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Anaerobic Digester Design
Jae K. (Jim) Park, Professor Dept. of Civil and Environmental Engineering University of Wisconsin-Madison
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Information Checklists for Design of Sludge Stabilization Facility
1. Select the ultimate sludge disposal method as the degree of sludge stabilization will depend on the requirements of the disposal practice. 2. Develop the characteristics of thickened sludge that will reach the sludge stabilization facility. 3. Select the sludge stabilization method that is compatible with the influent sludge characteristics, dewatering, and ultimate disposal method. 4. Develop design parameters (organic loading, hydraulic loading, chemical dosage, reaction period, etc.) for the selected sludge stabilization facility. 5. Obtain the design criteria from the concerned regulatory agency. 6. Obtain necessary manufacturers’ catalogs and equipment selection guides.
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Design Criteria for Anaerobic Digester Design (1)
1. Select anaerobic sludge digestion for stabilization of organic solids. 2. Provide two completely-mixed, high-rate anaerobic heated digesters with digestion temperature of 35°C. 3. The design flow to the sludge digester shall be equal to thickened sludge under the daily design flow condition. 4. Total volatile solids loading to the digester shall not exceed 3.6 kg/m3·day under extreme high loading condition. 5. The solids retention time at extreme high-flow condition shall not be less than 10 days. 6. The digester mixing shall be achieved by internal gas mixing. 7. The solids content in digested sludge is 5% and S.G. is 1.03. 8. The TSS content in the supernatant is 4,000 mg/L. 9. The ratio TVS/TS = 0.71, Y = 0.05 g VSS produced/g BOD5 utilized, E = 0.8, and kd = /day.
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Design Criteria for Anaerobic Digester Design (2)
10. The digester heating shall be achieved by recirculation of sludge through external heat exchanger. The sludge recirculation system shall also be designed to provide digester mixing. 11. Provide floating digester cover for gas collection. 12. The heat loss from the digester cover, side walls, and floor shall be calculated using the standard heat transfer coefficients for the digester construction material. 13. Provide gas-fired hot water boiler for external heat exchanger. 14. Explosion prevention devices shall be provided to minimize the possibility of an explosive mixture being developed inside the floating covers. Proper flame traps shall be provided to assure protection against the passage of flame into the digester, gas storage sphere, and supply lines. 15. The digester design shall include supernatant withdrawal system, sight glass, sampler, manhole, etc. 16. Arrangement shall be provided to break the scum that may form on the sludge surface.
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Characteristics of Sludge Reaching Anaerobic Digester
Average Extreme Extreme Factors flow low flow high flow Sludge production, kg/day 8,180 6,952a 8,681b Solids concentration, % dry wt 6 8 4 Specific gravity Average daily flow rate, m3/day c Pumping rate into each digester 0.85d during the pumping cycle, m3/min Influent temperature, °C Volatile solids fraction before digestion aExtreme low solids to the digester = 85% of the average solids loading bExtreme high solids to the digester = quantity of thickened sludge withdrawn under sustained loading = 10,213 kg/day (p. 664 Step A.3) × 0.85 (solids capture) = 8,681 kg/day c8,681 kg/day×103 g/kg(0.04 g/g×1.02×1 g/cm3×103 L/m3) = 213 m3/day dThe pumping rate of 0.85 m3/min gives a velocity of 0.8 m/sec in the 15-cm diameter pipe.
