5519 United States Office of Water Program Office of Research and
Environmental Protection Operations (WH-547) Development (MERL)
Agency Washington DC 20460 Cincinnati OH 45268
_ r . I
Water September 1980
&EPA Innovative
Technology
Meeting the
Challenge of the 80's
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5519 United States Office of Water Program Office of Research and
Environmental Protection Operations (WH-547) Development (MERL)
Agency Washington DC 20460 Cincinnati OH 45268
r.t
Water September 1980
&EPA Innovative
Technology
Meeting the
Challenge of the 80's
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The Honorable Don H Clausen, Representative from the 2nd District,
Crescent City, California in describing Congressional commitment to
the Innovative Technology Program during House-Senate
Conference debate-
The advantages of innovative technology are many They include
acceleration of efforts to meetthe long-range objectives and goals
of the act, development of simpler options to conventional
secondary treatment with concomitant lessening of operating
costs and energy consumption, and the facilitation of reclamation
and recycling efforts.
I am convinced that this new departure will yield substantial
dividends in advancing technology in the water pollution control
field leading to improved water quality at lesser capital or
operating costs, or the combination of the two
The opportunities are enormous, as are the benefits
" •'*?:•
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INNOVATIVE TECHNOLOGY
THE CHALLENGE OF THE 80's
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF WATER PROGRAM OPERATIONS
WASHINGTON, D,C, 20460
U.3. Environmental Rrotecttoa >AgeJIC^j
Rjjion V, Library
230 Couth Dearborn Street
Chicago, Illinois 60604
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U.S. Environmental Protection Agency
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Introduction
The Clean Water Act of 1977 and the
implementing regulations encourage the use of
both innovative and alternative (I/A) technologies
as solutions to municipal wastewater and sludge
management needs Special emphasis is given to
technologies that conserve or recover energy,
reduce total costs, reclaim or reuse water, recycle
wastewater constituents, or eliminate surface
discharges
This brochure disseminates recent information on
innovative technology in context of the initial three
year I/A Program (Information concerning
alternative technology can be found in other EPA
publications) Presented first is a brief discussion
of innovative technology and the concept of risk
followed by a summary of the "Active" I/A
Program Finally, several selected case histories
are featured out of the over one hundred
applications received by EPA for innovative
technology funding during the first two years of
the program Innovative technologies are
classified as (1) those approved for funding by the
EPA Regional offices, and (2) those under
consideration as part of the Active I/A Program
Since innovative technology is determined on a
case-by-case basis by the EPA Regional offices,
this brochure does not serve as an endorsement of
any of the presented technologies — rather it is
intended to be informational in nature by
describing representative projects that have been
submitted at this point in time
As part of the EPA Active I/A Program, technical
and administrative assistance can be provided to
consultants and municipalities who wish to pursue
consideration of the technologies presented or
other emerging technologies on a case-by-case
basis National, Regional, and State I/A contacts
and coordinators are shown on the last page of
this brochure
Innovative Technology and the Concept
of Risk
Innovative Technology is defined as processes and
techniques that are developed methods which have
not been fully proven under the circumstances of
their contemplated use and which represent a
significant advancement over the state-of-the-art
in terms of meeting the national goals
In contrast, conventional concepts of treatment are
defined as biological or physical-chemical
processes with direct point source discharge to
surface waters
Innovative Technology must have some element of
increased risk and associated benefit Traditional
engineering practice has always dictated a very
low element of risk for the construction of full-
scale public works projects supported by federal
expenditures In passing PL 95-217, Congress
clearly intended that a higher degree of risk be
permitted and encouraged for innovative
technology High risk, high potential state-of-the-
art advancement projects may be judged
acceptable for funding where high risk, low
potential state-of-the-art advancement projects
may be deemed unacceptable The concept of
risk vs stage of technology advancement used in
the innovative technology program is shown in the
accompanying figure The innovative technology
program is designed to encourage use of
technologies that are within this window of
acceptable risk. This calls for a conscious decision
on the part of the designers to depart from
traditional practice and propose higher than normal
risk designs that have increased potential for
achieving cost, energy, or other benefits This is a
key element in this new national program
Conceptual illustration showing risk versus stage of technology
development and the window of acceptable risk
In recognition of the inherent conservatism in the
design of wastewater treatment facilities EPA's
I/A Program includes a comprehensive set of
positive incentives to encourage Innovative
Design These include increased federal
construction grant assistance for I/A technologies,
increased design fees for innovative technology,
sole source procurement and patent exemptions
for innovative technology
Also, in recognition of the risks involved in
encouraging this departure from business as usual,
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the EPA will make 700% grants to cover the total
cost of modifying or even replacing innovative
systems that do not perform as intended
The Active I/A Program
As a further inducement for the consideration and
use of Innovative Technologies, on March 20, 1980
EPA's Administrator announced the formation of
an Active I/A program The Active I/A
technology program is a joint effort of the EPA
Construction Grants and Research and
Development Programs. The overall thrust of
this program is to
• Identify recently developed emerging I/A
technologies ready for implementation.
