TABLE OF CONTENTS

EXECUTIVE SUMMARY 2
SLUDGE TREATMENT IN WASTEWATER TREATMENT 3
SLUDGE TREATMENT IN PAAKY 7
RETURN SLUDGE PUMPING STATIONS ............................................................................................................. 7
EXCESS SLUDGE PUMPING STATIONS .............................................................................................................. 7
DISSOLVED AIR FLOATATION UNIT ................................................................................................................... 7
SLUDGE STORING TANK ........................................................................................................................................ 8
SLUDGE DEWATERING BUILDING ...................................................................................................................... 8
FILTRATE PUMPING STATION .............................................................................................................................. 9
AS IS DESIGN 10
PROCESS CALCULATION ...................................................................................................................................... 10
HYDRAULIC CALCULATIONS ............................................................................................................................. 15
COST ANALYSIS ........................................................................................................................................................ 26
MODIFIED DESIGN 27
CALCULATIONS ........................................................................................................................................................ 27
COST ANALYSIS ........................................................................................................................................................ 27
NEW DESIGN 28
ANAEROBIC DIGESTION 32
DESIGN CRITERIA FOR ANAEROBIC DIGESTION ...................................................................................... 33
DESIGN OF ANAEROBIC DIGESTER 34
PROCESS CALCULATION ...................................................................................................................................... 34
COST ANALYSIS ........................................................................................................................................................ 49
1
EXECUTIVE SUMMARY
his report is prepared to present the design of sludge treatment in Paaky
Wastewater Treatment Plant and Anaerobic digestion. The flowrate is taken
as 100,000 m
3
/ day and the peak flowrate is 125,000 m
3
/ day. It includes an
as is, a modified and a new design of the sludge lines and a new design
for anaerobic digestion. T
In as is design of sludge treatment units of Paaky Wastewater Treatment Plant all
process and hydraulic calculations are done for the DAF, sludge storage tank and centrifuge
units. The approximate cost of this project is 4,300,000 $.
In modification of Paaky Wastewater Treatment Plant, sludge storage detention time
is minimized and tank is reconstructed according to chosen storage day. The approximate cost
of this project is 10,000 $.
In new design of Paaky Wastewater Treatment Plant is average flowrate is taken as
100,000 m
3
/ day. This new design is performed to adapt the range of design criteria. The
approximate cost of this project is 4,700,000 $.
Anaerobic digestion has been designed according to Paaky influent wastewater
parameters. All calculations were done including dimensioning, amount of gas production, heat
requirements. The approximate cost of this project is 10,000,000 $.
2
SLUDGE TREATMENT IN WASTEWATER TREATMENT SLUDGE TREATMENT IN WASTEWATER TREATMENT
Wastewater treatment objectives are accomplished by concentrating impurities into solid form
and then separating these solids from the bulk liquid. These concentration of solids, referred to
as sludge, contains many objectionable materials and must be disposed of properly. The sludge
resulting from wastewater treatment operations and process is usually in the form of a liquid or
semisolid liquid that typically contains from 0.25 to 12 % solids by weight, depending on the
operations and processes used. Of the constituents removed by treatment, sludge is by far the
largest in volume, and its processing and disposal is perhaps the most complex problem facing
the engineer in the field of wastewater treatment. Sludge disposal facilities usually represent 40
to 60 % of the construction cost of wastewater treatment plants, account for as much as 50 %
of the operating cost, and are the cause of a disproportionate share of operating difficulties.
[1]
[2]
Gravity Thickening
Gravity thickening is accomplished in a tank similar in design to a conventional sedimentation
tank. Normally, a circular tank is used. Dilute sludge is fed to a center - feed well. The feed
sludge is allowed to settle and compact, and the thickened sludge is withdrawn from the bottom
of the tank. Conventional sludge - collecting mechanisms with deep trusses or vertical pickets
are used to stir the sludge gently, thereby opening up channels for water to escape and
promoting densification. The supernatant flow that results is returned to the primary settling
tank or to the headworks of the treatment plant. The thickened sludge that collects on the
bottom of the tank is pumped to the digesters or dewatering equipment as required; thus, storage
space must be provided for the sludge. Gravity thickening is most effective on primary sludge.
A photo of gravity thickener is shown below.
3
Gravity thickeners used dewatering the treatment sludge are designed on the basis of solids
loading. To maintain aerobic conditions in gravity thickeners, provisions should be made for
adding 24 to 30 m
3
/m
2
.day of final effluent to the thickening tank. Typical concentrations of
unthickened and thickened sludges and solids loadings for gravity thickener are shown below.
[3]
[4]
An operating variable, sludge volume ratio normally range between 0.5 and 20 day; the lower
values are required during warm weather. For operation, alternatively, sludge - blanket depth
should be measured. Blanket depths may range from 0.6 to 2.4 m; shallower depths are
maintained in the warmer months.
Flotation Thickening
There are three basic variations of the flotation thickening operation ; dissolved - air flotation
(DAF), vacuum flotation, and dispersed - air flotation. Dissolved - air flotation is being
widely preferred for especially waste activated sludge. Air is introduced into a solution that is
being held at an elevated pressure. When the solution is depressurized, the dissolved air is
released as finely divided bubbles carrying the sludge to the top, where it is removed. Photos of
DAF are shown below. [5]
[6]
4
[7]
Activated sludge solids from the secondary clarifiers which are not returned to the aerators are
wasted. The DAF (Dissolved Air Flotation) thickener tanks receive the wasted solids. Solids
enter the DAF tank where they are mixed with water and compressed air. As the air and water
mix, solid particles are lifted to the surface by rising air bubbles in the tank.
The floating solids are then collected by a series of tank skimmers while the water is recycled
back to the raw sewer to be processed through the plant. The solids from the DAF are pumped
to the anaerobic digesters. [8]
5
[9]
6
SLUDGE TREATMENT IN PAAKY SLUDGE TREATMENT IN PAAKY
RETURN SLUDGE PUMPING STATIONS RETURN SLUDGE PUMPING STATIONS
Return sludge from the clarifiers is pumped back to the distribution chamber before the Bio-P
Tanks.
For each two clarifiers a Return Sludge Pumping
Station is constructed. Each pumping station is
equipped with 5 return sludge pumps, 2 for each
clarifier plus a common stand by. The pumps are
submersible pumps. The pumps are automatically
operated, controlled by the inlet flow meter in order to
achieve a constant return sludge rate.
EXCESS SLUDGE PUMPING STATIONS EXCESS SLUDGE PUMPING STATIONS
Excess sludge is taken from channel 4 and 2 in each of the Process Tank. A total number of 3
eccenter screw pumps are used. Each has a capacity of 167 m/h, 3
rd
is stand-by. The pumps are
controlled by a timer to remove a preset amount of excess sludge every day. The starting order
of the pumps is alternated once a day to distribute the running time of pumps as equally as
possible.
DISSOLVED AIR FLOATATION UNIT DISSOLVED AIR FLOATATION UNIT
The excess sludge is concentrated in dissolved air flotation unit (DAF Unit). The sludge is
mixed with recycled reject water, which is over saturated with atmospheric air under pressure.
When this mixture enter the DAF Unit, fine air
bubbles will from and carry the sludge to the
surface of the DAF Unit, where it is scraped off.
In the unit two pumps are in operation and one
is stand-by. The pumps are operated at the same
time and with the same capacity as the excess
sludge pumps. The starting order of the pumps
alternated once a day to distribute the running
time of pumps as equally as possible.
7
Each pressure tank is equipped with a pressure transmitter for the pressure tank in the tank a
pressure switch to activate the compressor.
SLUDGE STORING TANK SLUDGE STORING TANK
The concentrated sludge from the DAF Unit gratitates to a Sludge Storage Tank. The tank is
equipped with slow moving mixers to keep the sludge homogenized and bottom air diffusors to
keep it aerobic. The blowers for the diffusors are controlled by the oxygen transmitter in the
tank. One blower is on duty one is stand-by. The starting order of the blowers is alternated
weekly to distribute the running time of blowers as equally as possible.
Sludge Storage tank before dewatering (centrifuge)
SLUDGE DEWATERING BUILDING SLUDGE DEWATERING BUILDING
The sludge is dewatered in 2 centrifuges. The sludge is fed into each centrifuges with a 2 step
eccenter screw pump. Each pump has a capacity of 10 m/h. Polymer is added by 2 step
eccenter screw pumps working in parallel with the feeding pumps. The polymer is added on the
suction side of the feeding pumps and mixed with the sludge in the pipe using in line static
mixer.
The sludge pumps and dosing pumps are automatically operated controlled by the pressure in
the centrifuges. The dewatered sludge is transported by a system of eccenter screw pump to an
outside container area situated at the backside of the Sludge Dewatering Building.
The centrifuges and the Sludge Storage Tank are interconnected so that centrifuge cannot be
started unless sufficient amount of sludge is available in the storage tank.
8
FILTRATE PUMPING STATION FILTRATE PUMPING STATION
Filtrated water from the centrifuge is sent to the collection distribution chamber. There are 2
submersible pumps one is stand-by.
9
AS IS DESIGN AS IS DESIGN
PROCESS CALCULATION PROCESS CALCULATION
DISOOLVED AIR FLOATATION
( ) ( )
1.3 1
a
a
s f P R
A
S S Q

