Tube Stube Settlers
Tube Stube Settlers
Tube Stube Settlers
A pilot study for the application of one- and two-stage tube settlers as a
secondary clarifier for wastewater treatment
A. Faraji1, G. Asadollafardi2,*, A. Shevidi3
Received: June 2012, Revised: April 2013, Accepted:August 2013
Abstract
Secondary clarifiers with large areas are widely applied in wastewater treatment plants. A pilot study was conducted to
examine the possibility of applying one and two-stage inclined tube settlers instead of conventional secondary clarifiers. Tube
diameter in the first stage of the two-stage settler was wide as the conventional ones, but in the second stage, it was narrow to
improve the efficiency. The results indicated that in short detention times, the tube settler was more effective in shorter
detention time than the conventional secondary sedimentation basin, and its effluent of TSS and turbidity was acceptable to
discharge into the surface waters. The average removal of TSS, BOD5, and COD, in a 20-minute detention time in the tubes, in
the one-stage tube settler pilot plants was 97.6%, 96.4%, and 96.36%, respectively, while in the conventional secondary
sedimentation basin was 98.2%, 99%, and 98.6%, respectively. There was a good agreement between theoretical analyses and
experimental results of the pilot plant. Two-stage tube settlers in the series could improve hydraulic condition and removal
efficiency of TSS, in comparison with the one-stage tube settler. The average TSS removal, in shorter detention times than that
the one-stage, was 97.8%.
Keywords: Wastewater treatment, Sedimentation, Tube settlers, Solids and turbidity removal, Two-stage tube settler.
Q Q
Vo
NA d 2 (4)
N
4
International Journal of Civil Engineering, Vol. 11, No. 4, Transaction A: Civil Engineering, December 2013 273
(1980) [5], Oswald and Nurdogan (1996) [15], Jimenez tube settlers. The samples were collected in different
and Ramos (1997) [6], Saleh and Hamoda (1999) [7], operation periods. The effluent samples from the first and
Sarkar et al. (2007) [8], Navarro et al. (2008) [16], Jardin second stage were analyzed according to the procedures
et al. (2008) [17], and Silva et al. (2009) [18], showed outlined in "Standard Methods for the Examination of
advantages of the high-rate sedimentation in their works. Water and Wastewater" [19] to determine the following
parameters: MLSS of the aeration basin. For monitoring of
2. Materials and Methods turbidity and TSS of the wastewater of the pilot plant a
standard turbidimeter (HACH-2100P) and
2.1. Pilot Plants spectrophotometer (HACH DR-5000) were applied, and
subsequently the results were compared with the
One - and two-stage tube settler pilot plants were consequence of the EWTP’s secondary sedimentation
utilized concurrently. The main body of the settlers was basin effluent (number 2), simultaneously.
made of a polyvinyl chloride (PVC) with 20 cm in First of all, the possibility of the sedimentation in the
diameter and an angle of 45 degrees related to horizontal. two–stage tube settler was investigated by the using of the
The pilot plants were installed at the Ekbatan wastewater theoretical equations. The value of the average flow
treatment plant (EWTP), close to the aeration basin velocity (Eq. (4)) and the Reynolds number (Eq. (2)) were
number 2. The tubes diameter in the two-stage tube settler calculated for the first and second stage of the pilot plants
had an inner diameter of 5 and 1.2 centimeters in the first in the different detention times [11,20].
and second stages, respectively. Tube length was 60 cm in
both stages. A submersible pump was used to deliver the 2.2. Study Site
effluent from the activated sludge aeration basin to the
pilot plants. The effluent of the pilot plants and the settled The EWTP which is located in the west of the capital
sludge were returned to the inlet of the aeration basin. The of Iran, Tehran, is a 600 m3/h conventional activated
sketch of the experimental set-up is shown in Figure 3. sludge treatment plant with the A2O system. The EWTP
The samples were taken at the inlet and outlet of each has two aeration basins (15 hour detention times, 8930 m3
stage separately. volumes) and two circular secondary sedimentation basins
(36.6 diameters, 6-8 hour detention times). In design flow,
surface loading is 0.57 m/h and weir loading rate is 5.22
m3/m.h.
