United States Environmental Protection Agency Research and Development ‘Municipal Environmental Research Laboratory Cincinnati, OH 45268 EPA-600/52-64-131 Sept. 1964 Project Summary Hydraulic Characteristics of Activated Sludge Secondary Clarifiers Jon Bender and Robert M. Crosby ‘The hydraulic characteristics of several common types of full-scale activated ‘sludge secondary clarifiers were evalu- made to ated. Attempts were then modify and improve repre ‘examples. The tanks ‘wore inferred by the use of dye tracer techniques. The modifications were evaluated on the basis of effluent quality. ‘The dominant hydraulic characteristic of all clarifiers studied was density flow. In most cases, the density flow had a significant effect on effluent suspended solids concentrations. When effluent ‘weirs were placed in the path of density flow, effluent quality was generally poor. Preventing density current forma- tion by inlet modification was not nearly ‘effective as interrupting flows at mid- radius and near the weirs Problems alto occurred with balancing flows between parallel clarifiers. Tho was improper application of ced liquor feed valves, poor splitter box design, and inadequate flow mea- ‘surement. in addition, strong evidence ‘oxists that flow transients are not at tenuated by upstream unit processes ind may significantly affect the solids ‘transport through clarifiers. This Project Summary was developed by EPA‘s Municipal Environmental Research Laboratory, Cincinnati. OH, to announce key findings of the research project that is fully documented in @ ‘separate report of the same title (s Project Report ordering information at back]. Introduction Theories of clarification and secondary clarifier design standards for wastewater treatment facilities assume that inlet and ‘outlet structures create certain patterns of flow or hydraulic characteristics within the clarifier. The major purpose of this project was to determine whether these hydraulic characteristics were actually created within several types of full-scale, activated sludge secondary clarifiers. If the anticipated hydraulic characteristics were not found, the clarifier inlets and/or outlets were to be modified, and the changes in hydraulic characteristics’ and improvements in effluent quality were to be measured. ‘The dye dispersion test has been used in the past to measure the hydraulic characteristics of clarifiers. This test may indicate whether a clarifier has hydraulic problems, but is useless for identifying their causes, Another purpose of this project was to evaluate a new dye tracer technique that allows visualization of the flow within full-size clarifiers. These goals seemed straightforward at the beginning of the project, but they had to be modified after simple relationships between inlet and outlet structures, hydraulic characteristics, and effluent performance were not found. The project then evolved into a more comprehensive evaluation of the factors believed to affect clarifier performance at eight different activated sludge secondary treatment facilities, Types of Clarifiers Studied Activated sludge wastewater treatment facilities use many different types of secondary clarifiers. This study did not attempt to identify all types or to ‘document their hydraulic behavior. Of the eight clarifiers studied, five different modifications were made on three tanks ore Basin an attempt to increase solids capture. It ‘was judged that some clarifiers included in the study could not benefit from the kinds of changes that were within the budgetary scope of this project. Table 1 lists the general types of clarifiers that were studied to some degree, Clarifier Analytical Procedures The dispersion of dye in a clarifier following the instantaneous release of a slug has been the most commontest used by clarifier analysis in the past. This study needed to show the movement of fluid from the clarifier inlet to the outlet and the distribution of solids that results from fluid motion. Since dispersion tests alone ‘could not accomplish this goal, other test procedures were developed. Several of these tests had not previously been used in clarifier analysis. Multi-point Dispersion Test The multi-point dispersion test is a variation of the usual point-of-discharge dispersion test. A slug of dye is released instantaneously upstream of the clarifier, as before, but the multi-point version measures dye concentration versus time at several weir locations. The new test was intended to reveal whether tank throughflow assumed some preferred directions or pathways. Flow Pattern/Solids Distribution Test The flow pattern/solids distribution test has two final results: 1) A visualization of the tank through- flow route 2) Ameasurement of the distribution of solids resulting from throughflow The test is conducted by continuously releasing dye upstream of the test clarifier, then “instantaneously” sampling 25 or more places in a radial or longitudi ‘nal section of the tank several times after the start of dye injection. After the samples have been analyzed for dye and suspended solids, data are contoured ot plotted as isolines of concentration of the two parameters. Flow patterns and the resulting solids distributions were both foundto be useful tools in deciding on hydraulic modifica: