Sludge Treatment

(Sludge Disposal)
Dr. Eng. Joni
Aldilla Fajri
 Sludge Disposal

Sludge treatment and disposal may account

for up to 80% of the total wastewater
treatment cost.

Options:
Land disposal - cheapest
Landfill
Incineration - most expensive
Influent Effluent
Wastewater Treatment

Raw sludge

Sludge Treatment ?
Large catalog of
available technology

Processed
Sludge Disposal
sludge • Land application
• Landfill
• Incineration

3
Influent Effluent
Wastewater Treatment
(Septage?)

Raw sludge,
grit, screenings

Sludge Treatment

What goes here depends on

Sludge Disposal
• Land application
the method of final disposal. • Landfill
• Solids concentration • Incineration
• Pathogen reduction

4
Influent Effluent
Wastewater Treatment
(Septage?)

Raw sludge, grit, screenings

Sludge Treatment
• Gravity thickening
• Gravity belt filter
• Vacuum filter Sludge Disposal
• Filter press
• Land application
• Anaerobic digestion
• Landfill
• Aerobic digestion
• Incineration
• Heat treatment
• Alkaline stabilization
• Composting
• Irradiation

5
Thermal Treatment

6
 Land Application of Sludge

40 CFR Part 503 Regulations

• Domestic biosolids and septage
• Rules incorporated into NPDES permits
• Quality requirements for bulk or bagged
biosolids applied to land for beneficial use
• Apply at agronomic rates to agricultural land,
pasture, forest, parks, golf courses, mine spoils1,
etc.
1 Intermixed unconsolidated rock, rock fragments and
soil that result from a surface mining operation
 Background – 503 Rule
As Required by the Clean Water Act
• EPA developed the 40 CFR Part 503 Rule to protect
public health and the environment from any reasonably
anticipated adverse effects of certain pollutants that
might be present in sewage sludge/biosolids.
• Biosolids are a primarily organic solid product produced
by wastewater treatment processes that can be
beneficially recycled (or disposed of).
• Sewage Sludge vs. Biosolids (untreated vs. treated)
• Part 503 establishes requirements for the final use and
disposal of sewage sludge/biosolids when:
– Biosolids are applied to the land for beneficial use (soil
conditioner/fertilizer)
– Placed on a surface disposal site for final disposal
– Fired in an incinerator
 Risk Assessment
• Many of the requirements of the 503 Rule are based
on the results of an extensive multimedia risk
assessment:
– 25 pollutants were addressed
– 14 exposure pathways
• Concurrently, EPA developed a new methodology that
provided for the protection of the environment and
public health.
• This methodology was reviewed and approved by EPA’s
Science Advisory Board
• Most recently, it was concluded that more research is
needed. However, there is no evidence that we have
failed to protect the public health and environment.
• From these observations, one might conclude that
biosolids may be safely recycled when treated and
used as prescribed in the 503 Rule.
 40 CFR Part 503 Overview

• 5 Subparts to Part 503 (parts is parts)

– Subpart A – general provisions, applicability, purpose, etc.
– Subpart B – requirements for land application (beneficial
use)
– Subpart C – requirements for surface disposal
– Subpart D – requirements for Pathogen and Vector
Attraction Reduction (treatment)
– Subpart E – incineration requirements
• Applicability
Any person who:
– Land applies - biosolids
– Land disposes - biosolids/sewage sludge
– Incinerates - biosolids/sewage sludge
• Part 503 is Self-Implementing
– Persons are required to follow the rule even if they have
not been issued a permit for such activities…EPA can take
enforcement actions against persons who violate the Part
503 requirements (permitted or not)
 Land Disposal of Sludge
Two quality levels with respect to:
1. Heavy metals
Ceiling concentration (4,300 mg/kg for Cu)
Pollutant concentration (1,500 mg/kg for Cu)
2. Pathogens
– Class A: Fecal coliform < 1000 MPN/g TS, Salmonella
sp. < 3 MPN/g TS, enteric virus < 1 plaque forming
unit (PFU)/4 g TS, helminth ova < 1 #/4 g TS
– Class B: Fecal coliform & Salmonella sp. < 2 million
MPN/g TS
3. Vector attraction reduction (insects, rodents, birds)
– Processing
– Barrier
 Class A Biosolids
• Fecal < 1000 MPN/g or Salmonella sp. < 3 MPN/4 g
(based on seven individual samples per event)
AND
Use one of 5 approved methods to Further Reduce
Pathogens:
• Time/temp depending on solids content
• pH/time then dry to at least 50% solids
• Testing for enteric viruses/viable helminth ova
• Testing for reduction of these analytes
• PFRP: composting, heat drying, heat treatment,
Thermophillic aerobic digestion (TAD), beta ray
irradiation, gamma ray irradiation, pasteurization,
other methods as approved by the permitting
authority