250 First Stage of Tube
Settler
Reynolds Number
200
Second Stage Of Tube
150 Settler
100
50
0
0 10 20 30 40 50
Hydraulic Residence Time in Tubes, (min)
Fig. 4 The relationship between the Reynolds number and hydraulic residence time, kinematic viscosity of water is 0.864×106 m2/s at 27°C [9]
1.2
1
Surface Loding Rate
First Stage of Tube
(m3/m2.hr)
0.8 Settler
Second Stage of Tube
0.6
Settler
0.4
0.2
0
0 10 20 30 40 50
Hydraulic Residence Time in Tubes, (min)
Fig. 5 The relationship between surface loading rate and hydraulic residence time
Table 1 The performance results of inclined tube settlers in the hydraulic residence time of 5 min in the tubes.
of BOD5
Percentage of BOD5
sedimentation basin
removal of the one-
stage unit
COD removal of
TSS removal of
TSS removal of
TSS removal of
turbidity of the
turbidity of the
turbidity of the
removal of the
two-stage unit
one-stage unit
belongs to the
sedimentation
sedimentation
sedimentation
Percentage of
Percentage of
of
TSS removal
basin (NTU)
effluent
the Ekbatan
the Ekbatan
stage unit
stage unit
Percentage
Ekbatan
Ekbatan
The(NTU)
(NTU)
MLSS
mg/l
b i
b i
Percentage
second
1260 96 48.6 97.9 96.9 --- --- --- --- --- --- ---
880 94.9 50 97.4 95.6 --- --- --- --- --- --- ---
1580 97 36.2 98.1 97.5 --- --- --- --- --- --- ---
660 93.8 22 95.2 98.5 --- --- --- 87.9 94 --- ---
1260 95.9 44.3 97.7 99.4 44 19 5 81.7 87 99.3 99.5
1060 96.4 52.6 98.3 99.6 28 9 4 92.9 93.3 98.6 97.7
1100 95.1 42.4 97.2 99.1 40.5 20 5 --- --- --- ---
Average 1114 95.6 42.3 97.4 98.1 37.5 16 4.7 87.5 91.4 99 98.6
International Journal of Civil Engineering, Vol. 11, No. 4, Transaction A: Civil Engineering, December 2013 275
276
Average
Average
Average
MLSS MLSS
660
880
MLSS
1114
1100
1060
1260
1580
1260
mg/l
660
880
1114
1100
1060
1260
1580
1260
660
880
mg/l
1100
3420
1060
1260
1580
1260
mg/l
1402.5
Percentage of TSS removal Percentage of TSS
Percentage of TSS
---
---
---
removal of the one-stage
96.4
96.7
97.5
96.9
93.9
97.6
95.5
96.9
96.5
96.8
97.5
95.5
96.3
of the one-stage unit
98
removal of the one-stage
97.6
99.3
97.9
98.3
96.1
97.8
95.7
97.3
unit
unit
Percentage of TSS removal
Percentage of TSS
Percentage of TSS belongs to the second stage
50
35
30
41
---
---
---
removal belongs to the
38.6
43.5
44.4
26.3
34.5
52.5
22.5
22.5
40.4
26
23
removal belongs to the unit
34.2
43.1
36.4
36.4
38.6
31.6
38.2
second stage unit
second stage unit
Percentage of TSS removal Percentage of TSS
---
---
---
98
97.8
98.1
98.6
98.5
96.1
98.2
96.8
98.2
97.7
98.5
96.5
97.8
97
97
removal of the two-stage unit
98.3
98.5
99.6
98.7
98.9
98.6
98.3
unit
Percentage of TSS removal Percentage of TSS
Percentage of TSS of the Ekbatan removal of the Ekbatan
98.1
99.1
99.6
99.4
98.5
97.5
95.6
96.9
98.1
99.1
99.6
99.4
98.5
97.5
95.6
96.9
98.2
99.1
99.7
99.6
99.4
98.5
97.5
95.6
96.9
sedimentation basin sedimentation basin
sedimentation basin
The effluent turbidity of The effluent turbidity of the The effluent turbidity of
---
---
---
---
---
---
18
18
---
---
---
---
18
15
17
---
---
---
---
11
11
18
16.7
13.2
12.8
the one-stage unit (NTU) one-stage unit (NTU) the one-stage unit (NTU)
The effluent turbidity of The effluent turbidity of the The effluent turbidity of
9
9
8
6
6
9
7
7
---
---
---
---
---
---
---
---
---
---
---
---
---
---
6.7
6.7
7.7
the two-stage unit (NTU) two-stage unit (NTU) the two-stage unit (NTU)
5
4
5
5
4
5
---
---
---
---
Ekbatan sedimentation
---
---
---
the Ekbatan sedimentation ---
5.1
6.5
4.7
5
4
5
---
---
---
---
---
---
---
---
---
---
---
---
---
95
96.4
97.4
97.7
94.2
95.5
96.4
95.2
of the one-stage unit of the one-stage unit Percentage of BOD5 removal
---
---
---
---
---
---
92.2
92.2
---
---
---
---
---
---
---
---
---
97
95
96.6
95.5
95.9
95.2
97.5
---
---
---
---
---
---
96.36
of the one-stage unit the one-stage unit
93.8
93.8
---
---
---
---
---
---
of the Ekbatan sedimentation
---
---
---
---
---
99
99
Table 2 The performance results of inclined tube settlers in the hydraulic residence time of 10 min in the tubes.
