Wisconsin Department of Natural Resources
Wastewater Operator Certification
Introduction to Mechanical Sludge Handling Study Guide
January 1994 Edition
Subglass G
Wisconsin Department of Natural Resources
Bureau of Science Services
Operator Certification Program
P.O. Box 7921, Madison, WI 53707
http://dnr.wi.gov/org/es/science/opcert/
The Wisconsin Department of Natural Resources provides equal opportunity in its employment, programs, services, and functions under
an Affirmative Action Plan. If you have any questions, please write to Equal Opportunity Office, Department of Interior, Washington, D.C.
20240. This publication is availab le in alternative format (large print, Braille, audio tape. etc.) upon request. Please call (608) 266-0531
for more information.
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Introduction to Mechanical Sludge Handling Study Guide - January 1994 Edition
Preface
This operator's study guide represents the results of an ambitious program. Operators of
wastewater facilities, regulators, educators and local officials, jointly prepared the objectives and
exam questions for this subclass.
How to use this study guide with references
In preparation for the exams you should:
1. Read all of the key knowledges for each objective.
2. Use the resources listed at the end of the study guide for additional information.
3. Review all key knowledges until you fully understand them and know them by memory.
It is advisable that the operator take classroom or online training in this process before attempting
the certification exam.
Choosing A Test Date
Before you choose a test date, consider the training opportunities available in your area. A listing
of training opportunities and exam dates is available on the DNR Operator Certification home
page http://dnr.wi.gov/org/es/science/opcert/. It can also be found in the annual DNR "Certified
Operator" or by contacting your DNR regional operator certification coordinator.
Acknowledgements
Special appreciation is extended to the many individuals who
contributed to this effort.
Thomas A. Kroehn, Director of Office of Operations and
Maintenance, DNR.
Thomas P. Mickelson, Coordinator, Operator Certification and
Training, DNR.
Wastewater operators were represented by:
Pete Albers - Kewaskum
Bob Kennedy - DePere
Thomas Bast - James River Corp.
James Kirk - Heart of Valley
Bill Becker - Grand Chute Menasha
Bob Lamal - Green Bay
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Jerry Bethke - Racine
John Leonard - Fond du Lac
Jack Boex - Green Bay
John Lutz - Green Bay
Jack Budde - Brookfield
Rick Navarre - Milwaukee
Bob Carey - Brillion
LaMont Risseeuw - Cedar Grove
Dave Carlson - Menasha
Pat Rocheleau - Green Bay
John Davis - Heart of the Valley
Avtar Sandhu - Milwaukee
Kip Decker - PH Glatfelter Paper
Scott Thompson - Green Bay
Jim Deppiesse - Belgium
Don Wydeven - Appleton
Richard Elmergreen - Seymour
Mike Grall - Green Bay
Chuck Isham - Oshkosh
VTAE and educational interests were represented by:
Pat Gomez, Moraine Park Technical College
DNR District Offices were represented by:
Tom Mugan, Southern, Fitchburg
Tom Tewes, Lake Michigan, Green Bay
DNR Central Office was represented by:
Bruce Moore, Madison
Ron Wilhelm, Madison
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Introduction to Mechanical Sludge Handling Study Guide - January 1994 Edition
Table of Contents
Chapter 1 - Principle, Structure and Function
Section 1.1 - Principle of Mechanical Sludge Handling pg. 1
Section 1.2 - Structure and Function pg. 1
Chapter 2 - Operation and Maintenance
Section 2.1 - Operation pg. 3
Section 2.2 - Maintenance pg. 7
Chapter 3 - Monitoring and Troubleshooting
Section 3.1 - Monitoring pg. 7
Section 3.2 - Troubleshooting pg. 9
Chapter 4 - Safety and Calculations
Section 4.1 - Safety pg. 10
Section 4.2 - Calculations pg. 13
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Chapter 1 - Principle, Structure and Function
Section 1.1 - Principle of Mechanical Sludge Handling
1.1.1 Discuss the purposes of mechanical sludge processing.
The main purpose of mechanical sludge processing is to reduce the amount of water in the
sludge which reduces the volume of material to be handled, stored, or transported. This
reduction in volume represents a cost-saving to the facility. The addition of chemicals
conditions the sludge changing its characteristics.
