INTRODUCTION OF

SLUDGE MANAGEMENT
Presented by Ho Yoke Ping

Verification Ref No @30042024/01

 Ho Yoke Ping
Email: [email protected]

Manager
Process Design Unit
Engineering Services Section
Planning and Engineering Department

Bac. Sc. (Hons) Environment

Registered Trainer No: 21042
MBOT Members: GT19010037
DOE: CePIETSO(BP)/00675
2
Contents

Day 1 Morning Day 2 Morning

1st Introduction
Source
3rd Sludge Production
Treatment Facilities Overview
Characteristic
Terminology
Day 1 Afternoon Day 2 Afternoon
2nd Sludge Production 4th Facilities of Sludge Treatment
Final Disposal of Sludge
Terminology
3
Introduction to
Sludge Facilities

4
 Sewerage Treatment System

Conveyance Liquid Line Solid Line

System
5
 Facilities at Sewage Treatment Plant
Anoxic Tank Aeration Tank
(2 nos.) Sludge Drying bed (2 nos.) STP < 5000PE

Blower and
Control
Room

Grit and
Grease
Clarifier (2
Secondary nos.)
Screen
Chlorination
Inlet chamber
Chamber

Primary
Screen

Pump
Sump Grit Sand Bed Grease Sand Sludge Holding Tank
Bed
Facilities at Sewage Secondary
Final
Effluent
Screen, Grit
Treatment Plant and Grease
Chamber
Biological Reactor

Sludge
holding tank

Primary screen
chamber and Sludge Treatment Facility
inlet pumping

Anaerobic Digester Area 7

Sewerage Treatment System

Source: "Integrated Waste Management - Volume II", book edited by Sunil

Kumar, ISBN 978-953-307-447-4, Published: August 23, 2011 under CC BY-
NC-SA 3.0 license. © Helmut Kroiss, Helmut Rechberger and Lukas Egle).

8
What is Sludge?

• Sludge is by-product from the liquid treatment system

• Appearance (colour, weight and nature) depending on the source
• Characteristic
– Mainly water (99%)
– Dissolved solids
– Settled and suspended solids
Fecal matter  Metals
Bacteria and other micro-organisms  Energy
Nutrients (N, P, K)
• Content mostly biological solids, for this reason, it is also known
as Biosolids
9
Source of Sludge

10
Source of Sludge at STP
Common Type of Sludge
Type Source Typical Description
Concentration
(% Dry Solids)

Septage

Black – produces H2S and other

Septic Tank <2 gases; offensive odour unless
well digested (long storage).

Primary / Raw

Primary
Grey – offensive odour, can be
Sedimentation 0.5 to 2
readily digested.
Tank /Clarifier
Common Type of Sludge
Type Source Typical Description
Concentration (%
Dry Solids)

Secondary Activated Sludge / Waste

Activated Sludge
Lighter brown - may indicate under-
aeration with a tendency for slow
Secondary
solids settlement.
Sedimentation 0.5 to 2
Brown – if the colour is quite dark,
Tank
Darker brown – approaching
septicity or longer sludge age

Digestate

Aerobically digested sludge:

Brownish to black with flocculant
Aerobic or
appearance. No offensive odour.
Anaerobic 2 to 4
Anaerobically digested sludge:
Digesters
Dark brown to black, contains large
quantities of gas. Relative faint odour.
Septage Sludge

14
Septage in Imhoff Tank

15
Primary and Raw Sludge

Typical Diagram of a Primary Clarifier

Retrieved from https://www.monroeenvironmental.com/water-and-wastewater-treatment/circular-clarifiers-and-thickeners/

16
Secondary Activated Sludge And
Waste Activated Sludge

Secondary Activated Sludge Process Flow

Retrieved from http://techalive.mtu.edu/meec/module21/images/WastewaterAeration.jpg

17
Presentation footer here 1/10/2024
Waste Sludge from Sequential Batch Reactor (SBR) cycle
Retrieved from http://www.hydrofluxindustrial.com.au/wp-content/uploads/2017/02/HySmart-
SBR-Sequencing-Batch-Reactor-Hydroflux-Web-3.png 18
Digestate
Typical Diagram of Digester

Retrieved from
https://ehp.niehs.nih.gov/wp-
content/uploads/2015/07/ehp.123-
A180.g002-300x203.jpg
New life for
WATER
Characteristic of
Sludge

21
 Sludge Characteristic
Characteristics of Sludge Descriptions

Moisture / Solid Content  Typically more than 80% water content

Organic Content  Mostly organic materials such as fats, protein, paper and food
residue
 Leads to odour generation and potential source of food for
bacteria and rodents

Inorganic Content  Consists of ash, sand grit, mud and other mineral salts

Toxins  Small amount of toxic materials

 May contaminate land, crops and food stuffs

Nutrients  Contains nutrient element of nitrogen, phosphorus and

potassium
Pathogens  Presence of pathogens due to feacal material (E. coli,
Salmonella)
22
Typical Sludge Characteristic

Organic

Solids
1%
70%

Inorganic
30%

Water
99%

Water Solids

23
Typical Sludge Characteristic - IWK
• Analysis of final sludge
cake/biosolids at least once a
month for large STPs with
potential for biosolids reuse
• A representative sample shall be
taken from the sludge for disposal
• Analysis to be conducted by an
external laboratory
• ALL data shall be entered into
SAP

24
Terminology of
Sludge

25
Sludge Treatment Terminology

Thickening Mass of dry Percentage of

Volume 1 m3

solids Dry Solids

990 L
Dewatering
Water
490 L 240 L
Water Water 40 L Water
10kg Solids 10kg Solids 10kg Solids 10kg Solids
1% DS 2% DS 4% DS 20% DS
© 0418@IWK/PED Density of sludge, ρ = water = 1000kg/m3
• Density of sludge can be assumed = 1000kg/m3 (water density)

• However, density of sludge cake will be much higher depending on

the nature of the sludge cake. The compaction of sludge cake
storage could be poor as previously reported at 700kg/m3.

• Mass Conversion

𝑚𝑎𝑠𝑠 𝑠𝑜𝑙𝑖𝑑𝑠 (𝑡𝑜𝑛𝑛𝑒𝑠 𝑑𝑟𝑦 𝑠𝑜𝑙𝑖𝑑𝑠)

= volume (𝑚3 ) Mass
% 𝑑𝑟𝑦 𝑠𝑜𝑙𝑖𝑑𝑠

Vol x Conc
27
Example

• What is the % dry solids with 250m3 of wet sludge with

2500kg dry solids content?
Answer
Density of sludge = 1000kg/m3

Sludge Weight = 1000kg/m3 x 250m3

= 250,000kg sludge

Dry solids content = 2500 kg

% dry solids = 2500 / 250,000 * 100%

= 1%
28
Exercise

• What is the dry solids content of a wet sludge flow of 150m3

with 2% Dry Solids?
Answer
Weight of sludge = 1000kg/m3 x 150m3
= 150,000kg sludge

Dry solids percentage = 2%

Dry Solids Content = 150,000kg x 2%

= 3,000kg

29
Exercise – 5 mins

• What is the wet sludge flow @ 4% DS and 200kg DS?

Answer
Dry Solids = 200kg @ 4%

Dry solids percentage = 4%

Wet Sludge Weight = 200kg / 4%

= 5000kg

Wet sludge flow = 5000kg / 1000kg/m3

= 5 m3
30
Exercise

• What is the % dry solids with 110m3 of wet sludge with

5000kg dry solids content?
Answer
Density of sludge = 1000kg/m3

Sludge Weigh = 1000kg/m3 x 110m3

= 110,000kg sludge

Dry solids content = 5000 kg

% dry solids = 5500 / 110,000 * 100%

= 5%
31
Exercise – 5 mins

• What is the wet sludge flow @ 2% DS and 300kg DS?

Answer
Dry Solids = 300kg @ 2%

Dry solids percentage = 2%

Wet Sludge Weight = 300kg / 2%

= 1500kg

Wet sludge flow = 1500kg / 1000kg/m3

= 1.5 m3
32
Exercise

1. What is the % dry solids with 900m3 of wet sludge with

6000kg dry solids content?
2. What is the dry solids content of a wet sludge flow of 750m3
with 4% Dry Solids?
3. What is the wet sludge flow @ 4% DS and 800kg DS?
4. What is the % dry solids with 6000m3 of wet sludge with
50，000kg dry solids content?
5. What is the wet sludge flow @ 2% DS and 2000kg DS?

