Aerobic/anaerobic sludge digestion process

Claim 2

A process for digestion of sludge comprising the steps of: (a) introducing said sludge and aeration feed gas comprising at least 20 percent oxygen (by volume) to a first digestion zone and mixing same therein in sufficient quantity and rate for aerobic digestion of the sludge while maintaining total suspended solids content (MLSS) of the sludge at least at 20,000 mg/l and temperature of the sludge in the range of from 35° to 75° C. in said first digestion zone; (b) continuing the aerobic digestion of step (a) for sludge retention time (duration) of from 4 to 48 hours to partially reduce the biodegradable volatile suspended solids content of the sludge introduced to said first digestion zone and thereby form partially stabilized sludge, and discharging said partially stabilized sludge from said first digestion zone; (c) anaerobically digesting the partially stabilized sludge discharged from said first digestion zone in a covered second digestion zone while maintaining temperature of the sludge therein in the range of from 25° to 60° C. for sufficient solids retention time (duration) to further reduce the biodegradable volatile suspended solids content of the sludge to less than about 40 percent of the biodegradable volatile suspended solids content of the sludge introduced to the first digestion zone in step (a), and form methane gas; and (d) separately discharging further stabilized sludge and said methane gas from said second digestion zone.

Claim 3

A process according to claim 1 wherein said oxygen-containing aeration feed gas and said sludge are mixed in said first digestion zone in sufficient quantity and rate to obtain utilization of from 0.10 to 0.35 lbs. oxygen per lb. of volatile suspended solids (VSS) in said sludge introduced to said first digestion zone.

Claim 4

A process according to claim 1 wherein the volatile suspended solids content of the sludge introduced to said first digestion zone is reduced by from 5 to 20 percent in said first digestion zone.

Claim 5

A process according to claim 1 comprising providing said first digestion zone with a cover to form a gas space overlying the sludge therein, and wherein said aeration feed gas comprises at least 50 percent oxygen (by volume).

Claim 6

A process according to claim 4 comprising recirculating one of the aeration gas and sludge fluids against the other fluid in said first digestion zone and discharging oxygen-depleted digestion gas of at least 21 percent oxygen (by volume) from said first digestion zone separately from said partially stabilized sludge discharged therefrom.

Claim 7

A process according to claim 1 wherein said sludge introduced to said first digestion zone has a total suspended solids content of between 20,000 and 80,000 mg/l.

Claim 8

A process according to claim 1 wherein sludge retention time (duration) of said sludge in said first digestion zone is from 12 to 30 hours.

Claim 9

A process according to claim 1 wherein said sludge is heated prior to said introduction to said first digestion zone, to maintain said temperature of from 35° to 75° C. in said first digestion zone.

Claim 10

A process according to claim 1 wherein said temperature of the sludge in the second digestion zone is maintained in the range of from 35° to 40° C., or mesophilic digestion of sludge in said second digestion zone.

Claim 11

A process according to claim 1 wherein said temperature of the sludge in the second digestion zone is maintained in the range of from 45° to 50° C., for thermophilic digestion of sludge in said second digestion zone.

Claim 12

A process according to claim 1 wherein sludge retention time of sludge in the second digestion zone is sufficient to further reduce the biodegradable volatile suspended solids content of the sludge to less than about 20% of the biodegradable volatile suspended solids content of the sludge introduced to said first digestion zone in step (a).

Claim 13

A process according to claim 1 wherein sludge retention time of sludge in the second digestion zone is from 4 to 12 days.

Claim 14

A process according to claim 1 wherein each of said first and second digestion zones has a surface-to-volume ratio less than 0.8ft 2 /ft 3 .

Claim 15

A process according to claim 1 wherein the sludge in said second digestion zone is mixed by recirculation of methane gas against the sludge therein.

Claim 16

A process according to claim 1 wherein said aeration feed gas is heated prior to said introduction to said first digestion zone, to maintain said temperature of from 35° to 75° C. therein.

Claim 17

A process according to claim 1 wherein said sludge is heated prior to said introduction to said first digestion zone by indirect heat exchange with said further stabilized sludge discharged from said second digestion zone.

Claim 18

A process according to claim 16 wherein said temperature of sludge in the second digestion zone is maintained in the range of from 35° to 40° C. and said heated sludge is further heated prior to said introduction to said first digestion zone by indirect heat exchange with said partially stabilized sludge discharged from said first digestion zone.