In the case of the wet air oxidation process (zimpro) sludge solids are oxidized under heat
and pressure which provides additional stabilization and reduction of pathogens.
The two processes in sludge handling are generally referred to as thickening and
dewatering. The thickening process refers to reducing moisture content prior to dewatering.
Dewatering refers to producing a sludge cake (greater than 10% solids) for final disposal.
1.1.2 Describe the basic purpose of preconditioning sludge before thickening or dewatering.
Preconditioning of sludge before thickening or dewatering usually involves chemical
processes. Chemical methods include: the use of organic and inorganic flocculation
chemicals, the use of polymers, and chlorine oxidation. The purpose of preconditioning is
to get better solid/liquid separation in the mechanical processes which follow. One physical
process thermal conditioning (wet air oxidation-zimpro) is used to stabilize sludge prior to
dewatering.
1.1.3 Discuss the difference between batch processing and continuous sludge handling
operations.
Batch processing uses a fixed amount of material (sludge) to complete an operation.
Examples of batch operations would be gravity thickening or sludge drying beds. The
sludge is placed in a thickener or bed and the entire process is completed without any other
flow-through.
Continuous processing implies that material (sludge) is being fed continuously. Examples
of continuous operations would be vacuum filtration, centrifugation, gravity and filter
presses, dissolved air flotation, and gravity thickening. The continuous process is a flow-
through system.
Section 1.2 - Structure and Function
1.2.1 Describe the gravity thickening process and the percent solids in thicked product.
Gravity thickening is the use of tankage very similar to clarifiers (either round or rectangular)
to allow settling and compactions of the sludge.
Gravity thickening can be either a batch or continuous type operation and usually involves
the use of preconditioning chemicals. Detention times are usually much longer than with
regular clarifiers. The sludge collection arms on round clarifiers may have vertical pickets
("picket fence") installed to provide gentle stirring to help release entrapped moisture and
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gases.
Depending on the type of sludge or combined sludges being thickened, the thickened
sludge concentrations can vary as follows:
Type of sludge --- Concentration
Primary --- 5-10% solids
Activated --- 2.5-3% solids
Trickling filter --- 7-9% solids
Combined sludges --- Concentration
Primary and waste activated --- 4-6% solids
Primary and trickling --- 7-9% solids
1.2.2 Describe the belt press thickening process and the percent solids in thickened product.
The belt press consists of an endless belt of filter media rotating around a drum. The sludge
is dewatered by gravity drainage and the pressing of the sludge with additional rollers. The
belt press is similar in operation to a papermaking machine. With a belt press the
dewatered sludge can have a solids concentration of 10-28% depending on the type of
equipment.
1.2.3 Describe the vacuum filter thickening process and the percent solids in thickened product.
Solids are separated from liquid with the use of a round drum which rotates partially
submerged in a tank of sludge. The drum is divided into sections by seal strips. Vacuum is
applied between the drum deck and filter media causing filtrate to be removed. The filter
cake stays on the media. Solids capture with vacuum filtration ranges from 85% for coarse-
mesh media to 99% with close-weave fabric media. Filtrate solids cause a load on the
treatment process and should be kept as low as possible. Cake solids concentration varies
from 20-30% by weight depending on the type of sludge and cycle time.
1.2.4 Explain the wet air oxidation process (zimpro).
This is a thermal process using heat and pressure to oxidize organic matter. This process
is carried out in a closed system operating at 250 degrees to 700 degrees F with a
pressure range of 100 to 400 PSI. The sludge to be processed is "ground" to reduce
particle size and pumped to the process using a positive displacement high-pressure
pump. The supernatant from this heat/pressure conditioning is high in ammonia, volatile
acids, and BOD. The over-all strength is similar to supernatant from an anaerobic digester.
The process produces bacteriologically sterile sludge that is easily dewatered without
chemical conditioning.
Problems with this process comes in the handling of the supernatant (larger secondary
treatment facilities), the acid condition of the sludge (which may require ventilation), and
odor problems from the gases generated (may need a catalytic combustion unit).
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1.2.5 Describe the air flotation thickening process including percent solids capture and percent
solids in thickened product.