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Design Example (1) A. Digester Capacity and Dimensions 1. Compute digester capacity at average flow condition using 15 days digestion period Assume average flow to the digester = 132 m3/day Digester volume = 132 m3/day × 15 days = 1,980 m3 2. Compute digester capacity using volatile solids-loading factor Assume VS loading at ave. flow condition = 2.5 kg/m3·day (< 3.6) Total VS reaching the digester = 8,180 × 0.71 = 5,808 kg/day Digester volume = 5,808 kg/day × 2.5 kg/ m3·days = 2,323 m3 3. Compute digester capacity using volume per capita allowance Assume 0.03 m3 digester capacity per capita Population served = 80,000 Digester capacity = 80,000 × 0.03 m3 = 2,400 m3 4. Compute digester capacity using volume reduction method (67%) Volume of the digested sludge = 97 m3/day (AS Design Slide #24) Volume of raw sludge to the digester = 132 m3/day (AS Design Slide #24) Digester capacity = [132 – 0.67× (132 – 97)] × 15 = 1,630 m3
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Design Example (2) 5. Select digester capacity
Select active digester capacity of 2,500 m3. B. Digester Dimensions and Geometry 1. Correct for volume displaced by grit and scum accumulations, and floating cover level Provide 1-m depth for grit accumulation Provide 0.6-m depth for scum blanket Provide 0.6-m min. space between floating cover and max. digester level Total displaced height = = 2.2 m Assume that the active side water depth is 8 m (26.3 ft). additional volume will be available in the cone. Volume of each digester = 1,250 m3
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Design Example (3) Area of each digester = 1,250 m3 8 m = 156.3 m2
Diameter of each digester = (4/ × m2)0.5 = 14.1 m Because floating covers come in 5-ft (1.5-m) diameter increments, provide digesters with 45-ft (13.7 m) diameter. Revised side water depth = 1,250 m3 [/4 × (13.7 m)2] = 8.5 m (27.9 ft) Provide two digesters each 13.7 m (45 ft) diameter and 8.5 m (28 ft) side water depth. 2. Check the active vol. of the digesters, including vol. of cone The floor of the digester is sloped at 1 vertical to 3 horizontal. 1 (vertical):3 (horizontal) = h:(13.7/2) → h = 2.28 m ≈ 2.3 m The bottom cone depth of 2.3 m adds additional volume. Active digester volume = (Vol. of active cylindrical portion) + (Total vol. of the cone) - (Allowance for grit accumulation) = /4 (13.7 m)2 × 7.3 m† + 1/3 × /4 × (13.7 m)2 × 2.3 m - 1/3 × /4 × (6.0 m)2 × 1 m = m m m3 = 1,179.7 m3 2.3 m 1 m †8.5 m – Scum blanket (0.6 m) – Space below floating cover (0.6 m) = 7.3 m
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Design Example (4) Active vol. of two digesters = 2 × 1,179.7 m3 = 2,359.4 m3 Total vol. of two digesters = 2 × (/4 × 13.7 m2 × 8.5 m + 113 m3) = 2,732 m3 Active vol. ratio including cone = 2,359.4 m3 2,732 m3 = 0.86 C. Actual Solids Retention Time and Solids Loading 1. Compute actual digestion period at average, extremely low, and extremely high flows Digestion period at average flow = 2,359.4 m3 132 m3/day = 17.9 day Digestion period at extreme high flow = 2,359.4 m3 213 (#5) m3/day = 11.1 day > 10 days – O.K. Digestion period at extreme low flow = 2,359.4 m3 84 (#5) m3/day = 28.1 day 2. Compute actual solids loading at average, extreme low, and extreme high conditions
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Design Example (5) Solids loading at ave. loading condition = 8,180 kg TS/day × VS/TS 2,359.4 m3 = 2.5 kg VS/m3·day Solids loading at ave. loading condition = 6,952 kg/day × 0.71 VS 2,359.4 m3 = 2.1 kg VS/m3·day Solids loading at ave. loading condition = 8,681 kg/day × 0.71 VS 2,359.4 m3 = 2.6 kg VS/m3·day D. Gas Production 1. Calculate gas production BOD5 in the thickened sludge (Stream 10) = 4,253 kg/d (AS Design Slide #24) BODL in sludge = 4,253 kg/d × BOD5/0.68 BODL = 6,254 kg/d Assume 65% solids are biodegradable and 1 g of biodegradable solids = 1.42 g BODL, Y = 0.05, kd = /day, and E = 0.8.
