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TNRCC LIBRARY 628.54 881S C.1 Design report for a waste disposal syste 3 6238 00016 7746 DESIGN REPORT FOR A WASTE DISPOSAL SYSTEM FOR SOUTHLAND PAPER MILLS, INC. LUFKIN, TEXAS LIBRARY TEXAS WATER DEVELOPMENT BOARD AUSTIN, TEXAS J3R0WN & ROOT, INC. Engineers and Consultants PREFACE This report is intended to characterize clearly the waste of the Lufkin mill and determine the most economical treatment to hring the effluent within what the State of Texas might require for effluent standards. The design is based on the treatment producing a 20 ppm B.O.D. or less, and 20 ppm Suspended Solids, or less, effluent. This report must be considered in the light of its two prime limi tations which are (l) there is no provision for color removal except that color removal could be accomplished in the primary clarifier with a very heavy chemical dosage that would not be economical for full time opera tion and (2) the facilities as designed do not provide for fiber removals over about 50 ppm in the primary clarifier. If the fibers are not recovered ahead of the primary clarifier, the excess fibers will cause problems throughout the plant which will re sult in a very poor effluent. The tests results show that the mill effluent contains fibers in amounts varying from 170 to 550 ppm. This represents fiber losses from the mill of 1^.16 tons to L5.82 tons per day. The average during the test period from February 6 thru February l6, 1965, was 25*72 tons per day. Thc-;c fibers seriously interfere with the primary clarification process, make the biological process virtually uncontrollable, and prevent the effluent from the aeration units from settling in the final clarifier and conse quently degrading the effluent. With these limitations we believe this report represents a thorough analysis of the mill wastes, a proven process for treatment, and equipment to accomplish the process most economically. SECTION I SUMMARY This engineering report represents a great deal of detailed study for waste treatment facilities for Southland Paper Mill's Lufkin, Texas plant. The process recommended for the treatment of this waste is clarification followed by biological oxidation. This method of treatment is recommended as a result of extensive research by agencies cited in this report. The recommended process flow for treating the Southland mill waste is (a) primary clarification to remove, as far as possible, all suspended materials, (b) aeration for biological oxidation and (c) final clarification. Settled sludge for final clarification will be returned to the aeration stage for complete mixing with the incoming raw waste. Waste activated sludge will be thickened and combined with sludge from primary clarification for disposal. Primary clarification will be accomplished with a combined reactorclarifier -unit. Aluminum sulfate and. activated silica will be added at this stage to aid flocculation. Aeration, for biological oxidation, will be done by mechanical, turbinetype surface entrainment aerators in large open aeration basins. Nutrients in the form, of liquid ammonia and phosphoric acid will be added in the aeration basins to promote biological oxidation. Special final clarification equipment must be used in the final clarifier. That is, a vacuum type sweep for rapid sludge return. Return activated sludge will he removed by three non=clog centrifugal pumps. Excess activated sludge, and sludge from the primary clarifiers will be gravitied to a sludge thickener before being wasted in existing oxidation ponds. All flow through the plant other than return activated sludge will be by gravity. Total project cost will be about $1,987,000. A summary of this project cost is as follows: Site Preparation Entrance Structures Influent Flow Divider Primary Clarification Chemical Feed Wells Aeration Basins Final Clarification Sludge Thickener Sludge Return Chemical Storage Chemical Feed Building Yard Piping Effluent Pipeline .10$ Contingencies Overhead & Indirect Profit Total Construction Engineering @ 5$ TOTAL PROJECT $208,000.00 .2.325.00 1 760.00 168.400.00 2,900.00 367,000.00 184.000.00 31.400.00 27,000.00 43.500.00 60,000.00 80.300.00 185.000.00 $1,361,585.00 136.415.00 222.000.00 172,000.00 $1,892,000.00 95,000.00 $1,987,000.00 It is recommended, that sludge disposal be accomplished by wasting to the existing oxidation ponds only until the necessary tests can be made to deter mine the dewaterability and fuel value of the thickened sludge. It is then recommended that disposal be handled by incineration. The incinerator will cost approximately $300,000 installed. SECTION II INTRODUCTION The Lufkin, Texas min operations of Southland Paper Mills, Inc. consists of kraft and groundwood facilities. At the present time (1965), the mill produces 20 million gallons per day (MGD) of total mill effluent which includes rejects, miscellaneous storm and sanitary sewers and wastes from aii components of the mill. The mill effluent is treated for fiber recovery by a Sveen-Peterson flotation unit and then discharged to a series of lagoons for the settling or retention of non-recoverable fibers and possible reduction of biochemi cal oxygen demand (BOD) through stabilization. The effluent is eventually discharged to the Angelina River. The discharged effluent is high in BOD and has the dark color characteristic of kraft mill waste. Table II-l shows the flow contributions of the various plant components, together with the contributed BOD. TABLE XI-1 BIOCHEMICAL OXYGEN DEMAND BALANCE (Furnished by Southland Paper Mills, Inc.) Stream Volume mn B0D5 lbs/day Rejects Machine Sewer 0.3 2.0 1,250 Groundwood White Wate: Pulp Mill Bleach Plant 575 4.5 3.6 5,750 6,4oo 3,000 Evaporator Condensate 0.6 2,500 Miscellaneous Sewers TOTAL 00 nn -- 18,900 MOWN *11? The raw mill waste contains approximately 46,000 lbs/day of suspended solids, and it is estimated that approximately 36,000 Ibs/day are removed in the lagoons, so that the effluent discharged to the river contains about 10,000 lbs/day. It is proposed to construct waste treatment facilities that will produce an effluent containing not more than 20 ppm of BOD (3,300 lbs/day) and 20 ppm of suspended solids (3,30 lbs/day). No color removal is to be provided. This report contains the results of research, process and design investigations carried out in order to determine the recommended treatment plant layout end component sizes. Section I is a summary of the report and findings and Section II is the introduction, in which a recapitulation of existing conditions is made. Section III presents the process analysis and design, together with a discussion of the recommended process. Section IV presents a detailed engineering design of the treatment plant. Section V is a detailed cost estimate of the recommended layout. Section VI is a bibliography noting ail references cited in the report. Section VII is the appendix which contains an investigation of incineration processes and an investigation of possible conversion of the existing activated sludge treatment unit into a chemical pretreatment plant. A SECTION III PROCESS DESIGN RESEARCH The Lufkin mill of Southland Paper Mills, Inc., is a fully- integrated operation and the waste includes streams from ground- wood, pulping, "bleaching and paper making operations plus the 1,2 miscellaneous equipment and processes. Research has "been accomplished and an analysis of four waste streams and the total effluent indicated that all waste streams were amenable to biological treatment. Although the waste treatment criteria are established in terms of BOD removal, the research and design criteria for indus trial waste treatment at the Lufkin mill have been established in terms 3 of the total biological oxygen demand (TbOD) . TfcOD provides a more reliable, absolute and more easily deter mined measure of the biochemically available soluble organics in the waste streams. The T^OD test measures the degradable organic content by the change in chemical oxygen demand (COD) before and after aeration in the presence of an acclimated culture cf microbial organisms (acti vated sludge). The measured T^OD is approximately 1.5 times the BOD of a given sample. Laboratory analysis of the mill waste showed the T^OD for the total effluent to be 38,300 Ibs/day, or 230 ppm. Ninety percent of the total T^OD is furnished by effluent from the grcrordvood mill, the pulp mill, the bleach plant and the evaporator condensate. On January 29, 19^2, a seven day composite sample of total mill effluent was analyzed by Curtis Laboratories, analytical.and consulting chemists, to determine the chemical constituents of the waste. The results of this analysis are shown on Table 111=1. TABLE IIX-l RESULTS OF ANALYSIS (Furnished by Curtis Laboratories) Milligrams per Liter Total Alkalinity as CaCO^ 152 Chlorides as NaCL 412 Sulphates as NagSO^ 154 Chemical Oxygen Demand BOD 71 225 pH 7 4 Analysis of these results and the comments of A. W, Busch indi cates that there are two characteristics cf the vaste that deserve special emphasis. 1. The waste is essentially devoid of the primary nutrients, nitrogen and phosphorus and will require supplementary feeding. 2. There is a critical concentration of the waste which is toxic to the micro-organisms used in biological treatment, and the process design must give cognizance to this fact. Examination and study of the research results leads to the follow ing conclusions concerning the process design: 1. Pretreatment will be Required for Solids Removal. Based on data furnished by Southland, approximately 10,000 lbs/day cf suspended solids are being discharged in the final effluent to the Angelina River. In the raw effluent (after treatment in the Sveen-Peterscn flotation unit), there are approximately 46,000 mown.mt lbs/day of suspended solids. Effective biological treatment is extremely difficult when the waste introduces 5 tons of solids per day to the pro cess, and is certainly so when 23 tons per day are introduced. The exis ting ponds or lagoons are heavily loaded and clogged with fiber, and their efficiency can be seriously questioned. It is apparent, therefore, that some sort of pretreatment will be required in order to remove these suspended solids before biological treatment begins. The suspended solids are nearly all tiny cellulose fibers which have no nutrient value and which can damage seriously any aerobic process. 2. Biological Treatment is most Desirable. The waste is'readily de graded by biological processes. A biological treatment process should be used so that maintenance problems will be reduced and excessive chemical costs avoided. 3* The Process roast be Relatively Insensitive to Shocks. The toxicity of certain contributors to the waste requires that the treatment process he able to absorb relatively mild shock loads without upsetting the micro bial culture. 