600R10100 (Nutrient Control Design Manual)

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Nutrient Control Design Manual

Office of Research and DevelopmentNational Risk Management Research Laboratory - Water Supply and Water Resources Division

EPA/600/R-10/100 | August 2010 | www.epa.gov/n


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EPA/600/R10/100August2010

NutrientControlDesignManual

by

TheCadmusGroup,Inc

57WaterStreet

Watertown,MA02472

Scientific,Technical,Research,Engineering,andModelingSupport(STREAMS)

TaskOrder68

ContractNo. EPC05058

GeorgeT.Moore,TaskOrderManager

UnitedStatesEnvironmentalProtectionAgency

OfficeofResearchandDevelopment/NationalRiskManagementResearchLaboratory

26WestMartinLutherKingDrive,MailCode445

Cincinnati,Ohio,45268


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NutrientControlDesignManual iii August2010

Foreword

TheU.S.EnvironmentalProtectionAgency(EPA)ischargedbyCongresswithprotectingtheNations

land,air,andwaterresources. Underamandateofnationalenvironmentallaws,theAgencystrivesto

formulateandimplementactionsleadingtoacompatiblebalancebetweenhumanactivitiesandthe

abilityofnaturalsystemstosupportandnurturelife.Tomeetthismandate,EPAsresearchprogramisprovidingdataandtechnicalsupportforsolvingenvironmentalproblemstodayandbuildingascience

knowledgebasenecessarytomanageourecologicalresourceswisely,understandhowpollutantsaffect

ourhealth,andpreventorreduceenvironmentalrisksinthefuture.

TheNationalRiskManagementResearchLaboratory(NRMRL)istheAgencyscenterforinvestigationof

technologicalandmanagementapproachesforpreventingandreducingrisksfrompollutionthat

threatenhumanhealthandtheenvironment. Thefocusofthelaboratorysresearchprogramison

methodsandtheircosteffectivenessforpreventionandcontrolofpollutiontoair,landwaterand

subsurfaceresources;protectionofwaterqualityinpublicwatersystems;remediationofcontaminated

sites,sedimentsandgroundwater;preventionandcontrolofindoorairpollution;andrestorationof

ecosystems. NRMRLcollaborateswithbothpublicandprivatesectorpartnerstofostertechnologies

thatreducethecostofcomplianceandtoanticipateemergingproblems. NRMRLsresearchsolutionsto

environmentalproblemsby:developingandpromotingtechnologiesthatprotectandimprovethe

environment;advancingscientificandengineeringinformationtosupportregulatoryandpolicy

decisions;andprovidingthetechnologicalsupportandinformationtransfertoinsureimplementationof

environmentalregulationsandstrategiesatthenational,state,andcommunitylevels.

ThispublicationhasbeenproducedaspartoftheLaboratorysstrategiclongtermresearchplan. Itis

publishedandmadeavailablebyEPAsOfficeofResearchandDevelopmenttoassisttheuser

communityandtolinkresearcherswiththeirclients.

SallyGutierrez,Director

NationalRiskManagementResearchLaboratory


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NutrientControlDesignManual iv August2010

Notice

ThisdocumentwaspreparedbyTheCadmusGroup,Inc.(Cadmus)underEPAContractNo.EPC05058,

TaskOrder68.TheCadmusTeamwasleadbyPatriciaHertzlerandLauraDufresnewithSeniorAdvisors

CliffordRandall,EmeritusProfessorofCivilandEnvironmentalEngineeringatVirginiaTechandDirector

oftheOccoquanWatershedMonitoringProgram;JamesBarnard,GlobalPracticeandTechnology

LeaderatBlack&Veatch;DavidStensel,ProfessorofCivilandEnvironmentalEngineeringatthe

UniversityofWashington;andJeanetteBrown,ExecutiveDirectoroftheStamfordWaterPollution

ControlAuthorityandAdjunctProfessorofEnvironmentalEngineeringatManhattanCollege.

Disclaimer

Theviewsexpressedinthisdocumentarethoseoftheindividualauthorsanddonotnecessarily,reflect

theviewsandpoliciesoftheU.S.EnvironmentalProtectionAgency(EPA). Mentionoftradenamesor

commercialproductsdoesnotconstituteendorsementorrecommendationforuse.Thisdocumenthas

beenreviewedinaccordancewithEPAspeerandadministrativereviewpoliciesandapprovedfor

publication.


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NutrientControlDesignManual v August2010

Abstract

ThepurposeofthisEPAdesignmanualistoprovideupdated,stateofthetechnologydesign

guidanceonnitrogenandphosphoruscontrolatmunicipalWastewaterTreatmentPlants(WWTPs).

SimilartopreviousEPAmanuals,thismanualcontainsextensiveinformationontheprinciplesof

biologicalnutrientremovalandchemicalphosphorusremovaltoserveasthebasisfordesign.Adetaileddescriptionoftechnologies,bothconventionalandemerging,servesasaresourceforpreliminary

technologyselection. BecausemostWWTPsintheUnitedStatesareequippedwithsecondary

treatment,thefocusofthisdesignmanualisonretrofitstoaddnutrientremovaltoexistingWWTPs

ratherthanonnewtreatmentplantdesign,althoughguidanceforgreenfielddesignispresented. Also

newfrompreviousversions,designguidancehereinisbasedontheuseofmathematicalmodelsand

simulators.Simulatorsallowdesignerstostudykinetic aswellastimebasedsolutionswhile

determiningthetotalmassbalancesofmanyconstituents.Theyhavebecomeincreasinglypowerful,

easytouse,andwidelyacceptedforthedesignofbiologicalnutrientremovalfacilities. Themanualalso

includesnewinformationonemergingissuesintheindustrysuchassustainabilityinwastewater

treatmentdesignandoperation,nutrientrecoveryandreuse,effluentdissolvedorganicnitrogen,and

measurementoflowphosphorusconcentrations.

ThisreportwassubmittedinfulfillmentofEPAContractNo.EPC05058,TaskOrder68,byThe

CadmusGroup,Inc.underthesponsorshipoftheUnitedStatesEnvironmentalProtectionAgency.This

reportcoversaperiodfromNovember2007throughApril2010andrepresentsworkcompletedasof

April2010.


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NutrientControlDesignManual vi August2010

Contents

AcronymsandAbbreviations ....................................................................................................... xviii

Acknowledgements ....................................................................................................... xxii

1. Introduction ....................................................................................................... 111.1 HistoryofNutrientRemoval.................................................................................... 11

1.2 PurposeandScopeofthisManual.......................................................................... 13

1.3 ManualOrganization............................................................................................... 15

1.4 References ....................................................................................................... 16

2. NeedforandBenefitsofNitrogenandPhosphorusRemoval............................................. 21

2.1 Introduction ....................................................................................................... 21

2.2 SourcesofNitrogenandPhosphorusinWastewater.............................................. 22

2.2.1 Nitrogen...................................................................................................... 22

2.2.2 Phosphorus................................................................................................. 23

2.3 StatusofWastewaterTreatmentintheUnitedStates........................................... 23

2.4 NutrientImpairmentofU.S.Waterways................................................................. 25

2.4.1 NorthernGulfofMexico............................................................................. 25

2.4.2 ChesapeakeBay......................................................................................... 26

2.4.3 GreatLakes................................................................................................. 26

2.4.4 LongIslandSound....................................................................................... 26

2.5 ClimateChangeImpacts.......................................................................................... 27

2.6 FederalandStateRegulationsandInitiativestoReduceNutrientPollution..........28

2.6.1 WaterQualityStandards............................................................................ 28

2.6.2 TotalMaximumDailyLoads(TMDLs)......................................................... 210

2.6.3 NPDESPermitting....................................................................................... 210

2.6.4 WaterQualityTrading................................................................................ 211

2.6.5 TechnologyEvaluationandGuidance......................................................... 212

2.7 IndustryInitiativesTheWERFNutrientRemovalChallenge................................. 213

2.8 BenefitsofNutrientRemoval.................................................................................. 214

2.8.1 ImprovedPlantPerformance...................................................................... 214

2.8.2 CoRemovalofEmergingContaminants..................................................... 214

2.8.3 NutrientRecoveryandReuse..................................................................... 215

2.9 ChallengesofNutrientRemoval.............................................................................. 215

2.9.1 EnergyRequirements.................................................................................. 215

2.9.2 ReleaseofNitrousOxide............................................................................ 217

2.10 References ....................................................................................................... 218

3.

Principles

of

Phosphorus

Removal

by

Chemical

Addition

....................................................