A/S = Air to solids ratio, ml(air)/mg (solids)

0.005 0.06 [13]
sa = air solubility, ml/l
f = fraction of air dissolved at pressure P, usually 0.5 [13]
P = pressure ,atm
p = gage pressure, kPa ( 275-350 kPa) [15]
S
a
= influent suspended solids, g/m
3
(mg/L)
R = pressurized recylce, m
3
/d
Q = mixed-liquor flow, m
3
/d
Temp.,
o
C 0 10 20 30
s
a
, mL/L 29.2 22.8 18.7 15.7
[13]
s
a
= 18.7 mL/L
P =
101.35
101.35
p +
=
275 101.35
101.35
+
= 3.71 atm
( ) ( )
1.3 18.7 0.5 3.71 1
0.05
300 1600
R

R = 1385.6 m
3
/d
Velocity of the solids = 8 160 L/m
2
.min
Surface Area =
3 3 3
2
1385.6 / 10 /
8 / . min 1440min/
m d L m
L m d

= 120.3 m
2
10
A =
2
4
D
= 120.3 => D = 12.5 m => A = 122.7 m
2
Solids Loading = 1.2 3 kg/m
2
hr [13]
Solids Loading =
( ) ( )
2
1600 1385.6 4
4 / .
122.7
R
Q Q x
kg m hr
A
+ +
(NOT N THE RANGE)
DAF detention time =
3
3
600
0.37 9
1600 /
m
d hr
m d

SLUDGE STORAGE TANK
Diameter = 27 m
Depth = 4.3 m
Volume =
2 2
3
27
4.3 2460
4 4
D
depth m
_ _


, ,
Sludge storage tank detention time =
3
3
2460
15.4
160 /
m
d
m d
(NOT IN THE RANGE) [13]
SLUDGE MASS BALANCE
Input Parameters;
BOD
influent
= 320 g/m
3
SS
influent
= 300 g/m
3
Organic N = 10 g/m
3
NH
4
= 17 g/m
3
TN = 27 g/m
3
TP = 5 g/m
3
Waste Activated Sludge
Biomass Production;
,
1000000, 4(240 135) 0,15 0, 081 100000 0, 4(240 135)9, 23 100000 0,12 20
1 (0, 081 9, 23) 1 (0, 081 9, 23) 1 (0, 081 9, 23)
6235.23 /
x bio
x x x x x
P
x x x
kgVSS d

+ +
+ + +

11
3
1 1
6235.23 / 1558.8 /
1000 0, 004
kg d m day
% Total Solids is assumed 0,4
WASN =
3 3
1 12.2
1558.8 / (1 8) / 6235.23 0.8 622.56 /
1000 100
m day g m kgN d
1 1
+ +
1 1
] ]
BOD in WAS =
[ ]
6235.23 0.65 1.42 0.68 3913.3 / kg d
NDN =
3 3
3
1 1
100, 000 27 / 100, 000 9 / 622, 56
1000 1000
1177.44 /
kg kg
g m g m
g g
kgNO N day
1 1

1 1
] ]

NDN = (Q
IR
+ Q
R
)NO3.N
effluent
1177.44 = (Q
IR
+ 100,000) x 8
Q
IR
= 47,180 m
3
/day
IR = 0,47
WASP =
( )
3 3 3
100, 000 / 5 / 2 / 300 / m d g m g m kg day
% TP in SS =
300 /
4.8%
6235.23 /
kg day
kg day

% TP in in VSS =
300 /
6%
6235.23 / 0.8
kg day
kg day

P release =
( ) 6% 2.3% (6235.23 0.8) 184.55 / kg day
WAS : C
60
H
81
O
23
N
12
P mw = 1374 g
TN = (12 x 14) / 1374 = 12.2 %
TP = 31g / 1374g = 2.26 %
Dissolved Air Floatation
Biomass Production;
,
1000000, 4(240 135) 0,15 0, 081 100000 0, 4(240 135)9, 23 100000 0,12 20
1 (0, 081 9, 23) 1 (0, 081 9, 23) 1 (0, 081 9, 23)
6235.23 /
x bio
x x x x x
P
x x x
kgVSS d