• Identify and recommend project sites
throughout the country that can potentially
benefit from emerging technologies
• Assist local communities and their consulting
engineers with assessment and analysis of
emerging technologies that may be applicable
to their specific wastewater treatment control
or management problems
• Provide consulting engineers with detailed
planning and engineering assistance on a
project-by-project basis
A special emphasis of the Active I/A technology
program is to provide direct technical and
administrative EPA assistance to municipalities in
the actual development of I/A projects at the local
level The EPA is working closely with local and
state governments, public participation groups,
consultants, and equipment manufacturers in this
new effort
Activities of the Active I/A program will include a
series of ten emerging technology seminars to be
held during October, November, and December in
Boston, New York, Philadelphia, Atlanta, Chicago,
Dallas, Kansas City, Denver, San Francisco, and
Seattle The Water and Wastewater Equipment
Manufacturers Association is sponsoring the
seminars with EPA as a cooperating agency. A
special announcement for these seminars is
available
Also, as part of the Active I/A effort, a number of
emerging technology assessment reports (40-60
pages) are being published to disseminate
information on recent advances in the field of
wastewater treatment that have strong potential as
innovative technology. They will soon be available
through state and regional I/A coordinators or
from MERL-Cmcmnati. Assessments which have
been completed include overland flow, vertical tube
reactor, anaerobic upflow expanded bed, deep
shaft technologies, and solar applications in the
treatment of wastewater and sludge
Innovative Technology
Presented are eight EPA approved Innovative
Technology projects and five that are currently
under review as part of the Active I/A program.
Those under review have been
preliminarily determined to be within the window
of acceptable risk and offer a potential
advancement in the state-of-the-art. Final
classification will depend on their meeting the 15%
life cycle cost, 20% net primary energy savings or
improved application qualifying criteria in the
particular site specific application.
EPA Regional I/A Coordinators,
Headquarters and Cincinnati
Staff meet to discuss I/A
program and visit project sites.
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Innovative Technology Projects
Approved for Funding by EPA
Hillsborough, New Hampshire
Adopts Innovative Energy
Design
The town of Hillsborough, New Hampshire is
implementing an alternate energy systems
approach in the design of their 0.45 mgd
wastewater treatment plant Many of the plant
features are similar to those found in the Wilton,
Maine wastewater treatment facility shown in the
accompanying figure. These include active and
passive solar comfort and hot water heating, active
solar heating of the anaerobic digestion, passive
solar heating of the rotating biological contactors,
recovery, storage and use of methane to run gas
generators, gas generator coolant heat recovery,
ventilation system heat recovery via air to air heat
exchangers, effluent heat recovery via heat pumps
Special architectural design features include
underground construction where possible
Processes will be kept close together and the
facility will be completely enclosed The consultant
for the Hillsborough project is Anderson-Nichols
and Company Inc. and the consultant for Wilton is
Wright-Pierce, Architects and Engineers
View of the Wilton, Maine wastewater treatment plant looking
north
Exposure of the facility to the north was
minimized. The roof is designed to hold a heavy
load of snow, a natural insulator Concrete block
and brick were used in conjunction with heavy
insulation to hold heat in at night A screw pump
is to be used at the head of the plant in
conjunction with gravity flow through the plant to
minimize energy demand for pumping Covered
rotating biological contactors were selected to treat
the wastewater, in part, because the large surface
area of the contactor is alternately exposed to
warmer air, which is passively heated by the sun,
and to the cooler wastewater This procedure adds
heat to the wastewater which is projected to
improve RBC performance, reduce sludge heating
requirements, and improve effluent heat recovery
Although many of the design features and unit
processes mentioned above would be considered
conventional taken separately, both the
Hillsborough and Wilton designs represent a
comprehensive and conceptually innovative total
energy conserving design approach
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In addition to reducing the net primary energy
requirements of the Hillsborough plant to less than
80% of a conventional design which was the basis
for innovative technology approval by EPA Region I,
the operating costs of the facility were reduced
Other possible innovative alternate renewable
energy source designs which can be considered
include the use of windmills which are presently
being studied for application at Livingston,
Montana, low head hydroelectric facilities, and
geothermal sources
Close-up view of solar collectors and anaerobic digesters at
Wilton, Maine
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WET
WELL INFLUEN-
PUMPING
DEWATERING
BELT FILTE
PRESS
Process schematic showing Hillsborough, New Hampshire
energy saving design features
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Lackawanna, New York Uses
Dual Aerobic/Anaerobic
Sludge Digestion and Obtains
Innovative Technology Grant
The city of Lackawanna, New York is replacing
existing anaerobic sludge digestion facilities at
their 4.5 mgd oxygen activated sludge wastewater
treatment plant with a new combined aerobic/
anaerobic digestion process This concept first
studied at Hagerstown, Maryland has been
approved for innovative technology funding by EPA
Region II at Lackawanna, New York. The consultant
for the project is Nussbaum and Clark The
combined digestion process (CDP) receives heat
necessary for anaerobic digestion under mesophihc
or thermophilic conditions from a preceding
oxygen-fed aerobic digestion step which oxidfzes
part of the incoming sludge
Sludge from primary clanfiers and thickened waste
activated sludge from a pure oxygen secondary
process will be first treated in an aerobic tank with
a retention time of 1 2 days which generates
enough heat for either mesophilic or thermophilic
anaerobic digestion in a second step In the aerobic
digester, pure oxygen will be used to minimize
heat losses through the vent gas The vent gas,
which will contain unused oxygen will be recycled
in the secondary treatment process Additional
oxygen-generating capacity will be required as the
amount of additional oxygen required in the first
step of the sludge digestion process exceeds the
spare capacity of the secondary treatment oxygen-
generating units Enough heat will be generated by
the process to maintain a 1 29°F temperature
where pasteurization of the sludge will occur.
