21 .3
19.0
13.1
26.6
% Volatile
Solids
93.3
84.4
86.4
90.9
87.8
72.4
% Total
Solids
6.6
4.1
6.6
8.9
7.0
7.1
% Volatile
Solids
50.9
55.4
52.0
47.9
52.3
56.5
% Total
Solids
9.0
4.9
7.6
7.0
4.4
6.2
% Volatile
Sol ids
50.1
52.6
53.6
51 .3
64.8
55.6
18.7
85.9
6.7
52.5
6.5
54.7
                                                                   FREEHOLD TREATMENT PLANT

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                                TABLE 20

                       HYDRASIEVE SOLIDS COLLECTED
        Date
24 Hour Period Ending
Solids Collected
  Wet Wt.  Ibs.
Sewage Flow
  Gal Ions
0830
0830
0900
0800
0830
AVERAGE
4/12/73
4/13/73
4/14/73
4/15/73
4/17/73

45
40
24
46
46
40.2
24,315
29,807
28,611
26,857
26,019
27,122
                                                 FREEHOLD TREATMENT PLANT

-------
       A vacuum coil  filter was installed  and  tested  for  sludge
dewatering.  This unit was able to produce a  filter  cake  of  twelve
to twenty percent solids with a sludge feed of five  to  ten  percent
solids.  Suspended solids in the filtrate  ranged  from 6,000  to
20,000 mg/1.   The filter required considerable operator attention
and could not be left operating unattended for long  periods  of
time.  It was removed.

       When the sand  filter was removed it became necessary  to  use
a different technique to feed sludge to the incinerator.  A  spare
nozzle about 30.5 cm  (12 inches) above the air distribution  plate
was fitted with a plug valve and a packing gland.  A  sludge  feed
gun consisting of a length of 1.25 cm diameter (0.5  inch) type  RA
330 stainless steel pipe with a full bore  ball valve  on the  outer
end was inserted through the packing gland, plug  valve  and  nozzle,
extending about 10.16 cm (4 inches) into the  sand bed.   The  sludge
line with an air purge was connected to this  gun.  The  small  gun
would plug once or twice a day.  This gun  was  replaced  with  one
2.54 cm (1 inch) in diameter and an air purge  rotometer was  in-
stalled so the purge  could be regulated at about  0.028 cubic meters
per minute (1 SCFM).   Gun plugging was no  longer  a problem.

    3. Incineration

       The "Fluidhearth" fluid bed incinerator, instrumentation,
and related auxiliary equipment including  that necessary for car-
bon regeneration was  designed, fabricated, and installed under  the
supervision of the Procedyne Corporation.   It  is  described  in
detail in Section IV-B-2.

       Installation was completed in November  1972.   The refractory
was dried, thirteen hundred pounds of sand was charged  to the unit
and it was heated to  816°C (1500°F).  The  procedure developed to
dry and cure the refractory whenever major alterations  or repairs
were made consisted of heating to about 71°C  (16QOF)  with a propane
torch, inserted through the recycle sand nozzle.   After holding at
71°C for eight hours  the temperature was increased to 110°C (2300F)
at a rate of about 11°C (2QOF) per hour, and held at 110°F  for
eight hours.  The temperature was then increased  to 316°C (600°F)
at a rate of 28°C  (50°F) per hour and held for four hours after
which the regular start-up procedure was followed.

       The original start-up procedure consisted  of charging the
incinerator with 590 kg (1300 Ibs.) of 20-40 mesh flintshot sand,
igniting the oil fired start-up burner in the plenum and heating
to a bed temperature of 621°C  (1150°F).  The sand bed at this point
was fluidized and the safety temperature interlocks allowed fuel
oil to be injected directly into the bed via the  gun burner.  The
bed temperature was increased to 816°C (1500°F),  the start-up
burner was shut down, and the controls set for automatic operation.
                                120