PFRP: Process to Further Reduce Pathogens

 Class B Biosolids
• 7 samples - Geometric Mean < 2,000,000 MPN/g or
CFU (based on seven samples per event)
OR
Use 1 of 5 Approved PSRP methods:
• Aerobic Digestion: 40 days at 20°C no less than 60 days
at 15°C
• Air Drying: 3 months with two months above 0°C
• Anaerobic Digestion: 15 days at 35-55°C no less than
60 days at 20°C
• Composting: Minimum 40°C for 5 days with min 4
hours at 55°C
• Lime Stabilization: Add lime to raise pH to 12 after two
hours of contact
• Other as approved by the permitting authority

PSRP: Process to Significantly Reduce Pathogens

 Distribution & Marketing

Class A Unrestricted Use (lawn & garden)

• Table III Metals
• Exceptional Quality (EQ)
Class A Restricted Use (containerized or bulk)
• Table I Metals - Pollutant Concentration
• Subject to APLR – Annual Pollutant Loading Rate
Class B Restricted Use – (agricultural)
• Table III Metals – Pollutant Concentration (PC)
• Table I Metals Subject to CPLR – Cumulative Pollutant
Loading Rate
 Vector Attraction Reduction (VAR)
1. 38% VSR
2. Anaerobic - bench scale test (40 days)
3. Aerobic - bench scale test (30 days)
4. Aerobic - SOUR ≤ 1.5mg O2/hr at 20°C
5. Aerobic - 14+ days at > 40°C (avg. > 45°C)
6. pH - 12+ for 2 hrs then 11.5+ for 22 hrs
7. Dry to 75% when stabilized solids used (digested)
8. Dry to 90% when unstabilized solids used (undigested)
9. Subsurface injection (no significant after 1 hr)
10. Surface application w/ incorporation (within 6 hrs)
 Land Disposal of Sludge

• Bulk biosolids applied to lawns and home

gardens must be Class A and meet pollutant
concentration limits and vector reduction
restrictions.

• Class B biosolids can be applied to farms,

forests, etc.
 Disposal Methods - Class A
Pathogen Reduction

1. Composting
• In-vessel or static aerated pile ≥ 55°C for 3 days
• Windrow ≥ 55°C for 15 days (min 5 turns)
2. Heat Drying - ≥ 50°C for 30 minutes
dryness ≥ 75% total solids
(no unstabilized biosolids)
3. Alkaline Stabilization
pH > 12 for 72 hours and temp > 50°C for 12 hr
dryness > 50% total solids
 Disposal Methods - Nonbeneficial Use

4. Surface Disposal
• Monofill
• Dedicated surface application site
piles or mounds on POTW site
impoundments or lagoons
5. Incineration
• Emission limits: Total hydrocarbon < 100 ppm
(monthly average, corrected to 0% H2O and 7% O2)
• NESHAPs (National Emission Standards for Hazardous Air Pollutants) for
Be and Hg; limits on Pb, As, Cd, Cr, and Ni
 Septage

• Septage can be applied to farmland at a

rate of

lb N required by crop Annual application rate


0.0026 (gal/acre - year)
 Class B Crop Class B Crop
Harvesting Restrictions
• Food crops with harvested parts that touch
biosolids or grow above surface – 14 months
• Food crops with harvested parts below surface
and biosolids remain on surface for 4 months
prior to incorporation – 20 months
• Food crops with harvested parts below surface
and biosolids remain on surface for less than 4
months prior to incorporation – 38 months
• Food, feed and non-food crops – 30 days
 Class B Class B
Site Restrictions
• No domestic livestock grazing for
30 days after application

