Design of a Wastewater Treatment Plant in Leeds, UK

Professor: Dr. C. Tizaoui EG-M09/EGA327 Water and Wastewater Engineering

Group D: Frederico Halfeld Clark Gomes, Luiza Pessoa Moreira, Luiza Nunes Rocha, Pedro Henrique Guerra Alves, Thales Said Orichio, 744484 744482 744499 744486 744488 College of Engineering Swansea University Swansea Wales, UK

Contents
1. Introduction ..................................................................................................................... 4 2. Population ....................................................................................................................... 4 3. Flow rates Calculations ................................................................................................... 4 4. Domestic Wastewater ..................................................................................................... 5 4.1. 4.2. 4.2.1. 4.2.1.1. 4.2.1.2. 4.2.1.3. 4.2.2. 4.2.3. 4.2.4. 4.2.5. 4.2.6. 4.2.7. 5.1. 5.2. 5.2.1. 5.2.2. 5.2.2.1. 5.2.2.2. 5.2.2.3. 5.2.3. 5.2.4. 5.2.5. 5.2.6. 5.2.7. 6.1. 6.2. 7.1. 7.2. 7.3. Domestic Wastewater Characterization ...................................................................... 5 Designed Plant and Flow sheet ................................................................................... 6 Aerobic BioOxidation reactor ................................................................................. 8 Substrate (Dsticwaste) degradation...................................................................... 8 Nitrification .......................................................................................................... 8 Biomass decay ..................................................................................................... 8 Clarifier .................................................................................................................... 9 Granular media filter ............................................................................................... 9 Flow Splitting ........................................................................................................ 10 Belt Filter ............................................................................................................... 10 Sludge Drying ........................................................................................................ 10 Mixing unit ............................................................................................................ 11 Industrial Wastewater Characterization .................................................................... 11 Designed Plant and Flow sheet ................................................................................. 12 Mixing Unit ........................................................................................................... 14 Aerobic BioOxidation reactors .............................................................................. 14 Glucose degradation........................................................................................... 14 Phenol degradation............................................................................................. 15 Biomass decay ................................................................................................... 15 Clarifier .................................................................................................................. 15 Granular media filter ............................................................................................. 15 Flow Splitting ........................................................................................................ 16 Belt Filter ............................................................................................................... 16 Sludge Drying ........................................................................................................ 16 Domestic Wastewater Treatment Plant ..................................................................... 16 Industrial Wastewater Treatment Plant ..................................................................... 18 Domestic WWT Plant Analysis ................................................................................ 20 Industrial WWT Plant Analysis ................................................................................ 20 Final Effluent Characteristics .................................................................................... 21

5. Industrial Wastewater Treatment .................................................................................. 11

6. Economic Evaluation .................................................................................................... 16

7. Environmental Impact Analysis .................................................................................... 20

8. Alternatives for Sludge Disposal .................................................................................. 22 9. Conclusion .................................................................................................................... 23 10. References ................................................................................................................. 23 Appendix A Units Mass Balances and Streams Composition .......................................... 25 Appendix B Meetings Minutes ......................................................................................... 35

1. Introduction
This project aimed to design a new municipal wastewater treatment plant using SuperPro Designer package for the city council of Leeds. The purpose of it is to replace the old WWT plant, which was not capable to achieve compliance with discharge standards. The WWTP was designed to serve a current population of 50,000 people and that after 50 years. The effluent to be treated is composed by a domestic wastewater stream and an industrial stream from a textile industry. Leeds is a city situated in the West Riding, in the middle of the United Kingdom. It is a huge manufacturing centre for clothing, with many wool industries in particular [1].

2. Population
It is known that population statistics are widely used to shape and plan services across the cities. Hence, understanding how the population is growing and changing is critical for the effective planning of a Wastewater Treatment Plant. Analyses were made through the results of the Census conducted in Leeds and showed that the population has increased by 5.1% from 2001 to 2011 [2]. This rate was used in the calculation of population projections, thus considering that in every ten years the population would increase by 5,1%, in 50 years it would grow by (5,1%)5. The results are shown below:

70000 65000

Population Projections

Population

60000 55000 50000 45000 2013 2023 2033 2043 2053 2063

Year

Figure 1: Population Projections

By the end of 2063, the population would be 64119 but in order to make the calculations easier, it was assumed a value of 65000 citizens for this year.

3. Flow rates Calculations

It is known that in the UK the current volume of water consumption is around 150 L/capita.day [3]. Using this value it was possible to calculate the flow rate, in litters per day, defined by:

(Equation 1) Where Q = flow rate (L/day); V = volume (L/capita.day); P = population. The value was obtained in L/day. In order to obtain the flow rate in litters per hour, it was divided by 24. So, the flow rate was found in litters per hour. With this value and the concentration of each component of the wastewater it was possible to calculate the flow rate of all of it. (Equation 2) Where Q= flow rate of each component (kg/h); C = concentration of each component (kg/L); In order to determinate the quantity of water present in the effluent, the difference between the total flow rate and the sum of all components flow rates would be the amount of water input. All of these calculations were used for the design of both, the domestic and industrial wastewater plant.

4. Domestic Wastewater 4.1.Domestic Wastewater Characterization

Initially, the flow rate found for domestic wastewater was 406250 L/h. Using this value and the Equation 2, the values below were found.

Table 1: Components Information

Component
Dsticwaste A_VSS I_VSS N_VSS NonBio_SS NonBio_TDS NO2_NO3 Ammonia Carbon dioxide

Concentration (mg/L)
250 70 35 6.2 78 250 2.5 19 30

Flow rate (kg/h)