4. Nutrients must he Added. The primary nutrients, nitrogen and phosphorous, must he added to the waste in order to develop a satisfactory microbial culture. The recommended nitrogen source is anhydrous ammonia (NH3) and the recommended phosphorous source is phosphoric acid (H3FO4.) RECOMMENDED PROCESS There are several possible methods of treating wastes biologically. The most common are the use cf trickling filters, oxidation ponds (lagoons) or variations of the activated sludge process. The trickling filter is not recommended because cf its extreme sensitivity to toxic material and shocks, and because of the highly empirical and relatively .uncertain ION lit' nature of its design and operation. Oxidation ponds are not recommended because of the space requirements and because the process kinetics of oxidation ponds are not suited to the particular situation in question. Activated sludge is the general name given to the process whereby sewage is aerated with an admixture of previously aerated sludge. The sludge, which is light and flocculent, serves as a vehicle for aerobic bacteria. The bacteria oxidize' the organic matter both in solution and suspension and the sludge, as it moves rapidly through the sewage, -5 absorbs suspended and colloidal matter . Aeration may be provided by either forced air or mechanical aerators. It is recommended that mechanical aeration be used. An inherent disadvantage to forced-air is the possibility of clogged diffusers, since the diffusers are always submerged. Although manufacturers advertise "non-clog" diffusers they do, nevertheless, clog. When this happens, they must be removed from the sewage and cleaned, resulting in an inter ruption in the treatment process. Mechanical aerators, on the other hand, are much more easily maintained and there is no possibility of clogging. In most sewage treatment processes the problem of sludge digestion is solved by the use of anaerobic digesters. These are large, covered tanks where the sludge is drawn and held in order to be digested by anaerobic bacteria. This method of sludge digestion produces problems of gas generation and disposal, corrosion, maintenance and other nuisances that render its usefulness subject to serious question. Sludge digestion using aerobic bacteria has the advantages of eliminating many corrosion problems, producing no obnoxious gases and producing a more stable sludge for disposal. It is recommended that all phases of the LIBRARY TEXAS WATER DEVELOPMENT BOARD AUSTIN, TEXAS Southland waste treatment plant be aerobic. The completely-mixed activated sludge process satisfied all of the conditions outlined above and is the recommended treatment process. Com pletely-mixed activated sludge is the process vhereby the untreated wastes are instantaneously mixed throughout the entire aeration tank. In effect, the organic load on the aeration tank is uniform from one end to the other and produces a uniform oxygen demand and a uniform biological growth. This is the ideal case, of course, which is rarely equalled in the field. The process kinetics are such that these conditions can be closely approximated, however, in several ways. Analysis of the mathematics of 6 the system and of the fundamental biochemistry have shown that the aeration tank actually behaves as a surge tank, enabling the system to absorb shock loads and certain toxic loads without upsetting the process. Moreover, in the completely-mixed system, control of the mixed liquor suspended solids ratio (MLSS) in the aeration tank will determine time required to stabilize and treat the waste. This makes it possible to combine waste treatment and sludge digestion in a single basin in a 7 completely aerobic process. McKinney has given an excellent description of the microbiology that accomplishes this. The recommended process flow pattern for treating the Southland mill waste is (a) primary clarification to remove, as far as is possible, all suspended materials, (b) aeration for biological oxidation and (c) final clarification. Settled sludge from final clarification will be returned to the aeration stage for complete mixing with the incoming raw waste. Waste activated sludge will be thickened and combined with the sludge from primary clarification for disposal. Sludge disposal will be either by incineration or lagooning. Figure I shows the process flow diagram. The (Own tiki final, treated effluent vill "be conveyed for eventual discharge into the Angelina River. IROCESS DESIGN jBusch has made the recommendations in Table III-2, based on data obtained in the cited research. TABLE III-2 RECOMMENDED DESIGN CRITERIA Flow: TfcOD (Removable COD): Effluent quality: Mixed liquor suspended solids (M.L.S.S.) required: Aeration Volume Recommended: M.L.S.S. concentration: Clarification area: Solids produced (excess): Oxygen required: Nitrogen requirement: Phosphorus requirement: 20 million gallons per day 42)500 lbs/day 20 mg/1 B0D5 35 mg/l Tb0D - 20 mg/l suspended solids 24.500 lbs 2.5 MG 1,200 mg/l 33,333 ft2 (6oo gpd/ft2) 7,340 lbs/day 26.500 lbs/day 1.500 lbs N.; 1,800 lbs NH,/day 300 lbs Pj 950 lbs H^POij/day Busch further recommends that the aeration volume be divided into at least two units. This will give the plant a desired degree of operational flexibility. A thickener will be provided to concentrate excess solids. The TbOD remaining in a 35 ppm effluent is: 35 ppm x 20 MGD x 8.345 lbs/MS - 5,84l lbs/day. Therefore, the T^OD removal required to produce a 35 ppm effluent is (42,500 - 5,841.5) lbs/day - 36,658.5 lbs/day. Consequently, the minimum plant efficiency must be = 0.8625 = 86.25 percent. A 35 ppm T^OD is roughly equal to a 20 ppm BOD^, since BOD5 "2/3 T^OD. To complete the process design, a detention time of 3 hours will be used in the design of the aeration basins and a surface loading of 600 gallons per square foot per day will be used in the design of final clarification. Jk SECTION IV FACILITIES DESIGN PRIMARY CLARIFICATION Primary clarification, to remove the load of suspended solids from the raw waste, is required. Fiber recovery prior to the facilities shown in this report must he effected so that not more than 50 ppm of fibers enter into the primary clarifier. Tests show that the final effluent from the existing mill contains 170 to 550 PPm of fibers. This is an average of 25*72 tons of fiber per day in the waste effluent. If allowed to enter the waste treatment plant, these fibers would seriously interfere with the primary clarification process, making the biological process virtually uncontrollable and making biological solids removal very inefficient. These solids are, for the most part, tiny cellulose fibers, much like soda straws, which contain air that is trapped and held by surface tension. These particles are very light and are not readily settleable, so that chemical coagulation and sedimentation must be provided. The most obvious and probably the easiest method of doing this is to use a combined reactor-clarifier unit. It is proposed to add aluminum sulfate (alum), in the reactor-clarifier as a flocculating agent. Because of the lightness of the suspended solids, it will be necessary to add a flocculating aid. Activated silica will be used for this purpose. Alum will be fed as aluminum sulfate solution by chemical, feed units. Chlorine activated silica will be added from a Fischer and Porter chlorine activated silica feeder. The location of the chemical feed equipment, in the chemical feed will be fed to the waste through a chemical feed well. The two feed wells are located between the primary clarifiers and the aeration basins. The liquid ammonia, and phosphoric acid will be stored in two poxyglas tanks next to the alum and silica tanks, gravitied to the chemical feed building and pumped from the chemical building by two small solution pumps. Aqueous ammonia will be purchased in tank car lots with a maximum concentration of 29-4$ ammonia by weight. The amount of ammonia fed will be controlled by a Fischer and Porter recorder and controller. This device both controls and indicates. Phosphoric acid feed will be controlled with a device similar to that used for alum feed. The amount of phosphoric acid fed will be recorded on a continuous strip chart indicator and totalizer. Another design criteria to be met in aeration basin sizing, is to assure that the aeration volume is.adequate to meet the requirements of the Mixed Liquor Suspended Solids (MLSS) ratio. Busch states in his recom mended process design that 24,500 lbs/day of MLSS are required for oxida tion. Based on an MLSS concentration of 1,200 mg/l the aeration volume required is: 24,500 lbs/day x 1 1200 ppm 8.345 lbs/day = This requirement is less than the 2.5 MG available. 2.45 MG The Engineers propose to design the two aeration cells from earthen levees, and to pave the levee slopes with concrete. SURFACE AERATOR DESIGN To supply the oxygen requirement for biological degradation, the Engineers will install mechanical, turbine-type surface entrainment aerators in the aeration basins. MOWNtHl From the information obtained from technical publications, it has been- indicated that the horsepower necessary for the mixing process in the aeration basin is one horsepower per 1000 cubic feet cr basin. As previously shown, each cell will have a volume of 167,100 cubic feet. Based on this criteria, approximately 167 horsepower is necessary for each basin. As recommended by Busch, the oxygen uptake required to satisfy the total demand is 26,500 lbs/day. Assuming that two pounds of oxygen per horse power per hour can be supplied by the mixers, a total requirement of: 26,500 lbs/day = 550 hp 2 lbs/hp/hr x 24 hrs is necessary for mixing. Because of the size range of these aerators, eight seventy-five horsepower mixers will be required. Turbine-type aerators, similar to the units manufactured by either the Infilco Co. or the Yeomans Co. are quite adequate to supply oxygen requirements. FINAL CLARIFIER DESIGN In the design criteria, a surface loading of 600 gallons per square foot per day was proposed for the final clarifier. Then, the necessary clarifier surface area is: 20,000,000 gal/day - 33,400 sq ft. 600 gals/ft2/day If final clarification surface area is divided into two units, the area per unit is 16,700 sq ft. The diameter of each clarifier is Tld2 = 16,700 sq ft, then "Ild^ = 66,800 sq ft or d2 = 21,250 sq ft or d = 1^5 ft. Using a 145 foot diameter clarifier unit with a .10 foot side liquor depth gives a clarifier volume of: TTx (145 ft)2 x 10 ft = 165,500 cu ft. Based on a flow of 20 MGD, a detention time of 2.95 hours would be allowed by the final clarifier. Therefore, it is recommended by the Engineers that a final clarifier having a tank diameter of 1^5 feet and a side liquor depth of 10 feet be uti lized for final clarification. It is also recommended that mechanical clarifier equipment similar to the Rex Unitube Tow-Bro Sludge Remover as manufactured by the Chain Belt Co. be used. The installation of this equip ment in a final clarifier tank is shown by Figure V. As with the primary clarifier and aeration basin, it is proposed to construct the final clarifier basin from earthen embankments with sides and bottom paved with concrete. SIZING OF SLUDGE TRANSFER PUMPS Sludge transfer from each final clarifier to each aeration basin is equal to Q/4 3500 gpm. Pumping