Sewage sludge treatment describes the processes used to manage and dispose of sewage sludge produced during sewage treatment. Sludge treatment is focused on reducing sludge weight and volume to reduce transportation and disposal costs, and on reducing potential health risks of disposal options. Water removal is the primary means of weight and volume reduction, while pathogen destruction is frequently accomplished through heating during thermophilic digestion, composting, or incineration. The choice of a sludge treatment method depends on the volume of sludge generated, and comparison of treatment costs required for available disposal options. Air-drying and composting may be attractive to rural communities, while limited land availability may make aerobic digestion and mechanical dewatering preferable for cities, and economies of scale may encourage energy recovery alternatives in metropolitan areas.
Sludge is mostly water with some amounts of solid material removed from liquid sewage. Primary sludge includes settleable solids removed during primary treatment in primary clarifiers. Secondary sludge is sludge separated in secondary clarifiers that are used in secondary treatment bioreactors or processes using inorganic oxidizing agents. In intensive sewage treatment processes, the sludge produced needs to be removed from the liquid line on a continuous basis because the volumes of the tanks in the liquid line have insufficient volume to store sludge. (Spanish and Arabic versions are available online for free) This is done in order to keep the treatment processes compact and in balance (production of sludge approximately equal to the removal of sludge). The sludge removed from the liquid line goes to the sludge treatment line. Aerobic processes (such as the activated sludge process) tend to produce more sludge compared with anaerobic processes. On the other hand, in extensive (natural) treatment processes, such as ponds and constructed wetlands, the produced sludge remains accumulated in the treatment units (liquid line) and is only removed after several years of operation.
Sludge treatment options depend on the amount of solids generated and other site-specific conditions. Composting is most often applied to small-scale plants with aerobic digestion for mid-sized operations, and anaerobic digestion for the larger-scale operations. The sludge is sometimes passed through a so-called pre-thickener which de-waters the sludge. Types of pre-thickeners include centrifugal sludge thickeners, rotary drum sludge thickeners and belt filter presses. Dewatered sludge may be incinerated or transported offsite for disposal in a landfill or use as an agricultural soil amendment.
Energy may be recovered from sludge through methane gas production during anaerobic digestion or through incineration of dried sludge, but energy yield is often insufficient to evaporate sludge water content or to power blowers, pumps, or centrifuges required for dewatering. Coarse primary solids and secondary sewage sludge may include toxic chemicals removed from liquid sewage by sorption onto solid particles in clarifier sludge. Reducing sludge volume may increase the concentration of some of these toxic chemicals in the sludge.
Terminology
Biosolids
"Biosolids" is a term often used in wastewater engineering publications and public relations efforts by local water authorities when they want to put the focus on reuse of sewage sludge, after the sludge has undergone suitable treatment processes. In fact, biosolids are defined as organic wastewater solids that can be reused after stabilization processes such as anaerobic digestion and composting. The term "biosolids" was introduced by the Water Environment Federation in the U.S. in 1998. However, some people argue that the term is a euphemism to hide the fact that sewage sludge may also contain substances that could be harmful to the environment when the treated sludge is applied to land, for example environmental persistent pharmaceutical pollutants and heavy metal compounds.
Treatment processes The sludges accumulated in a wastewater treatment process must be treated and disposed of in a safe and effective manner. In many large plants the raw sludges are reduced in volume by a process of digestion.
Thickening
Thickening is often the first step in a sludge treatment process. Sludge from primary or secondary clarifiers may be stirred (often after addition of clarifying agents) to form larger, more rapidly settling aggregates. Primary sludge may be thickened to about 8 or 10 percent solids, while secondary sludge may be thickened to about 4 percent solids. Thickeners often resemble a clarifier with the addition of a stirring mechanism. Thickened sludge with less than ten percent solids may receive additional sludge treatment while liquid thickener overflow is returned to the sewage treatment process.
Dewatering
Water content of sludge may be reduced by centrifugation, filtration, and/or evaporation to reduce transportation costs of disposal, or to improve suitability for composting. Centrifugation may be a preliminary step to reduce sludge volume for subsequent filtration or evaporation. Filtration may occur through underdrains in a sand drying bed or as a separate mechanical process in a belt filter press. Filtrate and centrate are typically returned to the sewage treatment process. After dewatering sludge may be handled as a solid containing 50 to 75 percent water. Dewatered sludges with higher moisture content are usually handled as liquids.
Digestion Many sludges are treated using a variety of digestion techniques, the purpose of which is to reduce the amount of organic matter and the number of disease-causing microorganisms present in the solids. The most common treatment options include anaerobic digestion, aerobic digestion, and composting. Sludge digestion offers significant cost advantages by reducing sludge quantity by nearly 50% and providing biogas as a valuable energy source.
