I.

SECONDARY TREATMENT; ACTIVATED SLUDGE DESIGN (Simple Model Approach)

Model of CMAS (Completely Mixed Activated Sludge) Performance

Flow Schematic
Configure control volume using either Garrett or conventional biomass wastage
configuration:

QW, X, SSe
Garrett Wastage

Q, SS0 Q - QW
Bioreactor Clarifier
X0 = 0 Xe, SSe

V, X, SSe

Recycle RQ, XR, SSe

QW, XR, SSe

Conventional Wastage

Definitions:
Q = flow rate
QW = wastage flow rate (QWG, Garrett configuration; QWC, conventional configuration)
SS = wastewater concentration (SS0 , influent; SSe , effluent)
X = biomass concentration (X, reactor; Xe, effluent; XR, recycle)
R = fraction of flow that is recyled
V = reactor volume
 = Hydraulic Residence Time, HRT = V/Q
θC = Solids Residence Time, SRT =
VX
Q W X W + (Q − Q W ) X e

CIEG 328 Activated Sludge Design Pt I-1

Concept

Since the growth rate of the bacteria in the reactor is controlled by the concentration of the
growth rate-limiting substrate surrounding them (i.e., Monod kinetic relationship), and since
the reactor is reasonably homogeneous, then if we can control the specific growth rate we can
control the output substrate concentration. Thus, a very important aspect of designing
activated sludge systems is to control the specific growth rate.

Mass Balance – Determine SSe

Perform a mass balance on biomass within the dashed control boundary on the previous
process schematic. The clarifier should be designed and operated to make the amount of
biomass in it negligible with respect to the amount in the reactor.

dX
V = Q X0 - Qw X - (Q - Qw ) Xe + μ XV - k d XV
dt

If we assume steady-state (dX/dt = 0) and rearrange we get:

Qw X + (Q - Qw ) Xe
μ= + kd or
VX

1
μ= + kd Equation 1
θC

Thus, as long as we control the SRT, we will control µ, which controls the
effluent substrate concentration.

From Monod we know:

μ max SSe
μ=
KS + SSe

1 μ max SSe
 + kd =
θc KS + SSe

Therefore, by rearrangement:

KS (1/ θc + k d )
SSe = Equation 2a
μ max - (1/ θc + k d )

CIEG 328 Activated Sludge Design Pt I-2

rearrangement to solve for θC yields:

KS + SSe
θc = Equation 2b
SSe ( μ max - kd ) - KS kd

Thus, once θc is fixed, SSe is fixed. One key decision that is made during design is to
select θC. This is done based on the value of SSe one wants to achieve, and is calculated
by equation 2b. The calculated θC is then multiplied by a safety factor of between 1.5
and 2.5 to obtain a design θC (note, nitrification typically controls here). However, θC >
3 days is the minimum practical limit which is set based on the time required to obtain
bacteria that settle well. It is necessary to use SRTs beyond 3 days, however, or else
you have a good chance of violating your TSS level due to gravity sludge settling
problems. Therefore, for carbon oxidation it is often necessary to select a θC greater
than that obtained from equation 2b above (solved for θC) after applying a safety
factor. In short, the safety factor for carbon oxidation will be greater than 2.5. Once θC
is determined, SSe needs to be calculated for the design θC using equation 2a. That
value of SSe is used for subsequent calculations.

Mass Balance - Determine X or 

After choosing SRT, you must choose either X or . You cannot choose both because they are
interrelated. This interrelatedness can be seen by performing a mass balance on substrate.

dSSe μ
V = Q SS0 - Qw SSe - (Q - Qw ) SSe - X V
dt Y

mg biomass COD formed

where Y has units of
mg substrate COD used

Assume steady state and rearrange to get:

Y (SS0 - SSe )
X=
μτ

SS0 represents the total biodegradable COD (soluble + particulate) entering the
activated sludge system. This assumes that the particulate will be solubilized
and consumed by the bacteria within the time frame of the treatment process, a
reasonable assumption.

CIEG 328 Activated Sludge Design Pt I-3

Mass Balance - Determine X or  (continued)

Substitution for μ and rearrangement gives:

Y (SS0 − SSe )
Xτ = Equation 3
1
+ kd
θC

Note that once θc is fixed, SSe is fixed, so that X ·  is fixed. You have one degree of freedom, so
you may choose either X or , and the other will be fixed.

Factors to Consider in making choices:

1. X (biomass concentration) should be between 3000 < X < 7800 mg/L as COD for a CMAS to
obtain an economically feasible secondary clarifier size. This range changes to 1,200 to
3,600 mg/L as COD for a conventional activated sludge (CAS) system (CSTRs-in-series).
Note that solids loading (Q * X/A) to the secondary clarifier is an important design decision.
Note that 1.2 g COD = 1 g mixed liquor suspended solids (MLSS = TSS of “sludge”)

2. The HRT should be within typical guidelines for the type of activated sludge system being
used. For a CMAS system, 3 – 5 hours is typical for domestic wastewater treatment. For
CAS systems, 4 to 8 hours is typical.

