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EuropeAid/138712/ID/WKS/RS
Technical Solution
Form 4.6.9.2
Process Design & Calculations
Operation Costs
08.03.2017
Version 1.0
file: 359998200.doc
editor: kb
INDEX
1. GENERAL..............................................................................................................4
page 2 of 54
3.6.1 Excess Sludge Pre-Thickening (Primary Thickening)..................................35
3.6.2 Sludge Stabilisation Tank.................................................................................36
3.6.3 Stabilised Sludge Thickening (Secondary Thickening)...............................40
3.6.4 Mechanical Sludge Dewatering.......................................................................42
4. OPERATION COSTS...........................................................................................47
page 3 of 54
1. General
page 4 of 54
2. WWTP Plant Capacities and Performance
The WWTP is designed on loads, flows and effluent limits provided by Tender
Documents. The loads and flows for the design calculations are stated below.
As design values, the following inlet loads are defined by the Tender
Documents:
COD 1.980 kg/d
BOD5 990 kg/d
SS 1.155 kg/d
Ntot 198 kg/d
Ptot 33 kg/d
page 5 of 54
2.2 Hydraulic Load
page 6 of 54
3. Waste Water Treatment Stages
page 7 of 54
Gravity stabilised sludge thickening (secondary thickening)
Mechanical sludge dewatering
Exhaust air treatment
Administration & control building
Emergency Diesel generator
page 8 of 54
Automatic coarse screen
required flow acc. Tender 1.290 m/h
design flow for installed screen 1.290 m/h
type of screen bar / rotating rake
number of units 1
penstocks per line 2
bar spacing 50 mm
width per screen field 1,0 m
number of screw conveyors incl. press-zone 1
type of screen control level difference
page 9 of 54
Hydraulic loss of coarse screen (max. flow through one line):
ho flowmax. 4 cm
page 10 of 54
3.2.2 Inlet Pumping Station
Inlet pumps
required capacity acc. Tender per unit 45 l/s
capacity per installed unit 45 l/s
type submersible
number of units 4
duty/standby 4/0
spare pumps (stored) 1
total installed duty capacity 180 l/s
control frequency converter
page 11 of 54
3.2.3 Internal Pumping Station
To lift raw water collected from right bank of river Ibar and all
waste water collected at the new WWTP up to the further
treatment of the WWTP, an internal pumping station is
implemented.
The pump sump of the internal pump station is separated from a
chamber housing the penstocks and non-return valves. Therefore,
all fittings are dry accessible. Pumps are lifted by a manual lifting
device.
page 12 of 54
3.2.4 Storm Water Detention Tank & Pump Station
page 13 of 54
3.2.5 Inlet & Distribution Chamber
This chamber is collecting the flows from the inlet pump station
and the internal pump station. In addition, the pump station from
the storm water detention tank returns stored storm water to the
chamber in case that incoming flow is appropriate. Three manual
adjustable overflow weirs ensure proper flow distribution towards
the mechanical treatment and the storm water detention tank.
Measurements for water level, pH-value, temperature and
conductivity are installed at the chamber. For the subsequent
laboratory analyses, an automatic 24 hours or 2 hours flow
proportional sampling device is positioned at the chamber as
required by the Employer`s Requirements.
For the fine screening and removal of grit & grease, two compact
plants are implemented downstream of the inlet & distribution
chamber. Both plants are positioned out-door on a concrete slab
in accordance to the Employer`s Requirements. In accordance to
the Employer`s Clarifications, both compact plants are fully
covered / capsulated and designed for proper outside installation
and proper outside operarion. Blowers are noise insulated to keep
the requirements in view of noise. Both compact plants are
connected to the exhaust air treatment. Therefore, Employer`s
Requirements resp. Clarifications in view of odour are kept.
Removed screening is washed, compacted and discharged in to
containers (1,1 m). Removed grit is treated by grit classifiers and
is discharged into containers (1,1 m).
page 14 of 54
Grease is pumped into a grease pit. In total, 6 containers with a
volume of 1,1 m each are provided for the screenings and grit.
The blowers for aeration system are situated beside the compact
plants. In accordance to Employer`s Requirements, an actuated
crane for the screens is provided.