Claim 19

A process according to claim 1 wherein said second digestion zone comprises an acidification sub-zone and methane fermentation sub-zone, partially stabilized sludge from said first digestion zone is introduced to said acidification sub-zone and maintained therein for sludge retention time of 24 to 60 hours for sludge acidification, and acidified sludge is discharged from said acidification sub-zone and introduced to said methane fermentation sub-zone and maintained therein at temperature of from 35° to 40° C. for sludge retention time of from 4 to 8 days.

Claim 20

A process according to claim 18 wherein sludge in said methane fermentation sub-zone is maintained at temperature of from 37° to 38° C.

Claim 21

A process according to claim 18 wherein sludge in said acidification zone is maintained at temperature of between 45° and 75° C. and acidified sludge discharged from said acidification sub-zone is cooled to temperature of from 35° to 40° C. prior to introduction to said methane fermentation sub-zone.

Claim 22

A process according to claim 1 comprising treatment of wastewater containing biodegradable suspended solids for BOD removal therefrom, including the steps of: separating a primary sludge comprising said biodegradable suspended solids from said wastewater to form solids-depleted primary effluent: mixing said primary effluent and recycle sludge and aerating same at sufficient rate and for sufficient time to form mixed liquor of reduced BOD content; separating the mixed liquor into purified liquid and activated sludge; and returning at least a major portion of the activated sludge for mixing with said primary effluent as said recycle sludge, wherein said primary sludge and unreturned activated sludge are introduced to said first digestion zone in step (a), as sludge feed therefor.

Claim 23

A process according to claim 1 wherein said methane gas discharged from said second digestion zone is mixed with oxygen-containing gas and combusted as fuel to provide heat for maintaining sludge in at least one of said first and second digestion zones at elevated temperature.

Claim 24

A process according to claim 22 wherein said methane gas and oxygen-containing gas are mixed and combusted as fuel to provide heat for maintaining sludge in said first digestion zone at temperature of from 35° to 75° C.

Claim 25

A process according to claim 1 wherein temperature of sludge in the first digestion zone is maintained in the thermophilic range of from 45° to 75° C. and temperature of sludge in the second digestion zone is maintained in the range of from 30° to 60° C.

Claim 26

A process according to claim 1 wherein the mixing of sludge and aeration feed gas in the first digestion zone in sufficient quantity and rate for aerobic digestion of sludge therein is effected by oxygenating the sludge in the first digestion zone at a rate which is equal to at least 10% of the empirically calculated specific oxygen uptake rate (SOUR) value.

Claim 27

A process according to claim 1 wherein the mixing of sludge and aeration feed gas in the first digestion zone in sufficient quantity and rate for aerobic digestion of sludge therein is effected by sludge oxygenation with the relative quantities of aeration feed gas and sludge and rate of aeration being sufficient to obtain utilization of at least 0.03 lbs. of oxygen per lb. of volatile suspended solids in the sludge introduced to the first digestion zone.

Claim 28

A process according to claim 1 wherein a dissolved oxygen content (DO) of the sludge in the first digestion zone is maintained at least at 2 mg/l.

