ChE 485 - Lectures 10-13 Unit Operations

ChE 485: Industrial Pollution Control
Unit Operations
Lecture 10 - 13
Unit Operations:
Physical Units of ETP
&
Chemical Dosing
Dr. Mohidus S. Khan 2016
Wastewater Treatment:
Physical Unit Operations
Unit Operations
Physical/Mechanical Unit Operations

1) Screening
2) Flow Equalization
3) Mixing/Reactors
4) Flocculator
5) Sedimentation: Primary and
High-rate Clarification
6) Oxygen Transfer/Aeration
Typical Physical Unit Operations Used For

Wastewater Treatment
Operation
Application
Device
Screening, Coarse
Removal of coarse solids such as sticks, rags,

and other debris in untreated wastewater by
interception (surface straining)
Bar rack
Screening, fine
Removal of small particles
Fine scree
Flow equalization
Temporary storage of flow to equalize flowrates Equalization tank

and mass loadings of BOD and suspended
solids
Mixing
Blending chemicals with wastewater and for

homogenizing and maintaining solids in
suspension
Rapid mixer
Flocculation
Promoting the aggregation of small particles

into larger particles to enhance their removal
by gravity sedimentation
Flocculator
Unit Operations
Typical Physical Unit Operations Contd

Operation
Application
Device
Sedimentation
Removal of settable solids.

Thickening of solids and biosolids.
Clarifier
Gravity thickener
Flotation
Removal of finely divided suspended solids and Dissolved-air flotation

particles with densities close to that of water
(DAF)
also thickens biosolids.
Aeration
Addition of Oxygen
Post-aeration of treated effluent
Removal of oil and grease
Diffused-air aeration
Mechanical aerator
Cascade aerator
Induced-air flotation
Membrane Filtration
Removal of suspended and colloidal solids, and Reverse osmosis and other
dissolved organic and inorganic matter
membrane systems
Air stripping
Removal of ammonia, hydrogen sulfide, and

other gases from wastewater and digester
supernatant
Packed tower
Location of Physical Unit Operations in a Wastewater Treatment

Plan Flow Diagram
Metcalf and Eddy, 2003

Unit Operations
Reactors
Definition Sketch:
a) batch reactor,
b) complete-mix reactor,
c) plug-flow open reactors,
d) plug-flow closed reactor
(tubular reactor)

Reactors Contd
e) complete-mix reactors in
series,
f) packed-bed reactor,
g) packed-bed upflow
reactors, and
h) expanded-bed upflow
reactors

Unit Operations
Principal Applications of Reactor Types used for

Screen Devices used in Wastewater Treatment
Metcalf and Eddy, Inc. Wastewater Engineering

Treatment and Reuse (Fourth Edition)
Unit Operations
Typical Mixers used in Wastewater Treatment
In-line static mixer with internal vanes
In-line static mixer with orifice for mixing

dilute chemicals
High-speed induction mixer
in-line mixer
in-line mixer with internal mixer
Pressurized water jet mixer with reactor

tube
Typical Mixers Cont`d
Over and under baffled reactor
Turbine mixer in baffled tank
Unit Operations
Primary Sedimentation
The objective of treatment by sedimentation is
to remove readily settleable solids and floating
material and thus reduce the suspended solids
content.
Primary sedimentation is used as a preliminary
step in the further processing of the
wastewater.
Efficiently designed and operated primary
sedimentation tanks should remove from 50 to
70 per cent of the suspended solids and from
25 to 40 per cent of BOD.
(water.me.vccs.edu)
(www.dmb-menawater.com)
Typical Circular Primary Sedimentation Tank
Centre Feed
Peripheral Feed
Unit Operations
Typical Design Information of Primary Sedimentation Tank

Typical Dimensional Data for Primary Sedimentation Tank

Unit Operations
Sedimentation Tank Performance

1) BOD and TSS Removal
2) Scouring Velocity
8 1
=

VH = horizontal velocity that will just produce scour, m/s

k = constant that depends on type of material being scoured = 0.05
s = specific gravity of particles = 1.25
g = acceleration due to gravity = 9.81 m/s2
d = diameter of particles = 100 m
f = Darcy-Weisbach friction factor = 0.025
Unit Operations
Sedimentation Tank Performance