Compact plants for fine screening and aerated grit & grease
removal
required flow per unit 181 m/h
design flow per unit 181 m/h
type compact plant
number of units 2
number of fine screens per unit 1
spacing of fine screen 6 mm
by-pass for fine screen manual
number of compacting conveyors per unit 1
screening compacting efficiency 40 % compaction
screening compacting efficiency 25 % DS
number of grit and grease removal per unit 1
separated solids (grit removal) 0,2 mm
number of grit classifiers per unit 1
number of blowers per unit 1
total number of grease pits 1
page 15 of 54
Blower
capacity per unit 58 Nm/h
number per compact plant 1
control direct
Grease pump
capacity per unit 3 m/h
number per compact plant 1
type eccentric screw pump
operation direct
dimensioning diagram
Abscheideleistung = separation degree
Verweilzeit = retention time
page 16 of 54
fine screen
Q max 50,3 l/s
type of screen Ro1 ----
size of screen 780 ----
bar space 6 mm
grit separation
separation degree 90 %
grain size 0,20 mm
check of design
Q max 50,3 l/s
calculated retention time 145 s
required retention time 140 s
grease removal
grease removal yes
length 4.300 mm
width 400 mm
page 17 of 54
3.2.7 Inlet Flow Measurement
page 18 of 54
3.3 Biological Stage
page 19 of 54
Flows at plant inlet
Qd 3.136 m/d
Qmax. (PWWF) 334 m/h
Qmax. (dry weather flow) 232 m/h
According to Tender Documents, the design peak flow per tank shall be
181 m/h (conservative approach).
page 20 of 54
The relevant process design data i.e. volumes, surface areas, sludge
age, sludge loads, hydraulic / surface loads, surplus sludge production
and return sludge ratio are shown within the EDP-excerpt below. The
actual version 2.01 of official ATV-DVWK BelebungsExpert for standard
A-131 is used.
page 21 of 54
Volume of aeration tank
MDS,AB = tDS, calc + SSd [kg]
VAB = MDS,AB / DSAB [m]
BR = Bd,BOD / VAB [kg BOD5/m d]
BDS = BR / DSAB [kg BOD5/kgTS d]
Oxygen capacity
OVd,C = Bd,BOD * (0,56 + (0,15 * tDS * FT) / (1 + 0,17 * tDS * FT)) [kg O2/d]
OVd,N = Qd * 4,3 (SNO3,D - SNO3,ZB + SNO3,AN) / 1000 [kg O2/d]
OVd,D = Qd * 2,9 SNO3,D / 1000 [kg O2/d]
OVh = (fC * (OVd,C - OVd,D) + fN * OVd,N) / 24 [kg O2/h]
Secondary sedimentation
DSBS = 1000 / ISV * tE1/3 [kg/m]
DSAB = RV * DSRS / (1 + RV) [kg/m]
qA = qSV / (DSAB * ISV) [m/h]
ASST = Qm / qA [m]
h1 = min. 50 cm
h2 = (0,5 * qA * (1 + RV)) / (1 VSV / 1000) [m]
h3 = (1,5 * 0,3 * qSV * (1 + RV)) / 500 [m]
h4 = (DSAB * qA * (1 + RV) * tE) / DSBS [m]
page 22 of 54
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page 26 of 54
3.3.1 Aeration Tanks
Aeration tanks
type circular tank
number of units 2
inner diameter 15,0 m
water depth 5,4 m
usable volume per tank 954 m3
usable volume total, existing 1.908 m3
mixer units per tank 1
page 27 of 54
For process supervision and process control, each tank is
equipped with one online measurement for O 2 and temperature.
One mixer unit per tank serves for proper suspension of activated
sludge.
Both tanks are equipped with a circular effluent weir including a
scum baffle.
