ENC - MBBR Noting
ENC - MBBR Noting
ENC - MBBR Noting
TI NO. 06/201
0 11
SEW
WAGE
E TRE
EATM
MENT
T PLA
ANTS
TECHNICAL INSTRUCTIONS
ON
SEWAGE TREATMENT PLANT
WORKS DIRECTORATE
ENGINEER-IN-CHIEF BRANCH
MILITARY ENGINEER SERVICES
INTEGRATED HQ OF MINISTRY OF DEFENCE
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CONTENTS
2. POLLUTANTS IN WASTEWATER 2
3. SEWAGE CHARACTERISTICS 2
4. DEGREE OF TREATMENT 4
1. OBJECTIVE
5 to 10 years. STPs are to be designed for average flow of wastewater per day.
Generally these are designed for present loads with possibility of augmentation for
future increase. Care should be taken to see that the plant is not considerably under
loaded In the initial stages.
3. POLLUTANTS IN WASTEWATER
The three chief categories of pollutants in wastewater are the dissolved and
suspended solids and the water-borne organisms. These are tabulated hereunder-
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5. DEGREE OF TREATMENT
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The sewage after treatment may be disposed either into a water body such as
lake, stream, river, or onto land. It may also be utilised for several purposes such as
agriculture, washing of vehicles, cooling systems, golf courses or boiler feed. If the
sewage effluent is to be discharged into inland surface waters, tolerance limits
prescribed by statutory agencies, IS: 4764 or as mentioned above, should be followed.
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7.2.1 Screening: This removes large floating, suspended and settleable solids.
7.2.2 Grit Removal: Removal of inorganic suspended solids.
7.2.4 Reactor: Any container in which the chemical or biological reactions occur can
be termed as a reactor. Reactors are basically classified as:
a) Batch Reactors
b) Continuous flow Tank Reactors (CSTR)
c) Plug Flow (PF)
d) Arbitrary Flow Reactors.
7.2.5 Biological Reactor: Biological reactors are reactors in which organic matter,
which serves as substrate or food to micro organisms, is utilized for the growth of
micro organisms. These processes are-
a) Aerobic Biological Suspended Growth Process: Conversion of colloidal,
dissolved and residual suspended organic matter into settleable biofloc and
stable inorganics.
b) Aerobic Biological Attached Growth Process: Conversion of colloidal,
dissolved and residual suspended organic matter into settleable biofloc and
stable inorganics.
c) Anaerobic Biological Growth Process: Conversion of organic matter into
CH4 & CO2 and organic relatively stable organic residue.
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8.1.1.2 Aerobic Attached Growth Processes (AGP) Under the AGP, two
proven and fairly known treatment processes are available as following:
a) Moving Bed Biological Reactor (MBBR) The Moving Bed Biological
Reactor may be known by different names as under, however the process remaining
same with free floating media of different shapes, sizes and materials (generally
plastic).
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8.1.2 Anaerobic Units These can be generally grouped into the following:-
a) Anaerobic ponds/ stabilization ponds
b) Upflow Anaerobic Sludge Blanket (UASB) reactor followed by lagoons
etc (Suitable for large capacity plants say 20 mld or above).
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Parameter Moving Bed Bio- Sequencing Batch Reactor Upflow Anaerobic Activated Sludge Rotating Biological
reactor (MBBR - (SBR) Sludge Blanket Process (ASP) - Contactors (RBCs)
FAB) Reactor (UASB) Extended aeration
Type of BOD reduction BOD reduction takes place This is strictly anaerobic BOD reduction takes This is an attached
Process takes place aerobically. Suspended growth process. BOD reduction place aerobically. growth process, much
aerobically. Fixed process. Improvised Activated takes place by converting Suspended growth similar to trickling filters.
film process. Sludge Process organic matter to methane process. The biomass is attached
/ carbon di-oxide and to rotating media.
other gases, through
bacterial systhesis.