+ +
+ + +

12
3
1 1
6235.23 / 155.88 /
1000 0, 04
kg d m day
% Total Solids is assumed 4%
DAFN =
3 3
1 12.2
155.88 / (1 8) / 6235.23 0.8 609.93 /
1000 100
m day g m kgN d
1 1
+ +
1 1
] ]
13
Sludge
amount(kg/d) 6235,23
% solid 0,4
solid
sludge(m3/d) 1558,81
EFFLUENT
Sludge
amount(kg/d) 6235,23
Sludge
amount(kg/d) 6235,2
Sludge
amount(kg/d) 6235,23
% solid 4 % solid 4 % solid 25
solid
sludge(m3/d) 154,337
solid
sludge(m3/d) 151,34
solid
sludge(m3/d) 24,21
AERATION
CENTRIFUGE
DAF
SLUDGE
STORAGE
14
HYDRAULIC CALCULATIONS HYDRAULIC CALCULATIONS
Headloss through Pipe from Secondary Clarifiers to RAS Pumping Station
Q = 100,000 m
3
/d / 4 = 25,000 m
3
/d
D = 500 mm
L = 27.53 m
Assume % 1 sludge
K
entrance
= 0.5
K
exit
= 1
e (roughness coefficient) = 0.045mm = 0.000045m for steel
= 1.14x10
-3
N.sec/m
2
for 15 C
= 1000 kg/m
3

00009 . 0
5 , 0
000045 . 0
10 4 . 6
sec/ . 10 14 . 1
) / 47 . 1 ( ) 5 . 0 ( ) / 1000 (
Re
/ 47 . 1
4 / ) 5 . 0 (
/ 28 . 0
/
5
2 3
3
2
3

D
e
m N
s m m m kg DV
s m
s m
A Q V

f = 0.020 (from Moody Diagram)

H = Hmajor + Hminor
m
g
s m
g
s m
m
m
H
g
V
K K K
g
V
D
L
f H
exit entrance
23 . 0
2
) / 47 . 1 (
) 1 5 . 0 (
2
) / 47 . 1 (
5 . 0
53 . 27
020 . 0
2
) 2 (
2
2 2
2
90
2
+ +
+ + +
RAS Pumping Station
There are 4 + 1 pump:
Type: Submercible
Flowrate: 3.6 m
3
/h
Head: 10m
15
Power: 2.4 kW
Rotation: 2830 d/d
Brand: Flyt/CD 3085 HT 250
Cost: 2.4 kW x 4 x 0.07$ x 365 x 24 = 5,887 $ / year
Headloss through Pipe from RAS Pumping Station (Clarifiers 1 & 2) to CDC 2
Q = 100,000 m
3
/d / 2 = 50,000 m
3
/d
D = 700 mm
L = 391 m
Assume % 1 sludge
Find yield stress from Figure 14-6, (a) (Ref: M&E, 2003)
s
y
= 0.05 N/m
2
Find coefficient of rigidity from Figure 14-6, (b) (Ref: M&E, 2003)
= 0.001 kg/m/s
s m
s m
V
A
Q
V
/ 50 . 1
4
) 7 . 0 (
/ 58 . 0
2
3

Reynolds Number:

VD
N
R

where:
N
R
: Reynolds number, dimensionless
: density of sludge, kg/m
3
= 1000 kg/m
3
V: average velocity, m/s
: coefficient of rigidity, kg/m/s
6
3
10 1
/ / 001 . 0
) 7 . 0 )( / 5 . 1 )( / 1000 (
x
s m kg
m s m m kg
N
R

16
Hedstrom Number:
2
2

y
s D
He
9
2
3 3 2
10 47 . 1
) / / 001 . 0 (
) / 1000 )( / 03 . 0 ( ) 7 . 0 (
x
s m kg
m kg m N m
He
where:
He: Hedstrom number, dimensionless
s
y
: yield stress, N/m
2
Find friction factor from Figure 14-6, (c) [13]
f = 0.0025
D
LV f
P
2
2

2
2 3
/ 4189
) 7 . 0 (
) / 5 . 1 )( 391 )( / 1000 )( 0025 . 0 ( 2
m N
m
s m m m kg
P
m
s m m kg
m N
P 42 . 0
) / 81 . 9 )( / 1000 (
/ 4189
2 3
2

H
minor
=
g
V
K K K K
exit ent
2
) 2 (
2
90 45
+ + +
H
minor
= m
g
x 41 . 0
2
) 5 . 1 (
) 2 75 . 0 6 . 0 1 5 . 0 (
2
+ + +
H
T
= 0.42m + 0.41m = 0.83m
Headloss through Pipe from RAS Pumping Station (Clarifiers 3 & 4) to CDC 2
Q = 100,000 m
3
/d / 2 = 50,000 m
3
/d
D = 700 mm
L = 468 m
Assume % 1 sludge
Find yield stress from Figure 14-6, (a) [13]
17
s
y
= 0.05 N/m
2
Find coefficient of rigidity from Figure 14-6, (b) [13]
= 0.001 kg/m/s
s m
s m
V
A
Q
V
/ 50 . 1
4
) 7 . 0 (
/ 58 . 0
2
3

Reynolds Number:

VD
N
R

where:
N
R
: Reynolds number, dimensionless
: density of sludge, kg/m
3
= 1000 kg/m
3
V: average velocity, m/s
: coefficient of rigidity, kg/m/s
1050000
/ / 001 . 0
) 7 . 0 )( / 5 . 1 )( / 1000 (
3

s m kg
m s m m kg
N
R
Hedstrom Number:
2
2

y
s D
He
24500
) / / 001 . 0 (
) / 1000 )( / 05 . 0 ( ) 7 . 0 (
2
3 3 2

s m kg
m kg m N m
He
where:
He: Hedstrom number, dimensionless
s
y
: yield stress, N/m
2
Find friction factor from Figure 14-6, (c) [13]
f = 0.002
18
D
LV f
P
2
2

2
2 3
/ 6017
) 7 . 0 (
) / 5 . 1 )( 468 )( / 1000 )( 002 . 0 ( 2
m N
m
s m m m kg
P
m
s m m kg
m N
P 45 . 0
) / 81 . 9 )( / 1000 (
/ 6017
2 3
2

H
minor
=
g
V
K K K K
exit ent
2
) 3 (
2
90 45
+ + +
H
minor
= m
g
x 5 . 0
2
) 5 . 1 (
) 3 75 . 0 6 . 0 1 5 . 0 (
2
+ + +
H
T
= 0.45m + 0.50m = 0.95m
Headloss through Pipe from 4
th
Aeration Tank to Excess Sludge Pumping Station
Q = 1558.8 m
3
/d
D = 400 mm
L = 99 m
Assume % 0.4 sludge
K
entrance
= 0.5
K
exit
= 1
e (roughness coefficient) = 0.045mm = 0.000045m for steel
= 1.14x10
-3
N.sec/m
2
for 15 C
= 1000 kg/m
3