The second step anaerobic digestion will take place
in two existing 50 foot diameter tanks which will
be remodeled to include fixed covers and mixing
The temperature at this stage is estimated to be
122°F. Digested sludge from the first of two
anaerobic tanks will be fed to the second tank for
supernatant separation and additional gas
collection Digested sludge from the anaerobic
second stage can be recycled to the first stage. The
gas spaces between the two anaerobic tanks will
be interconnected Total retention time in the
anaerobic digesters is eight days. Sludge will be
dewatered by centrifugation with existing drying
beds as standby. Supernatant and centrate will be
treated to remove phosphorus In this dual
digestion process, auxiliary heating of the
anaerobic digester is unnecessary because of
View of the aerobic digester portion of the dual digestion
demonstration project at Hagerstown, Maryland
exothermic first-stage oxidation due to closed tank
use of O2 This allows utilization of digester gas
energy for other than anaerobic digester heating
purposes such as mplant heating and power
generation
The combined aerobic/anaerobic digestion seeks to
incorporate advantages of each type of digestion
and minimize their drawbacks Aerobic digestion is
inherently a more stable and quicker oxidation
process, but it consumes more energy Anaerobic
digestion, although a slow process and susceptible
to upset, has a low energy requirement and
produces methane Using the processes in an
improved operational sequence allows the aerobic
reactor (oxygen fed) to provide adequate heat for
improved operation of anaerobic digestion, which
in turn frees the methane produced for other
"high" energy uses
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Utilization of aerobic followed by anaerobic sludge
digestion allows potentially more reliable and
stable sludge treatment operation. A unique aspect
of the process is the possibility to pasteurize the
sludge because of the relatively high temperatures
and detention times encountered in thermophilic
aerobic digestion If properly stabilized and
excessive heavy metals are not present, the sludge
can be disposed on land
In summary, this process proposed for use at
Lackawanna has adequately demonstrated the
potential'for increased operational stability,
additional environmental benefits, and possible
cost and/or energy savings over conventional
anaerobic digestion which served as the basis for
approval as innovative technology by EPA Region
Schematic showing the dual aerobic/anaerobic sludge
digestion process
Excess 02 to A.S
Activated
Sludge
Thickener
Primary
Wet Well
•^.Supernatant
Sludge '
u
Sludge 1
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Supernatant
Separation
Anaerobic
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Supernatant
Dewatermg
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Fluidized Bed Biological
Treatment (FBBT) is Used in
an Innovative Approach to
Expand a New York Plant
Nassau County, New York is presently designing
additional secondary wastewater treatment
facilities to upgrade and expand their existing Bay
Park Wastewater Treatment Plant from 60 to 70
mgd Expansion facilities will utilize fluidized bed
biological treatment (FBBT) This design is another
example of an improved biological treatment
process approved by EPA for increased grant
funding under the I/A Program
The FBBT process consists of a columnar
bioreactor partially filled with fine grained media
such as carbon or sand having an effective size
approximately 0 6 mm and a uniformity coefficient
of 1 4 Primary effluent is passed up through the
bottom with enough velocity to expand or
"fluidize" the media The media acts as a support
surface upon which a firmly attached biomass
eventually grows and thrives Intimate contact
between attached biomass and wastewater is
assured thereby improving treatment efficiency
Oxygen is provided by a 200 feet deep oxygen fed
U-tube reactor. Reactor effluent at the Bay Park
plant passes through a conventional secondary
clanfier before discharge, even though a proposed
proprietary sand separation device may reduce
effluent SS to acceptable levels without
clarification
View of the overflow launder on fluidized-bed reactor
View of four fluidized-bed reactors
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Oxygen
Sand
Separation
Pump
Final Clanfier
(Optional)
Effluent
Fluid Bed Bioreactor Waste Biological
Solids
U-Tube
Process diagram showing the fluidized-bed system as used at
the Nassau County Bay Park Facility
The FBBT operation is expected to meet secondary
discharge permit standards more cost effectively
and energy efficiently than conventional activated
sludge plants. The fluidized-bed reactor allows
higher loadings, lowers volume of sludge
production; potentially eliminates secondary
clarification requirements These advantages can
result in fewer and smaller treatment units
performing the same degree of treatment.
Preliminary indications are that overall operation
and maintenance costs will remain approximately
the same as activated sludge
The reactor requires no recirculation to maintain
high concentrations of biomass Furthermore, pilot
reactors have resulted in mixed liquor volatile
suspended solids (MLVSS) greater than 14,000
mg/l compared to typical conventional activated
sludge MLVSS concentrations of 1,500 mg/l As a
result, treatment time and bioreactor volume are
reduced. Pilot plant evaluations using wastewater
from the Bay Park Wastewater Treatment Plant
have indicated that with a recycle ratio of 1 5,
satisfactory secondary treatment of primary
sewage is possible in as little as 15 minutes
detention time compared to the several hours for
conventional activated sludge treatment Recycling
is necessary because dissolved oxygen content is
limiting It has not yet been possible to add
sufficient oxygen to the wastewater in a single
pass to support the biological oxidation that occurs
in the high MLVSS reactor This technology was
determined to meet EPA's energy criteria for
innovative technology The consultant for this
project is Consoer, Townsend and Associates
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An Innovative Hybrid
Approach Solves an Industrial
Waste Problem in Michigan
The city of Kalamazoo, Michigan has selected the
use of powdered activated carbon addition for
treatment of a combined industrial/domestic (53.3
mgd) waste. EPA Region V has approved the
Kalamazoo project for innovative technology
funding. The consultant is Jones and Henry
Engineers.
The proposed single-stage biophysical system
includes screening, degrittmg, comminution,
primary sedimentation, activated carbon addition
(The PACT Process) aeration, final clarification,
effluent filtration, disinfection, and post aeration.