3

1

3.1 Introduction ....................................................................................................... 31

3.2 AvailableFormsofMetalSaltsandLime................................................................. 31

3.3 EquationsandStoichiometry................................................................................... 32

3.3.1 RemovablePhosphorus.............................................................................. 32

3.3.2 ReactionsofMetalSaltsandPhosphorus.................................................. 32

3.3.3 ReactionsofLimewithPhosphorus............................................................ 35

3.4 SolidsSeparationProcesses..................................................................................... 35


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3.5 EffectsonSludgeProductionandHandling............................................................. 36

3.6 TwoFactorsthatMayLimittheAbilityofPlantstoAchieve

VeryLowEffluentLevels.......................................................................................... 37

3.7 References ....................................................................................................... 38

4. PrinciplesofBiologicalNitrogenRemoval........................................................................... 41

4.1 Introduction ....................................................................................................... 41

4.2 NitrogenRemovalbyBiomassSynthesis................................................................. 42

4.3 MicrobiologyofNitrification.................................................................................... 43

4.4 ReactionsandStoichiometryofNitrification........................................................... 45

4.5 NitrificationKinetics................................................................................................. 46

4.5.1 AOBkinetics................................................................................................ 410

4.5.2 NOBkinetics................................................................................................ 413

4.5.3 EffectsofTemperatureandDissolvedOxygenonNitrificationKinetics....414

4.5.4 AOBandNOBKineticsatHighTemperature(SHARONprocess).............416

4.6 InhibitoryEffectsofEnvironmentalConditionsonNitrification............................. 417

4.7 DenitrificationFundamentals.................................................................................. 420

4.8 MicrobiologyofDenitrification................................................................................ 420

4.9 MetabolismandStoichiometryofHeterotrophicDenitrification........................... 421

4.10 BiologicalDenitrificationKineticswithInfluentWastewater.................................. 422

4.11 DenitrificationCarbonSourcesandRelativeConsumptionRatios.......................... 424

4.12 DenitrificationKineticsofExogenousCarbonSources............................................ 428

4.12.1 DenitrificationKineticswithMethanol....................................................... 428

4.12.2 AlternativeExogenousSubstratesandDenitrificationKinetics.................430

4.12.3 AcclimationTimeandDegradativeAbilityofDenitrifyingBacteriawith

ExogenousSubstrates................................................................................. 431

4.13 SpecificDenitrificationRates(SDNR)....................................................................... 432

4.14 SimultaneousNitrificationDenitrification............................................................... 434

4.15

Metabolism

and

Stoichiometry

and

Kinetics

of

ANAMMOX

.................................

4

35

4.16 ImpactsonSludgeProductionandHandling........................................................... 436

4.17 EffluentDissolvedOrganicNitrogen........................................................................ 436

4.18 References ....................................................................................................... 439

5. PrinciplesofBiologicalPhosphorusRemoval....................................................................... 51

5.1 OverviewoftheBiologicalPhosphorusRemovalProcess....................................... 51

5.2 SubstrateRequirements.......................................................................................... 53

5.3 SourcesofVolatileFattyAcids................................................................................. 55

5.3.1 FermentationintheCollectionSystem...................................................... 56

5.3.2 AnaerobicFermentationofPrimaryorReturnActivatedSludge...............57

5.3.3 CommercialSources................................................................................... 510

5.4 EnvironmentalConditions....................................................................................... 511

5.4.1 DissolvedOxygenandNitratesintheAnaerobicZone.............................. 511

5.4.2 OxygenintheAerobicZone........................................................................ 511

5.4.3 pH ....................................................................................................... 512

5.4.4 Temperature............................................................................................... 512

5.4.5 Cations ....................................................................................................... 513

5.5 Kinetics ....................................................................................................... 513

5.5.1 SolidsRetentionTime(SRT)........................................................................ 513


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5.5.2 HydraulicRetentionTime(HRT) ................................................................ 514

5.6 ImportantDesignandOperationalConsiderations................................................. 514

5.6.1 AvoidingSecondaryReleaseofPhosphorus............................................... 514

5.6.2 AvoidingBackmixing................................................................................... 516

5.6.3 FlowandLoadBalancing............................................................................ 517

5.7 ImpactsonSludgeProcessingandHandling........................................................... 517

5.8 References ....................................................................................................... 518

6. OverviewofNitrogenandPhosphorusRemovalTechnologies........................................... 61

6.1 Introduction ....................................................................................................... 61

6.2 NitrogenRemovalTechnologies.............................................................................. 62

6.2.1 NitrogenRemovalinSingleProcessUnit.................................................... 63

6.2.1.1ModifiedLudzackEttinger(MLE)Process..................................... 63

6.2.1.2 4StageBardenpho........................................................................ 65

6.2.1.3MLEor4StageBardephowithMembraneBioractor(MBR)........65

6.2.1.4 SequencingBatchReactor(SBR).................................................... 66

6.2.1.5 OxidationDitchwithAnoxicZone................................................. 67

6.2.1.6 StepFeedBiologicalNitrogenRemoval(BNR).............................. 68

6.2.1.7 SimultaneousNitrificationDenitrification(SNdN)........................ 69

6.2.1.8 IntegratedFixedFilmActivatedSludge(IFAS)............................... 610

6.2.1.9MovingBedBiofilmReactor(MBBR).............................................. 611

6.2.2 SeparateStageProcessesNitrification.................................................... 612

6.2.2.1 SuspendedGrowthNitrification.................................................... 612

6.2.2.2 AttachedGrowthNitrification....................................................... 612

6.2.3 SeparateStageProcessesDenitrification................................................ 613

6.2.3.1 DenitrificationFilters..................................................................... 614

6.3 PhosphorusRemovalTechnologies......................................................................... 616

6.3.1 PhosphorusRemovalbyChemicalAddition............................................... 616

6.3.2

Biological

Phosphorus

Removal

..................................................................

6

19

6.3.2.1 Phoredox(A/O)............................................................................. 620

6.3.2.2 OxidationDitchwithAnaerobicZone............................................ 621

6.4 CombinedNitrogenandPhosphorusRemovalTechnologies................................. 622

6.4.1 Biological..................................................................................................... 622

6.4.1.1 3StagePhoredox(A2/0)............................................................... 622

6.4.1.2 5StageBardenpho........................................................................ 623

6.4.1.3 UniversityofCapetown(UCT),ModifiedUCT,andVirginiaInitiative

Project(VIP)................................................................................... 624

6.4.1.4Westbank....................................................................................... 626

6.4.1.5 OxidationDitchwithAnoxicandAnaerobicZones....................... 626

6.4.1.6 SequencingBatchReactor(SBR).................................................... 627

6.4.2 HybridChemical/Biological....................................................................... 627

6.4.2.1 BluePlainsProcess........................................................................ 628

6.4.2.2 BiologicalChemicalPhosphorusandNitrogenRemoval(BCFS)

Process.......................................................................................... 628

6.5 EffluentFiltration..................................................................................................... 629

6.5.1 ConventionalDownflowFilters................................................................. 629

6.5.2 ContinuousBackwashingUpflowSandFilters(Dynasand)........................ 629

6.5.3 PulsedBedFilters........................................................................................ 630


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6.5.4 TravelingBridgeFilters............................................................................... 630

6.5.5 Discfilters.................................................................................................... 630

6.5.6 MembraneFilters....................................................................................... 631

6.6 SidestreamManagement........................................................................................ 632

6.7 TechnologyPerformance......................................................................................... 634

6.7.1 RemovalEfficienciesofBNRTechnologiesGeneralDiscussion...............636

6.7.2 TechnologyPerformanceStatisticsbasedonFullScaleOperatingData...637

6.8 FactorsinSimultaneouslyAchievingLowNitrogenandPhosphorusEffluent

Concentrations ....................................................................................................... 642

6.9 References ....................................................................................................... 643

7. EstablishingDesignObjectives.............................................................................................. 71

7.1 Introduction ....................................................................................................... 71

7.2 CharacterizingExistingTreatment........................................................................... 72

7.3 DesignFlowRates.................................................................................................... 73

7.3.1 CharacterizingExistingFlow....................................................................... 73

7.3.2 ProjectingFutureConditions...................................................................... 75

7.3.3 SettingDesignFlowRates........................................................................... 76

7.4 Wastewatercharacteristics..................................................................................... 77

7.4.1 DataCollection............................................................................................ 77

7.4.2 DataVerification......................................................................................... 710

7.5 TargetEffluentConcentrationsforTotalNitrogenandTotalPhosphorus..............715

7.6 GoalsforReliability,Sustainability,andProcessFlexibility..................................... 716

7.7 SludgeTreatmentOptions....................................................................................... 718

7.8 SiteConstraints ....................................................................................................... 718

7.9 SelectinganOverallProcessDesignFactor............................................................ 719

7.10 References ....................................................................................................... 720

8.

Selecting

Candidate

Treatment

Processes

for

Plant

Upgrades

...........................................

