\\1.

1 liT 2005

OPTIMIZATION OF NITRIFICATION I DENITRIFICATION PROCESS PERFORMANCE AND RELIABILITY AT THE BLUE PLAINS ADVANCED WASTEWATER TREATMENT PLANT
Janice Ruhl Carroll*, Paul Pitt!, Andre van Niekerk!, Allen SehlofF,
Walter Bailel, Sudhir Murthl, Salil Kharkar3, Aklile Tesfaye3

*Hazen and Sawyer, P.C., 11242 Waples Mil Road, Suite 250, Fairfax, VA 22030 ! Hazen and Sawyer, 2 Brown and Caldwell, 3 DC Water and Sewer Authority

ABSTRACT
In the Chesapeake Bay region, the focus on nutrient removal has heightened, to the extent that planning for future enhanced nutrient removal (ENR) with permit limits of 3 to 5 mg/l total nitrogen (TN) is underway. Until such time as ENR upgrades can be made, W ASA has made a commitment to continuously meet the TN goals currently promulgated by the Chesapeake Bay Agreement (CBA), as detailed in Table 1, and is working to improve nutrient removal within their 370 milion gallon per day (mgd) Blue Plains Advanced Wastewater Treatment Plant
(A WTP).

Table 1 - Current and Future CBA TN Goals:

CBA Goals

Annual Average
7.5
3 - 5

Current: Total Nitrogen (mg/L)

Future: Total Nitrogen (mg/L)

To continuously meet the CBA goals, and to prepare for future ENR requirements, optimization of the nitrification/denitrification (N/DN) process to improve the performance and reliability is required. To improve both process performance and reliability, specific design features were incorporated into the current N/DN upgrade project. This paper highlights ten process objectives that were identified to improve process performance and reliability and details the design features incorporated to satisfy the process objectives. Process objectives include: providing equal flow distribution to process units, optimizing settling, optimizing wet weather operations, selectively removing foam, providing flexible aerobic and anoxic mass fractions, improving
mixing and aeration while reducing operating costs, improving control of

the supplemental

carbon feed, and providing for future multi-stage denitrification.

Design features incorporated to satisfy these process objectives include: positive flow splitting for N/DN reactors and sedimentation basins, retrofits to existing mixers for anoxic and swing zones, conversion to a serpentine flow path with step feed, flexible aerobic/anoxic mass fractions, a fine bubble aeration system, foam wasting stations, automated methanol feed controls, and provisions for a future return activated sludge (RAS) denitrification (methanol feed to RAS line and future mixer).

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KEYWORDS
Nitrification, Denitrification, Nutrient Removal, Step Feed, Flow Splitting

INTRODUCTION
In the 1970's, before nutrient removal was widely employed, Blue Plains was designed as an advanced wastewater treatment plant with separate, suspended growth systems planned for carbonaceous BOD removal, for nitrification, and for denitrification. The nitrification facilities were placed on-line in the late 1970s/early 1980s; however, the denitrification-specific facilities were never built. In the early 1990s, denitrification was piloted at Blue Plains and from 1996 to 1998 the Denitrification Demonstration Project, which included full-scale denitrification utilizing supplemental carbon feed (methanol) for half ofthe design flow, was conducted. Based on the results of the Denitrification Demonstration Project, additional methanol facilities were added and full scale denitrification was brought on-line in 2000.

In anticipation of more stringent, futue effuent limits for nitrogen, DC W ASA is curently upgrading its nitrification facilities to improve process performance and reliability within the existing structures. This paper presents relevant information on the existing facilities, and identifies the process objectives and design features incorporated to optimize process performance and reliability.
EXISTING NITRIFICATION FACILITIES

performance and reliability of

the design features included to optimize the the N/DN process, knowledge ofthe existing facilities is required. The N/DN facilities curently in use include (Refer to Figure 1 for a plan view of the existing
In order to allow for a meaningful presentation of

facilities ):
. Nitrification/Denitrification (N/DN) Reactors - Twelve reactors, arranged in parallel

banks of six (even side and odd side). Each reactor is 30 feet deep, and has a volume of 4.6 milion gallons, distributed evenly amongst five stages. Flow moves through the reactors in an over/under flow pattern, as shown in Figure 2. Aeration is provided via five 4,000 Hp three-stage, horizontally split centrifugal blowers and two sparged turbines per stage. Air is cross-fed to the reactors, with one air header providing the air for one stage across six adjacent, parallel reactors.
Methanol is added at the end of Stage 3, and Stages 4 and 5 (or Stage 4 only, as a minimum) are operated in an anoxic mode to enable denitrification. The mixed liquor effluent channels are aerated.

