LUCAS® CYCLIC ACTIVATED SLUDGE SYSTEM
THE BLUE GOLD
BIOLOGICAL WASTE WATER TREATMENT
People are becoming increasingly aware of the importance and scarcity of clean water. Households, agriculture and industry produce large quantities of waste water every day. These waters are polluted by a mixture of all sorts of inorganic (sand, clay, salts) and organic (proteins, sugars, oils and fats...) components. Some of them appear in dissolved and other in suspended form.
Biological wastewater treatment is the process that removes the majority of the contaminants from wastewater or sewage (like BOD, COD, Nitrogen and Phosphorus) and produces both a liquid effluent (clean water) suitable for disposal to the natural environment and stabilised biosolids. It’s actually the accelerated version of nature’s own way of water cleaning.
Waterleau is committed to develop sustainable solutions to protect one of nature’s most precious gifts: water.
AEROBIC AND ANAEROBIC WASTEWATER TREATMENT Treating sewage and industrial wastewater is a bacterial process where bacteria rapidly consume organic matter. Depending on the wastewater characteristics Waterleau offers aerobic, anaerobic and anaerobic/aerobic wastewater treatment solutions.
AEROBIC TREATMENT
ANAEROBIC TREATMENT
Presence of O2
Absence of O2
Organic pollutants are biologically oxidized
Fermentation, Digestion
CO2 + H2O + new bacteria
Organic pollutants are anaerobically degraded through multiple steps
Stabilised biosolids CO2 + H2O + CH4 (methane gas)
Often post treatment of the effluent
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CH4 = used for electricity production and/or heating purposes
AEROBIC OR ACTIVATED SLUDGE WASTEWATER TREATMENT The process for treating sewage and industrial wastewaters using dissolved oxygen (aerobic treatment) and floc forming bacteria (activated sludge) consists of 3 consecutive steps.
1.
ACCUMULATION
The sludge is fed and aerated. Micro-organisms accumulate the organic materials quicky (absorption)
2.
REGENERATION
The accumulated and absorbed substrates are oxidized into H O and CO while 2 2 producing energy. The generated energy is used to take up substrates and generate new micro-organisms.
3.
SEDIMENTATION
Sludge starts to settle in a quiescent zone and is seperated from the supernatant effluent (= treated wastewater). The purified water can now be removed.
WASTEWATER TREATMENT TECHNOLOGIES Different technologies have been developed and are being used for the activated sludge treatment process.
CONVENTIONAL SYSTEM In its most generic form, the conventional aerobic activated sludge system consists of an activated sludge reactor tank connected with a separate sedimentation tank. The reaction and sedimentation processes are separated in place. Sludge is recycled from the clarifier to the aerobic tank. The tank level is always constant and both tanks have a continuous inflow and outflow.
LUCAS ® SYSTEM LUCAS ® is the family name for a complete range of wastewater treatment processes developed by Waterleau. LUCAS® stands for Leuven University Cyclic Activated Sludge but also for Low-cost Unobtrusive Compact Advanced Sustainable, summarizing the advantages of this technology
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LUCAS® CYCLIC ACTIVATED SLUDGE SYSTEM The LUCAS® water technology is Waterleau’s proven concept solution for the treatment of industrial and municipal wastewater. Depending on the daily flow, the organic load and the presence of nutrients to be removed out of the wastewater, a complete portfolio of LUCAS ® systems allows to treat any type of wastewater.
STANDARD LUCAS® CHARACTERISTICS
The reactor volume and the level in the units are constant. Influent can be directed to every unit. Effluent can be discharged from the outer units. Every unit can be aerated. Sludge can be wasted from the outer units. The units can be built in either square or circular shape. The reactor units are hydraulically interconnected. All the equipment follows an operational sequence controlled by a PLC.
ADVANCED LUCA S® CHARACTERISTICS In the advanced lay-out, all the tanks are interconnected by means of valves and pumps, allowing putting a single tank out of service for maintenance, without interrupting the treatment process.
Every compartment follows exactly the same process cycle. Effluent can be discharged from every unit. Sludge can be wasted from every unit. The gatereactor valves. units can be separated by closing the common
ADVANTAGES OF THE LUCAS ® TECHNOLOGY Within the total concept of LUCAS ®, the pretreatment, post treatment, sludge treatment and off-gas treatment can be integrated in the compact and modular design. The LUCAS® concept gives a complete economical and sustainable solution for the advanced purification of wastewater, including solutions for biosolids reduction and valorization COMPOSTELLA ®, complete odour treatment BELAIR ® and water reuse AQUALITY®. COMPACT AND MODULAR
Common walls, easy to extend, easy to cover, small footprint.