arrangement and capacity must be provided so that each clarifier will be provided with at least one standby pump avail able. To meet this requirement, three pumps with a capacity of 3500 gpm each will be required. To transfer this sludge, it is recommended that non-clog centrifugal pumps be used. SLUDGE THICKENER DESIGN The sludge thickener will be designed on the basis of a surface loading of 200 pounds per square foot per ton of solids produced per day. Based on this criteria, it is recommended that a 65 foot diameter thickener, with a 10 foot side liquor depth, similar to a Type H thickener as manufactured by Dorr-Oliver, Incorporated be installed. Figure VI shows the installation of this equipment in an earthen paved basin. The basin sides will be on a 1:1 slope. SLUDGE DISPOSAL Excess sludge is thickened and combined with the sludge from primary clarification for disposal. Sludge disposal may be carried out in either of two ways: incinera tion or lagooning. The use of sludge drying beds has been dismissed because of the large area required (approximately 1.75 acres). Lagooning can be done in the existing aeration ponds, but the ponds will have to be cleaned of the existing heavy accumulation of fiber. However, it is recommended that sludge disposal initially be carried out by wasting into these existing aeration ponds. It will be necessary to run tests on the sludge to determine the degree to which it can be dewatered before a final recommendation on sludge incineration can be made. The problem of sludge disposal by incineration is discussed in some detail in the appendix of this report. EFFLUENT DISPOSAL The final treated effluent will be conveyed, by gravity pipe line, around the existing aeration ponds to a discharge point on Mill Creek for eventual disposal into the Angelina River. The location of this proposed pipeline is shown by Figure VIII. All gravity pipe line should be designed for 1.50 times the normal flow in order to assure adequate capacity during storm water surges. There fore, for an average flow of 20 MOD, the design flow is 30 MGD. Using an n value of 0.013, would require a minimum pipe size of 36-inches to handle the design flow. The effluent pipe will be laid on a grade that would main tain a minimum velocity of 2.0 feet per second. The layout of each treatment component as it exists at the proposed plant site is shown by Figure VII. SECTION V COST ESTIMATE The following is a detailed cost estimate for the waste treatment facilities at the Lufkin mill. A. SITE PREPARATION 1. Excavation; 150,000 cu yd @ $0.50 $ 75,000.00 2. Steel Crib-Type Retaining Wall; a. 6'-12' high, 850' @ $50.00 b. 12'-l6' high, 325' @ $85.00 c. 16'-18' high, 300' @ $110.00 3. Roads and Misc. $42,500.00 $27,500.00 $33,000.00 $30,000.00 $ 103>000.00 ENTRANCE STRUCTURE 1. Excavation; 50 cu yd @ $1.50 $ 75.00 2. Reinforced Concrete; 22 cu yd @ $90.00 $ 2,000.00 3. Accessories and Misc.; $ 250.00 $ 2>325.00 INFLUENT FLOW DIVIDER 1. Excavation; 54 cu yd @ $1.50 $ 80.00 2. Reinforced Concrete; 21 cu yd @ $90.00 $ 1,680.00 $ 1,760,00 PRIMARY CLARIFICATION 1. Excavation; 11,800 cu yd @ $1.00 $11,800.00 2. Reinforced and Misc. Concrete; 456 cu yd @ $80.00 $36,600.00 3. Reactor-Clarifier Mechanisms; 2 each @ $57,500 $115,000.00 4. Electrical $ 5,000.00 $168,400.00 E. CHEMICAL FEED WELLS (2) $ 2,900.00 F. AERATION BASINS 1. Excavation; 14,000 cu yd @ $1.00 2. Reinforced and Misc. Concrete; 1,400 cu yd @ $80.00 3- Mechanical Aerators, Starters and Motors; 8 each @ $17,75 4. Misc. Piping, Walkways and Equipment 5 Electification G. FINAL CLARIFICATION .1 Excavation; 13, cu yd @ $1.00 2. Reinforced and Misc. Concrete; 321 cu yd @ $80.00 3'. Clarifier Mechanisms; 2 each @ $71,500 4. Electrification $14,000.00 $112,000.00 $142,000.00 $24,000.00 $75,000.00 $13,000.00 $26,000.00 $143,000.00 $ 2,000.00 SLUDGE THICKENER - Excavation; 2,000 cu yd @ $1.00 2. Reinforced and Misc. Concrete; 130 cu yd @ $80.00 3- Thickener Mechanism 4. Electrical . $ 2,000.00 $10,400.00 $17,000.00 $ 2,000.00 SLUDGE RETURN .1 35OO gpm Pumps and Motors; 3 each @ $4,000.00 .2 Foundations and Misc. $12,000.00 $15,000.00 $367,000.00 $184,000.00 $ 31,400.00 $ 27,000.00 J. CHEMICAL STORAGE 1. 16,000 Gal. Poxyglas Storage Tanks; 4 @ $3,000 2. Foundation 3. Unloading Apparatus 4. Piping and Fittings .s Railroad Spur CHEMICAL FEED BUILDING 1. Building; 670 sq ft @ $12.00 2. Chemical Feeders, Pumps and Instrumentation 3 Chlorine Shed and Miss. Equipment 4. Utilities YARD PIPING *1 X 42" Concrete Pipe; 550 lio. _t @ $21.00 2. 30" A-C Pipe'; 580 lin ft @ $18.00 3- 30" C.I. Pipe; 200 lin ft @ $20.00 4. 18" A-C Pipe; 300 lin ft @ $14.00 5- 16" C.I. Pipe; 80 lin ft @ $15.00 6. 12" A-C Pipe; 1,080 lin ft @ $8.50 7- 12" C.I. Pipe; 300 lin ft @ $14.00 8. 6" C.I. Pipe; 1,500 lin ft @ $7.00 9- Misc. Valves, Fittings and Meters $12,000.00 $ 4,000.00 $15,000.00 $ 5,000.00 $ 7,500.00 $ 8,000.00 $36,000.00 $11,000.00 $ 5,000.00 $11,600.00 $10,400.00 $ 4,000.00 $ 4,200.00 $ 1,200.00 $ 9,200.00 $ 4,200.00 $10,500.00 $25,000.00 $ ^3,500.00 $ 60,000.00 $ 80,300.00 lOWM-tm M. EFFLUENT PIPELINE 1. 36" Gifford-Hill Concrete Pretensioned Pipe; 7,600 lin ft $18.00 $145,000.00 2. Structures and Clearing $ 1(0,000.00 $185,000.00 Sub-Total $1,361,585.00 Contingencies @ 10$ Sub-Total Overhead & Indirect Sub-Total 136,415.00 $1,4-98,000.00 222,000.00 1,720,000.00 Contractor's Profit @ 10$ TOTAL CONSTRUCTION 172,000.00 $1,892,000.00 Engineering @ 5$ 95,000.00 TOTAL PROJECT COST $1,987,000.00 SECTION VI BIBLIOGRAPHY 1. Busch, A.W. and Hiser, L.L.; "Study of Waste Water Streams for Southland Paper Mills, Inc.", Technical Report - Phase I, Southwest Research Institute, Houston,Texas; December 18, 1964. .2 Hiser, L.L.; "Study of Waste Water Streams for Southland Paper Mills, Inc.", Technical Report - Phase II, Southwest Research Institute, Houston, Texas; March 11, 1965* 3- Hiser, L.L. and Busch, A.W.; "An 8-Hour Biological Oxygen Demand Test Using Mass Culture Aeration and COD", Journal of the Water Pollution Control Federation; April, 1964. 4. Busch, A.W.; "A Report on Waste Treatment Process Design for Southland Paper Mills, Inc., Lufkin and Sheldon, Texas Plants"; March, 1965* 5- Steel, E.W.; Water Supply and Sewerage, 3rd. Edition, McGraw-Hill Book Company, New York; 1953i page 498. .6 McKinney, Ross E.; "Mathematics of Complete-Mixing Activated Sludge", Transactions, ASCE, Vol..128, Part III; 1963, page 497. 7. McKinney, Ross E.; Microbiology for Sanitary Engineers, McGrawHill Book Company, New York; 1962; pp. 216-219 SECTION VII APPENDIX SLUDGE DISPOSAL The solution to the problem of 6ludge disposal at the Lufkin mill is dependent on two factors: the dewaterability and the BTU value of the sludge. Neither of these qualities can be determined until the treatment plant is in actual operation and the thickened primary and activated sludge from the thickener can be sampled and tested. In this report, it has been recommended that sludge disposal be accomplished by wasting to the existing oxidation ponds until these sludge qualities can be determined. If it can be shown that the sludge can be dewatered sufficiently and that it has a BTU value that will support reasonable combustion, it is recommended that the sludge be incinerated. Waste activated sludge is notoriously difficult to dewater. The reason is that the sludge is very low in suspended solids (in the normal sense of the term) and consists almost entirely of microbes. These tiny animals are themselves over 95$ water and are very light. Some activated sludges, however, prove more amenable to dewatering than others, depending on the character of the sludge (the types and characteristics of the microbes present). Primary sludge, on the other hand, is much easier to dewater because it is relatively high in suspended solids and very low in microbial content. Again, however, the dewaterability will vary depending on the sludge in question. A sludge that is high in floatables will have different dewater ing characteristics than a heavy sludge with few floatables. When the primary sludge and waste activated sludge are combined for disposal, as at the Lufkin A MOWMlHl mill, then the sludge characteristics are a combination that can only be deter mined by testing the combined sludge as it comes from the thickener. Economical incineration also depends on the BUJ value of the sludge. Incinerator operation is usually based on some utilization of the heat value of the waste in the burning process. The channelling of this heat back into the burning cycle makes it possible, after a time, to turn off the external fuel supply and to use this recycled heat to consume the incoming waste. The heat produced by the burning of the incoming waste is in turn, recycled and the process begins again. In a real sense, the incinerator "runs itself". If the BHJ value of the waste is very low, however, then the heat produced during combustion is very low. The length of time during which fuel must be supplied to the process varies inversely as the BUI value of the waste being burned. The BTU value of activated sludge is dependent on the types of microbes present but is usually low. Primary sludge, on the other hand, usually has a relatively high BIU value. The BIU value of any combination of the two sludges, therefore, cannot be determined until the combination is actually produced. It is recommended that testing of the thickened sludge begin as soon as the treatment plant is placed in operation so that the burning charac teristics can be determined. ADDITIONAL REPORTS The following is a reproduction of a report prepared by Arthur W. Busch, Consulting Engineer, containing the process recommendations for waste treatment at the Lufkin mill. MOWN.IIIT A.W. BUSCH CONSULTING ENGINEER P.O. EOX 1892 HOUSTON, TEXAS 77001 March 31, 1965 Mr. R. M. Millvee, Jr. Project Engineer Brown & Root, Inc. P. 0. Box 3 Houston, Texas 77001 Dear Mr. Millwee: Attached is my report on Waste Treatment Process Design for Southland Paper Mills, Inc., Lufkin and Sheldon, Texas Plants as authorized in your letter of October 22, 196^. As a result of the extensive laboratory study made by Southwest Research Institute in cooperation with Southland Mills personnel, an effective, economical process design is possible. If there are questions regarding the contents, I shall be pleased to discuss these with you. Yours very truly, AWB:tr Attachment A. W. Busch A REPORT ON WASTE TREATMENT PROCESS DESIGN FOR SOUTHLAND PAPER MILLS, INC., LUFKIN AND SHELDON, TEXAS PLANTS Prepared for Brown & Root, Inc. P. 0. Box 3 Houston, Texas 77001 by A. W. Busch Consulting Engineer P. 0. Box 1892, Houston, Texas March, 1965 TABLE OF CONTENTS SUMMARY PURPOSE AND SCOPE GENERAL WASTE CHARACTERISTICS Lufkin Mill Sheldon Mill PROCESS DESIGN General Recommended Process Design Lufkin Mill Sheldon Mill OTHER RECOMMENDATIONS Fiber Removal Plant Start-up and Operation PaS 2 3 3 4 4 4 6 6 7 8 8 8 A tOWH'lllT SUMMARY This report, authorized by Mr. R. M. Millwee, Jr., of Brovn & Root, Inc., on October 22, 1964-, has as its purpose the presentation of process design recommendations for