0001125 . 0
4 , 0
000045 . 0
10 26 . 5
sec/ . 10 14 . 1
) / 15 . 0 ( ) 4 . 0 ( ) / 1000 (
Re
/ 15 . 0
4 / ) 4 . 0 (
/ 018 . 0
/
4
2 3
3
2
3

D
e
m N
s m m m kg DV
s m
s m
A Q V

f = 0.021 (from Moody Diagram)

H = Hmajor + Hminor
19
m
g
s m
g
s m
m
m
H
g
V
K K K
g
V
D
L
f H
exit entrance
094 . 0
2
) / 15 . 0 (
) 5 . 1 1 5 . 0 (
2
) / 15 . 0 (
4 . 0
99
021 . 0
2
) 2 (
2
2 2
2
90
2
+ + +
+ + +
Excess Sludge Pumping Station
Type: monopump
Flowrate: 167 m
3
/h
Pressure: 3 bar
Head: 20m
Power: 30 kW
Rotation: 270 d/d
Brand: CB 12 K AC IRS/monopumps Dresser
Cost = 30kW x 2 x 365 x 24 x 0.07$ = 36792$/year
Headloss through Pipe from Excess Sludge Pumping Station to DAF Unit
Q = 1558.8 m
3
/d
D = 400 mm
L = 62.15 m
Assume % 0.4 sludge
K
entrance
= 0.5
K
exit
= 1
e (roughness coefficient) = 0.045mm = 0.000045m for steel
= 1.14x10
-3
N.sec/m
2
for 15 C
= 1000 kg/m
3

20
0001125 . 0
4 , 0
000045 . 0
10 25 . 5
sec/ . 10 14 . 1
) / 15 . 0 ( ) 4 . 0 ( ) / 1000 (
Re
/ 15 . 0
4 / ) 4 . 0 (
/ 018 . 0
/
4
2 3
3
2
3

D
e
m N
s m m m kg DV
s m
s m
A Q V

f = 0.021 (from Moody Diagram)

H = Hmajor + Hminor
m
g
s m
g
s m
m
m
H
g
V
K K K
g
V
D
L
f H
exit entrance
064 . 0
2
) / 15 . 0 (
) 75 . 0 1 5 . 0 (
2
) / 15 . 0 (
4 . 0
15 . 62
021 . 0
2
) (
2
2 2
2
90
2
+ + +
+ + +
Headloss through Pipe from DAF Unit to Sludge Storage Tank
Q = 155.88 m
3
/d
D = 200 mm
L = 120.65 m
Assume % 4 sludge
Find yield stress from Figure 14-6, (a) [13]
s
y
= 5.5 N/m
2
Find coefficient of rigidity from Figure 14-6, (b) [13]
= 0.012 kg/m/s
s m
s m
V
A
Q
V
/ 057 . 0
4
) 2 . 0 (
/ 018 . 0
2
3

Reynolds Number:

VD
N
R

21
where:
N
R
: Reynolds number, dimensionless
: density of sludge, kg/m
3
= 1010 kg/m
3
V: average velocity, m/s
: coefficient of rigidity, kg/m/s
10 . 2
/ / 5 . 5
) 2 . 0 )( / 057 . 0 )( / 1010 (
3

s m kg
m s m m kg
N
R
Hedstrom Number:
2
2

y
s D
He
1543055
) / / 012 . 0 (
) / 1010 )( 5 . 5 ( ) 2 . 0 (
2
3 2

s m kg
m kg m
He
where:
He: Hedstrom number, dimensionless
s
y
: yield stress, N/m
2
Find friction factor from Figure 14-6, (c) [13]
f = 1
D
LV f
P
2
2

2
2 3
/ 122
) 2 . 0 (
) / 01 . 0 )( 65 . 120 )( / 1010 )( 1 ( 2
m N
m
s m m m kg
P
m
s m m kg
m N
P 012 . 0
) / 81 . 9 )( / 1000 (
/ 122
2 3
2

H
minor
= negligible
H
T
= 0.012m
22
Headloss through Pipe from Sludge Storage Tank to Centrifuge
Q = 155.8 m
3
/d
D = 200 mm
L = 22.5 m
Assume % 4 sludge
K
entrance
= 0.5
K
exit
= 1
e (roughness coefficient) = 0.045mm = 0.000045m for steel
= 1.14x10
-3
N.sec/m
2
for 15 C
= 1000 kg/m
3

000225 . 0
4 , 0
000045 . 0
10 1
sec/ . 10 14 . 1
) / 057 . 0 ( ) 2 . 0 ( ) / 1000 (
Re
/ 057 . 0
4 / ) 2 . 0 (
/ 018 . 0
/
5
2 3
3
2
3

D
e
m N
s m m m kg DV
s m
s m
A Q V

f = 0.021 (from Moody Diagram)

H = Hmajor + Hminor
m
g
s m
g
s m
m
m
H
g
V
K K K
g
V
D
L
f H
exit entrance
006 . 0
2
) / 057 . 0 (
) 1 5 . 0 (
2
) / 057 . 0 (
2 . 0
5 . 22
021 . 0
2
) 2 (
2
2 2
2
90
2
+ +
+ + +
Headloss through Pipe from Centrifuge to CDC 2 for Supernatant
Q = 130.93 m
3
/d
D = 300 mm
L = 129.3 m
K
entrance
= 0.5
K
exit
= 1
23
e (roughness coefficient) = 0.045mm = 0.000045m for steel
= 1.14x10
-3
N.sec/m
2
for 15 C
= 999 kg/m
3
for 10 C
00015 . 0
3 , 0
000045 . 0
10 52 . 5
sec/ . 10 14 . 1
) / 021 . 0 ( ) 3 . 0 ( ) / 999 (
Re
/ 021 . 0
4 / ) 4 . 0 (
/ 0015 . 0
/
3
2 3
3
2
3

D
e
x
m N
s m m m kg DV
s m
s m
A Q V

f = 0.036 (from Moody Diagram)