Example 5-10
Example 5-10: Solution
10
Unit Operations
Example 5-10: Solution contd
11
Unit Operations
Inclined Plate and Tube Settling

Inclined plate and tube settlers are shallow settling
devices consisting of stacked offset trays or bundles of
small plastic tubes of various geometries.
Theory: Settling depends on the settling area rather
than detention time.
To be self-cleaning, plate or tube settlers are usually
set at an angle between 45 and 60 degree above the
horizontal.
Efficiency decreases for inclined angle more than 60
degree or less than 45 degree.
Nominal spacing between plates is 50mm (2 in), with
an inclined length of 1 to 2 m (3 to 6 ft).
Lamela Plate Settler
12
Unit Operations
Inclined Plate and Tube Settling Cont`d

a) Module of inclined tubes,
b) Tubes installed in a
rectangular sedimentation tank,
c) Operation,
d) Sketch for the analysis of
settling in tube settler

Inclined Plate and Tube Settling Cont`d
(www.brentwoodindustries.com)
13
Unit Operations
Aeration
Porous Air Diffusers
Aluminium Oxide Disk
Polyethylene Disk
Ceramic Dome
Perforated Membrane
Static Tube Mixer
Jet Aerator
Jet Reactor
Aspirating Aerator
14
Unit Operations
Low-speed Surface Aerator
High-speed Surface Aerator
Rotary Brush
Disk Aerator
Membrane Aeration
Panel

15
Unit Operations
Oxygen Transfer Efficiency
Oxygen Transfer Efficiency Contd
16
Unit Operations
Oxygen Transfer Efficiency
Video Clip 1:45 min; DISC DIFFUSERS SCM Tech
Video Clip 3:02 min; Aerostrip Ultra Fine Bubble Diffusers
Wastewater Treatment:
Chemical Unit Operations
17
Unit Operations
Key Chemical Unit Processes in

Chemical Neutralization
Chemical Coagulation
Chemical Oxidation
Electrochemical Coagulation
Chemical Precipitation
Ion Exchange
Nature of particles in Wastewater
Suspended Particles:are generally larger than 1.0m and can be

removed by gravity sedimentation.
Colloidal Particles:typically in the range from 0.01 to 1m, and

cannot be removed by sedimentation in a reasonable period of time.
Particle-Solvent Interactions:there are three general types of colloidal

particles in liquids: hydrophobic (water-hating), hydrophilic (waterloving), and association colloids (surface active agents: soaps, synthetic
detergents, and dyestuffs which form organized aggregates known as
micelles).
18
Unit Operations
Chemical Coagulation:
The Electrical Double Layer
Chemical Coagulation:chemical
destabilization of particles and in the
formation of larger particles through
perikinetic flocculation (aggregation
of particles in the size range from
0.01 to 1 m).
Coagulants:
19
Unit Operations
Coagulants: contd
Coagulants: contd
20
Unit Operations
Coagulants: contd
21
Unit Operations
Coagulants: contd
Short Training Course for Effluent Treatment Plant. Bangladesh PaCT. Dr. Mohidus S. Khan 2015
Case Study: Training for ETP Operator

A textile dyeing industry produces 75m3/hr wastewater, which contains 250 mg/L total suspended solids (TSS),
45mg/L total alkalinity (as CaCO3),
275mg/L BOD5 and
435mg/L COD.
During the treatment process, in absence of any chemical coagulant, the primary clarifier can remove 55
per-cent of TSS. Using chemical coagulants, TSS removal can be improved up to 85 per cent. Ferric
Chloride and Ferric Sulfate are two favourable options as chemical coagulants. Assume that the chemical
sludge properties (specific gravity and moisture content) are the same for any of the chemical coagulants.
For maximum TSS removal using chemical coagulation, ETP operator uses following dosing rates: 50kg
Ferric Chloride per 1000m3 wastewater or 55kg Ferric Sulfate per 1000m3 wastewater.
Estimate the mass and volume of sludge produced per day from wastewater with and without
chemical coagulants. Given that the specific gravity of raw sludge is 1.03 with moisture content 94
percent. For chemical sludge, the specific gravity is 1.06 and moisture content is 92.5 percent.
Also report if lime is required for chemical coagulation; if yes, calculate the amount of lime required.
Considering the sludge quantity and lime requirement, which chemical coagulant would be more
preferred for the given treatment process, and why?
22
Unit Operations
Case Study Contd