101.5625 28.4375 14.21875 2.51875 31.6875 101.5625 1.015625 7.71875 12.1875

The flow rate of the water was obtained as described before and it was found to be 388103 kg/L. At this point, it was necessary to characterize each constituent for use the SuperPro Designer software. All the components properties were provided in the coursework paper task.
Table 2: Components Environmental Properties
Property\Component COD (g O2/g) ThOD (g O2/g) BODu/COD (g/g) BOD5/BODu (g/g) TOC (g C /g) TP (g P /g) TKN (g N /g) NH3-N (g N /g) NO3-N (g N /g) Kmaxo (mg substr/g biomass.h) Ks (mg/L) CaCO3 (g/g) TS (g solids/g) TSS/TS (g/g) VSS/TSS (g/g) DVSS/VSS (g/g) VDS/TDS (g/g) DVDS/VDS (g/g) Dsticwaste 1.80 1.80 1.00 0.68 0.60 0.00 0.07 0.00 0.00 76 0.4170 0.00 0.00 0.00 0.00 0.00 0.00 0.00 A_VSS biomass 1.36 1.36 0.85 0.68 0.50 0.05 0.12 0.00 0.00 0.00 0.00 0.00 1.00 1.00 0.90 0.80 0.00 0.00 I_VSS biomass 1.45 1.45 0.83 0.68 0.50 0.05 0.12 0.00 0.00 0.00 0.00 0.00 1.00 1.00 0.90 0.80 0.00 0.00 N_VSS biomass 1.38 1.38 0.80 0.68 0.50 0.05 0.12 0.00 0.00 0.00 0.00 0.00 1.00 1.00 0.90 0.80 0.00 0.00 NonBio_SS 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.00 1.00 0.00 0.00 0.00 0.00 NonBio_TDS 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.00 0.00 0.00 0.00 0.00 0.00 NO2_NO3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.23 0.00 0.00 0.00 1.00 0.00 0.00 0.00 0.00 0.00

In the interest of achieving the UK wastewater discharge standards the following unit operations were chosen to constitute the process.

4.2. Designed Plant and Flow sheet

The flow sheet of the domestic wastewater treatment plant is presented in. The units specifications, dimensions and input and output streams are described in the sub items as follow.

Figure 2 : Domestic WWT Plant Flowsheet

4.2.1. Aerobic BioOxidation reactor

It was needed to operate with two aeration biooxidation reactors in parallel. These bioreactors were used in order to digest the domestic waste, transforming the organic matter and other compounds in a well-mixed basin under aerobic conditions. In favour of the use of this process its necessary to define the reactions that will occur in the reactor. Besides that, the kinetic constant and the stoichiometry also had to be predetermined. The reactions are described below.

4.2.1.1. Substrate (Dsticwaste) degradation

Dsticwaste NH 3 O A _ VSS H 2 2 O CO 2
1g 0.1g 1.4 g 0.8 g 0.8 g 0.9 g

k = 2.4 mg BOD5/(mg vss.d). The above rate constant is assumed to apply for T = 20 oC. The impact of temperature variations is accounted for by assuming a theta value of 1.08. Ks = 8.1 mg BOD5/L It was necessary to convert the kinetic constants from milligrams of BOD5 per litter to milligrams of domestic waste (Dsticwaste) per litter. To accomplish this step the information in Table 2 were used.

4.2.1.2. Nitrification
NH 3 O2 CO2 N _ VSS H 2O NO 2 _ NO3 7.5 g
24.6 g 1.8 g 1.0 g 7.7 g 25.2 g

k = 0.95 mg NH3-N/(mg N_VSS.d) The above rate constant is assumed to apply for T = 20 oC. The impact of temperature variations is accounted for by assuming a theta value of 1.023. Ks = 1.5 mg NH3/L

4.2.1.3. Biomass decay

Reaction 1: A _ VSS O I _ VSS NonBio _ SS H NH 3 CO 2 2O 2 0.1g
1.05 g 1.15 g 0.2 g 0.1g 0.35 g 1.45 g

Reaction 2: N _ VSS O I _ VSS NonBio _ SS H NH 3 CO 2 2O 2 0.1g

1.05 g 1.15 g 0.2 g 0.1 g 0.35 g 1.45 g

kd = 0.00325 1/h

The above rate constant is assumed to apply for T = 20 oC. The impact of temperature variations is accounted by assuming a theta value of 1.089. Both reactors have the same dimensions. The tank depth was 3.50 m, the length of the tank was 56.07, and width was 22.43 m. The Hydraulic Residence Time of determined as 18 h, and the dissolved oxygen was 2 mg/L, for one and the other. On the first reactor there are four streams the S-126 is the one that feeds the reactor. The S-108 is the input of air into the unit process. Those are the input streams. The output streams are the S-104, which is the nitrogen emission stream, and the S-127 that is the stream that carries on the effluent further to complete the treatment (main branch). The second reactor follows the same standard of the first one. Although the feed input is the S-125, the air input is the S-119. The nitrogen emission output is the S-124 and the last one is the S-128. In both reactors all the reactions above happened with the extend achieved present in the table below:

Table 3: Reactions efficiency Reaction

Biomass Decay 1 Biomass Decay 2 Nitrification Dsticwaste Degradation

Extend Achieved
100% 7% 100% 100%

4.2.2. Clarifier
This unit operation was used to remove solid particulates from liquids. The outputs are clarified water and sludge. It was use two clarifier, one before the aerobic BioOxidation reactor and another after the reactor. The first one has the following dimensions, a surface area of 306.24 m2, a tank depth of 3.00 m, the tank diameter is 19.75, and a volume of 918,711.48 L. This clarifier removed 10% of A_VSS biomass, I_VSS biomass, N_VSS biomass and had a removal efficiency of 70% of NonBio SS. The particles in sludge were 10 g/L. The stream Input feed this unit and there are three output streams accomplishing it. The stream S -102 is the output for emissions but for this unit none of the components were chosen to be emitted. The S-101 is the main line and the S-106is the sludge stream. Beyond the point of the second clarifier the influent was divided in two parts, one was directed to recycling while the other was sent to a granular media filter. The surface area of the second clarifier is 372 m2, the tank depth is 3.00 m and the tank diameter is 21.79m. The volume of tank is 1,118,984.57 L. The A_VSS biomass, I_VSS biomass, N_VSS biomass and NonBio SS had 90% of removal efficiency. Additionally, the particles in sludge were 10 g/L. The input of this unit is the stream S-103 and the outputs are the S-110 which represents an emission that follows the same as S-102, the S-112 that is the main line and the Sludge stream.

4.2.3. Granular media filter

Granular media filter removes additional suspended solids and oils. It is also a polishing step that lowers the levels of suspended solids and associated contaminants in treated wastes. The removal of particles takes place either on the

surface of the media (cake filtration) or throughout the depth of the media (depth filtration). In the granular media filtration process, particles typically adsorb or attach to the grains of sand or anthracite in the filter [4].The bed depth is 2.13 m and the bed diameter is 1.50 m. As the volume that we are working with is huge, it would be needed six units of granular media filters with the dimensions mentioned above. The A_VSS biomass, N_VSS biomass and NonBio SS had 90% of removal effectiveness. There are two input streams which are the S-112 carrying the feed and the S-116 that adds water to the process. The S-105 is the backwash flow that contains A_VSS biomass, N_VSS biomass and NonBio SS, and the other stream is the output of the domestic WWTP.

