report on the use of scicorp biologic sr2 activated sludge ... sr2 success... · 4/14/2003 · sr2...

1273 North Service Road, E. F2 Oakville, ON, L6H 1A7

Tel: 905 829 1749 Fax: 905 829 5859

Report on the Use of SciCorp BIOLOGIC® SR2

Activated Sludge Wastewater Treatment Plant Flow of 2.9 MGD (11,000 m3/D)

Prepared by:

Maat Environmental Engineering Corp. 1273 North Service Road East, Unit F2

Oakville, Ontario L6H 1A7

March, 2014

Report on the Use of BIOLOGIC SR2 at P a g e | 2

Maple Lodge Farms Activated Sludge Wastewater Treatment Plant

Table of Contents

1.0 Project Background .............................................................................................................................................................. 3

2.0 Wastewater Treatment Process Description ............................................................................................................. 3

2.1 MLF WWTP Configuration ............................................................................................................................................ 3

2.2 Plant Operation .................................................................................................................................................................. 5

2.3 Raw Wastewater Characteristics ............................................................................................................................... 5

3.0 Plant Operating Review, Product Dosing and Performance Assessment ....................................................... 5

3.1 MLF WWTP Improvement Targets ............................................................................................................................ 5

3.2 Product Dose Determination ....................................................................................................................................... 6

3.3 Plant Performance Assessment................................................................................................................................... 6

4.0 Treatment Performance Results ..................................................................................................................................... 7

4.1 Aeration Energy Savings ................................................................................................................................................ 8

4.2 Sludge Reduction .............................................................................................................................................................. 8

4.3 General Operating Conditions (Odour, Turbidity, Plant Upset) ................................................................... 9

5.0 Cost Benefit Analysis ......................................................................................................................................................... 10

6.0 How BIOLOGIC® SR2 Impacts Biological Treatment of Wastewater .......................................................... 11

6.1 Bacteria in Wastewater ............................................................................................................................................... 11

6.2 Micronutrient Requirements .................................................................................................................................... 12

7.0 Conclusions ........................................................................................................................................................................... 14

8.0 References ............................................................................................................................................................................. 15



1.0 Project Background The purpose of this paper is to document the finding of an in depth study of the effectiveness of the use of a micronutrient known as BIOLOGIC® SR2 to a full scale activated wastewater treatment plant (WWTP) suffering from odour issues, sludge accumulation, and poor effluent quality. BIOLOGIC® SR2 is a plant-based organic micronutrient that provides odor control and serves as a bio-stimulant for the treatment of biological waste and wastewater. BIOLOGIC® SR2 is manufactured by SciCorp International Corp. in Barrie, ON. The WWTP where the study was conducted is located in Mississauga, Ontario and is owned and operated by Maple Lodge Foods (MLF). The MLF WWTP consists of a conventional activated sludge treatment facility that treats the wastewater flows generated within the poultry processing plant. The plant was designed to treat an average wastewater flow of 2.9 MGD (11,000 m3/day). SciCorp International Corp. of Barrie, Ontario provided the BIOLOGIC® SR2 product for the study, which was purchased by the WWTP owner. The plant manager made the choice to begin using BIOLOGIC® SR2 in January 2013 in order to reduce plant electrical and sludge handling costs and to address odour and effluent quality issues. Comparison analysis of daily plant operating data from April to June of 2012 (when the product was not used) and from April to June of 2013 (when the product was used) was carried out to assess operational cost savings and improvements to operational efficiency. A summary of this in depth cost benefit analysis of the benefit of adding BIOLOGIC® SR2 is included.

2.0 Wastewater Treatment Process Description

2.1 MLF WWTP Configuration The existing WWTP consists of screens, a dissolved air flotation system, an aeration basin with surface aerators, secondary clarifiers and a polishing aerated lagoon followed by settling lagoon and two storage ponds. The treated effluent is then discharged to an adjacent watercourse. The waste sludge from the secondary clarifier is further digested through a two-cell aerobic sludge digestion system. The digested sludge is then pumped to a belt filter press where it is dewatered for further disposal. The MLF WWTP model was constructed in GPS-X™ version 6.2. The GPS-X plant layout is presented below in Figure 2.1.

