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Free Operator Tools

Free calculators for operators. Load a White River example or enter your own plant numbers.

These are teaching tools. They show how the numbers fit together. Check every result against your own plant data, your sampling and your procedures before you change anything.

Secondary clarifier state point and RAS

Will the clarifiers hold at this flow, MLSS and SVI, and what is the least RAS flow that keeps the blanket from climbing? This tool runs the two state point checks: clarification (is the state point under the settling curve?) and thickening (does the RAS underflow line stay under the curve?).

Load an example:

Plant and sludge
Clarifiers in service

Clarifiers of the same size go in one group. The flow and RAS shares for the groups in service must each add up to 100%. Area is worked out for you.

GroupNumber in serviceDiameter (ft)Area (sq ft)Flow share (%)RAS share (%)
Group 1–
Group 2–
Group 3–
Clarifier area in service–sq ft
Surface overflow rate–gpd/sq ft
State point, percent of curve–%
Modeled minimum RAS–MGD
Trial RAS as percent of flow–%
Applied solids load at trial RAS–lb/ft²/d
Applied solids load at current RAS–lb/ft²/d
Settling flux at the MLSS–lb/ft²/d
RAS concentration at trial RAS–mg/L
RAS concentration at current RAS–mg/L
Peak of the settling curve at–g/L
Peak settling flux–lb/ft²/d

Settling flux chart

Dark curve: gravity settling flux for this SVI. Dots: the state point for each group (red when it is above the curve). Solid lines: underflow lines at the trial RAS. Dashed lines: the current RAS. A clarifier holds when the state point is under the curve and the underflow line does not cross it.

By group

GroupArea (sq ft)Flow (MGD)Trial RAS (MGD)SOR (gpd/sq ft)State point (% of curve)Minimum RAS (MGD)Result

What if SVI or MLSS changes?

State point as a percent of the settling curve at this plant flow and clarifier area (clarification check only). Over 100% (red) means clarification failure. The 80% line between green and amber is a teaching rule of thumb, not a design standard.

Summary


    
How it works and where the numbers come from

Settling flux at a solids concentration X (g/L): G = X × γ × e−δ·SVI × e−(α + β·SVI)·X, with α = 0.261 L/g, β = 0.00166, δ = 0.0037 and γ = 14.9 m/h, converted to the units you pick.

State point flux = 8.34 × 1,000 × Q × X / A (lb/ft²/d with Q in MGD, X in g/L, A in sq ft). Applied solids load = 8.34 × 1,000 × (Q + R) × X / A. Underflow concentration XR = X (Q + R) / R.

Minimum RAS: the smallest R that keeps the underflow line 8,340 [(Q + R) X − R x] / A at or under the settling curve G(x) for every concentration x above X. If the state point is already above the curve, no RAS rate can fix it, and the tool says so.

SVI: use the settling test your plant runs every day. Stirred and unstirred tests give different numbers, so keep to one method and watch the trend. The White River examples use the standard unstirred 30-minute test in a 2 L settleometer.

Sources. Settling coefficients: E.J. Wahlberg, Brown and Caldwell settling flux spreadsheet (1996), built on Wahlberg, E.J. and Keinath, T.M. (1988), “Development of settling flux curves using SVI,” Journal WPCF 60(12), 2095, and their 1995 addendum in Water Environment Research 67(5), 872. State point analysis: Keinath, T.M. (1985), “Operational dynamics and control of secondary clarifiers,” Journal WPCF 57(7), 770.

Cutaway illustration of a secondary clarifier with a Unitube suction header collector. Mixed liquor enters through the center pier and influent well, floc settles into the sludge blanket, the suction header draws sludge through its orifices to the sludge withdrawal line for RAS and WAS, clear water spills over the effluent weir into the launder, and scum is skimmed into the scum trough.
A secondary clarifier like the ones at White River: mixed liquor in at the center, sludge out through the suction header, clear water over the weir.
Bar charts of WRRRF secondary clarifier loading. Surface overflow rate: 314 gpd/sq ft at design average (8.0 MGD), 250 on September 3 (6.36 MGD), 574 during the September 13 storm (14.4 MGD) and 943 at the 24 MGD peak hour, against a peak guide of 1,000. Solids loading rate: 12, 8, 15 and 28 lb/day/sq ft, against guide lines of about 30 on average and 40 to 50 at peak.
White River clarifier loading from design day to the September storm and the design peak hour.

Gravity belt thickener

Solids load, belt loading, capture, thickening factor and polymer dose for a gravity belt thickener.

Load an example:

Feed, product and polymer
Feed solids–lb/h
Dry solids–tons/day
Solids capture–%
Thickening factor–times
Hydraulic loading–gpm per ft of belt
Solids loading–lb/h per ft of belt
Polymer dose–lb active per dry ton
Volume reduction–%
Power cost–$ per day

How it works

Feed solids (lb/h) = gpm × 60 × 8.34 × solids % / 100. Dry tons per day = lb/h × hours / 2,000. Capture = thickened solids (lb/h) / feed solids (lb/h) from the flows and solids you enter; confirm it with filtrate TSS. Polymer dose (lb active per dry ton) = gal/h × lb/gal × active % / 100 × hours / dry tons. Hydraulic loading = gpm / belt width. Volume reduction = (feed gpm − thickened gpm) / feed gpm.

Sludge volume index (SVI)

SVI = settled volume at 30 minutes (mL/L) × 1,000 / MLSS (mg/L).

Load an example:

SVI–mL/g

White River reads under 130 as its target and over 150 as a bulking concern.

Settleometer test after 30 minutes: good settling at 300 mL/L (SVI 114), bulking at 390 mL/L (SVI 172), and old pin floc sludge at 215 mL/L (SVI 65), with the SVI formula SVI = SSV30 x 1,000 / MLSS.
The 30-minute settling test at White River: good settling, bulking and pin floc.

Pounds per day

Pounds per day = flow (MGD) × concentration (mg/L) × 8.34.

Load an example:

Load–lb/day

Practice on a whole plant

Every example button on this page comes from our fictional training plant. See its process, design data and a month of operating data on the White River Resource Recovery Facility (WRRRF) page, then follow a learning path through the classes.

Want this taught at your plant?

We teach these calculations with your own plant numbers, on site or online.

Call 503-701-2766 or email help@ActivatedSludge.com.