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Tighter discharge permits often require wastewater treatment plants to maximize utilization of available facilities in order to cost-effectively reach these goals. Important aspects are minimizing internal disturbances and using available information in a smart way to improve plant performance. In this study, flow control throughout a large highly automated wastewater treatment plant (WWTP) was implemented in order to reduce internal disturbances and to provide a firm foundation for more advanced process control. A modular flow control system was constructed based on existing instrumentation and soft sensor flow models. Modules were constructed for every unit process in water treatment and integrated into a plant-wide model. The flow control system is used to automatically control recirculation flows and bypass flows at the plant. The system was also successful in making accurate flow estimations at points in the plant where it is not possible to have conventional flow meter instrumentation. The system provides fault detection for physical flow measuring devices. The module construction allows easy adaptation for new unit processes added to the treatment plant.

Floc characteristics were studied at a full scale activated sludge treatment plant with a unique process solution incorporating pre-denitrification with post-nitrification in nitrifying trickling filters. Since greater nitrogen removal is achieved when more secondary settled wastewater is recirculated to the trickling filters, the secondary settlers are always operated close to their maximal capacity. The flocculation and settling properties are therefore crucial and have an effect on the overall plant performance. Since the plant is operated at a short sludge age, these properties change quickly, resulting in variable maximal secondary settler capacity. The dynamics in floc structure and microbial community composition were studied and correlated to the secondary settler performance. Fluorescence in situ hybridisation was used to investigate the microbial community structure and their spatial distribution. The floc structure could to some extent be related to the flocculation and settling properties of the sludge. Even small differences had an influence suggesting that colloidal properties also play a significant role in determining the floc properties. No correlation between microbial community composition and settling properties could be established with the group-specific probes investigated.

The effect of rain events on effluent quality dynamics was studied at a full scale activated sludge wastewater treatment plant which has a process solution incorporating pre-denitrification in activated sludge with post-nitrification in trickling filters. The incoming wastewater flow varies significantly due to a combined sewer system. Changed flow conditions have an impact on the whole treatment process since the recirculation to the trickling filters is set by the hydraulic limitations of the secondary settlers. Apart from causing different hydraulic conditions in the plant, increased flow due to rain or snow-melting, changes the properties of the incoming wastewater which affects process performance and effluent quality, especially the particle removal efficiency. A comprehensive set of on-line and laboratory data were collected and analysed to assess the impact of rain events on the plant performance.

Secondary settling dynamics at maximal capacity were investigated at a full scale wastewater treatment plant which utilizes a unique process solution incorporating pre-denitrification with post-nitrification in nitrifying trickling filters. Since nitrogen removal is greater when more secondary effluent is recirculated to the trickling filters, the secondary settlers generally operate at close to their maximal capacity. The settling and flocculation properties of the activated sludge are therefore a major capacity-determining factor for plant operation. Due to the short sludge age, the flocculation properties, with respect to both thickening and clarification, can change quickly. The dynamics in these changes were studied and the factors that determine the maximal settling capacity were assessed. Solids flux curves were constructed from batch settling tests and compared with the actual maximal settling capacities.

As on-line instrumentation becomes increasingly important for operating modern wastewater treatment plants it is necessary to have diagnostic methods that can indicate sensor deviation at an early stage. Examples of on-line diagnosis methods used at the Rya WWTP (Göteborg, Sweden) are presented. These include on-line mass balance calculations and soft sensors, which make indirect parameter estimates. By comparing the estimates with the corresponding on-line sensors it is possible to make control decisions and to chose alternative strategies. These comparative methods are often useful for process monitoring and diagnosis as well. Some other soft sensor applications using exponential filters are also presented.