Organic matter is The organic matter is brought in Pre-treated sewage is The organic matter is The media is in a form
brought in contact contact with bacteria in passed through a blanket brought in contact with of circular / octagonal
with bacteria suspension. Oxygen (bed) of sludge in an bacteria in suspension. discs, mounted on a
attached to plastic supplementation is normally done upwards direction. Upon Oxygen central shaft. The discs
media, which is in by surface aerators or diffused air contact with the organic supplementation is are submerged in a
suspension. Excess aeration. The biomass is matter, the bacteria normally done by 'VAT' (upto about 45%).
sludge is sloughed separated in same tank. The anaerobically convert the surface aerators or The discs slowly rotate,
off automatically, operation of the process is in two organics to methane and diffused air aeration. thereby submerging in
and separated in main phases & two intermediate other gases. The gas The biomass is the sewage for half the
the clarifier. No phases. The sewage is fed to the bubbles get released from separated in time and then in the air
sludge recycle is 1st compartment & mixed with the sludge bed and rise subsequent clarifier. for remaining time. The
required. activated sludge. After partial upwards. Gas - Solid and Settled biomass is "air time" induces
absorption of organic matter the Liquid separation is recycled to aeration oxygen, allowing
sewage is taken into 2nd achieved in a separator tank to maintain Mixed bacterial biomass to
compartment & continuously placed at the top of the Liquor suspended synthesize the organic
aerated for further absorption of reactor. Additional settling Solids of the desired matter, when the discs
organic matter. Finally the sewage devices may be provided level (usually between are submerged.
is taken into 3rd compartment for outside the reactor. 2,500 to 4,000 mg/l). Sloughing takes similar
sedimentation. The operation is to that in trickling filter
cyclic in nature. Excess sludge system.
has to be wasted form the last
compartment. In the next cycle the
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Parameter Moving Bed Bio- Sequencing Batch Reactor Upflow Anaerobic Activated Sludge Rotating Biological
reactor (MBBR - (SBR) Sludge Blanket Process (ASP) - Contactors (RBCs)
FAB) Reactor (UASB) Extended aeration
Process No sludge volume Need to maintain certain level of Upflow velocity plays a Need to maintain The disc speed must be
variables. index / recycle MLSS, sludge volume index like very crucial role in certain level of MLSS, precisely controlled,
need be checked. activated sludge process. MLSS performance. Also sludge volume index else process efficiency
System is self levels upto 5000 mg/l are possible. variation in inlet BOD / like SBR system. MLSS drops drastically.
sriaustaining. Higher levels hinder settling and COD affects performance. levels upto 5000 mg/l
Excess biomass results in poor performance. Sludge bed height and are possible. Higher
automatically gets sludge concentration are levels hinder settling
wasted off. MLSS very important variables. and results in poor
levels upto 12,000 performance.
mg/l are easily
achieved.
Sensitivity of Sensitivity is low, Moderately sensitive. UASB is also very Moderately sensitive to Highly sensitive to load
process owing to very high sensitive to low flow fluctuations, variations, hydraulic
bacterial temperatures, and organic loading rates loading and power
population. No performance drastically etc. failures.
sensitivity to reduces with lower
temperature. temperatures. Flow
fluctuations can disturn
the sludge blanket,
thereby affecting
performance.
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Parameter Moving Bed Bio- Sequencing Batch Reactor Upflow Anaerobic Activated Sludge Rotating Biological
reactor (MBBR - (SBR) Sludge Blanket Process (ASP) - Contactors (RBCs)
FAB) Reactor (UASB) Extended aeration
Area Very small area Area required is higher than Area required is larger Very large area Very large area is
requirements required as MBBR but less then ASP. than ASP and other required for aeration required since the
compared to SBR, processes. tank as well as for loading rates on the disc
ASP, UASB, RBC secondary clarifiers. are limited by the
surface area available.
Power Power requirement Power required is more than Power requirement is Large power is required Low power than ASP,
requirement is lower than MBR. MBBR or equal to activated sludge lower than most of the for aeration, return higher than UASB.
process. processes. However sludge pumping etc.
