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T H U R S D A Y, D E C E M B E R 0 3 , 2 0 1 5

Design of UASBR Upflow Anaerobic Sludge Blanket Reactor

These are the 4 top applications of the UASB reactors:
o

Breweries and beverage industry

Distilleries and fermentation industry

Food Industry, Slaughter Houses.

Pulp and paper

Together, these four industrial sectors account for 87% of the applications. However, the
applications of the technology are rapidly expanding, including:
1.

treatment of chemical and petrochemical industry effluents

2.

textile industry wastewater

3.

landfill leachates

4.

Conversions in the sulfur cycle and removal of metals.

YOU NEED AN EXPERT WITH SPECIFIC INDUSTRY WISE EXPERIENCE TO

DESIGN A PROPER UASBR SYSTEM.
The UASB reactor can be designed as circular or rectangular. Modular design can be preferred
when the volume of reactor exceeds about 400 m3. It is necessary to select proper range of
operating parameters for design, such as, OLR, SLR, superficial liquid upflow velocity (referred as
liquid upflow velocity), and HRT. The literature recommendations for all these parameters and
design procedure to account these recommendations are given below.

What is Upflow Anaerobic Sludge Blanket?

Upflow anaerobic sludge blanket, or UASB, is a form of anaerobic (oxygen-free)
digester used in wastewater treatment. It is a methane-producing digester which
uses an anaerobic process and forming a blanket of granular sludge and is
processed by anaerobic microorganism.
UASB was developed in 1970s by Letinga in the Netherlands. It is essentially a
suspended growth system in which proper hydraulic retention time
(HRT) and organic loading rate (OLR) is maintained in order to facilitate the
dense biomass aggregation known as granulation.

How to Design UASB Pond

About a week ago, I asked the appointed vendor who will design and supply
wastewater treatment unit about design calculation of UASB pond. The design of
UASB pond is a function of:
COD input of wastewater
Flow of wastewater
Organic loading rate
Hydraulic retention time

Organic loading rate is a measure of the biological conversion capacity of

the anaerobic digestionsystem. It is expressed in kg Chemical Oxygen Demand
(COD) or Volatile Solids (VS) per cubic meter of reactor. A relatively high organic
loading rate facilitated the formation of anaeronic granules in UASB systems.
In general, there are two ways to design an UASB reactor.
1.

If input COD is 5000 15000 mg/L or more, the design

method should be used based on Organic Loading Rate
2.
If input COD less than 5000 mg/L, the design method should
be based on velocity
Lets take an example.
Data
Waste water input flow rate (Q) = 62.5 m3/day
COD = 15,000 mg/L = 15 kg/m3
Organic loading rate = 5.5 kg COD/m3.day (I found that organic loading rate is
sometimes state of art in wastewater treatment design. Some vendors may have
already had the data)
Volume of tank = Q x C /OLR = 62.5 x 15 / 5.5 = 170 m3
Note: the above volume is the actual volume. You need to add more volume (as void
volume).
Calculating an UASB Tank Based on Velocity
When input COD < 5,000 mg/l, using the method base on ORL is not effective in operation process
because the granular sludge will be hardly formed. Therefore, the design criteria must be:
Up-flow velocity V 0,5 m/h. Hydraulic retention time HRT 4 h Chosen in table 1, the height of
sludge is Hs = 3 5 m The height of setting area HSe 1.2 m The volume of the UASB reactor: W
= Q x HRTThe area of the UASB reactor: A = V / Q
Read on http://www.slideshare.net/nitinyadav16/anaerobic-treatment-of-industrail-wastewater
GSL Separator Design

Slope of the separator bottom from 45 60oFree surface in the aperture between the gas
collectors: 15 20% of reactor area.Height of separator from 1.5 2 m
The baffles to be installed beneath the gas domes should overlap the edge of the domes over a
distance from 10 20 cm
Construct material: In the anaerobic conditions of an UASB reactor, there is a risk of corrosion in
two main situations:
Some H2S gas can pass the GSL separator and accumulate above the water level in the top of the
reactor. This will be oxidized to sulphate by oxygen in the air to form Sulphuric Acid that will in
turn cause corrosion of both concrete and steel. Below the water level: Calcium Oxide, (CaO), in
concrete can be dissolve with by Carbon Dioxide, (CO2), in the liquid in low pH conditions. To avoid
these problems, the material used to construct the UASB reactor should be corrosion resistant,
such as stainless steel or plastics, or be provided with proper surface coatings, (e.g. coated
concrete rather than coated steel, plastic covered with impregnated hardwood for the settler,
plastic fortified plywood, etc).