4.2.4. Flow Splitting

A procedure was used to split two bulk flow streams. It was used two flows splitting. The first one was used to split the stream S-115, which comes out of the first clarifier, into the streams S-125 and the S-126. Those two streams are the ones who feed both reactors. The S-115 was split in half. The second flow splitting was used to separate the sludge stream that comes out of the second clarifier into the S-114 and the sludge recycle stream. The flow was split in 25% to the top stream and the remaining to the down stream. The top stream, which is the sludge recycle one, feed a mixer that sends this flow to the aerobic biooxidation reactor. The S-114 stream was also linked to a mixer that later on would feed the Belt filtration process.

4.2.5. Belt Filter

A Belt Filter Press is a sludge dewatering device that applies mechanical pressure to a chemically conditioned slurry, which is sandwiched between two tensioned belts, by passing it through a serpentine of decreasing diameter rolls. The material balances are based on the removal percentage of particulate components and the solids content of the cake. The belt width is 0.49 m. The A_VSS biomass, I_VSS biomass, N_VSS biomass and NonBio SS had 90% of removal efficiency. The specific sludge rate was 300 (kg/h)/m and the solids recovery were 90%. Also, the solids presents in the cake were 15 wt/wt cake. The sludge treatment line is the feed stream of influent and the S-111 is the input of water. There are two output streams: the S-113 which takes the filtrate to the biooxidation reactor and the S 120 which carries the sludge to the sludge drying.

4.2.6. Sludge Drying

Sludge drying procedures are based on contact, convection or radiation processes. Large amounts of air are not necessary during the contact drying, because the warmth is supplied by the contact between the damp product and a heated wall. Only a minimum gas flow is often planned for the evacuation of steam [5].The evaporative capacity of the sludge drying is 531.92 kg/h. The solids present in dried sludge were 35%. The input of sludge is the S-120, while the S-121is the air input. The S-122 is the output for nitrogen, I_VSS biomass and oxygen whilst the other output stream is the dried sludge.

4.2.7. Mixing unit

The mixing unit precedes the biological treatment aiming to mix the four streams, which constitute the total stream entering the biological treatment units. The mixing unit mixes the wastewater from the domestic process itself, the sludge recycling stream, the waste stream from the Belt Filtration unit and the waste stream from the Granular Medium Filtration unit. The waste streams are added in intention to reduce the liquid waste from the WWT plant. The second mixing unit was used before the clarifier with the purposes to gather the streams, S-127 and S-128, which were getting out of both aerobic biooxidation reactor. The third mixer preceded the belt filtration with the intention to converge the streams S-106 and S-114 into the sludge treatment line.

5. Industrial Wastewater Treatment 5.1. Industrial Wastewater Characterization

The industrial wastewater comes from a textile industry and the characteristics of the stream were determined with data from the literature, which will be presented ahead. The flow rate found for the sewage of a textile industry that processes 1000 meters of textile fabric was 342700 L/h [6]. The characteristics of the industrial influent are given on Table 4.

Table 4: Components information Component

Glucose NO2_NO3 Ammonia Phenol Carbon dioxide Heavy Metals

Concentration (mg/L)
806 2.4 1.18 0.285 376 12.91

Flow rate (kg/h)

276.216 0.822 0.404 0.098 128.855 4.424

The COD and alkalinity data were taken from the average on the six textile industries analysed by Paul et al. (2013). The COD average is 859.2 mg/L. Hence, considering that 1g of glucose gives 1.066 g of COD, we could find the concentration of glucose in the stream. The alkalinity average is 376 mg/L, which represents carbon dioxide in its dissolved forms. The value of 0.285 mg/L was selected for phenol as an average of the data from the mixed points of the textile effluent according to Nosheen et al. (2000). From Khan et al. (2006) we have the parameters for nitrate and ammonia as an average of the wastewater parameters for different industries. The component Heavy Metals was determined as a sum of concentration of the metals (Cd, Cr, Cu,

Fe, N, Mn and Zn) analysed by Imtiazuddin et al. (2012). The contribution of each metal is presented in Table 5.
Table 5: Heavy Metals Concentration Metals
Cd Cr Cu Fe Ni Mn Zn Total Heavy Metals

Average Composition (mg/L)

0.07 1.39 2.72 1.96 0.99 1.27 4.51 12.91

5.2.Designed Plant and Flow sheet

The flow sheet of the industrial wastewater treatment plant is presented in. The units specifications, dimensions and input and output streams are described in the sub items as follow.

Figure 3: Industrial WWT Plant flowsheet

5.2.1. Mixing Unit

The mixing unit has the same function as described in 3.1 but it mixes other four streams, the input, the sludge recycling, S-117and S-105. The S-117 stream is the backwash flow from the granular medium filter and the S-105 stream is the waste flow from the belt filter. The output stream of this unit is the S-102 stream.

5.2.2. Aerobic BioOxidation reactors

The bioreactors were used in order to digest the organic content of the industrial waste under aerobic conditions and to remove heavy metals by sorption to the biomass produced, which will be removed in the clarifier. The reactions occurring in this unit and their kinetic constants and stoichiometry are described below in sections 4.2.2.1 to 4.2.2.3. Two aerobic bio oxidation reactors in series were required to produce water in accordance to United Kingdom standards for wastewater discharge. Both aeration basins have a total volume of 2,099,980.92 litres. The reactors have a rectangular configuration, with length of 38.73 m and width of 15.49 m, and depth of 3.5 meters. The hydraulic detention time is 6 hours, with a dissolved oxygen concentration of 2 g/L. The reactors work with a surface aeration system. For the design, 90 % of the heavy metals are removed by sorption to the biomass. The first aeration tank receives the S-102 stream and an air stream to supply oxygen for the aerobic reactions (S-113). This reactor emission is represented as the S-103 stream, which is composed of carbon dioxide. The S-104 stream continues to treatment entering the second reactor. The second reactor also has an input air stream (S-120) to provide oxygen. The gas emission of this reactor is also composed of carbon dioxide and is represented by S-108 stream. The output stream of the reactor (S-106) goes to the clarifier to solids sedimentation. The extend achieved for each reactions is presented in table 6.
Table 6: Reactions extend achieved Reaction
Glucose Degradation Phenol Degradation Biomass decay

Aeration Basin 1
86.193% 99.057% 59.702%

Aeration Basin 2
100% 0.00% 19.870%

5.2.2.1. Glucose degradation

Glu cos e A _ VSS H 2 O CO 2
1g 0.4 g 0.3 g 0.3 g

k = 0.08 1/h. The above rate constant is assumed to apply for T = 20 oC. The impact of temperature variations is accounted by assuming a theta value of 1.04. Ks = 5 mg glucose/L.