UASB alone cannot
produce desired outlet
quality. Additional ASP /
ponds must be provided,
thereby increasing the
power requirement.
Moving parts No moving part in Moving parts in biological process. No moving parts within Depending on the Main moving part is the
biological process. Decanter mechanism is UASB. However aeration system, there central shaft and drive,
mechanically activated and hence downstream ASP has can be moving parts which come under
needs continuous maintenance. typical maintenance such as surface continuous stress
Without decanter, SBR does not requirements. aerators, brush rotors
function at all. Very high level of etc, which need
instrumentation is required. maintenance.
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Parameter Moving Bed Bio- Sequencing Batch Reactor Upflow Anaerobic Activated Sludge Rotating Biological
reactor (MBBR - (SBR) Sludge Blanket Process (ASP) - Contactors (RBCs)
FAB) Reactor (UASB) Extended aeration
Operation & No scum formation The entire plant operation is cyclic Gas hoods need to be Relatively simpler Prone to lot of
Maintenance in the process & in nature & controlled by PLC cleaned every 06 months maintenance of maintenance of shaft /
less moving parts in only. The process requires very or so, to remove scum mechanical equipment drive parts. In few
the system. Hence high level of instrumentation & that accumulates at the such as aerators, cases, media discs
very low sequencing operation. The entire top surface. This is a blowers, pumps etc. have been seen to be
maintenance. instrumentation & control major operation, needing Because of shock buckled under biomass
Therefore the equipment are usually imported. to take the UASB out of loadings, filamentous weight, needing
manpower cost is The entire plant performance service. Maintenance of growth takes place and complete replacement.
low. All the depends on functioning of all the other related equipments makes the sludge
components of the instruments & sequence of in the downstream ASP is particles to float in
system are operation. Needs spares of all the also required. secondary clarifier.
indigenous & are imported instruments in stock for Once formed, it is
readily available. repairing / replacing so that the difficult to remove such
Media for FAB plant is in operation within a short growth, making
never needs period. Availability of spares needs operation more
replacement of to be checked. The decanter operator dependent.
cleaning. Media life mechanism is motorized and
of more than 25 hence high degree of maintenance
years can be is required. Spares must be
guaranteed. imported, Indian spares are not
suitable.
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Parameter Moving Bed Bio- Sequencing Batch Reactor Upflow Anaerobic Activated Sludge Rotating Biological
reactor (MBBR - (SBR) Sludge Blanket Process (ASP) - Contactors (RBCs)
FAB) Reactor (UASB) Extended aeration
Excess The excess sludge Excess sludge must be removed Excess sludge must be Excess sludge must be Not much control
sludge wasting is from with manual intervention. Any removed with manual removed with manual required, since sludge is
control secondary clarifier, higher withdrawal will result in intervention. Any higher intervention. Any higher not recycled back to
which is like any SBR operating at lower efficiency. withdrawal will result in withdrawal will result in aeration system.
other ASP system Hence control of process becomes UASB operating at lower ASP operating at lower Sloughing is automatic
and hence simple. very sensitive and instrument efficiency. efficiency. hence manual
No sludge recycle dependent. intervention is not
hence extent of required.
wastage does not
affect performance.
Power shut Prolonged power At power shut down, all the sludge The downstream ASP At power shut down, all Power failure causes
downs shutdowns does settles down and becomes septic process is severely the sludge settles down serious process
not affect within short span of time. Hence affected during power and becomes septic problems since top half
performance since quick restart is not possible. shut-downs. UASB itself within short span of of the disc remains in
after power cut-off, has little effect. time. Hence quick air, and becomes dry.
media floats at the restart is not possible. The submerged portion
top, keeping the remains in sewage and
micro-organisms, becomes septic, hence
alive quick restart is not
possible.