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Design Example (6) S0 V = 0.35 m3/kg × (EQ0S0 × 10-3 kg/g Px) = 0.35 m3/kg × (0.8 × 132 m3/day × 6,254 g/m3 × 10-3 kg/g – 1.42 × 163 kg/day = 1,670 m3/day If methane is 66% in the digester gas, Digester gas production = 1,840 m3/day 0.66 = 2,531 m3/day 2. Estimate gas production from other rules of thumb a. Based on VS loading using VS = 0.75 of TS and gas production rate of 0.5 m3/kg VS Gas produced = 8,180 kg/day × 0.71 × 0.5 m3/kg = 2,904 m3/day b. Based on VS reduction Stabilization Slide #26
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Design Example (7) Assume average VS reduction of 52% and gas production of 0.94 m3/kg VS reduced Total VS reduced = 8,180 × 0.71 × 0.52 = 3,020 kg/day Gas produced = 3,020 kg/day × 0.94 m3/kg = 2,839 m3/day c. Based on per capita Total population served = 80,000 Used gas production rate of m3/capita Gas produced = 80,000 persons × m3/person·day = 2,560 m3/day Based on the above analysis, assume a conservative gas production rate of 2,550 m3/day at standard conditions (0°C and 1 atm). E. Digested Sludge Production Compute the quantity of solids in digested sludge TVS = 8,180 kg/day × 0.71 = 5,807 kg/day TVS destroyed = 5,807 kg/day × 0.52 = 3,020 kg/day
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Design Example (8) TS remaining after digestion = Nonvolatile solids + VS remaining = (8, ,807) kg/day × 5,807 kg/day = 5,159 kg/day Compute total mass reaching the digester Total solids reaching the digester = 8,180 kg/day (AS Design #24) Total solids in thickened sludge = 6% by wt Total mass reaching digester = 8,180 kg/day 0.06 kg/kg = 136,317 kg/day Compute volume and TSS in digested sludge and the digester supernatant Assume that no liquid volume change occurs in the digester Vol. of influent thickened sludge (Vinf) = Vol. of digested sludge removed from digester (Vsludge) + Vol. of digester supernatant (Vsupernatant) Vsludge = 132 m3/d; Wremaining = 5,139 kg/d Vsludge = Wsludge/(0.05 g/L × 10-3 kg/g × 103 L/m3× 1,030) Vsupernatant = Wsupernatant/(4,000 mg/L × 10-6 kg/mg × 103 L/m3 × 1,000) 132 m3/d = Wsludge/(0.05 × 1,030) + Wsupernatant/(0.004 × 1,000)
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Digested sludge, kg/d (Stream 12)
Design Example (9) Wsupernatant = Total solids remaining after digestion in digested sludge – Wsludge = 5,159 kg/d - Wsludge Wsludge = 5,021 kg/d; Wsupernatant = 138 kg/d; Vsludge = 98 m3/d; Vsupernatant = 35 m3/d (similar to mass balance) 4. Determine the mass and concentration of the components in digested sludge and supernatant Parameter Digested sludge, kg/d (Stream 12) Supernatant (Stream 13) kg/d mg/L Flow, m3/d TSS BOD5 Org.-N NH4+-N NO3—N TN NPP PP TP TVSS/TSS ratio Biodeg. solids/TSS Org.-N/TVSS NPP/TVSS 97 (98a) 5,008 (5,021a) 1,596 320 44 364 67 126 193 0.54 0.33 0.12 0.025 35 (35a) 140 (138a) 105 19 16 9 35 7.4 - 4,000 (3,942a) 3,000 533 453 986 211 a computed
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Design Example (10) 5. Select a supernatant selector system
To withdraw liquid from the top. a. Allow direct visual inspection of sludge b. Allow removal of clear liquid from the top c. Permit operation by one person d. Be extremely reliable e. Minimize the danger of allowing air to enter the digester f. Be easy to service in case of blockage grease, scum or by sludge
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Design Example (11) F. Influent Sludge Line to the Digester
Intermittent pump operation at 0.85 m3/min for each thickener controlled by a timer. 15-cm (6-in) diameter
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Design Example (12) G. Digester Heating Requirements
1. Compute heating required for raw sludge HR = Q0 × Cp (T2 – T1) where HR = heat required, J/day; Cp = specific heat of sludge (same as for water = 4,200 J/kg·°C or 1 BTU/lb·°C); T2 = digestion temperature, °C; and T1 = temperature of the thickened sludge, °C. The critical heat requirement for raw sludge is reached when sludge flow is maximum and influent temperature is lowest: Heat req. = 8,681 kg/day × 4,200 J/kg·°C × (35 – 12)°C 0.035 kg/kg = 2.39 × 1010 J/day 2. Compute heat loss from the digester HL = UA × (T2 – T1) where HL = heat loss, J/hr; U = overall coefficient of heat transfer, J/sec·m2·°C (BTU/hr·ft2·°F); A = area through which heat loss occurs, m2 (ft2); T2 = digester operating temperature, °C (°F); and T1 = outside air temperature, °C (°F)†. † Critical average air and ground temperatures are 0 and 5°C, respectively.
