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March 2013 Solids Settleability prepared 2012 Emerging Technologies Technology Summary Magnetite Ballasted Activated Sludge Objective: State of Development: Increase settling rates of activated sludge flocs and Innovative. capacity of activated sludge processes without expansion of reactor volume. Description: The mixed liquor suspended solids concentration of a typical activated sludge process is limited to 3,500 to 6,000 mg/L depending on the loading rates and settleability characteristics of the biomass. Operating with mixed liquor concentrations above this range tends to overload the secondary clarifiers with respect to solids loading. Enhanced sedimentation activated sludge processes increase settling velocities and improve floc formation, thereby allowing for greater solids loadings at the secondary clarifiers while maintaining effluent quality. These improved settling characteristics allow for activated sludge systems to be operated at higher mixed liquor concentrations than typical activated sludge systems, providing increased biomass to treat larger loads or to maintain the longer solids retention time necessary for stable nitrification. Facilities can take advantage of this capability by reducing the required aerobic volume (because of the increased mixed liquor concentration) and converting the previously aerobic volume to anoxic or anaerobic treatment stages to provide nutrient removal in the same reactor volume. Example Process – BioMagTM BioMagTM: The BioMagTM process adds magnetite to the mixed liquor as a ballast to enhance settling characteristics. The magnetite is an inert and fully oxidized form of iron ore (Fe3O4), which increases the density of activated sludge flocs to increase settling rates by as much as 30 times conventional settling rates. The enhanced settling characteristics allow the activated sludge system to be operated at up to three times the mixed liquor concentration of conventional systems. The magnetite is added to the mixed liquor in a ballast mix tank. The majority of the magnetite remains with the biomass and is returned with the RAS. As sludge is wasted from the system, the waste activated sludge passes through a shear mill to liberate the magnetite before passing over a magnetic drum separator to recover the magnetite before sludge wasting. Approximately 95 to 99% of the magnetite is recovered in the process. The BioMagTM process is suitable for BOD, nitrogen, and biological phosphorus removal. This process was developed from the CoMag enhanced sedimentation process, which uses magnetite to improve settleability of raw wastewater for treating overflows or for tertiary removal of effluent suspended solids (see the process description in Chapter 2). Comparison to Established Technologies: Magnetite-ballasted activated sludge competes with conventional activated sludge and with other process enhancements that allow operation with increased biomass such as Integrated fixed-Film Activated Sludge and Membrane BioReactor. The main benefit of the magnetite-ballasted activated sludge process is its ability to enhance the capacity and nutrient removal performance of activated sludge systems without adding capital- intensive new tankage or energy-intensive operating costs. The aerobic granular sludge process (AGSP, e.g., Nereda) is another approach to increasing the density of biological solids. Available Cost Information: The primary applications for magnetite-ballasted active sludge are in upgrading municipal WWTPs and treating strong organic wastes from the food and beverage industry. Most of these applications involve integrating BioMagTM in an existing facility, thereby requiring custom solutions. As a result, prices are driven by multiple factors. Nonetheless, early experience has shown that BioMagTM capital and operating costs are comparable to or lower than competing solutions. For example, at the 5.5-MGD Easterly WWTP in Marlborough, MA, the capital cost to implement BioMagTM was estimated at $12.1 million (including structures), whereas implementing the tertiary ballasted sedimentation alternative was estimated at $16 million. Annual operating cost for BioMagTM was estimated at $740,000 versus $650,000 for the alternative. Wastewater Treatment and In-Plant Wet Weather Management 3-25PDF Image | Emerging Tech for Wastewater Treatment
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