33
Sludge
Treatment
Stages
 Sludge Treatment
• Objective of Sludge Treatment: • Methods of Sludge Treatment:

Reduce the sludge volume reduce disposal cost Screening

Reduce/remove odour Thickening

Stabilisation (Digestion)
Reclaim useful by-product, i.e biogas, soil
Dewatering
conditional

Reuse with conversion of sludge into other

reusable material, i.e. fertilizer for agriculture
(non-food crops)

Safe/appropriate disposal & recycling

35
Sludge Treatment and Disposal Strategy

Adapted from Malaysian Sewerage Industry Guidelines

(Volume IV-Sewage Treatment Plants, 3rd Edition (pg. 143)
by National Water Services Commission (SPAN), 2009

36
Type of Sludge Generated in Urban Water
Treatment Process

Source: Good Practice in Sludge Management, 2012

http://www.purebalticsea.eu/index.php/gpsm:good_practices

37
Solids Treatment in STP

Source: "Integrated Waste Management - Volume II", book edited by Sunil

Kumar, ISBN 978-953-307-447-4, Published: August 23, 2011 under CC BY-
NC-SA 3.0 license. © Helmut Kroiss, Helmut Rechberger and Lukas Egle).

38
 Solids Treatment in STP (IWK’s Context)

External sludge

Source: "Integrated Waste Management - Volume II", book edited by Sunil

Kumar, ISBN 978-953-307-447-4, Published: August 23, 2011 under CC BY-
NC-SA 3.0 license. © Helmut Kroiss, Helmut Rechberger and Lukas Egle).

39
Mass Balance

• Mass balance is the quantitative description of all materials

that enter, leave and accumulate in a system with defined
boundaries
• Basically it tells, how much entering, leave and accumulate in
the system
• Smaller PE and less process system in a STP will have simple
Mass Balance

40
 Example of Mass Balance

Mass
Balance is
required for
optimal
process
selection

41
Ref: Nor Azuana Ramli, and Mohd Fairuz Abdul Hamid J Water Reuse Desalination 2017;7:103-110 ©2017 by IWA Publishing
Example of Mass Balance STP Smaller PE

42
Example of
Mass
Balance for
Pantai 2

43
Sludge Production

Adapted from Malaysian Sewerage Industry Guidelines

(Volume IV-Sewage Treatment Plants,
3rd Edition (pg. 113) by National Water Services
Commission (SPAN), 2009

Adapted from Malaysian Sewerage Industry Guidelines

(Volume IV-Sewage Treatment Plants,
3rd Edition (pg. 139) by National Water Services
Commission (SPAN), 2009 44
Primary Clarifier

• Gravity separation of solids from liquid

• Sludge production in 1o Clarifier depends on SS removal
Efficiency (solids capture)
• SS Removal Efficiency, E = 50% (MSIG Vo. 4)
Sludge Generated
= Average flow (Q) x SS Concentration x E
from 1o Clarifier

45
Example
Calculate sludge generated from 1O clarifier with 50% removal
efficiency which receive flow of 50,000PE. Design basic based
on MSIG Vol. 4.
Information: Calculation:
Qaverage = 0.225m3/day x 50,000PE
Flow per PE = 0.225m3/day = 11,250m3/day
SS based on design = 300mg/l Sludge
Generated from = Average flow (Q) x SS Concentration x E
1O Clarifier removal Efficiency 1o Clarifier

= 50%
Sludge
= 11,250 m3/day x 300/1000kg/m3 x 50%
Flow receiving = 50,000PE Generated
from 1o
= 1,687.5kg/day
Clarifier
46
Simple Mass Balance Development
PE = 50,000PE BODin = 250mg/l STP at Std A
Q = 0.225m3/day/PE SSin = 300mg/l Catchment

Primary
Qin = 11,250 m3/day
SSin = 3,375 kg/day Clarifier Qout= 11,248.3 m3/day
SSout = 1687.5 kg/day

Qprimary sludge = 1.69 m3/day

SSps = 1,687.5 kg/day

47
Exercise
A newly STP with 75,000PE will be designed with a 1O clarifier
in the system. The removal efficiency of the 1O clarifier is
expected at 50% which will be entering into thickening system.
Calculated the sludge generated from 1O clarifier.
Information:
Flow per PE = 0.225m3/day
SS based on design = 300mg/l
1O Clarifier removal Efficiency
= 50%
Flow receiving = 75,000PE
48
Simple Mass Balance Development
PE = 75,000PE BODin = 250mg/l STP at Std A
Q = 0.225m3/day/PE SSin = 300mg/l Catchment

Primary
Qin = m3/day
SSin = kg/day Clarifier Qout= m3/day
SSout = kg/day

Qprimary sludge = m3/day

SSps = kg/day

49
Exercise
A newly STP with 2,000,000PE will be designed with a 1O
clarifier in the system. The removal efficiency of the 1O clarifier
is expected at 50% which will be entering into thickening
system. Calculated the sludge generated from 1O clarifier.
Information:
Flow per PE = 0.225m3/day
SS based on design = 300mg/l
1O Clarifier removal Efficiency
= 50%
Flow receiving = 2,000,000PE
50
Simple Mass Balance Development
PE = PE BODin = 250mg/l STP at Std A
Q = 0.225m3/day/PE SSin = 300mg/l Catchment

Primary
Qin = m3/day
SSin = kg/day Clarifier Qout= m3/day
SSps = kg/day

Qprimary sludge = m3/day

SSps = kg/day

51
New life for
WATER
Secondary Sludge Calculations
Type of Process Sludge Generation Rate
(kg sludge / kg BOD5 removed)
Guided CAS 0.8 to 1.0
design EA / OD 0.4 to 0.6

value RBC/SBC/High
Rate Trickling
0.8

Hybrid system 0.4

MSIG Vol. 4, pg. 111 & 113 MSIG Vol. 4, pg. 139, Table 5.24

 VT is the aeration tank of the design, must be same as DC and Drawings

 MLSS selected must be same in the whole design document, adopted based of
type of system
 Sludge Age is calculated in the liquid line, should be same in the whole design
document
 Underflow concentration normally adopted in range of 8,000mg/l to 12,000mg/l.
53
 Secondary Sludge Calculations
Type of Process MLSS Range (mg/l) Typical
CAS 1500 – 3000 2500
EA 2500 – 5000 3000
SBR 3000 – 4500 3500
Hybrid system 2000 - 6000 N/A depending on actual type of
system
Adapted from Malaysian Sewerage Industry Guidelines (Volume IV-Sewage Treatment Plants,
3rd Edition (pg. 110, 112 & 119) by National Water Services Commission (SPAN), 2009

• Designer should design based on the following to identify the sludge generation from the
liquid process:
a) Type of process in liquid line
b) Interrelated of process kinetic, i.e. volume of aeration tank, MLSS, SRT and F/M ratio
c) Mass Balance must be provided to account the sludge generated and amount of filtrate
water from each unit processes
d) Simulation in worst case scenario

54
Sludge Age
• Retention time of a solid in a system
• Also known as Solids Retention Time (SRT) or Mean Cell Retention Time
(MCRT)
• Various according to type of process
• Sludge generated is more stable with extension of the sludge age

Type of Process Recommended Sludge Age (days)

Adapted from Malaysian Sewerage
CAS 5 – 10 Industry Guidelines
(Volume IV-Sewage Treatment Plants,
EA > 20 3rd Edition (pg. 110, 112 & 119) by
National Water Services Commission
SBR 20 – 30 (Continuous) 10 – 30 (Intermittent) (SPAN), 2009

55
Example 1: Sludge Age Calculation
Calculate the sludge age of EA system with the following
information.
Information:
PE = 1500
Flow rate = 0.225m3/day
AT Volume = 330 m3
MLSS selection = 3500mg/l
Excess Sludge Concentration = 10,000mg/l
WAS pump flow rate = 4.8m3/day
Solids in Effluent = Compliance = 20mg/l

56
 Example 1: Sludge Age Calculation
Calculate the sludge age of EA system with the following
information.
Step 1: Identify total solids in AT Step 3: Identify Solids in Effluent
Total solids in AT = AT Volume x MLSS in AT Solids in Effluent = Incoming Flow x SS effluent
= 330 m3 x 3.5kg/m3 = 1500PE x 0.225m3/PE x
= 1,155kg 0.02kg/m3
= 6.75kg
Step 2: Excess Sludge Wasting
Step 4: Calculate Sludge Age
Excess sludge wasting = Concentration x WAS
Sludge Age = Step 1 divided by Step 2 + Step 3
pump flow rate 1115
= 10kg/m3 x 4.8m3/day =
48+6.75
= 48 kg/day = 21 days