• Turf may not be harvested for 1

yr

• High public exposure sites - limit

access for 1 yr

• Low public exposure sites – limit

access for 30 days
 Wisconsin NR 204
Domestic Sewage Sludge Management

• Discharge standards, monitoring and record

keeping and reporting requirements for the
use and disposal of sewage sludge and
screenings
• Permit required to discharge any pollutant
into “waters of the state ”. “Waters of the
state” is defined to include groundwater.
• “beneficial use is encouraged…”
 NR 204 Applies to:
1. Use and disposal of sludge, grit and screenings
generated by any domestic wastewater
treatment plant.
2. Quantity and quality of sludge that is applied to
land or landfilled, including sludge that is
combined with any other material (septage,
manure, composting material).
3. Land on which sludge is applied and any landfill
which receives sludge
 NR 204 Does not Apply to
1. Use or disposal of sludge that is defined as hazardous
waste by NR 600.
2. Septage (NR 113), except when combined with sewage
sludge
3. Sludge that is incinerated
4. Bulk or bagged material that is derived from exceptional
quality sludge.
5. Industrial sludge
6. Sludge with PCB conc. > 50 mg/kg
7. Incinerator ash
8. Sludge generated through treatment of drinking water
 NR 204.07 - Land Application of Sludge

Approved Sites - each site must be inspected and

approved.
Site Criteria Surface Incorporation Injection
Depth to bedrock 3 ft 3 ft 3 ft
Depth to high GW 3 ft 3 ft 3 ft
Allowable slopes 0-6% 0-12% 0-12%
Distance to wells
community 1000 ft 1000 ft 1000 ft
private 250 ft 250 ft 250 ft
Min distance to
residence 500 ft 100 ft 100 ft
 NR 204.07 - Land Application of Sludge

Site Criteria Surface Incorporation Injection

Min distance to streams, lakes, ponds, or wetlands
• Slope 0% to < 6% 200 ft 150 ft 100 ft
• Slope 6% to 12% not allowed 200 ft 150 ft

Min distance to grass waterways, or dry run with 50 ft grass strip

• Slope 0% to < 6% 10 ft 50 ft 25 ft
• Slope 6% to 12% not allowed 100 ft 50 ft

Soil permeability 0.2 - 6.0 0 - 6.0 0 - 6.0

range (inch/hr)
 Minimum Duration between Application
and Harvest/Brazing/Access for Class B
Sludge Applied to Land
Criteria Surface Incorp. Injection
Food crops whose
Harvested parts may 14 mos. 14 mos. 14 mos.
touch sludge/soil
Food crops whose
harvested parts grow 20/38 mos. 20/38 mos. 38 mos.
in the soil
Feed or other food crops
(Corn, hay, etc.) 30 days 30 days 30 days
Grazing of animals 30 days 30 days 30 days
Public access restriction (30 days or 1 year, depending on
exposure)
27
 Heavy Metals - Ceiling Concentrations
Sludge may not be applied to land if the conc. of pollutants
in the sludge exceeds the ceiling conc. Limits in Table 1 of
NR 204.07

Pollutant Ceiling conc. (mg./kg = ppm dry wt)

Arsenic 75
Cadmium 85
Copper 4,300
Lead 840
Mercury 57
Molybdenum 75
Nickel 420
Selenium 100
Zinc 7,500
 Heavy Metals - Pollutant Concentrations

Sludge that meets the pollutant concentration limits can be

bulk applied to land, subject to cumulative loading limits

Pollutant Monthly Average conc. (mg./kg dry wt)

Arsenic 41
Cadmium 39
Copper 1500
Lead 300
Mercury 17
Molybdenum deleted until EPA revises
Nickel 420
Selenium 100
Zinc 2,800
 Heavy Metals
Cumulative & Annual Loading Rates
Lifetime cumulative Annual pollutant
Pollutant metal loadings loading rate
kg/ha lb/acre kg/ha lb/acre
Arsenic 41 36 2.0 1.78
Cadmium 39 34 1.9 1.69
Copper 1500 1339 75 66.9
Lead 300 268 15 13.4
Mercury 17 15 0.85 0.76
Nickel 420 375 21 18.7
Selenium 100 89 5 4.4
Zinc --- --- 140 125
 Application Rates
Amount of available nitrogen from sludge and other
nitrogen sources shall not exceed the nitrogen
requirement of the crop, as determined by University
of Wisconsin-Extension Bulletin A-2100 (April 1991).

