Comparing cost and process performance of activated sludge (AS) and biological aerated filters (BAF) over ten years of full sale operation

Abstract

In the early 1990s, the Wastewater Treatment Plant (WWTP) of Frederikshavn, Denmark, was extended to meet new requirements for nutrient removal (8 mg/L TN, 1.5 mg TP/L) as well as to increase its average daily flow to 16,500 m3/d (4.5 MGD). As the most economical upgrade of the existing activated sludge (AS) plant, a parallel biological aerated filter (BAF) was selected, and started up in 1995. Running two full scale processes in parallel for over ten years on the same wastewater and treatment objectives enabled a direct comparison in relation to operating performance, costs and experience. Common pretreatment consists of screening, an aerated grit and grease removal and three primary settlers with chemical addition. The effluent is then pumped to the two parallel biological treatment stages, AS with recirculation and an upflow BAF with floating media. The wastewater is a mixture of industrial and domestic wastewater, with a dominant discharge of fish processing effluent which can amount to 50% of the flow. The maximum hydraulic load on the pretreatment section as a whole is 1,530 m3/h. Approximately 60% of the sewer system is combined with a total of 32 overflow structures. To avoid the direct discharge of combined sewer overflows into the receiving waters, the total hydraulic wet weather capacity of the plant is increased to 4,330 m3/h, or 6 times average flow. During rain, some of the raw sewage can be directed through a stormwater bypass to the BAF, which can be modified in its operation to accommodate various treatment needs:•either using simultaneous nitrification/denitrification in all filters with recirculation•introducing bottom aeration with full nitrification in some filters for storm treatment•and/or post-denitrification in one filter. After treatment, the wastewater is discharged to the Baltic Sea through a 500 m outfall. The BAF backwash sludge, approximately 1,900 m3 per 24 h in dry weather, is redirected to the AS plant. Primary settler sludge and the combined biosolids from the AS plant are anaerobically digested, with methane gas being used for generation of heat and power. On-line measurements for the parameters NO3, NO2, NH4, temperature as well as dissolved oxygen (DO) are used for control of aeration and external carbon source (methanol). Dosing of flocculants for P-removal is carried out based on laboratory analysis and jar tests. This paper discusses the experience gained from the plant operation during the last ten years, compiling comparative performance and cost data of the two processes, as well as their optimisation.