8

1

8.1 Introduction ....................................................................................................... 81

8.2 TechnologySelectionFactors.................................................................................. 81

8.2.1 SeasonalPermitLimits................................................................................ 81

8.2.2 Footprint..................................................................................................... 82

8.2.3 HydraulicConsiderations............................................................................ 83

8.2.4 Chemicalneeds........................................................................................... 83

8.2.5 AvailableSludgeTreatmentandOptions................................................... 83

8.2.6 EnergyConsiderations................................................................................ 84

8.2.7 StaffingandTrainingRequirements........................................................... 85

8.2.8 TechnologySelectionConsiderationsforSmallFlowSystems...................85

8.3 AdvantagesandDisadvantagesofTechnologyTypes............................................. 86

8.4 OverviewofRecommendedApproach.................................................................... 88

8.5 RecommendedUseofAdvancedTools................................................................... 811

8.6 Patentissues ....................................................................................................... 812

8.7 References ....................................................................................................... 813

9. DesignApproachforPhosphorusRemovalbyChemicalAddition ...................................... 91

9.1 Introduction ....................................................................................................... 91

9.2 SelectingaChemicalPrecipitant.............................................................................. 91


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9.2.1 AdvantagesandDisadvantagesofMetalSalts........................................... 91

9.2.2 AdvantagesandDisadvantagesofLime..................................................... 93

9.2.3 Costs ....................................................................................................... 93

9.3 SelectingPoint(s)ofApplication.............................................................................. 94

9.4 DeterminingtheChemicalDose.............................................................................. 97

9.5 DesigningaChemicalFeedSystem.......................................................................... 910

9.5.1 Liquidfeedsystems.................................................................................... 911

9.5.1.1 Storagetanks................................................................................. 911

9.5.1.2 FeedMethods................................................................................ 911

9.5.2 DryFeedSystems........................................................................................ 912

9.5.2.1 Storage........................................................................................... 912

9.5.2.2 FeedMethods................................................................................ 913

9.5.2.3 LimeSlaking................................................................................... 914

9.6 DesigningforRapidMixandFlocculation............................................................... 915

9.6.1 TypesofMixers........................................................................................... 915

9.6.2 DesignFactors............................................................................................. 917

9.6.2.1 VelocityGradient........................................................................... 917

9.6.2.2 PowerRequirements..................................................................... 918

9.6.2.3 HydraulicRetentionTime.............................................................. 919

9.6.2.4 VesselGeometry............................................................................ 920

9.6.3 SummaryofTypicalDesignParameters..................................................... 920

9.7 SolidsSeparationProcesses..................................................................................... 921

9.7.1 PrimaryandSecondaryClarification........................................................... 922

9.7.2 TertiaryProcesses....................................................................................... 922

9.8 OperationalFactors................................................................................................ 922

9.8.1 DoseControl............................................................................................... 922

9.8.2 MakeupWater........................................................................................... 923

9.8.3 SludgeProductionandHandling................................................................ 923

9.8.4

pH

Adjustment

............................................................................................

9

25

9.8.5 EffectonBiosolidsApplications.................................................................. 925

9.9 References ....................................................................................................... 925

10. DesignApproachforBiologicalNutrientRemoval............................................................... 101

10.1 Introduction ....................................................................................................... 101

10.2 PreliminaryDesignApproach.................................................................................. 103

10.3 OverviewofRecommendedApproachforPlantModeling..................................... 105

10.4 EstablishingModelingObjectivesandRequirements............................................. 107

10.4.1 IntendedModelUse................................................................................... 107

10.4.2 GoalsforModelAccuracy........................................................................... 107

10.4.3 Dynamicvs.SteadyStateSimulation.......................................................... 108

10.5 SelectingaProcessSimulationModel..................................................................... 109

10.6 DataCollection ....................................................................................................... 1012

10.6.1 ProcessConfiguration................................................................................. 1013

10.6.2 OperatingConditions.................................................................................. 1016

10.7 CharacterizationofOrganicMaterial...................................................................... 1016

10.7.1 RelationshipofOrganicMaterialandSuspendedSolidsinWastewater...1020

10.7.2 MethodsforDeterminingCODFractions................................................... 1022

10.7.3 DataChecks................................................................................................. 1025


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10.8 CharacterizationofNutrientFractions.................................................................... 1026

10.8.1 Nitrogen...................................................................................................... 1026

10.8.2 Phosphorus................................................................................................. 1029

10.9 KineticandStoichiometricParameters................................................................... 1032

10.10 Calibration ....................................................................................................... 1033

10.11 Validation ....................................................................................................... 1037

10.12 SimulationofDesignAlternativesforNutrientRemoval........................................ 1038

10.13 AdditionalProceduresforDesign............................................................................ 1039

10.13.1SequencingBatchReactors(SBRs)............................................................. 1039

10.13.2DenitrificationFilters.................................................................................. 1040

10.13.3PrimarySludgeFermenters........................................................................ 1041

10.14 DesignChecksforBiologicalNitrogenandPhosphorusRemoval........................... 1042

10.15 References ....................................................................................................... 1047

11. DesignApproachforEffluentFiltration............................................................................... 111

11.1 Introduction ....................................................................................................... 111

11.2 SelectionofFiltrationTechnology........................................................................... 112

11.3 GranularMediaFilters............................................................................................. 113

11.3.1 InfluentWaterQuality................................................................................ 114

11.3.2 MediaSpecifications................................................................................... 114

11.3.3 FilterLoadingRate...................................................................................... 116

11.3.4 Headloss...................................................................................................... 116

11.3.5 BackwashRequirements............................................................................. 117

11.3.6 FlowControl............................................................................................... 119

11.4 ClothMediaFilters................................................................................................... 1110

11.5 LowPressureMembranes....................................................................................... 1111

11.5.1 MembraneMaterial.................................................................................... 1112

11.5.2 MembraneConfiguration........................................................................... 1113

11.5.3

Process

Considerations

...............................................................................

11

14

11.5.4 PressureDrop............................................................................................. 1115

11.5.5 FluxDetermination..................................................................................... 1115

11.5.6 PerformanceData....................................................................................... 1116

11.6 EmergingFiltrationTechnologiesforPhosphorusRemoval.................................... 1116

11.6.1 TwoStageFiltration.................................................................................... 1116

11.6.2 IronOxideCoatedMedia............................................................................ 1117

11.7 References ....................................................................................................... 1118

12. OperationandOptimizationtoEnhanceNutrientRemoval............................................... 121

12.1 Introduction ....................................................................................................... 121

12.2 AnalysisofExistingOperations................................................................................ 121

12.2.1 DataAnalysis............................................................................................... 122

12.2.2 UseofProcessSimulationModels.............................................................. 125

12.3 IncorporatingSCADAandotherInstrumentation................................................... 126

12.4 CommonOperationalChanges................................................................................ 126

12.4.1 AdjustSRT................................................................................................... 126

12.4.2 AdjustAerationRates................................................................................. 127

12.4.3 AddBafflestoCreateHighFoodtoMicroorganism(F/M)Conditions.......127

12.4.4 ChangeAerationSettingsinPlugFlowBasins............................................ 127


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12.4.5 MinimizeImpactofRecycleStreams.......................................................... 128

12.4.6 ReconfigureFlowthroughExistingUnits.................................................... 128

12.4.7 IncreaseVFAsforBiologicalPhosphorusRemoval..................................... 129

12.5 References ....................................................................................................... 1210

13. InstrumentationandControls..................................................................................................... 131

13.1 Introduction ....................................................................................................... 131

13.2 FactorsinSelectingInstrumentation....................................................................... 132

13.3 BasicOnlineInstrumentation.................................................................................. 133

13.3.1 Flow ....................................................................................................... 133

13.3.2 TotalSuspendedSolids(TSS)...................................................................... 134

13.3.3 SludgeBlanketDepth.................................................................................. 135

13.3.4 DissolvedOxygen(DO)............................................................................... 135

13.3.5 pH ....................................................................................................... 135

13.3.6 ORP ....................................................................................................... 136

13.4 OnlineInstrumentationforNutrientControl.......................................................... 136

13.4.1 NitrogenCompounds.................................................................................. 136

13.4.2 PhosphateandTotalPhosphorus............................................................... 137

13.4.3 NADH(activebiomass)............................................................................... 138

13.4.3 Respirometry.............................................................................................. 138

13.5 TypesofControl....................................................................................................... 139

13.5.1 Feedforward.............................................................................................. 139

13.5.2 Feedback..................................................................................................... 1310

13.5.3 Feedforwardandfeedback........................................................................ 1310

13.5.4 Cascade....................................................................................................... 1310

13.5.5 AdvancedControl....................................................................................... 1310

13.6 ControlEquipmentSCADA.................................................................................... 1311

13.7 References ....................................................................................................... 1313

14. SustainableNutrientRecoveryandReuse............................................................................ 141

14.1 Introduction ....................................................................................................... 141

14.2 SeparatingandTreatingWasteOnSite................................................................... 141

14.3 UsingWastewaterTreatmentByproducts.............................................................. 142

14.3.1 Durham,OR,AdvancedWastewaterTreatmentFacility............................ 143

14.3.2 EastBayMunicipalUtilityDistrict,CA........................................................ 144

14.4 References ....................................................................................................... 145


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NutrientControlDesignManual xiii August2010

Appendices

AppendixA. RecommendationsforMethanolSafety

AppendixB. OrganicCompoundsandInhibitoryConcentrationstoNitrification

AppendixC. MathematicalModelsforWastewaterTreatment


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NutrientControlDesignManual xiv August2010

Tables

Table31. ChemicalPrecipitants.............................................................................................. 32

Table41. PhylogenyofAmmoniaOxidizingBacteria.............................................................. 44

Table42. PhylogenyofNitriteOxidizingBacteria................................................................... 45

Table43. SummaryofTestResultsonMeasuringSpecificEndogenousDecayCoefficient

Rates(AllRatesat20C)........................................................................................... 411

Table44. SummaryofAOBNitrificationKineticCoefficientValues........................................ 412

Table45. ComparisonofNitrificationHalfVelocityCoefficients(mg/L)inMBRand

ConventionalActivatedSludge(CAS)Systems........................................................ 412

Table46. SummaryofNOBNitrificationKineticCoefficientValues....................................... 414

Table47. NH4NandNO2NConcentrationsthatMayInhibitNitrificationasaFunction

ofpHat20C. ....................................................................................................... 419

Table48. HeterotrophicBacteriaKineticCoefficientsinAnoxic/AerobicActivated

Sludge ....................................................................................................... 424

Table49. BiomassYieldsReportedforExogenousCarbonSources....................................... 428

Table

4

10.