57
Example 2: Sludge Age Calculation
Calculate the sludge age of EA system with the following
information.
Information:
PE = 1500 F/M Ratio = 0.1 (given)
Flow rate = 0.225m3/day Sludge Yield, Y obs = 0.4
AT Volume = 330 m3 Influent BOD = 250mg/l
MLSS selection = 3500mg/l Effluent BOD = 10mg/l
HRT = 24 hrs Effluent SS = 20mg/l

58
 Example 2: Sludge Age Calculation
Calculate the sludge age of EA system with the following
information.
Step 1: Identify total solids in AT Step 3: Identify Solids in Effluent
𝑘𝑔
𝐵𝑂𝐷 𝑖𝑛 −𝐵𝑂𝐷 𝑒𝑓 𝑚3𝑥 0.225𝑚3 𝑥 1500𝑃𝐸 Solids in Effluent = Incoming Flow x SS effluent
Total solids in AT = 𝐹 = 1500PE x 0.225m3/PE x
𝑀
𝑟𝑎𝑡𝑖𝑜

= 810kg 0.02kg/m3
= 6.75kg

Step 2: Sludge Yield as Excess Sludge Step 4: Calculate Sludge Age

Sludge yield as excess sludge Sludge Age = Step 1 divided by Step 2 + Step 3
810
= 𝑆𝑙𝑢𝑑𝑔𝑒 𝑦𝑖𝑒𝑙𝑑 𝑥 𝐵𝑂𝐷 𝑟𝑒𝑚𝑜𝑣𝑒𝑑 =
32.4+6.75
= 0.4 x (250-10)/1000 kg x 1500 PE x 0.225m3/PE = 20.7 days
= 32.4 kg /day

59
Group Exercise – 10 Mins
Calculate the sludge age of EA system with the following
information.
Information:
PE = 4500 F/M Ratio = 0.08
Flow rate = 0.225m3/day Sludge Yield, Y obs = 0.4
AT Volume = 900 m3 Influent BOD = 250mg/l
MLSS selection = 3500mg/l Effluent BOD = 10mg/l
Excess Sludge Concentration = 10,000mg/l Effluent SS = 20mg/l
WAS pump flow rate = 13.5 m3/day
Solids in Effluent = Compliance = 20mg/l

60
 Mass Balance Development

Qin = Qflow = Qout =

m3/day m3/day m3/day

Qflow1 = m3/day
QRAS
= m3/day

QWAS
= m3/day

61
Sludge Holding Tank (SHT) Design

• Temporary holding of sludge before transfer into the next

sludge treatment system, i.e. thickening or dewatering

Adapted from Malaysian Sewerage Industry Guidelines

(Volume IV-Sewage Treatment Plants,
3rd Edition (pg. 110, 112 & 119) by National Water Services
Commission (SPAN), 2009

62
Design Requirement of SHT Common Design
Description Requirement
HRT/SRT With on-site sludge dewatering facility – 15 days
Without on-site sludge dewatering facility – 30 days
Mixing Mechanical mixer – 8 watt/m3 sludge
Air Mixing – 20 m3/min/1000 m3 sludge
Number of Mixer 2 units (1 duty, 1 standby)
Numbers of blower PE ≤ 5000 – 1 unit *
PE > 5000 – 2 units (1 duty, 1 standby) **
Note:
• * Separate blower from AT. Air pipe connection with isolation valve is to be
provided
• ** Combined with aerated grit and grease chamber with proper isolation
valve.

63
Design Requirement of SHT – Design
Adjustment
Description Requirement
HRT/SRT Thickened SHT – normally 3 days
(>3 days created odour issue due to deteriorate of sludge
and increase difficulty of dewatering)
Mixing Mechanical mixer – 8 watt/m3 sludge
Air Mixing – 20 m3/min/1000 m3 sludge
Number of Mixer 2 units (1 duty, 1 standby)
Numbers of blower PE ≤ 5000 – 1 unit *
PE > 5000 – 2 units (1 duty, 1 standby) **
Note:
• * Separate blower from AT. Air pipe connection with isolation valve is to be
provided
• ** Combined with aerated grit and grease chamber with proper isolation
valve.
64
Flow Diagramme

65
Example Drawing of SHT – Standard STP

66
Section View - SHT

67
 Example of Calculation
A plant with average flow of 450 m3/day, with aeration tank of 375m3 of volume. Mixed liquor in the plant
is maintain at 2000mg/l and with solid retention time allow at 20 days. The underflow concentration at
10,000mg/l. Assuming the plant is required to meet Standard A, what will be the excess sludge produced
and the volume of a sludge holding tank with 30 days retention time?
Answer:
Options 2: Calculation based on selected SRT and MLSS
Options 1: Direct Calculation
Dry weight basis sludge generation = 0.5
kgSS/kgBOD
2000
Sludge generation in solids 375 𝑚3 ×1000𝑘𝑔/𝑚3 10
− 450𝑚3 /𝑑𝑎𝑦×1000𝑘𝑔/𝑚3
20 𝑑𝑎𝑦𝑠
= 0.5 kgSS/kgBOS x 450m3/day x (250 - WAS = 10,000
𝑘𝑔/𝑚3
10)/1000 kgBOD/m3 = 54 kgSS/day 1000

54 𝑘𝑔𝑆𝑆/𝑑𝑎𝑦 WAS = 3.3 m3/day

𝑊𝐴𝑆 =
1% 𝐷𝑆 𝑥 1000𝑘𝑔/𝑚3 SHT Volume = WAS rate x retention time
=5.4 m3/day = 3.3 m3/day x 30 days
SHT volume = 5.4 m3/day x 30 days = 162 m3 = 99m3
68
 Mass Balance Development

Qin = 450m3/day Qflow = 657 Qout = 450m3/day

m3/day

Qflow1 = 228.3 m3/day

QRAS
= 225 m3/day

QWAS
= 3.3 m3/day

69
Example
Develop a Mass Balance for 3000PE EA system with on-site
dewatering system.
Information:
PE = 3000PE Influent BOD = 250mg/l
Flow rate = 0.225m3/day Effluent BOD = 10mg/l
Solids in Effluent = Compliance = 20mg/l Effluent SS = 20mg/l

70
 Mass Balance Development
Qflow = Qin + QRAS m3/day Qeff = Qflow – QWAS m3/day
Qin = m3/day SS = SS =
SSin = kg/day

Aeration Tank

Qflow1 = QRAS + QWAS m3/day

QRAS = MLSS X Q / (Cu – MLSS) m3/day

SS =
QWAS = m3/day
SS =

71
Group Exercise – 10 Mins
Develop a Mass Balance for 10,000PE EA system with on-site
dewatering system.
Information:
PE = 10,000PE Influent BOD = 250mg/l
Flow rate = 0.225m3/day Effluent BOD = 10mg/l
Solids in Effluent = Compliance = 20mg/l Effluent SS = 20mg/l

72
 Mass Balance Development
Qflow = Qin + QRAS m3/day Qeff = Qflow – QWAS m3/day
Qin = m3/day SS = SS =
SSin = kg/day

Aeration Tank

Qflow1 = QRAS + QWAS m3/day

QRAS = MLSS X Q / (Cu – MLSS) m3/day

BOD =
SS =
QWAS = m3/day
SS =

73
Common Design Issue

No continuation in the design calculation

MLSS selected used in Sludge Age ǂ F/M ratio and QWAS
Calculation
Sludge age calculated different from Qwas calculation
SHT retention time has no related to Qwas
Applied digestate sludge volume in SHT
Volume of SHT smaller than required, i.e. designed should based on
sludge feeding into SHT (Qwas)
Not considered the actual pumping capacity
Volume of SHT shall be determined with actual pumping rate

74
Sludge Production
 Dry sludge refers to sludge for final disposal, typically > 15%DS (dry solids)
 Sludge is differentiated by its solids content and is normally defined in dry solids
 The volume of sludge produced each year for different types of sewage treatment plant can
been calculated using a sludge production factor.
 The sludge production factor however is dependent on type of sewage treatment facilities
(ie. EA, SBR, IST), influent loading, catchment area (ie. urban and suburban) and optimal
operational condition (ie. sludge age, MLSS).
 Volume of sludge produced in Malaysia may be estimated from existing and future
populations served by these treatment plants and this will continue to increase due to
population increment, rationalisation and increased in connected sewers.
 Through strategic planning, facilities are designed to accommodate the projected increment
in sludge production.

75
 Example of Calculation
A plant with average flow of 450 m3/hr, with aeration tank of 9000m3 of volume. Mixed liquor in
the plant is maintain at 3000mg/l and with solid retention time allow at 20 days. The underflow
concentration at 10,000mg/l. Assuming the plant is required to meet Standard A, what will be the
excess sludge produced and the tonne per dewater sludge at 20%DS for a year?