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       Shortly after start-up the  differential  pressure  readings
across the fluid bed and the air distribution  plate  indicated  an
absence of sand.  The unit was cooled  and  examined.   The ceramic
plate had cracked, several ceramic tuyeres were broken,  and  the
sand had drained into the plenum.   The tuyeres  were  replaced with
ones made of high temperature alloy (RA330) and a new ceramic
plate was cast on top of the old one.   The plate was cured,  the
incinerator was loaded with sand,  and, following the regular
procedure heated to operating temperature.  Again, it was found
that there was considerable leakage of sand to  the plenum.   In
addition, several hot spots developed  on the shell.   Upon cool-
ing the unit it was found that the packing around the plate  had
blown out.  The plate was repaired by  packing  around the edge
with "Fiberfrax" then building a refractory brick ledge  to hold
the packing in place.  The hot spots were  repaired by removing
the refractory and deteriorated insulating brick in  those areas
and replacing with new materials.   The unit was reheated and put
on automatic control in late January,  1973.

       During the spring and early summer  of 1973 the incinera-
tor was operated intermittently burning sludge first from the
sand filter then directly from the sludge  holding tank.   The
major operating problem was to maintain continuity of operations,
especially during the sand filter operating period.   The scrubber
water circulating pump corroded and failed.  It was  replaced
with a stainless pump.  Oil tended to carbonize in the oil feed
gun at low oil flow rates. An air purge similar to that on the
sludge gun was installed.  The fluidizing  ai> blower failed  and
was replaced.  The fuel oil pressure regulator failed and was
replaced.

       As the sewage flow to the plant and thus the amount of
sludge collected increased, it became desireable for the incinera-
tor to operate burning sludge automatically at night and at other
times when no operator was in attendance.   The sludge feed pump
motor circuit was connected via relays to a high-low temperature
controller which allowed  the pump to run only when the fluid bed
temperature was  in the desired range of about 760° to 843°C
(1400-1550°F).  This worked very well.

       During this period the carbon regeneration equipment was
tested and made  ready for operation.  The  incinerator carbon
overflow  valve was relocated to a better position.  The carbon
feed screw was redesigned to provide a new cooling jacket and
stuffing  box and a drain  line was installed on the feed screw
drain section.   The  after burner and controls were tested.  The
system was then  put  in stand-by because the carbon was not yet
exausted  and did not require regeneration.  Later in the year
it  became apparent that the  life of the carbon was much  longer
than originally  believed.  The incinerator was modified which
precluded carbon regeneration.


                               121

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       On July 13, 1973 when restarting the unit after a power
failure, a hot spot developed.  An inspection revealed that the
plate had cracked again. A 2.54 cm (1 inch) high temperature
alloy type RA330 plate and tuyeres were installed.   To insure
fluidization in case of seal leakage a 3.18 cm diameter
(1-1/4 inches) type RA330 air sparge pipe was inserted into the
center of the bed from the top of the unit and valved to the
fluidizing air blower.  This system operated satisfactorily.

       On August 31 the unit was examined by a licensed pro-
fessional engineer from an independent laboratory while it was
burning sludge at about design rate.   Stack gas samples were
taken as described in the New Jersey and Federal air pollution
regulations.   The results certified to the state show a particu-
late content of 0.011 grains/ftj and an opacity reading of zero.

       During September the unit operated continuously and auto-
matically to burn sludge, unattended at nights and  checked only
briefly on weekends.   It shut down automatically on September 29,
reason unknown, and was restarted September 30.  The unit burned
sludge faster than it was produced, thus when the holding tank
level was low the sludge feed pump was stopped and  the incinera-
tor idled until the sludge inventory increased.  During the month
approximately 16,805 liters (4,440 gals.) of sludge at an average
7.8% solids was burned in 415 hours, a rate of 40.5 1/hr (10.7
gal/hr).  Fuel oil consumption was 10.2 1/hr (2.7 gals/hr). Total
ash removed from the dry cyclone was 360.6 Kg (795  Ibs.) Fuel
consumption averaged 730 gallons per ton of dry solids.  At a
fuel price of 18.4 c/gal the fuel cost per ton of dry solids was
$130. These data are contained in Table 21.