tions for the clarifiers. Table 1. Ctartior Type ‘Rectangular Center Feed - Peripheral Overfiow Peripheral Feed - Peripheral Overflow Types of Clartiers Studied Weir-Wall Solids Test ‘The weir-wall solids test measures the suspended solids concentration versus time near the effluent walls. Originally Intended to confirm a suspected wave of solids being moved around circular tanks by the rotating mechanisms, this test was helpful in identitying time-varying effects from other causes. Sludge Dispersion/Sludge Jet Test The sludge dispersion and sludge jet tests use 9 dye that readily adsorbs onto the solids flo particles, butisinsoluble in water. The route and timing of solids throughflow are thereby traced, The sludge dispersion test consists of ‘an instantaneous release of an emulsion of mixed liquor and Oil Red "0" dye and subsequent sampling in the sludge return to define the residence time ofthe sludge in various parts of the tank. The sludge jet test allows a visualiza- tion of the sludge flow route as it seeks the Blanket. This procedure was conduc ted only once during the study. Aninstan- taneous emulsion of Oil Red “O” and mixed liquor was released upstream of the clarifier. After a time defined by the sludge dispersion test, 30 samples were taken instantaneously at mid-radius of the circular tank in plane parallel tothe tank periphery near the sludge blanket. Lines of equal concentration of dye and suspended solids were then plotted. The two sludge tracer tests helped to confirm the existence of inlet jets that had been ‘only minimally dispersed by inlet baffing Typical Hydraulic Characteristics of the Clarifiers and Modifications Implemented The hydraulic characteristics of the clarifiers in this study were inferred from the results of alltests conducted. Firstthe clarifier's baseline hydraulic behavior was measured at one or more flow rates. These data were used to determine whether modifications could be made within the budget of the project. In the three plants to which clarifier modifica ns were made, subsequent hydraulic tests were followed by long-term evalua- Total Number Total Number ‘Studied ‘Moditod 2 7 5 2 1 o Tion of the effiuent quality of the modified unit compared with that of an unmodified parallel clarifier receiving the same flow and mixed liquor Rectangular Clarifiers This study evaluated two different rectangular secondary clarifiers. One is a relatively small, shallow unit, and the cther is longer and deeper. Characteri ties were very different in the two units. ‘The small rectangular clarifier was part of @ 4540 m°/day (1.2 mgd) activated sludge facility. The plant had two secondary clarifiers 19.3 m (65 ft) long and 4.9 m (16 ft) wide with a 2.7 m (9 ft) sidewater depth. Mixed liquor flowed from the eration basins to an open channel at the head of the clarifiers where it splits to the two tanks. Mixed liquor then enters each secondary clarifier through four square inlet ports at the surface. A chain and flight sludge scraper mechanism transports settled sludge to a sump at the inlet end of each clarifier Figure 1 shows a flow pattern that was measured in this clarifier before any modifications. Flow moves downward from the inlet to the sludge sump, then proceeds in a horizontal layer along the top of a sludge blanket. At the weir endof the tank, throughflow turns upward. This flow pattern entrained flow particles and carried excessive concentrations to the weirs. The clarifier was modified with a reaction baffle and several other flow- ‘modifying structures at the inlets. Figure 2 shows the final version of the baffle Figure 3 shows that the flow pattern in the clarifier following all inlet modifica tions resulted in very little improvement in flow pattern. Sludge sump scouring ‘was reduced, however. This change alone resulted in a 13.8% reduction in effluent total suspended solids (TSS). ‘At this plant, very large flow transients, ‘were induced at the point of secondary clarifier discharge by raw sewage lift stations in the city. As a second modifica tion, a stop-gate was placed in @ channel upstream of the aeration basins to reduce transient amplitude, This modification was tested on a 1-week-on, 1-week-off basis because it affectedthe performance of both clarifiers. As a result, the effluent quality of the newly baffled clarifier with the stop-gate in place was 31.5 % lower in effluent TSS than the unmodified clarifier without the stop-gate. The second, larger rectangular clarifier is 62.8 m (206 ft) long and 22.8 m (75 ft) Wide ‘with @ sidewater depth of 3.9 m (12.9 ft), Four inlet ports direct the mixedEffluent Weirs Reaction Battle Inlet Ports ‘Sludge Sump Figure 1. Original flow pattem for small rectanguler clarifier. Distribution of the dye ‘concentration Note: Vertical scale is exaggerated. liquor flow downward with the help of a deflection baffle. Longitudinal effluent weirs covering about half of the clarifier's surface area are located at the opposite fend of the basin. A traveling bridge with airlift pumps removes the sludge only dduring the part of the eycle in which the bridge is moving from the weir end to the inlet end of the tank. Figure 4 shows a flow pattern for this clarifier. The hydraulic characteristic is very different from the smaller tank described earlier, The