Answer:
Thickener Dewatering Disposal
Source of Sludge Dry Solids % Mass of Sludge Mass of water Total Mass of Sludge
From holding tank
Thickened sludge
Dewatering sludge

76
© 0418@IWK/PED
 Example of Calculation - Cont
1. Calculation based on selected SRT and MLSS
3000
9000 𝑚3 × 𝑘𝑔/𝑚3 10
1000 − 450×24 𝑚3 /𝑑𝑎𝑦× 𝑘𝑔/𝑚3
20 𝑑𝑎𝑦𝑠 1000
WAS = 10,000
1000
𝑘𝑔/𝑚3
WAS = 124.2 m3/day @ 1000kg/m3 density
= 124.2 m3/day x 1000kg/m3
= 124,200 kg/day
Total DS = 124,200kg/day x 1% DS = 1,242 kg/day
Mass of water = 124,200 – 1,242 kg = 122,958 kg/day

77
© 0418@IWK/PED
 Example of Calculation
A plant with average flow of 450 m3/hr, with aeration tank of 9000m3 of volume. Mixed liquor in
the plant is maintain at 3000mg/l and with solid retention time allow at 20 days. The underflow
concentration at 10,000mg/l. Assuming the plant is required to meet Standard A, what will be the
excess sludge produced and the tonne per dewater sludge at 20%DS for a year?

Answer:

1,242kgSS/day
1% DS Thickener Dewatering Disposal
4% DS 20% DS
Source of Sludge Dry Solids % Mass of Sludge Mass of water Total Mass of Sludge
From holding tank 1% 1,242 kgSS/day 122,958 kg/day 124,200 kg/day
Thickened sludge
Dewatering sludge

78
© 0418@IWK/PED
 Example of Calculation - Cont
1. Calculation based on selected SRT and MLSS
3000
9000 𝑚3 ×1000𝑘𝑔/𝑚3 10
− 450×24 𝑚3 /𝑑𝑎𝑦× 𝑘𝑔/𝑚3
20 𝑑𝑎𝑦𝑠 1000
WAS = 10,000
𝑘𝑔/𝑚3
1000

WAS = 124.2 m3/day @ 1000kg/m3 density

= 124.2 m3/day x 1000kg/m3
= 124,200 kg/day
Total DS = 124,200kg/day x 1% DS = 1,242 kg/day
Mass of water = 124,200 – 1,242 kg = 122,958
kg/day
2. Calculate mass of water after thickener
Mechanical thickener is to be used to thicken
sludge to 4%
Total DS = remain the same
Total sludge stream = 1,242 kg/day / 4% DS
= 31,050 kg/day
Mass of water = 31,050 – 1,242 kg/day
= 29,808 kg/day 79
© 0418@IWK/PED
 Example of Calculation
A plant with average flow of 450 m3/hr, with aeration tank of 9000m3 of volume. Mixed liquor in the
plant is maintain at 3000mg/l and with solid retention time allow at 20 days. The underflow
concentration at 10,000mg/l. Assuming the plant is required to meet Standard A, what will be the
excess sludge produced and the tonne per dewater sludge at 20%DS for a year?

Answer:
1,242 kgSS/day
1,242kgSS/day Thickener Dewatering Disposal
1% DS 4% DS
Source of Sludge Dry Solids % Mass of Sludge Mass of water Total Mass of Sludge
From holding tank 1% 1,242 kgSS/day 122,958 kg/day 124,200 kg/day
Thickened sludge 4% 1,242 kgSS/day 29,808 kg/day 31,050 kg/day
Dewatering sludge

80
© 0418@IWK/PED
 Example of Calculation - Cont
1. Calculation based on selected SRT and MLSS
3000
3. Calculate mass of water after dewatering
9000 𝑚3 ×1000𝑘𝑔/𝑚3 10
− 450×24 𝑚3 /𝑑𝑎𝑦× 𝑘𝑔/𝑚3 Mechanical thickener is to be used to thicken
20 𝑑𝑎𝑦𝑠 1000
WAS = 10,000
1000
𝑘𝑔/𝑚3 sludge to 20%
Total DS = remain the same
WAS = 124.2 m3/day @ 1000kg/m3 density Total sludge stream = 1,242 kg/day / 20% DS
= 124.2 m3/day x 1000kg/m3 = 6,210 kg/day
= 124,200 kg/day Mass of water = 6,210 – 1,242 kg/day
Total DS = 124,200kg/day x 1% DS = 1,242 kg/day = 4,968 kg/day
Mass of water = 124,200 – 1,242 kg = 122,958
kg/day
2. Calculate mass of water after thickener
Mechanical thickener is to be used to thicken
sludge to 4%
Total DS = remain the same
Total sludge stream = 1,242 kg/day / 4% DS
= 31,050 kg/day
Mass of water = 31,050 – 1,242 kg/day
= 29,808 kg/day 81
© 0418@IWK/PED
 Example of Calculation
A plant with average flow of 450 m3/hr, with aeration tank of 9000m3 of volume. Mixed liquor in the
plant is maintain at 3000mg/l and with solid retention time allow at 20 days. The underflow
concentration at 10,000mg/l. Assuming the plant is required to meet Standard A, what will be the
excess sludge produced and the tonne per dewater sludge at 20%DS for a year?

Answer:
1,242kgSS/day 1,242 kgSS/day 1,242 kgSS/day
Thickener Dewatering Disposal
1% DS 4% DS 20% DS
Source of Sludge Dry Solids % Mass of Sludge Mass of water Total Mass of Sludge
From holding tank 1% 1,242 kgSS/day 122,958 kg/day 124,200 kg/day
Thickened sludge 4% 1,242 kgSS/day 29,808 kg/day 31,050 kg/day
Dewatering sludge 20% 1,242 kgSS/day 4,968 kg/day 6,210 kg/day

82
© 0418@IWK/PED
 Example of Calculation - Cont
1. Calculation based on selected SRT and MLSS
3000
3. Calculate mass of water after dewatering
9000 𝑚3 ×1000𝑘𝑔/𝑚3 10
− 450×24 𝑚3 /𝑑𝑎𝑦× 𝑘𝑔/𝑚3 Mechanical thickener is to be used to thicken
20 𝑑𝑎𝑦𝑠 1000
WAS = 10,000
1000
𝑘𝑔/𝑚3 sludge to 20%
Total DS = remain the same
WAS = 124.2 m3/day @ 1000kg/m3 density Total sludge stream = 1,242 kg/day / 20% DS
= 124.2 m3/day x 1000kg/m3 = 6,210 kg/day
= 124,200 kg/day Mass of water = 6,210 – 1,242 kg/day
Total DS = 124,200kg/day x 1% DS = 1,242 kg/day = 4,968 kg/day
Mass of water = 124,200 – 1,242 kg = 122,958
4. Calculate mass of sludge to be disposed a year
kg/day
2. Calculate mass of water after thickener Total sludge stream = 1,242 kg/day / 20% DS
Mechanical thickener is to be used to thicken = 6,210 kg/day
sludge to 4% Total sludge for disposal a year
Total DS = remain the same = 6,210kg/day x 365 days / 1000kg/tonne
Total sludge stream = 1,242 kg/day / 4% DS = 2,266.65 tonne / year
= 31,050 kg/day No digestion within the system! Why?
Mass of water = 31,050 – 1,242 kg/day
= 29,808 kg/day Where is the water from thickener and
© 0418@IWK/PED
dewatering goes to? 83
 Example of Calculation
A plant with average flow of 450 m3/hr, with aeration tank of 9000m3 of volume. Mixed liquor in
the plant is maintain at 3000mg/l and with solid retention time allow at 20 days. The underflow
concentration at 10,000mg/l. Assuming the plant is required to meet Standard A, what will be the
excess sludge produced and the tonne per dewater sludge at 20%DS for a year?
Answer:
1,242kgSS/day 1,242 kgSS/day 1,242 kgSS/day
Thickener Dewatering Disposal
1% DS 4% DS 20% DS
Source of Sludge Dry Solids % Mass of Sludge Mass of water Total Mass of Sludge
From holding tank 1% 1,242 kgSS/day 122,958 kg/day 124,200 kg/day
Thickened sludge 4% 1,242 kgSS/day 29,808 kg/day 31,050 kg/day
Dewatering sludge 20% 1,242 kgSS/day 4,968 kg/day 6,210 kg/day

Mass of sludge to be disposed at 20% DS will be 2,265tonne per year

84
© 0418@IWK/PED
 Mass Balance Development
Clarifier
Aeration Tank

Thickened
Sludge
Sludge Holding Thickener
Holding Tank
Tank

Sludge Storage
Dewatering
Hut
85
Chemical Conditioning
• Chemical Conditioning is apply to improve the effectiveness of water removed at the sludge treatment
process
• It is a flocculation (aggregation) process
• Chemical conditioning
– Inorganic chemicals – ferric chloride, ferrous sulfate, aluminium sulfate and aluminium chloride
– Water soluble polymers – organic polyelectrolytes – dissociate upon additional of water into negatively and
positively charges species
• Polymers are proprietary chemicals performance varies according to electrical charges, charge
density, molecular weight and molecular structure.
• How to chose:
– Ensure achievement of desired dewatering
– Cost effectiveness
– Space for storage and handling of the product
– Requirements for polymer make down, aging and feeding equipment, and
– Safety considerations
• Polymers is added to mechanical machines, such as thickener and dewatering machine.