5.2.2.2. Phenol degradation

Phenol A _ VSS H 2 O CO 2
1.0 g 0.3 g 0.4 g 0.3 g

k = 0.097 1/h. The above rate constant is assumed to apply for T = 20 oC. The impact of temperature variations is accounted by assuming a theta value of 1.0. Ks = 7.462 mg Phenol/L

5.2.2.3. Biomass decay

A _ VSS O I _ VSS NonBio _ SS H NH 3 CO 2 2O 2 0.1g
1.05 g 1.15 g 0.2 g 0.1g 0.35 g 1.45 g

kd = 0.00325416 1/h. The above rate constant is assumed to apply for T = 20 oC. The impact of temperature variations is accounted by assuming a theta value of 1.089.

5.2.3. Clarifier
The Clarifier in question was set with a surface area of 355.80 m2, with diameter of 21.28 meters, and a depth of 3m, resulting in a total volume of 1,218,035.15 L. In this equipment 90% of the A_VSS and 90% of NonBio SS were removed. The clarifier receives the S-106 stream from the second aeration tank. No emissions were considered in this unit. The output streams are the S-121 that continues to the treatment entering the granular media filter, and the sludge stream. The sludge stream is lead to the flow splitting unit.

5.2.4. Granular media filter

Generally used after gravity separation, Granular Media is a polishing step that lowers the levels of suspended solids and associated contaminants in treated wastes. Particle removal takes place either on the surface of the media (cake filtration) or throughout the depth of the media (depth filtration). It was used a base unit with a bed depth of 2.02 m and a bed diameter of 1.5 m. In order to achieve the total volume of wastewater that needs to be treated, 10 granular media filters were used in this step. The overall removal efficiency was 90%. The S-121 stream from the clarifier is filtered and the main product of this unit, and also of the whole process, is represented by Output stream. The S-119 stream represents the backwash water input and the S-117 is the waste from this process, which is orientated to the mixing unit at the beginning of the plant.

5.2.5. Flow Splitting

The flow splitting unit of the plant splits the sludge stream that comes from the clarifier in two streams: 25% of the sludge stream is recycled to the first aeration tank and the left amount goes to the sludge treatment line, entering the Belt Filtration unit.

5.2.6. Belt Filter

A belt filter was selected to provide increase in solids concentration of the sludge with a low area requirement. The belt width is 0.34 m. The belt filter works with 90% of sludge recovery and 15% of solids in cake. The unit works with 90% of removal of A_VSS biomass, I_VSS biomass and NonBio SS. The unit receives the sludge treatment line and a water stream (S-112). The S-105 stream is the waste stream of the unit process and is redirected to the mixing unit. The S-111 stream goes to the sludge drier with a higher solids concentration then before.

5.2.7. Sludge Drying

The sludge drying process consists in a reduction of moisture through evaporation of water, using energy to reach the evaporation rate desired. In this case, the evaporative capacity used was 337.86 kg/h, reaching 35% of solids in dried sludge. The S-111 stream enters the unit and is concentrated, resulting in the dried sludge stream. The S-114 stream is the air to the process and the S-116 stream is composed of the air and water evaporated in the process.

6. Economic Evaluation 6.1. Domestic Wastewater Treatment Plant

Analysing the data given and, adding to it, the knowledge obtained through research, the simulations were performed in SuperPro Designer and an Economic Report was generated. In an executive summary, the Total Capital Investment obtained was 101,178,000 $, with an Operating Cost of in 21,020,00 $/yr. As part of an initial investment analysis, the Costs of Units were taken into account and the results obtained are shown as in Table 7.
Table 7: Equipment Costs Quantity
1 1 6 1 1 1 1

Name
Aeration Basin [1] Clarifier [1] Granular Media Filter Belt Filter Sludge Dryer Clarifier [2] Aeration Basin [2]

Unit Cost ($)

4,944,000 333,000 500,000 244,000 31,000 296,000 4,944,000

Total Cost ($)

4,944,000 333,000 3,000,000 244,000 31,000 296,000 4,944,000

The sum of all costs with the units results in a total cost of 13,792,000 $ for the plant. Along the Economic Evaluation a Fixed Capital Estimate Summary is made, based on the data of the software used, resulting in Table 8:
Table 8: Fixed capital estimate summary Total Plant Direct Cost (TPDC) (physical cost)
Equipment Purchase Cost Installation Process Piping Instrumentation Insulation Electrical Buildings Yard Improvement Auxiliary Facilities TPDC 17,240,000 2,587,000 6,034,000 6,896,000 517,000 1,724,000 7,758,000 2,586,000 6,896,000 52,239,000

Total Plant Indirect Cost (TPIC)

Engineering Construction TPIC 13,060,000 18,283,000 31,343,000

Total Plant Cost (TPC = TPDC+TPIC)

TPC 83,582,000

Contractor's Fee & Contingency (CFC)

Contractor's Fee Contingency CFC 4,179,000 8,358,000 12,537,000

Direct Fixed Capital Cost (DFC = TPC+CFC)

DFC 96,119,000

As a following step, the Labor Cost Analysis was made based on the selected labour type, such as Dryer Operator, and the rates of Unit Cost ($/h) combined with the total of hours of usage. These calculations resulted in a total annual cost of 2,709,275 $, with an annual amount of hours of 38,469 h. Similarly to the Labor Cost Analysis, an Utilities Cost Evaluation is made taking into account Std Power and Steam and its Unit Costs combined with the Annual Amount, resulting in a total cost of 50,668 $. As a final step in the Economic Evaluation, an Annual Operating Cost is made compiling all the costs in the plant. Summing the costs from the plant, a Total Annual Operating Cost obtained is equal to 21,020,000 $.