       The incinerator operated continuously until  October 15
burning sludge as required. Air leakage around the  plate seal
became excessive and the unit was shut down.  It was decided to
relocate the start-up burner from the plenum to the top of the
incinerator, remove the plate and in its place install an in-
verted concical shaped stainless distribution plate can. The
tuyeres were on the top of the can and fluidizing air was piped
from the blower through the plenum wall to the low  point of the
can.  Sand was then added to the incinerator.  The  diameter of
the distributor plate can was about 12.7 cm (5 in.) less than
the inside diameter of the refractory thus the can  was surrounded
on all sides by sand and was free to expand and contract as the
temperature increased and decreased.   In addition there were no
plate seals to erode.  The unit was heated by down  firing using
the start-up burner on the top of the incinerator.   The gun
burner interlocks were changed so that the bed oil  gun could be
started when the temperature reached 566°C (1,050°F).
                               122

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                           TABLE  21

                  INCINERATOR OPERATING  DATA

                        SEPTEMBER 1975
Hours of sludge burning                       =     415
Volume of sludge burned             gals.      =   4,440
Weight of sludge burned             Ibs.       =  37,740
Sludge analyses                     % Solids  =       7.8
Weight of dry solids burned         Ibs.       =   2,944
Fuel oil used                       gals.      =1 ,120
Gallons fuel per dry ton solids               =     761
Cost of fuel                        
-------
        The  Incinerator was restarted  in February 1974. The new
 air distributor  plate can concept worked well.  Bed fluidization
 appeared good, however hot spots developed at points on the shell
 above the oil and sludge feed gun nozzle.  The cast refractory at
 these nozzles was found to be cracked and the insulation eroded.
 This was repaired by drilling holes and pumping in castable
 insulation  which sealed the cracks and filled the eroded voids.
 however upon subsequent operation, hot spots developed at other
 places  on the shell.  It was concluded that to make the unit
 operable the original brick-type insulation should be removed
 and the area between the refractory brick and the shell be filled
 by pouring  castable insulation.

        By the spring of 1974 the price of fuel oil and power
 were twice  that  in September 1973 and economics of operating such
 small units dictated hauling the sludge to landfill as long as
 sites were  available and regulations  permitted.  It was finally
 decided to  remove the incinerator and use the space for other
 purposes.


 c•  PLANT MODIFICATION^

       During the 2 year period since the spring of 1974 an
 attempt has been made to achieve reduced operating costs,  lower
 attendant  requirements,  achieve greater consistency of results
 and measure the local community acceptance and reaction to the
 facility.    Listed plant  modifications are as follows:

       1.    Installed automatic hot water spray system for  the
 Bauer Screen with timing devices controlling frequency and
 duration of flushing to  eliminate grease and solid buildup on
 screens.

       2.    Installed a retention loop consisting of water  storage
 tanks in series after the surge tank and prior to the clarifier
 for chemical mixing.

       3.    Added positive displacement pumps to the pump station
 eliminating the problems of the prior type which required  fre-
quent operator attention and caused recycling in the plant during
 periods of  ailure.

       4.    Eliminated the magnetic filter with its head loss  and
power needs.                                                     '

       5.    Removed  the incinerator.

       6.    Installed a water pump to permit more efficient back-
wash with  effluent  rather than fresh water.
                               124

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       7.   Replaced the carbon column  supports  with  stainless
steel  and  modified piping  to simplify  maintenance.

       8.   Added 2" decanting line from Bauer screen hopper.

       9.   Installed a 4,860-gallon ferric chloride  storage
tank to permit bulk delivery and allow automated feed and
mi xi ng.

      10.   Installed pH meter.

      The  above modification program has significantly reduced
operating  costs identified in the financial section.
                              125

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                           SECTION VII
                    FINANCIAL CONSIDERATIONS
INTRODUCTION
        Treatment plants have two major elements of cost (capital
and operating costs) which are of concern to both the initial
and ultimate owner.  Funding, initially, is often the burden of
a developer, but ultimately, all costs must be borne by the
homeowner.  The major problem is to balance the capital and
operating expenses to achieve the best economic solution for the
project.  In today's society with changing criteria and more
stringent qual i ty requirements for effluent discharge, together
with frequent moratoriums on new connections to the sewage
system, a simple low labor intensive treatment plant producing
a high quality effluent is very desirable.  By low labor cost
we are reflecting the desire to utilize part-time operators for
four hours or less per day on a six-day basis with alarm systems
and dualization of key elements to avoid breakdown problems.
Such a plant can be justified to permit residential growth if
the capital  cost per dwelling unit and subsequent operating
costs fall within the following ranges:

        1.  capital cost:   $500-1,900 per dwelling unit
        2.  operating cost: $100-200 per dwelling unit per year

        The above costs must be weighed against all alternates in
the following situations:

        1.  Cost of pump station and force main to a trunk sewer.
        2.  Will interim facilities meet all quality needs and
if so can the effluent meet stream discharge permitting require-
ments or will ground water recharge have a more desirable environ-
mental impact.
        3.  Will the facility permit use of land that is currently
unusable and is the enhanced land value greater than the total
plant cost.

        The system being constructed may be for an interim
facility which will be ultimately abandoned, or it may be one
which will have an extended life, requiring modifications to
provide for future growth and for changing criteria.   Such a
plant may initiaially be owned and operated by a developer and
                                126

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may ultimately be deeded to or purchased by a government agency.
These factors should be considered in the design of the proposed
plant as its future fate will  effect choice of process  and
equipment and lead to design considerations which will  be directly
related to the ultimate costs  to the customer.
         n this project of extremely limited size a major attempt
was made to arrive at lowest potential  operating costs while at
         time recognizing that capital  costs, although important,
         the major variable consideration.
        In
        t
the same time recognizing that capital  cos
were not the major variable consideration.

SIGNIFICANT COST DATA
        During the research phase of this project extensive cost
records were maintained which are not significant in the long-
range operational mode because of the high cost of sampling.
most of which would not be required for routine operation, and
because the continuous modification occurred in this experimental
plant.

        Subsequently, the second series of costs were developed
which indicated serious underestimating of operating cost in the
original designs due to the following:

        1.  Plant design produced excessive chemical need
requirements;

        2.  Major increase in utilities cost because of fuel
adjustment and rate increases to the power company;

        3   Increased cost of chemicals.

        4.  Significantly increased labor costs.

        The estimated costs of Table 22  (top set of numbers)
were prior to construction and the actual costs in Table 22
(middle set of numbers) were during the  evaluation phase. Sub-
sequently, the following major modifications were made in the
plant to  improve operations, reduce labor, and permit lower
purchase  prices  for the necessary chemicals:

        1.  Positive head pumps were installed at the lift
station to reduce recycling and thus eliminate a major main-
tenance problem.

        2.  Underground bulk storage of  ferric chloride was
provided  reducing its purchase price and  handling costs to
less than  half of those previously incurred.
                                 127

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                       TABLE 22

                    OPERATING COSTS
               FREEHOLD TREATMENT PLANT

                   ESTIMATED COST^1 )
              EPA GRANT APPLICATION 1970
ITEM                               COST $/1.000 GAL

Direct Labor  (8 hrs./week)             $ .092
Materials     (includes chemicals)        .134
Electric                                  .208
Gas                                       .038
Maintenance                               .046
                                        $0.518

                    ACTUAL COST(2)
             STEADY STATE OPERATING PERIOD
                 JULY 1973-MARCH 1974
ITEM                               COST $/1,000 GAL

Labor    (6  hrs./day,  7 days/week)      $ .793
Chemicals                                 .400
Electric                                  .266
Fuel Oil                                  .150
Maintenance                               .066
Sludge Hauling                            .350
Telephone                                 .050
                                        $2.075

                    PRESENT COST(2)
                    1976 OPERATION
HE!                               COST $/1 .000 GAL

Labor    (4  hrs./day,  7 days/week)      $ .57
Chemicals                                 .27
Electric                                  .32
Fuel Oil                                  .08
Maintenance  & Supplies                    .20
SludgeHauling                            .39
Telephone (Ans.  Service)                  .02
                                        $1 .85

^ ^Cost based on 50,000 GPD
        based on 28,000 GPD

                         128

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        3.   Major modifications  were  made  in  the  flow  pattern
permitting  increased  mixing  and  detention  time  prior to  the
clarification thus reducing  the  quantity of  chemicals  required
per 1,000 gallons of  flow treated.