86
Application Chemical Conditioning
• Factors to the selection of the polymers • Dosage of polymer is varies and actual
include: dosage required laboratory test, i.e. Jar
– Properties of sludge, e.g solid Test. However it can be estimated during
concentration, electrical charge, design stage for OPEX requirement
biopolymer content and rheology of 1O • Uniform and intimate mixing is between
sludge, 2O sludge or digested biosolids
sludge and biosolids with polymer is
– Mixing conditions of the polymer and essential for proper conditioning.
sludge – type of mixing
• Mixing requirement is varies on the
– Type dewatering devices to be used
dewatering method.

• Filter press - separate mixing tank for sludge

and polymer
• Belt press – polymer added at the sludge feed
line
HLT419
• Centrifuge – using inline mixer

87
 Application Chemical Conditioning
• Filter press - separate mixing tank for sludge and polymer
• Belt press – polymer added at the sludge feed line
• Centrifuge – using inline mixer
• The following sludge type normally required high dosage of polymer due to difficulty to
dewater, the list is in approximately order of increasing conditioning chemical requirements:
1. Untreated raw primary sludge 6. Aerobically digested mixed primary and WAS
2. Untreated mixed primary and trickling filter sludge 7. Autothermal Thermophilic aerobic digestion
3. Untreated mixed primary and WAS biosolids (ATAD)
4. Anaerobically digested primary sludge 8. Aerobically digested WAS
5. Anaerobically digested mixed primary and WAS 9. Untreated WAS

• Polymer dosages greatly depending on the molecular weight, ionic strength and activity
levels of polymers
• Manufacturers should be consulted for applicability and dosage performance

88
Polymer Make Up
• Chemical most easily applied and metered in liquid form
• Polymer performance can be ensured with identify with the viscosity measurement by using
viscosity meter – the higher viscosity – better performance
• Polymer preparation factor:
– Water hardness - > 400ppm required softener – breakdown the polymer bonding
– Chlorine concentration - > 3ppm reduce viscosity of polymer and the shelf live of the polymer
solutions
– Temperature of water apply for mixing – 4 to 38 degree Celsius
– SS concentration - <10ppm
– pH - 3 to 10
• Mixing tank volume that sufficient for the
storage of polymer solutions at least a shift.
• Material of the tank shall be corrosion-
resistant
• Pumps – positive displacement with VSD for
flow rate control

89
Ref: https://youtu.be/8SZTFOKyokQ?si=Qa4Ldf9Mznz6LRa4
Polymer Make Up

Preferable two stage make up

system with either mechanical or
hydraulic system Moment of
initial wetting

90
Ref: https://youtu.be/8SZTFOKyokQ?si=Qa4Ldf9Mznz6LRa4
Final Disposal –
Day 2
Treatment
Facilities
Overview
92
Sludge Screening
•Purpose of Screening
 To remove rubbish (e.g. plastics, clothing materials)
 To protect downstream equipment such as pumps, digesters and
dewatering equipment
 To prevent rubbish from entering the environment
 To improve quality and homogeneity of sludge
•Type of Screening
 Bar Screen
- Manual Raked
- Mechanically Raked
 Fine Screen
- Rotary Screen
• Primary (25mm opening) and secondary screens (12mm
opening)

93
 Sludge Thickening
Gravity Thickener

• Purpose of Thickening
To increase solids content in sludge by reducing the volume of
free water
To minimize load on downstream processes such as digestion
and dewatering

• Types of thickening
Gravity Mechanical
- Drum Thickener
Flotation (none within IWK)
- Gravity Belt
Centrifuge (not used for - Screw Thickener (not used in IWK)
Gravity Belt Thickener

thickening within IWK)

Centrifuge Thickener
• Polymer usage
Added to improve separation

94
Gravity Thickener
 Similar in design to a Sedimentation Tank, fitted with a picket fence-like mechanism which slowly
rotates, breaking up scum mats and releasing entrapped gas.

 As sludge enters the thickener tank, the heavier sludge gravitates to the bottom (hence ‘gravity
thickeners’) forming a sludge blanket.

 The liquid fraction (supernatant) is decanted over a weir and conveyed to downstream for further
treatment.

 Typically used for primary sludge

 Odor is often an issue

 Design Criteria:
- % Dry Solid Feed in = 0.5 – 1%
- % Dry Solid in Thickened Sludge = 4 -5%

 STP with gravity thickeners are such as Pantai 1 RSTP (KLR348) and Sunggala RSTP (PDN111)

95
Gravity Thickener
ADVANTAGES AND DISADVANTAGES OF GRAVITY
THICKENERS
ADVANTAGES DISADVANTAGES
Provides greatest sludge storage capabilities Requires largest land area

Requires the least operation skill Contributes to the production of odors

Provides lowest operation (especially power) and
For some sludge,
maintenance cost
- solid/liquid separation can be erratic
- can produce the thinnest least concentrated
sludge

Schematic diagram of a gravity thickener.

96
Gravity Thickener – Performance Result

Source: Good Practice in Sludge Management, 2012

http://www.purebalticsea.eu/index.php/gpsm:good_practices

97
New life for
WATER
Belt Thickener
 Solids are concentrated as free water drains by gravity through a porous horizontal belt
 Usually polymer is required
 Commonly used in IWK for secondary sludge
 Belt has vanes for drainage path
 Can alter pitch of fabric belt so that sludge moves back and increases retention time on belt.
 Thickened sludge is scraped off and belt requires washing
 Require control on hydraulic loading
 Design Considerations :-
- Typical solids and volumetric loading range 6 – 15 L/m2 (~ 10 L/m2) for a feed of 0.5 – 1 %
solids
- Need to be able to control sludge feed rate and polymer dosing to avoid overloading and
maintaining good flocculation of the feed sludge
- Pressure drop requirements for the solids/polymer mixing device
- Provision of adequate flow and pressure for belt washwater supply
- Building ventilation and odour control
99
Belt Thickener
ADVANTAGES AND DISADVANTAGES OF GRAVITY BELT THICKENERS
ADVANTAGES DISADVANTAGES
High pressure machines are capable of producing Very sensitive to incoming feed characteristics and chemical
drier cake than any machine except a filter press conditioning
Low power requirements Machines hydraulically limited in throughput
Low noise and vibration Short media life as compared with other devices using cloth
media
Operation easy to understand for inexperienced Washwater requirement for belt spraying can be significant
operators because all operational changes are
quickly and readily apparent
Continuous operation Frequent washdown of area around press required

Media life can be extended when applying the low Requires prescreening or grinding of sludge to remove large
belt tension typically required for municipal sludges objects and fibrous material

Requires greater operator attention than centrifuge

Condition and adjustment of scraper blade is a critical feature that

should be checked frequently
Tyoically requires greater polymer dosage than a centrifuge

Schematic Diagram of a Typical

Gravity Belt Thickener

100
Rotary Drum Thickener
 Operate on the principle of conveying polymer treated (flocculated) sludge through slowly
rotating drum filters.

 The sludge remains in the drum while the water phase passes through the filter cloth.

 The thickened sludge rolls out at the end of the drum, while separated water decants through
the screens.

 The sludge concentration can be regulated by adjusting the feed rate, angle and speed of the
drum.

 Similar to gravity belt but uses rotating drum with wedge, stainless steel or polyester fabric as
porous media.