6.2. Industrial Wastewater Treatment Plant

Following the same steps as did with the Domestic Wastewater, an Economic Evaluation of the Industrial Wastewater Plant is performed using the data from the simulations in SuperPro Designer. The Executive Summary generated for this plant gives a Total Investment Cost of 86,041,000 $. Besides that, an Operating Cost rate is calculated, resulting in 18,158,000 $/yr. As did before in the previous Economic Evaluation, the equipment costs were used to give an overall cost for the major units. The results can be seen as in Table 9:
Table 9: Equipment Costs Quantity
1 10 1 1 1 1

Name
Clarifier Granular Media Filter Belt Filter Sludge Dryer Aeration Basin [1] Aeration Basin [2]

Unit Cost ($)

324,000 485,000 244,000 31,000 3,079,000 3,079,000

Total Cost ($)

324,000 4,850,000 244,000 31,000 3,079,000 3,079,000

The sum of the costs of all units results in a total equipment value of 11,607,000 $. As a part of consummating the evaluation, a fixed capital summary is made and the values obtained are shown as in Table 10:

Table 10: Fixed capital estimate summary Total Plant Direct Cost (TPDC) (physical cost)
Equipment Purchase Cost Installation Process Piping Instrumentation Insulation Electrical Buildings Yard Improvement Auxiliary Facilities TPDC 14,509,000 2,623,000 5,078,000 5,804,000 435,000 1,451,000 6,529,000 2,176,000 5,804,000 44,408,000

Total Plant Indirect Cost (TPIC)

Engineering Construction TPIC 11,102,000 15,543,000 26,645,000

Total Plant Cost (TPC = TPDC+TPIC)

TPC 71,053,000

Contractor's Fee & Contingency (CFC)

Contractor's Fee Contingency CFC 3,553,000 7,105,000 10,658,000

Direct Fixed Capital Cost (DFC = TPC+CFC)

DFC 81,711,000

Moving forward in the process of doing an Economic Evaluation, a Labor Cost Summary is made using the same labor types as did before and the results obtained culminated in a Total Annual Cost of 2,631,206 $, with an annual amount of hours of 37,337h. Following the same steps as in the previous evaluation, the Utilities Cost Evaluation uses again the Std Power and the Steam to obtain a total cost of 50,668 $. Finally, in order to accomplish a complete Economic Evaluation, a Total Annual Operating Cost is obtained, resulting in 18,158,000 $.

7. Environmental Impact Analysis 7.1. Domestic WWT Plant Analysis

The environmental properties of the input and output of the domestic wastewater treatment plant and the removal efficiency of the parameters are shown in Table 11.
Table 11: Environmental Parameters Parameter
TOC (mgC/l) COD (mgO/l) ThOD (mgO/l) BODu (mgO/l) BOD5 (mgO/l) TKN (mgN/l) NH3 (mgN/l) NO3/NO2 (mgN/l) TP (mgP/l) TS (mgSlds/l) TSS (mgSlds/l) VSS (mgSlds/l) DVSS (mgSlds/l) TDS (mgSlds/l) VDS (mgSlds/l) DVDS (mgSlds/l)

Domestic Input (kg/h)

204.56 601.447 601.447 576.953 392.328 30.688 0 0.572 5.532 439.465 188.243 99.574 79.659 251.222 0 0

Domestic Output (kg/h)

10.334 29.151 29.151 24.591 16.722 2.44 0 8.086 1.001 279.997 21.311 18.019 14.415 258.686 0 0

Removal Efficiency
95% 95% 95% 96% 96% 92% 0 -1314% 82% 36% 89% 82% 82% -3% 0 0

It can be seen in the table above that the domestic wastewater plant had a satisfying removal efficiency of COD and BOD5 as expected, once that the high organic matter removal is a characteristic of the activated sludge process. Although, the removal efficiency of NO3/NO2 was negative but this was expected once that these components are formed in the nitrification reaction (3.1.2.). Besides, the TDS rate was negative, which can be related to the increase of NO3/NO2.

7.2. Industrial WWT Plant Analysis

The environmental properties of the input and output of the domestic wastewater treatment plant and the removal efficiency of the parameters are shown in Table 12.

Table 12: Environmental Parameters

Parameter TOC (mgC/l) COD (mgO/l) ThOD (mgO/l) BODu (mgO/l) BOD5 (mgO/l) TKN (mgN/l) NH3 (mgN/l) NO3/NO2 (mgN/l) TP (mgP/l) TS (mgSlds/l) TSS (mgSlds/l) VSS (mgSlds/l) DVSS (mgSlds/l) TDS (mgSlds/l) VDS (mgSlds/l) DVDS (mgSlds/l) Industrial Input (kg/h) 321.3 856.36 856.07 626.361 563.725 0 0 0.55 0 805.096 0 0 0 805.096 802.706 802.706 Industrial Output (kg/h) 8.391 23.456 23.276 19.393 13.188 1.981 0 0.436 0.826 18.609 16.712 14.86 11.888 1.897 0 0 Removal Efficiency 97% 97% 97% 97% 98% -100% 0 21% -100% 98% -100% -100% -100% 100% 100% 100%

As observed, the plant had shown high removal rates of organic matter as expected and these values were slightly higher than the domestic WWT plant since the activator sludge reactors were set in series. The values obtained for TKN, TP, TSS, VSS and DVSS were -100% due to the fact that these parameters were only produced during the process.

7.3. Final Effluent Characteristics

The output of both plants is going to be mixed before discharge in the environment. The final effluent characteristics are defined in Table 13.

Table 13: Final Effluent Environmental Parameters

Final Effluent (kg/h) 9.381 26.358 26.269 22.042 14.989 2.215 0.000 4.334 0.915 151.794 19.055 16.470 13.176 132.739 0.000 0.000

Parameter TOC (mgC/l) COD (mgO/l) ThOD (mgO/l) BODu (mgO/l) BOD5 (mgO/l) TKN (mgN/l) NH3 (mgN/l) NO3/NO2 (mgN/l) TP (mgP/l) TS (mgSlds/l) TSS (mgSlds/l) VSS (mgSlds/l) DVSS (mgSlds/l) TDS (mgSlds/l) VDS (mgSlds/l) DVDS (mgSlds/l)

The final effluent is in accordance to the United Kingdom standards for wastewater discharge, which are 20mg/L of BOD5 and 30mg/L of TSS. Additionally, the nutrients concentrations also met the standards for sensitive areas (P: 1-2 mg/L and N: 10-15 mg/L) [11, 12].