narrow horizontal flow layer that existed in the inlet region changed to a more uniform flow at the ‘outlet. The flow distribution recommended by design standards appears tohave been achieved in this clarifier. Effluent TSS concentrations were typically 10 mg/Lor less This study did not determine the exact reasons for this clarfier’s exceptional hydraulic characteristic, Gas bubbles observed near the inlet have led to one theory. The solids distribution tests New Raction Battle Inet Po Figure 2. New reaction bates for smell rectangular clarifier. New Reoctign Battles Figure 3. Flow pattern after moditication of small reetengular clarifier with new reaction bates. Distribution of the dye concentration. Note: Vartial scale is exaggerated. indicated that the Waveling bridge piles sludge near the inlet without completely removing it. The sludge then turns septic. ‘and produces fine rising bubbles that appear to help distribute the throughflow Vertically. No modifications were attempted on this clarifier. Center-Feed, Peripheral Overflow, Circular Clarifiers Most activated sludge facilities in the United States use center-feed, peripheral overfiow, circular clarifiers. Five of these tanks were included in the study. Two modifications were made on one and a third modification was made on another Figure 5 shows the flow pattern ina 24- m-diameter (80 ft), 3.1-m-sidewater depth (10 ft) clarifier in @ pure oxygen activated sludge plant. A very thin, high: velocity layer of horizontal throughtiow rebounded off the peripheral wall, inducing excessive floc particles to approach the weirs. In addition, @ weir- wall solids test and a multi-point disper- sion test suggested excessive rotational ‘speed for the sludge removal mechanism. The first modification slowed the sludge riser pipe mechanism to 56% ofits Previous speed by means of a sprocket change. This modification reduced efflu ent TSS by 10.5%. After completing this modification on both secondary clarifiers, a cylindrical ring battle flocculation chamber was installed at mid-radius of the test tank Figure 6). The baffle extends ‘rom mid-depth to ust off the bottom and rotates with the mechanism, Figure 7 shows the considerable effect. of the baffle onthe claritier's flow pattern. After an extended test of comparative performance, effiuent TSS was found to be 37.5% lower in the newly baffled secondary clarifier. ‘A39.6-m-diameter (130 ft), 40-m- sidewater depth (13 ft) secondary clarifier in an air activated sludge facility received ‘another modification - a baffle placed just beneath the weirs at the periphery. Figure 8 shows the baffle. The post modification flow pattern appears. in Figure 9, As expected, the new battle decreased the tendency for density flow induced upflow at the periphery. Ina 52-day, side-by-side comparison of effluent TSS from the modified and unmodified parallel secondary clarifiers, the newly baffled tank showed effluent TSS that was 38.3% lower. Peripheral-Feed, Peripheral- Overflow, Circular Clarifier A peripheral-feed, peripheral-overtlow, circular clarifier was evaluated at 65%, 3Figure 4. Dettection Battie. Etugnt Weirs Flow pattorn forthe large rectangular clarifier. Distribution ofthe dye concentration. ‘Note: Vertical scale is exaggerated. Inlet Feed Welt Ertluant weirs Figure 5. Figure 6. Original tow pattern for » center-teed, peripheral-overflow, circular clair. Distribution of the dye concentration. Note: Vertical scale Is Ring Bottle/Flocculation Chamber moditcs overllow, cireuar clarifier. raggerated s peripheral- 100%, and 160% of design overflow rate. The secondary clarifier, in a pure oxygen activated sludge process, was one of 12 Identical units. The tank is 42.7 m (140) indiameter with a4.3-m(14-Mt)sidewater depth. Figure 10 shows a typical flow pattern with the clarifier operating ata design overflow rate of 26.48 m’/m* per day (650 gal/ft® per day). The initial flow pattern was similar to other clarifiers, with flow moving across the sludge blanket from the inlet region. In this type of clarifier, however, the flow converges at the centerrather than meet an obstacle ‘such as an end or peripheral wall. Later “snapshots” in the flow pattern time series confirmed that upflow was gradual ‘and relatively uniform over the surface area Other Factors Thought To Affect Clarifier Performance The investigators considered factors both within and upstream of secondary clarifiers—factors thought to affect the effluent quality of the tanks. Although the study did not subject their observations to rigorous proof, facility designers should at least consider them, Sludge Removal Mechanism Except for the small, rectangular ‘secondary clarifier discussed, all clarifiers included in this study had so-called hydraulic sludge removal mechanisms, All appeared to have some degree of problem in uniformly removing sludge. Reasons varied from plugging of individu- al riser pipes of orifices with sludge or debris to operator uncertainty about how to-adjust them, The rotational speed of mechanisms might be greater than needed to maintain sludge quality. At one facility, a 10.5% reduction in affluent TSS resulted from a reduction to 56% of design speed. Balancing of Flows Between Parallel Clarifiers—Inadequate Flow Control and Measurement Devices ‘Most