Figure 2.1 - MLF Wastewater Treatment Plant Configuration

2.2 Plant Operation The MLF WWTP receives 95% of its flow from Monday to Friday, during the period that the chicken processing facility is in operation. During weekends hydraulic flow and organic load drop off dramatically. This significant drop off in flow during the weekend has historically caused plant upsets and poor operating conditions at the commencement of flows during weekly startup of plant operations. Effluent from the aerobic plant is directed to two (2) polishing lagoons for flow attenuation prior to discharge to a receiving stream that has limited assimilative capacity.

2.3 Raw Wastewater Characteristics The WWTP raw influent has its characteristics as shown in the table below.

Table 2.1 Raw Wastewater Characteristics at MLF WWTP

Parameters Values Unit

Flow 11,000 m3/d

2.9 MGD

BOD 400 - 1,180 mg/L

Population Equivalent 75,000 - 216,000 p.e.

TSS 100 - 800 mg/L

FOG 20 - 200 mg/L

Temp. 10 - 27 °C

Malodor Noticeable n/a

3.0 Plant Operating Review, Product Dosing and Performance Assessment

3.1 MLF WWTP Improvement Targets The MLF WWTP was motivated to implement the use of the BIOLOGIC® SR2 product because it was seeking to improve the performance of the plant in the following ways:

Prevent upset of the plant under various loading conditions

Improve turbidity of discharge effluent

Reduce energy costs related to aeration

Reduce sludge handling and disposal costs

Reduce odour and foaming throughout the plant



3.2 Product Dose Determination The dose rate of the BIOLOGIC® SR2 product was determined based on the average hydraulic flow rate and the average BOD loading. The product dose rate was calculated to be 35 L of product per day. The product was diluted at a ratio of 10:1 (water to product) and added to the system at the wet well pumping station in the processing plant. 3.3 Plant Performance Assessment Product use at the plant was begun in January 2013. After a three month operating period where anecdotal observations by the plant operator showed a marked improvement in the plant operating performance, a decision was made to carry out an in depth data analysis to assess the impact of the product on plant operations. As result a three month analysis of operating data was carried out between April and June of 2013. In order to measure the impacts of the product use, the plant data from the period of April – June 2012 (when product was not used at the plant) to April – June of 2013 (when the product was in use). Daily operating data that was obtained from multiple locations in the plant (influent, clarifiers, lagoon, discharge) included the parameters listed below. Flow Temperature Oxygen uptake Sludge production FOG loading Total phosphorus Alum/caustic use Sludge settling Nitrate/Nitrite BOD MLSS Ecoli TSS MLVSS Daily Aerator Hp pH DO (min/max) TKN

A detailed and comprehensive data assessment was required in order to get meaningful comparisons between the control data (2012) and the test data (2013). Due to the variable operating conditions of the WWTP, the flow and BOD loading varied significantly day to day, week to week and year to year. A significant example of this was that that the average daily BOD loading to the plant was approximately 40% higher in 2013 compared with 2012. As a result, it was necessary to normalize the data so that the treatment performance of the plant could be compared to the control performance on a similar basis. To do this the key parameters were calculated and reported based on a basis of 1,000 kg/BOD loading per day. Normalizing the data to a consistent basis allowed for meaningful comparison and assessment of plant performance parameters. The impact of the product addition could not be quantified for all of the parameters because not all parameters were measured in the effluent (ie nitrate/nitrite, FOG etc.). A detailed cost benefit analysis was also carried out using cost factors including energy cost, chemical costs and sludge handling costs. Parameters that were not numerically measured at the plant were assessed with by the plant operators, who compared the test conditions with what they knew to be normal operating conditions These parameters included overall plant capacity, foaming, FOG accumulation, odour production and effluent clarity.



4.0 Treatment Performance Results A comparison of operating data allowed for a meaningful assessment of treatment plant performance between the time periods April – June 2012 (the period used as the control data when the product was not used) and April – June 2013 (the period used as the test data when BIOLOGIC® SR2 was used). Improvement in general operating performance was confirmed by the observation of plant operators in relation to the general operating conditions of the plant. Key observations included:

24% increase in treatment plant capacity without causing upset while improving effluent quality

Odour reduction in all treated areas of the plant Persistent brownish color associated with final effluent was eliminated.