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SODIUM HYDROXIDE FEED FACILITY

- WASTE S IIOGE GAllERY

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. EFLUENT CHANNEL

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FIGURE i PLAN VIEW OF EXISTING FACILITIES

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FOR NITRIFICATIONI DENITRIFICATION MODE

NORMALLY ANOXIC
SECONDARY EFFLUENT

r~==- NORMALLY AEROBIC

SPARGED TURBINE wl50 HP MOTOR (TYP 6)

DIFFUSER RING (TYP 10)

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N

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Fi ure 2 : Existin Nitrification/Denitrification Reactor Confi uration

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Nitrification Sedimentation Basins - 28 rectangular sedimentation basins, arranged in

parallel banks of 14. Each sedimentation basin has four inlet slide gates. The total surface area of the Nitrification Sedimentation Basins is 12.4 acres (540,000 square feet),
with overflow rates in the range of

720 - 1,650 gpdlft2. Available sedimentation basins

also include eight Dual Purpose Sedimentation Basins (DPSBs), which can be used to augment Secondary Sedimentation or Nitrification Sedimentation Basins. Typically, four DPSBs are used in nitrification service, which results in overflow rates in the range of 610 - 1,400 gpdlft2. Sludge collection is provided via chain and flight scrapers and 42 horizontal centrifugal pumps, which return sludge to the N/DN Reactors. Activated sludge is wasted via four horizontal centrifugal pumps.

Methanol Feed Facilties - duty and stand-by hose pumps for each reactor (24 total),
seven storage tanks (four 8,700 gallon underground tanks, three 10,000 gallon aboveground tanks), day tank (1,650 gallons), transfer pumps and truck fill station. Two trucks, containing approximately 5,000 gallons each, deliver methanol daily.

Alkalinity Addition - Full-scale sodium hydroxide feed facilities were brought on-line
in 1998 and consist of six 25,000 gallon storage tanks for storage of 50% sodium hydroxide, and three metering pumps. Alkalinity addition is to a common point upstream of the flow split to the two parallel banks ofN/DN reactors. Alkalinity addition is not normally required.

PROCESS OBJECTIVES
Ten process objectives were identified as having the potential to improve process performance or reliability. Each objective and the design features included in the current upgrade project to achieve the objective are presented in the following sub-sections. In several cases, one design
feature may meet several process objectives.

Provide Equal Flow Distribution to N/DN Reactors

Currently the distribution of

the main process flow, which is effuent from the Secondary

the six reactors in a parallel

Sedimentation Basins, is very poor. The flow distribution to each of

bank should be approximately 17 percent; however, the actual distribution, as determined by Computational Fluid Dynamics (CFD) modeling, varies considerably, as tabulated in Table 2 and shown graphically in Figure 3. Under the existing reactor configuration, shown in Figure 2, the flow split to the reactors is poor, since the flow distribution is controlled by submerged weirs between Stages 4 and 5.
The poor flow distribution causes a number of problems, including over or under feed of both methanol and air (oxygen). The overfeed of methanol can result in excessive consumption of dissolved oxygen (D.O.) in the tertiary filters, and difficulties meeting effuent D.O. limits. Since the air is cross-fed, and there is no automatic control of aeration at the individual stages, the poor flow splitting can result in overfeed of air in some reactors, which negatively impacts the denitrification process for that reactor. Overfeed of air also results in unnecessary blower

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Table 2 - Flow Distribution to One Parallel Bank of Reactors (Based on CFD Modeling
Results)
Reactor
1
Percentage of

Flow (%)

26
11

3 5

14
15

7 9
11

17 18

Figure 3 - CFD Results for Flow Split to One Parallel Bank of N/DN Reactors

operating costs. Underfeed of air in some reactors can result in incomplete nitrification and higher than desirable effluent ammonia concentrations.
To provide an easy-to-control, positive flow split that is effective for both dry and wet weather operating scenarios, each reactor's three influent gates wil be modified to include free flowing rectangular weirs at the influent end of the reactors. Available weir lengths can be modified by lowering a slide gate to blank-off portions of the weir, in order to allow for different step feed

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percentages or modified operations for wet weather. Weir boxes for Stages lA, 1B, and 2A are weir. Stage 1B wil have 26 feet of weir, and shown in Figure 4. Stages 1A wil have 14 feet of weir. Moving the headloss to the upstream end of the reactor, and Stage 2 wil have 46 feet of utilizing the headloss through the influent gates and over weirs, results in excellent distribution, as shown in Table 3, and wil improve methanol feed and aeration, and ultimately increase the reliability of nitrogen removal in the N/DN reactors. The distribution percentages cited in Table 3 represent the ratio of flows between the reactor receiving the lowest flow and the reactor receiving the highest flow, and indicates that under all flow conditions the difference between the highest and lowest flows is less than 3%.

