DIGESTION AND DISPOSAL OF PRIMARY AND SECONDARY SLUDGE

9.25. Sludge and Its Moisture Content

The sludge, which is deposited in a primary sedimentation tank, is called the Raw sludge; and the
sludge which is deposited in a secondary clarifier is called the Secondary Sludge. Raw sludge is
odourous, contains highly putrescible organic matter, and is, thus, very very objectionable.
Secondary sludge is also putrescible, though a little less objectionable.

The sludge withdrawn from the bottom of the sedimentation basins must, therefore, be stabilised
before its final disposal. In addition to its putrescibility, another problem posed by the sludge is its
high moisture content. In case of raw sludge, the moisture content is about 95%; in case of
secondary sludge from a trickling filter plant, it is about 96 to 98%; at of case of secondary sludge
from an activated sludge treatment plant, it is about 98% to over 99%. The sludge containing high
moisture content becomes very bulky, and difficult to handle. For example, sludge with 95%
moisture, contains 5 litres of solid matter in 100 litres of sludge. Similarly, the sludge with 90%
moisture will contain 10 litres of solid matter in 100 litres of sludge, i.e. 5 litres of solid matter in 50
litres of sludge. Thus, the sludge with 90% moisture will be half in quantity as compared to that of
the sludge with 95% moisture, for the same volume of solids. Similarly, a sludge with 99% moisture
contains 1 litre of solids in 100 litres of sludge, whereas, a sludge with 95% moisture contains 5 litres
of solids in 100 litres of sludge, i.e. 1 litre of solids in 20 litres of sludge. Hence, the sludge with 99%
moisture will be 100/20 = 5 times

more bulky than the sludge with 95% moisture, for storing the same solid content. = 5 times

It, therefore, follows that if the moisture content of the sludge is reduced, its volume will go on
decreasing. If moisture content is reduced to about 70 to 80%, the sludge becomes viscous; and at
about 10% moisture content, it becomes dry, and assumes powder form. The complete moisture
can, however, be removed only by special treatments, since the water is so tenaciously held in the
sludge.

Example 9.17. A sedimentation tank is treating 4.5 million litres of sewage

per day containing 275 ppm of suspended solids. The tank removes 50% of suspended solids.
Calculate the quantity of sludge produced per day in bulk and weight, if (a) moisture content of
sludge is 98%; (b) moisture content of sludge is 96%.

Solution.

Volume of sewage treated = 4.5 M-litres/day

Since suspended solids amount to 275 mg/l,

we have the mass of suspended solids present in sewage

275× 4.5 6
6
×10 kg/day = 1237.5 kg/day
10

Since 50% of solids are removed in sedimentation tank, we have The mass of solids removed in
sedimentation tank = 1237.5 x 50/100= 618.75kg/day

(a) When moisture content of sludge is 98%, then 2 kg of solids (dry sludge) will make

= 100 kg of wet sludge

618.75 kg of solids (dry sludge)

will make 100/2×618.75

=30937.5 kg = 30940 kg (say).

[1 ton = 103kg.]

Hence, wet sludge or sludge produced per day

30,940 kg = 30.94 tonnes.

Assuming the sp. gravity of wet sludge (sludge) as 1.02, we have Unit wt. of sludge = 1.02 x 1 t/m3 =
1.02 t/m³

[ Unit wt. of water = 1 t/m³]

Vol. of wet sludge produced per day

Wt
unit Wt × 30.94 =¿ ¿ 30.33 m³
¿ 1.02

Vol. of sludge (when its m.c. is 98%) = 30.33 m³. Ans.

(b) When moisture content is 96%, then 4 kg of solids will make

= 100 kg of wet sludge.

⋰ ⋱618.75 kg of solids will make

100/4x618.75 kg of wet sludge =15,470 kg (say) of wet sludge

= 15.47 tonnes of wet sludge.

Hence, wt. of sludge (when its m.c. is 96%) = 15.47 tonnes. Ans.
If sp. gravity of sludge is 1.02, then

Vol. of sludge (when its m.c. is 96 %) = 15.47/ 1.02m³ = 15.17 m³.

Hence, the vol. of sludge at 96% m.c. = 15.17 cu. m. Ans.

Note. It shows that the sludge is reduced to half its volume when its m.c. is lowered from 98% to
96%

Example 9.18. There is a sewage sludge with volume containing a certain moisture content P, (per
cent). What will be the volume of this sludge if its moisture content is reduced to p (per cent).
Solution.

