Sewage and Industrial Effluent Treatment
Sewage
treatment (municipal wastewater treatment) and industrial effluent treatment
are processes designed to remove physical, chemical, and biological
contaminants from wastewater before its discharge into natural water bodies or
reuse. The primary objective of wastewater treatment is to protect public
health, prevent environmental pollution, and comply with regulatory discharge
standards. These treatment systems generally involve physical (primary),
biological (secondary), and chemical or advanced (tertiary) treatment processes.
Overall Treatment Flow
Influent → Screening → Grit Removal → Skimming → Primary
Sedimentation → Biological Treatment (Trickling Filter / Activated Sludge /
Oxidation Ditch) → Secondary Sedimentation → Tertiary Treatment → Treated
Effluent
1. Physical Treatment (Preliminary
and Primary Treatment)
Physical
treatment involves the removal of large, floating, settleable, and suspended
solids using mechanical and gravitational methods. It mainly reduces the load
on subsequent biological treatment processes.
1.1 Preliminary Treatment
Preliminary
treatment is the first step in wastewater treatment and aims to remove gross
solids, grit, and floating materials that may damage equipment or hinder treatment
efficiency.
a. Screening
Screening
is used to remove large floating and suspended materials such as rags,
plastics, paper, cloth, sticks, cans, and dead animals. Wastewater is passed
through bar screens made of vertical or inclined steel bars spaced about 5 cm
apart. Coarse and fine screens are used depending on the treatment requirement that
trap large objects. The collected screenings are disposed of by incineration,
composting, or landfilling.
b. Grit Removal
Grit
consists of heavy, non-biodegradable inorganic particles such as sand, gravel,
silt. Grit removal is carried out in
grit chambers by controlling the flow velocity so that grit settles while
organic matter remains in suspension. Common units include horizontal flow grit
chambers, aerated grit chambers, and vortex grit chambers. Grit removal
prevents abrasion of pumps and accumulation of sediments in tanks.
c. Skimming
Skimming
is the process of removing floating fats, oils, grease, waxes, and soap scum
from wastewater. In skimming tanks, air is bubbled from the bottom, causing
oily materials to float to the surface, where they are mechanically skimmed
off. Removal of grease prevents interference with oxygen transfer during
biological treatment.
1.2 Primary Treatment
Primary
treatment focuses on removing remaining suspended solids and reducing the
organic load of sewage.
Sedimentation (Primary
Clarification)
Sedimentation
tanks allow wastewater to flow slowly (1–2 feet per minute), enabling suspended
solids to settle at the bottom as primary sludge, while lighter
materials float as scum. Sludge scrapers are used to remove settled solids
periodically. Primary sedimentation removes approximately 50–70% of
suspended solids and 25–40% of BOD.
Note- Sometimes there is the
provision of Mechanical and chemical Flocculation
Mechanical Flocculation- Mechanical flocculation improves the removal of fine
suspended and colloidal particles. Wastewater is gently stirred using rotating
paddles at controlled speeds (~0.43 m/s), causing small particles to aggregate
into larger flocs that settle more easily.
Chemical Coagulation and
Flocculation- Chemical
treatment involves the addition of coagulants such as alum, ferric chloride, or
lime. Alum forms aluminum hydroxide [Al(OH)₃] precipitates that trap suspended
and colloidal particles, forming larger flocs which settle at the bottom. This
method is effective when wastewater contains high colloidal content.
2. Biological Treatment (Secondary
Treatment)
Secondary
treatment removes dissolved and colloidal organic matter using microorganisms.
Microbial metabolism converts organic pollutants into stable inorganic
compounds, significantly reducing biochemical oxygen demand (BOD).