Table 3 - Distribution of Secondary Effuent to N/DN Reactors

Distribution Design Design Anual A vg Max Day
373

Current
Annual A vg

Design Peak Hour

755

Flow (mgd)

352

564

Dry Weather Conditions 25% lA, 75% 2A 50% lA, 50% IB 50% lA, 50% 2A
Wet Weather Conditions All Secondary Effluent (SE) flow to Stage 2, RAS and SE to all 12 reactors 8 reactors receive SE and RAS (Stage 1B and 2),4 reactors receive RAS only * Secondary Effuent Flow = 400 mgd

97.8% 99.6% 99.3%

98.4% 99.2% 98.7%

97.2%*

99.8%

99.1%

99.1 %

Maximize Performance of Existing Sedimentation Basins

Existing sedimentation basin capacity has historically been a weak spot in terms of the reliability the N/DN process. In response to this, additional sedimentation basin capacity was added as of Dual Purpose Sedimentation Basins in the late 1980s. The additional sedimentation basin capacity can be used to augment either the Secondary Sedimentation Basins or the Nitrification Sedimentation Basins, and thus, the additional capacity is not always available. Given site limitations, construction of additional sedimentation basins is not feasible, and therefore, the existing sedimentation operations is required. As shown by Van Niekerk optimization of (2003), provision of step feed in the existing N/DN reactors results in lower mixed liquor suspended solids (MLSS) concentrations and higher clarifier factors of safety for a variety of operating conditions while maintaining required levels of nutrient removaL. Step feed in the N/DN reactors is therefore required to improve existing settling operations.

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LEGEND
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The existing reactor configuration (Figure 2) does not lend itself

to provision of step feed without introducing the possibility of short-circuiting. Therefore, a step feed configuration wil be provided by converting the reactor to a serpentine flow path, which promotes a plug flow
in Figure 4. With the conversion to step feed with a serpentine flow path and the weir boxes described earlier, step feed can be controlled to Stages lA, 1B and 2A to allow for at least the following operating scenarios:
. 50% to Stage lA, 50% to Stage 1B

regime, and adding baffe walls between Stages lA and 1B, 3A and 3B and 5A and 5B, as shown

. 25% to Stage lA, 75% to Stage 2A

. 25% to Stage lA, 25% to Stage 1B and 50% to Stage 2

. 50% to Stage lA, 50% to Stage 2

. 100% to Stage 2 (wet weather)

A limited number of additional operating scenarios (e.g. 30% to Stage 1B, 70% to Stage 2) can be created by using combinations of available weir lengths for Stages lA, 1B and 2, so long as suffcient weir length is made available to maintain the upstream water surface elevation at an elevation that wil not submerge the upstream Secondary Sedimentation Basin effuent weirs. The inclusion of step feed and the conversion to a serpentine flow path assist in meeting several other process objectives, as described in detail in the following sections.
Optimize Wet Weather Operations

Blue Plains receives flow from a combined sewer system, and accordingly, the NPDES permit requires that peak flows up to 740 mgd (2.0 times design flow of370 mgd) receive full treatment up to 511 mgd (1.4 times design flow of370 mgd) continue for the first four hours and flows of to receive full treatment for the duration ofthe wet weather event. Wet weather can potentially result in a substantial shift of mixed liquor solids from the N/DN reactors to the Nitrification
Sedimentation Basins. This may result in solids wash-out from the sedimentation basins, which

can be extremely detrimental to the N/DN process, or, under a worst case scenario, can result in complete loss of nitrification. The installation of weir boxes, as well as the conversion to step feed with a serpentine flow path, also serve to optimize wet weather operations. Wet weather operations are optimized by sequentially moving towards operation in quasi-contact stabilization or solids-holding mode, where portions of reactors, and eventually entire reactors are used for
solids retention. This limits the solids loading on the sedimentation basins. The main features of

the proposed wet weather operations are as follows:

. Divert Secondary Effuent in excess of 400 mgd directly to Stage 2 of

the N/DN reactors, utilizing the provisions made for step feed and a serpentine flow path, and continue to feed return activated sludge (RAS) to Stage lA, which wil increase solids inventory storage. The serpentine flow path ensures the Secondary Effuent introduced into Stage 2 wil not short circuit into Stage 3, thus stil achieving reliable nitrification.