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Design Example (13) Heat losses from the digester occur from the roof, bottom, and side walls Compute area of roof Roof slope = 15:1 = (13.7/2) m:0.46 m Roof area = D(slant length)/2 Roof area = ( × 13.7 m × 6.87 m)2 = m2 Compute area of side walls Area of side wall above ground level = D × Exposed height Assume 50% side wall is exposed Side wall area above ground = ×13.7 m×8.5 m/2=182.9 m2
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Design Example (14) Area of side wall below ground = 182.9 m2
c. Computed bottom area Digester bottom is sloped at 1 vertical to 3 horizontal. Total drop of the bottom slope at the center = D (2 × 3) = 13.7 m (2 × 3) = 2.3 m Bottom area = × 13.7 m × ½ × (13.7 m/2)2 + (2.3 m)2 = m2 d. Select overall coefficients of heat transfer for different areas Digester floating covers and roofing consist of 6.5-mm (1/4-in.) plate steel, 76-mm (3-in.) rigid foam insulation*, inside air space, and buildup roofing - 1,236 kg/m2 (70 lb/ft2) – U† = 0.9 J/sec·m2 ·°C (BTU/hr·ft2·°F) * Common insulating materials are glass wool, insulation board, urethane foam, lightweight insulating concrete, dead air space, etc. † J/sec·m2 ·°C × = BTU/hr·ft2·°F
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Design Example (15) Exposed digester side 300-mm (12-in.) concrete, 76-mm (3-in.) urethane foam insulation, 100-mm (4-in.) brick siding – U = 0.68 J/sec·m2 ·°C Buried digester side 300-mm (12-in.) concrete surrounded by moist soil – U = 0.8 J/sec·m2 ·°C Digester bottom surrounded by moist soil – U = 0.62 J/sec·m2 ·°C e. Computed heat loss from the digester Heat loss from the cover and roofing = m2 × 0.9 J/sec·m2 ·°C × (35 – 0)°C × 86,400 sec/day = 4.03 × 108 J/day Heat loss from exposed wall = m2 × 0.68 J/sec·m2 ·°C × (35 – 0)°C × 86,400 sec/day = 3.76 × 108 J/day Heat loss from buried wall = m2 × 0. 8 J/sec·m2 ·°C = 4.43 × 108 J/day
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Design Example (16) Heat loss from bottom = m2 × 0.62 J/sec·m2 ·°C × (35 – 5)°C × 86,400 sec/day = 2.50 × 108 J/day Total heat loss from each digester = × 108 J/day Total heat loss from both digesters, including 20% minor losses, and 25% emergency condition = 14.72× 108 J/day × 2 × 1.45 = 5.09 × 109 J/day f. Compute the heating requirements for the digester Heat requirements for raw sludge under critical condition = 2.39 × 1010 J/day Heat loss from the digester = × 108 J/day Total heating requirement = 2.82 × 1010 J/day = × 109 J/hr = × 106 kJ/hr
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Design Example (17) H. Selection of Heating Units and Energy Balance
1. Select external heat exchanger Provide two heating units each rated as 1.25 × 106 kJ/hr (1.19 × 106 BTU/hr) with natural gas. The digester gas has approx. 65% of the heating value of the natural gas (37,300 kJ/m3). Therefore, each unit will be derated at 1.25 × 0.65 (0.813) × 106 kJ/hr (0.77 × 106 BTU/hr). Total heat provided by two units = 2 × × 106 = × 106 kJ/hr. The actual average heat requirements are substantially less. 2. Compute digester gas requirements At 75% efficiency of heating units
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Design Example (18) Total quantity of digester gas produced = 2,550 m3/day This gives approx. 20% excess gas under the most critical condition when the digester heating demand is greatest. Excess gas will be used to produce heated water for other plant uses. 3. Design makeup heat exchangers for external sludge heating a. Compute average temperature rise of the sludge through the external exchangers Provide 23-cm (9-in) diameter sludge recirculation pipe, and a constant flow recirculation pump for each digester. A common external jacketed type heat exchanger will be used to heat the recirculated sludge. If velocity of 1 m/sec is maintained in the pipe.