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Parameter Moving Bed Bio- Sequencing Batch Reactor Upflow Anaerobic Activated Sludge Rotating Biological
reactor (MBBR - (SBR) Sludge Blanket Process (ASP) - Contactors (RBCs)
FAB) Reactor (UASB) Extended aeration
Sludge Sludge is fully Sludge is active hence anaerobic Sludge is active and must Sludge is mostly Sludge is mostly
properties digested hence can (or aerobic) digester is a must, for be further digested digested and does not digested and does not
be dewatered complete destruction of biomass. aerobically. Because of need further treatment, need further treatment,
directly without any This increases plant cost and presence of SRB, sludge similar to MBBR similar to MBBR
further treatment operator attention. can smell very bad (rotten system. Dewatering is system. Dewatering is
egg smell). relatively easier. relatively easier.
Amount of Sludge age is very Sludge age is low hence sludge Excess sludge production Excess sludge Excess sludge
excess high, and hence production is about 0.3 – 0.6 kg / of UASB itself is low, production is low, since production is low, since
sludge sludge production kg BOD destroyed. Which means lower than most of the Mean Cell Residence Mean Cell Residence
is about 0.1 – 0.15 that the amount of excess sludge processes. However Time is high. Time is high.
kg / kg of BOD generated is about 200 to 400% downstream ASP sludge
destroyed, hence higher than MBBR. This calls for production is high.
very small amount large sludge handling system.
of excess sludge is
generated.
Expandability High. Higher loads Very low. Higher loads can not be Very low. Overloading is Low. Usually extended Low. Multiple modules
can be accepted accepted. However, Modular not possible. Parallel units aeration systems are need to be installed.
with extra media construction is possible. must be added to expand not suitable for Expansion within
filling. Modular capacity. expansion. Separate existing system is not
construction is parallel tanks and possible.
possible. clarifiers must be built,
which can be very
expensive.
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Parameter Moving Bed Bio- Sequencing Batch Reactor Upflow Anaerobic Activated Sludge Rotating Biological
reactor (MBBR - (SBR) Sludge Blanket Process (ASP) - Contactors (RBCs)
FAB) Reactor (UASB) Extended aeration
Usage of No further Treated effluent "as-such" can be Treated effluent "as-such" Treated effluent "as- Treated effluent "as-
treated treatment required used for low end purposes such as can not be used for even such" can not be used such" can not be used
effluent for gardening & construction, floor washing etc. low end purposes such as for even low end for even low end
horticulture. For gardening or higher end uses, construction, floor purposes such as purposes such as
chlorination and filtration are a washing etc. Secondary construction, floor construction, floor
must. treatment in form of ASP., washing etc. Tertiary washing etc. Tertiary
followed by tertiary treatment must be treatment must be
treatment must be provided even for low provided even for low
provided even for low end end uses. end uses.
uses.
Treated About 2 - 3 ppm About 10 - 15 ppm chlorine About 10 - 15 ppm About 15 - 20 ppm About 15 - 20 ppm
sewage dis- chlorine required to required to reduce "E-Coli" to less chlorine required to chlorine required to chlorine required to
infection : reduce "E-Coli" to than 1000 MPN / 100 ml. reduce "E-Coli" to less reduce "E-Coli" to less reduce "E-Coli" to less
Chlorine less than 1000 than 1000 MPN / 100 ml, than 1000 MPN / 100 than 1000 MPN / 100
demand MPN / 100 ml. provided there is an ASP ml. ml.
process succeeding
UASB system.
"SIZE-WISE" Suitable for any Suitable for any size, no limitation. Suitable for any size, no Suitable for any size, Suitable only for small
suitability of size, no limitation. Larger sizes demand much higher limitation. Larger sizes no limitation. Larger sizes. Larger sizes
the process space. demand much higher sizes demand much demand much higher
space. higher space. space, and also much
higher maintenance.