Organic nitrogen available in first year of application

= 25% (??) of total organic nitrogen in sludge

Mineralization rates to calculate carryover of previous

years’ application:
25% - 12% - 6% in years 1, 2 and 3
 Storage Facilities

Storage for 180 days

 Guiding Principle

Nitrogen requirement of crop satisfied by

sludge nitrogen

Nitrogen uptake by crop

= nitrogen available from sludge
 Corn Yield Potential of Soil

Code Level Quantity

1 Very high 120-140 bu/acre
2 High 100-120 bu/acre
3 Medium 80-100 bu/acre
4 Low 60-80 bu/acre

(Dane County is code 1 to 3)

 Nitrogen Requirements for Corn
(lb N/acre)

Code Organic Matter Content (T/ac)

0-20 21-35 36-50 ≥50
1 160 140 120 100
2 140 120 100 80
3 120 100 80 60
4 100 80 60 60
 N, P, and K Uptake by Crops
(P = 0.437 P2O5, K = 0.83 K2O)

Crop Yield Uptake (lb/acre)

(bu/acre) N P2O5 K2O
Corn 120 150 65 170
140 185 80 185
Soybeans 50 257 50 120
60 336 65 145
Wheat 60 125 50 110
80 186 55 160
Alfalfa 8 tons 450 80 480
 Other Issues
• Phosphorus in sludge may exceed that
needed by the crop.

• Presently no limit on phosphorus applied in

sludge - this may change.

• Potassium must be added as commercial

fertilizer.
 Nitrogen Available from Sludge

N a  2000(NO-3 + f v NH+4 + f n N o )
lb N % as
% as NO-3 % as NH+4
ton  yr organic N

fv = volitilization factor
1.0 for injected sludge
0.5 for surface application
fn = mineralization factor
(refers to availability of organic nitrogen
applied in previous years)
 N Available from Mineralization of
Organic N Applied in Previous Years

N ap  2000(f n1 N o1 + f n 2 N o2 + f n3 N o3 + ... + f n n N on )

Time after Mineralization

application factor
1 year fn1 = 0.25
2 years fn2 = 0.12
3 years fn3 = 0.06

Wisconsin NR 204.07(8)
 Allowable Annual
Sludge Application Rate
 Ton dry solids   Crop uptake of N 
R n   
 acre  yr   N a + N ap 


Land requirement
Total sludge production
A (acres) 
Design sludge loading rate

Ton dry solids/yr

A (acres/yr) 
Ton dry solids/acr e
 Example - Land Application

Sludge = 600 dry tons solids per year

Crop = corn
Surface application (fv = 0.5)
0% NO3, 2% NH4+, 2% organic N
Year 1
Na = 2000 [ 0 + 0.5(0.02)+0.40(0.02)]
= 2000(0.018)
= 36 lb N/ton dry solids
 Example - continued
Crop uptake = 180 lb/acre-year

Allowable annual sludge application rate

= 180/36 = 5 ton/acre-year

Land area required (year 1)

= (600 tons/yr) /(5 ton/ac)
= 120 acres
 Example - continued (Year 2)
• Fraction of of organic N applied in year 1 that carries
over in soil = 0.02 – 0.4(0.02) = 0.0012
• Fraction of year 1 carryover becoming available
= 0.25
• Fraction organic N available from “new” sludge
= 0.009 (same as year 1)
• Total available N
= 2000[ 0 + 0.5(0.02)+ 0.4(0.02) + 0.25(0.0012)
= 2000(0.0183) = 36.6 lb N/dry ton sludge solids
 Example - continued (Year 2)
Allowable sludge application rate
= (180 lb N uptake/ac·yr)/(36.6 lb N/ton)
= 4.9 ton/acre·yr
Land area required
= (600 ton/yr)/(4.9 ton/acre·yr)
= 122.5 acres
Because of carryover from years 1 and 2, the allowable
sludge application rate will be lower in year 3 and the
land requirement will increase.
After 3 years the application rate does not change much.