Claim 29

In a process for BOD-removal from waste-water in a covered aeration zone and digestion of activated sludge with oxygen gas, including the steps of: (a) introducing first gas comprising at least 40% oxygen (by volume) and mixing same as aeration gas with the wastewater and recycled sludge in said covered aeration zone to form mixed liquor and contacting said aeration gas with the mixed liquor in sufficient quantity and rate to maintain the dissolved oxygen content (DO) of the mixed liquor at least 0.5 mg/l, separating the mixed liquor into purified liquid and activated sludge, and discharging unconsumed oxygen-containing gas from the aeration zone at rate such that its oxygen count is not more than 40% of the total oxygen introduced to the digestion zone; (b) returning at least about 85% by weight of the activated sludge to the aeration zone as said recycled sludge; (c) providing second gas comprising at least 80% oxygen (by volume) and including part of said first gas; (d) introducing said second gas and the unreturned activated sludge from step (b) to a covered digestion zone and mixing same therein in sufficient quantity and rate for aerobic digestion of the sludge while maintaining total suspended solids content (MLSS) of the sludge at least at 20,000 mg/l; (e) maintaining the sludge in the digestion zone during step (d) at temperature in the range of from 35° to 75° C.; (f) separately discharging partially stabilized sludge and oxygen-depleted digestion gas of at least 40% oxygen purity from said digestion zone at rate such that the oxygen content of the oxygen-depleted digestion gas is at least 35% of the oxygen content of said second gas entering said digestion zone; (g) providing said oxygen-partially depleted digestion gas from step (f) as at least the major part of said first gas introduced to said covered aeration zone in step (a); the improvement comprising the steps of: (h) continuing step (e) for sludge retention time (duration) of from 4 to 48 hours to partially reduce the biodegradable volatile suspended solids content of the sludge introduced to said first digestion zone and thereby form partially stabilized sludge; (i) introducing said partially stabilized sludge from step (f) to a second covered digestion zone; (j) maintaining a sludge in the second digestion zone under anaerobic conditions at temperature of from 25° to 60° C. for sufficient sludge retention time (duration) to further reduce the biodegradable volatile suspended solids content of the sludge to less than about 40% of the biodegradable volatile suspended solids content of the activated sludge introduced to said digestion zone in step (d), and form methane gas, and separately discharging further stabilized sludge and said methane gas from the second digestion zone.

Claim 30

In a process for BOD-removal from waste-water in a covered aeration zone and digestion of activated sludge with oxygen gas, including the steps of: (a) introducing first gas comprising at least 40% oxygen (by volume) and mixing same as aeration gas with the wastewater and recycled sludge in said covered aeration zone to form mixed liquor and contacting said aeration gas with the mixed liquor in sufficient quantity and rate to maintain the dissolved oxygen content (DO) of the mixed liquor at least 0.5 mg/l, separating the mixed liquor into purified liquid and activated sludge, and discharging unconsumed oxygen-containing gas from the aeration zone at rate such that its oxygen count is not more than 40% of the total oxygen introduced to the digestion zone; (b) returning at least about 85% by weight of the activated sludge to the aeration zone as said recycled sludge; (c) providing second gas comprising at least 80% oxygen (by volume) and including part of said first gas; (d) introducing said second gas and the unreturned activated sludge from step (b) to a covered digestion zone and mixing same therein in sufficient quantity and rate for aerobic digestion of the sludge while maintaining total suspended solids content (MLSS) of the sludge at least at 20,000 mg/l; (e) maintaining the sludge in the digestion zone during step (d) at temperature in the range of from 35° to 75° C.; (f) separately discharging partially stabilized sludge and oxygen-depleted digestion gas of at least 40% oxygen purity from said digestion zone at rate such that the oxygen content of the oxygen-depleted digestion gas is at least 35% of the oxygen content of said second gas entering said digestion zone; (g) providing said oxygen-partially depleted digestion gas from step (f) as at least the major part of said first gas introduced to said covered aeration zone in step (a); the improvement comprising the steps of: (h) continuing step (e) for sludge retention time (duration) of from 4 to 48 hours to partially reduce the biodegradable volatile suspended solids content of the sludge introduced to said first digestion zone and thereby form partially stabilized sludge; (i) introducing said partially stabilized sludge from step (f) to a second covered digestion zone; (j) maintaining a sludge in the second digestion zone under anaerobic conditions at temperature of from 25° to 60° C. for sufficient sludge retention time (duration) to further reduce the biodegradable volatile suspended solids content of the sludge to less than about 40% of the biodegradable volatile suspended solids content of the activated sludge introduced to said digestion zone in step (d), and form methane gas, and separately discharging further stabilized sludge and said methane gas from the second digestion zone.

