Optimization of a large industrial wastewater treatment plant using a modeling approach: A case study

The objective of this paper is to find the optimum solid retention time (SRT) of a wastewater treatment plant (WWTP), which minimizes operating costs, using a modeling approach with WEST software by MIKE DHI®. For the determination of the kinetic and stoichiometric parameters (used for the correct calibration of the model implemented), respirometric and kinetic batch tests were carried out. Each Oxidation ditch was modeled by a sequence of four aerated activated sludge units (ASUs) and four anoxic ASUs with recirculation. The model is able to simulate the separation efficiency of the secondary settler, which is generally quite low: in fact, the industrial origin of the wastewater induces the formation of small flocs, the dimensions of which can be further reduced by the presence of surface aerators. The nitrification/denitrification process is also accurately predicted. Using data obtained from the model, mass balances at the steady state for COD and N were made and compared to the ones obtained using measured data. After calibration and validation of the model, steady-state simulations were carried out by increasing and decreasing the SRT of the system under two different operational conditions used by the managing company and by evaluating the costs related to the water treatment line and the sludge treatment line for each scenario. It is interesting to note how the total costs are lower in summer than in winter (7.2 €cent/m³ in summer and 8.7 €cent/m³ in winter, in scenario 0). In general, the increase in the SRT led to a decrease in the total management costs. In fact, differences between scenario 0 and the scenario with the lowest total treatment costs (corresponding to an SRT of 11.4 d in winter and 10.0 d in summer) could give rise to total savings of about 44·000€/year in summer and 93·000€/year in winter.