waste treatment at two Southland Paper Mills, Inc., plants. The scope is limited to the removal of organic matter and biological solids. The recommended process, biological oxidation (activated sludge), is based on analytical and experimental data contained in two Southwest Research Institute reports, dated December 18, 1964, and March 11, 1965. The data presented in these reports have permitted the design of waste treatment processes to meet the effluent requirements' imposed by the Texas Water Pollution Control Board. Recommendations are made for treatment process design, fiber removal studies, and consideration of start-up and operation of the treatment plants. PURPOSE AND SCOPE This report was authorized by a letter, dated October 22, 1964, from Mr. R. M. Millwee, Jr., Project Engineer, Brown & Root, Inc. The purpose of the report is to present process design recommendations based on the analytical and experimental data contained in the Southwest Research Institute reports of December 18, 1964 and March 11, 1965* The scope of this report encompasses treatment of wastes at two plants: 1) The existing integrated mill at Lufkin, Texas, 20 M.G.D. flow; and 2) The new groundwood mill to be built at Sheldon, Texas, 2.5 M.G.D. flow. The effluent criteria for both treatment processes are 20 mg/l B.O.D. and 20 mg/l suspended solids. The color problem is specifically excluded ^ from the scope of this report. The process design calculations presented are based on prior removal of fiber. While fiber removal processes are not within the scope of the report, comments regarding recommended procedures are included. GENERAL WASTE CHARACTERISTICS Lufkin Mill The Lufkin plant of Southland Paper Mills, Inc. is a fully integrated mill and the waste includes streams from groundwood, pulping, bleaching, and paper making operations plus the miscellaneous ancillary equipment and processes. The design flow used in this report is 20 M.G.D. Detailed analyses of this waste are presented in a joint report of the writer and Southwest Research Institute, dated December 18, 1964, and in the South west Research Institute report of March 11, 1965 The waste is amenable to biological treatment without prior adjustment of pH. Two characteristics of the waste deserve special emphasis: 1) The waste is essentially devoid of the primary nutrients, nitro gen and phosphorus and will require supplementary feeding. 2) There is a critical concentration of the waste which is toxic to the micro-organisms used in biological treatment. The process design must give cognizance to this factor. Sheldon Mill The mill to be built at Sheldon will initially produce only groundwood. The waste characteristics are fully detailed in the two previously referenced reports. The only critical factor in biological treatment of this waste is the need for supplementation of nitrogen and phosphorus for bacterial nutrition. MOWM-tllt PROCESS DESIGN General The experimental data obtained by the Southwest Research Institutes are of excellent consistency and lend themselves to a rigorous process design for the production of an effluent of specified quality. The major limita tion of the data (common to all laboratory studies) is that they were obtained under conditions of only one, uniform, temperature. Because the micro-organ isms operative in biological oxidation are temperature sensitive, this para meter can not be neglected. Of greatest significance is the temperature of the mixed liquor during winter operation for lower temperatures decrease the rate at which the organisms accomplish their work. A brief summary of biological oxidation is pertinent for effective process design evaluation. Biological oxidation is simply a conversion process wherein dissolved organic compounds are converted into bacterial cells which can then be removed from the waste water. The process is discrete and can be described by stoichiometric equations. In an aerobic environment not limited by mixing or nutrients the unit rate of conversion, or removal. Of organics is proportional to the concentration of organics present. Thus, a fixed mass of organisms is required, to remove a predetermined number of pounds of organics per unit time for a specific effluent quality. In con trast to this rigid requirement, the hydraulic environment is immaterial. That is, the required mass of or ganisms may be dispersed in any volume which can be adequately mixed and aerated. Thus the hydraulic hold-up time is not a fundamental parameter of design. Once the organism mass has been determined, the rate of net increase of the population can be evaluated. This rate is a function of process environment and is of significance in controlled solids operation and in predicting excess solids production. Controlled solids operation can meet temperature effects readily by simply increasing the population concentration to compensate for a decrease in unit rate of removal. Recommended Process Design The following recommendations are based on the waste criteria presented below and on the experimental data contained in the Southwest Research Institute report of March 11, 1965: Lufkin Mill Flow: 20 million gallons per day Tvf) .D. (Removable COD): 42,500 lb. /day Effluent quality: 20 mg/l BOD,. 35 mg/l TtoB 20 mg/l suspended solids M.L.S.S. required: 24,500 lb. Aeration volume recommended: 2.5 MG A M.L.S.S. concentration: 1,200 mg/l Clarification area: 33,333 ft.2 (600 gpd/ft2) Solids produced (excess): 7,3*+0 Tb/day Oxygen required: 26,400 lb/day Nitrogen requirements: 1500 lb. N; 1800 lb. NH^/day Phosphorus requirement: 300 lb. P; 950 It. H^POyday The aeration volume should be divided into at least two units. The volume of the waste stream carrying the excess solids will, of course, depend on the concentration of the solids. If a single unit system such as the Aero-Accelator is used, a thickener should be provided to concentration excess solids. This unit should be sized to handle 73^0 Its. of solids per day in a flow of 515 gpm. The underflow from the thickener, containing the excess solids would be about 3 gpm. (2$ solids concentration). If separate aeration and clarification units are used, the underflow from the excess solids unit would amount to about 60 gpm (l$ solids con centration) and no thickener would be required. The separate clarifier for excess solids should be sized for 0.8 MOD at a surface loading of 600 gpd/ft2. A schematic drawing of the two flowsheets is presented in Figure 1. Sheldon Mill Flow: 2.5 million gallons per day Tb0D (Removable COD): 6000 lb/day Effluent quality: 20 mg/l BOD5 35 mg/l T^Ofi 20 mg/l suspended solids M.L.S.S. required: 3,000 lb. Aeration volume recommended: O.36 M.G. M.L.S.S. concentration: 1,000 mg/l Clarification area: 4,200 ft2 (600 gpd/ft2) Solids produced (excess): 1,600 lb./day Oxygen required: 3,100 lb./day Nitrogen required: 200 lb. N; 240 lb. NH^/day Phosphorus required: 40 lb. P; 125 lb. H^POl^/day Again two units are preferable for the provision of the aeration volume. If Aero-Accelators are used the excess solids stream to the thickener would be approximately 135 gpm and the under flow at 2 per cent solids would be about 7 gpm. If separate aeration and clarification units are used, the underflow from the excess solids unit would be about 15 gpm. The separate clarifier for excess solids should be sized for 135 gPm at the recommended surface loading of 600 gpd/ft2. OTHER RECOMMENDATIONS Fiber Removal The problem of fiber removal is so vital to effective control of the by ..AV.'B.......... catb3/27/65 subject.. Southland ..Paper .Mills,... Inc........ CHKD. BY ...DATE.................................................................................................................................................... r sheet no................of JOB NO................................. j Effluent INTEGRAL AERATION AND CLARIFICATION WITH EXTERNAL THICKENING Ret.urr.fd Solids SEPARATE AERATION AND CLARIFICATION' THOUT THICKENING FIGURE I - SCHEMATIC DRAV.INGS 0r ALTERNATE FLOWSHEETS biological treatment process that further comment is felt justified. Ex perience at numerous mills has shown that plain sedimentation is not effective for fiber removal. The only methods which have proved workable involve chemical treatment, either in flotation or gravity units. It is strongly recommended tha laboratory studies be made to determine the chemical costs involved and to provide a basis for process and equipment design. It is furthermore recommended that fiber removal be made an inherent part of the waste treatment plant design. Plant Start-up and Operation Because of the stringent effluent quality criteria which must be met, proper start-up and operation of the treatment process is especially signi ficant. While a detailed discussion of these points is not within the scope of this project, continued emphasis on these important factors is recommended. TNRCC LIBRARY 62S54 B96S C 1 A repo's or waste treatment process Oesi II lim|:|IJIIII 3 6238 00016 7704 CONS U L T ; N G ENGINEER P. G. BOX 1 G G 2 KO'JSTGN, TEXAS 7700* ^ G- -T- a 7001 j- \j v-/.; C. t'c. G : _ c C --c ;s as c G. 5v _ o.. : u--AG v G ^^ . ;tive. Vw. ^ - - > r G >_1 J^ .'AUo ss rU *cU \J U' Us) -- I'.'u- J uy^Aui'i vJj. j T'ju-C^b r'xuA^TS csrcc ior CO . 0 u- ^ -AC . 0 Ij ox 77G0I 0 3- 3-0 0 _j 'l6 o LIBRARY TEXAS WATER DEVELOPMENT BOARD AUSTIN. TEXAS CM r r-pl c-"x2J or O oV< S PURPOSE AND SCOPE GRniariAD V/AST-Cj CriAR-. CTniRIST.J-Cl) LVi Pk in H i 11 She la oi-i Mill process design General Eecoirar.ended Process OUlXlTi Zi_L 1 Sheldon Mill Design OTHER RECOMMENDATIONS Fiber Rerrioval Plant boart_up ano Goera u a o a 2 3 3 4 8 8 8 - t vo vo tv- r SUMuMARY This report, authorized by Mr. R. M. Miliwee, Jr., of Brown & Root, Inc., on October 22, 1969, has as its purpose the presentation of process design recommendations for waste treatment at two Southland Paper Mills, Inc., plants. The scope is limited to the removal of organic matter and biologi cal solids. The recommended process, biological oxidation (activated sludge), is based on analytical and experimental data con tained in two Southwest Research Institute reports, dated December 18, 19c4, and March 11, 19o5- The data presented in these reports have permitted the design of waste treatment pro cesses to rr.eet the effluent requirements imposed by the Texas Water Pollution Control Board. Recommendations are made for treatment process design, fiberremoval studies, and consideration of start-up and opera tion of the treatment plants. -2- purpose and sccl-e This report v:as authorize-:; by a letter,, dated October 22, 19ot, fro.r. i-lr. R. h. hiliwee, Jr., Project Engineer, Brown & Root, Inc. The purpose of the report is to present process design recommendations based on the analytical and experimen tal data contained in the Southwest Research Institute reports of December IS, 1964 and Karen II, 1965 The scope of this report encompasses treatment of wastes at tv/o plants: 1) The existing integrated mill at Lufkin, Texas, 20 K.G.D. flow; and 2) The new groundwood mill to be built at Sheldon, Texas, 2.5 K.G.D. flow. The effluent criteria for both treatment processes are 20 m.g/l B.O.D.