The treated plant effluent is discharged to the
Kalamazoo River. Liquid alum is added before
primary and final clarification to achieve
phosphorus removal The primary sludges are
treated by gravity thickening, heat conditioning,
decanting, vacuum filtration, and incineration, with
ash disposal to landfill The secondary sludges go
through gravity thickening, activated carbon
regeneration, wet air oxidation and settling, with
final disposal of the residual to landfill The design
criteria which must be met include a daily
maximum of 10 mg/l BOD , 2 mg/l NHa-N, 5 mg/l
DO minimum, and a 7-day average of 15 mg/l SS
during the period from May 1 to October 31. For
the period from November 1 to April 30, the
following limitations are required daily maximum
of 30 mg/l BOD , 5 mg/l DO minimum, 7-day
average of 45 mg/l SS. The annual total
phosphorus removal requirement is 80% with
effluent total phosphorus concentration of 1 mg/l
or less, and effluent pH to be within the range of
6 5 to 9 5
In order to accomplish these seasonal limits for a
high strength domestic/industrial waste, the
addition of powdered activated carbon to the
activated sludge basin with wet oxidation
regeneration will be practiced. This project met the
15% life cycle cost saving criteria over the most
cost effective non-innovative two-stage biological
design as the basis of innovative designation.
Advantages offered for the process in this
application include
• Ability to carry active biomass at levels two to
three times higher than activated sludge and
thus reduce aeration basin size and hydraulic
detention time.
• The massive amounts of carbon present in the
aeration basin tend to serve as an "organic
sink" for shock loads of toxic or refractory
materials
• Oxygen transfer is improved — probably as the
result of adsorption-desorption of gas from the
activated carbon
• A larger portion of marginally degradable
organics is biologically assimilated due to the
long sludge residence time This enables the
carbon to carry a higher load of truly refractory
materral.
• Nitrification is easily achieved with the long
sludge residence time
• Odor, color, and foaming problems are
reduced
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View of one of PACTs clarifiers (foreground)
with aeration tanks, virgin carbon silo, and
wet air regeneration building in the back-
ground
Interior view of wet regeneration buildings
showing the regeneration units steam
generators in the foreground and heat
exchangers and reactor in the background
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Improved Aeration of
Oxidation Ditch Plants Meet
Innovative Technology
Qualifying Criteria in Selected
Cases
The towns of Atmore, Alabama (EPA Region 4);
Santa Fe, New Mexico (EPA Region 6), and
Fairfield, Iowa (EPA Region 7) employ a new
concept of aeration of oxidation ditches in the
construction of new or expanded municipal
wastewater treatment facilities The consultants
for these cities are Goodwyn and Mills Consulting
Engineers, Scanlon and Associates, and French-
Reneker-Associates, Inc This new draft-tube
aeration method utilizes a barrier across the entire
cross-sectional area of the narrow elongated
oxidation ditch channel. One or more draft-tube
circulators are installed which circulate the entire
channel contents by pumping thru draft tubes
installed under the barrier as shown in the
accompanying figure Air is separately pumped via
blowers into the circulating draft tube to provide
process oxygen requirements. The draft-tube is
sized such that the air is carried down with the
wastewater The depth of the draft-tube increases
dissolved oxygen due to increased hydrostatic head
at a small energy cost. The entire flow passes
under the dam via the draft-tube, and is aerated
before beginning another circuit around the
channel The use of two prime movers in this
manner decouples oxygenation from channel
velocity, thereby providing greater process control
and flexibility This process has been approved as
innovative technology in selected applications due
to the 20% net primary energy savings criteria.
Turbine
Draft Tube
Barrier. /Aerators
'FLOW
PLAN VIEW
Draft Tube Aerator-
(See Sketch)
SECTION A-A
Deep Draft
Tube
Use of draft tube aerators in an oxidation ditch
Blow-up sketch of a typical draft tube aerator
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Upper Eagle Valley Sanitation
District Uses Upflow Packed
Tower in Innovative Design
for Nitrogen Control
The Upper Eagle Valley Sanitation District in
Colorado will use an upflow packed bed reactor for
nitrification to meet an effluent ammonia
requirement of 1 mg/l The packed bed reactor
will be used in conjunction with a 3 2 mgd
activated sludge process Results from an EPA
sponsored laboratory bench scale study at
Stanford, a plant size demonstration study at Los
Angeles County and independent research at Iowa
State University showed that a flooded packed
tower with internal aeration could produce an
effluent with no more than 1 mg/l of ammonia
nitrogen The reactor will be constructed partly
underground and will contain gravel and plastic
media Internal aeration will be by fine bubble
diffusers The new process was judged to be
developed, but to still contain sufficient risk to
qualify as innovative technology Secondary
clarification will not be necessary The packed bed
reactor will save over 15% life cycle costs
compared to the most cost effective conventional
alternative and was therefore approved for
innovative technology funding by EPA Region VIII
The consultant for the project is M & I, Inc
Cut-away sketch showing the upflow packed-bed reactor
design for Upper Eagle Valley, Colorado
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Overland Flow as an
Innovative Land Treatment
Alternative
Overland flow is one of several types of land
treatment In general, land treatment is the
controlled application of liquid wastes onto the
land surface by spray or surface spreading to
achieve a designed degree of wastewater
renovation through natural physical, chemical, and
biological processes within the soil matrix
Land treatment systems are designed to meet one
or more of the following objectives: wastewater
treatment as a final or intermediate process to
meet regulatory limitations, wastewater disposal
(zero discharge), water conservation; crop or forest
growth enhancement, or landscale irrigation.
In overland flow land treatment, wastewater is
applied over the upper reaches of sloped terraces
and allowed to flow across the vegetated surface
to runoff collection ditches The wastewater is
renovated by physical, chemical, and biological
means as it flows in a thin film down the relatively
impermeable slope. There is relatively little
percolation involved either because of an
impermeable soil or a subsurface barrier to
percolation.
