Download Report

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
2
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 H2O and CO2 while
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
3
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 LUCAS® 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 reactor units can be separated by closing the common
gate valves.
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).
4
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
INTERMEDIATE 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
B Wastewater enters and is aerated
C Calm conditions for sludge to settle
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
5
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
C
A
B
B
C
C
MAIN PHASE 3
(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
6
MAIN PHASE 2
(3H)
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 PHASE 1
(3H)
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 SYSTEM
9
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
10
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
11
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 TRACK 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.
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
13
“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 stream to be discharged safely or to be further treated
for reuse purposes, making use of EXSEL® 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
15
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
16
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
17
LUCAS®: A SMART & COMPACT DESIGN TO TREAT MUNICIPAL
1
2
3
4
5
6
7
8
9
1
Castel, Lomé - Togo
LUCAS® anaerobic +re-aeration
Capacity: 2.450 m³/d - 7.500 kg COD/d
2
Taipa, Macao, municipal wwtp
LUCAS ® aerobic - AQUALITY® ultrafiltration
69.000 m³/d - 320.000 PE - 5 years O&M
3
4
5
18
6
7
Heineken, South Africa, effluent treatment plant
LUCAS ® anaerobic - aerobic
6.000 m³/day - 18.000 kg COD/d
8
Coloane, Macau, municipal wwtp
LUCAS ® undercover
130.000 m³/d - 550.000 PE - 3 years O&M
9
Nanjing, China, municipal wwtp
LUCAS ® undercover
300.000 m³/d - 54.000 kg COD/d - 1.000.000 PE
AB InBev, Russia, effluent treatment
LUCAS® anaerobic - aerobic
Capacity: 30.600 kg COD/d
Biogas production: 8.400 Nm³/d
Fiaes, Portugal, municipal wwtp
LUCAS ® aerobic
5.500 m³/d - 50.000 PE
Guangzhou, China, municipal wwtp
LUCAS ® -3 multiple lane
220.000 m³/d - 232.400 kg COD/d - 600.000 PE
Baghdad, Iraq, municipal wwtp
LUCAS ® municipal
200.000 m³/d - 40.000 kg COD/d - 750.000 PE
AND INDUSTRIAL WASTEWATER
10
11
12
13
14
15
16
17
MORE THAN
200 REFERENCES
WORLDWIDE ...
10
Bouskoura, Morocco, municipal wwtp
LUCAS ® municipal
8.000 m³/d - 50.000 PE - 10 years O&M
14
Diageo, Ghana, effluent treatment plant
LUCAS ® anaerobic - aerobic
9.300 kg COD/d - Biogas production: 2.600 Nm³/d
11
Zambian Breweries, Zambia, effluent treatment plant
LUCAS ® plug & play
1.333 m³/d - 3.330 kg COD/d
15
12
Castel, Bom Jesus, Angola, effluent treatment plant
LUCAS ® anaerobic
5.750 kg COD/d - Biogas production: 1.400 Nm³/d
Diageo Kumasi, Ghana, effluent treatment
LUCAS® anaerobic + conventional aerobic
Capacity: 10.000 kg COD/d
Biogas production: 3.200 Nm³/d
16
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
17
AB Mauri, China, effluent treatment
LUCAS® two-stage aerobic
Capacity: 2.400 m³/d - 11.500 kg COD/d
13
19
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 1000 references for municipal
and industrial clients around the world.
Radioweg 18, 3020 Herent (Leuven), Belgium
t. +32 (0) 16 65 06 57 - f. +32 (0) 16 65 06 63
info@waterleau.com - www.waterleau.com