CONTINUOUS OPERATION
Allows for use of smaller pump capacities and piping diameters.
ROBUST
No moving mechanical parts, no variation in pressure on walls.
CONSTANT REACTOR LEVEL
No need for moving weirs, simple construction.
CONSTANT REACTOR VOLUME
100% use of the volume.
IDENTICAL REACTOR CONFIGURATION
Every compartment can have the same size and the same equipment.
FLEXIBLE
Every unit can be shut off while keeping the plant in operation.
COMPLETE CONTROL
The optimal circumstances for all essential biological and physical processes.
OPTIMAL PERFORMANCE
Optimal BOD, COD, N and P removal efficiencies.
INTEGRATED EFFECT
As in SBR systems, LUCAS® favors well setting sludge formation.
REDUCED OPERATIONAL COST
Sludge moves around without pumping, this results in lower energy consumption.
CONSTRUCTION
No need for difficult underground piping networks (reduces construction time).
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STANDARD LUCAS® CYCLE: DILUTED WASTEWATER For the treatment of diluted or municipal wastewater, the standard asymmetric treatment cycle allows a cost effective operation. The tanks are hydraulically interconnected without making use of pumps and valves. The influent is free to move from one tank to the adjacent tank through openings in the separating walls.
MAIN PHASE 1 (3H)
8H INTERMEDI ATE PHASE 2 (1H)
INTERMEDIATE PHASE 1 (1H)
MAIN PHASE 2 (3H)
MAIN PHASE 1
INTERMEDIATE PHASE 1
A Wastewater enters and is aerated
A Aeration is stopped
B Aeration without direct feeding C Calm conditions for sludge to settle
B Wastewater enters and is aerated C Clean water is removed
MAIN PHASE 2
INTERMEDIATE PHASE 2
A Calm conditions for sludge to settle
A Clean water is removed
B Aeration without direct feeding
B Wastewater enters and is aerated
C Wastewater enters and is aerated
C Aeration is stopped
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ADVANCED LUCAS® CYCLE: INDUSTRIAL WASTEWATER For highly polluted, industrial wastewater treatment, or wastewater with a high concentration of N & P, an advanced symmetric treatment cycle using pumps and valves to connect each tank with the two others allows the separation of each tank for maintenance without having to interrupt the water treatment process.
CIRCULAR LUCAS® DESIGN
A
A
B C
B
A
B C
C
MAIN PHASE 1 (3H) INTERMEDIATE PHASE 3 (1H)
INTERMEDIATE PHASE 1 (1H)
12H A
A
B
B C
C A
B C
MAIN PHASE 3 (3H)
MAIN PHASE 2 (3H) INTERMEDIATE PHASE 2 (1H)
MAIN PHASE 1
MAIN PHASE 3
A Wastewater enters and is aerated
A Calm conditions for sludge to settle
B Aeration without direct feeding
B Wastewater enters and is aerated
C Calm conditions for sludge to settle
C Aeration without direct feeding
MAIN PHASE 2
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INTERMEDIATE PHASES
A Aeration without direct feeding
Regeneration: the non-fed aerated
B Calm conditions for sludge to settle
tank is being prepared as the next
C Wastewater enters and is aerated
settling tank (lowest BOD/COD).
RECTANGULAR LUCAS® DESIGN
MAIN(3H) PHASE 1
INTERMEDIATE PHASE 3 (1H)
12H
MAIN PHASE 3 (3H)
MAIN PHASE 2 (3H)
INTERMEDIATE PHASE 2 (1H)
Diageo, Jamaica, effluent treatment plant LUCAS ® anaerobic-aerobic 16.340 kg COD/d - 3.000 Nm³/d
INTERMEDIATE PHASE 1 (1H)
“THE MODULAR SYSTEM OF THE LUCAS ® TECHNOLOGY OFFERS A SOLUTION FOR THE TREATMENT OF EVERY TYPE OF WASTEWATER, ORGANIC CONCENTRATION OR NUTRIENT LOAD, EVEN WITH STRONG VARIATIONS IN WATER FLOW”
Coloane, Macau, municipal wwtp LUCAS ® undercover 130.000 m³/d - 550.000 PE - 3 years O&M
LUCAS® NP: ADVANCED BIOLOGICAL NITROGEN (N) & PHOSPHORUS (P) REMOVAL Wastewater not only contains organic matter, but often also nutrients such as nitrogen and phosphorus compounds. LUCAS ® NP is the LUCAS ® system with additional enhanced biological nutrients removal. Biological COD, N and P removal is achieved by manipulating three biochemical reactions (aerobic, anoxic, and anaerobic) to perform a nitrification, de-nitrification and P removal process.