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4 Cost of O & M/Annum (Rs.Lakh/ MLD) 10-11 7.5 - 8.5 7.65 - 8.65
5 Quality of Sludge short life and needs to short life and needs to sludge can be stored for several
be disposed off early be disposed off early months in underground storage
tank
7 Additions
8 Fitness of Effluent for Irrigation 1 to 2 dilution water for 1 to 2 dilution water only totally fit without dilution
tolerant and semi for semi tolerant type of
tolerant crops crops
Criteria 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
1. WSP (Unlined) 2. WSP (Lined) 3. ASP BIOFOR 4. ASP 5. UASB+ 6. UASB+ ASP
7. TF (Plastic, High 8. TF (Gravel, 9. FAB 10. MBBR 11. SBR 12. SAFF
Rate) Slow Rate)
13. TF (Gravel, 14. ASP + C-F+ 15. UASB + FPU 16. FAL 17. MBR 18. BIOFOR
High Rate)
19. SBR+ C-F+
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1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 1
Resource Generation
Manure / Soil
C
Fuel
Electricity
G
Food
Impact of STP
Impacts on
Impacts fon
S
S
Energy
Land
Capital Cost
Recurring Cost
Reinvestment
C
Level of Skill
O&
1. WSP (Unlined) 2. WSP (Lined) 3. ASP BIOFOR 4. ASP 5. UASB+ 6. UASB+ ASP
7. TF (Plastic, High 8. TF (Gravel, Slow 9. FAB 10. MBBR 11. SBR 12. SAFF
Rate) Rate)
13. TF (Gravel, High 14. ASP + C-F+ 15. UASB + FPU 16. FAL 17. MBR 18. BIOFOR
Rate)
19. SBR+ C-F+
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8.9 Nitrification
Activated sludge plants are ordinarily designed for the removal of only
carbonaceous BOD. However, there may be incidental nitrification in the process.
Nitrification will consume part of the oxygen supplied to the system and reduce the DO
level in the aeration tank. Nitrification will also lead to subsequent denitrification.
8.10 Maintenance
Due consideration must be given in the design of aeration tanks to the need for
emptying them for maintenance and repair of the aeration equipment. Intermediate walls
should be designed for empty conditions on either side. The method of dewatering should
be considered in the design and provided for during construction.
Effluent parameter should be well within pollution norms laid down by Central
Pollution Control Board/ State Pollution Control Board, whichever is more stringent. In this
connection please refer our policy letters. This may also be referred on web site
www.cpcb.nic.in.
9.1 General
Tertiary treatment is supplementary to primary and secondary treatment for the
purpose of removing the residual organic and inorganic substances and in some cases for
even the refractory and dissolved substances to the degree necessary. Tertiary Treatment
of sewage is increasingly being adopted in India.
Re-use of treated wastewater should invariably be planned while selecting the
overall scheme. Reuse may be restricted to only non potable applications i.e. irrigation,
arboriculture, recreation lake, eco lake, gardening, golf-courses fire fighting, air
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conditioning, water in cooling systems, flushing, car wash or ground water recharge for
augmenting ground water resources.
The tertiary treatment may be considered only to the extent of quantity of water to
be reused and hence designed accordingly to achieve cost economy. All technologies
except Soil Bio-technology (SBT) require tertiary treatment before wastewater is reused. It
consists of filtration, adsorption and chlorination.
Tertiary treatment is quite use-specific and may involve only one item like simple
chlorination of treated sewage or several items depends on end use. It is, therefore, very
important that clear cut specifications of the reusable water are first obtained.
A tertiary treatment plant, therefore, generally, looks like a sewage treatment plant
followed by a typical industrial water treatment plant.
10.1 General
The effluent from sewage treatment plants may be discharged in receiving waters
such as lakes, streams, rivers, estuaries, oceans or on land. The nature and degree of
treatment given to the sewage depends upon the requirements imposed by the regulatory
authorities. It is necessary to adhere to the standards laid down by the Pollution Control
Boards with regard to the quality of the sewage to be discharged into a body of water,
inland or marine or on land for farming purposes or underground for purposes of recharge
aquifers.