8. Alternatives for Sludge Disposal

After passing through the Dryer, the sludge in the end of the process could have different destinations, such as Landfill, Composting Plant or even Blending. In case the option chosen as final destination is landfill, the sludge would be transported in special trucks to the landfills and in there the sludge would be correctly disposed in areas with the proper equipment to receive and storage it. As a second option, the sludge could be transported from the Wastewater Plant to a Composting Plant. Once it reaches the destination, the sludge would be properly treated and its nutrient levels would be enhanced in order to be used in different agricultural areas, such as farms and plantations, working as a fertilizer. One new alternative that is becoming more frequent in many different countries is the process of blending the sludge. This process involves mixing industrial waste including sludge - with diverse physical characteristics, turning them into a homogeneous product for energy use in the cement industry. The process reduces the volume of waste for final disposal and extends their life cycle, allowing their return to productive sector. In countries like Brazil this practice is becoming very popular.

9. Conclusion
The objective of the coursework was accomplished, once that the wastewater was properly treated and the final effluent reached the UK standards required in legislation. The SuperPro Designer package had a really important role on generating the environmental and economic reports, which aided achieving accurate results. Besides that, the software also has a large amount of data available and a friendly interface simplifying the assembly of the project and its units. As shown before, the volume of influent reaching the plant was large. Consequently, the size of the unit processes was relatively sizable which leaded to high costs associated to assembly and operating of both of the WWTP. Finally, the project shown itself feasible considering all the parameters analysed during the design of the plant.

10.

References

[1] West Wind Yorkshire Teasroom (2010) Leeds From Industrial Centre to Call Centre I. Available at: http://www.westwindsinyorkshire.co.uk/attachments/LeedsI.pdf (Accessed at 2 November 2013). [2] Leeds Population (no date). http://www.leeds.gov.uk/council/Pages/Leeds-population.aspxx November 2013). Available at: (Accessed at 3

[3] Downing, T.E, Butterfield, R.E., Edmonds, B., Knox, J.W., Moss, S., Piper, B.S. and Weatherhead, E.K.(and the CCDeW project team) (2003). Climate Change and the Demand for Water, Research Report, Stockholm Environment Institute Oxford Office, Oxford. Available at: http://cfpm.org/ccdew/Climate_Change_and_Demand_for_Water2003.pdf (Accessed at 3 November 2013). [4] Granular Media Filter (no date). Available at: http://www.mcilvainecompany.com/brochures/liqfil%20brochure/liqfil%20charts/gran %20media%20filters.htm (Accessed at 13 November 2013). [5] Lenntech Water Treatment Solution (no date). Available http://www.lenntech.com.pt/biblioteca/lamas/sludge-drying.htm#ixzz2mGZbIZuS (Accessed at 15 November 2013). at:

[6] BELTRAME, L. T. C. Caracterizao de Efluente Txtil e Proposta de Tratamento (Characterization of Textile Industry Effluent and Treatment Proposal). 2000. 179p. Masters Thesis (Chemical Engineering). Chemical Engineering Pos-Graduated Program, Federal University of Rio Grande do Norte, Natal/RN, Brazil. 2000. [7] PAUL, S. A.; CHAVAN, S. K. and KHAMBE, S. D. (2012) Studies on Characterization of Textile Industrial Waste Water in Solapur City, International Journal of Chemical Science, 10(2), pp 635-642.

[8] NOSHEE, S.;NAWAZ, H. and KHALIL-UR-REHMAN. (2000). Physico-Chemical Characterization of Effluents of Local Textile Industries of FaisalabadPakistan, International Journal of Agriculture & Biology, Vol. 2, No 3, pp 232-233. [9] Khan, M. S., Knapp, J., Clemett, A., and Chadwick, M. (2006). "Improving Effluent Treatment and Management." Report, Key Document, R8161 - Section7, Research for Development, Department for International Development (DFID), UK. [10] Imtiazuddin, S.M.; Mumtaz, M. and Mallick, K. A. (2012). Pollutants of Wastewater Characteristics in Textile Industries, Journal of Basic and Applied Science, 8, pp 554-556. [11] Environmental and Heritage Service. (2001). Regulation of Water Service Discharge. Available at: http://www.doeni.gov.uk/niea/reg_wsd.pdf (Accessed at 22 November 2013). [12] Council (91/271/EEC) 30 of May 1991, Council Directive concerning urban wastewater treatment [1991]. No L 135/40.

Appendix A Units Mass Balances and Streams Composition

1. Domestic Wastewater Treatment Plant

Clarification P-6 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) Input 28.438 7.719 12.188 101.563 14.219 2.519 0.000 1.016 31.688 101.563 0.000 388103.732 388404.641 408316.213 S-101 25.594 7.719 12.188 100.875 12.797 2.267 0.000 1.009 9.506 100.875 0.000 385476.077 385748.905 405646.338 Output S-102 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 S-106 2.844 0.000 0.000 0.688 1.422 0.252 0.000 0.007 22.181 0.688 0.000 2627.655 2655.736 2669.875

Mixing P-4 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) S-101 25.594 7.719 12.188 100.875 12.797 2.267 0.000 1.009 9.506 100.875 0.000 385476.077 385748.905 405646.338 S-105 37.189 0.000 0.000 0.000 0.000 1.019 0.000 0.000 5.280 0.000 0.000 217.440 260.928 262.317 Sludge Recycle 278.916 0.000 0.000 0.021 32.294 7.643 0.000 1.317 39.601 9.172 0.000 35286.575 35655.538 35845.364 S-113 9.582 0.000 0.000 0.664 1.219 0.280 0.000 0.426 3.538 3.579 0.000 16068.015 16087.302 16172.949 Output S-115 351.280 7.719 12.188 101.560 46.310 11.208 0.000 2.752 57.925 113.625 0.000 437048.106 437752.673 457926.967

Flow Splitting P-10 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) S-115 351.280 7.719 12.188 101.560 46.310 11.208 0.000 2.752 57.925 113.625 0.000 437048.106 437752.673 457926.967 S-125 175.640 3.859 6.094 50.780 23.155 5.604 0.000 1.376 28.963 56.813 0.000 218524.053 218876.336 228963.484 Output S-126 175.640 3.859 6.094 50.780 23.155 5.604 0.000 1.376 28.963 56.813 0.000 218524.053 218876.336 228963.484