The data confirmed significant improvement throughout the plant during the period of treatment with BIOLOGIC® SR2. Specific consistent results were seen in the reduced energy requirements for the aeration blowers to maintain desired dissolved oxygen levels, reduced sludge generation and improved TSS, COD, BOD and Total Phosphorus removal rates. The results are presented in Table 4.1. Table 4.1 Comparison of WWTP Operating Data – Control vs Biologic SR2 Use

Average Average

Daily Value Daily Value Percent

Parameter Unit 2012 2013 Change

(Control) (Biologic SR2)

BOD Load kg/day 4,329 6,235 44%

Max. D.O. in Aeration Tank mg/L 3.13 3.32 6%

Min. D.O. in Aeration Tank mg/L 2.12 2.14 1%

Air Supplied m3/ 1000kg BOD/day 4,105 3,211 -22%

Daily Aerator Hp HP/1000kg BOD 210 163 -22%

Sludge Settleability SVI 94 88 -6%

Wet Sludge Produced ton /1000kg BOD/day 10.21 7.55 -26%

Daily Alum Dose mg/L/1000kg BOD 35 26 -27%

Clarifier Filtered COD(May and June) mg/L 45.6 37.8 -17%

Clarifier BOD (May and June) mg/L 7.4 4.2 -43%

Final Effluent TSS mg/L 11.1 8.9 -19%

Clarifier Total Phosphorus mg/L 1.71 0.84 -51%



As can be seen from Table 4.1, despite a significant increase in loading from the control period to the test period, performance of the plant was significantly enhanced as a result of the addition of the product. Plant performance benefits included a reduction in energy consumption by the blowers (hp), a decrease in sludge produced, an increase in sludge settleability (despite decreasing alum dosing) and an increase in COD, TSS and phosphorus removal rates. 4.1 Aeration Energy Savings As can be seen in Table 4.1 and Figure 4.2 (below), the WWTP required 22% less air supply on a normalized basis to maintain required minimum and maximum dissolved oxygen levels in the aeration basin, when BIOLOGIC® SR2 was in use at the plant. As a result, 22% less energy (hp) was expended per kg of BOD removal in blower operation. This was identified as a key benefit to the WWTP because of the associated energy savings.

4.2 Sludge Reduction As can be seen in Table 4.1, as the WWTP produced 26% less sludge on a normalized basis when BIOLOGIC® SR2 product was in use at the plant. Further, the data also confirmed that 27% less alum was needed to promote sludge settleability. Sludge settleability, as measured by SVI, also improved

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30-Mar 19-Apr 9-May 29-May 18-Jun 8-Jul

Ae

rato

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ors

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Figure 4.1 Aerator Energy Consumption Before and After Biologic SR2 Application

2012 (without SR2)

2013 (with SR2)

210

163



by measureable amount. A reduction is sludge produced was very important to the plant because it allowed for significant savings in sludge dewatering, processing and disposal costs. 4.3 General Operating Conditions (Odour, Turbidity, Plant Upset)

The plant operators also reported a significant improvement in general operating conditions at the plant after beginning treatment with BIOLOGIC® SR2. One major benefit that was noted was that according to the plant manager odour was significantly reduced in all areas of the plant with no odour noticeable at any location within 100 feet of the facility. A second major benefit was the elimination of the persistent brownish colour that had been present in the final effluent of the plant. According to the plant manager,

“If the Ministry of the Envrionment personnel could google-map the lagoons after the SR2 application and compare with those prior to the SR2 usage, they would see significant improvements in clarity and colour change. The yellowish tainted colour in the final effluent, which has always been there since I started to work 30 years ago, is totally gone.”

A third operational benefit was that after beginning treatment with BIOLOGIC® SR2 the system was able to handle significant spikes in loading without upset – whereas similar loadings caused upset historically. Computer modelling of the WWTP plant based on the control and treatment operating data showed a 24% increase in treatment plant capacity without plant upset while maintaining final effluent quality.

Settling Lagoon



5.0 Cost Benefit Analysis The use of BIOLOGIC® SR2 allowed for a significant reduction in energy use required for aeration as well as a significant reduction in sludge generated at the plant requiring disposal. The cost benefit implications of these two benefits were calculated based on the plants known energy costs and sludge handling costs. Based on the cost assessment that was carried considering only the aeration energy savings and sludge handling cost reductions it was determined that the use of BIOLOGIC® SR2 resulted in a daily operational cost savings of $1,119. This cost benefit calculation does not quantify or include the additional benefits of odour reduction, improvement in plant capacity, improvement in effluent quality and reductions in FOG and foam throughout the plant. A summary of the cost savings calculations are presented below:

Aeration Energy Savings* hp/1000 kg BOD/d in 2012 before SR2 Usage = 210 hp

hp/1000 kg BOD/d in 2013 after SR2 Usage = 163 hp

hp reduction/1000 kg BOD/d after SR2 Usage = 47 hp

Average loadings in kg BOD per day in 2013 = 6100 kg

Savings in Aeration Energy Calculation @ $0.11/kWh = 47x6100/1000x24x0.75x0.11

Savings in Aeration Energy, $/d = $568/day

Wet sludge ton/1000kgBOD/d in 2012 before SR2 Usage = 10.21 kg

Wet sludge ton/1000kgBOD/d in 2013 after SR2 Usage = 7.55 kg

Wet sludge haulage fee per wet ton, $/ton $30/ton

Savings in wet sludge haulage calculation = (10.21-7.55)x6100/1000x30

Savings in Wet Sludge Haulage, $/d= $487/day

Belt Filter Press polymer cost per day After SR2 Usage**, $/d $124/day

Belt Filter Press polymer cost per day before SR2 Usage, $/d $188/day

Savings in Polymer Consumption, $/d $64/day

Total Savings, $/d (dollars per day) = $1,119/day

*Based on Data from April-June of 2012 and 2013 ** Based on the usage in the month of May of 2012 and 2013



6.0 How BIOLOGIC® SR2 Impacts Biological Treatment of Wastewater 6.1 Bacteria in Wastewater

The breakdown of organic waste is accomplished by a wide variety of bacteria that are present in wastewater and are generally native to the human and animal digestive tracts. These bacteria are classified in many ways but in general can be described in terms as functioning as aerobic, anaerobic, and facultative. These classifications describe the ability of the bacteria to survive and multiply in the presence and/or absence of oxygen. This characteristic is important in organic decomposition of wastewater. The design and operation of wastewater treatment facilities and sewage holding tanks, among other applications, will dictate which groups of bacteria thrive and dominate in the system, based on a variety of factors including oxygen availability, macronutrient supply, and the presence of micronutrients.

Often, the availability of micronutrients, which include vitamins and minerals needed in trace amounts for optimal growth and reproduction, are the limiting material for growth and synthesis of new individual bacteria within a microbial population. This is especially true in wastewater systems where organic macronutrients are plentiful. For this reason, the input of select micronutrients can cause drastic change to the dominant bacterial populations. An overview of metabolic patterns of major bacterial groups present in wastewater treatment systems is presented as follows:

A. In Aerobic Wastewater Treatment Systems 1, 2, 4 1. Hydrolyzing bacteria break down solids and generate dissolved organics generally

measured as BOD (Biochemical Oxygen Demand) and COD (Chemical Oxygen Demand) 2. Acidifying bacteria then break down the dissolved organics to acetic acid 2 3. Aerobes convert 75% of the generated acetic acid to new sludge, consuming O2 and

releasing CO2

The problems encountered as hydrolyzing bacteria digest solids are important to note. The rate of reaction is generally limited in the first step, i.e. in the breakdown of solids to BOD and COD, causing overall inefficiencies in the process. The demand for O2, in the third step, is high and can be costly, especially in large wastewater treatment plants that operate aeration systems to provide the necessary oxygen. Finally, as 75% of the dissolved acetic acid generated in step 2 is converted to new sludge 3 in the third step, high sludge dewatering and disposal costs are incurred.

B. Anaerobic Wastewater Treatment Systems 1, 2, 4 1. Hydrolyzing bacteria break down solids and generate dissolved organics generally

measured as BOD and COD 2. Acidifying bacteria then break down dissolved organics to acetic acid 2

1 Wastewater Bacteria, Geradi, 2006 2 Handbook of Waste and Wastewater Microbiology, Mara, 2003 3 Operation of Municipal Wastewater Treatment Plants, Sixth Edition (20-7) 4 Wastewater Bacteria, Gerardi, 2006



3. Without oxygen, anaerobic bacteria convert 10% of acetic acid to new sludge, and the remaining acetic acid to methane and CO2. 4 Sulphur-reducing bacteria are active in anaerobic conditions and generate hydrogen sulphide gas

Anaerobic processes are typically not used for domestic wastewater treatment due to odour problems. The generation of hydrogen sulphide, a noxious gas, causes odour and has the potential to cause respiratory and neurological illness at high concentrations.