. In a peak wet weather-operating mode, the Secondary Effuent and RAS wil be directed

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to four (4) N/DN reactors on each side of

the plant (8 reactors out of 12). The remaining

four reactors wil receive RAS only. The trigger point for this shift in Secondary Effluent flows depends on sludge settleability at the time of the wet weather event, and wil vary from 430 mgd to 460 mgd.

As shown in Figure 5, which is based on Biowin process modeling, the wet weather operating strategy results in a dilution of the MLSS concentration in N/DN Reactors receiving the peak Secondary Effuent flow. The N/DN Reactors that receive only RAS, experience an increased MLSS concentration. The net result is a reduction in solids loading to the downstream sedimentation basins, which keeps the solids loading on the sedimentation basins in the acceptable range for wet weather conditions (Figure 6) and prevents solids washout from the sedimentation basins.

Provide for Flexible Aerobic and Anoxic Mass Fractions

To achieve and optimize nutrient removal throughout the year, including periods oflow temperatures and wet weather, it is desirable to have a reactor configuration that provides flexibility in terms of aerobic and anoxic mass fractions. The configuration of the existing reactors, with only five stages, provided limited flexibility to alter the aerobic and anoxic mass fractions; specifically, portions of the reactor could only be changed from anoxic to aerobic service, or visa versa, in 20% increments. In addition, the over/under flow pattern does not adequately prevent back-mixing from aerobic zones downstream of anoxic zones, which decreases the efficiency of the anoxic zones.

To provide increased flexibility in the aerobic and anoxic mass fractions, the reactor wil be converted to a serpentine configuration with three swing zones (Stages 3A, 3B and 5A) and provisions for a future swing zone (Stage 1A). To accommodate the change in the initial aerobic mass fraction, multiple methanol feed points wil be provided, as shown in Figure 4.

The future swing zone wil be Stage lA, which may be utilized for RAS denitrification. Each the reactor volume, as shown in Figure 4. To prevent backswing zone wil contain 10% of mixing from downstream aerobic zones into upstream anoxic zones, anoxic-aerobic baffe walls wil be included between Stages 1A and 1B, 4B and 5A, and 5A and 5B. These baffle walls wil be designed with a minimum of 0.1 feet of head loss to ensure there is no back-mixing. The headloss wil be achieved through use of a weir at the top of the wall, which wil allow for free surface flow to ensure transport of foam through the reactor, and a submerged port, which wil the swing zones, the zones allow for draining the reactor. To further optimize the operation of wil be outfitted with both mixers and fine bubble diffusers; this allows for the most efficient aeration when the stage is operated in the aerobic mode and the most efficient mixing without the risk of imparting D.O. when the stage is operated in the anoxic mode.

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Figure 5 - MLSS Concentration in N/DN Reactor with/without Secondary Effuent Feed

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Increase Mixing Effciency in Anoxic/Swing Stages

The original design for the N/DN reactors used sparged turbines to provide aeration. A sprged turbine consists of a diffuser ring, which is mounted to the reactor floor and connected to the blower discharge piping, and a vertical shafted mixer, mounted in-line over the diffuser ring (Refer to Figure 2). The mixer blades are designed and sized to shear the air bubbles to improve oxygen transfer; mixing is a secondary function. The original sparged turbines at Blue Plains utilize 75 Hp motors, and are located two per stage (total of 120 sparged turbines). When Blue Plains converted the original Nitrification Reactors to N/DN Reactors, anoxic stages were created by turning off the air to the diffuser ring, and utilizing 48 of the existing mixers for mixing. In addition, the sparged turbines in the initial two (aerobic) stages were retrofitted with
new 50 Hp motors and new gear boxes (total of 48 sparged turbines). Because the existing

mixers are designed primarily for shearing air bubbles, they do not provide good mixing, as evidenced by the striation shown in the mixed liquor in Figure 7, and the existing mixers are expensive to operate, as shown in Table 4. In addition, there have been concerns regarding the vibration induced by the existing mixers.