Aerobic BioOxidation P-1 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) S-125 175.640 3.859 6.094 50.780 23.155 5.604 0.000 1.376 28.963 56.813 0.000 218524.053 218876.336 228963.484 S-119 0.000 0.000 0.000 0.000 0.000 0.000 76.712 0.000 0.000 0.000 23.288 0.000 100.000 84801.702 S-128 199.448 0.000 41.489 0.102 23.817 5.205 1.117 1.472 29.293 56.810 0.000 218541.993 218900.745 244062.539 Output S-124 0.000 0.000 0.000 0.000 0.000 0.000 75.592 0.000 0.000 0.000 0.000 0.000 75.592 66018.017

Aerobic BioOxidation P-2 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) S-126 175.640 3.859 6.094 50.780 23.155 5.604 0.000 1.376 28.963 56.813 0.000 218524.053 218876.336 228963.484 S-108 0.000 0.000 0.000 0.000 0.000 0.000 76.712 0.000 0.000 0.000 23.288 0.000 100.000 84801.702 S-104 0.000 0.000 0.000 0.000 0.000 0.000 75.592 0.000 0.000 0.000 0.000 0.000 75.592 66018.017 Output S-127 199.448 0.000 41.489 0.102 23.817 5.205 1.117 1.472 29.293 56.810 0.000 218541.993 218900.745 244062.539

Mixing P-11 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) S-127 199.448 0.000 41.489 0.102 23.817 5.205 1.117 1.472 29.293 56.810 0.000 218541.993 218900.745 244062.539 S-128 199.448 0.000 41.489 0.102 23.817 5.205 1.117 1.472 29.293 56.810 0.000 218541.993 218900.745 244062.539 Output S-103 398.895 0.000 82.979 0.205 47.634 10.410 2.233 2.943 58.586 113.620 0.000 437083.985 437801.490 488125.078

Clarification P-3 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) S-103 398.895 0.000 82.979 0.205 47.634 10.410 2.233 2.943 58.586 113.620 0.000 437083.985 437801.490 488125.078 S110 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 Output S-112 41.321 0.000 99.508 0.237 4.784 1.132 2.233 14.555 5.867 101.374 0.000 390019.572 390290.582 449532.655 Sludge 371.888 0.000 0.000 0.029 43.059 10.190 0.000 1.756 52.801 12.229 0.000 47048.766 47540.718 47793.818

GM Filtration Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) S-112 41.321 0.000 99.508 0.237 4.784 1.132 2.233 14.555 5.867 101.374 0.000 390019.572 390290.582 449532.655 S-116 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 217.440 217.440 218.597 S-105 37.189 0.000 0.000 0.000 0.000 1.019 0.000 0.000 5.280 0.000 0.000 217.440 260.928 262.317 Output Output 4.132 0.000 99.508 0.237 4.784 0.113 2.233 14.555 0.587 101.374 0.000 390019.572 390247.094 449488.936

Flow Splitting P-5 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) Sludge 371.888 0.000 0.000 0.029 43.059 10.190 0.000 1.756 52.801 12.229 0.000 47048.766 47540.718 47793.818 Output Sludge S-114 Recycle 278.916 92.972 0.000 0.000 0.021 32.294 7.643 0.000 1.317 39.601 9.172 0.000 35286.575 35655.538 35845.364 0.000 0.000 0.007 10.765 2.548 0.000 0.439 13.200 3.057 0.000 11762.192 11885.179 11948.455

Mixing P-12 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) S-114 92.972 0.000 0.000 0.007 10.765 2.548 0.000 0.439 13.200 3.057 0.000 11762.192 11885.179 11948.455 S-106 2.844 0.000 0.000 0.688 1.422 0.252 0.000 0.007 22.181 0.688 0.000 2627.655 2655.736 2669.875 Output Sludge Treatment Line 95.816 0.000 0.000 0.695 12.187 2.799 0.000 0.446 35.381 3.745 0.000 14389.847 14540.916 14618.330

Belt Filtration Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) Input Sludge Treatment Line 95.816 0.000 0.000 0.695 12.187 2.799 0.000 0.446 35.381 3.745 0.000 14389.847 14540.916 14618.330 Output S-111 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 2423.486 2423.486 2436.388 S-113 9.582 0.000 0.000 0.664 1.219 0.280 0.000 0.426 3.538 3.579 0.000 16068.015 16087.302 16172.949 S-120 86.234 0.000 0.000 0.031 10.968 2.519 0.000 0.020 31.843 0.166 0.000 745.318 877.100 881.769

Sludge Drying Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide dsticwaste I_VSS biomass N_VSS biomass Nitrogen NO2_NO3 NonBio SS NonBio TDS Oxygen Water TOTAL (kg/h) TOTAL (L/h) S-120 86.234 0.000 0.000 0.031 10.968 2.519 0.000 0.020 31.843 0.166 0.000 745.318 877.100 881.769 S-121 0.000 0.000 0.000 0.000 0.000 0.000 3643.249 0.000 0.000 0.000 1106.020 0.000 4749.269 4027461.098 S-122 0.000 0.000 0.000 0.000 7.714 0.000 3643.249 0.000 0.000 0.000 1106.020 524.204 5281.187 6183622.038 Output Dried Sludge 86.234 0.000 0.000 0.031 3.254 2.519 0.000 0.020 31.843 0.166 0.000 221.114 345.182 351.528

2. Industrial Wastewater Treatment Plant

Mixing P-9 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide Glucose Heavy Metals I_VSS biomass Nitrogen NO2_NO3 NonBio SS Oxygen Phenol Water TOTAL (kg/h) TOTAL (L/h) Input 0.000 0.404 128.855 276.216 4.424 0.000 0.000 0.822 0.000 0.000 0.098 270219.100 270629.920 344106.222 S-105 9.770 0.000 0.000 0.000 0.517 0.106 0.000 0.030 0.197 0.000 0.003 11415.034 11425.656 11486.027 Sludge Recycling 293.094 0.000 0.000 0.000 13.650 3.180 0.000 0.093 5.915 0.000 0.009 10258.816 31092.387 31245.842 S-117 39.079 0.000 0.000 0.000 3.520 25.259 0.000 0.000 0.789 0.000 0.000 271656.578 411.877 410.956 Output S-102 341.943 0.404 128.855 276.216 22.111 28.544 0.000 0.945 6.901 0.000 0.109 312753.811 313559.840 387249.047

