Physical Water and Wastewater Treatment Processes 9-73
Sludge Collectors/Conveyors
There are a variety of patented sludge collection systems offered for sale by several manufacturers. The
two general kinds of sludge removal devices are “flights” or “squeegees” and “suction manifolds.”
The first consists of a series of boards, called “flights” or “squeegees,” that extend across the width of
the tank. The boards may be constructed of water-resistant woods, corrosion-resistant metals, or engi-
neering plastics. In traditional designs, the flights are attached to continuous chain loops, which are
mounted on sprockets and moved by a drive mechanism. The flights, chains, and sprockets are submerged.
The drive mechanism is placed at ground level and connected to the sprocket/chain system by some sort
of transmission. In addition to the primary flight system, which moves sludge to one end of the tank,
there may be a secondary flight system, which moves the sludge collected at the tank end to one or more
hoppers.
In some newer designs, the flights are suspended from a traveling bridge, which moves along tracks
set at ground level along either side of the clarifier. Bridge-driven flights cannot be used with high-rate
settlers, because the flight suspension system interferes with the tube modules. Bridge systems also require
careful design to assure compatibility with effluent launders. If finger launders extending the whole length
of the settling zone are used, bridge systems may not be feasible.
In either system, the bottom of the tank is normally finished with a smooth layer of grout, and two
or more longitudinal rails are placed along the length of the tank to provide a relatively smooth bearing
surface for the flights. The tops of the rails are set slightly above the smooth grout layer. The grout surface
is normally pitched toward the sludge hopper to permit tank drainage for maintenance. The recom-
mended minimum pitch is 1/16 in./ft (0.5%) (Joint Task Force, 1969).
The flights are periodically dragged along the bottom of the tank to scrape the deposited sludge into
the sludge hoppers. The scraping may be continuous or intermittent depending on the rate of sludge
deposition. Flight speeds are generally limited to less than 1 ft/min to avoid solids resuspension (Joint
Task Force, 1969).
In some traveling bridge designs, the flights are replaced by perforated pipes, which are subjected to
a slight suction head. The pipes suck deposited solids off the tank floor and transfer them directly to the
sludge processing and disposal systems. Suction manifolds dispense with the need for sludge hoppers,
which simplifies and economizes tank construction, but they tend to produce dilute sludges, and they
may not be able to collect large, dense flocs.
TABLE 9.3 Range of Composition of Wastewater Sludges
Sludge Component Primary Sludge Waste-Activated Sludge Trickling Filter Humus
pH 5–8 6.5–8 —
Higher heating value (Btu/lb TSS) 6800–10,000 6500 —
Specific gravity of particles 1.4 1.08 1.3–1.5
Specific gravity of sludge 1.02–1.07 1 + 7 ¥ 10
–8
X 1.02
Color Black Brown Grayish brown to black
COD/VSS 1.2–1.6 1.4 —
C/N — 3.5–14.6 —
C (% by wt of TSS) — 17–44 —
N (% by wt of TSS) 1.5–4 2.4–6.7 1.5–5.0
P as P
2
O
5
(% by wt of TSS) 0.8–2.8 2.8–11 1.2–2.8
K as K
2
O (% by wt of TSS) 0.4 0.5–0.7 —
VSS (% by wt of TSS) 60–93 61–88 64–86
Grease and fat (% by wt of TSS) 7–35 5–12 —
Cellulose (% by wt of TSS) 4–15 7 —
Protein (% by wt of TSS) 20–30 32–41 —
Source: Anonymous. 1979. Process Design Manual for Sludge Treatment and Disposal, EPA 625/1–79–011.
U.S. Environmental Protection Agency, Municipal Environmental Research Laboratory, Technology Transfer,
Cincinnati, OH.