Table 4 - Comparison of Power Costs for Existing and Modified Mixers

Existin2 Mixer
Horsepower Draw
Number of Mixers 46 48 $0.55/kwh $793,000

Modified Mixer
17

48

Power Cost Annual Power Cost

$0.55/kwh $293,000

To achieve the process objective of improving the mixing, without increasing the D.O., while reducing the mixer power cost, the existing mixers wil be modified. Proposed modifications include: reusing the existing drives, replacing the 75 Hp motors with 20 Hp motors, shortening and reusing existing shafts and providing new hydrofoil type blades to effect mixing via downward pumping action. Pilot testing was conducted to ensure that the proposed mixers would meet the process objective. Pilot testing included retrofitting two mixers in anoxic Stage 4, and obtaining D.O., vibration and amp draw measurements. Mixer retrofits and testing were conducted by Philadelphia Mixing Solutions, Inc. Based on visual observations, the retrofitted mixers appear to be working well; as shown in Figure 8, there is no discernable striation in the mixed liquor and eddy currents are visible on the surface. D.O. testing results are shown in Table 5, and confirm that the new mixers did not increase the D.O. Power measurements show that the mixers were drawing 17 Hp, which is inline with the power calculated for providing 0.3 Hp/lOOO ft3 for good mixing (18 Hp). Vibration results confirm that the vibration of the retrofitted mixers (maximum vibration 0.069 inch/second) is lower than the vibration of the existing mixers (maximum vibration 0.097 inch/second), and is within the recommended range ofless than 0.3 inch/second, per ANSIIAGMA 6000-B96, Specification for Measurement of Linear Vibration on Gear Units. Given the improvements in mixing and potential for power savings observed, forty-six additional existing mixers wil be upgraded as part of the current project.

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Figure 7 - Striated Mixed Liquor in Anoxic Stage 4 Mixed with Existing Mixers
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Table 5 - D.O. Test Results from Mixer Pilot Testing

Depth (feet)
10
I Samples Taken at Downstream End of I

D.O. (mg/L)
Stage 3
I I

0.90 0.92 I I Samples taken at Downstream End of Stage 4 10 0.16 0.15 I I 20 0.15 0.15 I I *Sparged turbine closest to the test point in Stage 3 was not operating
20
1.0 1.05
I

0.3* 0.37*

I I

0.18 0.18

Increase Aeration Effciency

As noted previously, the existing N/DN reactors were originally designed to achieve nitrification only, utilizing 100% of the N/DN reactor volume and 10 sparged turbines per reactor. When the reactors were converted to N/DN reactors, only 60% of the volume was used for nitrification. Process modeling shows that the process oxygen demands begin to exceed the existing sparged turbine oxygen transfer rate in the initial aerobic stages of the reactor (1,2 and 3) under some peak month, week, day and hour operating conditions. Under such conditions, it would be necessary to utilize more of the reactor volume (to place more sparged turbines into service, thus adding more oxygen) for nitrification, which decreases the reactor volume available for denitrification. Given that the sparged turbines are less efficient (13 to 20% oxygen transfer effciency), which increases blower operating costs significantly, a comparison of the life cycle costs of operating modified sparged tubines to allow for nitrification in 60% of the reactor volume and the life cycle costs of installing and operating a fine bubble diffuser aeration system was developed. A summary of the analysis is presented herein.
Components of the life cycle costs for modifying and continuing to operate the sparged turbines include: equipment modification costs, operating costs, and maintenance costs. Costs associated with each component are listed in Table 7 below, and are based on a 20 year period and a 5% interest rate.
Equipment modification costs - To increase the oxygen transfer effciency of

the sparged

turbines, the following modifications to the existing mixers are required:

Replace the existing impellers with new disc impellers, 6-bladed aqua "Ruston" type, sized to draw 75 Hp in the ungassed condition.
Relocate or replace motors such that all aerobic stages have 75 Hp motors (i.e. remove and replace the 50 Hp motors installed during the previous upgrade).

Replace the existing shafts with new shafts designed for the loads imposed by the
new operating conditions.

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Replace or retrofit the existing sparge rings with rings with smaller diameter holes, to increase oxygen transfer efficiency by creating smaller bubbles.
The total present worth for the equipment modifications is $6.3 milion.
. Operating Costs - The power cost for operating the blowers and turbine mixers are the

the sparged turbine system, therefore, most substantial costs associated with operation of the simplifying assumption that the operational costs consist only of power costs for the
blowerlsparged turbine combination, was made. Table 6 summarizes the power cost for
the sparged turbine system.