Reported

Maximum

Specific

Growth

Rates

at

20C

and

Temperature

CoefficientsforMethanolUtilizationunderAnoxicandAerobicconditions..........429

Table411. ReportedKsvaluesforNO3Nreductionwithmethanolat20C............................. 429

Table412. ComparisonofMaximumSpecificGrowthratesforMethanol,Acetate,andCorn

SyrupatHighandLowTemperatures..................................................................... 430

Table413. ForBNRActivatedSludge,RatioofDenitrificationRatewithSubstrateAddition

toDenitrificationRatewithNoAddition................................................................. 431

Table414. RatioofDenitrificationRatesforOtherSubstratesatDay50withEthanolor

MethanolAdditionVersusnoAddition................................................................... 432

Table415. RangeofreportedSDNRvaluesinBNRactivatedsludgetreatment...................... 433

Table4.16. ANAMMOXBacteriaBiokineticParametersat300C............................................. 435

Table51. VolatileFattyAcidsTypicallyFoundinFermentedWastewater............................. 54

Table52. MinimumRatiosforAchievingTotalPhosphorusEffluentConcentrationof

lessthan1.0mg/L.................................................................................................... 54

Table53. EffectofCorrosionandOdorControlTechniquesonVFAProductionin

WastewaterCollectionSystems.............................................................................. 57

Table61. MatrixofBiologicalNitrogenRemovalTechnologies.............................................. 63

Table62. IFASMediaTypes,Applications,andDesignConsiderations.................................. 610

Table63. MatrixofPhosphorusRemovalTechnologies........................................................ 616

Table64. MatrixofCombinedBiologicalPhosphorusandNitrogenRemovalTechnologies.622

Table65. MatrixofTertiaryFiltrationTechnologies............................................................... 629

Table71. InfluentFlowComponents...................................................................................... 74

Table72. FlowCharacterization.............................................................................................. 74

Table73. ComparisonofFlowRatesandFlushVolumesBeforeandAfterU.S.Energy

PolicyAct ....................................................................................................... 75

Table74. ExamplePermitLimitsforNutrients........................................................................ 716

Table81. AdvantagesandDisadvantagesofTechnologyTypes............................................ 87

Table82. ExternalCarbonSources......................................................................................... 812

Table83. IFASMediaTypes,Applications,andDesignConsiderations.................................. 815

Table91. AdvantagesandDisadvantagesofCommonAluminumandIronSalts...................92

Table92. AdvantagesandDisadvantagesofMetalSaltApplicationPoints........................... 96


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NutrientControlDesignManual xv August2010

Table93. TypesofChemicalFeeders...................................................................................... 910

Table94. CommonlyUsedEquipmentforRapidMixing......................................................... 916

Table95. ValuesofNPandNQforVariousTypesofImpellers................................................ 918

Table96. TypicalDesignParametersforTurbineandPropellerMixer................................... 921

Table101. CommonlyUsedProcessSimulators....................................................................... 1010

Table102. CODandParticulateFractionsinMunicipalWastewater....................................... 1019

Table103. TKNFractionsinMunicipalWastewater.................................................................. 1028

Table104. TotalPhosphorusFractionsinMunicipalWastewater............................................ 1031

Table105. DesignChecksforBiologicalNitrogenRemoval...................................................... 1043

Table106. DesignChecksforBiologicalPhosphorusRemoval................................................. 1045

Table111. CommonFilterMediaandCharacteristics.............................................................. 115

Table112. FilterMediaDepthsandParticleSizes.................................................................... 115

Table113. MembraneCharacteristics....................................................................................... 1114

Table114. AdvantagesandDisadvantagesofMembraneMaterials........................................ 1115

Table115. PhosphorusRemovalReportedFromMembranePilotStudies.............................. 1119

Table116. PilotTestResultsfortheBlueWaterBluePROSystem........................................ 1121

Table121. RecommendedParametersforDataEvaluation..................................................... 123

Table131. SummaryofBasicOnLineInstrumentation............................................................ 132

Table132. ComparisonofOnlineNitrateAnalyzers ................................................................ 137


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NutrientControlDesignManual xvi August2010

Figures

Figure21. PopulationservedbyPOTWsnationwideforselectyearsbetween1940and2004

andprojectedto2024(ifallneedsaremet),organizedbywastewater

treatment type........................................................................................................ 25

Figure22. WaterqualitybasedapproachoftheCleanWaterAct.......................................... 210

Figure41. PercentnitrogenremovalduetobiomasssynthesisasafunctionofSRTand

influentBOD/Nratio................................................................................................ 43

Figure42. EffectofSRTandtemperatureoneffluentNH4+NandNO2

Nconcentrations

usingkineticdatainTable46and44forCMAS.................................................... 415

Figure43. EffectofDOconcentrationoneffluentNH4+NandNO2

Nconcentrations

usingkineticdatainTable44and46andat15CforCMAS............................... 415

Figure44. EffectoftemperatureonminimalwashoutSRTAOB,HandNOB,Hfrom

Hellingaetal.(1998)andAOB,MandNOB,MfromTables42and44................417

Figure45. RatioofCODrequiredtoNO3NcompletelyreduceNO3N(CRNO3)asa

functionofthebiomassyield.................................................................................. 426

Figure51. TheoryofBPRinactivatedsludge........................................................................... 51

Figure52. BPRataWWTP ....................................................................................................... 53

Figure53 BiologicalPathwaysofMethaneFormation............................................................ 5.8

Figure54. Exampleofsecondaryreleaseinsecondanoxiczone............................................. 514

Figure61. ModifiedLudzackEttinger(MLE)process............................................................... 64

Figure62. 4stageBardenphoprocess..................................................................................... 65

Figure63. Commonconfigurationforamembranebioreactor4stagebardenphotreatment

system ....................................................................................................... 66

Figure64. Operatingperiodsofasequencingbatchreactor................................................... 67

Figure65. Exampleoxidationditchconfiguration.................................................................... 68

Figure66. Stepfeedbiologicalnitrogenremoval..................................................................... 67

Figure67. Downflowdenitrificationfilter................................................................................ 614

Figure68. Continuousbackwashupflowsand(CBUS)filters................................................... 615

Figure69. Closeupofcontinuousbackwashupflowsand(CBUS)filter.................................. 615

Figure610. Densadeghighrateclarificationprocessflowdiagram......................................... 618

Figure611. CoMagTMprocessflowdiagram............................................................................ 619

Figure612. Phoredoxprocess(A/O)......................................................................................... 621

Figure613. Oxidationditchwithanaerobiczone....................................................................... 622

Figure614. 3StagePhoredoxprocess(A2/O)........................................................................... 623

Figure615. 5stageBardenphoprocess.................................................................................... 624

Figure616. UCTandModifiedUCTprocess............................................................................... 625

Figure617. Westbankprocess.................................................................................................... 626

Figure618. VT2processschematic............................................................................................. 627

Figure619. TheBluePlainsprocess............................................................................................ 628

Figure620. Probabilityplotofsecondaryeffluentphosphorusdata......................................... 639

Figure621. Technologyperformancestatisticsfornitrogenremovalplants............................. 640

Figure622. Technologyperformancestatisticsforphosphorusremovalplants....................... 640

Figure71 Netsludgeproductionversussolidsretentiontimeandtemperature ..................714

Figure91. Possibleapplicationpointsforchemicaladdition(C)............................................. 94

Figure92. Schematicofcommonjartestingapparatus........................................................... 99


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NutrientControlDesignManual xvii August2010

Figure93. Typicaldrychemicalfeedsystem............................................................................ 913

Figure101. Unifiedprotocolforactivatedsludgemonitoring.................................................. 106

Figure102. Essentialrequirementsforwastewatertreatmentprocesssimulation..................1013

Figure103. Examplesimulatorconfigurationforabiologicalnutrientremovalplant..............1014

Figure104. CODcomponentsformunicipalwastewater........................................................... 1018

Figure105. RelationshipbetweenBOD,COD,TSS,andVSS...................................................... 1021

Figure106. TKNcomponentsformunicipalwastewater........................................................... 1027

Figure107. Phosphoruscomponentsinmunicipalwastewater................................................ 1030

Figure111. Upflowcontinuousbackflowfilter.......................................................................... 1111

Figure112. OperationalmodelsoftheFuzzyFilter.................................................................. 1112

Figure113. CutawayviewofAquaDiskclothmediafilter........................................................ 1113

Figure114. Hollowfibermembraneconfigurationwithinsidetooutsideflow........................ 1116

Figure115. ParksonDynasandD2advancedfiltersystem......................................................... 1120

Figure116. BluePROprocess................................................................................................... 1121