YOU NEED ONE TECHNICAL PERSON WITH

EXPERIENCE TO RUN A PROPER UASBR SYSTEM.
Operation & Maintenance (O&M)
Operation criteria: The optimum pH range is from 6.6 to 7.6 The wastewater temperatures should
not be < 5 C because low temperatures can impede the hydrolysis rate of phase 1 and the
activity of methanogenic bacteria. Therefore in winter season, methane gas may be needed to
heat the wastewater to be treated in the reactor.
Always maintain the ratio of COD : N : P = 350 : 5 : 1 If there is a deficiency of some of these
nutrients in the wastewater nutrient addition must be made to sustain the micro-organisms.
Chemicals that are frequently used to add nutrients (N, P) are NH4H2PO4, KH2PO4, (NH4)2CO3
Suspended solid (SS) can affect the anaerobic process in many ways:
Formation of scum layers and foaming due to the presence of insoluble components with floating
properties, like fats and lipids. Retarding or even completely obstructing the formation of sludge
granules. Entrapment of granular sludge in a layer of adsorbed insoluble matter and sometimes
also falling apart (disintegration) of granular sludge. A sudden and almost complete wash-out of
the sludge present in reactor Decline of the overall methanogenic activity of the sludge due to

the SS concentration in the

feed to the reactor should not exceed 500
mg/l In phase 2 and 3 the pH will be reduced and the buffer capacity of wastewater may
accumulation of SS Therefore,

have to be increased to provide alkalinity of 1000 5000 mg/l CaCO3

Start-up:

An UASB reactor requires a long time for start-up, e.g. from 2 3 weeks in good conditions (t >
20oC) and sometimes the start-up can take up to 3 4 months. In start-up process, hydraulic
loading must be 50% of the design hydraulic loading.
The start-up of the UASB reactor can be considered to be complete once a satisfactory
performance of the system has been reached at its design load.

Source: http://nptel.ac.in/courses/105104102/Lecture
%2032.htm
UASB Units
UASB type units are one in which no special media have to be used
since the sludge granules themselves act as the 'media' and stay in
suspension. UASB system is not patented. A typical arrangement of a
UASB type treatment plant for municipal sewage would be as follows:
1. Initial pumping
2. Screening and degritting
3. Main UASB reactor
4. Gas collection and conversion or conveyance
5. Sludge drying bed
6. Post treatment facility
In the UASB process, the whole waste is passed through the anaerobic
reactor in an upflow mode, with a hydraulic retention time (HRT) of only
about 8-10 hours at average flow. No prior sedimentation is required. The
anaerobic unit does not need to be filled with stones or any other media;
the upflowing sewage itself forms millions of small "granules" or particles
of sludge which are held in suspension and provide a large surface area
on which organic matter can attach and undergo biodegradation. A high
solid retention time (SRT) of 30-50 or more days occurs within the unit.
No mixers or aerators are required. The gas produced can be collected
and used if desired. Anaerobic systems function satisfactorily when
temperatures inside the reactor are above 18-20C. Excess sludge is

removed from time to time through a separate pipe and sent to a simple
sand bed for drying.
Design Approach
Size of Reactor: Generally, UASBs are considered where temperature in
the reactors will be above 20C. At equilibrium condition, sludge
withdrawn has to be equal to sludge produced daily. The sludge produced
daily depends on the characteristics of the raw wastewater since it is the
sum total of (i) the new VSS produced as a result of BOD removal, the
yield coefficient being assumed as 0.1 g VSS/ g BOD removed, (ii) the
non-degradable residue of the VSS coming in the inflow assuming 40% of
the VSS are degraded and residue is 60%, and (iii) Ash received in the
inflow, namely TSS-VSS mg/l. Thus, at steady state conditions,
SRT= Total sludge present in reactor, kg

Sludge withdrawn per day,

kg/d
= 30 to 50 days.
Another parameter is HRT which is given by:
HRT= Reactor volume, m3
Flow rate, m3/h
= 8 to 10 h or more at average flow.
The reactor volume has to be so chosen that the desired SRT value is
achieved. This is done by solving for HRT from SRT equation assuming (i)
depth of reactor (ii) the effective depth of the sludge blanket, and (iii) the
average concentration of sludge in the blanket (70 kg/m3). The full depth
of the reactor for treating low BOD municipal sewage is often 4.5 to 5.0 m
of which the sludge blanket itself may be 2.0 to 2.5 m depth. For high
BOD wastes, the depth of both the sludge blanket and the reactor may
have to be increased so that the organic loading on solids may be kept
within the prescribed range.
Once the size of the reactor is fixed, the upflow velocity can be
determined from
Upflow velocity m/h = Reactor height
HRT, h
Using average flow rate one gets the average HRT while the peak flow
rate gives the minimum HRT at which minimum exposure to treatment
occurs. In order to retain any flocculent sludge in reactor at all times,
experience has shown that the upflow velocity should not be more than

0.5 m/h at average flow and not more than 1.2 m/h at peak flow. At
higher velocities, carry over of solids might occur and effluent quality may
be deteriorated. The feed inlet system is next designed so that the
required length and width of the UASB reactor are determined.
The settling compartment is formed by the sloping hoods for gas
collection. The depth of the compartment is 2.0 to 2.5 m and the surface
overflow rate kept at 20 to 28 m3/m2-day (1 to 1.2 m/h) at peak flow. The
flow velocity through the aperture connecting the reaction zone with the
settling compartment is limited to not more than 5 m/h at peak flow. Due
attention has to be paid to the geometry of the unit and to its hydraulics
to ensure proper working of the "Gas-Liquid-Solid-Separator (GLSS)" the
gas collection hood, the incoming flow distribution to get spatial
uniformity and the outflowing effluent.
Physical Parameters
A single module can handle 10 to 15 MLD of sewage. For large flows a
number of modules could be provided. Some physical details of a typical
UASB reactor module are given below:
Reactor
configuration

Rectangular or circular. Rectangular shape is preferred

Depth

4.5 to 5.0 m for sewage.