The objectives of overland flow are wastewater
treatment and crop production Treatment
objectives may be either to achieve secondary or
better effluent quality from screened primary
treated, or lagoon treated wastewater, or to
achieve high levels of nitrogen and BOD removals
comparable to conventional advanced wastewater
treatment from secondary treated wastewater.
Treated water is collected at the toe of the
overland flow slopes and can be either reused or
discharged to surface water Overland flow can
also be used for production of forage grasses and
the preservation of greenbelts and open space.
Perennial grasses (Reed Canary, Bermuda, Red
Top, tall fescue and Italian Rye) with long growing
seasons, high moisture tolerance and extensive
root formation are best suited to overland flow.
Harvested grass is suitable for cattle feed
Surface methods of distribution include the use of
gated pipe or bubbling orifice Gated surface pipe,
which is attached to aluminum hydrants, is
aluminum pipe with multiple outlets. Control of
flow is accomplished with slide gates or screw
adjustable orifices at each outlet. Bubbling orifices
View of a "typical" overland flow site at the Easley, South
Carolina demonstration project, showing the perimeter storm
water diversion ditch
are small diameter outlets from laterals used to
introduce flow Gravel may be necessary to
dissipate energy and ensure uniform distribution
of water from these surface methods
Slopes must be steep enough to prevent ponding
of the runoff, yet mild enough to prevent erosion
and provide sufficient detention time for the
wastewater on the slopes (generally 2-8%) Slopes
must have a uniform cross slope and be free from
gullies to prevent channeling and allow uniform
distribution over the surface. The network of
slopes and terraces that make up an overland
system may be adapted to natural rolling terrain
The use of this type of terrain will minimize land
preparation costs.
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Storage must be provided for non-operating
periods. Runoff is collected in open ditches When
unstable soil conditions are encountered or flow
velocities are erosive, gravity pipe collection
systems may be required
Common preapplication practices include the
following, screening or comminution for isolated
sites with no public access, screening or
comminution plus aeration to control odors during
storage or application for urban locations with no
public access
A common method of distribution is with
sprinklers Recirculation of collected effluent is
sometimes provided and/or required Effluent
disinfection is required where stringent fecal
cohform criteria exist, generally, from 1 6 to 110
acres are needed for each mgd treated
Overland flow is a relatively new treatment
process for municipal wastewater in the United
States It is generally accepted as a well developed
technology which has not been fully proven The
equipment used in overland flow systems such as
pumps, pipes, valves, gates, and farm equipment
are readily available
Overland flow is specifically defined as an
alternative technology. However, because of the
recent development of this technology, and its
environmental benefits, overland flow has been
approved as innovative technology in Lamar,
Arkansas and the following cities in Louisiana:
Castor, Estherwood, Franklmton, Forrest Hill,
Morse, and Spearsville
Close-up view of the raw wastewater distribution system at the
Easley. South Carolina overland flow demonstration project
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Innovative Odor Control
Features of the Sacramento
Sludge Management System
The odor control elements of the Sacramento
Regional County Sanitation District Sludge
Management System were approved by the State
of California and EPA Region IX as innovative
technology in July of 1979. Since that time, the
State Water Resources Control Board and the
State Innovative/Alternative (I/A) Technology
Committee have designated individual components
of the system at a total cost of about $10,000,000,
as eligible for the additional 10 percent I/A
funding
The Sacramento sludge management system
involves storing anaerobically digested sludge from
the regional treatment plant in specially designed
facultative sludge lagoons (FSL's) for up to five
years Odor control, a major problem in any kind of
sludge storage system, poses special difficulties in
open lagoons Brown and Caldwell, lead firm in
the Sacramento Area Consultants joint venture,
conducted and managed over four years of field
studies to develop the special features for odor
control
An especially noteworthy innovation for reducing
odors is the vacuum deodonzation process. This
process involves vacuum stripping of anaerobically
digested sludge to remove odorous gases before
the sludge is discharged to the FSL's A blending
digester will be used upstream of the
deodonzation process to reduce short-circuiting of
raw sludge through the digestion process and
reduce odors
Light winds or calm conditions and strong near-
ground temperature inversions at the lagoons can
cause localized buildup of odors Barrier walls and
wind machines are innovative features which are
A 12-foot high barrier has been erected around the Sacramento.
California facility FSL's to provide greater vertical mixing of
odors
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strategically placed around the lagoons to ensure
maximum dispersion of odor during these critical
periods.
Operation procedures and controls at the lagoons
are also designed to reduce odors Innovative
features include the control strategies and
automatic feed valves, the mechanical surface
mixers, and on-site micrometeorological
monitoring stations which will be used to identify
critical periods when special operating procedures
will be employed Control of basin levels and
sludge removal operations are also important for
odor control
Wind machines are strategically placed around the Sacramento,
California facility FSL 's for odor control, and are operated
during periods of calm coinciding with strong inversion
conditions
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Innovative Technology Projects
Under Consideration by EPA as
Part of the Active I/A Program
Proposed Use of a Vertical
Tube Reactor (VTR) for
Treatment of a High Strength
Municipal Wastewater at
Montrose, Colorado
A recent example of an active I/A project that
shows promise is the use of a Vertical Tube
Chemical Reactor as a part of an overall plant
design to provide secondary treatment for a design
flow of 3 2 mgd of high strength municipal/
industrial wastewater at Montrose, Colorado.
Region VIM EPA and MERL Active I/A Staff have
been working with the city of Montrose, Colorado,
the consulting firm of Roy F Weston, and VTR, Inc.
to investigate the application of the newly
developed process. A preliminary determination
has been made based on pilot tests usmq a 1700
feet deep well and laboratory reactor studies that
the process exhibits a significant potential for
advancement of the state-of-the-art and is within
the window of acceptable risk. Preliminary
engineering studies indicate that this process
exceeds EPA's Innovative Technology energy
savings criteria for the Montrose or similar high
strength waste streams The process also exhibits
significant potential for chemical oxidation of
sludge to generate excess energy
For the Montrose application, final qualification as
innovative technology will be made following
completion of a cost effective analysis.