Figure121. Spatialandtemporalprofilesofammonia.............................................................. 125


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NutrientControlDesignManual xviii August2010

AcronymsandAbbreviations

A/O Anaerobic/Oxic,Phoredox

A2/O Anaerobic/Anoxic/Oxic,3StagePhoredox

AMO AmmoniaMonooxygenase

ANAMMOX AnaerobicAmmoniaOxidation

AOB AmmoniaOxidizingBacteria

AS ActivatedSludge

ASCE AmericanSocietyofCivilEngineers

ASM ActivatedSludgeModel

AT3 AerationTank3

BABE BioAugmentationBatchEnhanced

BAF BiologicalAeratedFilter

BAR BioAugmentationRegeneration/Reaeration

BCFS BiologicalChemicalPhosphorusandNitrogenRemoval

bDON BiodegradableFractionofDissolvedOrganicNitrogen

BHRC

Ballasted

High

Rate

Clarification

Processes

BNR BiologicalNutrientRemoval

BOD BiochemicalOxygenDemand

BOD5 BiochemicalOxygenDemand(5day)

BPR BiologicalPhosphorusRemoval

CCF ContinuousContactFiltration

CFD ComputationalFluidDynamic

CIP CleaninPlace

CMAS CompletelyMixedActivatedSludge

C/N CarbontoNitrogenRatio

COD ChemicalOxygenDemand

COV CoefficientofVariation

CR ConsumptiveRatio

CSO CombinedSewerOverflow

CSTR ContinuousStirredTankReactors

CWA CleanWaterAct

CWSRF CleanWaterStateRevolvingFund

DAF DissolvedAirFlotation

DO DissolvedOxygen

DON DissolvedOrganicNitrogen

DSS DesignatedSuspendedSolids

EBPR EnhancedBiologicalPhosphorusRemoval

EDC EndocrineDisruptingChemicals

EDTA EthyleneDiamineTetraaceticAcid

ENR EnhancedNutrientRemoval

EPA U.S.EnvironmentalProtectionAgency

FFS FixedfilmSystems

F/M FoodtoMicroorganismratio

FWPCA FederalWaterPollutionControlAct

FWS FreeWaterSurface

GAO GlycogenAccumulatingOrganism


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NutrientControlDesignManual xix August2010

GMP GoodModelingPractices

HRSD HamptonRoadsSanitationDistrict

HRT HydraulicRetentionTime

iDON InertDissolvedOrganicNitrogen

IFAS IntegratedFixedFilmActivatedSludge

ISF IntermittentSandFilter

ISS InertSuspendedSolids

IWA InternationalWaterAssociation

JHB JohannesburgProcess

LOT LimitofTechnology

MAUREEN MainstreamAutotrophicRecycleEnhancedNremoval

MBBR MovingBedBiofilmReactor

MBR MembraneBioreactor

MCL MaximumContaminantLevel

MF Microfiltration

MGD MillionGallonsperDay

mg/L Milligramsperliter

MLE ModifiedLudzackEttinger

MLSS MixedLiquorSuspendedSolids

MLVSS MixedLiquorVolatileSuspendedSolids

MMDF MaximumMonthDesignFlow

MUCT ModifiedUniversityofCapetown

MWRDGC MetropolitanWaterReclamationDistrictofGreaterChicago

N Nitrogen

NF Nanofiltration

NTU NephelometricTurbidityUnits

NOAA NationalOceanicandAtmosphericAdministration

NOB NitriteOxidizingBacteria

NPDES

National

Pollutant

Discharge

Elimination

System

NTT NitrogenTradingTool

ORD EPAOfficeofResearchandDevelopment

ORP OxidationReductionPotential

OSHA OccupationalSafetyandHealthAdministration

OUR OxygenUptakeRate

OWASA OrangeWaterandSewerAuthority

OWM EPAOfficeofWastewaterManagement

P Phosphorus

PACl PolyaluminumChloride

PAH PolycyclicAromaticHydrocarbons

PAO PhosphateAccumulatingOrganism

PHA Polyhydroxyalkanoate

PHB Polyhydroxybutyrate

PHV Polyhydroxyvalerate

PID PhasedIsolationDitch

PLC ProgrammableLogicController

POTW PubliclyOwnedTreatmentWorks

PPCPs PharmaceuticalsandPersonalCareProducts

RAS ReturnActivatedSludge


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NutrientControlDesignManual xx August2010

RBC RotatingBiologicalContactor

rbCOD ReadilyBiodegradableChemicalOxygenDemand

rDON RecalcitrantDissolvedOrganicNitrogen

RO ReverseOsmosis

RSF RecirculatingSandFilters

SAV SubmergedAquaticVegetation

SBCOD SlowlyBiodegradableChemicalOxygenDemand

SBR SequencingBatchReactors

SCADA SupervisoryControlandDataAcquisition

SCM SurfaceComplexationModeling

SDNR SpecificDenitrificationRate

SHARON SingleReactorHighActivityAmmoniaRemovalOver Nitrite

SNdN SimultaneousNitrificationDenitrification

SRT SolidsRetentionTime

SSO SanitarySewerOverflow

STAC ChesapeakeBayProgramScientificandTechnicalAdvisory

Committee

SWIS SubsurfaceWastewaterInfiltrationSystem

TAL TechnologyAchievableLimit

TAN TotalAmmoniaNitrogen

TDS TotalDissolvedSolids

TKN TotalKjeldahlNitrogen

TMDL TotalMaximumDailyLoads

TN TotalNitrogen

TP TotalPhosphorus

TSS TotalSuspendedSolids

TUDP BioPModeloftheDelftUniversityofTechnology

UCT UniversityofCapetownProcess

UF

Ultrafiltration

UOSA UpperOccoquanSewageAuthority

USDA U.S.DepartmentofAgriculture

USEPA U.S.EnvironmentalProtectionAgency

USGS U.S.GeologicalSurvey

VFA VolatileFattyAcid

VIP VirginiaInitiativePlant

VSS VolatileSuspendedSolids

WAS WasteActivatedSludge

WEF WaterEnvironmentFederation

WEFTEC WaterEnvironmentFederationTechnicalExhibitionand

Conference

WERF WaterEnvironmentResearchFoundation

WQS WaterQualityStandards

WWTP WastewaterTreatmentPlant


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NutrientControlDesignManual xxi August2010

Acknowledgements

Theprincipleauthorsofthisdocument,titledNutrientControlDesignManual,were:

Dr.CliffordRandall,ProfessorEmeritusofCivilandEnvironmentalEngineeringatVirginiaTechand

DirectoroftheOccoquanWatershedMonitoringProgram

Dr.JamesBarnard,GlobalPracticeandTechnologyLeaderatBlack&Veatch

Dr.H.DavidStensel,ProfessorofCivilandEnvironmentalEngineeringattheUniversityofWashington

LauraDufresne,SeniorEngineer,theCadmusGroup,Inc.

EPAtechnicaldirectionandoversightwereprovidedbyDanMurray,EPAOfficeofResearchand

Development,NationalRiskManagementLaboratory.

EPAtechnicalreviewsofthedocumentwereperformedby:

EPAOfficeofResearchandDevelopmentDonaldBrown

DouglasGrosse

RichardBrenner

JamesSmith

MarcMills

JeffryYang

EdwinBarth

EPAHeadquartersDonaldAnderson

PhilZahreddine

JamesWheeler

EPARegionsDavidPincumbe,Region1

RogerJanson,Region1

RussMartin,Region5

DaveRagsdale,Region10

Externaltechnicalreviewsofthedocumentwereperformedby

JeanetteBrown,StamfordWaterPollutionControlAuthority

TanyaSpano,MetropolitanWashingtonCouncilofGovernments(MWCOG)

S.JohKang,TetraTech


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ThefollowingmembersoftheOhioWaterEnvironmentAssociation:

DaleE.Kocarek,StantecConsulting,Inc.

WilliamBarhorst,ARCADIS

DennisP.Meek,DMEngineering

KimRiddell,CityofDelphos

PaulFletcher,Jones&HenryEngineers

JasonTincu,CityofXenia

GaryHickman,CityofColumbus

RogerF.Gyger,m2tTechnologies

TedMarten,CityofTwinsburg

DavidWilson,ButlerCountyWaterandSewer

KarenHarrison,Jordan,Jones,Goulding

MaryLong,Black&Veatch

RobertHollis,SummitCounty

RickNoss,StantecConsulting

ThepingChen,AECOM

ShaunBeauchesne,HachCompany

DavidFrank,ARCADIS

ThefollowingmembersoftheWaterEnvironmentResearchFoundation(WERF)NutrientsChallenge

Team:

JBNeethling,HDREngineering,Inc.

MarioBenisch,HDREngineering,Inc.