^ and 20 mg/i suspended solids. The color pro blem is specifically excluded from the scope of this report. The process design calculations presented are based on prior removal of fiber, while fiber removal processes are not within the scope of the report, comments regarding recommended proce dures are included. GENERAL TASTE CHARA.CTuRrSTICS The Lufkin plant of Southland Paper hills, Inc. is a fully integrated mill and the waste includes streams from ground-wood, pulping, bleaching, and paper making operations plus the miscel -3- r iar.oous ancillary equipment. and processes. The design flow used ir, this report, is 20 H.G.D. Detailed analyses of this' waste are presented in a joint report of the writer and South- rest Research Institute, dated December 18, 1964, and in the Southwest Research Institute report of March 11, 1965. The waste'i-s amenable to biological treatment without prior adjust ment of pH. Two characteristics of the waste deserve special emphasis: 1) The waste is essentially devoid of the primary nutrients, nitrogen and phosphorus, and will require supplementary feeding. 2) There is a critical concentration of the waste which is-toxic to the micro-organisms used in biological treatment. The process design must give cognizance to tms factor. Sheldon Hill The mill to be built at Sheldon 'will initially produce only gr'undwood. The waste characteristics are fully detailed in the two previously referenced reports. The only critical factor in biological treatment of this -waste is the need for supplementation of nitrogen and phosphorus for bacterial nutrition. - PROCESS DESiGH Lr n ^ d1 c; J. The experimental data obtained by the Southwest Research -4- r -r. 0 ^misuse are of excellen: t c c er.cy and lend themselves to c. r:. 3 O r 0 U 3 p I*10 C 3 5 3 C 3 S 3 P 1 for' t fl 2 production of an effluent of S p,e;: ifie d L- si _L u . rt i, m jor' -i-- ration of' she data (common to a!1 labor;-:tory studies) i. s 0 r.,at on.ey were obtained under conai- t a. on13 oi oniy 0n0 y uniior'31, t emper ature . 3ecause the micro or ga,n _ srr.s operative in bi Oiog;icai oxidation are temperature se ns itive, ms paraiteter can non be neglected. Of greatest si O' 1 ifleanice as toe teriipe ra tu re of the mixed liquor during winte op e r a cion for iovrer tempe r a t u res c ecrease the rate at which the or e0* no srr.s accomplish thei r w 0 rk. a 0 r i.ef summary of b ioio gicai oxidation is pertinent for . ex' fe ctive process design evai ua t a 0 n. Biological oxidation is si mp ly a c onversion proce 3 s w herei'n dissolved organic compounds a r e c onver tec into cacter li ceils 'which can then be removed 1 r 0S'. the vr aste v;ater. Hi e pr oce 3 s is discrete and can be des- cr ed by s 10 i c n i orr.e trie e qua u .0 Cl >i> In an aerobic environment no r limits d by nixing or 1 e n 13i i dx u- A. the unit rate of conversion. or r'err.ovai y or or6aruCo m --O y~ yi oport ionai to she concentration of or*ga:a i c s p resent. Thus, a 11 xeo riass of organisms is required to r<emove a predetermined n urn'der 0.f pounds of organics per unit `cl::.? for a specific effluent quality. In contrast to this rigid requirement, the hydraulic environment is immaterial. That is, the required mass of organisms may be dispersed in any volume which can be adequately mixed and aerated. Tnus the hydraulic TjOj-G-up cirr.e us ncu 5. 1 uricurnsnu 3. r p3 runev 3 r of1 dcsipn. Once the organism mass has teen determined, the rate of net increase of one population can be evaluated/ This rate is -5- LIBRARY JEXAS WATER CO. ELG~J'TENT BOARD AUSTIN, TEXAS a : ur.etaor. o: process envarcr.nenc a no is of sagna:icance in cc;,arc__sc so_acs cperataon arc or. p-rscactang excess sOiics paCu .- n oO.xro__eu so-ics coeratacn can meet temiperature eisects readily by simply increasing she population concentration to comoensare ior a cecrease an unat rate oi removal. -rcce^o Ire i oiaovrang recommencataons are oasea on tne v:aste criteria'presented below and on the experimental data contained in she Southwest Research Institute report of March 11, 19d5; i 20 million gallons per d 1/ 0 . D . (ns mova o _ s C<j^) : *42 poO /clay Z. I 1 j. U 6 n "0 g U a J. S 20 mg/1 BOD p OP ' t.g/i -v-.Oa 20 m.g/l suspended solids > __J kJ O i. _< 1. " x o,poO ic. :raaicn vomama lommerdec: 2.5 MC-. . x. a . S . c or. ce n i-r a l. a on: ^ you mg/x Clarisacataor area: 33^333 rtf (500 gpd/ft2') Solids produced (excess): 73^ lb/day 'Oxygen required: 25,000 lb/day nitrogen requirem.en t: ap^G io.y aoOO ao. l.r.-./cay Pnosphorus requirement: qCO. xC . ?; 9p0 ac. H-?0: /c< .on vOxU/a s;.ol(_g o3 c.-- viOcc m to a . S o uV/ 0 . td latr X Ux Ciii,. C^x x ./ _Li ;Xi.cS: -> 'w* -- ___. X) _. cooroo j 'oc -xiy Oij ono concei, L'jTii t j.or. w x tne ^ ^ Ci id X. . j x. X- i , x. D id bd sucn as she /.ero^acceletor 6 r _ c u s c u _j a ^;i*CAc,jcr ;jnomc e ^ruV-Cto ^o corjcsru x s t e 0xcs3s , H j -- it ^ X _ v o *0 G u - 0 C c S.Zcu oO X1X G 1S f 0 "r ^ 103 01 S 011G 3 o 11" :iy ix a f lev; of 515 5?-. The uxeerf lov: from the thickener , conosxxsxg exc excess so^ics vrouic oe s.ooui gprn (2)j sonos C CX C 0 r, 11 a tl OX ) xi seos.xe.Gc ssxaoiox axe c i a x 11 s c s c i o x exits axe useci^ o h s v.xcexi xov,: ixox. oxe excess soiics exit v/ouiG snvount to shout cj gpm. (xjj soloes coxcsx t xsosox ) ana xo txicxexex would oe requires. Txe sspsxsoe ciarnisx xox excess soloes sxoulo oe siico fox 0,o xGD so s surface loscixg of oOO gpc/ft , A schematic cixswsxg ox oxe tv;o ij-owsxeets is presentee ~ v* TT1 - 'y- * vn jz> 1 -l-.J -i- .cor. Flow: 2.5 rr.iIj.ion gallons per oay iq GD (r.err.ovaois COD) : oGuO ao/oay Effluent quality: 20 rr.g/l BODc 35 rrg/i .i'.^OD 2v ;rg/a seesonos r. t r a vi O'^u^ U-S# v O -- i_i. ..c X c C u..--.cX O C G I 0,0 ^ l*i * Cr , .'. , 1j , , S U U j.jCC*j 1/ X C. U _L O . j * j U - - - _L Clarification area: A .,200 fX2 (oOG gpd/ft 2 ) i'Oiics procuceo (excess) : e_,ooe ao./cay oxyger. requareo: r,.ic./cay Miurogen required: 200 it.N; 2AO lb. iIH-/day o r'nosonorus required: AC ao.Pj a25 Id, h-,?0;;//cay Again tv:o units are preferable for the provision oi one aerauicr. volume. If Aero-Accelators are used the excess solids soream to the thickener would be approximately 135 gpm and the 7 SHU =.T NO JOB NO. ..OF , r.o.-w iUA FIGURE I - SCHE.V-ATIC DRAWINGS 0? ALTERNATE FLOWSHEETS C. - 0 ^ O M o w___ ' .'. w -- '-i ______c _ _ u. e.'.Cw. > ^___ O CwUw*L- j ~ j-z; ^ x U- eb? Li x -. C. O leading of 600 god/ftO. " Oi^C/ vA'-'-OA-An. - _LVJ;\ O y-1 co -- crr. 0i ~ -- o0o ocmo\< C oJ. - o -- o- - !_ S SO VluGx uO 6I10COILV0 " 00 0 0 0 ss trial/ 1000000 c orr.* :U3 uli IcC. , iXOcOlGOCS 3 c- O'JroeOOUS 100-!__ S 03 S 30000 ooa' s a. i/ x. cA j xb ., o ifecoive foo fiOeo C . ..o V I o o. -- y r.*. e o o o o s v/o o c o oeve proved v.'oooc -C -A . w' O . fiooaoioo oo goavioy uoios. z . -- k_- O' ^aoooaoooy soucigs 00 rr.age 00 eoc:.:_c a-- cos* 10voaVGc a0.c L/o p00vc0 a cas_is j ~ o' x- C O ^ CA . < ' U o - .. go . ao os luocoeoroooe oe coraoe nee c _ S_ ... o ' ocdx'x- 'sx'x L- Oi ' a b c c v a d o " \A -- u _ - 4 'C? o -- __..1 ^ O -- -- o * , O' j, 0.__0 a c e ^ a 1__a' . S d uOblUt 0-0 01 tfilS icOOi y j C 0 0 :00s is 000000000300. Q L I H W E 5 1 R E 5 E A R C H 1 N 5 T .1 T U T E 8500 Culebra Road. San Ar.tor.io, Texas 78206 SwRI -KOuS TOR 3600 Yoakum Boulevard, Houston, Texas 77006 STUDY OF WASTE WATER STREAMS, FOR SOUTHLAND PAPER MILLS, INC, Technical Report - Phase II SvvRI Project No. 21-1617 by Leiand L. Hiser to Browr, U Root Lee. P. O. Box 3 Houston Texas 7 7001 Job No. E-367 & E-51S March 11, 1965 fEXAS WAtERc-' AUSTIN' -TEXAi= gOAr^E) APPROVED BY- c Herbert C. McKee Assistant Director Department of Chemistry ar.d Chemical Engineering $o \ ^ TABLE OF CONTENTS I. SUMMARY E. PURPOSE AND SCOPE III. EXPERIMENTAL PROCEDURE IV. DISCUSSION AND RESULTS V. CONCLUSIONS TABLES I - VI F i O U R E S 1 16 APPENDIX . ~ Pag e 1 2 3 5 13 I 'MM A R, V Laboratory experiments were conducted at the Research Laboratory of Southlar.d Paper M:A s Inc Lufkin. Texas to provide the data, needed ior waste treatment plant design. This report contains the necessary information concerning treatment plant process kinetics for 20 MGD of total mi.! waste at the Lufkin Mill and for 2. 5 MGD of grour.dwood mill waste from the proposed Sheldon Mill near Houston Pr et r eatmer.' for removal of fibers was considered for both waste systems It w- s concluded tf.-t .fiber removal was necessary prior to biological treatment oi these wastes Use of completely mixed aerobic systems is recommended for biological tie-'.men! oi both wastes. Completely mixed systems provide optimum st eady - s' at e conditions for the biological culture and inherent protection from sudden shock loads and high cone extra tion levels whic.n might impede culture m a r- b o ] t s m BoTt w-. sees were found to be deficient m nitrogen and phosphorus Th-t-reior e nut r text feed must be provided for tr.e biologica l treatment systems Iret'cd eff.uerf standards oi 20 mg/i BOD and 20 mgh suspended scuds are re-1 son- b! e for these w-stes. Proper design and operation should prodi.ee etimer.ts or this quality without difficulty. Colui reduitior. oi total rm;l.wastes was specifically excluded trom tins itudv However a. record was made of color before and after biological treatment ar.d showed that essentially no change was effected It is felt . that co.or wu: be of major concern m the receiving waters of the Lufkin mill eiAuont. H is tr.ereiore recommended t'r a t studies be mili-ted to r e d u c e 'r.e co.o: mat etiiuent. Cc.or should not be r- problem in ground- wcioci m i.i effluent at the Sheldon II. PURPOSE AND SCOPE Plus study was authorized by letter front Mr. R. M. Millwee, Jr. , Project Engineer, Brown L Root, Inc. . This study completes Pitase II of this project. Technical Report, Phase I of December 18, 19o4 characterized the wastes involved as to the magnitude and difficulty of the problem anticipated in producing an effluent low in oxygen demand. The purpose of this study was to provide the rate data necessary for the complete design of adequate treatment facilities for mill waste at two locations. The first consideration was for the exist ing mill at Lufkin, Texas and second was for the new mill to be constructed at the Sheldon site, near Houston, Texas. The Lufkin treatment plant was to be designed for biological treatment of 20 MGD of the total mill waste effluent. Treatment plant design for the new mill at the Sheldon site,was to handle 2. 