        4.   pH control  of the process permitted reduced  (required)
dosage of ferric chloride.

        5.   The magnetic filter  was eliminated.

        6.   Adjustments were made to  improve the backwash
capability in the carbon column.

        The modifications cited  above resulted in reducing the
operating costs to the levels recorded in  Table 22 for 1976
operations (lowest set of numbers).

IDEAS ON FURTHER COST REDUCTION

        Based on the experience  with this  plant, further cost
reductions are possible if initial designs incorporate the
following concepts:

        1.  A new configuration  of the plant can reduce  labor
needs and energy costs.

        2.  Proper design with  equipment  selected for long life
and minimum maintenance will reduce  the operating cost.

        3.   Increased sludge tank  holding capacity will  decrease
the frequency of  trucking sludge and also reduce costs.

        4.  Using ferric chloride  to achieve phosphate  removal
in high quality  effluent may not be  the most economic selection
of coagulant.  At other  locations, other  chemicals might be used
such  as  primary  polymer  or alum and  polymer  and  thus  simultan-
eously  reduce  the need  for caustic soda which  we have had  to
use to  correct  pH.   (Ferric  chloride as used in  this  plant
reduced  the  pH  to a  point where it was necessary to raise  it
with  sodium  hydroxide  in order  to  provide the  optimum pH for
coagulation).

         5.   The  substitution of alternate coagulants  for the
ferric  chloride  would  eliminate the  need  for  PVC piping  and
epoxy coated  tank linings and thus reduce total  equipment  and
mixing  requirements  and  costs.

         Based on the above  considerations a  projection  of
operating  costs  independent  of  capital costs  and independent
of inflation costs  has  been  made for different size  plants as
 shown on Figure 43  and Table 23.
                                 129

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           FIGURE 43

          ESTIMATED
OPERATING COST vs. PLANT SIZE
                150  200 250
500
       PLANT SIZE GPD x I03
             FREEHOLD TREATMENT PLANT
            130

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                                        TABLE 23
                               PROJECTED OPERATING COSTS
                                     $/l,000 GALLONS
                                                         PLANT SIZE
ITEM
LABOR
ELECTRIC
FUEL OIL
REPAIR AND
MAINTENANCE
CHEMICALS
FERRIC CHLORIDE
SODIUM HYDROXIDE
CHLORINE
POLYMER
TOTAL OPERATING
COST/1,000 GALLONS
55,000 GPD
$ .28
.18
.04
.16

.10
.13
.02
.02
$ 0.93
100,000 GPD
$ .18
.14
.03
.12

.08
.12
.02
.02
$ 0.71
250,000 GPD
$ .16
.14
.03
.12

.08
.10
.02
.02
$ 0.67
500,000 GPD
$ .14
.12
.02
.10

.07
.10
.02
.02
$ 0.59
LO
                                                                FREEHOLD TREATMENT PLANT

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                          APPENDIX A

           PROCEDURES FOR ANALYZING FREEHOLD SAMPLES
     Freehold samples which were analyzed at the Marshallton lab
were performed in accordance with the references and procedures
listed below.  Where a test is referenced to Standard Methods or
EPA, it was done as directed in the reference.   Any modifications
of a standard are listed.  Those tests which are performed by
some technique other than Standard are listed with backgrounds
and explanations for their use.
Suspended Sol ids:
Coliform:
Chemical Oxygen DemandL
Total Solids:
Volatile Solids
A1 k a 1 i n i ty:
Chloride:
Biochemical Oxygen Demand
Phosphorus:
Standard Methods for the Examina^
tion of Water and Wastewater, 13th
                               Edition
                               p. 537.
         (1971) Method 224 C
Standard Methods. Method 407 A & D
p. 664.

Standard Methods, Method 220,
p. 495.

Standard Methods. Method 224 A,
p. 535.

Standard Methods. Method 224 B,
p. 536.

Standard Methods. Method 102,
p~! 52, modified  on 1 y by using
methyl purple instead of methyl
orange as indicator.