Air is fed into the sludge under pressure (40-80 PSI) so a large amount of air can be
dissolved. Sludge flows to an open tank where much of the air comes out of solution as
small air bubbles attaching themselves to sludge solids particles floating them to the
surface. Flotation works well on activated sludge which is difficult to thicken by gravity.
Effluent recycle ratios can range from 30-150% of the influent flow. Sludge particles are
floated to the sludge blanket and the clarified effluent flows over the weirs. Thickened
sludge is removed by skimmers. Bottom sludge collectors are used to remove any settled
sludge or grit. A 3-7% flotation solids concentration can be expected. Using flotation 90-
95% of suspended solids can be removed with flotation aids (polymers) or 70-90% without
the aid of polymers.
1.2.6 Describe the frame press thickening process and percent solids in thickened product.
A frame press is a batch device used to process sludge that is difficult to dewater. Filter
cloth covers each plate. Frame presses usually need a pre-coat material (incinerator ash or
diatomaceous earth) to assist in binding reduction and help release cake. Water passes
through the cloth while solids are held on the cloth. Sludge pumping is stopped when the
section between trays is completely filled. Filtrate quality should be good. Frame presses
can be operated at pressures ranging from 5,000 - 20,000 times the force of gravity. The
percent solids in the thickened product could range between 15-30% depending on sludge
type and pressure applied.
1.2.7 Identify the locations in a mechanical sludge handling plant that should have ventilation
equipment.
Ventilation equipment should be provided in all areas where sludge gases might be
released. This would include: storage of mixing tanks, open feed lines, at any of the
dewatering devices, any conveyor systems, or sludge storage areas.
1.2.8 List the types of pumps used for mechanical sludge handling.
1. Piston pump (positive displacement pump)
2. Progressive cavity pump
3. Centrifugal pump (not as commonly used as piston or progressive pumps)
Chapter 2 - Operation and Maintenance
Section 2.1 - Operation
2.1.1 Explain the purpose of the following chemicals used for sludge conditioning:
1. Polymers
2. Ferric chloride
3. Lime
4. Hydrogen peroxide
5. Soda ash
6. Sulfuric acid
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1. Polymers: are used as preconditioning chemicals prior to dewatering; causes
coagulation and flocculation by reducing particle surface charge affects
2. Ferric chloride: is used as a preconditioning chemical prior to dewatering; assists with
pH control and phosphorus removal; acts as a coagulant to aid in concentrating solids
3. Lime: is used for pH control, odor control, and as a conditioner for digestion or filtration
4. Hydrogen peroxide: is used for odor prevention; it is an oxidant and assists in
elimination of common gases (hydrogen sulfide)
5. Soda ash: is used for pH control
6. Sulfuric acid: is used for pH control
2.1.2 Describe the physical appearance of sludge at the following solids concentrations:
A. 5 percent
B. 15 percent
C. 40 percent
A. A 5% solids sludge has the appearance of thick slurry; flows and pumps readily
B. At 10-15% solids sludge has the appearance of damp soil; it will hold its shape (stands-
up) but is not suitable for conventional pumping; it is normally handled with conveyor
equipment
C. A 40% solids sludge has the appearance of dry soil; it can only be handled with
mechanical equipment, such as end loaders or shovels
Note: There are pumps available for industrial applications that can pump sludge at 25%
solids.
2.1.3 Discuss the operating procedures that will help maintain the quality of the sludge product.
To ensure a good quality sludge product an operator needs to properly operate and
maintain upstream sludge treatment units, provide good preconditioning by using jar testing
to optimize chemical additions, apply good operation and maintenance of sludge
dewatering equipment, and perform good sampling and testing procedures to verify that
results are correct. Good historic recordkeeping will aid in determining if operational
problems are occurring.
2.1.4 State the importance of sludge blanket depth measurement in gravity thickening.
It is critical in determining the concentration of removed sludge and in avoiding pumping
and/or odor problems.
2.1.5 List the data needed to evaluate pumping rates from a gravity thickener.
1. The moisture content of the sludge
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2. The sludge blanket depth
2.1.6 Describe the relationship of the depth of the sludge blanket to pumping rates while under
routine opearting conditions.