municipal wastewater treatment plants have several identical clarifiers operating in parallel. Splitting the influent equally among the clarifiers should generally produce the best effluent, but this project found that achieving this balance of flows was usually difficult if not impossible at all flow rates, The inability to balance the flows was caused by inadequate flow control and a lack of flow measurement devices. GateRing Battle/Flocculation Chamber Flow pattern etter modification at 2 center-feed, peripheral-overtiow, circular Clarifier with » Ring Batle/Floceulation Chamber. Distribution ofthe dye concen: tration. Note: Vertical scale is exaggerated. Figure 7. me oe Peripheral Battle moditication to @ center Seed, peripheral-overfiow, circular clare. Figure 8. Inlet Feed Well Poriphorg! Bato. \entvene ‘ian Figure 9. Flow pattern atter modification of » conter-feed, peripheral-overtiow, circular Clarifier with Peripheral Battle. Distribution ofthe dye concentration. Note: Vertical ‘is exaggerated. valves or slide gates were the only means of flow control at some plants, These ‘satisfactory for stapping flow, ut they are inappropriate for control because their head loss characteristics are a nonlinear function of flow rate. Therefore, a flow split adjusted for one flow rate’ will change with flow. Such gates and valves also tend to collect debris when operated partially closed. ‘Some splitter boxes also complicate the problem. ‘The problem of splitting and balancing flows between parallel clarifiers is further exacerbated by a lack of flow measurement devices to confirm a balanced operation. Typically, underflow Is measured and mixed liquor feed and offiuent flow rates are not. Elaborate flow measurement devices are not necessary, but an operator should be able to determine flow rates without installation of special equipment. Flow Variation and Solids Transport The general perception is that activated sludge secondary clarifiers are not significantly affected by flow variation because tanks upstream of the second- aries will equalize the flow. This is true only in a very limited sense; flow transients undergo very little attenuation in a typical plant. A mathematical model developed for this project indicates that the amplitude and frequency of flow variations may greatly increase solids transport through the clarifier, thus increasing effluent TSS. Conclusions and Recommendations © None of the clarifiers evaluated in this project hadthe hydraulic charac- teristics called for in design standards for wastewater treatment plants. All of the clarifiers had some similar hydraulic characteristics, character- ized by a horizontal flow layer, prob- ably caused by density flow. Perform- ance suffered only in those clarifiers where the effluent weirs were placed in the path of the density currents ‘The sludge jet effect may intensify these density currents and their effect on performance. © Baffles at the inlets of rectangular clarifiers did not prevent the forma- ton of density currents. Breaking the density flows up after they had formed improved clarifier perform-Ettlyert Weirs Taph Peripheral wail Figure 10. Flow pattern for the peripheralteod, penpherat-overtiow, circular cleriir. Distnbution ofthe dye concentration Note: Vertical scale s exaggerated. © Clarifiers with effective control of density currents may be capable of producing acceptable effluents at higher hydraulic loading rates than those of conventional design, © Sludge blanket level affects clarifier hydraulic chactersstics. A moderate blanket level just below the bottom of the inlet baffling may be the worst condition, producing high levels of solids-transporting turbulence © Balancing of flows between parallet clarifiers 1s impossible without proper control devices and some form of flow measurement device on each clantier ‘© wastewater treatment plant design: ers and operators mustbe aware that conventional treatment process tankage does not greatly attenuate flow transients and that any flow variation induced in the system could significantly inerease solids trans- port in the activated sludge secondary clantiers © The flow pattern/solids distribution test 1s an effective technique for evaluating the hydraulic phenomena ‘occurring within full-seale, operating, activated sludge secondary clarifiers, The full report was submitted in fulfillment of Contract No. 68-03-2782 by Crosby. Young and Associates under the sponsorship of the US. Environment Protection Agency, sussapo:1984-759-102-10700 The EPA author, Jon Bender/also the EPA Project Officer, see below), is with the ‘Municipal Environmental Research Laboratory, Cincinnati, OH 45268; Robert 'M. Crosby is with Crosby, Young and Associates, Plano, TX 75074. The complete report. entitled “Hydraulic Characteristics of Activated Sludge ‘Secondary Clarifiers,” (Order No. PB 84-229 665; Cost: $23.50, subject to change! will be available onty from: ‘National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 Telephone: 703-487-4650 The EPA Project Officer can be contacted at: ‘Municipal Environmental Research Laboratory US. Environmental Protection Agency Cincinnati, OH 45268Center for Environmental Research Information Cincinnati OM 45268 Official Business Ponalty for Private Use 8300 T qT TON AGENCY REET