H = Hmajor + Hminor
m
g
s m
g
s m
m
m
H
g
V
K K K
g
V
D
L
f H
exit entrance
004 . 0
2
) / 021 . 0 (
) 5 . 1 1 5 . 0 (
2
) / 021 . 0 (
3 . 0
3 . 129
036 . 0
2
) 2 (
2
2 2
2
90
2
+ + +
+ + +
Supernatant Pumps
# of pumps: 2:
Type: submercible
Flowrate: 360 m
3
/h
Head: 6m
Power: 8.8 kW
Brand: Flyt/CP 3140 LT 610
Headloss through Pipe from DAF Unit to CDC 2 for Supernatant
Q = 1402.2 m
3
/d
D = 300 mm
L = 24.34 m
K
entrance
= 0.5
K
exit
= 1
24
e (roughness coefficient) = 0.045mm = 0.000045m for steel
= 1.14x10
-3
N.sec/m
2
for 15 C
= 999 kg/m
3
for 10 C
000015 . 0
3 , 0
000045 . 0
10 95 . 5
sec/ . 10 14 . 1
) / 22 . 0 ( ) 3 . 0 ( ) / 999 (
Re
/ 22 . 0
4 / ) 4 . 0 (
/ 016 . 0
/
4
2 3
3
2
3

D
e
m N
s m m m kg DV
s m
s m
A Q V

f = 0.020 (from Moody Diagram)

H = Hmajor + Hminor
m
g
s m
g
s m
m
m
H
g
V
K K K K
g
V
D
L
f H
exit entrance
011 . 0
2
) / 22 . 0 (
) 75 . 0 6 . 0 1 5 . 0 (
2
) / 22 . 0 (
3 . 0
34 . 24
020 . 0
2
) (
2
2 2
2
90 45
2
+ + + +
+ + + +
Centrifuges
There are 2 centrifuges.
Capacity: 255 kg solid/h
Nominal velocity (Va): 3500d/d
Nominal Power: 30kW
Boul diameter: 340mm
Brand: Guinard/D3LLC 30C HP
25
COST ANALYSIS COST ANALYSIS
UNIT UNIT COST COST
Construction 1,000,000 $
Excess Sludge Pumps 3 20,000$ 60,000$
Compressors (250 l / day) 2 50,000$ 100,000$
Mixers 4 50,000$ 200,000$
Diffusers (9) 340 200$ 68,000$
Sludge Blender 2 10,000$ 20,000$
Sludge feeding pumps 2 5,000$ 10,000$
Polyelectrolyte feeding
pumps
2 3,500$ 7,000$
PE ring pump 1 5,000$ 5,000$
Exit sludge pump 2 5,000$ 10,000$
Centrifuges 2 1,000,000$ 2,000,000$
Liquid PE feeding pump 1 10,000$ 10,000$
TOTAL COST
4,300,000$
26
MODIFIED DESIGN MODIFIED DESIGN
Storage should be provided to smooth out the fluctuations in the rate of solids and biosolids
production and to allow solids to accumulate during periods when subsequent processing
facilities. Storage is particularly important in providing a uniform feed rate ahead of the
following processes; mechanical dewatering, lime stabilization, heat drying and thermal
reduction.
Sludge tanks may be sized to retain the sludge for a period of hours to a few days. If sludge is
stored longer than 2 to 3 days, it will deteriorate, become odorous, and be more difficult to
dewater.
In as is design sludge retention time is too long (15 days). Therefore diameter of the tank is
reduced by constructing inner sidewall.
CALCULATIONS CALCULATIONS
Sludge Retention Time is assumed 4 days
Required Volume of storage tank = (4days) x (154,337 m
3
/day)
[ (D
2
) / 4] x 4,3 m = 617 m
3
D= 13.5 m
Diameter is taken 13.5 m.
Sludge Retention Time = 4 days
COST ANALYSIS COST ANALYSIS
COST
Construction 10,000$
TOTAL COST
10,000$
27
NEW DESIGN NEW DESIGN
MECHANICAL SLUDGE THICKENER
In wastewater treatment plants, the sludge cannot be or is not desired to be directly taken into
the dewatering equipment as the sludge content is too low. The solids content of sludge has to
be brought to a higher level, in other words, the sludge has to be thickened prior to dewatering
to obtain maximum efficiency form the dewatering equipments.
Various mechanical thickening devices have started to be frequently utilized in treatment plants
in the last years, including pre-dewatering belts. The pre-dewatering belts can either be used as
a compact unit together with the beltpress, or be used separately as an independent unit.
Advantages;
No separate building
construction is required.
When utilized as a compact
unit with the beltfilterpress,
it does not take up any extra
land, it only causes an
increase in height.
Even in cases where it is
used as a separate unit, it
requires less land than a
DAF thickener or a gravity
thickener of the same capacity.
The initial investment costs are low.
It requires lower polymer and energy consumption compared to other mechanical
thickeners.
The selection of the most suitable pre-dewatering belts is based on the properties of the sludge
to be thickened and the capacity.
The pillow blocks used in the pre-dewatering belt allow effective contact between the sludge
and the belt surface, and thus maximize the efficiency of the equipment. The number of and the
space between the pillow blocks are determined based on the process.
28
Comparison of Capacity of Mechanical Thickeners
models Hydraulic capacity (for sludge with a solid content of %0.4-0.8)m
3
/h
PDWB-
L
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105
10 X X X X
15 X X X X X
20 X X X X X X X
25 X X X X X X X
Belt width m 2
width m 2.32
Length m 4.5
Height m 1.3
Filtration length m 3.6
29
Motor power kW 0.75
Belt speed m/min 3.7-10.9
Washing water requirement m
3
/h 7
Air requirement lt/min 50
Belt tension Mechanical
Belt aligment Pneumatic
Sludge scraping Mechanical
Belt protection With proximity limit sensor
Washing nozzles Manually cleaned
COST ANALYSES
UNIT UNIT COST COST
Construction 800,000 $
Excess Sludge Pumps 3 20,000$ 60,000$
Compressors (250 l / day) 2 50,000$ 100,000$
Mixers 4 50,000$ 200,000$
Diffusers (9) 200 200$ 40,000$
Sludge Blender 2 10,000$ 20,000$
30
Sludge feeding pumps 2 5,000$ 10,000$
Polyelectrolyte feeding
pumps
2 3,500$ 7,000$
PE ring pump 1 5,000$ 5,000$
Exit sludge pump 2 5,000$ 10,000$
Centrifuges 2 1,000,000$ 2,000,000$
Liquid PE feeding pump 1 10,000$ 10,000$
Mechanical Sludge
Thickener
1 1,000,000$ 1,000,000$
TOTAL COST
4,700,000$
31
ANAEROBIC DIGESTION ANAEROBIC DIGESTION
Anaerobic digestion is among the oldest process used for the stabilization of solids and
biosoldis.In the anaerobic digesters another group of bacteria begin to digest and dissolve the
solids to their basic components. This process uses bacteria which do not need atmospheric
oxygen to survive, so therefore, no air is bubbled into the tanks. In fact, air mixed with the
gasses may be explosive, so we strive to keep all air out. The anaerobic digesters produce a
stable sludge which is readily dewatered. The process is also a source of methane gas, which is
used as a fuel source for heating the digesters, heating several buildings, and fueling the engine
generator to produce electricity. The digester is kept at an optimum temperature of between 90-
95 degrees F. About 40,000 cubic feet of methane gas is produced per day. [10]
[11]
32
Flow Diagram of a Basic Anaerobic Digester
DESIGN CRITERIA FOR ANAEROBIC DIGESTION DESIGN CRITERIA FOR ANAEROBIC DIGESTION
PARAMETER UNITS VALUE
Solids Loading Rate kgVSS/m
3
.d 1,6 4,8
Solids Retention Time days 15 20
VS destroyed m
3
/kg 0.75-1.12
33
DESIGN OF ANAEROBIC DIGESTER DESIGN OF ANAEROBIC DIGESTER
The purpose of this project was to design and build an anaerobic digester to meet the following
criteria.
The design should
Attempt to maximize the amount of biogas produced per unit time,
Be simple and easy to understand so that the average person is able to grasp the function
and theory behind each component of the design with only a small amount of guidance.
The idea here is to encourage people looking at the design to think and understand the
requirements for controlled anaerobic digestion and the continuous flow model.
Be a durable, compact, versatile design which is capable of being shifted around if
necessary to be displayed.
Be operated with a minimum of monitoring, regulating, and adjusting (in other words,
be easy to operate).
Attempt to reduce time and money costs associated with maintenance
Attempt to minimize the cost of setting up and running the digester without
compromising the performance of operation or the other specifications of the brief
PROCESS CALCULATION PROCESS CALCULATION
Observed Yield for BOD Removal
5
1
5
,
/ 24 . 0
) 25 )( 06 . 0 ( 1
/ 60 . 0
1
kgBOD kgTVSS
d d
kgBOD kgTVSS
k
Y
Y
C BOD d
BOD
obs