Let the given sewage contains solids = W kg. Let its volume be V

at a moisture content of P, (per cent), and V at a moisture content of p (per At moisture content of
p,, we have (100-p,) kg of solids will make

= 100 kg of wet sludge.

W kg of solids will make

100. w/(100-P₁)kg of wet sludge.

or Wt. of sludge produced = (100-P₁)

If y, is the unit wt. of sludge, in kg/m³, then

Vol. of sludge produced v= 100. W / (100 P1) .1/Ys m³.

or

V₁ =100. W /100-P1.1/ Ys

At moisture content of p (per cent), similarly, we have

Vol. of sludge produced (V) =100. W/ 100-p .1/ Ys m³…………[1]

оr

From equation (i), we have

W = (100-P1) V₁.Ys/ 100

From equation (ii), we have

W= (100-p) V. Ys/ 100

Equating (iii) and (iv), we get

(100-p₁) V₁-Y/100 = (100-p) V. Ys/ 100

V=V1[(100-P10 /(100-p)]

Ans.

Example 9.19. The moisture content of a sludge is reduced from 95 to 90% in a sludge digestion tank.
Find the percentage decrease in the volume of sludge.

Solution.

Using Eqn. (9.38), we have

V=V₁ [100- P1 / 100-p ]

5
V=V1 [100-95 / 100-90] = V₁×
10

= V1/ 2

Or, Thus, the volume at 90% moisture will be half of that at 95% moisture. Hence, the percentage
decrease in moisture will be 50%. Ans.

9.26. Sludge Digestion Process

As pointed out earlier, the sludge withdrawn from the sedimentation basins contains a lot of
putrescible organic matter, and if disposed of without any

treatment, the organic matter may decompose, producing foul gases and a lot of nuisance, pollution,
and health hazards. In order to avoid such pollutions, the sludge is, first of all, stabilised by
decomposing the organic matter under controlled anaerobic conditions", and then disposed of
suitably after drying on drying beds, etc. The process of stabilisation is called the sludge digestion;
and the tank where the process is carried out is called the sludge digestion tank. In a sludge
digestion process, the sludge gets broken into the following three forms:

(i) Digested sludge. It is a stable humus like solid matter, tary black in colour, and with reduced
moisture content, and, is therefore, having reduced volume (about times the undigested sludge
volume). Moreover, the quality of digested sludge is much better than that of the undigested sludge,
and it is free of pathogenic bacteria which are killed in the digestion process. It may still, however,
contain cysts and eggs of bacteria, protozoa and worms.

(ii) Supernatant liquor. It includes the liquified and finely divided solid matter, and is having high BOD
(about 3000 ppm).

(iii) Gases of decomposition. Gases like methane (65 to 70%), carbon dioxide (30%), and traces of
other inert gases like nitrogen, hydrogen sulphide, etc. are evolved. They may be collected
(particularly the methane which has a high calorific value) and used as a fuel.

The sludge gas, having 70% methane, has a fuel value of about 5800 kilo calorie/cu. m (i.e. 650 Btu
per cu. ft. app.). The amount of gas produced, on an average, is about 0.9 cu. m. per kg of volatile
solids reduced in digestion. The gas produced thus varies with the sewage produced, and works out
to about 14 to 18 litres per capita per day (usually 17 l/c/d).

The digested sludge is dewatered, dried up, and used as fertiliser; while the gases produced are also
used for fuel or for driving gas engines. The supernatant liquor contains about 1500 to 3000 ppm of
suspended solids; and is, therefore, re-treated at the treatment plant along with the raw sewage.

9.27. Stages in the Sludge Digestion Process

Three distinct stages have been found to occur in the biological action involved in the natural
process of sludge digestion. These stages are:

(i) Acid fermentation;

(ii) Acid regression; and

(iii) Alkaline fermentation.

These stages are briefly summarised here:

(i) Acid Fermentation Stage or Acid Production Stage. In this first stage of sludge digestion, the fresh
sewage-sludge begins to be acted upon by anaerobic and facultative bacteria, called acid formers.
These organisms solubilize the organic solids through hydrolysis. The soluble products are then
fermented to volatile acids and organic alcohols of low molecular weight like propionic acid, acetic
acid, etc. Gases like methane, carbon dioxide and hydrogen sulphide are also evolved. Intensive acid
production makes the sludge highly acidic, and lowers the pH value to less than 6. Highly
putrefactive odours are evolved during this stage, which continues for about 15 days or so (at about
21°C). BOD of the sludge increases to some extent, during this stage.