MajorBiological Changes
- Organic
carbon → CO₂ + H₂O
- Organic
nitrogen → NH₃ → NO₃⁻ (nitrification)
- Colloidal
matter → biologically coagulated and settled
2.1 Aerobic Treatment (With Oxygen)
Aerobic
microorganisms degrade organic matter in the presence of oxygen.
a. Trickling Filter
A
trickling filter is an attached-growth system consisting of a filter bed
(gravel, stones, or plastic media), rotating spray arms, and a collection
system. The sewage effluent or wastewater is sprayed over the bed by using an overhead sprayer, which is rotating
at a constant speed;
the spraying saturates the effluent with O2. There is a development of a gelatinous
microbial layer called the zoogleal layer (bacteria, algae, protozoa,
fungi). The fed surface becomes covered with aerobic
microbial population comprising bacterial species, including Sphaerotilus natans, Beggiatoa, Flavobacterium, Achromobacter, Zooglea and Pseudomonas, microalgae, microfungi and protozoa. As wastewater trickles through or percolates over the media, organic matter is oxidized. The aerobic microflora decomposes the organic
materials into small soluble molecules. Later, the treated effluent collected
at the bottom of the tank is passed through the sedimentation tank. Natural airflow provides oxygen.
Treated effluent is usually passed to a secondary clarifier.
b. Activated Sludge Process
This
is the most widely used aerobic biological treatment method. Wastewater is
mixed with activated sludge (microbial biomass) in an aeration tank, where air
or oxygen is supplied continuously. Microorganisms consume organic matter,
forming flocs. The mixture is then sent to a secondary clarifier where sludge
settles. A portion of sludge is recycled (return activated sludge), while
excess sludge is removed. This process removes 85–95% of BOD and suspended solids.
Activated sludge system consists of an
aeration tank, a settling tank and a sludge return system. At first, sewage
from the primary treatment plant is mixed with sludge drawn from the previous
batch, which is known as activated sludge or return sludge. The activated
sludge contains a large number of microorganisms and serves as an inoculum of
microorganisms. After mixing the activated sludge, sewage is placed in an aeration
tank. In an aeration tank, Sewage is continuously aerated for 6-8 hours. During
this period, microorganisms oxidizes the organic compounds to form CO2,
H20 and NO3, etc.
So, activated sludge
is a process for the treatment of domestic and industrial sewage using air and
biological flocs composed of bacteria and protozoa that substantially reduce
organic materials. This process starts when air is introduced into a sewage
that is held in a large aeration tank, combined with the following aerobic
microbial decomposers to develop biological floc that decomposes organic matter
into simple soluble molecules, amino acids, ammonia, phosphorus, nitrates, CO2,
H2O, etc.
·
Bacteria: Escherichia, Enterobacter, Achromobacter, Flavobacterium,
Pseudomonas, Zooglea, Micrococcus, Sphaerotilus, Beggiatoa,
Thiothrix , etc.
·
Protozoa: Amoaebe, Spriotrich and Verticillium.
·
Filamentous fungi: Geotrichum, Cephalosporium, Penicillum and Cladodsporium.
After oxidation, sewage is passed to the settling tank
and left undisturbed for 2-3 hours. Sludge settles to the bottom. This sludge
is called activated sludge, which is fully oxidized and is very offensive. This
activated sludge can be used as inoculum for the next batch of sewage. Most of
the sludge is removed and some is returned to the aeration tank for the next
round of treatment.
By the sludge digestion process, the BOD of sewage is
reduced by 5-15%.
c. Oxidation Pond (Lagoon / Stabilization Pond)
Oxidation
ponds, also known as lagoons, stabilization ponds, or reduced ponds, are large,
shallow, open basins used for biological treatment of wastewater. This method
is primarily aerobic in nature and is suitable for areas with warm climates and
sufficient land availability. In this system, sewage from the primary treatment
plant is retained in the pond for a long detention period, typically 10 to 40 days. During this time,
microorganisms oxidize the organic matter present in the sewage.