The principal feature of the VTR system is its use
of an extended vertical U-tube (two concentric
tubes) reactor for achieving optimum reaction
pressures, temperatures, and retention time for
wet chemical oxidation The tubes are suspended
from the top of a conventionally cased well and
may extend to depths over 5,000 feet The waste
fluid and air are injected into a tube at the earth's
surface. As the waste stream and air flow down
the tube, they undergo natural pressunzation due
to hydrostatic head. Thus, water pumps and air
compressors need only be sized to overcome
friction and gravity losses and do not need to
develop the high pressures actually experienced at
the bottom of the U-tube.
Although the thermodynamic principles involved in
wet oxidation are well established, the VTR system
is a recent and unique engineering application of
these principles which offers the following
advantages First, heat losses are mmimized.once
surrounding earth is at thermodynamic equilibrium
promoting efficient heat transfer and energy
conservation This includes significant potential for
recovering and selling the energy (heat from the
hot water) gained from the exothermic reactions
for waste streams with a COD greater than 450
mg/l Secondly, its configuration promotes land
conservation Finally, the concept itself is
extremely efficient because it takes advantage of
natural hydrostatic head to create the pressures
desired
18
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Conceptual vertical tube reactor layout
19
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Consideration of the Deep
Shaft Biological Reactor
(DSR) at Ithaca, New York
A DSR is basically a vertical oriented activated
sludge reactor which has the potential to reduce
land area required for treatment, life cycle costs,
and energy requirements Treatment of raw
wastewater occurs at elevated pressures with
turbulent mixing promoting efficient oxygen
dissolution and intimate contact of waste and
microorganisms This method differs from the VTR
in that it affords biological treatment rather than
chemical oxidation
Influent raw wastewater and sludge recycle are fed
to the head tank located directly above the DSR
The DSR is divided into an upflow section (called
the riser) and a downflow section (called the
downcomer)
The initial circulation of the mixed liquor in the
shaft is induced by a simple air lift pump principle
using compressed air injected into the riser side of
the shaft Once shaft circulation is established, the
air supply is gradually transferred to the
downflowmg side. Since the velocity of the rising
bubbles injected into the downcomer is 4-7 times
less than the liquid velocity in the downcomer,
these bubbles are carried downward to the bottom
of the shaft A large portion of the bubbles will be
completely dissolved before they reach the bottom
of the shaft. As the liquid travels up the riser,
pressure decreases and bubbles of nitrogen,
Schematic showing the DSR demonstration treatment project
at Ithaca, New York
Ji .,, Fnam . ^_
1
'
Transfer Line
t-J &
Uw Head
Foam
Tank
Tank
L-
1
Deep
Shaft
p*
*
V
— *—
T
4
=3
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1 A
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Air
Influent
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,
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20
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carbon dioxide, and residual oxygen are formed
and then released to the atmosphere in the head
tank. Treated effluent then overflows to the solids
separation system
The USEPA is supporting a municipal
demonstration project of the DSR at Ithaca, New
York. Full-scale DSRs are being presently operated
at the 0.55 mgd Molson's brewery facility m
Barne, Canada, and at the 0 6 mgd domestic
waste facility in Virden, Manitoba (Reid Crowther
& Partners, Ltd , were the consulting engineers)
Another DSR is presently under construction at
the city of Portage la Prairie in Manitoba to treat a
combined municipal food processing waste.
The Ithaca municipal demonstration DSR is 446
feet deep and has a main steel casing grouted to
the geological formation with cement The primary
downcomer is 11 75 inches outside diameter
Compressed air is added to both the downcomer
and the riser The DSR acts as a plug flow
bioreactor. Operation is based on an average
influent BOD of 150 mg/l. The combination of high
intensity mixing in the shaft and elevated
pressures produce high oxygen utilization
efficiencies for influent BOD of 500 mg/l or more
With the Ithaca influent, oxygen utilization is
expected to be lower
The Ithaca municipal demonstration plant project is
providing scale-up data for building a full-scale
plant Average flow at Ithaca is approximately 10
mgd In a full-scale facility at Ithaca, high grade
waste heat would be available from two proposed
150 HP compressors The recovered energy could
be used to heat an enclosed process facility
The full-scale design is identified as an active I/A
project and is being considered as a potential
innovative design in the facility plan The
consultant for the project is Stearns and Wheeler
The process has been preliminarily determined to
be within the window of acceptable risk by EPA
Cut-away artist's rendition of the Virden, Manitoba DSR
21
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Design of an Anaerobic Fixed
Film Expanded Bed (AFFEB)
at Hanover, New Hampshire
In New Hampshire, as part of the Active I/A effort,
the EPA has been working closely with the city of
Hanover, the State, and the consulting firms of
Hoyle and Tanner and J I. Associates in the
proposed use of an anaerobic expanded bed fixed
film process to treat 2 mgd of domestic primary
effluent. In general, anaerobic systems are
receiving renewed attention as a cost and energy
efficient method of treating domestic wastewaters
The city of Hanover is pursuing a facility planning
revision and work on a design report for this
process In a departure from a business as usual
approach, the EPA will be one member of a joint
design review team and will provide direct aid in
the further development of this process as it is
undergoing full-scale design. In the
implementation of the Hanover project, EPA will be
encouraging sole source procurement and patent
exemptions in accordance with recently issued
policy directives in these areas.