(ii) Acid-Regression Stage. In this intermediate stage, the volatile organic acids and nitrogenous
compounds of the first stage, are attacked by the bacteria, so as to form acid carbonates and
ammonia compounds. Small amounts of hydrogen sulphide and carbon-dioxide gases are also given
off. The decomposed sludge has a very offensive odour, and its pH value rises a little, and to be
about 6.8. The decomposed sludge, also, entraps the gases of decomposition, becomes foamy, and
rises to the surface to form scum. This stage continues for a period of about 3 months or so (at about
21°C). BOD of the sludge remains high even during this stage.

(iii) Alkaline Fermentation Stage. In this final stage of sludge digestion, more resistant materials like
proteins and organic acids are attacked and broken up by anaerobic bacteria, called methane
formers, into simple substances like ammonia, organic acids and gases. During this stage, the liquid
separates out from the solids, and the digested sludge is formed. This sludge is granular and stable,
and does not give offensive odours. (It has a musty earthy odour). This digested sludge is collected at
the bottom of the digestion tank, and is also called ripened sludge. Digested sludge is alkaline in
nature. The pH value during this stage rises to a little above 7 (about 7.5 or so) in the alkaline range.
Large volumes of methane gas (having a considerable fuel value) alongwith small amount of carbon
dioxide and nitrogen, are evolved during this stage. This stage extends for a period of about one
month or so (at about 21°C). The BOD of the sludge also rapidly falls down during this stage.

It is, thus, seen that several months (about 4 months or so) are required for the complete process of
digestion to take place under natural uncontrolled conditions at about 21°C. This period of digestion
is, however, very much dependent upon the temperature of digestion, and other factors. If these
factors are controlled, quicker and effective digestion can be brought about, as discussed below.

9.28. Factors Affecting Sludge Digestion and Their Control The important factors which affect the
process of sludge digestion, and are, therefore, controlled in a digestion tank, are:

1. Temperature;

2. pH value;

3. Seeding with digested sludge; and

4. Mixing and stirring of the raw sludge with digested sludge. Besides these important factors,
certain other minor conditions like quality of water supply; presence of copper, fluorides, and radio
active substances etc., may also affect the rate of digestion, but not to any appreciable extent The
important factors which are largely responsible for controlling the rate and effectiveness of sludge-
digestion are discussed below:

(1) Telaperature. The process of digestion is greatly influenced by temperature; rate of digestion
being more at higher temperatures and vice- versa. The effect of temperature on digestion period is
shown in Fig. 9.27. In this figure, two distinct temperature zones are indicated; i.e.

(i) Zone of Thermophilic Digestion. In this zone of high temperature, digestion is brought about by
heat loving thermophilic organisms. The temperature in this zone ranges between 40 to 60°C. The
optimum temperature in this zone is about 54°C, and at this temperature, the digestion period can
be brought down to about 10-15 days only. However, thermophilic range temperatures are generally
not employed for digesting sewage sludge, owning to odours and other operational difficulties.

a) Zone of Mesophilic Digestion. In this zone of moderate temperature, digestion is brought about by
common mesophilic organisms. The temperature in this zone ranges between 25 to 40°C. The
optimum mesophilic temperature is about 29°C; and at this temperature, the digestion period can
be brought down to about 30 days.

Hence, it can be concluded that the sludge can be quickly digested, if the temperature in the
digestion tank is kept high. The best results are obtained

at about 29°C (i.e. the optimum mesophilic temperature) when about 90% of digestion takes place in
about 30 days. But it may, however, be pointed out that it is difficult to control temperature in
practice, as it mainly depends Upon the prevailing local climatic conditions. Although external
heating devices may sometimes be employed to control temperature in the digestion tanks,
especially in cold countries.

lot of volatile organic acids are formed, as an intermediate step, in the (2) pH Value. It was
breakdown of organic material. These volatile acids are then converted into methane gas by a
specialised group of strictly anaerobic and slow growing pointed out earlier that during the digestion
process, a bacteria, called methane formers. If the methane formers are not operating to a value as
low as 5.0, which will suppress further bacterial action. Hence, properly, an accumulation of volatile
acids may occur, causing the pH to drop