5 MGD of groundwood mill waste only, as it is understood that the initial construction will complete the groundwood section or.lv. The scope of the study was limited to process and design kinetics required for satisfaction of biological oxygen demand of the waste and removal of suspended matter produced in the biological system. Total suspended matter (non-filtruble residue) and BOD standards for the treated effluents at both sites were each set at 20 mg/1. Any require ment for color removal was specifically excluded from the scope of liiis study. J III. EXPERIMENTAL PROCEDURE 0 A Gor.eral Technical Report, Pr.ase I provided a background of information as to the feasibility of biological treatment of the wastes involved m tins studv. Description of the TbOD test technique and COD determination methods is contained in that report. The requirement of this study was to pro vide the rate data necessary for the proper sizing of mixed aeration basins, design of sludge wastage systems, selection of final clarifier overflow rates, and other design parameters. Two waste streams were studied--total mill waste lor Kufkin and ground.wood waste for Sheldon. Separate studies were made on each of these wastes to evaluate the effect of fiber content on treatment plant design and operation. To do this, each waste was filtered through a Buchner funnel and laboratory filter paper to simulate pretreatment for suspended solids removal. Comparison was then made between the treatment ki netics of filtered and unfiltered waste. Thus, in total, four separate systems were studied. The equipment necessary for these studies was set up in the Southland Paper Mills Research Laboratory in Lufkin, Texas. This equipment consisted primarily of two continuous flow biological reactor units with the necessary feed and effluent systems. Batch rate equipment was al ready on hand in the Research. Laboratory. Equipment was also provided for sample filtering and solids determinations and for the COD deter mine tions required. 'fine temperature at which laboratory studies were made' was somewhat lower (5 - 10 C) than actual waste temperature. However, waste te mperntures are well below the maximum allowable for biological activity. Since tins high temperature would, if anything, improve treatment efficiency, it was accepted as a safety factor on design data. The efforts of Mr. Fred Bishop tt.nd David Tarazi and the other research, personnel were instrumental in the success uf this studv. B Continuous Flow Reactor S'udies^ I'm- bench scale reactors were used for a twofold purpose in this study. First, they provided a simulated treatment plant in the laboratory winch A. W. Busch, ''Laboratory Units for Bench Sca.le Bio-Oxidation Studies, '' Water and Sewage Works 106, 1959, p- 254. co'> j.-ciy (.-.'itiruilcd &nd i.'jumioreC Second, they pro\ ided a. means i o r r.ycimu:1. c ci a 5 s 111 c at ion ct the active- cult are tor use in batch rate studies A detailed procedure was set up for operation of these units. This procedure and schematic flow diagram are included as the An non dux to this report. The continuous flow reactors were operated 24 hours a day, seven days a week. This continuous operation is necessary since living organisms are involved and they require continuous feeding lor proper results. Grab samples of the particular waste being studied were prepared each morning, and nutrients (nitrogen and phosphorus) were added in excess. The change in COD between influent and effluent composite sample was used as the measure of biological treatment through the system. The TbOD " test was set up on the effluent composite from each day's run. A solids balance was obtained on the system each day by measuring suspended matter in the reactor feed, reactor mixed liquor, and reactor effluent. However, it was found that the Chain-O-Matte balance m the laboratory was not sensitive enough to produce as close a solids balance as can normally be obtained. While this might have seriously impaired short term data, the rate studies were continued for a sufficient time to average out this factor. The volume of one continuous flow reactor was 5. 25 liters and the other 5. 9 livers. These numbers are used i.n ail calculations involving MLSS according to the reactor used. It shouid be noted also that on January 31 the existing pulp mill biological treatment system was discontinued in order to reflect this load in the total mill effluent. Previously, tr.e TbOD load being removed in the pulp mili treatment system amounted to approximately 10% of the total mill effluent TbOD C. _Batch Rate Studies Tito batch rate study procedures were very similar to the TbOD tests used in Phase 1 of this study tor cha ractenzation of tne waste. The difference was that classified organisms were used from the continuous liow reactors at sufficient concer.tr-'tion to remove all soluble materials within a few t.our;. This removal was followed closely by taking samples of tno" completely mixed system every 15 to 30 minutes Total suspended matter and soluble COD determinations were made on these samples. Titus, a removal rate per unit of mixed liquor solids as weii as solids growth was measured during the batch studies. Membrane filters (0. 45 micron pore size} were used for suspended solids determinations, it war= assumed that any material passing through these filters was soluble. All COD determinations were made on filtered samples. L. L, Hiser and A. W. Busch, "An 8-Hour Biological Oxygen Demand Test Using Mass Culture Aeration and COD, " Journal Water Pollution Control Federation, 36, April 1964, pp. 505-51 5. IV DISCUSSION AND RESULTS A T o r1 Milt Waste 1 Nc:;ci-L Tables I and II record the laboratorv data obtained from the continuous ilow reactor units for the period December 22. 1964 through February 23. 19o5. Tables II! and ! V list the variables computed from Tables I and II and are used m constructing the curves in Figures 1 through lo During the initial period front December 22 through January16. the reactor was operated on filtered grab samples from the total null etiluet'.l sewer. Reactor effluent volume varied from 8 to 24 liters/day during this period The first week of this period was spent in acclimating the culture and smoothing operating and laboratorytechniques. Building up the mixed liquor culture was difficult at first and a solids balance could-not be achieved due to the compli cation of returning unknown quantities of solids carried over to the effluent each day The data prior to January o. although listed in the Tables, tor the most part were ignored m subsequent computations and de sc notion Tor all oractical purposes the test period on filtered total mill v. aste (with urn1 j eed pump m operation:' was from January n. 1903 to 'anuarv 16, 1965. On :anuarv 19 a batch removal and growth, rate study was made using the culture classified during the prec vdinu period in the continuous flow reactor . Or J.inuary 20 two feed pumps were installed on the continuous : low re.'tc tor to e s s ._ n t: a 1 i v double the feed rate The reactor was continued on. filtered waste at tins higher feed rate through January 28, at which time a not lie r batch rate study wu-s mode- Tiie initial waste rone ci'.tra t:o:i it: tins batch studv exceeded toxic limits of the culture and no COD removal or solids growth was measured in the system. A. discussion o: this phenomenon is included later 1 it e total m lil reactor was then continued at the high flow re:j r ua r v -t 19 6 5 and a oateh rate = .v.dy was completed on V 1905 Tills completed work on the- filtered waste. On February - the continuous flow reactor was started on unaltered total mill effluent Two feed pumps were operated during the period Febrv.arv 5 through February- lb to give a direct comparison wit;-, trie preceding studv on filtered waste. On February- 17 a batch D rate study ui; made usmy i 'jimre irom the ur.lilierod waste system. Tit is rat<- c tuclv vompleted iaburatorv work on t It e total null effluent wa s te 2 Ur. it Remotal and Loads r, g R a t e s Figure 1 is a p'.ot o: the unit removal rate fgm TbOD removal/ gm.MLS5/day) as a function ot the reactor effluent TbOD concentration. Two sets of data are plotted on this curve, the first set for the period during winch only one teed pump was being used with the reactor, and the second set o! data for the period when two feed pumps were being used. The removal rate curve is higher for the low flow period than for the high, flow period This is probably explained by the fact that the low flow culture was quite dispersed This provides rela tively more reaction sites than are apt to be found in an equal con centration of a more flocculated culture. During the high flow rates the non-floccul ant or dispersed portion? of a culture are washed out in the effluent It is precisely for this classification purpose that continuous fiow units are indispensable to biological rate studies The low flow culture was selected at a clarifier overflow rate of about 200 gal/dav/ft" clarification area while the high flow culture was selected at a claritier overflow rate ol 650- 700 gal/dav/ft~ Figure 2 is a plot of the same variables'as in Figure 1 for the umilte'red waste. Thr unliltered culture was selected at a lower overflow rate 1 approximate! v 550 ga ]! dav i'ft- than the filtered waste culture . Figures 3 and 4 relate unit loading -'em TbOD applied/gmMLSS/ day) as.a function of reactor effluent TbOD concentration. .These curves are similar to Figures 1 and 2 except that "applied" TbOD is used rather than "removed1' TbOD These figures are important in the sizing of aeration basins for biological systems. Figure 3 plots two curves for the filtered waste system, one for the low flow period and one for the high liow period. Figure 4 plots tlm relationship for the unfiitered waste. Figures 5 ar.d 6 plot unit removal as a function of unit loading for the continuous fiow reactors. The slope of the curve is a measure of the efficiency of the system. It wilt be noted that the filtered waste system maintains its efficiency at loadings up to 2. 2 gm/gm/day. The .unfiltered waste system efficiency shows a tendency to become irregular at higher loadings although only 3 loadings are plotted over 1. 0 gm/gm/day. ( Growth Rates and Solids Pro; : :o r. Biolgoical waste treatment is essentially a process bv which soluble organic contaminants are converted to bacterial cell materials. 'In this form they may be removed from the system hydraulically. Thus, an excess of solids is alwavs produced which must be removed from the system. Figures 7 and & plot growth, rate ( A MLSS/Avg MLSS/day) as a function of unit loading It can be seen on Figure 7 that, at unit loadings from 1 to 3 grnTbOD / gnuMLSS/day, growth rate was fai-rly constant between 0. 1 and 0.2 dav' * . The effect of the waste fiber con tent of the unfiltered waste is seen quite readily by comparison to Figure 8. In this svstem, growth rate varied from 0. 8 to 1.5 day" ^ over a unit loading range of 0. 5 to 1.5 gm/gm/day. This reflects, of course, the accumulation of inert fiber in the culture rather than growth rate, per se. Data on solids produced as gm per gm of filtrate COD destroved is shown on Tables III and IV. Solids production varied con siderably during the low flow rate period shown on Table III. This was due to the fact that the entire system was operating at a solids level below sensitivitv of the laboratory balance. Further the culture ex hibited the poor settling qualities cha rac te r i s tic of food limited cultures and varving quantities of mixed liquor solids were carried over to the e ff lue nt. The solids production as shown on Table IV is a better measure of what is expected during plant operation. Here again the efiecl of effluent solids (fiber' was seen. Solids produced varied from 0. 