BugJuice – Sludge Reduction

Correctional Facility Sludge Storage

Challenge

A wastewater treatment plant located at a correctional facility in Wisconsin operates an oxidation ditch with a primary flow of 150,000 gallons per day. They have two sludge storage tanks that were filled to the brim. This caused them to haul sludge often, costing them thousands of dollars each year.

Solution

To reduce hauling, this summer (2014) the operators applied 5 gallons of BugJuice initially and then dropped back to ½ a gallon per week. The biochemical catalysts went to work by degrading the immense sludge buildup caused by papers and grease from the correctional facility.

Results

By November 2014, the sludge levels dropped two-thirds. The sludge thickened and went from 1.4% to 3%. The operator calculated a savings of $17,000 in sludge hauling costs.

Aerobic Digester #1

Challenge

One municipality operates a 300,000 gpd activated sludge plant. All of their solids go into one of two 100,000 gallon digestors. Once a month one of the digesters is hauled off to a field for land application. It cost roughly $4,000 per month to haul sludge.

Solution

They added 1 gallon per 100,000 gallons per week.

Results

This municipality reduced the amount of sludge hauled by 86,500 gallons.

Aerobic Digestor #2

Challenge

A small city in southern Wisconsin operates a wastewater plant with a 100,000 gallon digestor. They are always looking for the best way to haul less sludge. Their sludge was between 2.0% to 2.5% thick and they were hauling every two months. It cost them $5,000 every time they hauled.

Solution

They began adding Foam Buster and BugJuice.

Results

Solids went up to 3.0% to 3.5% and they reduced their hauling to every four months. This program was able to save this small city $15,000 per year.

Chicagoland Wastewater Treatment plant, USA

Flow: 1 MGD

Waste Type: Municipal

Incoming BOD 150-200

Challenge

Improve belt press dewatering of activated sludge A municipal wastewater operator called looking to improve his belt press dewatering. He said “It’s not dewatering properly. Instead of a nice solid cake we have a slimy mess, and our belt filter press keeps blinding “. He went on to explain that despite increasing their polymer use the situation wasn’t improving. Problems like blinding of the belt press are often related to the health of the biological populations, filaments, zooglea and polysaccharide formation all play a role. The operator sent a sample to our lab and we found the filaments Nocardia and Microthrix, in addition we found high levels of polysaccharide slime. All three are common in systems with high fats, oils and grease and long sludge ages.

Solution

BugJuice

Results

The biocatalysts in BugJuice convert insoluble BOD to soluble BOD that is assimulated by bacteria. In this case grease and surfactants is what we had to breakdown. For this 1 MGD plant, the operator used 2.5 gallons per week for the first month and then dropped back to 1 gallon of BugJuice per week per digester. BugJuice is added straight into the digester. Within two weeks the sludge began dewatering better. In four weeks their sludge cake solids increased from 8% to 13%, a huge improvement in density and quality. BugJuice increased the percent solids by first breaking down the fats, oils, grease, paper, waxes and surfactants that had refused to break down before. The bacteria in the digester were then able to utilize the newly-soluble BOD sources, reducing polysaccarides to further refine the sludge. The result is a sludge that isn’t blinding the press, is holding less moisture, and can be compacted into a better cake. The cost of BugJuice has been more than offset by the decrease in hauling costs and lower polymer bills.