Table 6 - Power Costs for Sparged Turbine System

2.6 lbs 02/hp-hr
118,000 kwh 165,000 kwh $9,080
. Maintenance Costs - Manufacturer's recommended routine maintenance includes a daily

check of each sparged tubine to observe noise, vibration etc., and changing the oil in each sparged turbine twice a year. Assuming the daily observation for each sparged turbine takes 2 minutes, with 120 sparged turbines, 4 hours per day are required for inspection. Costs associated with the oil change include the oil and labor costs. Thirty gallons of oil are required for each change, for a total of 60 gallons per sparged turbine per year. With 120 sparged turbines, and an oil cost of$250 per 55-gallon drum, the total annual oil cost is $33,000. It was assumed that it takes two men four hours to change the oiL. For 120 sparged turbines, 1,920 man-hours are required for the two oil changes. At a rate of $40 per hour, the total annual maintenance labor cost is $135,000. The total annual the oil and labor costs, which is $168,000. maintenance cost is the sum of

Table 7 - Comparison of Life Cycle Costs for Sparged Turbines versus Fine Bubble
Diffusers
Item

Estimated Annual Cost

Sparged Turbines N/A
$500,000
Fine Bubble Diffusers

Debt Service Costs

Equipment Modification Costs

Operating Costs

$1,230,000 N/A $1,106,000

$6,400

$3,314,000
$168,000 N/A $3,982,000

Maintenance Costs

Equipment Replacement Costs TOTAL ESTIMATED ANNAL COST

$26,000 $2,368,000

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WIIII',C 2()05

Operating Cost - Since the power cost for operating the blowers is by far the most substantial cost associated with operation of the fine bubble diffuser system, for the purpose of this evaluation, the simplifying assumption that the blower power costs are the
only operational cost, was made. Table 8 summarizes the power costs for the fine

bubble diffuser system.

Table 8 - Power Costs for Fine Bubble Diffuser System

Calculated Standard Aeration Efficienc

Dail Power Re uired

Daily Power Required Adjusted for Control Variation:l 20% (Lower Variation With New Controls) Daily Power Cost $0.055/kwh

8.9 lbs 02/h -hr 46,000 kwh

55,000 kwh
$3,030

Maintenance Costs - Assuming that the system wil be air-bumped for cleaning purposes once per day, the annual maintenance requirements for the fine bubble diffuser system
are minimaL. Based on the manufacturer's recommendation that the reactors be drained

and the diffusers hosed down once per three years, and assuming that four reactors are subject to the required annual maintenance per year, the annual maintenance cost is estimated to be $6,400. Note: It was assumed that washdown of each reactor would take
40 man-hours (tank entr is not required).

Equipment Replacement Costs - Based on an anticipated service life of 10 years, it is assumed that complete replacement of the membranes wil be required after 10 years. Based on provision of 43,782 diffusers and a replacement cost of $4.50 per diffuser, the total cost to replace the diffusers in 10 years is $321,000. To accrue sufficient funds to replace the diffusers in 10 years, the annual cost is $26,000.
The estimated annual costs associated with providing process air via a fine bubble diffuser system and a sparged turbine system indicate that operation of a fine bubble diffuser system, even with repayment ofthe initial capital expenditure, is more cost effective. The annual savings would be approximately $1,614,000, which over the 20-year period has a present value of $20,025,000. In addition to providing cost savings, installation of a fine bubble diffuser system has intangible benefits, including:

By virte of providing more efficient aeration, the fine bubble diffuser system also provides an "expansion" by allowing for provision of significantly more oxygen to the process.
Aeration via fine bubble diffusers can be better controlled than aeration via sparged turbines, which allows the operation of the blowers to more closely track the process requirements, which ultimately provides more power savings.
Based on the potential savings, fine bubble diffusers and associated modifications wil be included to satisfy the process objective of increasing aeration efficiency, while simultaneously reducing operating costs.

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Remove Foam

Thus far, with use of coarse bubble aeration provided by the sparged turbines, there has been little foaming in the N/DN reactors. However, the current project wil include provision of fine bubble diffusers in the N/DN reactors, which increases the likelihood of foaming. The current over/under flow path through the reactor, and submerged effluent gates (refer to Figure 2)
preclude transport of foam between the stages of the reactor to a central

location for collection

and removaL. Design features incorporated to ensure foam removal include: conversion to a serpentine configuration with free surface ports between all stages, new effluent gates to provide for a free surface exit from the reactors to the mixed liquor effuent channel, and two new foam wasting stations. The serpentine flow path and new effuent gates are as shown in Figure 4.