Width or diameter

To limit lengths of inlet laterals to around 10-12 m for facilitating uniform

flow distribution and sludge withdrawal.

Length

As necessary.

Inlet feed

gravity feed from top (preferred for municipal sewage) or pumped feed from
bottom through manifold and laterals (preferred in case of soluble industrial
wastewaters).

Sludge blanket
depth

2 to 2.5 m for sewage. More depth is needed for stronger wastes.

Deflector/GLSS

This is a deflector beam which together with the gas hood (slope 60) forms a
"gas-liquid-solid-separator" (GLSS) letting the gas go to the gas collection
channel at top, while the liquid rises into the settler compartment and the
sludge solids fall back into the sludge compartment. The flow velocity through
the aperture connecting the reaction zone with the settling compartmentt is
generally limited to about 5m/h at peak flow.

Settler
compartment

2.0-2.5 m in depth. Surface overflow rate equals 20-28 m3/m2/d at peak flow.

Process Design Parameters

A few process design parameters for UASBs are listed below for municipal sewages with
BOD about 200-300 mg/l and temperatures above 20C.
HRT

8-10 hours at average flow (minimum 4 hours at peak flow)

SRT

30-50 days or more

Sludge blanket concentration

(average)

15-30 kg VSS per m3. About 70 kg TSS per m3.

Organic loading on sludge

blanket

0.3-1.0 kg COD/kg VSS day (even upto 10 kg COD/ kg VSS day

for agro-industrial wastes).

Volumetric organic loading

1-3 kg COD/m3 day for domestic sewage (10-15 kg COD/m3 day

for agro-industrial wastes)

BOD/COD removal efficiency Sewage 75-85% for BOD. 74-78% for COD.
Inlet points

Minimum 1 point per 3.7-4.0 m2 floor area.

Flow regime

Either constant rate for pumped inflows or typically fluctuating

flows for gravity systems.

Upflow velocity

About 0.5 m/h at average flow, or 1.2 m/h at peak flow,

whichever is low.

Sludge production

0.15-0.25 kg TS per m3 sewage treated.

Sludge drying time

Seven days (in India)

Gas production

Theoretical 0.38 m3/kg COD removed. Actual 0.1-0.3 m3per kg

COD removed.

Gas utilization

Method of use is optional. 1 m3 biogas with 75% methane

content is equivalent to 1.4 kWh electricity.

Nutrients nitrogen and

phosphorus removal

5 to 10% only.

HOW TO DESIGN BIO GAS HOLDER

GAS PRODUCTION & POWER GENERATION:
The gas flowing upward with the liquid will be prevented from escaping
with the treated flow by GLSS and beam deflector, which will divert it to
the gas collector domes. The gas produced shall be passed through 100
mm dia FRP pipe for individual domes and collected at a common point for
each reactor by a common header of 200 mm dia pipe from where it will
conveyed to the gas holder for constant flow to the gasomete generator
or flaring in open atmosphere at about 6 meter above ground level.
Quantity of Gas Production:
PARAMETER

INLET OF UASB

OUTLET OF UASB REMOVAL IN

UASB
BOD

1700 ppm

340 ppm

80%

COD

3300 ppm

1320 ppm

60%

TSS

1800 ppm

450 ppm

75%

FLOW IN UASB = 1500 KLD (Taking full future capacity into

account)
Influent COD@ 3300 ppm = 4950 Kg
Effluent COD = 1980 Kg
COD removed in a day = 2970 kg
Bio gas produced @ 0.1 cu mtr per kg of COD removed = 297 cu mtr per day.

Capacity of gas holder:

The primary purpose of a gas holder is to adjust the difference in the rate of gas production and
consumption. As bio gas enters or leaves, the holder rises or falls by guide rails.

Provide a gas holder of 300 cu mtr capacity.

POWER GENERATION:

The bio gas produced in UASB process should be utilized for production of
electric power. The amount of electric power generated shall be as under:
Bio Gas production = 297 cu mtr /day
Methane content (65.75%) = 195.28 cu mtr
Calorific value =28.9 MJ/N.cu mtr
Energy content 195.28x28.9x273/(273+30)=5048 MJ/Day
Generator efficiency--- 30%
Electricity generated =0.3x5048x1000000/3600x1000
= 420.66
Electric power generated = 420.66x0.04167=17.5289 kw say17 kw
= 1.25x 17= 21.25 kva.
We can go for a gas engine of capacity 10 KW . If any gas is left , it will
be flared or supplied to staff quarters.
NOTE: A 56 mld UASB plant having Inlet COD =400 ppm can safely run a 45 KW gas engine.

INDIAN STANDARDS

ENVO PROJECT"S FIRST UASBR PROJECT WAS IN 2005. SOME OF OUR

PROJECT PHOTOS

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