A high blanket would indicate not enough sludge is pumping. A low blanket would indicate
too much sludge is pumping.
2.1.7 Describe how to change the flow rates for the following equipment:
A. Piston pump (positive displacement)
B. Progressive cavity pump
C. Diaphragm pump (positive displacement)
D. Telescoping valves and sludge pits
A. Piston pump: adjust the stroke travel of the pump
B. Progressive cavity pump: adjust the motor speed
C. Diaphragm pump:
1. For air driven pumps - adjust the air flow
2. For oil driven pumps - adjust the oil delivery rate
3. You also can adjust the motor RPM
D. Telescoping valves and sludge pits: adjust (raise/lower) the valve position to increase or
decrease flow
2.1.8 List the operational measurements the operator must accurately take for the following
equipment:
A. Chemical feed pumps
B. Sludge pumps
C. Sludge density meters
A. Chemical feed pumps:
1. Flow measurement
2. Pressure measurement
3. Time-of-run measurement
4. Chemical concentrations
5. Characteristic of the raw sludge (total suspended solids) to be treated
B. Sludge pumps:
1. Flow measurement
2. Pressure measurement
3. Sludge concentration
4. Time-of-run measurement
5. Temperature
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6. Discharge point
C. Sludge density meters:
1. Comparative laboratory test
2.1.9 Explain the reasons why secondary sludge should be aerated if being stored.
The reason that secondary sludge should be aerated if stored is to prevent it from becoming
anaerobic (septic). This can cause odor problems and changes in sludge characteristics.
Aeration also provides mixing and some minor reduction in organic content.
2.1.10 Discuss the relationship of sludge pH to odor control and pathogen content.
Low pH (less than 6.6) - causes more odor problems and higher pathogen content
High pH (greater than 9) - causes less odor problems and lower pathogen content
2.1.11 List three purposes for ventilation regarding the following:
1. Safety
2. Odor control
3. Corrosion prevention
1. Safety: ventilation removes toxic gases from work areas
2. Odor control: ventilation pulls outside air into work areas and reduces odor
3. Corrosion prevention: ventilation keeps the humidity and hydrogen sulfide down which
reduces corrosion
2.1.12 List two operating strategies that will reduce the harmful affects caused by return streams on
wastewater treatment.
1. Gradually feed filtrate into headend of the plant to minimize shock loading
2. Maximize efficiency of dewatering equipment (i.e. minimal solids in the return flows)
2.1.13 List the factors that affect the costs of operating mechanical sludge handling equipment.
1. The type of equipment (gravity thickener, vacuum filter, gravity belt, belt press, dissolved
air floatation, and thermal processing, etc.)
2. The type of sludges being processed
3. Chemical costs
4. Power costs for pumping and operating other equipment
5. Maintenance and repair costs
6. Hauling costs for final disposal
2.1.14 Compare direct hauling of sludge versus hauling dewatered sludge.
The hauling of sludge is primarily a matter of cost and time spent in actual hauling. For
example going from a 5% sludge to a 15% sludge would reduce the volume needed to be
hauled by two thirds. This would directly affect the total hauling costs.
2.1.15 Compare direct land spreading of sludge to the incorporation of sludge into the soil.
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Direct land spreading of sludge may result in some immediate minor odor problems, the
possibility of run-off, and the visual appearance of drying sludge on the field. Incorporation
into the soil virtually eliminates all of the problems but requires more power and specialized
equipment to accomplish.
2.1.16 List the sludge qualities that make its disposal difficult.
1. Odor problems
2. High or low pH
3. Possible organic toxics
4. Heavy metals content
5. Large volumes if moisture content is high
2.1.17 Describe the qualities that improve public acceptance of sludge end-products.
The most important factor in the acceptance of dewatered sludge is to have a good
educational program explaining the benefits of sludge in terms of nutrient value (fertilizer)
and the soil conditioning it provides. The sludge should be well digested to minimize odors.
Direct soil incorporation or "tilled-in" application aids the acceptance. Low moisture
content of the sludge is desirable to reduce traffic to the application site. All spreading
equipment should be clean and well maintained to provide a good overall appearance.