AmitPramanik,WERF

Diagramsforillustrationofspecificconceptswereprovidedby:

Dr.CliffordRandall,VirginiaTech

Dr.JamesBarnard,BlackandVeatchDr.H.DavidStensel,UniversityofWashington

NutrientControlDesignManual xxii August2010


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1.IntroductionChapter1covers:

1.1 HistoryofNutrientRemoval

1.2 PurposeandScopeofthisManual1.3 ManualOrganization

1.4 References

1.1 HistoryofNutrientRemoval1Biologicalnutrientremoval(BNR)atwastewatertreatmentplants(WWTP)beganintheearly

1960s.PioneerssuchasLudzackandEttinger(1961)andWuhrman(1964)madeeffortstodevelop

biologicalnitrogenremoval(nitrificationdenitrification)wastewatertreatmentsystems.Levinand

Shapiro(1965)researchedbiologicalphosphorusremoval,anddevelopedapatentedprocessforit,

knownasPhoStrip.However,thesystemsdevisedbyLudzack,Ettinger,andWuhrman,didnotutilizean

internalrecycletoobtainsignificantutilizationoftheinfluentbiochemicaloxygendemand(BOD),and

theproposedbiologicalmechanismsofthePhoStripprocessremainedcontroversialbecauseitstwo

finalstepswerethereleaseofphosphorusfromactivatedsludgeunderanaerobicconditionsandthen

chemicalprecipitationofthereleasedphosphorusinaseparatereactor.

Themajorprocessdevelopmentbreakthroughsforbiologicalremovalofbothnitrogenand

phosphorusutilizingtheinfluentBODresultedfromtheworkofJamesBarnardinSouthAfricainthe

early1970s.Hefirstdevelopedasinglesludgeprocessconfigurationwithinternalrecyclethatutilized

theinfluentBODfordenitrification(1973).Itsubsequentlybecamethestandardnitrogenremoval

processforthewastewaterindustry.ItisnowknownasthemodifiedLudzackEttinger(MLE)process.

Healsodemonstratedthatanaerobicaerobicsequencingofactivatedsludge,withinfluentBODfirst

flowingintotheanaerobiczone,wasnecessarytoobtainrobustbiologicalphosphorusremoval(BPR).

Thisdiscoverywasfirstpublishedin1975.Theoreticalsupportthatthemechanismwasbiologicaland

notchemicalwassuppliedbyFuhsandChen(1975)inthesameyear.Barnarddevelopedseveral

processconfigurationsforbothseparateandcombinedbiologicalremovalofnitrogenandphosphorus.

Afourstageanoxicaerobicanoxicaerobicprocessdesignedprimarilyfornitrogenremovalwas

patentedastheBardenphoProcess(1978).Thefivestageversion,createdbyaddingananaerobiczone

asthefirststagebecameknownastheModifiedBardenphoProcess.

Alsoduringthemid1970s,ananaerobicaerobicwastewatertreatmentconfigurationwasbeing

developedintheUnitedStatesforcontroloffilamentousgrowthsinactivatedsludge.Thisprocesswas

patented

by

Marshall

Spector

and

acquired

by

Air

Products

and

Chemical,

Inc.

They

learned

from

BarnardthatanaerobicaerobicsequencingofactivatedsludgealsocouldbeusedtoaccomplishBPR

andpatentedtheconfigurationastheAnaerobicOxic(AO)process,whichwasidenticaltothePhoredox

configurationdevelopedbyBarnardinSouthAfrica.Theythencombineditwithananoxiczoneand

patentedtheresultingconfigurationastheAnaerobicAnoxicOxic(A2/O)process,againidenticaltoa

configurationdevelopedbyBarnard.Atthistime,thedetrimentalimpactsofnitraterecycleinreturn

1ByDr.CliffordRandall,ProfessorEmeritus,VirginiaTech

NutrientControlDesignManual 11 August2010


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activatedsludge(RAS)totheanaerobiczoneonBPRperformancewasnotfullyunderstood,andmany

ofthePhoStrip,Phoredox/A2/O,andModifiedBardenphoplantswereremovingphosphoruserratically.

TheSouthAfricanGovernmentrequestedthatProfessorGerritMaraisandhiscoworkersatthe

UniversityofCapeTowninvestigateandresolvetheissue.Theydevelopedamodificationofthe

Phoredox/A2/Oconfiguration,dubbedtheUniversityofCapeTown(UCT)process,thatfirstsentthe

RAStotheanoxiczonethenaddedasecondinternalrecycletorecycledenitrifiedmixedliquorfromthe

effluentoftheanoxiczonebacktotheinfluentoftheanaerobiczone.Basedonthesuppositionthat

denitrificationwouldoccuronlyintheanoxiczone,amodifiedversionoftheUCTprocesswas

developedforwastewaterswithahighTotalKjeldahlNitrogen(TKN)toBODratio.

BNRwasintroducedtoNorthAmericaintheearly1980sthroughimplementationofBNR

facilitiesatKelowna,BC,Canada,andatOrangeCounty,FL.BNRwasintroducedtotheChesapeakeBay

regionin1984byaseminarandaworkshoporganizedbyDr.CliffordRandall(VirginiaTech)andheldat

Richmond,VA.Then,workingwiththeHamptonRoadsSanitationDistrict(HRSD)andtheVirginiaWater

PollutionControlBoard,apilotplantstudyofahighrateUCTprocesswasconductedattheHRSD

LambertsPointprimarytreatmentplantin198586,andfollowedbyfullscaleresearchdemonstrations

oftheA/O,A2/OandUCTprocessesattheHRSDYorkRiverPlantfrom198690.OverlappingtheYork

Riverdemonstrations,whichresultedinpatentingoftheVirginiaInitiativePlant(VIP)BNRprocess,were

fullscaledemonstrationsofBNR(bothNandPremoval)attheAnneArundelCounty,MD,Maryland

CityWWTP,andtheBowie,MD,WWTP.Alsooverlappingtheseeventswerethedesignand

constructionoftheMauldinRoadWWTP,Greeneville,SC,andmodificationoftwoplantsinCharlotte,

NC.NorthAmericanBNRdevelopmentsmovedrapidlyinthelate1980sandearly1990s,resultingin

BPRandBNRimplementation,designandconstructionatsitesasdiverseastheBonnybrookWWTP,

Alberta,Canada,HillsboroughCounty,FL,Frederick,MD,Atlanta,GA,andmodificationoftheHoward

County,MD,WWTPfromthePhoStriptothePhoredox/A2/Oconfiguration.

BNRbegantobeimplementedinEuropeonawidespreadbasisin1987,firstinGermanyand

TheNetherlands,followedbyDenmark,Austria,CzechRepublic,ItalyandFrance.SchreiberKlarenlagen

with

their

unique

Simultech

Process

wherein

BPR,

nitrification,

and

denitrification

all

occurred

simultaneouslyinonecontinuousflowreactorwasapacesetterinGermanywhileKruger,Inc.,ledthe

wayinDenmarkundertheguidanceofProfessorPoulHarremoesandhiscoworkersattheDanish

InstituteofTechnology.

TheengineeringartofBNRhasprogressedtowardsmaturityduringthepasttwodecadeswith

theadditionofadvancedpracticessuchasprefermentationofprimarysludgetoenhanceBPR,

integrationoffixedfilmmediaintoactivatedsludge(IFAS)toenhancenitrogenremoval,utilizationof

biologicalfiltersfornitrogenremoval,andwidespreaduseoftertiaryfiltersfordentrificationand

chemicalphosphorusremovaltolowerlevels.Recenteffortstodevelopeconomicalmethodsforthe

nutrientremovalinsiteswithlimitedspaceforexpansionhaveresultedintheemergenceoftwo

innovativetechnologicalapproaches:

1) Technologiessuchasmembranebioreactorsorballastedflocculationtoremovesuspended

solidstoverylowconcentrationsandsimultaneouslyeliminateorgreatlyreducethesizeof

secondarysettlingbasins.

2) SidestreamprocessessuchasSHARON,ANAMMOX,INNITRIandotherstoeitherremove

nitrogenfromammoniarichflowsfromsludgeprocessingorenhanceremovalinthemain

streamprocess.


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NitrogenremovalhasbeenwidelyimplementedalongtheConnecticutcoastofLongIsland

Sound.Morestringenteffluentstandards,typically3.0milligramsperliter(mg/L)totalnitrogen(TN)and

0.1orlowermg/Ltotalphosphorus(TP),inregionssuchastheChesapeakeBaywatershed,coastal

areasofNorthCarolina,OkanaganLakeareaofBritishColumbia,Canada,midColoradoandKalispell,

WY,haveadvancedtheartfromBNRtoenhancednutrientremoval(ENR).AcombinationofBNR,

chemicaladditionsandeffluentfiltrationaretypicallyusedtoaccomplishENR.

Acleartrendofthewastewatertreatmentindustryisagreateremphasisonincorporating

elementsofrecycle,recovery,andreuseintoplantdesignandoperation.Sustainablenutrientrecovery

andreuseisgainingnationalandinternationalattentionaswastewaterutilitieslookforwaysto

decreaseenergycostsandgreenhousegasemissions,utilizeexcesscapacity,generatenewrevenue,

andaddressevermorestringentregulatoryrequirements.Thisevolutioninthinkingismoving

wastewatertreatmenttoenhancedenergyefficiencyandchangingtheroleofwastewatertreatment

facilitiesfromwastegeneratorstoresourceproviders.