Standard Methods. Method 112 A,
p. 96.

Standard Methods. Method 219,
p. 489, modified for Weston and
Stack Dissolved  Oxygen Probe as
approved by Methods for Chemical
Analysis of Water and Wastes, EPA
(1971), p. 60.

Methods for Chemical Analysis of
Water and Wastes. EPA(1971) pp.
235-245.
132

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Nitrate and Nitrite:            Water  Analysis  Handbook. Hach
                               Chemical  Co.  (1973), modified
                               from Standard  Methods,  Method
                               213  B,  p.  458.

     The Hach procedure  is  like Standard  Methods  in that it  is
a photometric color adsorbtion of a sample  in which the nitrate
has been reduced by calmium.   However,  the  Hach  test  is much
faster and more convenient  because  it employs reagent powder
pillows instead of a  reduction column.

     A Nitra Ver IV Powder  Pillow is  added  to 25  ml of sample
and shaken for one minute.   If nitrate  or nitrite are present,
a pink color will develop which is  measured against a blank  in
a Fisher Electrophotometer  II using  a greem filter with  a  wave-
length of 525 m/1.  The  number from the Photometer scale  is
then applied to a calibration curve  from which the Photometer
scale is then applied to a  calibration curve from which  Nitrate/
Nitrite - Nitrogen is read  in mg/1.

Total Oxygen Demand:            Instruction Manual Model  225,
                               Total  Oxygen Demand Analyzer,
                               Ionics, Inc. (1970).

     The Ionics Model 225 TOD Analyzer is an automatic accurate
instrument capable of graphically recording the oxygen demand of
dissolved and suspended  oxidizable constituents in an aqueous
sample.  Its advantages  over other common methods are that it is
rapid, automatic, more precise, and has a chemical reaction
efficiency at or  approaching theoretical.  The instrument can be
set  to perform within oxygen demand limits of 0-50 ppm for the
low  range, extending to 1000 ppm for high range applications.

     A 20 microliter sample  drop is automatically injected into
a furnace tube containing platinum catalyst at 900°C.  A nitrogen
stream containing a fixed,  known amount of oxygen continuously
flows  through the furnace tube and supplies  the oxygen necessary
for  combustion.   The vaporized, oxidized sample along with the
oxygen depleted  nitrogen stream, then passes through  a fuel
cell containing  platinum and lead electrodes in a medium of 20%
KOH  solution.  The fuel  cell reacts to the loss of oxygen in the
nitrogen stream  and converts this imbalance  to electrical  impulses
which  are translated to a chart read-out from which oxygen demand
is read in mg/1  TOD.

Total  Organic Carbon:          Analytical Chemistry,  Vol.  37,
                               No. 6, May 1965, p. 769; Vol. 39,
                               No. 4, April  1967, p.  503.

     The  same  sample which is  oxidized in the TOD analyzer
passes  through  a  MSA Lira Infrared Analyzer  Model 300 wherein
the  TOC of  the  sample is measured and recorded.  Prior to sampling


                                133

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by the TOD analyzer, the sample is adjusted to pH<3 and then
sparged with nitrogen to remove inorganic carbon compounds, thus
leaving only the organic carbon compounds to be oxidized to C02
and measured by the infrared optical  bench and graphed as mg/1
TOC.

Ammonia:                       Refer  to letter to J.  D. Beach
                               from R.  A. Conte, dated November
                               19, 1974, RE: Analysis for Ammonia
                               Ni trogen.

     Add about 50-80 ml of sample  into  a 100 ml beaker containing
a stirring bar.  To this, add 1 ml of 10 M NaOH for each 100 ml
of sample.  This addition raises the  pH of the sample above 11
so that all of the ammonium ion is converted to ammonia which
can be detected by the probe.  The probe is then inserted into
the sample solution which is agitated by a magnetic stirring bar.
The digital millivolt read-out is  then  applied to a calibration
curve which yields mg/1 ammonia.  Multiply mg/1 ammonia by 0.82
to get mg/1 ammonia nitrogen.  Rinse  probe well between samples.