A
symbiotic relationship exists between algae
and bacteria in oxidation ponds. Algae release oxygen during
photosynthesis, which is utilized by aerobic bacteria to oxidize organic
compounds. In turn, the carbon dioxide and nutrients released during bacterial
oxidation are used by algae for photosynthesis. Additional oxygen is also
supplied from the atmosphere since the pond is an open system. The oxidation
pond generally remains aerobic during daytime and the early hours of night,
allowing aerobic decomposition of organic matter. During late night hours, when
photosynthesis ceases, oxygen levels may drop, leading to partial anaerobic
conditions and anaerobic decomposition. Oxidation ponds are cost-effective,
require minimal mechanical equipment, and provide satisfactory removal of BOD
and pathogens.
2.2 Anaerobic Treatment (Without Oxygen)
Anaerobic
treatment is used for high-strength wastewater and sludge stabilization.
a. Anaerobic Digestion
In sealed,
oxygen-free digesters, anaerobic bacteria break down organic matter into biogas
containing 60–70% methane (CH₄) and carbon dioxide. Anaerobic digestion reduces
sludge volume, stabilizes organic matter, and produces renewable energy.
Anaerobic Treatment of Wastewater
Anaerobic treatment is
a biological wastewater treatment process carried out in the absence of oxygen. It is mainly used for high-strength wastewater and for stabilization of sludge produced during
primary and secondary treatment. This method is especially suitable for
wastewater with high organic load, such as that from distilleries, food
processing industries, and municipal sludge. Anaerobic treatment reduces
organic matter, produces less sludge compared to aerobic processes, and
generates useful energy in the form of biogas.
Septic Tank
A septic tank is a
simple anaerobic treatment system commonly used for domestic sewage in areas
without centralized sewer systems. It is a closed underground tank where sewage
is retained for several hours to days. During this detention period, heavier
solids settle at the bottom forming sludge, while lighter materials such as
oils and grease float on the surface forming scum. Anaerobic bacteria present
in the tank partially digest the organic matter, converting it into gases and
stabilized sludge. The clarified effluent flows out of the tank for further
treatment or disposal through soak pits or drainage fields. Septic tanks are
low-cost systems but provide only partial treatment.
Anaerobic Sludge Digestion
Anaerobic sludge
digestion is used for stabilizing sludge generated from primary and secondary
treatment units. The process takes place in sealed digesters under controlled
temperature conditions (mesophilic or thermophilic). Anaerobic microorganisms
decompose complex organic matter through stages such as hydrolysis,
acidogenesis, acetogenesis, and methanogenesis. This process significantly
reduces sludge volume, destroys pathogens, and produces biogas. Digested sludge
is more stable, less odorous, and easier to dewater and dispose of safely.
Biogas Production
Biogas is a valuable
by-product of anaerobic treatment and sludge digestion. It mainly consists of methane (60–70%), carbon dioxide
(30–40%), and trace amounts of hydrogen sulfide and other gases. Methane-rich
biogas can be used as a renewable energy source for cooking, heating, or
electricity generation in wastewater treatment plants. Biogas production not
only recovers energy but also improves the overall sustainability of wastewater
treatment systems.
Advantages of Anaerobic Treatment
·
Suitable for high-strength wastewater
·
Low energy requirement (no aeration needed)
·
Produces renewable energy (biogas)
·
Low sludge production
3. Chemical and Advanced Treatment (Tertiary Treatment)
Tertiary
treatment is employed when high-quality effluent is required, particularly for
reuse or discharge into sensitive environments.
Major Processes
- Coagulation and Flocculation: Removal of fine particles and
color
- Filtration: Sand filters, membrane
filtration
- Disinfection: Chlorination, UV radiation,
ozonation
- Nutrient Removal:
- Nitrogen:
Nitrification–denitrification
- Phosphorus: Chemical
precipitation using alum or lime
Sludge Treatment and Disposal
Sludge
generated during primary and secondary treatment is thickened, digested
(aerobically or anaerobically), dewatered, and safely disposed of or reused as
fertilizer if free from pathogens and toxic substances.