 Rotates at 5 – 80 rpm (normally 20rpm)

 Water drains through wedge wire drum, sludge is conveyed by internal screw

 Compact and flexible

101
 Rotary Drum Thickener
ADVANTAGES AND DISADVANTAGES OF ROTARY DRUM
THICKENERS
ADVANTAGES DISADVANTAGES
Filter is entirely automatic Maximum available pressure difference is limited as
it being a vacuum filter
Large capacity, hence large quantities can be Difficulty in filtration of hot liquids because of their
filtered tendency to boil
Cakes of varying thickness can be built by varying Initial cost of filter and vacuum equipment is high
speed which results in removal of fine or coarser
solids easily
Low maintenance cost These are inflexible and do not perform well if their
feed stream conditions are changing

Schematic Diagram of a
Typical Rotary Drum
Thickener

102
Others Type of Thickener

Screw Thickener Centifugal Thickener

103
Comparison of Mechanical Thickener

Source: Good Practice in Sludge Management, 2012

http://www.purebalticsea.eu/index.php/gpsm:good_practices

104
Sludge Stabilisation

• Purpose of Stabilisation

 To reduce pathogenic organism counts

 To reduce “activity” of sludge
 To reduce odour generation potential at
treatment plant and point of disposal/reuse
• Types of Stabilisation
 Aerobic Digestion (ie. Putrajaya WPJ019)
 Anaerobic Digestion (ie. Pantai KLR348,
Bunus KLR347, and Jelutong PEG227)

105
Aerobic Digestion
• Aerobic Digestion is a biological process that takes place in the presence of oxygen
• Air is pumped through the tank and the contents are stirred to keep the contents fully
mixed
• With oxygen, bacteria present in the sludge (activated sludge) consumes organic matter
and converts it into carbon dioxide and small quantities of other gases including
hydrogen sulphide

ADVANTAGES AND DISADVANTAGES OF

AEROBIC DIGESTION
ADVANTAGES DISADVANTAGES
Easy to control, easy start-up Does not produce energy
Low ammonia and BOD in return Process is energy intensive
stream
Few odors are experienced if properly Not usually used for primary sludge due to high
designed and operated oxygen demand and additional biomass
produced
Explosive gases (methane) are not Stabilized sludge may be difficult to dewater
produced
106
Anaerobic Digestion
• Anaerobic digestion is the process for the reduction of sludge without the use of air or
elemental oxygen
• In anaerobic digestion, organic pollutants are converted by anaerobic micro-organisms
to a gaseous product (including methane gas) that has the potential for reuse
• It is a very low energy process and is particularly recommended for treating wastewater
which is high in soluble BOD and/or COD

ADVANTAGES AND DISADVANTAGES OF

ANAEROBIC DIGESTION
ADVANTAGES DISADVANTAGES
Produce renewable energy Slow start-up
Destroys pathogenic organisms Extreme confined space hazard
Reduces volatile content of sludge Production of explosives gas
Sludge is more easily to dewater Sealed tanks - cleaning, maintenance is more
difficult

107
Anaerobic Digestion Handling Chain

Source: Good Practice in Sludge Management, 2012

108
http://www.purebalticsea.eu/index.php/gpsm:good_practices
 Sludge Dewatering
Drying Bed
• Purpose of Dewatering
 Produce sludge with an increased dry solids
content, typically 20-30%
 Reduce subsequent transport costs due to
reduced water content of sludge Sludge
 Reduce stockpile area requirements if Lagoon
storage is contemplated

• Types of Dewatering
1) Natural Drying
 Sludge Lagoon
 Drying Bed Filter Press Screw Press

 Geobag New trends in

2) Mechanical Equipment the market:
 Belt Press
2 stage
 Filter Press
 Centrifuge
combine
 Screw Press thickening and
dewatering
machine Belt Press Centrifuge 109
 Sludge Lagoons
• Sludge lagoon is a storage pond used to dewater sludge

• The solids are allowed to settle due to gravity to the bottom of

the lagoon while the top clarified water is removed

• Sludge lagoons of about 2 m depth are also used for sludge

stabilisation and drying.

• The sludge lagoons are sized to receive sludge for a period of at

least 6 months and are allowed to undergo stabilisation through
evaporation and drying for another 6 months period.

• The lagoons shall be lined with either PVC lining, concrete or

600 mm thick clay lining.

• Typical solids loading rate between 36-39 kg/m3/yr

• Reference sites: Assam Kumbang and Labuan

110
 Sludge Lagoon
ADVANTAGES AND DISADVANTAGES OF
SLUDGE LAGOON
ADVANTAGES DISADVANTAGES
Can be cost-effective to design and Require more land than other treatment
construct in areas where land is methods
inexpensive.
Use less energy than most treatment Less efficient in cold climates and may require
methods longer detention times in these areas

Simple to operate and maintain Possible generation of odours of difficult

control
Can handle intermittent use and shock Attraction to vectors, mainly mosquitoes and
loadings better than many systems flies
Very effective at removing disease- Not very effective at removing heavy metals
causing organisms (pathogens)

Effluent from lagoon systems can be Possible pollution of ground and surface
suitable for irrigation (where waters
appropriate), because of its high-
nutrient and low pathogen content

111
Drying Beds
• A sludge drying bed is a shallow tank with a
system of under-drainage overlaid with filtering
media
Sludge
• When sludge is first applied, dewatering occurs Sand
initially by fairly rapid drainage to underlying
drain over a few days – filtration process

Raw sludge is Gravel

applied

Filtrate

Water filters out leaving

dried sludge

112
Drying Bed
ADVANTAGES AND DISADVANTAGES OF
DRYING BEDS
ADVANTAGES DISADVANTAGES
Low construction costs Large area required
Operational simplicity Previous stabilization of the sludge required

Low level of attention required Slow removal of the sludge cake

Low or non-existent consumption of High risk of odour release and proliferation of

chemical products flies

Low sensitivity to variations of the Contamination risk of the groundwater, in case

sludge characteristics the bottom and the drainage system of the
beds are not well executed
Cake with high solids level

113
Construction of Drying Bed
1 2

3 1. Under-drainage pipe
2. Gravel
3. Sand

114
 Geobag
Standard geobag capacity used by IWK is 11m3 and 90m3 (90 microns pore size)
Polymers such as polyamine can be added to improve flocculation and dewatering duration
• Usage at IWK
• Replacing SDB due to public complaints (odour, aesthetic)
• Intermediate disposal for interwork desludging
• Intermediate disposal for DBU desludging
• Replacement of MDU/Dewatering facilities
• Intermediate disposal for upgrading projects by others
• Trenching sites

• DOE is considering to categorize IWK trenching site as permanent sludge disposal site for trial period of 3
years under several conditions. One of the condition is to implement geobag method no later than December
2016, for the trenching site that do not have sludge treatment facility.

115
Geobag
ADVANTAGES AND DISADVANTAGES OF
GEOBAGS
ADVANTAGES DISADVANTAGES
Requires minimal equipment May need a pump for filling
Economical option (compared to Space for storage over long periods
standard procedures)
No complicated procedures or parts Dried sludge before disposal must be solar-
dried to ensure pathogen eradication
Can run at all times with minimal labour

116
 Belt Press
The working principle of a belt press follows the functional characteristics of its main
components:
• Flocculator – The sludge is conditioned before arriving in the drainage zone. The sludge-
flocculant blend is done in the flocculator and the flocculated sludge is distributed evenly on
the filter belt. At this level the sludge is in the form of flocs with the free water in between the
flocs
• Gravity drainage zone – The flocculated sludge is drained on a first belt (lower belt) by
simple gravity. The drainage is helped by picket fences that lay freely on the belt. Water line
is created corresponds roughly to majority of the water freed by flocculation is eliminated
• Compression zone – After drainage of water, the sludge is then pressed between two filter
belts (up to 4 bars for low-pressure belt filters)
• Cake scraping zone – Once pressed, the sludge cake produced is then scraped off from the
surface of the two belts.
• High pressure washing station – Nozzles under 7 to 8 bars continuously cleans each belt

117
Belt Press
ADVANTAGES AND DISADVANTAGES OF BELT PRESS
ADVANTAGES DISADVANTAGES
Staffing requirements are low, especially is the Not well suited to sludges with high level of oils,
equipment is large enough to process the solids in greases and fats - tend to blind the filter belt thus
one shift degrades the performance
Maintenenance is relatively simple and can usually Requires washwater continuosly thus increase
be completed by maintenance crew power requirements
Accidental damage is limited, can handle a large Odour problem - require good ventilation system or
variety of foreign material passing thorugh it without fully enclosed system
major damage
Less noise Sometimes produce large amounts of aerosols,
Can be started and shut down quickly especially badly maintained units
Low polymer dosage rate

118
New life for
WATER
Filter Press
• Filter Press is a mechanised dewatering machine
• Batch Process
• Filter press operate by applying a very high pressure to the sludge cake
• Consists of a series of parallel plates, each fitted with a filter cloth and rigidly
held together in a structural frame