page 28 of 54
Blowers for aeration stage
type root type
total number of units 3 (4 incl. sludge stabilisation)
duty/standby 2/1 (3/1 incl. sludge stabilisation)
control frequency converter
alpha factor 0,7
peak oxygen demand acc. ATV-A-131 (wastewater) 75,2 kg/h
peak oxygen demand (clear water) 107,4 kg/h
calc. O2 input / m depth (pure water) 0,018 kgO2/Nm*m
required air amount for peak oxygen demand 19,3 Nm/min
max. designed input capacity per blower 13 Nm/min
max. total designed input capacity 26 Nm/min
max. designed input capacity of stand-by blower 14,7 Nm/min
page 29 of 54
3.3.2 Distribution Chamber 2
page 30 of 54
required diameter per tank (ATV A 131) 12,38 m
designed inner diameter 15,0 m
water depth (2/3) 4,60 m
sludge clearance blade scraper
Scum pumps
type submersible
capacity per unit 7 l/s
number of units 2
duty/standby 1/1
total duty capacity 7 l/s
control direct
page 31 of 54
3.4 Effluent Flow Measurement / Effluent Quality Measurement /
Process (Service) Water
Before purified wastewater flows off the new WWTP, it runs through an
open channel type (Venturi) flow measurement. For the subsequent
laboratory analyses, an automatic 24 hours flow proportional sampling
device is provided.
Downstream of the effluent measurements, one submersible pump for
technical (service) water preparation is provided (25 m/h). Within the
sludge dewatering building, a manual filter unit and an expansion vessel
are installed. The service water serves for internal washing / flushing of
machinery as required by Tender Documents.
page 32 of 54
3.5 Return Sludge & Excess (Waste) Sludge Pump Station
page 33 of 54
Excess (waste) sludge pumps
type submersible
required flow acc. Tender Documents min. 8 l/s
capacity per unit 8 l/s
duty capacity total 8 l/s
number of units 2
duty/standby 1/1
control direct
page 34 of 54
3.6 Sludge Treatment
page 35 of 54
In accordance to the Tender Documents, a sludge pump station is
adjected to the primary sludge thickening tank which forwards the
thickened sludge to the aerobic sludge stabilisation stage. Pumps
are positioned in a dry chamber according Tender Requirements.
The tank is covered and connected to the exhaust air treatment.
Therefore, Employer`s Requirements resp. Clarifications in view
of odour are kept.
page 36 of 54
Design of stabilisation tank (dimensioning load case 12 C)
min. thickened sludge flow acc. Tender Documents 39 m/d
designed thickened sludge flow 44 m/d
inlet sludge concentration 2,8 % DS
min. retention time acc. Tender Documents 20 d
designed retention time 22 d
min. volatile solids reduction acc. Tender Documents 40 %
designed volatile solids reduction 40 %
min. aeration capacity acc. Tender Documents
2,3 kg O2/kg VSS destroyed
designed aeration capacity 2,3 kg O2/kg VSS destroyed
min. required output sludge concentration acc. Tender Documents
2,0 % DS
designed output sludge concentration 2,1 % DS
page 37 of 54
page 38 of 54
The blowers for the sludge stabilisation are situated in the blower
room of the aeration stage blowers. The one stand-by unit serves
both for aeration tank stage and sludge stabilisation stage (please
see description of aeration tank blowers).
page 39 of 54
3.6.3 Stabilised Sludge Thickening (Secondary Thickening)
page 40 of 54
In accordance to the Tender Documents, a sludge pump station is
adjected to the secondary sludge thickening tank which forwards
the thickened sludge to the mechanical sludge dewatering stage.
Therefore and in accordance to the Employer`s Clarifications,
these pumps serves as feeding pumps of the sludge dewatering
units. Pumps are positioned in a dry chamber according Tender
Requirements.
page 41 of 54
3.6.4 Mechanical Sludge Dewatering
page 42 of 54
Polymer plant
number of units 1
max. polymer demand for 18 % DS 8 g AS/kg DS
page 43 of 54
3.7 Other Site facilities
3.7.1 Roads
page 44 of 54
Transformer station
One transformer is situated in a separate room of the blower
building.
page 45 of 54
3.7.3 Exhaust Air Treatment
3.7.4 Others
page 46 of 54
4. Operation Costs
Operation costs are calculated for the following inlet loads and flow
towards the plant (= 100 % load, Qd).:
COD 1.980 kg/d
BOD5 990 kg/d
SS 1.155 kg/d
Ntot 198 kg/d
Ptot 33 kg/d
Qd 3.136 m/d
waste water temperature averaged 12 & 20C
Backflow and back-loads are considered for operation cost calculations.
page 47 of 54
4.3 Amount of Dewatered Sludge
page 48 of 54
page 49 of 54
5. Future Extension of the WWTP (Realisation not Part of Actual Contract)
page 50 of 54
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