     To prepare a calibration curve,  use serial dilutions of
ammonia chloride for samples containing 100, 10, 1, and 0.1 mg/1
ammonia.  Using the 100 ppm ammonia sample and above  procedure,
set the meter at -75 mv.  Then run the  remaining standards and
record the mv for each.  Plotting  these data points on 4 cycle,
semi-log paper should give a straight line.
Total Kjeldahl Nitrogen:
Refer to letter to J.  D.  Beach
from R.  A.  Conte, dated November
19, 1974, RE:  Analysis for Ammonia
Ni trogen.
     This Kjeldahl test converts organic nitrogen to an ammonium
ion state which can then be readily converted to ammonia and read
by the Orion Ammonia Probe.

     Using a micro Kjeldahl apparatus, a 50 ml  sample is digested
in the presence of a digestion reagent (see Standard Methods,
13th Edition, p. 245, 3.a.).  The digestion is  carried out until
$03 fumes appear and then subside.  After cooling,  the digestion
flask is rinsed with distilled water into a 100 ml  volumetric
flask.  After several rinsings, the volume is made  up to 100 ml.
From this, a 20 ml aliquot is put into a 150 ml beaker to which
is added 0.5 ml of a Saturated KI solution and  78 ml distilled
water.  The beaker with a stirring bar is then  placed on a
magnetic stirring motor and the ammonia probe is inserted into
the solution.  Add 1.5 ml of the 10 M NaOH and  read the milli-
voltage; then add 10 ml of a 76.4 mg/1. NH4C1 solution and again
read the millivoltage on the meter.
                                134

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     This potential  difference is  applied  to a  known addition
chart supplied with  the ammonia probe.   The  chart reading is
then multiplied by 200 and this is reported  as  mg/1  Total
Kjeldahl  Nitrogen.
                               135

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                   APPENDIX B

                   PHOTOGRAPHS
            FREEHOLD TREATMENT PLANT
                  DECEMBER 1975
  VIEW OF PLANT AND MANASAQUAN RIVER TREE  LINE

                             *>
                                      •
VIEW OF PLANT EFFLUENT  LINE  INTO  MANASAQUAN  RIVER
                      136

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      View of main floor from
      carbon column to clarifier
      to chemical mixing loop
      against wall on the far
      end of building.  Entrance
      door is to the  left at the
      far end of bui1di ng .
     [-View  of  chemical mixing
       loop  with  ferric chloride
       caustic  soda  and polymer
       tanks .
          FREEHOLD TREATMENT PLANT
137

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U)
00
     View of  main  floor instrument  panel;
      carbon  column  and door  leading  to
           office  and  laboratory
View of basement floor carbon column
 and carbon column instrument panel
                                                                   FREEHOLD  TREATMENT  PLANT

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  View of basement  floor  with  retention  loop  for
 chemical mixing  to immediate  left,  sludge  holding
tank far left and carbon  column  feed tank  far right
       View of basement floor
     loop for chemical mixing
        primary feed pumps to
with retention
to the right and
the far left

    FREEHOLD TREATMENT PLANT
                        139

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                          APPENDIX C
                       CONVERSION TABLE
        (1)
TO CONVERT FROM
foot
ft2
gal lon(U.S. 1 iquid)
ga1(U.S. 11qu1d)/m1n.
grain(l/7000 Ib avoirdupois)
horsepower (electric)
inch
in2
in3
pound(lb avoirdupois)
ton(short,2000 Ib)
yard
yd2
y«3
degree Fahrenheit
   TO
metre(m)
     2  2)
metre (m'
     3  3
metre (m)
metre (m3)
     3      3
metre /sec(m /s)
kilogram (Kg)
watt (W)
metre(m)
     2  2
metre (m )
metre (m )
kilogram(Kg)
kilogram(kg)
metre(m)
     2  2
metre (m )
metre (m )
degree Celsius
  MULTIPLY BY
  3.048000 E-01
  9.290304 E-02
  2.831685 E-02
  3.785412 E-03
  6.309020 E-05
  6.479891 E-05
  7.460000 E+02
  2.540000 E-02
  6.451600 E-04
  1.638706 E-05
  4.535924 E-01
  9.071847 E+02
  9.144000 E-01
  8.361274 E-01
  7.645549 E-01
t°c=(t°f-32)/1.8
       As per Standard for Metric Practice E380-76
       American Society for Testing and Materials
                              140