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Design Example (19) Average sludge temperature entering the external heat exchanger = 35°C Assume average sludge temperature increase after passing through the heat exchanger = T°C Assume specific heat of sludge is 4,200 J/kg°C (same as for water) Total heat required from each digester = 2.82 × 1010 J/d (#22) = 1.41 × 1010 J/d. If the efficiency of the heat exchanger is 80%. 1.538 × 1010 × T J/day × 0.8 = 1.41 × 1010 J/day
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Design Example (20) Average temp. of the sludge entering heat exchanger = 35°C Ave. temp. of the sludge leaving heat exchanger = 36.15°C Sludge recirculation of 3,590 m3/day (660 gpm) in each digester will also provide digester mixing. b. Compute hot water recirculation rate through the external heat exchanger Provide one jacketed pipe heat exchanger for both digesters. Assume that the water enters the jacket pipe at 95°C and leaves at 60°C. Drop in heating water temperature = = 35°C Total heating required for each digester = 1.41 × 1010 J/day If 25%additional heating is provided to account for heat losses, Total heat required per digester = 1.41 × 1010 J/day × 1.25 = 1.76 × 1010 J/day Total heat required for both digesters = 3.52 × 1010 J/day Total heat available in digester gas = 23,000 kJ/m3 × kg/m × 2,550 m3/d × 1,000 J/kJ = 6.82 Using specific heat of water = 4,200 J/kg·°C Heating value of digester gas = 23,000 kJ/m3
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Design Example (21) Total heat supplied by water = 4,200 J/kg·°C × 35°C = 147,000 J/kg Hot water recirculation rate through the common heat exchanger = 3.52 × 1010 J/day 147,000 J/kg = 2.40 × 105 kg/day Volume of water recirculated = 2.4 × 105 kg/day × 1,000 g/kg (1 g/cm3 × 106 cm3/m3) = 240 m3/day c. Compute the length of sludge pipe in heat exchanger jacket Average temp. of the sludge in the heat exchanger = ( )°C 2 = 35.58°C Average temp. of the heating water in the heat exchanger = ( )°C 2 = 77.5°C Assume heat transfer coefficient of external water jacketed heat exchanger = 4,000 kJ/hr·m2 ·°C (196 BTU/hr·ft2·°F) Total heat radiated from the heating water = ( )°C × 4,000 kJ/hr·m2 ·°C × 24 hr/day = 4.02 × 106 kJ/day·m2
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Design Example (22) Total area of the sludge pipe for each heat exchanger = 1.76 × 1010 J/day (4.02 × 106 kJ/day·m2 × 1,000 J/kJ) = 4.38 m2 Length of 23-cm (9-in) diameter jacketed pipe = 4.38 m2 ( × 0.23 m) = 6 m Provide 6-m long, 23-cm diameter heat exchanger sludge pipe per digester into a common hot water jacket. I. Gas Storage and Compressor Requirements 1. Compute the diameter of the gas storage sphere Provide a total of 3-day gas storage to serve the digester heating requirements and other plant uses Total gas stored = 3 day × 2,550 m3/day = 7,650 m3 (standard condition, 0°C and 1 atm) Storage pressure = 5.1 atm (assume) Storage temperature = 50°C summer Storage volume, V2 = P1V1T2/P2T1 Subscript 1 stands for gas produced and 2 for gas stored.
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Design Example (23) V2 = 1 atm × 7,650 m3 ( )K [5.1 atm × (273 + 0)]K = 1,774.7 m3 Provide a high volume gas storage sphere Volume of sphere = /6 (diameter)3 Diameter of sphere = (1,774.7 m3 × 6/ )1/3 = 15 m (49 ft) Provide 15 m (49 ft) diameter sphere for gas storage 2. Compute size of high-pressure gas compressors Compressors are used to compress the digester gas into the gas storage sphere. Total weight of digester gas produced under standard conditions = 2,548 kg/day (Step E.3) Assuming weight of gas compressed is 200% of production rate, then w = 2 × 2,548 kg/day × 1/864,000 day/sec = kg/sec R = kJ/kmol·K e = compressor efficiency of 75% T0 = inlet temperature = ( )°C
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Design Example (24) P0 = 1.03 atm (gas pressure inside the floating cover is normally less than 0.4 m of water) P = 5.1 atm Provide two constant-speed compressors each driven by 7.5 kW (10-hp) electric motor. J. Digester Gas Mixing 1. Compute power requirements for gas mixing Power requirements for gas mixing of the digester P = G2µV where G = velocity gradient, 1/sec.