Anaerobic biological wastewater treatment has a
number of distinct advantages which make this
method more desirable than treatment by chemical
or aerobic biological processes The principle
advantages are (1) a high degree of waste
stabilization can be obtained, (2) production of
biological solids is low, and (3) methane gas is
produced which can be used as an on-site source
of energy The anaerobic nature of the process
eliminates the need for aeration equipment and its
associated power demand, the low solids
production reduces nutrient requirements and
minimizes the need for sludge disposal
The AFFEB is a new development based on
anaerobic treatment that provides high biomass
population as fixed films that can effectively
remove organics from dilute wastewaters while
operating at short hydraulic detention times and
low operating temperatures. Under these
conditions the process is capable of high organic
removal efficiencies when treating the domestic
wastes
The ability to effectively treat dilute wastes by an
anaerobic process is a significant development in
wastewater treatment. Previous attempts in
general, have not been particularly successful
because of washout problems or an inability to
develop adequate biomass to allow effective
stabilization The low retention times and low
solids in the effluent will result in significant cost
savings Because aeration is not required and
methane will be recovered, significant energy
savings will be realized.
The application of the AFFEB process at Hanover
has been judged to be within the window of
acceptable risk Final qualification as innovative
technology will be determined upon EPA review of
the revised facility plan.
22
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Methane Gas
Cleaning Recovery
and Reuse
Aerobic
Final Clanfier
(Optional)
Anaerobic
Fluidized
Sand Bed
Primary Effluent
1 ;; —
Gas
1st Stage
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Dutor
Secondary
Effluent
Inter Stage
Pumping or Control
Preliminary conceptual process schematic for the AFFEB
process
23
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Design of an Anaerobic/Oxic
(A/O) Process at Largo,
Florida for Nutrient Removal
The city of Largo, Florida is pursuing innovative
technology funding with EPA Region IV for the
A/O Process. The city of Largo, Florida began
operating a 3 0 mgd demonstration system in
August of 1979. The A/0 system is a unique two-
stage single sludge anaerobic/aerobic treatment
system which can reliably remove phosphorus and,
if needed, denitrify without the use of a
supplementary carbon source. With the A/0
system, pilot results indicate phosphorus levels can
be reduced to less than 1 mg/l Residence times
are low, and the rate of reaction is high The
process uses conventional equipment in a unique
conceptual design to achieve overall process cost
effectiveness
The mixed liquor is non-bulking since filamentous
organisms responsible for bulking do not
predominate under the normal loading, SRT and
cyclic oxic/anoxic conditions of the mixed liquor.
The waste sludge produced contains organically
bound phosphorus and is reported to have
improved settling properties In addition, the waste
sludge can exhibit an economic benefit because
the high phosphorus content upgrades it to a slow-
release organic fertilizer. The sludge produced at
Largo is dried and pelletized for sale as a fertilizer.
In the A/0 process, a conventionally designed
concrete tank is used as the reactor. The tank is
divided into two sections' m one, wastewater is
agitated and oxygen is excluded (anaerobic); in the
other, the liquid is vigorously mixed and air or pure
oxygen is introduced (aerobic). The anaerobic
section is equipped with mechanical mixers. The
two sections are subdivided even further into
stages to provide plug flow through the reactor. A
conventional secondary clanfier follows the
reactor. Demtrification is achieved without external
carbon by recycling mixed liquor from the aerobic
section to the anaerobic section. The A/0 process
has been judged to be within the window of
acceptable risk and was shown to meet EPA's 1 5%
life cycle cost saving criteria over the most cost
effective non-innovative alternative. The consulting
engineer for the Largo project is Quentm Hampton
and Associates.
The anaerobic/oxic system for BOD and phosphorus removal
Influent
u
V
Effluent
Filter
Clanfier
Anaerobic Section
Oxic Section
/
Waste Sludge
24
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View of covered anaerobic/aerobic reaction tanks at Largo,
Florida
25
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Paygro Mechanical
Composting of Sludge is to be
Used in New York
After analyzing several sludge treatment/disposal
alternatives, New York City has selected for use a
newly developed mechanical sludge composting
system as part of its accelerated sludge
management program to cease ocean disposal of
sludge by 1981.
The process, to be used in New York, was initially
developed to compost manure from a cattle feed
lot. The Paygro Composting System was originally
developed in 1972, and has been successfully used
for composting cow manure, bark mulch and
potting soil in a full-scale facility in South
Charleston, Ohio Recent studies have
demonstrated the feasibility of the approach for
municipal sludge
The mechanical composting system accomplishes
thermophihc aerobic composting of de-watered
sludge received from a Centnfugation Facility To
provide improved operational reliability and
increased environmental benefits, the composting
will take place in a confined reactor vessel housed
within a building Specifically, the system consists
of grinding and screening equipment, receiving
hoppers and metering equipment, materials
distribution conveyors, aeration equipment,
controls and instrumentation, reactors with under-
dram system and support bed, compost mixing and
transport machinery, and discharge conveyors The
composted-matenal becomes a valuable soil
conditioner having met all applicable EPA
regulations for pathogen destruction The system
produces a finished product of sufficient dryness
that it can be recycled as "bulking material" in the
process thereby greatly reducing operating costs
The City will be pursuing sole source procurement
of this technology under the innovative technology
sole source procurements provisions
View of the Paygro mechanical composting facility at South
Charleston, Ohio, showing the mixing and transport machinery
-------
Application of composting within a vessel to
municipal sludge is a recent emerging technology
and has advantages over static pile composting
such as improved operational control and more
reliable performance
While composting is identified as alternative
technology, this unique mechanical application is
the first of its kind to be used in the U S on a
large scale for municipal sludge This application
has been judged to contain additional risk
elements and is potentially considered innovative
technology. The city of New York engineering staff
has completed Step 2 design Region II will make a
final innovative technology determination upon
review of final plans and specifications.