Cycle of 1 LUCAS ® NP tank
In order to make the nitrogen and phosphorus available to the micro-organisms in the active sludge, a first step in the nutrient removal process consists of the hydrolysis of organic bound nitrogen and phosphorus to solubilized ammonia and ortho-phosphates. After the hydrolysis, the process of N and P removal is achieved by both assimilation and dissimilation. During assimilation, the N and P uptake in function of the sludge’s growth. During dissimilation, N and P uptake is favoured by intelligent manipulation and alteration of the aerobic, anoxic and anaerobic reactions. Waterleau has developed the MAKE SENSE® control & monitoring system measuring wastewater characteristics and responding with the appropriate reaction in each phase. MAKE SENSE ® also calculates or implements BOD-load, energy consumption, operational costs, and optimal cycle duration for nitrification, de-nitrification, phosphorus removal, sedimentation, sludge growth and sludge waste.
Sampling & control unit
LUCAS ® NP Unit A : Consecutive anoxic / anaerobic / aerobic conditions
Unit B : Consecutive anoxic / aerobic conditions
Unit C : Decanting
CONVENTIONAL S YSTEM
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LUCAS® MUNICIPAL The treatment of large flows of municipal wastewater implies sufficient land is available to build these treatment facilities. The LUCAS® system is particularly adapted to reduce the treatment plant’s footprint due to its compact and modular design. Designing shallow or deeper tanks allows matching the needed capacity to every building plot.
OPTION 1:
LOW COST – SHALLOW TANKS
When the treatment plant is to be built on the outskirts of the city, when land is available, and when there is no need to cover the plant, large shallow tanks with a depth of approximately 3 to 4 meters, equipped with surface aerators is the obvious solution of designing the plant.
CHARACTERISTICS SHALLOW TANKS SURFACE AERATORS ECONOMIC SOLUTION NO COVER
THE LUCAS® CLASSIC DESIGN OFFERS THE BEST COST-CAPACITY RATIO WHEN LAND IS AVAILABLE
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OPTION 2:
VERY ADVANCED – COMPACT
When the plant’s footprint is very restricted, it becomes necessary to build steeper tanks in order to maintain the plant’s capacity. Steep tanks of 7 meter in height are equipped with diffused bubble aerators, and lamella separators. The use of lamella separators is required to maintain sufficient sedimentation surface in the smaller tanks. Conventional clarification equipment requires a much larger surface footprint in order to match the solids removal capacity of an inclined plate clarifier. The functional LUCAS ® cycle takes care of the regular cleaning of the lamella during the aeration phase. The super compact design allows even to cover the complete plant, allowing air treatment and reducing its impact to the surrounding community.
CHARACTERISTICS STEEP TANKS DIFFUSED BUBBLE AERATORS LAMELLA SEPERATORS COVERED
LUCAS® LAMELLA DESIGN: MAXIMAL CAPACITY AND MINIMAL FOOTPRINT
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SABMiller, Uganda, effluent treatment plant LUCAS ® anaerobic - aerobic LUCAS ® plug & play 3.000 m³/d - 10.500 kg COD/d Biogas production: 4.200 Nm³/d
“THE LUCAS ® PLUG & PLAY DESIGN REDUCES CIVIL COSTS AND CONSTRUCTION TIME, ALLOWING TO SPEED UP OPERATION”
LUCAS® PLUG & PLAY: THE FAST TR ACK LUCAS® SOLUTION In the industry, speed, cost and flexibility are often key drivers in choosing the right solution. In order to overcome intense and time consuming civil works, Waterleau has come forward with an innovative, robust, modular and fast construction LUCAS® plug & play concept. The use of glass-coated steel reactors and pre-assembled key-components allow fast construction compared to a traditional concrete-based design. Besides shorter construction time, limiting the civil works is an additional advantage of choosing for the LUCAS ® Plug & Play solution. Being less dependent of civil contractors will contribute to reduced project risk. ®
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The LUCAS Plug & Play is available as a LUCAS aerobic, LUCAS anaerobic and LUCAS anaerobic-aerobic.