Section 2.2 - Maintenance
2.2.1 List three major categories of maintenance.
1. Scheduled lubrication
2. Equipment inspection and adjustment
3. Routine repair/parts replacement
2.2.2 Lists three major categories of equipment information operators should have for a planned
maintenance program.
1. Lubrication schedule
2. Detailed maintenance records
3. Operating procedures/manuals
2.2.3 Discuss special housekeeping and maintenance considerations associated with
mechanical sludge handling.
A. Avoid sludge spillage
B. Keep areas clean and ventilated
C. Control noise, temperature, and pressure
Chapter 3 - Monitoring and Troubleshooting
Section 3.1 - Monitoring
3.1.1 Describe the laboratory equipment needed to test for solids content.
The laboratory equipment needed to determine solids content is basically the same as that
needed to run a suspended solids test. This would include glass-fiber filter discs, gooch
crucible, suction flask, vacuum source, drying oven (103 degrees - 105 degrees C.),
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desiccator, and an analytical balance. If it is desired to determine volatile solids a muffle
furnace (550 degrees C.) is needed.
3.1.2 Describe the sampling locations and sampling frequency necessary to ensure good sludge
thickening/dewatering operations.
For sludge thickening/dewatering equipment the sample locations would include: the raw
feed sludge to the thickening/dewatering equipment and the finished sludge from the
thickening/dewatering equipment which is sludge cake from mechanical equipment,
underflow from gravity thickening, or float from dissolved air flotation (DAF) units. The
sampling frequency should be sufficient to ensure good operations (the unit should be
operating within the normal range based on historic sampling results). Additional sampling
should be done if there are any changes in the feed sludge characteristics, any changes to
polymer feed, any apparent change in the finished sludge, or any abnormalities in the return
sidestream flow characteristics from the thickening/dewatering unit.
3.1.3 Discuss how to determine volume and solids content of sludge being pumped.
A. Volume:
1. Flow meter
2. Graduated tank
3. Pump/motor hour meter
B. Solids:
1. Suspended solids test
3.1.4 Describe the jar test and its uses.
A jar test is a method of determining optimal chemical dosages. A number of jars are set-
up using different chemicals at different concentrations to determine the best settling
characteristics. When the best chemical dosage is determined it can be applied to the
sludge handling process.
3.1.5 List two methods of sludge blanket measurement.
1. Core samples (sludge judge)
2. Electronic sludge blanket monitoring
3.1.6 Describe the primary monitoring test used in sludge thickening/dewatering processes.
The primary monitoring test for sludge thickening/dewatering is used to determine the
amount of water removed in the process. The essential test would be either the solids
content or the moisture content of the sludge. The suspended solids test is used to
determine the percent solids in a given sludge. This test is normally run on both the feed
sludge and the sludge cake. Suspended solids are normally reported as percent solids
rather than mg/L. A 1% suspended solids result is equal to 10,000 mg/L.
3.1.7 Describe the difficulty in determining average moisture content in quantities of sludge and
describe ways to compensate for the difficulties.
The difficulty in determining moisture content of sludge is not a laboratory problem but in
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getting a representative sample. To overcome this difficulty composite samples should be
taken (flow proportional if possible) and care should be taken to make sure the composite
sample is well mixed before analyzing.
3.1.8 Discuss tests and measurements that should be run on return streams and the importance
of this flow on plant operations.
The return flows from mechanical sludge processing units should be tested for BOD and
suspended solids along with a flow volume measurement. In some cases pH and ammonia
might also be important. The main reasons for testing is to determine the organic strength
and suspended solids loading that is being returned to the treatment plant. These tests are
important to ensure that the treatment process will not be upset by these sidestream flows.
3.1.9 List the problems associated with sludge flow measurement and with obtaining
representative samples for lab tests.
1. The high viscosity of the sludge and high solids concentration
2. Flow measurement is difficult because it is usually being pumped (it is not in an open
channel)
3. Sampling taps do not necessarily give a representative sample
4. A dirty flow stream (effects of grease, hair, and debris)
Section 3.2 - Troubleshooting
3.2.1 Discuss the possible causes of odor at a mechanical sludge handling plant.
The main cause of odor with mechanical sludge handling of an anaerobically digested
sludge is the release of hydrogen sulfide. For aerobically digested sludge or waste
activated sludge there should be minimal odor (unless these sludges are allowed to
become anaerobic/septic). If sludge becomes septic hydrogen sulfide will cause odor
problems.