1.2 PurposeandScopeofthisManualResearchandtechnologydevelopmentthroughthemid70swerethebasisforEPAsfirstdesign

manualfornitrogencontroltechnologies.Thisdocument,ProcessDesignManualforNitrogen

Control,(EPA,1975)waspublishedin1975.Thismanualcoveredabroadrangeofprocessesthatwere

beingevaluatedandappliedatthetime.Theintentofthemanualwastopresentdesigninformationfor

technologiesthatappearedtohaveaviable,practicalapplicationtonitrogencontrol.Twobroad

categoriesoftreatmentprocesseswereaddressed.Thefirstgroupofprocessesprovidesforthe

conversionoforganicandammoniumnitrogenbyoxidationtonitratenitrogen.Theseprocessesare

biologicalandaregenerallyreferredtoasnitrification.Thesecondgroupofprocessesremovesnitrogen

fromthewastewater.Theseprocessesarealsobiological,usingananoxicdenitrificationstepwith

nitrification.Physical/chemicalprocesseswerealsopresentedfornitrogenremoval,includingion

exchange,ammoniastripping,andbreakpointchlorination.Betweenthepublicationofthefirstnitrogencontrolmanualandtheupdateofthemanualin1993,thetrendinnitrogencontroltechnologywas

almostexclusivelytowardsbiologicalprocesses.Biologicalprocessesbecameprovenandwell

demonstratedandweremostefficientlyexpandedorupgradedforbiologicalnitrificationortotal

nitrogenremoval.Thefocusofthe1993updateddocument,ManualNitrogenControl,(EPA,1993)

wasonbiological/mechanicalprocessesthatwerefindingwidespreadapplicationfornitrificationand

nitrogenremoval.

In1971,EPApublisheditsfirstphosphoruscontroldesignmanual.Thismanual,ProcessDesign

ManualforPhosphorusRemoval,(EPA,1971)focusedonphosphorusremovalmethodsthatinvolve

chemicalprecipitation.Primarily,themanualfocusedonthechemicalprecipitationofphosphorususing

saltsofaluminumandiron,andlime.Thechemicalapplicationpointsaddressedinthemanualwere

beforeprimarysettling,intheaerationtanks,beforefinalsettling,orinatertiaryprocess.In1976,

ProcessDesignManualforPhosphorusRemoval(EPA,1976)wasupdated.Specifically,design

guidanceforphosphorusremovalusingmineraladditionandlimeadditionbeforeprimarysettlingwas

revised.Also,guidanceforchemicalstorage,chemicalfeedsystemsandresidualshandlinganddisposal

wasupdated.In1987,EPApublishedtwotechnicaldocumentsthataddressedphosphoruscontrol.The

firstwasanupdatetothe1976ProcessDesignManualforPhosphorusRemoval(EPA,1987a).The

secondwasahandbooktitled,HandbookRetrofittingPOTWsforPhosphorusRemovalinthe

ChesapeakeBayDrainageBasin.(EPA,1987b)Theupdateofthedesignmanualincludedamajor


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additionofguidanceforbiologicalphosphorusremoval.Also,theuseoflimeadditionwasnotcovered

inthisupdateduetoitslossofpopularityinthe80s.Thetechnicalguidanceprovidedinthe1987

handbookwasfocusedontheuniquephosphorusremovalrequirementsbeingappliedtomunicipal

wastewatertreatmentplantsintheChesapeakeBaywatershed.Becauseofthevaryinglevelsof

phosphoruscontrolwithinthewatershed,thehandbookincludedanassessmentoftechnologiesfor

meetingtotalphosphoruseffluentlimitsof0.2mg/L,0.5mg/L,1mg/L,and2mg/L.Becausesome

treatmentplantsintheChesapeakeBaywatershedneedtocontrolbothnitrogenandphosphorus,the

handbookincludedachaptertitled,CompatibilityofChemicalandBiologicalPhosphorusRemovalwith

NitrogenControl.

In2007,EPAinitiatedtheprocesstodevelopupdateddesignguidanceforbothnitrogenand

phosphorusremovalatmunicipalWWTPs.Thefirststepwasanextensive,stateofthetechnology

reviewofnitrogenandphosphoruscontroltechnologiesandtechniquescurrentlyappliedandemerging

atmunicipalwastewatertreatmentplants.Thistechnologyreviewculminatedwiththepublicationof

theNutrientControlDesignManual:StateoftheTechnologyReviewReport(USEPA2009)asan

interimdocumentinthedevelopmentoftheupdateddesignmanuals.

ThepurposeofthisEPAdesignmanualistoprovideupdated,stateofthetechnologydesign

guidanceonnitrogenandphosphoruscontrolatmunicipalWWTPstowastewaterutilityownersand

operators,stateandEPApermitwriters,andenvironmentalengineeringprofessionals.Similarto

previousEPAmanuals,thismanualincludesextensiveinformationontheprinciplesofbiological

nutrientremovalandchemicalphosphorusremovaltoserveasthebasisfordesign.Adetailed

descriptionoftechnologies,bothconventionalandemerging,servesasaresourceforpreliminary

technologyselection.Themanualpresentsnewinformationonemergingissuesintheindustrysuchas

sustainabilityinwastewatertreatmentdesignandoperation,nutrientrecoveryandreuse,effluent

dissolvedorganicnitrogen,andmeasurementoflowphosphorusconcentrations.Althoughthismanual

providessomeexamplesofproprietaryandemergingtechnologies,EPArecognizesthattheindustryis

continuallyevolvingandthatnewtechnologiesnotidentifiedinthismanualmayemergeinthefuture.

BecausethemajorityofWWTPsintheUnitedStatesareequippedwithsecondarybiological

treatment,thefocusofthisdesignmanualisonprocessandtechnologymodifications/additionsfor

nutrientremovalatexistingWWTPsratherthanonnewtreatmentplantdesign,althoughguidanceforgreenfielddesignispresented. Alsonewfrompreviousversions,designguidancehereinisbasedonthe

useofmathematicalmodelsandsimulators.Simulatorsallowdesignerstostudykinetic aswellastime

basedsolutionswhiledeterminingthetotalmassbalancesofmanyconstituents.Theyhavebecome

increasinglypowerful,easytouse,widelyaccepted,andrecommendedbyWEFandASCE(2010)forthe

designofbiologicalnutrientremovalfacilities. EarlierversionsofEPAnutrientcontrolmanuals(USEPA

1993;USEPA1987a;USEPA1987b)stillcontainveryusefulguidance(includingexamples)onprocess

designusinghandcalculationsthatcanbeusedforverypreliminarysizingorchecksonsimulation

results.

Thismanualcomplimentsdetailedcostdataandindepthfacilitycasestudiespublishedinthe

MunicipalNutrientRemovalTechnologiesReferenceDocument(USEPA2008a)andanalysisofemerging

technologiesfornutrientremovalpresentedintheEmergingTechnologiesReportonWastewater

Treatment(USEPA2008b). BothdocumentsareavailablefordownloadfromEPAswebsiteat

http://www.epa.gov/OWM/mtb/publications.htm


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1.3 ManualOrganizationThisdesignmanualhas14chaptersand3appendices.Itisgenerallyorganizedwiththetheory

ofnutrientremovalpresentedfirstfollowedbyadescriptionofnutrientremovaltechnologies;guidance

onestablishingdesignobjectivesandselectingcandidatetreatmentprocesses;anddesignapproaches

forchemicalphosphorusremoval,biologicalnutrientremoval,andeffluentfiltration. Laterchapters

describeoperationalimprovementsforenhancingtechnologyperformanceandguidanceon

instrumentationandcontrols. Thelastchapter,Chapter14,discussessustainablerecoveryandreuse. A

moredetaileddescriptionofeachchapterisprovidedbelow.

Chapter2.NeedforandBenefitsofNitrogenandPhosphorusRemovalprovidesbackgroundinformationonsourcesofnitrogenandphosphorusinwastewater.Itreviewsthestatusof

wastewatertreatmentintheU.S.,theimpairmentofwaterwaysbyexcessivenutrients,

governmentandindustryinitiativestoreducenutrientpollution,andtheadditionalbenefitsand

challengesofnutrientremoval.

Chapter3.PrinciplesofPhosphorusRemovalbyChemicalAdditiondescribestheavailableformsofmetalsaltsandlimeandtheirreactionswithphosphorus.Itprovidesageneral

descriptionofsolidsseparationprocessandtheeffectsofvarioustreatmentoptionsonsludge

productionandhandling.

Chapter4.PrinciplesofBiologicalNitrogenRemovalexaminesthefundamentalmicrobiologybehindnitrificationanddenitrificationincludingstoichiometricsandkinetics.Itdiscusses

denitrificationkineticswithinternalandexternalcarbonsources.Simultaneousnitrification

denitrificationandpotentialimpactsonsludgehandlingarealsodiscussed.

Chapter5.PrinciplesofBiologicalPhosphorusRemovalprovidesadetaileddiscussionofthebiologicalphosphorusremovalprocessincludingkinetics,substraterequirements,

environmentalconditions,designandoperationalconsiderations,andimpactsonsludge

processingandhandling.

Chapter6.OverviewofNitrogenandPhosphorusRemovalTechnologiesdescribesthetechnologiesavailableforremovingnitrogen,phosphorus,orbothfromwastewater.Diagrams

areprovidedformosttechnologies.Itpresentsinformationontechnologyperformance

includingdesignandoperationalfactorsaffectingaplantsabilitytoachieveloweffluent

concentrations.