COBRA® + MAKE SENSE®: THE CAREFREE LUCAS® OPERATION UNIT Waterleau has developed a similar smart design for the LUCAS ® Plug & Play operation unit. Each LUCAS ® system is equipped with a COBRA® (COre & BRAins) operation unit containing interconnecting piping, automatic valves, and even the monitoring and control equipment, facilitating the patented functional operation of the LUCAS ® system. The COBRA® consists of two functional parts: the “wet” part (all hydraulic connections and sludge treatment) and the “dry” part (electrical cabines, PLC and central laboratory). The COBRA® is preassembled and tested in the Waterleau Workshop allowing speed in the construction process and a fast operation of the new LUCAS ® system.
COBRA ® SAB Miller, Onitsha - Nigeria LUCAS ®-3 aerobic - LUCAS ® Plug & Play Capacity: 1.050 m³/d - 3.680 kg COD/d
Baghdad, Iraq, municipal wwtp LUCAS ® municipal - LUCAS ® Plug & Play 35 100 kg COD/d - 650.000 PE
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“THE BIOGAS PRODUCTION FROM THE LUCAS® ANAEROBIC TREATMENT PROCESS CONTRIBUTES TO THE REDUCTION OF THE PLANT’S ENERGY FOOTPRINT.”
Heineken, Spain, effluent treatment plant LUCAS ® anaerobic 8.000 m³/day - 28.000 kg COD/d Energy production: 1 MWe
LUCAS® ANAEROBIC(–AEROBIC) ANAEROBIC In the food and beverage industry, the effluent’s organic load allows to reduce the energy footprint of the food processing plant or brewery. Anaerobic digestion of the effluent produces biogas, which can be used as a fuel for the production of heat and power. Waterleau has more than 400 references in the anaerobic treatment of industrial wastewater.
ANAEROBIC–AEROBIC In combination with aerobic treatment, up to 99% of the effluent’s organic load can be removed, allowing the final effluent to be discharged ® to be further treated for reusestream purposes, making use ofsafely EXSELor reverse osmosis and BOOMERANG ® ultra-filtration technology.
biogas
ADVANTAGES
effluent
High COD removal (up to 99%) High biogas production which can be converted into heat and/or electricity Low sludge production Robust and proven technology Very compact design Cost effective technology (ROI between 2 and 5 years)
influent
effluent recycling
Heineken, the Netherlands, effluent treatment plant LUCAS ® anaerobic 4.000 m³/d - 13.600 kg COD/d - Biogas production: 3.905 Nm³/d
Heineken Craiova, Romania, effluent treatment plant LUCAS ® anaerobic 48.000 kg COD/d - Biogas production: 4.800 Nm³/d
Diageo, Kenya, effluent treatment plant LUCAS ® anaerobic 7.215 m³/d - 32.280 kg COD/d - Biogas production: 10.080 Nm³/d
Heineken Ibadan, Nigeria, effluent treatment plant LUCAS ® anaerobic - aerobic 4.800 m³/d - 12.000 kg COD/d - Biogas production: 4.800 Nm³/d
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THE LUCAS® FAMILY Over the years, the LUCAS® family of wastewater treatment systems has been extended with new members, each showing specific additional features. Combinations of these features are also possible:
LUCAS® AEROBIC
LUCAS ®-3
Most typical LUCAS® with 3 reactor units
LUCAS ®-1, LUCAS®-2
The LUCAS ®-light designs
LUCAS ® multiple lane
The LUCAS ® design for large municipal wwtps
LUCAS ® two-stage aerobic
Two LUCAS® systems in series for high loaded and difficult biodegradable wastewater
LUCAS ® NP
Aerobic treatment including biological nutrient removal
LUCAS ® closing-the-loop
Advanced aerobic treatment including effluent recycling
LUCAS® ANAEROBIC
Particulary suited to treat high loaded wastewater. The UASB-technology (Upflow Anaerobic Sludge Blanket) and the LUCAS ® anaerobic can remove moe than 90% of the organic matter. The process design allows the production of biogas, reducing the plant’s energy footprint.
LUCAS® ANAEROBIC – AEROBIC
The LUCAS® anaerobic stage can be followed by a LUCAS ® aerobic stage to remove the remaining COD from the water and to remove nutrients (N & P).