3.2.2 Explain the potential damage to equipment if proper start-up and shut-down procedures are
not followed in operation of:
A. Wet air oxidation
B. Incineration
C. Positive displacement pump
A. Wet air oxidation: pressure and heat could damage the equipment and could be a safety
problem to operators
B. Incineration: excessive heat or even an explosion could damage equipment and be a
safety problem to operators
C. Positive displacement: there could be pump damage (sheared pump pin, packing blow-
out, or bent pump arm) and the possibility of valve damage or pipe rupture.
3.2.3 List the various operational problems that can be expected from the sidestream return flow.
1. Hydraulic loading: reduced detention times possible
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2. Organic loading: might affect secondary process
3. Toxic loading: metals and chemicals
4. Shock loading: temperature, BOD, suspended solids, and ammonia
Chapter 4 - Safety and Calculations
Section 4.1 - Safety
4.1.1 Outline a safety training program designed to avoid the following hazards associated with
sludge handling:
A. Suffocation and toxic gas
B. Bumps, slips, and falls
C. Fires and explosions
D. Eye injury
E. Infections
F. Getting caught in slow moving equipment
A. Suffocation and toxic gases:
1. Use a gas monitor
2. Utilize proper ventilation
3. Use a protective breathing apparatus if necessary
4. Use the buddy system
B. Bumps, slips, and falls:
1. Walk slowly in areas where polymers are used
2. Keep floors clean
3. Use railing when climbing stairs or ladders
C. Fires and explosions:
1. No smoking in critical areas
2. Store combustibles in a designated area
3. Properly store chemicals to prevent accidental mixing
D. Eye injury:
1. Always use eye protection
2. Use care around pressurized lines
3. Use full-face shield when handling chemicals
E. Infections:
1. Practice good sanitary wash-up procedures
2. Avoid hand to mouth contact
3. Provide protection for cuts and/or scratches
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F. Getting caught in slow moving equipment:
1. Do not wear loose clothing around running equipment
2. Shut equipment down and lock-out before doing maintenance
3. Do not wear rings around running equipment
4.1.2 Describe the special safety considerations for the following:
A. Centrifuge
B. Belts in belt presses
C. Sludge and scum pipelines
A. Centrifuge: before opening the bowl all equipment should be shut-off and locked-out
using proper lock-out tags
B. Belts in belt presses: all belts should be stopped and associated equipment shut-down,
locked out, and properly tagged; use care when hosing belts to prevent flying debris and
slippery work surfaces; sharp objects and tight spaces should be carefully watched to
prevent cuts and other injuries
C. Sludge and scum pipelines: care should be taken when cleaning pipes overhead to
avoid falling debris; avoid climbing on wet pipes
4.1.3 List the elements to include in an emergency plan.
1. Personnel with extensive safety training should be available
2. Emergency first aid kits should be strategically located throughout the area
3. Gas analyzers should be available, breathing equipment (SCBA, mask, or others), and
safety lines (confined space)
4. Chlorine repair kits should be available
5. Emergency evacuation plans should be developed and posted
6. Police, fire, and rescue personnel should be alerted
4.1.4 List the possible hazards at a treatment plant that would merit an emergency plan.
1. Chlorine leak
2. Chemical spill
3. Fuel spill
4. Confined space entry
4.1.5 Describe the safe storage requirements and personal hazards in handling the following
chemicals:
A. Powdered chemicals (in general)
B. Lime
C. Alum
All chemicals must be stored according to the manufacturers label instructions.