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                                  TECHNICAL REPORT DATA
                           (Please read Instructions on the reverse before completing)
1. REPORT NO.
   EPA-600/2-78-168
                             2.
                                                            RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
   Advanced Waste Treatment for Housing  and
   Community Developments
                                                             PORT DATE
                                                             eptember 1978(Issuing Date)
                                                           PERFORMING ORGANIZATION CODE
7. AUTHOR(S)

   Russell  Bodwell
                                                           . PERFORMING ORGANIZATION REPORT NO.
,
. PERFORMING ORGANIZATION NAME AND ADDRESS
  Levitt and Sons, Incorporated
  51  Weaver Street, Office Park  5
  Greenwich, Connecticut   06830
                                                          10. PROGRAM ELEMENT NO.
                                                            1BC611
                                                           11. CONTRACT/fcKXMX NO.

                                                            68-01-0077
 12. SPONSORING AGENCY NAME AND ADDRESS
   Municipal Environmental Research  Laboratory--Cinn., OH
   Office of Research and Development
   U.S. Environmental Protection  Agency
   Cincinnati, Ohio  45268
                                                          13. TYPE OF REPORT AND PERIOD COVERED
                                                           Final Report   4/71  - 6/75
                                                          14. SPONSORING AGENCY CODE
                                                           EPA/600/14
 15. SUPPLEMENTARY NOTES
   Project Officer:  Irwin J.  Kugelman
                                            513-684-7633
 16. ABSTRACT
             Treatment of wastewater from  a  subdivision in a physical-chemical  treatment
   plant (screening, chemical coagulation,-sedimentation, filtration, carbon  adsorption,
   chlorination) was evaluated.  The 190 nr/day (50,000 gal/day) plant was  housed  in the
   shell of a standard house on a standard lot in a 127 home subdivision.  During the
   18 month evaluation period excellent treatment was achieved  (99%  removal of BOD5>
   Suspended Solids, and Total Phosphorus).   Shock loadings had almost no effect on
   plant performance because an equilization tank leveled out peaks  and  because of the
   ability of the physical-chemical processes to absorb excess  loading.  Extensive data
   on temporal characteristics of wastewater from a subdivision were collected during
   the evaluation. An experimental  sludge  filter and fluidized  bed incinerator were in-
   stalled to process the sludge but were  not extensively used.  The former did not
   function, the latter suffered from  repeated mechanical breakdowns.  Sludge was  perio-
   dically hauled to a landfill by  a septic-tank-hauler.  Acceptance of  the presence of
   a sewage treatment plant  in the  midst  of the subdivision was excellent.  No complaints
   of any type were registered by the  homeowners.  The system cost was higher than for a
   conventional plant.  The  actual  construction cost exceeded $300,000 and  operational
   expenses were greater than  $0.53 per cubic meter ($2.00 per  1000  gallons).  At  the
   measured flow of 206 gal  per home per  day this represents a  cost  of $0.40  per home per
   day.  It is anticipated that significant reductions in these costs would result from
   a redesign based on the experiences gained during the demonstration
 17.
                                KEY WORDS AND DOCUMENT ANALYSIS
                   DESCRIPTORS
                                              b.IDENTIFIERS/OPEN ENDED TERMS
                                                                           COSATI Field/Group
   Sewage Treatment
   Sewers
   Sludge Disposal
                                              Subdivision Wastewater
                                              Small Flow Treatment
   13 B
 18. DISTRIBUTION STATEMENT

   Release to Public
                                              19. SECURITY CLASS (This Report)
                                                Unclassified
21. NO. OF PAGES
   153
                                               20. SECURITY CLASS (This page)
                                                 Unclassified
                                                                         22. PRICE
 EPA Form 2220.1 (R.v. 4-77)
                                            141
                                                                U.S. GOVERNMENT PRINTING i

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