The purpose of digestion is to reduce the amount of organic matter and the number of disease-causing microorganisms present in the solids. The process is often optimized to generate methane gas which can be used as a fuel to provide energy to power the plant or for sale.
Anaerobic digestion
Anaerobic digestion is a bacterial process that is carried out in the absence of oxygen. The process can either be thermophilic digestion, in which sludge is fermented in tanks at a temperature of 55 °C, or mesophilic, at a temperature of around 36 °C. Though allowing shorter retention time (and thus smaller tanks), thermophilic digestion is more expensive in terms of energy consumption for heating the sludge.
Mesophilic anaerobic digestion (MAD) is also a common method for treating sludge produced at sewage treatment plants. The sludge is fed into large tanks and held for a minimum of 12 days to allow the digestion process to perform the four stages necessary to digest the sludge. These are hydrolysis, acidogenesis, acetogenesis, and methanogenesis. In this process the complex proteins and sugars are broken down to form more simple compounds such as water, carbon dioxide, and methane.Biomass – Using Anaerobic Digestion. esru.strath.ac.uk
Anaerobic digestion generates biogas with a high proportion of methane that may be used to both heat the tank and run engines or microturbines for other on-site processes. Methane generation is a key advantage of the anaerobic process. Its key disadvantage is the long time required for the process (up to 30 days) and the high capital cost. Many larger sites utilize the biogas for combined heat and power, using the cooling water from the generators to maintain the temperature of the digestion plant at the required 35 ± 3 °C. Sufficient energy can be generated in this way to produce more electricity than the machines require.
The Sludge Treatment Facility ("T-PARK") is able to provide electricity for its own operation and even to the Hong Kong public power grid by making use of the heat generated during the process of the sludge incineration.
Aerobic digestion
Aerobic digestion is a bacterial process occurring in the presence of oxygen resembling a continuation of the activated sludge process. Under aerobic conditions, bacteria rapidly consume organic matter and convert it into carbon dioxide. Once there is a lack of organic matter, bacteria die and are used as food by other bacteria. This stage of the process is known as endogenous respiration. Solids reduction occurs in this phase. Because the aerobic digestion occurs much faster than anaerobic digestion, the capital costs of aerobic digestion are lower. However, the operating costs are characteristically much greater for aerobic digestion because of energy used by the blowers, pumps and motors needed to add oxygen to the process. However, recent technological advances include non-electric aerated filter systems that use natural air currents for the aeration instead of electrically operated machinery.
Aerobic digestion can also be achieved by using diffuser systems or jet aerators to oxidize the sludge. Fine bubble diffusers are typically the more cost-efficient diffusion method, however, plugging is typically a problem due to sediment settling into the smaller air holes. Coarse bubble diffusers are more commonly used in activated sludge tanks or in the flocculation stages. A key component for selecting diffuser type is to ensure it will produce the required oxygen transfer rate.
Sidestream treatment technologies Sludge treatment technologies that are used for thickening or dewatering of sludge have two products: the thickened or dewatered sludge, and a liquid fraction which is called sludge treatment liquids, sludge dewatering streams, liquors, centrate (if it stems from a centrifuge), filtrate (if it stems from a belt filter press) or similar. This liquid requires further treatment as it is high in nitrogen and phosphorus, particularly if the sludge has been anaerobically digested. The treatment can take place in the sewage treatment plant itself (by recycling the liquid to the start of the treatment process) or as a separate process.
Phosphorus recovery One method for treating sludge dewatering streams is by using a process that is also used for phosphorus recovery. Another benefit for sewage treatment plant operators of treating sludge dewatering streams for phosphorus recovery is that it reduces the formation of obstructive struvite scale in pipes, pumps and valves. Such obstructions can be a maintenance headache particularly for biological nutrient removal plants where the phosphorus content in the sewage sludge is elevated. For example, the Canadian company Ostara Nutrient Recovery Technologies is marketing a process based on controlled chemical precipitation of phosphorus in a fluidized bed reactor that recovers struvite in the form of crystalline pellets from sludge dewatering streams. The resulting crystalline product is sold to the agriculture, turf and ornamental plants sectors as fertilizer under the registered trade name "Crystal Green".
Composting
Composting is an aerobic process of mixing sewage sludge with agricultural byproduct sources of carbon such as sawdust, straw or wood chips. In the presence of oxygen, bacteria digesting both the sewage sludge and the plant material generate heat to kill disease-causing microorganisms and parasites. Maintenance of aerobic conditions with 10 to 15 percent oxygen requires bulking agents allowing air to circulate through the fine sludge solids. Stiff materials like corn cobs, nut shells, shredded tree-pruning waste, or bark from lumber or paper mills better separate sludge for ventilation than softer leaves and lawn clippings. Light, biologically inert bulking agents like shredded tires may be used to provide structure where small, soft plant materials are the major source of carbon.