LUCAS® plant lay-outs
The LUCAS ® system can be integrated into different plant lay-outs in order to reduce the plant’s impact into the environment. LUCAS ® undercover
A completely covered plant design
LUCAS ® chameleon
A plant design integrated in the environment
LUCAS ® plug & play
A fast erection steel tank plant design
LUCAS ® lagoon
The reactor units are shallow pits in the ground, reducing the cost of civil works
A SOLUTION FOR EVERY TYPE OF WASTEWATER
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LUCAS® -1
LUCAS® -2
LUCAS® -3
LUCAS® - 4
The modularity and flexibility of the LUCAS® technology allows the treatment of every type of wastewater independent of its flow or organic load. It is designed to guarantee optimal performance at minimal cost. More than 200 LUCAS ® wastewater treatment plants have been built for industries and municipalities throughout the world.
n x LUCAS®-3
Zhuhai, China, municipal wwtp LUCAS ® undercover 80.000 m³/d - 16.200 kg COD/d - 300.000 PE
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LUCAS®: A SMART & COMPACT DESIGN TO TREAT MUNICIPAL 1
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Castel, Lomé - Togo LUCAS ® anaerobic +re-aeration 2.450 m³/d - 7.500 kg COD/d
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Taipa, Macao, municipal wwtp LUCAS ® aerobic - AQUALITY ® ultrafiltration 69.000 m³/d - 320.000 PE - 5 years O&M
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Heineken, South Africa, effluent treatment plant LUCAS ® anaerobic - aerobic 6.000 m³/day - 18.000 kg COD/d
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Coloane, Macau, municipal wwtp LUCAS ® undercover 130.000 m³/d - 550.000 PE - 3 years O&M
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Nanjing, China, municipal wwtp ® LUCAS undercover 300.000 m³/d - 54.00 0 kg COD/d - 1.000.000 PE
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AB InBev, Russia, effluent treatment LUCAS ® anaerobic - aerobic 30.600 kg COD/d Biogas production: 8.400 Nm³/d
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Fiaes, Portugal, municipal wwtp LUCAS ® aerobic 5.500 m³/d - 50.000 PE
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Guangzhou, China, municipal wwtp ® LUCAS -3 multiple lane 220.000 m³/d - 232.400 kg COD/d - 600.000 PE
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AB Inbev, Belgium, effluent treatment LUCAS ® anaerobic - aerobic 30.000 kg COD/d Biogas production: 9,600 Nm³/d
AND INDUSTRIAL WASTEWATER 10
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MORE THAN 200 REFERENCES WORLDWIDE ...
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Bouskoura, Morocco, munic ipal wwtp LUCAS ® municipal 8.000 m³/d - 50.000 PE - 10 years O&M
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Diageo, Ghana, effluent treatment plant ® LUCAS anaerobic - aerobic 9.300 kg COD/d - Biogas production: 2.600 Nm³/d
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Zambian Breweries, Zambia, effluent treatment plant LUCAS ® plug & play 1.333 m³/d - 3.330 kg COD/d
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Diageo Kumasi, Ghana, effluent treatment LUCAS ® anaerobic + conventional aerobic 10.000 kg COD/d Biogas production: 3.200 Nm³/d
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Castel, Jesus, Angola, effluent treatment plant LUCAS ®Bom anaerobic 5.750 kg COD/d - Biogas production: 1.400 Nm³/d
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Antwerpen, Belgium, municipal wwtp LUCAS ® -3 multiple lane 18.000 m³/d - 5.670 kg COD/d 105.000 PE
DSM Nanjing, China, effluent treatment LUCAS ® aerobic Capacity: 6.480 m³/d, 9.720 kg COD/d
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AB Mauri, China, effluent treatment LUCAS ® two-stage aerobic Capacity: 2.400 m³/d - 11.500 kg COD/d
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THE LUCAS® CONCEPT PROVIDES A COMPLETE ECONOMICAL AND SUSTAINABLE SOLUTION FOR THE ADVANCED PURIFICATION OF WASTEWATER
DESIGN ENGINEERING CONSTRUCTION OPERATION MAINTENANCE
PROTECTING THE 4 ELEMENTS
We all have the responsibility to handle our natural resources in a careful and sustainable way. Waterleau develops environmental technologies and offers sustainable solutions for water, air and waste treatment, as well as for energy recovery. As an EPC contractor and operator, Waterleau counts more than 1500 references for municipal and industrial clients around the world.
Nieuwstraat 26, 3150 Wespelaar (Leuven), Belgium t. +32 (0) 16 65 06 57 - f. +32 (0) 16 65 06 63
[email protected] - www.waterleau.com