+

Observed Yield for Nitrogen Removal

N kgNH kgTVSS
d d
kgBOD kgTVSS
k
Y
Y
C N d
N
n obs

+

4 / 088 . 0
) 25 )( 05 . 0 ( 1
/ 20 . 0
1
1
5
,
,

Soluble BOD in the Effluent

Total Soluble
BOD in the =Total BOD in the effluent BOD exerted by TSS in the effluent
34
effluent(S)
BOD exerted
by TSS in = 30 mg/l x (0.65 biodeg.solids/kg TSS) x 1.42 BOD
L
/solid
the effluent x 0.68 kg BOD
5
/kg BOD
L
= 18.83 mg/l
S = 20 18.85
= 1.17 mg/l
Biological Solids increase due to BOD
5
Removal
TSS increase =
d kg S S Q Y
eff O obs
/ 7172 ) 17 , 1 300 ( 000 , 100 24 . 0 ) (
Biological Solids increase due to Nitrogen Removal
TSS increase =
d kg S S Q Y
eff O obs
/ 140 ) 1 17 ( 000 , 100 088 . 0 ) (
Total TSS increase
Ratio of TVSS/TSS is assumed as 0.8
Total TVSS increase =
d kg d kg d kg / 7312 / 140 / 7172 +
Total TSS increase =
d kg
kgTSS kgTVSS
d kg
/ 9140
/ 8 . 0
/ 7312

TSS loss in the effluent = 30 mg/l x 110,000 m

3
/day = 3000 kg/d
TSS in the WAS = 9140-3000 = 6140 kg/d
Volume of WAS
TSS increase =
3
/ 5
/ 8 . 0
/ 4000
m kg
kgTSS kgTVSS
L mgTVSS

Volume of WAS = day m m kg d kg / 1228 / 5 / / 6140

3 3

Total BOD in the WAS

35
BOD exerted by TSS=
d kg kgBOD kgBOD
solids kgbio kgBOD kgTSS solid kgbio d kg
L
/ 7 . 3853 / 68 . 0
. deg / 42 . 1 / . deg 65 . 0 / 6140
5
5


Soluble BOD
5
= 1.17g/m
3
x 1228 m
3
/day /1000 = 1.44 kg/day
Total BOD
5
= 3853.7 kg/day + 1.44 kg/day = 3855.14 kg/day
Return Sludge
10,000 g/m
3
x (Q
R
m
3
/day) = 5000 g/m
3
x [(Q+Q
R
) m
3
/day]
10,000 g/m
3
x (Q
R
m
3
/day) = 5000 g/m
3
x [(99,676+Q
R
) m
3
/day]
Q
R
= 99,676 m
3
/day
WASN (Total Nitrogen in WAS)
Org.N = 0.122 kg Org.N/kg TSS x 6140 kg TSS/day x 0.8 kg TVSS/TSS = 599.3 kg/d
NH
4
+
-N = 1 g NH
4
+
-N/m
3
x 1228 m
3
/d x (kg/1000 g) = 1.23 kg/d
NO
3

N = 8 g NO
3

N/m
3
x 1228 m
3
/d x (kg/1000g) = 9.8 kg/d
Total N = 610 kg/day
NDN = TN in the influent to the biological system TN lost in the effluent
TN in WAS
= 24.57 x 99,676/1000 897kg/day -610 kg/day
= 942 kg/day
WASP (Total Phosphorus in WAS)
WASP = 99,676 x (5-2)/1000 = 299.028 kg/day
% TP in SS = 299.028 / 6140 = 4.87 %
% TP in VSS = 299.028 / (6140 x 0.8) = 6.08 %
PO4P Release = ( 6.08-2.3) x (6140 x 0.8) = 185,7 kg/d P
ALUM ADDITION
TSS caused by Al
3+
precipitation as AlPO4
36
TSS increase = (molar wt. of Al / molar wt. of P ) x (amount of PO
4
3
P precipitated or
released )
=
27
185.7 / 209 /
31
x kg d kg d
TSS caused by precipitation as Al(OH)
3
TSS increase = (molar wt. of Al(OH)
3
/ molar wt. of P ) x (amount of PO
4
3
P precipitated or
released ) in primary sludge
=
78
185.7 / (2.5 1) 701 /
31
x kg d kg d
TSS increase = 910 kg/d
Total TSS increase = 6140 kg/d + 910 kg/d = 7050 kg/d
Total amount of Al
3+
applied = (amount of PO
4
3
P precipitated / molar wt. of P ) x applied
AL
3+
/P molar ratio x molar wt. of Al
=
185.7
2.5 27 404.3 /
31
x x kg d kg AL
3+
/day
Volumeof liquid alum solution =
Total amount of Al3+ applied x molar wt. of Al2(SO4)
2 x molar wt. of Al x 0.25 x 1300 kg/m3
=
3
3
404.3kg/d x 342
7.88 /
2 x 27 x 0.25 x 1300 kg/m
m d
Total volume of WAS = 1220.12 + 7.88 = 1228 m
3
/day
Characteristics of combined and blended sludge
Total TSS increase = 7050 kg/d + 15,000 kg/day = 22,050 kg/day
Total Volume of combined sludge = 324 m
3
/day + 1228 m
3
/day = 1552 m
3
/day
BOD
5
in combined sludge = BOD
5
in WAS + BOD
5
in primary sludge
= 9600 kg/day + 3855,14 kg/day = 13,553 kg/day
Thickener Area =
2
2
22050 kg/d
470
46,9 kg/d/m
m
37
Volume of dilution water =
3
3
2
9.8 470 1552 3054 /
.
m
m d
d m