Table 4. The performance results of inclined tube settlers in the hydraulic residence time of 20 min in the tubes
of the Ekbatan sedimentation
---
---
---
---
---
99
98.6
99.5
98.6
99.3
---
---
---
---
---
---
removal of the Ekbatan of the Ekbatan
---
---
---
---
---
98.6
97.7
99.5
---
---
---
---
---
sedimentation basin
Percentage of COD
Percentage of TSS
Percentage of TSS
Percentage of TSS
Percentage of TSS
second stage unit
basin (NTU)
MLSS
basin
mg/l
unit
unit
1060 98.1 34 98.8 99.6 7 5.4 4 98.6 97.7 98.6 97.7
1100 98 24 98.5 99.1 10 7 5 --- --- --- ---
1540 98.6 30.2 99 99.4 10.7 7 5.8 --- --- --- ---
Average 1233 98.2 29.4 98.8 99.4 9.2 6.5 4.9 98.6 97.7 98.6 97.7
99
The Average TSS Removal
98.5
98
Efficiency, (%)
97.5
97
96.5 TSS of one‐stage
96
95.5
95
0 10 20 30 40 50
Hydraulic Residence Time in Tubes (min)
Fig. 6 The effect of HRT on efficiency of total suspended solid removal.
Figure 7 illustrates the relationship between the HRT in tend to be flattened out as HRT is increased. Therefore, it
the tubes and the average effluent turbidity. The Figure seems that HRT of 15 min in the tubes is adequate for
demonstrates that while HRT increases, the average settling in the two-stage tube settler pilot plant. The
effluent turbidity decreases, and the two-stage unit has average TSS removal efficiency of 20 minutes in the tubes
better effluent quality than the one-stage one in all cases. in the one-stage, of 15 minutes in the tubes in the two-
After 20 minutes in the tubes of the one-stage unit and stage and of the EWTP’s conventional sedimentation basin
after 15 minutes in the tubes of the two-stage unit, there is is 97.6%, 97.8%, and 98.2%, respectively.
no significant difference in the effluents, and the curves
40
The Avrage Effluent
one‐stage
30
Turbidity
(NTU)
20
10
0
0 10 20 30 40 50
Hydraulic Residence Time in Tubes (min)
Fig. 7 The relationship between hydraulic residence time and the average effluent turbidity
International Journal of Civil Engineering, Vol. 11, No. 4, Transaction A: Civil Engineering, December 2013 277
Figure 8 shows the relationship between the average the turbidity of wastewater. This result has a good
effluent turbidity and the Reynolds number. As shown in agreement with the results of Shevidi et al. (2011) on pilot
Figure 8, while the Reynolds number increases, the plant studies[ 9].
average effluent turbidity increases, and the two-stage tube
settler are more effective than the one-stage for removal of
50
The Average Effluent 40 8.963e0.012x =y
0.945 =R²
Turbidity 30
(NTU)
20 Effluent Turbidity Of
One‐Stage
10 5.092e0.020x = y
0.988= R²
0
0 50 100 150
Reynols Number
Fig. 8 The relationship between the average effluent turbidity and Reynolds number
The relationship between the average effluent turbidity average TSS removal efficiencies of 5, 15, and 20 minutes
and the Reynolds number for the one- and two-stage unit in the one-stage unit, which is clear that the removal
could be explained by Eqs. (8) and (9): efficiency increases as MLSS of the pilot plant increases.