One foam wasting station wil be located in each mixed liquor effuent channel to collect foam reactors. The key components of the Foam Wasting Station are shown in Figure 9. The wasting stations wil utilize partially submerged baffes to direct the foam across the channel to a downward opening weir gate and into a sump that wil be
generated in each parallel bank of cantilevered on the inside of

the two southernost reactors. Rotary lobe pumps wil be used to

pump the foam with the waste activated sludge (WAS) to the Dissolved Air Flotation Units. Rotary lobe pumps were selected based on their advantages, which include: an ability to tolerate rags and solids without a grinder, long life when operated at low speeds, quick and easy replacement of moving parts, a small footprint (especially compared to a progressive cavity pump), good references for scum pumping applications, and an ability to break suction (be pumped dry). The controls wil be configured, through the use of two ultrasonic level sensors, to allow for two different modes of wasting. Wasting can either be 1) nearly continuous, based on maintaining the gate elevation just below the channel water surface elevation to preferentially waste foam and a small quantity of mixed liquor, (gate level to be adjusted on a periodic basis to track channel level) or 2) at periodic intervals throughout the day. Under mode 2, the gate wil normally be fully raised, and will be lowered at intervals to effect surface wasting. Timed intervals for adjustment of the weir gate elevation are included in operating mode 1 to prevent hunting and seeking ofthe gate, which could result in early bum-out of the gate actuator.

Improve Methanol Feed Controls

Currently, methanol is flow paced to each reactor. Automated monitoring of nitrate is not available, and thus makes process control ofthe methanol feed cumbersome, time consuming and imprecise. In addition, given the existing poor flow spit to the reactors, overfeed or underfeed to individual reactors can occur. The overfeed of methanol leads to unnecessary chemical expenses and, since it can result in carbon bleed-through, can result in an excessive D.O. drop in the tertiary filters, which requires additional aeration, as an additional expense. Underfeed of methanol can result in incomplete denitrification, which adversely affects meeting low TN effuent limits.

Although the modifications to the flow split previously described wil rectify the flow splitting problems, to optimize the methanol feed process further, on-line monitoring wil be provided for each reactor. Specifically, on-line analyzers wil be used to measure the nitrate concentration in

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J;\Ruhl\WEFTEC 200S'Fig-9.cdr

MIXED LIQUOR EFFLUENT CHANNEL

--

'1-:

"0

", ~ 'ROTARY LOBE PUMPS

::

~ --

.. N

" N ..t " G.

r~

./ -

;.-: 10

/,

7-

'/ r.

FigUl'e 9 : Foam Wasting Station

1\1,111,:(''' 2()(J5

the anoxic zone, and in the mixed liquor channeL. This the methanol feed to individual reactors and comparison of the process performance between reactors. As on-line instrumentation for nitrate is a relatively new application, DC W ASA wil make their decision based on a WEFT lIT A study of nitrate analyzers that is currently under way (WERF Project Number 03-CTS-8).
each reactor, immediately upstream of wil allow for adjustment of

Provide for Future Multi-Stage Denitrification

The current reactor configuration does not allow for multiple anoxic zones or isolation of the the RAS prior to introduction into the aerobic zones. In addition, the current configuration includes a carbon source only for the anoxic zone downstream of the initial aerobic zone. As lower effuent nutrient limits are promulgated within the Chesapeake Bay Region, optimization of nitrification and denitrification wil become even more criticaL. With the conversion to a serpentine flow path, it wil be possible to dedicate the initial half-stage (10% of the reactor volume) of the reactor to provide denitrification of the RAS. In addition, the design includes provisions for future installation of mixer (i.e. electrical supply and mounting platform retained intact) to operate Stage 1A in an anoxic mode. However, without supplemental carbon feed, the denitrification would be reliant on endogenous respiration, thus proceed slowly, and, according to observations by plant staff, be unreliable. Therefore, to enable future multi-stage
RAS (refer to Figure 2), which precludes separate denitrification of denitrification, methanol wil be added to the upstream end of which wil allow for utilization of stage of the 0.5 MG of

the RAS discharge force main,

volume in the RAS pipe as well as the first halfthe reactor for supplemental RAS denitrification.

Improve Mixed Liquor Distribution to the Sedimentation Basins

DC W ASA has historically had problems with the distribution of

the mixed liquor to the

sedimentation basins. Under design average flow conditions, sedimentation basin performance