120
Filter Press
ADVANTAGES AND DISADVANTAGES OF FILTER PRESS
ADVANTAGES DISADVANTAGES
High cake solids concentration with associated low Large quantities of inorganic conditioning chemicals are
biosolids storage, hauling and disposal costs commonly used
Little or no operator attention during dewatering Very high chemical conditioning dosages or thermal
phase of cycle conditioning may be required for hard-to-dewater sludges
Cake solids concentration is relatively independent High capital cost, especially for variable-volume filter presses
of feed solids concentration
High cake solids content improves release of cake Labour cost may be high if sludge is poorly conditioned and if
from filter cloth press is not automatic
Replacmeent of the media is both expensive and time
consuming
Noise levels caused by feed pumps can be very high
Requires grinder or prescreening equipment on the feed
Acid washing requirements to remove calcified deposits
caused by lime conditioning may be frequent and time
consuming
Batch discharge after each cycle requires detailed
consideration of ways of receiving and storing cake

https://www.medicinescomplete.com/mc/rem/2012 121
Screw Press

• Sludge is fed into the screw press, where it is compressed and dewatered gradually along the length
of the machine.
• A screw conveys the product through the machine at low speed, and the conical screw shaft makes it
possible to increase pressure gradually
• A pneumatic counter-pressure device prevents the product from moving too quickly, squeezing the
product and achieving maximum possible dryness
• The screw speed is adjusted continuously and automatically to maintain a constant feed pressure,
while a dual cleaning device cleans the thickening and squeezing zones separately from time to time
to ensure constant dewatering efficiency

Horizontal Screw Inclined Screw

Press Press

122
Screw Press
ADVANTAGES AND DISADVANTAGES OF SCREW PRESS
ADVANTAGES DISADVANTAGES
Enclosed system provides good odour Capture rate is low (less than 90%), and
containment sometimes less than 65%
Less noise Typically, cake solids expected to be lower than
centrifuge
Low power consumption High polymer consumption
Low maintenance requirements Continuous wash water is required
No filter cloth is required Screens need to be changed every 2-3 years

http://www.ubowedgewire.com/Wedge_
Wire_Pipe_Cylinder/pressure-flip-screen-
wedge-wire-rotary-drum-screen-281-
1.htm

123
 Integrated Thickening and Dewatering Machine

• Integrated of thickening and dewatering  Installed at Taman Mawar & SAM227

system  Potential issue pending for
• Currently favorable in the market due to: verification:
• Smaller foot print (1 machine for 2 function)  Unable to meet 20% DS
• Energy saving  More polymer consumption??
124
 Centrifuge Dewaterers
• A process which uses the force developed by fast rotation of a cylindrical drum or bowl to separate the
sludge solids from the liquid

• When a sludge slurry is introduced to the centrifuge, it is forced against the bowl's interior walls,
forming a pool of liquid

• Density differences cause the sludge solids and the liquid to separate into two distinct layers

• The sludge solids "cake" and the liquid "centrate" are then separately discharged from the unit

• The two types of centrifuges used for municipal sludge dewatering, basket and solid bowl, both operate
on these basic principles

• They are differentiated by the method of sludge feed, magnitude of applied centrifugal force, method of
solids and liquid discharge, cost, and performance.

125
Centrifuge Dewaterers
ADVANTAGES AND DISADVANTAGES OF CENTRIFUGE
ADVANTAGES DISADVANTAGES
Decanter centrifuges have a clean appearance and Cannot separate biological solids with very small density
have little to no odour problems differences (requires tubular-bowl centrifuge)
Easy to install and fast at starting up and shutting Can be very noisy and can cause vibration
down
Only requires a small area for operation High energy consumption

System can be pre-programmed with various design High equipment capital costs. Hard surfacing and abrasion
curves to predict the sludge type protection materials are required for the scroll to reduce wear
Can operate with higher throughput capacity - reduce
number of units required
Device is simple to optimise and operate
automatically and continuously
Low continuous maintenance and operator attention -
low labour costs

More process flixibility (can operate for either

thickening or dewatering) and high levels of
performance

Ref:
http://www.gncentrifuge.com/Blogs/decante
r-centrifuge-factors-screw-conveyor.html

126
Summary and Overview of
Dewatering Machine

Source: Good Practice in

Sludge Management, 2012
http://www.purebalticsea.eu/
index.php/gpsm:good_practi
ces

127
Local Design Adaption
Gravity thickener:
Overseas using higher % DS
compare to MSIG.

Belt/Drum/Centrifuge has
requested 3 polymer injection
point

Adapted from Malaysian Sewerage Industry Guidelines

(Volume IV-Sewage Treatment Plants, 3rd Edition (pg. 140)
by National Water Services Commission (SPAN), 2009 128
Local Design Adaption
Aerobic Digestion:
 O2 is required for the
digestion 2.3 kgO2 / kg VS
Destroyed
 The feed is volume is from
Upstream not the destructive
volume

Anaerobic Digestion:
 High ammonia in the
supernatant return, to be take
care in the liquid line
 Methane gas handling
Adapted from Malaysian Sewerage Industry Guidelines
(Volume IV-Sewage Treatment Plants, 3rd Edition (pg. 143)
by National Water Services Commission (SPAN), 2009 129
Local Design Adaption
 < 2000PE focus on manual
handling
 > 2000PE focus on
automation
 Many of new design has not
following the 5 days and 8 hrs
working time period
 The feed into the machine is
continuous if full automation
is applied
 Smaller capacity but the
flexibility shall be considered
in the designed
Adapted from Malaysian Sewerage Industry Guidelines
(Volume IV-Sewage Treatment Plants, 3rd Edition (pg. 142)
by National Water Services Commission (SPAN), 2009 130
Typical Process Flow Of Sludge Treatment
Facilities (STF)

Sludge Transfer from

STP

Sludge Dewatering
Tankered Sludge Sludge Reception Unit Dried sludge cake
Facility
Sludge Holding
Tank
Filtrate return to STP / Disposed / Reuse
Filtrate treatment
system
Remove rubbish Remove grit

Disposed
131
Typical Sludge Reception Facility

132
Typical Process Flow Of Mobile Dewatering
Unit (MDU)

133
List of MDU
No. Asset No. STF Name Unit Office Type
1 KSR144 TAMAN WIRA ALOR SETAR Centrifuge
2 IPH419 TANAH HITAM IPOH Centrifuge
3 IPH398 TAMAN MAS IPOH Centrifuge
4 SGA050 BULUH KASAP KLUANG Centrifuge
5 MUN166 LOT4068 & LOT4069 TMN BAKARIAH KLUANG Centrifuge
6 BPT063 TAMAN BUKIT PERDANA 11 KLUANG Centrifuge
7 TKN059 MDU TELOK KALONG KUALA TERENGGANU Centrifuge
8 TKN052 KERTEH KUALA TERENGGANU AVC - Dewatering
9 KTU113 GONG BADAK KUALA TERENGGANU Centrifuge
10 KUN217 B. I. M SEKTOR 1 (KUN005) KUANTAN Centrifuge
11 HTH079 TMN BKT BENDERA (3) (HTH008) KUANTAN Centrifuge
12 HMN024 TAMAN MARAN JAYA (HMN015) KUANTAN Centrifuge
13 HCH045 TMN BDR BARU JUTA VILLA KUANTAN Centrifuge
14 PTM060 SLIM RIVER STF MANJUNG Centrifuge
15 PTH046 JERAM MENGKUANG STF MANJUNG Centrifuge
16 PKB104 PAPAN TRENCHING SITE MANJUNG Centrifuge
17 LPG111 MANJUNG STP MANJUNG Centrifuge
18 JAN140 TAMAN PERINDUSTRIAN JASIN MELAKA Centrifuge
19 SED157 BANDAR SEREMBAN SELATAN (EA) SEREMBAN Centrifuge
20 NJU027 JELEBU MDU SEREMBAN Centrifuge
21 NJL088 TAMAN DESA PUTERI SEREMBAN Centrifuge
22 JPN042 TAMAN MEGAH SKUDAI Centrifuge
23 KMA324 BANDAR PUTERI JAYA (MDU) SUNGAI PETANI Centrifuge
24 PKN091 PARIT BUNTAR STF-MDU TAIPING Centrifuge
25 KRR144 SUNGAI SIPUT - STF (MDU) TAIPING Centrifuge 134
26 SPI478 Presentation footer here
MAK MANDIN SEBERANG PERAI 1/10/2024
Centrifuge
Current Disposal Method
Type Description and Advantages
Disposal Landfill
Most common method
Thickened sludge pumped into lagoons and surface water will
be removed after a period of time