1 to 0. 3 cm pel- cm COD destroved with fiber tree waste feed. When fed unfiltered waste solids production rose ten fold for a range of 1.0 to 2. 1 gin/cm COD destroyed. This higher figure again reflects the accumulation of fiber in the culture which masks the solids produc tion due to cell svnthesis. The accumulation of fiber in the active culture presents a very real problem in the control of a waste treatment plant Since the operator cannot tell what fraction of the MLSS is inert fiber, he cannot adequately control the solids level in the treatment plant and therefore will have no control on unit loading of the active fraction. This lack of control will be reflected in the treated waste quality. 4. Batch Rate Studies Results of total mill batch rate studies are shown on Figure 9A. TbOD and MLSS progressions with time are shown for filtered and 8 untiltcred waste batch studies, Tr.eso cur ve s arc typical o: batch rate curves . There is or.e anomaiv v. h 1 cii mav be s'een in the batch rate studv o: t ebr.ary r> (without fiber). A ' false" plateau of short dura cion was noted in the TbOD progression.. This plateau was also noted in the fil tered waste batcbi stud'/ run. J anna rv 19 (culture classified at low overhow rate) and ws ih the grouuclwood effluent svstems. Figure 9B plots the unit removal rate as a function of TbOD concentration on all three total mill waste batch studies. Unit removal rates for both filtered cultures were more than 1. 5 times higher than the unfiltered culture rate at 30 mg/1 TbOD concentration. However, all three rates are considerable' higher, than observed in continuous flowunits. Further discussion of this variance between batch and continuous flow rate data and the TbOD progression anomaiv mentioned above is included later in section IV B4. No attempt was made to determine growth rate on these batch studies due to laboratory balance insensitivity 5. Toxic itv and Nutrients Two instance:' Of toxicity were noted during this study. The first was on January 28 when a batch, studv was set up on total mill effluent, A. waste io culture proportion of 1.: 1 was used in setting up ihis parti cular study. This apparently exceeded the toxic limit of the culture such that no COD reduction was observed after 24 hours of operation. The second instance occurred with the continuous flow reactor on January 12. A. crab simple with an exceptionally low pH of 3. 1 was fed to the unit for that day s run As car. be seen m Tabie I and III. the reactor einciencv was serious!', impeded lor the next three days. The first instance of toxicit\ would not be met in a completely mixed biological system'as the influent waste is immediately diluted to effluent concenl ration levels Howe ve r . this factor precludes the use o: the conventional dIug flow design for the aeration basin unless a large recirculation flow volume were included m the system. The- problem of low pH is again handled m the completely mixed system by dilution. if. however . sue h a problem continued for a con siderable time t'r.e biological system could be - seriously impaired. X: t r o g e n nd phosphorus determinations showed the total mill waste to be almost comoletclv devoid.of those necessary nutrients. Total nitrogen, was less tut t> '1 and total ohosphorus (alter alum o pr l'i. v. o . r :: ; . : t w.l! b-.- !-,.\oi = ary to provide for nutric::! feed i:: ar.v b i ol o g n a I > re a tm <_ r.: .-wstem o. Solid; S-.-o': r auo.". Kau- .-vnot.-.e r olive t o; user c unten: on trie biological culture is seen in. Figure 10 which shows tvpical fettling c urves. Settling rate data was caretully selected tor these curves ir. order to present a valid comparison. Tiic mo cultures are pracucallv identical in total sus pended solids content and prior environmental conditions. The major dittereP.ee is that one is almost entirely a biological culture while the other is a. mixture ot` fiber and biological culture, in unknown pro portions. Two factors are important in this comparison. First, the unfiltered waste culture settling rate is about 1/iOth that of the filtered waste culture and therefore will require a much, larger final clarifier for proper separation of solids Second, the ur.tilte red waste will require a larger volume of sludge wastage for disposal of a given amount ot sludge due to poor compaction properties Cornpounding this problem would be the added weight of fiber brought in continually with the raw waste Maximum settling rates 'incites /minute! of system Mixed Liquor are listed on Tallies 1 and II. 7. Color Equip aier.t A PH A color was r .n daily on the influent and effluent of tr.e continuous flow reactor during the period January 7 to January 30, 19 65. Tim values obtained are recorded m Tables 1 and i: The purpose of this procedure v-.as to determine the effect of complete biological treatment on mill effluent color. No t on s i s ta r t change wn s observed in' waste color as a res ! t o; ib,:- treatment. All i o'or me a-tirement.T we re made on. membrane - filtered samples to eliminate turbiditv. borne small fraction of the color was un doubtedly absorbed on the membrane filter but this factor u as of no consequence since on.lv a relative cum pa risen was made. Color w a ? run b\ comparing absoroance at 425 m a wave length to a standard curve Tilts curve was made using APHA color standards. Hi gh.lv colored w asti; samples were diluted with distilled water where necemar-. UCW.PY fXAS WATZR DE'.S'.CPMENT BQAftQ AUSTIN, T.tXA 10 Groundwood Waste 1 . General Laboratory data obtained front the continuous flow reactor are recorded on Table V. Table \T is a tabulation of the variables com puted from the raw data in Table V. All rate calculations involving solids are based on average MLSS. One reactor was operated on filtered waste at low flow (one feed pump) from December 30, 1964 to January 16, 1965. Two reactors were then operated concurrently at high flow (two feed pumps on each reactor, for the period February 18 to February 23, 1965. One reactor treated filtered groundwood mill waste and the other unfiltered waste during this latter test period. Ail reactors were fed continuously on grab samples col lected daily from the groundwood mill effluent clarifier (SveenPedersonh Cultures developed rapidly on this waste, so that the entire operating period provided valid data. One butch rate study was run on January 19 using filtered waste culture h\draulicallv classified at 290 to 390 gal/ft^/day. Two batch rate studies were made concurrently on February 24, 1965. One used the filtered waste culture and the other used the unfiltered waste culture. Five first culture was hydraulically classified at about TOO c al /: t ~ / da v and the second at about 400 gal/ft-/day. These rate studies completed the laboratory work on the groundwood mill wa s te . 2 . h: n 11 Removal and Loading Rates Figure 11 shows the relation of unit-removal rate to reactor effluent TbOD for all three groundwood waste systems studied. The effect of fiber on unit removal rate is even more pronounced here than with the total mill waste systems. At comparable flows the culture system without fiber is capable of more than double the unit removal rate capacity of the culture system containing fiber. At an effluent TbOD concentration of 30 mg/1 (equivalent to BOD of 20 mg/1) unit removal rates are about 0. 8 and 1. 8 gm TbOD/gm MLSS/Day for unfiltered and filtered waste respectively. Figure 12, relating unit loading to effluent TbOD, is very similar to Figure 11 as the system efficiency is high. This is shown clearlv bv Figurt.- 13. where unit removals are nearly equivalent to unit load:::g . 11 Growth Rate Figure 14 is of a plot of growth rate as a Function of unit loading for the three systems studied. The filtered waste data for high and If', ilow merges into one curve as it should. Of significance is the fact that with fiber the "appa rent" growth rate is several times that without fiber, due to the effect of the fibers accumulating in the culture. Solids production as gm/gm filtrate COD destroved is listed on Table VI During the low flow period, solids produced varied from 0. 1 to 0. 2 gm/gm COD. However, it was felt the high flow period of February IS through 23 reflected a truer range of expected solids production on fiber free waste - Or 2 to 0. 3 gm/gm COD destroyed I he solids production figures for unfiltered groundwood waste varied from 0 4 to 1.2 gm/gm COD destroyed. These figures reflect the fiber content of the waste which accumulates in the culture. Therefore they are not a true measure of cell synthesis when applied to waste with, a high: fiber content. 4. Batch Rr.'e Studies COD and Mi_S3 progressions are shown or. Figure 1 5A for the two b - tot. rate studies made on February 24, 1965 The January 19 study is rot shown to avoid confusion, but similar results were obtains cl. Both of tr.e COD curves of Figure 1 5A show the two step pro gression noted in Figure 9A of the total mill waste systems. Sequential sub st rate uu.izMioi. is one possible reason for this phenomenon. 'However, was le.t fuither exp! o ra." ion of this point was beyond the scope of t: : ~ ;tudv Unit removal rates tor all three batch studies are plotted as a function o; TbOD concentration m Figure 15B. The filtered waste unit re mo-, a : rate ingh flow; is again several times those exhibited sn the continuous flow units. The two step progression of the batch removal curve is the probable answer to this. The second step of this removal is at .a higher rate and lower TbOD concentration tha.n the first step. It is this higher, rate that is reflected in Figure 15B. More of an over-ail rate is probt.bly obtained in the continuous flow reactor operating a.: steady state conditions. This emphasizes the need for continuous How data to properiv design waste treatment systems. r 12 o. 1 cxici'v and Nutrients No evidence of toxicity was noted with regard to the ground- w o o d m i i 1. w a s t e. Thus waste is deficient in nutrients. Total phosphorus (after alum lloc culatior.) is about 2 mg/1 and total nitrogen content is less than 2 mg/1. Supplemental nutrient feed must be supplied for bio logical treatment of this wa ste. 6. Solids Seuaration Rates Maximum, settling rates (inches/minute) are listed on Table V for mixed liquor from the filtered (high flow) and unfiltered systems. Culture with fiber content from the unfiltered system settles at 1/3 to 1 /1 0 the rate of the filtered waste mixed liquor. Figure 16 is a comparison of typical settling curves of the cultures from the filtered and unfiltered systems. Slower settling and poor compaction of the unfiltered waste culture would require considerably larger final clarifiers and increase sludge volume wastage. Further, fiber going to this system cannot be recovered for use. It is recommended that fiber recovery be complete prior to biological treatment. 