Chapter7.EstablishingDesignObjectivessummarizesthiscriticalstepinupgradingorretrofittinganexistingWWTP.Itprovidesguidanceonestablishingdesignflowrates,

characterizingflowandcontaminantsininfluentwastewaterincludingdetailedsampling

methodologiesanddataverificationsteps,andsettinggoalsforprocessreliability,sustainability,

andflexibility.Thechapteralsodescribessolidshandlingoptionsandsiteconstraints. Chapter8.SelectingCandidateTreatmentProcessesforPlantUpgradesdescribestechnology

selectionfactorsincludingtreatmentgoals,availablefootprint,hydraulicconsiderations,

chemicalneeds,solidsprocessingcapabilities,andenergyconsiderations.Itsummarizes

advantagesanddisadvantagesofdifferenttechnologytypes.Italsoprovidesanoverviewofa

recommendedapproachtotechnologyselectionanddiscussesuseofadvancedtools.


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Chapter9.DesignApproachforPhosphorusRemovalbyChemicalAdditionprovidesguidelinesonselectingachemicalprecipitant,choosingapplicationpoints,anddeterminingchemicaldose.Itprovidesdetailedguidanceondesigningachemicalfeedsystemandconsiderationsforrapid

mix,flocculation,andsolidsseparationprocessestomaximizephosphorusremoval.

Chapter10.DesignApproachforBiologicalNutrientRemovalpresentsastepbystepapproachfordesigningwastewatertreatmentupgradesfornutrientremovalusingmathematicalmodels.

Itprovidespracticalrecommendationsfordatacollectionandevaluationandmodelcalibration.

Itincludesdesignchecksfornitrogenandphosphorusremoval. Thischapteralsoprovidesan

alternativedesignapproachusinghandorspreadsheetcalculationsthatdesignerscanuseto

prepareroughestimatesand/ortocheckmodeloutputs.

Chapter11.DesignApproachforEffluentFiltrationdiscussestheoptionsinfiltrationtechnologyforeffluentpolishingandnutrientremoval. Itprovidesdesignguidanceongranular

mediafiltersandalternativetechnologiessuchasclothfilters,diskfilters,andmembranes.

Informationonemergingfiltrationtechnologiesforremovalofphosphorustoloweffluent

concentrationsisalsoprovided.

Chapter12.OperationandOptimizationtoEnhanceNutrientRemovalincludesinformationonhowtooptimizetheperformanceofexistingoperationsbyincorporatingSCADAandother

instrumentation.Thechapteralsodiscussescommonoperationalchangestoimprovesystem

performanceandenhancethecosteffectivenessoftreatmentprocesses. Chapter13.InstrumentationandControlsdiscussesonlineinstrumentationfornutrientcontrol

includingautomatedcontrolandoptimization,advancedautomatedcontrol,andSCADA

equipment,allofwhichcanleadtobetterprocessoptimizationandmorestabletechnology

performance.

Chapter14.SustainableNutrientRecoveryandReuseexaminesthelatestadvancesinnutrientrecoveryincludingseparatingandtreatingwasteonsiteandhowtousewastewatertreatment

byproductstodecreaseenergycostsandgreenhousegasemissions,takeadvantageofexcess

capacity,andgeneratenewrevenue.

The manual is supported by three technical appendices containing recommendations on

methanolsafety(AppendixA),alistoforganiccompoundsandinhibitoryconcentrationstonitrification

(Appendix B), and background information onmathematicalmodels for biological nutrient removal

(AppendixC).

1.4 ReferencesBarnard,J.L.1973.BiologicalDenitrification.JournalofWaterPollutionControl72(6):705720.

Barnard,J.L.1975.NutrientRemovalinBiologicalSystems.JournalofWaterPollutionControl,143154.

Barnard,J.L.1978.TheBardenphoProcess.In:AdvancesinWaterandWastewaterTreatmentBiological

NutrientRemoval.M.P.WanielistaandW.W.Eckenfelder,Jr.(eds.),AnnArborScience,AnnArbor,MI.


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Fuhs,G.W.andM.Chen. 1975.MicrobiologicalBasisofPhosphateRemovalintheActivatedSludge

ProcessfortheTreatmentofWastewater.MicrobialEcology.2(2):11938

Levin,G.V.andJ.Shapiro.1965.MetabolicUptakeofPhosphorusbyWastewaterOrganisms.Journalof

theWaterPollutionControlFederation(JWPCF),37(6):800821.

Ludzack,F.J.,andM.B.Ettinger.1961.ControllingOperationtoMinimizeActivatedSludgeEffluent

Nitrogen.JournaloftheWaterPollutionControlFederation(JWPCF),34(9):920931,1961

Wuhrman,K.1964.NitrogenRemovalinSewageTreatmentProcesses.Verhandlungenden

InternationalenVereinLimnologie,15:580596,1964.

USEPA.1971.ProcessDesignManualforPhosphorusRemoval.October1971.

USEPA.1975.ProcessDesignManualforNitrogenControl.October1975.

USEPA.1976.ProcessDesignManualforPhosphorusRemoval.EPA/625/176001a,April1976.

USEPA.1987a.DesignManualPhosphorusRemoval.EPA/625/187/001,September1987.

USEPA.1987b.HandbookRetrofittingPOTWsforPhosphorusRemovalintheChesapeakeBayDrainage

Basin.EPA/625/687/017,September1987.

USEPA.1993.ManualNitrogenControl.EPA/625/R93/010,September1993.

USEPAb.2008a.MunicipalNutrientRemovalTechnologiesReferenceDocument. OfficeofWastewater

Management,MunicipalSupportDivision. EPA832R08006. Availableonline:

http://www.epa.gov/OWM/mtb/publications.htm

USEPA.2008b.EmergingTechnologiesforWastewaterTreatmentandInPlantWetWeather

Management. EPA832R06006. Availableonline:http://www.epa.gov/OW

OWM.html/mtb/emerging_technologies.pdf

USEPA.2009.NutrientControlDesignManual:StateofTechnologyReviewReport.OfficeofResearch

andDevelopment.EPA/600/R09/012.January2009.Availableonlineat

http://www.epa.gov/nrmrl/pubs/600r09012/600r09012.pdf#22


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2.NeedforandBenefitsofNitrogenandPhosphorusRemoval

Chapter2covers:

2.1 Introduction

2.2 SourcesofNitrogenandPhosphorusinWastewater

2.3 StatusofWastewaterTreatmentintheUnitedStates

2.4 NutrientImpairmentofU.S.Waterways

2.5 ClimateChangeImpacts

2.6 FederalandStateRegulationsandInitiativestoReduceNutrient

Pollution

2.7 IndustryInitiativestheWERFRemovalChallenge

2.8 BenefitsofNutrientRemoval

2.9 ChallengesofNutrientRemoval

2.10 References

2.1 Introduction

Theharmfuleffectsofeutrophicationduetoexcessivenitrogenandphosphorusconcentrations

intheaquaticenvironmenthavebeenwelldocumented. Algaeandphytoplanktongrowthcanbe

acceleratedbyhigherconcentrationsofnutrients,leadingtoharmfulalgalblooms,hypoxia,andlossof

submergedaquaticvegetation(SAV).Dependingonthespecificwaterbodycharacteristics,either

nitrogenorphosphoruscanbelimiting(i.e.,presentinthesmallestamountcomparedtogrowth

requirements).Inadditiontostimulatingeutrophication,nitrogenintheformofammoniacanexerta

direct

demand

on

dissolved

oxygen

(DO)

and

can

be

toxic

to

aquatic

life.

Even

if

a

wastewater

treatmentplant(WWTP)convertsammoniatonitratebyabiologicalnitrificationprocess,theresultant

nitratecanstimulatealgaeandphytoplanktongrowth.

Fromapublichealthperspective,eutrophicationmayalsocauseriskstohumanhealth,resulting

fromconsumptionofshellfishcontaminatedwithalgaltoxinsordirectexposuretowaterbornetoxins.

Eutrophication,inparticular,cancreateproblemsifthewaterisusedasasourceofdrinkingwater.

Chemicalsusedtodisinfectdrinkingwaterwillreactwithorganiccompoundsinthesourcewaterto

formdisinfectionbyproducts,whicharepotentialcarcinogensandareregulatedbytheUSEPA. Excess

levelsofnitratesabovethemaximumcontaminantlevel(MCL)indrinkingwater(10ppm)cancause

numerousnegativehealtheffectsduetothebodysconversionofnitratetonitrite,includingserious

illnessandsometimesdeath.Infantsinparticulararesusceptibletotheseeffects,whichcaninterfere

withtheoxygencarryingcapacityoftheblood.Thisinterferencecanleadtoanacuteconditioninwhich

healthdeterioratesrapidlyoveraperiodofdays.Symptomsincludeshortnessofbreathandbluenessof

theskin(methemoglobinemia;alsoknownasBluebabySyndrome).

Forthesereasons,itisimportanttolimitnitrogenandphosphoruscontaminationofsurfaceand

groundwater. Onewaytominimizethiscontaminationistoreducelevelsofnitrogenandp

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