Aerobic BioOxidation P-7 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide Glucose Heavy Metals I_VSS biomass Nitrogen NO2_NO3 NonBio SS Oxygen Phenol Water TOTAL (kg/h) TOTAL (L/h) S-102 341.943 0.404 128.855 276.216 22.111 28.544 0.000 0.945 6.901 0.000 0.109 312753.811 313559.840 387249.047 S-113 0.000 0.000 0.000 0.000 0.000 0.000 76.712 0.000 0.000 23.288 0.000 0.000 100.000 84801.702 S-103 0.000 0.000 196.058 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 196.058 108988.809 Output S-104 424.512 1.613 21.784 38.137 22.111 30.962 76.712 0.945 8.110 9.385 0.001 312829.510 313463.782 403596.310

Aerobic BioOxidation P-8 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide Glucose Heavy Metals I_VSS biomass Nitrogen NO2_NO3 NonBio SS Oxygen Phenol Water TOTAL (kg/h) TOTAL (L/h) S-104 424.512 1.613 21.784 38.137 22.111 30.962 76.712 0.945 8.110 9.385 0.001 312829.510 313463.782 403596.310 S-120 0.000 0.000 0.000 0.000 0.000 0.000 76.712 0.000 0.000 23.288 0.000 0.000 100.000 84801.702 S-108 0.000 0.000 38.527 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 38.527 21417.236 Output S-106 435.692 2.178 4.281 0.000 22.111 32.091 153.421 0.945 8.674 26.181 0.088 312839.594 313525.255 474503.842

Clarification Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide Glucose Heavy Metals I_VSS biomass Nitrogen NO2_NO3 NonBio SS Oxygen Phenol Water TOTAL (kg/h) TOTAL (L/h) S-106 435.692 2.178 4.281 0.000 22.111 32.091 153.421 0.945 8.674 26.181 0.088 312839.594 313525.255 474503.842 S107 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 Output S-121 43.421 2.172 4.285 0.000 3.911 28.065 153.421 0.821 0.876 26.252 0.077 271656.578 271919.879 432740.944 Sludge 390.792 0.000 0.000 0.000 18.200 4.239 0.000 0.124 7.887 0.000 0.012 41035.262 41456.516 41661.123

GM Filtration Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide Glucose Heavy Metals I_VSS biomass Nitrogen NO2_NO3 NonBio SS Oxygen Phenol Water TOTAL (kg/h) TOTAL (L/h) S-121 43.421 2.172 4.285 0.000 3.911 28.065 153.421 0.821 0.876 26.252 0.077 271656.578 271919.879 432740.944 S-119 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 343.231 343.231 345.058 S-117 39.079 0.000 0.000 0.000 3.520 25.259 0.000 0.000 0.789 0.000 0.000 271656.578 411.877 410.956 Output Output 4.342 2.172 4.285 0.000 0.391 2.807 153.421 0.821 0.088 26.252 0.077 30776.447 271851.233 432675.046

Flow Splitting P-9 Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide Glucose Heavy Metals I_VSS biomass Nitrogen NO2_NO3 NonBio SS Oxygen Phenol Water TOTAL (kg/h) TOTAL (L/h) Sludge 390.792 0.000 0.000 0.000 18.200 4.239 0.000 0.124 7.887 0.000 0.012 41035.262 41456.516 41661.123 Sludge Recycling 293.094 0.000 0.000 0.000 13.650 3.180 0.000 0.093 5.915 0.000 0.009 10258.816 31092.387 31245.842 Output Sludge Treatment Line 97.698 0.000 0.000 0.000 4.550 1.060 0.000 0.031 1.972 0.000 0.003 0.000 10364.129 10415.281

Belt Filtration Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide Glucose Heavy Metals I_VSS biomass Nitrogen NO2_NO3 NonBio SS Oxygen Phenol Water TOTAL (kg/h) TOTAL (L/h) Sludge Treatment Line 97.698 0.000 0.000 0.000 4.550 1.060 0.000 0.031 1.972 0.000 0.003 0.000 10364.129 10415.281 S-112 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1669.934 1669.934 1678.824 S-111 87.928 0.000 0.000 0.000 4.033 0.954 0.000 0.001 1.774 0.000 0.000 513.716 608.406 608.078 Output S-105 9.770 0.000 0.000 0.000 0.517 0.106 0.000 0.030 0.197 0.000 0.003 11415.034 11425.656 11486.027

Sludge Drying Input Component Flowrates (kg/h) A_VSS biomass Ammonia Carb. Dioxide Glucose Heavy Metals I_VSS biomass Nitrogen NO2_NO3 NonBio SS Oxygen Phenol Water TOTAL (kg/h) TOTAL (L/h) S-111 87.928 0.000 0.000 0.000 4.033 0.954 0.000 0.001 1.774 0.000 0.000 513.716 608.406 608.078 S-114 0.000 0.000 0.000 0.000 0.000 0.000 2314.102 0.000 0.000 702.517 0.000 0.000 3016.619 2558144.012 S-116 0.000 0.000 0.000 0.000 0.000 0.000 2314.102 0.000 0.000 702.517 0.000 337.861 3354.480 3927684.292 Output Dried Sludge 87.928 0.000 0.000 0.000 4.033 0.954 0.000 0.001 1.774 0.000 0.000 175.854 270.545 271.900

Appendix B Meetings Minutes

21/10: First group meeting, when we made the Project Plan in order to organize the tasks and next meetings. It was noticed the need of a population projection and the composition of the industrial wastewater. Everyone agreed to do some study on the scope of the project until the next meeting. 28/10: The members of the group decided to do some research about the population projection in favour of choosing a good method for the estimates to be appropriate. In addition, the characteristics of the industrial wastewater required attention once that it is crucial for precise treatment. Another meeting was scheduled for 07/11. The project plan can be seen below:

07/11: The population projection was defined and calculated which also helped with the definition of the design of the plant. The members of the group are supposed to do some research for the next days in order to find out the best way of treatment and spend some time using SuperPro software to improve their abilities on it. 12/11: Meeting arranged for discussion about design of the Wastewater Treatment Plant considering the wastewater composition. All the members had a discussion about the domestic plant and started the design of it. 14/11: The group worked on the design of the domestic WWT plant, considering all the information collected before. 18/11: Start of the design on the industrial WWT plant. 22/11: The design of both plants was finished, and the flow sheets were properly organized to facilitate viewing. 23/11: The group began to write the report, explaining all the calculations and information used on it. 27/11: Meeting arranged for final adjustments in the report, formatting and revisions. 28/11: The group started to prepare the presentation, discussing the main issues to be addressed and the best way to do it, in order to meet the time set by the lecturer. 30/11: The presentation was finished and final revision was made to correct possible mistakes or inaccuracies and to ensure appropriate content of the project.