View of the Paygro composting bed at South Charleston, Ohio
27
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List of Federal and State
I/A Technology Coordinators and Contacts
Washington EPA
I/A Technology Contact
Alan Hais/Lam Lim/Robert Bastian/
Richard Thomas/John Walker
US EPA WH-547
Washington, DC 20460
202/426-8976
MERL EPA
I/A Technology Contact
John Smith/Gary Lubm/Bob Bowker
James Heidman/Jeremiah H McCarthy
USEPA, MERL
Cincinnati, OH 45268
513/684-761 1, 7630, 7620,
7632, 7616
R. S. Kerr EPA
I/A Technology Contact
Curtis Harlm
R S Kerr Environmental
Research Laboratory
PO Box 1198
Ada, OK 74820
405/743-2212
Region I
I/A Technology Contacts
Natalie Taub
USEPA
Boston, MA 02203
617/223-5604
Charles King
Augusta, ME 04333
207/289-2591
Robert Cady
Boston, MA 02202
617/727-6587
William Brierly
Montpeher, VT 05602
802/828-3345
Robert Cruess
Concord, NH 03301
603/271-3540
James Fester
Providence, Rl 02908
401/277-2234
Merwin Hupfer
Hartford, CT 061 15
203/566-3792
Region II
I/A Technology Contacts
Steve Vida
USEPA
New York, NY 10007
212/264-9596
Joseph R Tuttle
Albany, NY 12233
518/457-2866
Region III
I/A Technology Contacts
James Hagan
USEPA
Philadelphia, PA 19106
215/597-9131
Brig Garg
Harnsburg, PA 17120
717/787-3481
Richard Sellers
Annapolis, MD 21401
301/383-2761
Richard Aurich
Dover, DE 19901
302/678-4761
Alan Pollack
Richmond, VA 23230
804/257-6333
Michael Johnson
Charleston, WV 2531 1
304/348-0633
Lester Slocum
Washington, DC 20032
202/767-7603
Region IV
I/A Technology Contacts
Thomas Plouff
USEPA '
Atlanta, GA 30308
404/881-4015
Rusty Jones
Montgomery, AL 36130
205/277-3630
Richard Smith
Tallahassee, FL 32301
904/488-8163
James Mathis
Atlanta, GA 30334
404/656-4708
Jud Cramer
Frankfort, KY 40601
502/564-7885
David C Lewis
Jackson, MS 39209
601/961-5131
Allen Wahab
Raleigh, NC 2761 1
919/733-5501
Barney Harmon
Columbia, SC 29201
803/758-5067
Robert G Threadgill, Jr
Nashville, TN 37319
615/741-6615
Region V
I/A Technology Contacts
Steven Poloncsik/Charles Pycha
USEPA
Chicago, IL 60604
312/353-2147
Roger Kanerva
Springfield, IL 62706
216/972-1654
Steve W Kim
Indianapolis, IN 46206
317/633-0708
Brian Myers
Lansing, Ml 48909
517/373-9075
Perry Beaton
Roseville, MN 551 13
612/296-7201
Gregory A Binder
Columbus, OH 43216
614/466-8974
Richard Schuff
Madison, Wl 53703
608/266-2304
Region VI
I/A Technology Contacts
Ancil Jones
USEPA
Dallas, TX 75270
214/767-2845
Martin Roy
Little Rock, AR 72209
501/371-1135
Bharat Contractor
New Orleans, LA 70160
504/568-5101
Edward Stokes
Santa Fe, NM.87501
505/476-5271
28
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George McBryde
Oklahoma City, OK 73105
405/271-5205
Milton Rose
Austin, TX 78711
512/475-3926
Region VII
I/A Technology Contacts
Lynn Harrington/Paul Doherty
USEPA
Kansas City, MO 64106
816/374-2725
Nate Beasley
Lincoln, NE 68509
402/471-2186
Wayne Farrand
Des Momes, IA 50319
515/281-8983
Robert Reed
Jefferson City, MO 65101
314/751-3241
Karl Muldenar/Lavene Brendan
Topeka, KS 66620
913/862-9360
Region VIM
I/A Technology Contacts
Stanley Smith/Joel Webster
USEPA
Denver, CO 80203
303/837-2735
Ronald Schuyler
Denver, CO 80220
303/320-8333
Joseph Sterner
Helena, MT 59601
406/449-2406
Keith Dempke
Bismark, ND 58505
701/224-2354
Leon Schochenmaier
Pierre, SD 57501
605/782-5270
Don Ostler
Salt Lake City, UT 841 10
801/533-6146
Paul Schweiger
Cheyenne, WY 82002
307/777-7781
Region IX
I/A Technology Contacts
Irving Terzich/Jeff Fontaine
USEPA
San Francisco, CA 94105
415/556-8316
Gil Wheeler
Sacramento, CA 75801
916/552-6550
David Woodruff
Phoenix, AZ 85007
602/765-1272
Wendell McCurry
Carson City, NV 89710
702/885-4670
Ralph Yukumoto
Honolulu, HI 96801
Region X
I/A Technology Contacts
Carl Nadler
USEPA
Seattle, WA 98101
206/442-1266
Gary Rothwell
Olympia, WA 98504
206/754-2288
Robert Evans
Portland, OR 97205
503/229-5257
Robert Braum
Boise, ID 83720
208/384-4252
James Dorn
Juneau, AK 9981 1
907/465-2614
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U.3. C.T/iror.r.rntal Protection Agency
K;j:on V, Library
23£ Couth Dearborn Street
Chicago, Illinois 60604
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