At 30 mg/L
TSS with dilution water =
3054 30
91.62 /
1000
kg d

LIME ADDITION
TSS caused by Ca
2+
precipitation as Ca
3
(PO4)
2
TSS increase = (molar wt. of Ca / molar wt. of P ) x (amount of PO
4
3
P precipitated or
released )
=
3
/ 88 . 71 7 . 185
31
12
m kg x
TSS caused by precipitation as Ca(OH)
2
TSS increase = (molar wt. of Ca(OH)
2
/ molar wt. of P ) x (amount of PO
4
3
P precipitated or
released ) in primary sludge
=
3
/ 3 . 413 ) 1 5 . 2 ( 7 . 185
31
46
m kg x x
TSS increase = 485.2 kg/d
Total TSS increase = 6140 kg/d + 485.2 kg/d = 6,625 kg/d
Total amount of Cal
2+
applied = (amount of PO
4
3
P precipitated / molar wt. of P ) x applied
Ca
2+
/P molar ratio x molar wt. of Ca
= 7 . 179 12 5 . 2
31
7 . 185
x x kg Ca
2+
/day
Specific gravity of Ca(OH)
2
=481 kg/m
3
Volumeof hydrated lime =
3
2 4 3
2
kg/m 2509 x 0.25 x Ca of molar wt. x 2
) (PO Ca of molar wt. x applied Ca of amount total
+
=
day m / 86 . 2
kg/m 481 x 0.25 x 12 x 2
46 kg/d 179.7
3
3

Total volume of WAS = 1225.14 + 2.86 = 1228 m

3
/day
38
THICKENER
*
1 truck capacity = 10 m
3
Thickener effluent = ( ) 22050 91.62 0.85 18820.4 / kg d +
Volume =
3
18820.4 /
304.5 /
0.06 1030
kg d
m d

BOD
5
= 11478 kg/d
VSS =
18820.4 / 0.72 13551 / kg d kg d
VSS / SS = 0.72 [15]
13551 0.52 7046.5 /
stabilized
VSS kg d
VSS
destruction
= 52 % [15]
13551 7046.5 6504.5 /
remaining
VSS kg d
18820.4 7046.5 11774 /
remaining
SS kg d
Kg/d 18820.4
% TS 6
m
3
/d 304.5
Number of truck
*
30
39
ANAEROBIC DIGESTION ANAEROBIC DIGESTION
SUPERNATANT SUPERNATANT
304.5 m
3
/d
EFFLUENT EFFLUENT
11774 kg/d = W
sludge
+ W
supernatant
sup tan 3
304.5 /
0.05 1030 0.004 1000
sludge erna t
W W
m d +

W
sludge
= 11774 kg/d - W
supernatant
sup sup 3
11774
304.5 /
0.05 1030 0.004 1000
W W
m d

+

62727 = 47096 4 W
sup
+ 51.5 W
sup
W
supernatant
= 329 kg / d
3
sup tan
329
82.25 /
0.004 1000
erna t
m d

W
sludge
= 11774 kg/d - 329 kg/d
W
sludge
= 11445 kg/d
m
3
/d 82.25
% TS 0.4
m
3
/d 329
(kg/m
3
) 1000
BOD
5
3000
Org N 0.34
NH
4
N 0.05
m
3
/d 11445
% TS 5
m
3
/d 222.2
(kg/m
3
) 1030
BOD
5
4344.45
Org N 848.3
NH
4
N 127.25
Truck 22
40
3
11445
222.2 /
0.05 1030
sludge
m d

Total Mass of Other Components in Digested Sludge: Total Mass of Other Components in Digested Sludge:
BOD
5
=
( )
3
3
3
11478 / 1 0.6 3000 82.25 10 4344.45 /
g m
kg d kg d
m d


BOD
5
stabilized = 60 % [15]
Org N in the effluent of thickener =
18820.4 / 0.122 0.8 1837 / kg d kg d
Org N = ( )
11445 222.2
(1837) 1 0.1 0.15 (1837) 0.1 848.3 /
11774 304.5
kg d
_ _
+

, ,
Conversion of Org N into NH
4
-N = 15 % [15]
NH
4
-N =
848.3 / 0.15 127.25 / kg d kg d
Conversion of Org N into soluble org N = 10 % [15]
Conversion of non-precipitated phosphorus (NPP) into soluble P = 30 %
PP capture = 100 %
BOD
5
in supernatant = 3000 mg/L
Org N sup = ( )
329 82.25
(8.94) 1 0.1 0.15 (8.94) 0.1 0.34 /
11774 304.5
kg d
_ _
+

, ,
NPP in the effluent of thickener =
91.62 / 0.122 0.8 185.7 / kg d kg d
NPP = 185.7 kg /d
Centrifuge
W
sludge
= 11445 kg/d
Centrifuge = % 30
3
3
sup
11445 /
37 /
0.3 1030
up tan 222.2 37 185.2 /
11445 0.15 1716.7 /
11445 1716.7 9728.3 /
sludge
kg d
Dewateredsludge m d
S erna t m d
W kg d
W kg d

41
Kg/d (sludge) 9728.3
% TS 30
m
3
/d 3
Number of truck 4
Anaerobic Digestion Capacity & Dimensions: Anaerobic Digestion Capacity & Dimensions:
There are 4 methods to calculate digester capacity. According to below results suitable volume
will be chosen at worst conditions.
1) Q
avg
= 304.5 m
3
/d
Digestion period = 15 days

3
3
304.5 15 4567.5
m
Digester days m
d

2) High rate digerter = 2.5 kg / m
3
.day
TVSS =
18820.4 / 0.72 13551 / kg d kg d

3
3
13551 /
5345
2.5 / .
kg d
Digester m
kg m day

3) Volume per capita
Assume =
3
0.03m
capita
[15]
Population served = 250000

3
3
0.03
250000 7500
m
Digester m
capita

4) Volume reduction method
( )
2
3
in in out t
Q Q Q D
_


,
42
D
T
= Digestion period (d)
Q
in
= Sludge amount (m
3
/d) = 304.5 m
3
/d
Q
out
= Effluent sludge amount (m
3
/d) = 222.2 m
3
/d
( )
3
2
304 304 222.2 15 3744.5
3
Digester m
_