C. Facultative Wastewater Treatment Systems 1, 2, 4 1. Hydrolyzing bacteria break down solids and generate dissolved organics generally

measured as BOD and COD 2. Acidifying bacteria break down dissolved organics to acetic acid 3. In the presence of low oxygen levels, facultative bacteria convert 70-80% of acetic acid

to methane and CO2, with 20-30% of acetic acid converted to new sludge

6.2 Micronutrient Requirements

The micronutrient requirements for different bacterial populations can vary quite significantly. The presence or absence of micronutrients determines which groups of bacteria become dominant in a system. As micronutrients are depleted the ability of specific bacteria to function degrades. As a result, ensuring that desired micronutrients are continually present in a system will ensure that desirable bacteria populations will thrive. Testing of BIOLOGIC® SR2 in wastewater systems and systems that handle organic waste has consistently shown that the presence of the product at very low concentrations correlates with very significant reduction of hydrogen sulphide production and other malodors. In addition, sludge generation in systems where the product is in use is significantly inhibited, oxygen uptake is reduced and methane (no odor) production is enhanced. The results indicate that the micronutrients in BIOLOGIC® SR2 inhibit bacteria that produce hydrogen sulphide and stimulate bacteria that produce methane. Also, the efficiency of the bacteria in the system that breaks down organic material (BOD, COD, TSS, FOG, sludge) is significantly enhanced such that the breakdown occurs significantly more quickly with significantly less oxygen demand. These bacteria, (that are stimulated by BIOLOGIC® SR2) are also highly efficient utilizers of acetic acid, enhancing the denitrification process in the system. BIOLOGIC® SR2 products are a trademarked blend of organically derived and plant based micronutrients that promote the activity of bacteria by supplying the right vitamins, minerals, and amino acids in adequate amounts. BIOLOGIC® products have been shown to beneficially impact wastewater plants by:

Increasing overall removal rates for organic solids, fats, and grease by promoting the growth of hydrolyzing bacteria so that hydrolysis of waste is no longer rate-limiting



Decreasing new sludge production by allowing anaerobic and facultative bacteria to become more active in both aerobic and anaerobic systems, leading to lower sludge volume production and therefore reducing costs associated with sludge removal, dewatering, and disposal

Reducing oxygen demand by activating facultative bacteria in biomass flocs

Decreasing and/or eliminate the need for aeration in certain situations

Stimulating the acidification bacteria that convert dissolved organics to acetic acid

Stimulating the anaerobic bacteria in facultative/ anaerobic systems and in accumulated sludge layers

Eliminating production of malodors associated with activity of sulphur reducing anaerobic activity



7.0 Conclusions In conclusion, the operating performance of the MLF Activated Sludge Wastewater Treatment Plant has been shown to be significantly enhanced by the addition of BIOLOGIC® SR2 to the system. The use of BIOLOGIC® SR2 resulted in a daily savings of $1,119/day in energy and sludge handling costs. The following is a list of the additional measurable benefits to the MLF WWTP as a result of the use of BIOLOGIC® SR2.

22% reduction in aeration energy cost;

26% less sludge generated;

In excess of 24% increase in treatment plant capacity without plant upset while maintaining final effluent quality;

Resistance to organic load peaks;

Significantly improved removal rates of BOD, COD, TSS and total phosphorus;

Disappearance of odours throughout the facility;

Better floc and improved sludge settleability (SVI consistently less than 90) related to more efficient breakdown of FOG;

Less foam in the aeration basin due to significant breakdown of FOG;

At least 25% less polymer used for sludge dewatering;



8.0 References

Gerardi, Michael H., Wastewater Bacteria Hoboken, New Jersey: John Wiley & Sons Inc., 2006. Mara, Duncan, and Nigel J. Horan, Handbook of Water and Wastewater Microbiology. Academic

Press, 2003. Water Environment Federation, Operation of Municipal Wastewater Treatment Plants: MoP No.11

Sixth Edition. WEF Press: Toronto, 2008. Craig Oldham. Plant Manager, Maple Lodge Farms Wastewater Treatment Plant, Mississauga, Ontario,

June, 2013. This report was authored by: Derk Z. Maat M.Eng., P.Eng Maat Environmental Engineering Corp.

report on the use of scicorp biologic sr2 activated sludge ... sr2 success... · 4/14/2003 · sr2...

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