Nonetheless, the effluent of TSS is increasing as a result of
The average effluent t urbidity of one - stage (NTU) 8 .963 e 0 .012 R (8) high MLSS. The reason for this could be due to a high
concentration of MLSS and influence of particles together
The average effluent turbidity of one - stage (NTU) 8.963e 0.012 R (9) (type 3 of sedimentation) and; hence, the removal
efficiencies have been increased.
Figure 9 shows the relationship between MLSS and the
100
TSS Removal, (%)
98
96
94
92
0 1000 … 2000 3000 4000
Fig. 9 The relationship between the percentage of TSS removal and MLSS
3.3.1. Evaluation of BOD and COD Removal Efficiencies relationship between the SLR and the percentage of BOD
removal, and the relationship between the SLR and the
The effluent BOD of the activated sludge process percentage of COD removal for the one-stage tube settler,
depends on the solids removal in the clarifier. Dick stated respectively.
that one mg/l of solids lost over the weir of the final
settling basin commonly increases the effluent BOD by
about 0.6 mg/l[23]. Figures 10 and 11 show the
150
BOD Removal, (%)
100
50 BOD removal (%) = ‐18.06 × (SLR) + 99.51
0
0 0.2 0.4 0.6 0.8
Surface Loding Rate, (m3/m2.hr)
Fig. 10 The relationship between the percentage of BOD removal and SLR
COD Removal, (%)
80
COD removal (%) = ‐10.26×(SLR) + 98.14
60
40
20
0
0 0.2 0.4 0.6 0.8
3 2
Surface Loding Rate, (m /m .hr)
Fig. 11 The relationship between the percentage of COD removal and SLR
In both figures, while SLR increases, the percentage of authors would like to thank TPWW for providing financial
BOD and COD removal decreases. The average BOD and assistance and logistical (equipment) support for this work.
COD removal percentages of 20 minutes in the tubes were
96.4% and 96.36%, and for the EWTP’s conventional 5. Notation
sedimentation basin (with HRT of 6-8 hour) were 99% and
98.6%, respectively. In all cases, experiments show that The following symbols and abbreviations are used in
BOD and COD removal efficiencies for the one-stage at a this paper:
detention time of 20 minutes in the tubes were in the A2O: Anaerobic, Anoxic, Aerobic system;
standard range for Iran for discharge to the surface waters BOD: Biochemical Oxygen Demand;
[24] [Department of Environment (DOE)]. The results of COD: Chemical Oxygen Demand;
this study, as illustrated in Figures 9 and 10, have a good HRT: Hydraulic Retention Time;
agreement with the consequences of Saleh and Hamoda MLSS: Mixed Liquor Suspended Solids;
(1999) on pilot plant studies in wastewater treatment[7]. SLR: Surface Loading Rate;
TSS: Total Suspended Solid;
4. Conclusion t: hydraulic residence time in tubes;
Vf: average flow velocity;
The results of the study indicate that the effluent of the Vs : particle settling velocity;
tube settler pilot plant, with HRT of 20 minutes in the A: cross-section area (perpendicular to the flow);
tubes, meets the Iranian standard of TSS and turbidity for AE: effective sedimentation area;
discharging to the surface waters. The average removal dh : hydraulic diameter of the channel;
efficiencies of TSS, BOD5, and COD, at 20 minutes in the L: length of the tubes;
tubes, in the one-stage pilot plant were 97.6%, 96.4%, and N: number of cells
96.36%, respectively, while the effluent of the secondary P: perimeter of channel;
conventional sedimentation basin of EWTP,s with HRT of Q: flow rate through the device;
6-8 hours, were 98.2%, 99%, and 98.6%, respectively. R: Reynolds number;
Theoretical analyses and experiments in the pilot study θ: angle of the tube relative to horizontal;
had a good agreement. The pilot plant study outcomes υ: cinematic viscosity
showed that the two-stage tube settler had better hydraulic
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