Claim 31

A process for digestion of sludge, comprising the steps of: (a) introducing said sludge and aeration gas comprising at least 50 percent oxygen (by volume) to a first covered digestion zone and mixing same therein in sufficient quantity and rate for aerobic digestion of the sludge while maintaining the total suspended solids content (MLSS) of the sludge at least at 20,000 mg/l; (b) maintaining sludge in said first digestion zone during step (a) at temperature in the thermophilic range of from 45° to 75° C.; (c) continuing step (b) for sludge retention time (duration) of from 4 to 48 hours to partially reduce the biodegradable volatile suspended solids content of the sludge introduced to said first digestion zone and thereby form partially stabilized sludge; (d) separately discharging said partially stabilized sludge and oxygen-depleted digestion gas of at least 21% oxygen purity from said first digestion zone; (e) introducing said partially stabilized sludge from step (d) to a second covered digestion zone; (f) maintaining sludge in the second digestion zone under anaerobic conditions at temperature of from 30° to 60° C. for sufficient solids retention time (duration) to further reduce the biodegradable volatile suspended solids content of the sludge, to less than about 40% of the biodegradable volatile suspended solids content of the sludge introduced to said first digestion zone in step (a), and form methane gas, and separately discharging further stabilized sludge and said methane gas from the second digestion zone.

Claim 32

A process for digestion of sludge, comprising the steps of: (a) introducing said sludge and aeration gas comprising at least 50 percent oxygen (by volume) to a first covered digestion zone and mixing same therein in sufficient quantity and rate for aerobic digestion of the sludge while maintaining the total suspended solids content (MLSS) of the sludge at least at 20,000 mg/l; (b) maintaining sludge in said first digestion zone during step (a) at temperature in the thermophilic range of from 45° to 75° C.; (c) continuing step (b) for sludge retention time (duration) of from 4 to 48 hours to partially reduce the biodegradable volatile suspended solids content of the sludge introduced to said first digestion zone and thereby form partially stabilized sludge; (d) separately discharging said partially stabilized sludge and oxygen-depleted digestion gas of at least 21% oxygen purity from said first digestion zone; (e) introducing said partially stabilized sludge from step (d) to a second covered digestion zone; (f) maintaining sludge in the second digestion zone under anaerobic conditions at temperature of from 30° to 60° C. for sufficient solids retention time (duration) to further reduce the biodegradable volatile suspended solids content of the sludge, to less than about 40% of the biodegradable volatile suspended solids content of the sludge introduced to said first digestion zone in step (a), and form methane gas, and separately discharging further stabilized sludge and said methane gas from the second digestion zone.

Claim 33

A process for digestion of sludge comprising the steps of: (a) introducing said sludge and aeration feed gas comprising at least 20 percent oxygen (by volume) to a first digestion zone and mixing same therein in sufficient quantity and rate for aerobic digestion of the sludge while maintaining total suspended solids content (MLSS) of the sludge at least at 20,000 mg/l and temperature of the sludge in the range of from 35° to 75° C. in said first digestion zone; (b) conducting the aerobic digestion of step (a) so as to reduce the volatile suspended solids content of the sludge introduced to said first digestion zone by from 5 to 20 percent and thereby form partially stabilized sludge, and discharging said partially stabilized sludge from said first digestion zone; (c) anaerobically digesting the partially stabilized sludge discharged from said first digestion zone in a covered second digestion zone while maintaining temperature of the sludge therein in the range of from 25° to 60° C. for sufficient solids retention time (duration) to further reduce the biodegradable volatile suspended solids content of the sludge to less than about 40 percent of the biodegradable volatile suspended solids content of the sludge introduced to the first digestion zone in step (a), and form methane gas; and (d) separately discharging further stabilized sludge and said methane gas from said second digestion zone.

Claim 34

A process for digestion of sludge comprising the steps of: (a) introducing said sludge and aeration feed gas comprising at least 20 percent oxygen (by volume) to a first digestion zone and mixing same therein in sufficient quantity and rate for aerobic digestion of the sludge while maintaining total suspended solids content (MLSS) of the sludge at least at 20,000 mg/l and temperature of the sludge in the range of from 35° to 75° C. in said first digestion zone; (b) conducting the aerobic digestion of step (a) so as to reduce the volatile suspended solids content of the sludge introduced to said first digestion zone by from 5 to 20 percent and thereby form partially stabilized sludge, and discharging said partially stabilized sludge from said first digestion zone; (c) anaerobically digesting the partially stabilized sludge discharged from said first digestion zone in a covered second digestion zone while maintaining temperature of the sludge therein in the range of from 25° to 60° C. for sufficient solids retention time (duration) to further reduce the biodegradable volatile suspended solids content of the sludge to less than about 40 percent of the biodegradable volatile suspended solids content of the sludge introduced to the first digestion zone in step (a), and form methane gas; and (d) separately discharging further stabilized sludge and said methane gas from said second digestion zone.