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Design Example (25) The volume of each digester, V = 1,179.7 m3
µ = 2 times the viscosity of water at 35°C = 2 × 0.73 × 10-3 N·sec/m2 = 1.46 × 10-3 N·sec/m2 Velocity gradient for sludge above 5% solids is over 75 1/sec. Use G = 85 1/sec. P = 852 × 1,46 × 10-3 N·sec/m2 × 1,179.7 = N·m/sec (9,178 ft·lb/sec) = 12.4 kW = 16.6 hp Total power required for two digesters = 2 × 12.4 kW = 24.8 kW = 33.2 hp Provide three compressors each driven by 15-kw (20-hp) motor. Total power provided for mixing = 45 kw (60 hp) Two compressors will deliver the required power, while the third compressor will be a stand-by, serving both digesters. Compute gas flow The digester gas flow rate for mixing, w, can be calculated using the equation in the previous slide.
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Design Example (26) The volume of each digester, V = 1,179.7 m3
µ = 2 times the viscosity of water at 35°C = 2 × 0.73 × 10-3 N·sec/m2 = 1.46 × 10-3 N·sec/m2 Gas flow per digester = 0.14 kg/s (1.162 kg/m3 × 0.86) = 0.14 m3/s Select digester-mixing arrangement The digester mixing will be achieved by flow recirculation, raw sludge, and internal gas mixing. The sludge recirculation of 3,590 m3/day in each digester was calculated in step H3. The sludge will be withdrawn from the mid-depth and discharged above the scum blanket level to assist in scum mixing. A multi-port mixing system is provided for effective use of the gas. The gas is withdrawn from the top and recirculated by means of nine ports for gas injection. Density of digester gas = 86% of air (1.162 kg/m3)
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Digester Startup Haul approx. 250 m3 seed and transfer it into one digester. Fill the digester with raw wastewater. Start heating and mixing, and bring to operating temperature. Begin feeding raw sludge at a uniform rate approx. 25% of daily feed per digester. Increase the loading gradually. Maintain the following records Quantity of TVS fed daily TVS, VS/Alk ratio, and pH Temperature, gas production, and CO2 content in gas At low feeing rate, it is possible to bring normal operation without adding chemicals for pH control. If VA/Alk ratio rises to 0.8, and pH is below 6.5, addition of chemicals such as lime or soda ash may be considered. Fairly stable conditions should be reached in 30~40 days if loading is kept below 1 kg VS/m3·day.
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Common Operating Problems
A rise in VA/Alk ratio (> 0.3), increase in CO2 content, decrease in pH, rancid or H2S odors are indication of hydraulic or organic loading, excessive withdrawal of digested sludge, or incoming toxic materials. Poor supernatant quality may be due to excess mixing, insufficient settling time before sludge withdrawal, too low supernatant drawoff point, and insufficient sludge withdrawal rate. Foam in supernatant may be use to scum blanket breaking up, excessive gas recirculation, and organic loading. Thin digested sludge may be due to short circuiting, excessive mixing, or too high sludge-pumping rate. Tilting floating cover may be due to uneven distribution of load, thick scum accumulation around the edges, rollers or guide broken or rollers out of adjustment. Binding cover (even when rollers and guides are free) may be due to damaged internal guides or guy wires.
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Operation and Maintenance
Key Operational Goals Minimize excess water Control organic loading Control temperature Control mixing Reduce accumulation of scum Withdraw supernatant that is low in solids Routine Digester Operation and Maintenance Checklist Check digester gas pressure. Drain daily the condensate traps. Drain daily sediment traps. Check daily gas burner for proper flame. Record daily floating cover position, check cover guides, and check for gas leaks. Record daily digester and natural gas meter readings. Check daily and record fuel oil. Chemical daily gas-mixing equipment for flow and gas. Check daily pressure relief and vacuum breaker valves.
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