,
Chosen volume = 7500 m
3
Provide a 1 m depth for grit accumulation in the bottom cone.
Provide 0.6 m depth for scum blanket.
Provide 0.6 m between the floating cover and max. digester level.
Total inactive cone depth = 1 m
Total inactive upper depth = 1.2 m
Active side water depth = 20 m
Number of digester = 2
3
7500
3750
2
EachDigester m
2
3750
187.5
20
EachDigesterArea m
Diameter of each digester =
2
187.5 15.4
4
D
D m


15.4 0.4 = 15 m
3
2
3750
21.2
15
4
m
Verticalsidedepth m

1.2 m
20 m
43
2.5 m
1 m
3.16 m
1 m
3 m
1.5m
7.5 m
( )
2
2
2 3
20 15 1 1
15 2.5 3 2 1 3672.2
4 3 4 3 4
ActiveDigester m

_
+

,
3
3672.2 2 7344.4 TotalActive m
( )
2
2
3
1.2 15 1
3 2 1 221.4
4 3 4
TotalInactive m

_
+

,
3
7344.4 221.4 7565.8 Total m +
7344.4
0.97
7565.8
Active ratio > 0.8 IT IS IN THE RANGE! [15]
7344.4
24
304.5
DigestionPeriodatAverageFlow d
7344.4
15.1
487.2
DigestionPeriodatExtremeHighFlow d
7344.4
38.6
190.3
DigestionPeriodatLowFlow d
3
3
18820.4 /
2.56 / .
7344.4
kg d
SolidsLoading kg m d
m
[it is in the range] [13]
Gas Production Gas Production
44
There are 4 different methods to calculate the amount of gas production. The less value of gas
production will be chosen.
1) BOD
5
in thickened sludge = 11478 kg/d

11478 /
16879 /
0.68
0.05 0.8 16879
392.5 /
1 1 0.03 24
L
O
x
c
kg d
BOD insludge kg d
Y E S
P kg d
kd



+ +
Y = 0.04 0.1 mg VSS /mgBOD utilized
( )
3
3
0.35 0.8 16879 1.42 392.5 4531 /
m
ofmethane m d
kg

If methane volume is % 66 of digester gas:

3
1
4531 6865 /
0.66
Digestergasproduction m d
2) Gas production based on total volatile solids

3
0.50m
Gasproductionrate
kgTVSS

3
0.5 18820.4 0.71 6681.2 / Gasproduction m d
3) Gas production based on TVS reduction

3
0.9m
Gasproduction
kgTVSreduced
[13]

3
3
0.9
7046.5 6341.8 /
m
Gasproduction m d
kgTVSreduced

4) Gas production based on TVS reduction
45

3
0.032m
Gasproductionratepopulationbased
capita

3
0.032 250000 8000 / Gasproduction m d
Gas production volume = 6341.8 m
3
/d
Digester Heating Requirements
( )
2 1 R p
H flow C T T
C
p
= Specific heat of sludge = 4200 J / kg
o
C
T
2
= Digestion Temp = 35
o
C
T
1
= Sludge Temp = 12
o
C
( )
10
18820.4
4200 35 12 5.19 10 /
0.035
R
H J day
Heat Losses from digesters
( )
2 1 L
H U A T T
U = Heat transfer coefficent
A = Area in which heat losses occurs
T
2
= Digestion Operating Temp = 35
o
C
T
1
= Outside Temp
Roof Area:
2
Slantlength
RoofArea D
2 2
2
7.5 0.6 7.52
15 7.52
177.2
2
Slantlength m
RoofArea m

U = 0.90 J/sm
2 o
C
Heat losses from the cover & roofing
( )
8
0.90 177.2 35 0 86400 4.8 10 /
L
H J d
Area of Side Walls:
46
Assume 50 % below ground
exp
2
osedheight
Sidewallareaaboveground D
2
15 21.2
499
2
Area m


U = 0.68 J/sm
2 o
C
Heat losses from the side wall above the ground
( )
9
0.68 499 35 0 86400 1.03 10 /
L
H J d
Heat losses from the side wall below the ground
U = 0.80 J/sm
2 o
C
( )
9
0.80 499 35 0 86400 1.2 10 /
L
H J d
Roof Area:
2 2 2
1
15 7.5 2.5 186.3
2
BottomArea m +
U = 0.62 J/sm
2 o
C
Heat losses from the bottom cone
( )
8
0.62 186.3 35 5 86400 2.89 10 /
L
H J d
( )
8 8
2.89 4.8 10.3 12 10 30 10 /
L
TotalH J d + + +
% 20 minor losses
% 25 emergency conditions
8 10 6
30 10 2 1.45 6.06 10 / 2.56 10 /
L
H J d kJ hr
Selection of Heating Units Selection of Heating Units
External heat exchanger
Provide 2 units each rated 2.3 x 10
6
kJ/hr with natural gas
Digester gas for heating purposes, %65 of heating value of natural gas
Each unit will be derated =
6 6
2.3 10 0.65 1.49 10 / kJ hr
47
Total heat provided by 2 uints =
6 6
1.49 10 / 2 3 10 / kJ hr kJ hr
Extra available % =
6 6
6
3 10 / 2.5 10 /
%17
3 10 /
kJ hr kJ hr
kJ hr

Digester gas requirement

% 75 efficiency of heating units
6
3 3
2
3 10 /
164.6 / 3950.4 /
0.75 24300 /
kJ hr
Digestergasneeded m hr m d
kJ m

Produced gas = 6341.8 m

3
/d
6341.8 m
3
/d > 3950.4 m
3
/d
48
COST ANALYSIS COST ANALYSIS
UNIT UNIT COST COST
Construction 800,000 $
Excess Sludge Pumps 3 20,000$ 60,000$
Compressors (250 l / day) 2 50,000$ 100,000$
Mixers 4 50,000$ 200,000$
Diffusers (9) 340 200$ 68,000$
Sludge Blender 2 10,000$ 20,000$
Sludge feeding pumps 2 5,000$ 10,000$
Polyelectrolyte feeding
pumps
2 3,500$ 7,000$
PE ring pump 1 5,000$ 5,000$
Exit sludge pump 2 5,000$ 10,000$
Centrifuges 2 1,000,000$ 2,000,000$
Liquid PE feeding pump 1 10,000$ 10,000$
Mechanical Sludge
Thickener
1 1,000,000$ 1,000,000$
Primary Sedimentation 1 50,000$ 50,000$
Digester Tank 1 5,000,000$ 5,000,000$
Heat Exchanger 1 10,000$ 10,000$
Circulation Pump 1 10,000$ 10,000$
Compressor 1 50,000$ 50,000$
TOTAL COST
10,000,000$
49
50