7. Color Color is not a problem with grour.dwood w'aste and was not considered in this study. ti 13 \ . CONCLUSION'S Both Total Mil; Waste and Ground'vood Waste are amenable to biological removal ot soluble organic materials. This study has shown this by the operation o; laboratory bench scale treatment units and has provided the necessary information to enab.e complete design of treatment facilities. The effect of fiber content m the wastes is sufficiently detrimental to require removal of fiber prior to the biological systems. The Total Mill Waste exhibits a concentration toxicity which requires consideration in biological treatment. The completely mixed aeration basin is recommended as it provides an immediate dilution along with its other advantages. Both Total Mill Waste and Groundwood Waste will require nutrient feed (nitrogen and phosphorus) to satisfy the nutritional requirements of the mi c r oo rgar.i s m s The color of Total Mill Waste is not appreciably affected by aerobic biological treatment. It is felt that the "apparent" color level in this waste will be found objectionable, nd it is recommended that steps be taken to develop metrods of color- reduction Color will not be a problem c the Sheldon Mu', with groundwood eftluent only. t o t a l m i l l E r r u n n i k_k a ' io r c o m i n i 'ous f i .o 'a O' O O -J ~4 O' a -J N +2'JO' O- O IX x-J O' -J r-j -- O' 'j O' O o -- 3: -C sl'JO-1 A O ~1 O O' Cl 2 X S> C O L O H - A l'i'A U N I 1 -i V> r- r~ rv r. T A B L E III - T O T A L M IL L E F F LU E N T REACTOR KIN ETIC S DATA -j w -j o -- O' C O- O' c -J 'O ji *o ce - <r o' oo o o rj _ r\j tv r*j oc i-- r^ u> o > *-- lt w ui ~ -- . 'j o (NJ * 0-> .* O' -- -- -0 m Nl sO *>J A 03 UUW U C1 N ^ 'O N W O ^ W 05 U> Cw t rv -j r-J o N (J3 ~J M CD O O' -h- CC N O N cr- rv oc 00 |SJ >t- 00 l> O 0 N -U LP WNM c n -o cd oorjo o a- a- vfi -J N O CD O' O' ' O' O' O' I lb Ui cr- oc W W N N A Ui tg - N N O' oo 0s `j' O' O O -- CD O' CD CC b N ^ i- -- O fs; *-- f\j u - CD b - wwww U 4* I*. A N N/ N - C J W ib _ fV >-- -- ui o o i -WN- h- -- -o ~ ~ -- >-- c~> ~ -- -- rj o-- o -u r .*. oj o t\) -- O' CC CD --- NN " b b U N -- -- 03 N nO b -- *- N) a* o rv _ rv b O' 03 CD (V -- O O O' lb vO fv A O sO ~J vO -O -- to ^> c ?03 cK--r: TC,J 0m 1 o~ oo; a D . 0t n"-* o ^a 3 o _p c r~ -- W U- N fv T A B L E IV - T O T A L M IL L E F F L U E N T R EAC TO R K IN E T IC S DA TA rv tn tn ro 4- tn o -o to O' ro on ~ 4 t~ O' oc cr- cr -- l/l w w yi j' in c N O O' oo o c to -- on to o 00 fO ooo -- oo 03 O' Ul U 4i >-- -- -o 4 ro *-- ~J on 4* -J -O -J to 4* -0 4 to 4. tn to -- 4* -- 4* ~J ro ro oo 4* ro tn -J *j -- ft) 4^ ro ro oc--co 00 CD *"J 00 00 -J O - *vJ 4* -o to to to -- o oon -- tO o~-j.cc I - N N 4- to -- ro -o co -- oo o to to ro -- ro to to tn tn o oo to ro o o o to O' -j ~vl o o ro ro t/' otn oo --1 -O -- -Jon N O' LT (J1 CD 00 -- ~j ro ~j o ~j tn tn tn -- ~J tn 4* to O -n > O o c > on O 4k tn -- -- ro o ro ro ro -- ro -- -- to -- C -- ~j c ~o ro o o ooo tn tn OOO to O to tn tn ~ o o O to ' >o oc >* a -- -- to ro -- 4- -- Tw oH O -> cr *1 to -- fo -- ro ro o ro ro -- -- -- -- o ro O -- 4- -- ro ~j --j 4 ro -o H TC 0 =n ,5 C n cl O * i> ? c ^3 0"~ ac ra 3 0o T A B L E V, GROUND WOOD E F rL U K N T R EAC TO R CO NTINUO US FLO W D ATA 6* IT) 0 176 10' |S 10 Tv O C C -- cj> -- c- rv -- -- c O -- O' C -4 C o tv o a x U1 o o cc * c O -- tV O C O -si O cv -4 i Ct -- <V -- .A* Co I TA RLE VI - GROUND WOOD E F F L U E N T REACTOR KIN ETIC S DATA 153 3 .3 700 164 7 .1 490 179 7 .0 590 NM N a- o/ -- C cc O' o o W ffl N o 0 rv oo o ^X NO MW N- iN JNi -4 A* O -4 vv O W-- 0N-4N CD CC -J OocN^cNOoo*NJ UN NO' 4M M^ co o 4 yi 0 0 -- 030*-- O C-* o o o Ui 4 O' 43 N 00 4 O' CT O' -- -- o-- cr a* *4 m O ^ o- ^ iji CM 03 N O' oooOOo -- 0-4-4 0 rvi .a* .* cn o o 4. 1 2. 9 3. 5 -- -- N M rv w it A o O' >5 cn -4 -4 O 00 -- rv -- W CO W N NwOO 1900 1090 1780 AO'AAMO- -n vn O O O O oooo oooo p -- o-- J1 O O' t tc N cn O' o* O' O' cn 4' -- o a' o o O 0s A M C<1 Ui 'Ji A A CD -- --) OC A* -4 CD vn (vi -4 O' vi in v o -4 rv rv yi A v rv -- -- w CM w o I --' o -- CO CO co co rv rv -- O' O A o o. ooo oo ooo C C -- -- O 00 O' * fj N A S -- rv -- -- -- rv -- v.' rv c> O o o D> r a> * 4 rn 0 0 5 n * s; op aOa cr s-s ? c o c c. o N 00 CD u 'I N rv O' 'J3 rv rv o o rv o o- C' --oo-- 4 cn o A ' r* c 23 09 gin T b O D /g m M L S S /D a y O* O 1 /5/65 - 1 /1 6/65 - low fl ow rate A 1 /20/65 - 2/4/65 - high flow rate * Low pH shock FIGURE 1. TOTAL MILL REACTOR - WITHOUT FIBER UNIT REMOVAL RATE VS TbOD CONCENTRATION gm T b O D /jg m M L S S /D n y Jjf- Start-up Period FIGURE 2. TOTAL MILL REACTOR - WITH FIBER UNIT REMOVAL RATE VS TbOD CONCENTRATION 2/5/65-2/16/.6 5 U n it L o .)flin g - gm T h O D /g m M L S S /O n y O 1/5/65 - 1/16/65 - low flow A 1/20/65 - 2/4/65 - high flow # start-up period low pH shock FIGURE 3. TOTAL MILL REACTOR - WITHOUT FIBER UNIT LOADING VS TbOD CONCENTRATION U n it L o 'ichnp; - j>m T I iO D / jim M L S S /IX t ^Start-up Period FIGURE 4. TOTAL MILL REACTOR - WITH FIBER UNIT LOADING VS TbOD CONCENTRATION 2/5/65 - 2/16/65 T h O D /g m M L S S /D a y Unit Loading - gm TbOD/gm MLSS/Day O 1/5/65 - 1/16/65 - low flow A 1 /20/65 - 2/4/65 - high flow low pH shock FIGURE 5. TOTAL MILL REACTOR - WITHOUT FIBER UNIT REMOVAL RATE VS UNIT LOADING I j in T l'iO D /ijm M LSS 5 10 15 2 0 o'n:'. Lo:. d;r.iz ern IbOD, sm MLSS/cLy ^5 FiOo'RE 6 TOTAL MILL REALTOR - VOTTi FIBER LX: I REMO\'.:.L RA . E s'5 UNIT LOADING A / 5 / 6 3 - A i} c / T 5 ii I ( II A 0J C A zAA AO A\o A A A )ii J________ !!! : (i- ; -C j lJ - 1..0.-5 ri o ,Ai ft . . k" 77 . ;u; m grow i ,,: : 1.0 >.D G Altec*, ^d by h:gr. 55 load tr. f-?eci FIGURE S. TOTAL MILL REACTOR - WITH F-3ER GROWTH RATE VS 'OX:T LOADING 2/5/65-2/16/65 \ 1 M LSS - m ^/1 TbOD - m j/l A Without Fiber - Batch Rate Study of 2/5/65 With Fiber - Batch Rate Study of 2/17/65 FIGURE 9A. TOTAL MILL WASTE BATCH RATE TbOD ALT .\ILSS PROGRESSION >5.. I 1f Symbol 0 A Fiber No No Yes Overflow Rate 200 gpd/ sq. ft. 650 gpd/sq. ft. 550 gpd/ sq. ft. Batch Run 1/19/65 2/5/65 2/17/65 Culture Selected from Continuous Reactors FIGURE 9B. TOTAL MILL EFFLUENT - BATCH RATE STUDIES UNIT REMOVAL RATE VS TbOD CONCENTRATION I FIGURE 10. TOTAL MILL REACTOR TYPICAL MIXED LIQUOR SETTLING CURVES T b O D /g m M LS S /D ay Reactor Effluent TbOD Concentration - mg/1 O Without Fiber - high flow 2/18/65 - 2/23/65 A Without Fiber - low flow 1/6/65 - 1/16/65 With Fiber - high flow 2/18/65 - 2/23/65 FIGURE 11. GROUNDWOOD REACTOR UNIT REMOVAL RATE VS TbOD CONCENTRATION i ! i O Without Fiber - High Flow 2/ 18/65 - 2/23/65 With Fiber - High Flow 2/18/65 - 2/23/65 FIGURE 12. GROUNDWOOD REACTOR UNIT LOADING VS EFFLUENT TbOD CONCENTRATION TbO D R e m o ve d /ijm M L S S /D n y 1. 1. E a I r2 O Without Fiber - 1/6/65 - 1/16/65 k 2/18/65 - 2/23/65 With Fiber - 2/18/65 - 2/23/65 FIGURE 13. GROUNDWOOD REACTOR UNIT REMOVAL RATE VS UNIT LOADING G ro w th R ato - D ay ! Unit Loading - gm TbOD/gm MLSS/Day O Without Fiber - high flow 2/18/65 - 2/23/65 A Without Fiber - low flow 1/6/65. - 1/16/65 D With Fiber - high flow 2/ 18/65 - 2/23/65 FIGURE 14. GROUNDWOOD REACTOR GROWTH RATE VS UNIT LOADING M LSS COD - in R/l O Without Fiber With Fiber FIGURE 1 5 A. GROUNDWOOD WASTE BATCH STUDY COD & MLSS PROGRESSION BATCH RATE STUDY OF 2/24/65 gm TbO D R cm o vcd /p m M LS S /D ay i TbOD Concentration - mg/1 Svmbol O A Fiber No No Yes Overflow Rate 380 gpd/sq. ft. 700 gpd/sq. ft. 400 gpd/sq. ft. Batch Run Date 1/19/65 2/24/65 2/24/65 Cultures Selected from Continuous Reactors FIGURE 15B. GROUNDWOOD. WASTE - BATCH RATE STUDIES UNIT REMOVAL RATE VS TbOD CONCENTRATION In te r fa c e H e ig h t - % T o ta l H e ig h t (x 0. 14 = in d ie :- FIGURE 16. GROUNDWOOD REACTOR TYPICAL MIXED LIQUOR SETTLING CURVES a m I APPENDIX 1 \ i i j< \ * \i A PPEND1X A- BENCH SCALE BIOLOGICAL REACTOR - DAILY PROCEDURE It is important tf.at the reactor unit be down for a minimum of time during daily sampling. To expedite this, Sections II and III can be done concurrently with Section I of the following procedure. It is important that the unit be fed continuously and daily. It is per missible to defer sampling on holidays, etc. but the unit must be fed and samples composited for the holiday period. Basic data will include: Raw waste - COD, SS, pH and Volume Reactor - MLSS, pH and Settling Test Effluent - COD, SS, pH and Volume Feed Pump rate setting and stop-start times I. REACTOR PROCEDURE A. Turn off feed pump. B. Remove lid and effluent tube. DO NOT TURN OFF AIR. C. Wash innards ir. reactor contents (be sure all solids are returned to rea ctor --including those on lid). Remove cleaned innards. D. Allow reactor to mix for 1 minute. Remove 1 liter through side connection for settling test. Record interface height (P'5-minute intervals for 30-minute period. Record total height. E. While running settling test, sample mixed liquor for MLSS (2 - 25 ml aliquots). See Section IV. A and B for sampling procedure. F. Replace reactor innards and level up. G. Replace 1 liter used for settling test. H. Refer to 5ection I for new feed preparation. ,1. Refer to Section III for effluent handling. J. On completion of H and I, turn on feed pump. II. SAMPLE PREPARATION A. Filter 20 liters of sample through Buchner Funnel with coarse filter paper. B. Add 20 ml of 100 g/1 (NT-L)7HPO solution to 20 liters of filtered waste. (1 ml/liter). C. Pour in clean and empty feed jar -- record pH, start mixer. P. Sample for-SS ajid COD. See Section IVC A and B for sampling procedure. Use two 25 ml replicate samples. A-2 III. EFFLUENT ANALYSES A. Remove effluent tubing from bottle, invert bottle and mix well. B. Pour approximately one liter into beaker. C. Empty bottle and rinse well with tap water. D. Replace effluent tubing. NOTE: Before proceeding, return reactor to service. E. Mix beaker sample well and sample for SS and COD (2 - 25 ml replicate samples) and record pH. . . SEE SECTION IV. A AND B FOR SAMPLING TECHNIQUE. IV. SAMPLING PROCEDURE A. MLSS AND SS 1. Dessicate membrane filters overnight in aluminum dishes. 2. Tare filter and dish together. 3. Assemble filter apparatus on Test Tube. Draw 25 ml sample with open tip pipette and place in filter holder. 4. Rinse pipette with tap water into filter. 5. Rinse down filter holder sides with tap water as sample is drawn through. 6. Remove holder clamp and top - - cs r efully scrape solids from top assembly and place on membrane filter and place in aluminum pan. NOTE: Care must be taken to replace filter in same pan with which it was tared. 7. Dry pa.r. and filter in over. (S' 103 C for 1 hour--move to dessicator for stabilization. 8. Weigh dried and dessicated pan and filter. Carry significant figure to 0. 0001 g. 9. Calculation: Example - final wt. - 1. 7943 tare wt. - 1.7620 Ag - 0. 0323 X 4 x 104 MLSS or SS 1 292 mg/1 1 292 mg/1 B. COD SAMPLING PROCEDURE 1. Following Section IV. A-6 above, rinse dowm fritted glass filter with tap water to 40 ml/mark on test tube. - Jja.n.sfer content s of te^t.tubent.o^GOD fLask_and rinse tube. . .... i o ml tap water and add to' CbDTlasfe. E fflu e n t S ipho A-3 O E-i U < 2 cl < U o o 2 o c o 2 CO D 0 D 2--l H 2 O U w 2 < u co1 U 2 W C o 2 < a o < 5 u H < 2 w u co 2 < a O < 3