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A. Powdered chemicals (in general):
Storage: store in a dry area; make sure containers are tightly closed (to keep out moisture);
keep in original ontainers and make sure they are protected from physical damage
Hazards: depending on the powdered chemical, hazards could include: the possibility of
fumes, toxic gases, and the general problem of inhaling dust
B. Lime:
Storage: lime is generally supplied in two forms-
A. Quick lime (un-slaked) - store in its original container in a dry location as the powder is
very hydroscopic (readily absorbing moisture)
B. Hydrated lime (slaked) - is supplied as a slurry and should be stored in its original
container; slaked lime is a very corrosive chemical and containers used for mixing should
be rubber, PVC, or iron/steel
Hazards: dust from lime in powdered form can cause irritation of eyes, nose, and
respiratory system; of special concern when adding water to unslaked lime is that heat is
generated and splattering can occur; these chemicals are very corrosive and can cause
severe burns; protective clothing with full face protection is required when using lime
C. Alum:
Storage: alum is hydrated aluminum sulfate and is usually supplied in a liquid form; it is
moderately corrosive and can be stored in fiberglass reinforced plastic, 316 stainless steel,
steel lined with rubber or saran, PVC, or other plastic tanks; alum tanks must be kept above
25 degrees F.
Hazards: alum is moderately corrosive and protective clothing, gloves, and goggles should
be worn; in addition, chemical storage tanks are a level 2 confined space requiring meeting
the requirements of state and national safety standards.
4.1.6 Describe the safe storage requirements and personal hazards in handling the following
chemicals: [Continued]
D. Ferric chloride
E. Polymers
F. Acids (in general)
D. Ferric chloride:
Storage: ferric chloride is very corrosive and fume producing; it is usually supplied as a 35-
43% liquid product; it needs to be stored in tanks made of fiberglass, reinforced plastic,
rubber, or saran lined steel; certain other plastics and rubber are also adequately resistant;
the tank should be surrounded with a containment area equal in volume to the tank in order
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to control possible leaks
Hazards: ferric chloride is very corrosive; rubber protective clothing with a full face guard
should be used when handling this product; as with alum chemical storage tanks are a class
2 confined space
E. Polymers:
Storage: polymers are supplied in either liquid or powder form and should be stored in their
original containers; some of the liquid polymers can be fed directly using a "drumhead"
feeder; for dilution or mixing of polymers of most types storage containers can be used (e.g.
fiberglass, polyethylene, PVC, rubber, and various steels, etc.); since there are so many
different kinds of polymers it is best to check with the chemical supplier for any special
storage requirements for the polymer being used
Hazards: polymers are relatively benign chemicals as some are used in potable water
supplies for treatment purposes; the powdered forms do pose problems with the dust being
an irritant to the mucus membranes; the main problem with polymers is to thoroughly clean-
up spills as they cause extremely slippery surfaces that can cause falling accidents
F. Acids (in general):
Storage: all acids should be stored in recommended acid proof containers; in most cases
this will be glass or various types of plastic materials and almost never any metal
containers; one exception to using glass container would be for forms of hydrofluoric acid
which etches glass; acids should be stored in a safe location to prevent physical damage
as they are extremely corrosive spilled
Hazards: all acids are extremely corrosive especially the metals; they can cause severe
burns and fumes can cause respiratory problems; acids should be handled with extreme
care using rubber protective clothing, full face shields, and adequate ventilation; when
diluting acids it is very important to add acid to water; if water is added to a concentrated
acid splattering could occur and heat released
Section 4.2 - Calculations
4.2.1 Given data calculate the proper setting for a chemical feed pump in gallons per minute.
Given:
432 pounds of undiluted polymer required per day
1% feed concentration of polymer
10 pounds/gallon density of undiluted polymer
1 day = 1,440 minutes
Formula:
gallons of undiluted polymer used/day = polymer used ÷ density
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gallons = 432 ÷ 10 = 43.2 gal/day
diluted polymer used per day = gal/day ÷ concentration
diluted polymer = 43.2 ÷ 0.01 = 4,320 gal/day
diluted polymer used per min. = gal/day ÷ min/day
diluted polymer = 4,320 ÷ 1,440 = 3 gal/min.