Fe2(SO4)3 +
(399.9)
3Ca(HCO3)2
(3100 as CaCO3)
2Fe(OH)3
(2106.9)
2FeCl3
+
(2162.2)
3Ca(HCO3)2
(3100 as CaCO3)
2Fe(OH)3 + 3CaCl2 + 6CO2

(2106.9)
With Lime,
Fe2(SO4)3 +
(399.9)
3Ca(OH)2
(356 as CaO)
2Fe(OH)3
(2106.9)
+ 3CaSO4
2FeCl3
+
(2162.2)
3Ca(OH)2
(356 as CaO)
2Fe(OH)3
(2106.9)
+ 3CaCl2
CaCO3
(100)
CaO
(56)
+ 3CaSO4 + 6CO2
+ CO2
End
23

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ChE 485: Industrial Pollution Control

Dr. Mohidus S. Khan 2016

Dr. Mohidus S. Khan 2016

ChE 485: Industrial Pollution Control

Physical/Mechanical Unit Operations

Typical Physical Unit Operations Used For

Removal of coarse solids such as sticks, rags,

Removal of small particles

Temporary storage of flow to equalize flowrates Equalization tank

Blending chemicals with wastewater and for

Promoting the aggregation of small particles

Dr. Mohidus S. Khan 2016

Dr. Mohidus S. Khan 2016

ChE 485: Industrial Pollution Control

Typical Physical Unit Operations Contd

Removal of settable solids.

Removal of finely divided suspended solids and Dissolved-air flotation

Removal of ammonia, hydrogen sulfide, and

Dr. Mohidus S. Khan 2016

Location of Physical Unit Operations in a Wastewater Treatment

Metcalf and Eddy, 2003

Dr. Mohidus S. Khan 2016

ChE 485: Industrial Pollution Control

Metcalf and Eddy, 2003

Metcalf and Eddy, 2003

Dr. Mohidus S. Khan 2016

ChE 485: Industrial Pollution Control

Principal Applications of Reactor Types used for

Dr. Mohidus S. Khan 2016

Screen Devices used in Wastewater Treatment

Metcalf and Eddy, Inc. Wastewater Engineering

Dr. Mohidus S. Khan 2016

ChE 485: Industrial Pollution Control

Typical Mixers used in Wastewater Treatment

In-line static mixer with internal vanes

In-line static mixer with orifice for mixing

in-line mixer with internal mixer

Pressurized water jet mixer with reactor

Typical Mixers Cont`d

Over and under baffled reactor

Turbine mixer in baffled tank

Dr. Mohidus S. Khan 2016

Dr. Mohidus S. Khan 2016

ChE 485: Industrial Pollution Control

Dr. Mohidus S. Khan 2016

Typical Circular Primary Sedimentation Tank

Dr. Mohidus S. Khan 2016

Dr. Mohidus S. Khan 2016

ChE 485: Industrial Pollution Control

Typical Design Information of Primary Sedimentation Tank

Metcalf and Eddy, Inc. Wastewater Engineering

Dr. Mohidus S. Khan 2016

Typical Dimensional Data for Primary Sedimentation Tank

Metcalf and Eddy, Inc. Wastewater Engineering

Dr. Mohidus S. Khan 2016

Dr. Mohidus S. Khan 2016

ChE 485: Industrial Pollution Control

Sedimentation Tank Performance

Dr. Mohidus S. Khan 2016

VH = horizontal velocity that will just produce scour, m/s