transportation and treatment costs and the water quality standards and its end uses like
irrigation, arboriculture, recreation lake, eco lake, gardening, Golf-courses fire fighting, air
conditioning water in cooling systems, flushing and car wash, ground water recharge for
augmenting ground water resources. Some of these uses may need tertiary treatment as
discussed
11.1 General
Activated Sludge Process and Extended Aeration Systems give insignificant return
on capital investment. To overcome these limitations of currently practiced sewage
treatment technologies, researches have been carried out to develop alternative
technologies. Some of these emerging technologies include.
a) Duckweed· Pond Technology
b) Vermiculture Technology
c) Technology utilising raw sewage for forestry
d) Artificial wet Lands / Root Zone Technology
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Provision of STP is a specialist work and therefore, proper specification and makes
need to be given to ensure quality. In case any equipment/machinery is NOT
manufactured by plant supplier/OEM then the make/brand of same may be specifically
approved by Chief Engineer. The selected OEMs or their authorized firms should have
good track record along with certified confirmation that effluent pollution norms are being
fully satisfied by these STPs. These may also be independently ascertained. The firm
should fully operationalise the installed plant and be able to undertake operation and
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maintenance of STP with trained staff for a reasonable period of two to three years. In this
connection please refer our letters No.83519/Misc-38/E4(U3) dated 02 Apr 2007, 12 Jun
2008 and 29 Sep 2008. All the provisions of sewerage & sewage treatment manual/IS
codes and method of execution may be incorporated in the CAs.
It is further advised that once the technology for STP is approved, the consultant
should give construction drawings for complete sewerage system including STP. These
drawings should be vetted by IIT/Govt Engineering Colleges where Environmental
Engineering discipline exists at P.G. level. Based on these drawings the CEs can issue
the tender to enlisted contractors and No ‘T’ & ‘Q’ bid will be required. This will generate
better and healthy competition.
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15. CONCLUSION
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APPENDIX· 'A'
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APPENDIX ‘B’
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APPENDIX ‘C’
Following policy letters/guidelines have been issued for design of sewerage system
and STPs. These can be made part of job order/Tender for obtaining consultancy for
preparation of sewage related schemes:-
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APPENDIX ‘D’
SOIL PERCOLATION TEST
1. Percolation tests shall be carried out to design a suitable soil absorption system for
disposal of effluent from septic tanks, in the following manner-.
2. Six or more test holes shall be made spaced uniformly over the proposed
absorption field.
3. A square or circular hole with side width or diameter of 10 cm to 30 cm and vertical
sides shall be dug or bored to the depth of the proposed absorption trench. The
bottom and sides of the holes shall be carefully scratched with a sharp-pointed
instrument to remove any smeared soil surfaces and to provide a natural soil
interface into which water may percolate. The holes shall be filled for a depth of 5
cm with loose material to protect the bottom from scouring and settling.
4. Before the actual readings for percolation tests are taken, it is necessary to ensure
that the soil is given ample opportunity to swell and approach the condition it will be
in during the wettest season of the year. This is done by pouring water in the hole
upto a minimum depth of 30 cm over the gravel and be allowed to soak tor 24
hours. If water remains in the test hole after the overnight swelling period, the depth
of water shall be adjusted to 15 cm over the gravel. Then from a fixed reference
point, the drop in water level shall be noted over a 30 minute period. This drop shall
be used to calculate the percolation rate.
5. If no water remains in the hole at the end of 30 minutes period, water shall be
added to bring the depth of the water in the hole to 15 cm over the gravel. From a
fixed reference point, the drop in water level shall be measured at 30 min. intervals
for 4 hours, refilling to 15 cm level over the gravel as necessary. The drop that
occurs during the final 30 minutes period shall be used to calculate the percolation
rate. The drop during the earlier periods provides information for the possible
modification of the procedure to suit local circumstances.
6. In sandy soils or other porous soils in which the first 15 cm of water seeps away in
less than 30 minutes after overnight swelling period, the time interval between
measurements shall be taken as 10 minutes and the test run for one hour. The drop
that occurs in the final 10 minutes shall be used to calculate the percolation rate,
7. Based on the final drop, the percolation rate, which is the time in minutes required
for water to fall 15cm, shall be calculated.
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