4.2.2 Given data calculate the pounds of chemical to feed for a given sludge volume.
Given:
Desired chemical concentration = 10 mg/L
Sludge volume = 200,000 gallons
Formula:
pounds of chemical = volume (MGD) x concentration (mg/L) x 8.34
pounds = 0.20 x 10 x 8.34 = 16.7 pounds
4.2.3 Given data calculate the pounds of dry solids in a given sludge.
Given:
Solids = 4% (40,000 mg/L)
Volume = 100,000 gallons
Formula:
pounds = concentration (mg/L) x volume (mg) x 8.34
pounds = 40,000 x .1 x 8.34 = 33,360 pounds of dry solids
4.2.4 Given data calculate solids loading in dry tons.
Given:
Flow = 300 GPM = 300 x 10 x 60 = .18 mg
Feed suspended solids = 3.5% or 35,000 mg/L
Run time = 10 hours
Formula:
tons = flow (mg) x concentration (mg/L) x 8.34 ÷ 2,000 lbs/ton
tons = .18 MGD x 35,000 x 8.34 ÷ 2,000 lbs/ton = 26.3 tons
4.2.5 Given data calculate the wet sludge in tons when percent solids and dry tons are known.
Given:
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Tons of dry solids = 20
% solids = 14%
Formula:
tons of wet sludge = tons of dry sludge x 100 ÷ %solids
wet sludge = 20 x 100 ÷ 14 = 143 tons
4.2.6 Given data calculate the percentage solids capture of a thickening process.
Given:
Feed sludge solids = 2%
Return flow solids (filtrate) = 1,000 mg/L = 0.1%
Formula:
percent solids capture = (feed sludge % - return solids % ÷ feed sludge %) x 100
solids = (2 - 0.1 ÷ 2) x 100 = 95 %
4.2.7 Given data calculate the "mass balance" of solids in gallons.
Given:
Initial flow = 500 gallons per minute
Initial concentration = 3%
Final concentration = 10%
Formula:
initial flow x initial concentration = final flow x final concentration
500 x 3 = flow x 10
final flow = 500 x 3 ÷ 10 = 150 gallons per minute
4.2.8 Given data calculate the percent volume reduction through a sludge handling process.
Given:
Input = 100,000 gals of sludge at 5% solids
Output = thickened sludge at 15% solids
Formula:
C1V1 = C2V2
(5%) 100,000 = 15% V2
V2 = 33,300 gallons (thickened)
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percent volume reduction = (volume in - volume out ÷ volume in) x 100
volume reduction = (100,000 - 33,300 ÷ 100,000) x 100 = 67%
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References and Resources
1. ADVANCED WASTE TREATMENT.
1st Edition (1987), Kenneth D. Kerri. California State University, 6000 J Street, Sacramento,
CA 95819-6025. Phone (916) 278-6142.
http://www.owp.csus.edu/training/
2. CONTROLLING WASTEWATER TREATMENT PROCESSES.
(1984). Cortinovis, Dan. Ridgeline Press, 1136 Orchard Road, Lafayette, CA 94549.
3. DEWATERING MUNICIPAL WASTEWATER SLUDGES.
Design Manual EPA 626/1-85-014 (1982). U.S. Environmental Protection Agency, Office of
Research and Development, Municipal Environmental Research Laboratory, Cincinnati, OH
45268.
http://www.epa.gov/nscep/index.html
4. OPERATION AND MAINTENANCE OF SLUDGE DEWATERING SYSTEMS.
Manual of Practice OM-8 (MOP OM-8) (1987). Water Environment Federation (Old WPCF),
601 Wythe Street, Alexandria, VA 22314-1994. Phone (800) 666-0206.
5. OPERATION OF MUNICIPAL WASTEWATER TREATMENT PLANTS.
Manual of Practice No. 11 (MOP 11), 2nd Edition (1990), Volumes I, II, and III. Water
Environment Federation (Old WPCF), 601 Wythe St., Alexandria, VA 22314-1994. Phone
(800) 666-0206.
http://www.wef.org/
6. OPERATION OF WASTEWATER TREATMENT PLANTS.
Manual of Practice No. 11 (MOP 11) (1976). Water Pollution Control Federation, 601 Wythe
Street, Alexandria, VA 22314-1994. Phone (800) 666-0206. (Probably Out-of-Print, See
Reference Number 5)
http://www.wef.org/
7. SLUDGE DEWATERING.
Manual of Practice No. 20 (MOP 20) (1983). Water Environment Federation (Old WPCF),
601 Wythe Street, Alexandria, VA 22314-1994. Phone (800) 666-0206.
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