Trenching
Disposal into trenches in remote area or abandoned land site
Sludge may be disposed in liquid form
Constant monitoring and control of parameters such as surface
water and ground water

Reuse  For land reclamation to improve disturbed soils and as a

cheap alternative where no topsoil exist
 Reused as fertilizer
 Converted to biomass fuel
 Fed into anaerobic digesters to produce biogas

135
Trenching

• Trenching is a method of final sewage sludge disposal onto land

• Approval from DOE must be obtained prior to disposal.
• Sludge trenching is usually carried out in remote area away from residential
• It can also be done in abandoned land site or near landfill area.
• Since July 2015, only dry sludge (>15%dry solids) can be disposed to trenching sites
• There are two typical designs of sludge trenches normally adopted – narrow trench and wide trench
Cross section sludge trenching
NARROW TRENCH WIDE TRENCH
COVER SOIL

0.6m - 1.2m GROUND LEVEL GROUND LEVEL 0.6m - 1.0m COVER SOIL

SLUDGE & COVER SLUDGE & COVER SOIL

SOIL

GROUND WATER GROUND WATER

LEVEL LEVEL

GROUND LEVEL GROUND LEVEL

<10%
<20%

> 3.0m
0.6m - 3.0m

136
DOE Site Selection Guidelines (Revised Feb 1999
• Sites chosen for sludge disposal using trenching, lagoon or fertiliser technique should comply with the
following conditions:
• 1. The site must be above the seasonal flood level and not subject to water logging.
• 2. The site must be reasonably flat.
• 3. The site must be more than 200m from the boundary of any residential property and sensitive
receptor.
• 4. The site must be a minimum distance of 200m from any downstream source of public/private
water supply.
• 5. The land must be downstream of water supply abstraction point, or if upstream it should be at
least 5 km from the point.
• 6. Regular tanker movements must be able to take place safely and not cause nuisance to the public.
• 7. The site should be fenced, designated as restricted area and signed properly.
• 8. The site should have an access road no greater than 1 km from the public road
• 9. The site should have an economical distance away from the source of the sludge (each site should
at least be able to serve the sludge from within a 10 km radius)
• 10. The site should be available for use over 5 years period.
• 11. A minimum site area of 2 hectares or commensurate with the life span chosen is required
137
Trenching – Control and Monitoring

Soil Groundwater Surface water Sludge

• The soil samples shall be • Borehole is used for • The upstream and • During first week of
collected from at least 10 groundwater sampling at downstream of the applications.
locations within a 1 acre trenching site surface watercourses • After 3 months
area. (25 samples per • Groundwater samples within the disposal site (subsequently every 6
hectare) shall be taken at must be monitored months).
• Hand auger shall be used upstream and • This is to determine the • Random sampling.
• Samples shall be sieved downstream of disposal amount of pollutant from • Composite samples shall
after air drying for 1 day site the sludge disposal site if be tested/analysed.
• Parameters for analysis: • Samples shall be taken there is any
• Parameters for analysis:
pH, Zinc, Copper, Nickel, before commencement of • Samples shall be taken dry solids (TS in %),
Cadmium, Lead, Mercury, biosolids applications before commencement of organic content (VS in
Chromium, Arsenic, and (baseline) biosolids applications terms of % dry solids),
Molybdenum; total • Parameters for analysis: (baseline) Kjeldahl nitrogen, pH,
nitrogen and phosphorus pH, Zinc, Copper, Nickel, • Parameters for analysis: Zinc, Copper, Nickel,
• If any of the calculated Cadmium, Lead, Mercury, pH, Zinc, Copper, Nickel, Cadmium, Lead, Mercury,
metal additions reaches Chromium, E.coli, and Cadmium, Lead, Mercury, Chromium,
80% of the limit, then an oxidised nitrogen Chromium, E.coli, and
additional soil sample oxidised nitrogen
must be taken.
138
 Landfilling
• Landfilling of sewage sludge with domestic refuse is
the most common method of sludge disposal
• Sludge should be disposed of to the landfill in dried
form > 15% dry solids content
• Sludge is disposed to landfill by using lorry -
covered; to avoid spills on the road

139
Sludge Reuse

Brick Production

Cement Production Composting

Sludge
Reuse

Land Reclamation Green Area Use

Fuel for Incineration

Energy Production
Agricultural Use

140
Potential Sludge Reuse
Options Description
Agricultural Land  Reduce fertilizers requirement as sludge contains nitrogen and
phosphorus
 Able to improve water retaining capacity and structure of soils
Green Area Use  Certain countries only allow for sludge to be reused on green areas
such as golf course and recreational parks instead of agricultural
land due to concern of presence of heavy metals and pathogens

Land  Able to improve disturbed soils

Reclamation  Cheap alternative where no topsoil exist
Composting  Mixed with bulking agent such as wood chips, straw or municipal
waste
Fuel for  Dried sludge has high energy content which makes it suitable to be
Incineration used as fuel to drive incineration process
Energy  Exhaust heat from incinerator and furnace can be effectively
Production reused as energy source for power generation
Cement  Incineration ash resulted from incineration of dried sludge is used
Production as one of the ingredients in cement production
Brick Production  Incineration ash can be used as one of the ingredients in brick
production 141
Sludge Disposal System

Ref: Sewage Sludge Treatment, Institute of Wastewater Management, Hamburg University of 142
Technology
New life for
WATER
 Future Sludge Management In Malaysia

 The Malaysian government is keen to support the

industry by introducing the Malaysia’s Green
Technology Master Plan; to achieve target

• 50% of biosolids to be recycled

for reuse

• 50% of biosolids to be recycled

for electricity generation by 2030

144
 1,749.86

1,210.40

1,174

1,136.70

568.86

353.85

314.33

254.22

228.01

227.89

219.11

211.60

177

165.96

160.17

157.15

119.17

103.28

97.10

58.45

55.52

44.43

41.05

31

23.15
Sludge Production in Europe 2020

2020, BY COUNTRY (IN 1,000 METRIC TONS)

22.51

18.99

10.36
SEWAGE SLUDGE PRODUCED AND DISPOSED IN EUROPE IN

10

9.50

9.47

8.41
145
Sludge Production from STPs IWK
Biosolids Disposal
120,000 16
14
100,000
12
80,000
10
60,000 8
6
40,000
4
20,000
2
0 0
2017 2018 2019 2020 2021 2022 2023
Amount (tonne) 78,960 99,628 107,000 76,119 72,000 76,494 103,620
Cost (mil) 6.27 7.87 8.01 8.77 9.83 10.12 13.68

146
EA Approval for dedicated sludge disposal sites

NEGERI
TYPE OF SYSTEM KEDAH PERAK JOHOR MELAKA PAHANG TERENGGANU Total
SEMBILAN

TRENCHING SITES = 25 SITES + 2 SITES IN KELANTAN

Geobag with Trenching 1 1 6 3 11
MDU with Trenching 4 1 2 1 8
CSTF with Trenching 1 1
Trenching 2 1 2 5
SLUDGE TREATMENT FACILITIES (STF) = 5 SITES
Sludge Lagoon 1 1
Drying Bed 1 1 1 3
MDU 1 1
Total 1 7 3 2 7 7 3 30

MDU with trenching: 8 Nos. Trenching System: 5 Nos. Geobag with CSTF with Drying Beds: 3 Nos. Sludge Lagoon: 1 No. MDU: 1 No.
trenching: 11 Nos. trenching: 1 No.
EA Approval for dedicated sludge disposal site

Key Conditions for EA Approval

- Away from sensitive/residential area
- Sufficient buffer zone (with watercourses) COMPLY TO OPERATE
- Above flood prone area with flood control and mitigation
- Site security and fencing requirement with proper demarcation
- Proper access road
- Minimize reduce odour impact / landscaping
- Specific design capacity per each site
- Sludge is dried to 15% before disposal
- Post Environmental Monitoring Reporting
- Ground water quality monitoring (via borehole)
- Upstream and downstream surface water quality monitoring (at nearby stream / river)
- Effluent discharges compliance from MDU, Sludge Lagoon & Sludge Drying Beds
- Soil monitoring
- Requirement for environmental audit

Requirement for EA approval renewal / extension

- Submission of EA extension application letter to State DOE
- RM500/site
- Handle at IWK’s State / Unit Offices
EA Approval for dedicated sludge disposal site
EA Approval for dedicated sludge disposal site
EA Approval for dedicated sludge disposal site
152
New life for
WATER
Terima Kasih
Indah Water Konsortium Sdn Bhd
No. 44, Jalan Dungun, Damansara Heights
50490 Kuala Lumpur, Malaysia
t 03 2780 1100
f 03 2780 1101
e [email protected]
iwk.com.my