3. The mixing energy intensity in the aeration basin must be sufficient to maintain the solids
in suspension, but not so great as to break up the floc particles. Mixing energy comes from
aeration for oxygen transfer, and is a function of the basin volume.

➢ Mechanical aeration: 14 - 60 kW/1,000 m3 of reactor volume (0.5 - 2.25 HP/1000

ft3). The power imparted to achieve the desired level of oxygen for mechanical
aeration is defined as follows:
➢
RO
P= Equation 4a
ηP

where P = power in KW, RO is required oxygen (see next section) in kg/hour, and ηP
typically ranges from 0.7 to 1.2 kg O2/(kW – hr).

➢ Bubble aeration: 20 - 90 m3 of air/(min-1,000 m3 of reactor volume) (20 - 90

scfm/1000 ft3 ). Calculate air flow rate (Qair) in m3/min as follows:

6.0 RO
Q= Equation 4b
ηQ

CIEG 328 Activated Sludge Design Pt I-4

 where ηQ is field oxygen transfer efficiency expressed in percent, and is typically 6
to 15%.

➢ Lower aeration limit is set to sustain mixing.

➢ Upper aeration limit is set to prevent floc shear.

Mass Balance – Determine Oxygen Requirement

The rate of oxygen consumption is a function of oxygen consumed to fuel biomass generation and
to fuel maintenance and decay requirements:

1- Y 
r 02 = -   μ X - (1− f d ) k d  X
 Y 

Substitution for μ and X, incorporation of conversion factors, and rearrangement gives:

 (1+ f D k d θ C ) Y 
RO = Q (SS0 − SSe ) 1−  Equation 5
 1+ k d θ C 

Where RO = mass of O2 demanded per unit time

The advantage of using COD to express waste strength is that it allows this method to be
used to calculate RO. It is simply a balance on oxygen demand. Remember that this
equation is for the steady-state case. Must remember that additional oxygen will be
required for variations (i.e., if equalization is not used).

Mass Balance – Determine Biomass Generated

The mass of sludge produced can be determined by performing a mass balance on solids, X, about
the entire system; therefore, the excess sludge production rate is:

PX = Q W  X W + (Q − Q W ) X e Equation 6a

where PX = mass of biomass as COD generated per unit time

Remember that the amount of solids generated has to equal the amount of solids wasted
per day to maintain a steady operation state. Therefore, another way of estimating the
amount of sludge produced is:

Y Q (SS0 − SSe )
PX = Equation 6b
1 + θ C k d

CIEG 328 Activated Sludge Design Pt I-5

 You must be able to determine PX in order to design the sludge disposal system.

Summarize Steps for Activated Sludge Design

A. Select SRT based on desired SSe
Calculate θC based on desired SSe using equation 2b. Apply a safety factor to the calculated
θC of 1.5 to 2.5 to obtain a preliminary design θC. If design θC < 3 days, choose a design θC >
3 days but < 15 days. Recalculate SSe for the chosen design θC and use equation 2a to
calculate SSe. Use this value of SSe for subsequent calculations.

B. Calculate X ·  using equation 3 for winter conditions and choose a reasonable value for X
or , thereby fixing the other.
Constraints:
1. 2000 < X < 5000 mg/L as COD
2. HRT typically 3 – 5 hours for CMAS, 4 – 8 hours for CSTR-in-series.

C. Estimate oxygen requirement using Equation 5 for summer conditions. Note that RO units
are mass per time.
1. The above estimate is for steady state requirements. Add extra for transient flow
conditions using hourly peaking factor if equalization is not used.

2. Use the oxygen requirement to size the aeration system based on listed constraints.
Determine aeration system (diffused typical for CSTRs-in-series and mechanical
aerator typical for CMAS), and then calculate aeration intensity based on equations
4a or 4b. Adjust reactor volume if aeration intensity outside of suggested limits.
Recalculate X and  from equation 3, and iterate until all constraints for X,  and
aeration intensity are met.

D. Estimate the mass of sludge produced using equation 6b. Then use equation 6a to
estimate the wastage flow rate.
1. If sludge is wasted from the aeration basin, then X W = X. If sludge is wasted from
the settler underflow (sludge recycle concentration), then XW = XR. The value of XR
will depend on the sludge recycle rate, but can be assumed to be in the range of
6,000 to 18,000 mg/L as COD (0.5 to 1.5% on MLSS basis).

2. When using equation 6a, assume that Xe=0 because this will maximize the
estimated amount of intentional wasting and is a conservative approach.

E. Choose sludge recycle ratio, R.

This must be done in concert with the design of the secondary clarifier. Generally, pumps
and piping are sized to handle R (= QR/Q) up to 0.75, and ranges from 0.25 to 0.75. A
typical operating R is 0.5.

CIEG 328 Activated Sludge Design Pt I-6

CIEG 328 Activated Sludge Design Pt I-7
CIEG 328 Activated Sludge Design Pt I-8