is reported to be good with effuent TSS typically less than 10 mg/l. However, under peak flow conditions, solids loadings are higher in some basins than others, as indicated by rising sludge blankets and periodic high effuent solids, particularly from the sedimentation basins at the downstream end of the NSB influent channels.
Each bank of 14 sedimentation basins has an aerated influent channel that is 1,100 feet long and 16 feet wide, with a nominal side water depth of20 feet depending on flow. Each sedimentation basin currently has four 3-foot x 3-foot square inlets. Assuming an equal flow distribution, at design peak flow (755 mgd influent, 134 mgd spent filter wash water, and 291 mgd RAS flow) the velocities in the existing channel range from 2.86 fps (upstream end) and 0.22 fps (downstream end). Velocities and headloss through the existing influent openings are 1.95 fps and 0.16 feet, respectively. Given the length of the channel and the low influent headloss, the flow split to the sedimentation basins is poor. In addition, each NSB has 1,156 feet of V-notch weir, with minor differences in weir elevation potentially resulting in significant differences in flow distribution. To improve the flow distribution to the sedimentation basins, the same philosophy that was applied to improve the flow distribution to the reactors (creating headloss at the upstream end of the basins) wil be applied. Specifically, orifice plates wil be used to increase the headloss at the influent end of the sedimentation basins. Because of the limited

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\\11,11,( 2005

headloss available within the existing hydraulic profile, use of weirs is not possible. However, by lowering the sedimentation basin effluent weirs by three inches, and installing an orifice plate, as shown in Figure 10, in the existing stop plate grooves upstream of each influent gate, the distribution to the sedimentation basins can be improved. The loss through the modified inlets wil be 1.2 feet, at peak flow, approximately 10 times the change in the hydraulic grade along the length of the channeL. By incorporating a significant headloss at the point of distribution (the upstream end of the basins), differences in the flow distribution caused by minor irregularities in weir elevations and changes in the hydraulic grade line in the influent channel can be mitigated.

LIFTING APPARATUS

l~-iTRIFIC~T_ION SEDIMENTATION BASINJ

: I : j ~' -i

ENLARGED VIEW
~',

~j

Ii, '.i
~~ ~ l, ~, ~, i-' l"

, '
t
Ii

t~ ~r

~l

". -~; "', ~:,'

ORIFICE PLATE

Figure 10 : Orifce Plate at Influent to Nitrification

Sedimentation Basins

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\Vir ILC" 2005

Conclusions
For existing wastewater treatment plants, meeting increasingly more stringent nutrient limits the N/DN reactors at DC the existing facilities. Based on a case study of WASA's Blue Plains Advanced Wastewater Treatment Plant, design features that can be incorporated into the existing structues to satisfy process objectives that improve process performance and/or reliability are summarized in Table 9.
requires optimization of

Table 9 - Summary of Design Features Incorporated to Improve Process Performance and Reliabilty
Process Objective
Provide equal flow distribution to N/DN reactors Maximize performance of existing sedimentation basins
Design Feature Included to Satisfy the

Process Obiective
Free flowing rectangular weirs in weir boxes at influent end ofN/DN reactors Serpentine flow path with provisions for controlled operation (via weir boxes) in a step feed mode, which reduces solids loading to sedimentation basins Two-tiered operational approach to control solids loading on the sedimentation basins, and prevent solids washout. The two-tiered approach initially utilizes the serpentine configuration and step feed weir boxes to hold solids in Stage 1, while bypassing secondary
effuent to Stage 2. As flows continue to

Optimize wet weather operations

Provide flexible aerobic and anoxic mass fractions

increase, reactors are taken off-line to hold solids. Serpentine flow path with anoxic/aerobic
baffe walls, and mixers and fine bubble

Increase mixing efficiency

Increase aeration efficiency

Remove foam

Improve methanol feed controls

diffusers in swing zones Retrofits for existing sparged turbines for mixing, reusing existing gear boxes and portions of shafts Fine bubble diffusers in all aerobic and swing zones Free surface ports, new effuent gates and foam wasting stations Automated monitoring of nitrate for all reactors and mixed liquor channels, with feedback loop to trim methanol feed.

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\\Tiiie: 2005

Table 9 - Summary of Design Features Incorporated to Improve Process Performance and

Reliabilty (continued)
Process Objective

Provide for future multi-stage denitrification

Improve flow distribution to sedimentation basins

Design Feature Included to Satisfy the Process Objective Provisions for use of initial 10% of the N/DN reactor volume in an anoxic mode for supplemental RAS denitrification prior to entry into aerobic zone, with provisions for future installation of a mixer and future methanol feed to the RAS line. Orifice plate at the influent ports for the Nitrification Sedimentation Basins.

REFERENCES
Van Niekerk, A.; Ruhl, 1.; Pitt, P.; Parker, D.; Kharkar, S.; Tesfaye, A. (2003) Upgrading of

the Nitrification/enitrification Facility at the Blue Plains Advanced Wastewater Treatment Plant; WEFTEC 2003 Conference Proceedings.

Metcalf

and Eddy, Inc. (1991) Wastewater Engineering Treatment, Disposal and Reuse, 3rd ed.

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