Continuity-based model interfacing for plant-wide simulation: a general approach

In plant-wide simulation studies of wastewater treatment facilities, often existing models from different origin need to be coupled. However, as these submodels are likely to contain different state variables, their coupling is not straightforward. The continuity-based interfacing method (CBIM) provides a general framework to construct model interfaces for models of wastewater systems, taking into account conservation principles. In this contribution, the CBIM approach is applied to study the effect of sludge digestion reject water treatment with a SHARON-Anammox process on a plant-wide scale. Separate models were available for the SHARON process and for the Anammox process. The Benchmark simulation model no. 2 (BSM2) is used to simulate the behaviour of the complete WWTP including sludge digestion. The CBIM approach is followed to develop three different model interfaces. At the same time, the generally applicable CBIM approach was further refined and particular issues when coupling models in which pH is considered as a state variable, are pointed out.     

New generic mathematical model for WWTP sludge digesters operating under aerobic and anaerobic conditions: Model building and experimental verification

This paper presents a new mathematical model developed to reproduce the performance of a generic sludge digester working either under aerobic or anaerobic operational conditions. The digester has been modelled as two completely mixed tanks associated with gaseous and liquid volumes. The conversion model has been developed based on a plant wide modelling methodology (PWM) and comprises biochemical transformations, physicochemical reactions and thermodynamic considerations. The model predicts the reactor temperature and the temporary evolution of an extensive vector of model components which are completely defined in terms of elemental mass fractions (C, H, O, N and P) and charge density. Thus, the comprehensive definition of the model components guarantees the continuity of elemental mass and charge in all the model transformations and between any two systems defined by the model. The aim of the generic digester model is to overcome the problems that arise when trying to connect aerobic and anaerobic digestion processes working in series or to connect water and sludge lines in a WWTP. The modelling methodology used has allowed the systematic construction of the biochemical model which acts as an initial illustrative example of an application that has been experimentally verified. The variation of the temperature is also predicted based on a thermal dynamic model. Real data from four different facilities and a straightforward calibration have been used to successfully verify the model predictions in the cases of mesophilic and thermophilic anaerobic digestion as well as autothermal thermophilic aerobic digestion (ATAD). The large amount of data from the full scale ATAD and the anaerobic digestion pilot plants, all of them working under different conditions, has allowed the validation of the model for that case study.     

A new plant-wide modelling methodology for WWTPs

This paper presents a new plant-wide modelling methodology for describing the dynamic behaviour of water and sludge lines in WWTPs. The methodology is based on selecting the set of process transformations needed for each specific WWTP to model all unit-process elements in the entire plant. This "transformation-based" approach, in comparison with the conventional "process-based" approach, does not require the development of specific transformers to interface the resulting unit-process models, facilitates the mass and charge continuity throughout the whole plant and is flexible enough to construct models tailored for each plant under study. As an illustrative example, a plant-wide model for a WWTP that includes carbon removal and anaerobic digestion has been constructed, and the main advantages of the proposed methodology for integrated modelling have been demonstrated. As a final consequence, this paper proposes a rewriting of the existing unit-process models according to the new standard transformation-based approach for integrated modelling purposes.     

Modelling the energy balance of an anaerobic digester fed with cattle manure and renewable energy crops

Knowledge of the net energy production of anaerobic fermenters is important for reliable modelling of the efficiency of anaerobic digestion processes. By using the Anaerobic Digestion Model No. 1 (ADM1) the simulation of biogas production and composition is possible. This paper shows the application and modification of ADM1 to simulate energy production of the digestion of cattle manure and renewable energy crops. The paper additionally presents an energy balance model, which enables the dynamic calculation of the net energy production. The model was applied to a pilot-scale biogas reactor. It was found in a simulation study that a continuous feeding and splitting of the reactor feed into smaller heaps do not generally have a positive effect on the net energy yield. The simulation study showed that the ratio of co-substrate to liquid manure in the inflow determines the net energy production when the inflow load is split into smaller heaps. Mathematical equations are presented to calculate the increase of biogas and methane yield for the digestion of liquid manure and lipids for different feeding intervals. Calculations of different kinds of energy losses for the pilot-scale digester showed high dynamic variations, demonstrating the significance of using a dynamic energy balance model.     

Modified ADM1 structure for modelling municipal primary sludge hydrolysis

This study elaborates the rate-limiting steps of particle disintegration/hydrolysis of primary sludge using methane production rate (MPR) curves from multiple batch experiments. Anaerobic batch degradation of fresh primary sludge showed a complex MPR curve marked with two well-defined temporal peaks. The first immediate peak was associated with the degradation of relatively readily hydrolysable substrates, while the second delayed peak was associated with the degradation of large-sized particles. For simulating the second delayed peak, it was necessary to consider a more elaborate particle disintegration/hydrolysis model. Based on the anaerobic respirograms of 17 runs in four datasets and using a substrate characterisation approach similar to activated sludge models (ASMs), the primary sludge was classified into three biodegradable fractions having different kinetics. These are (1) a hydrolysable substrate (X(Settle-I)) showing a degradation typical to slowly biodegradable compounds, (2) a substrate fraction (X(Settle-II)) having a degradation similar to lysis of biomass fraction and (3) a substrate requiring disintegration before hydrolysis (X(Settle-III)) representing the large-sized particles in primary sludge. Based on these results, modifications in the model structure of anaerobic digestion model no. 1 (ADM1) are proposed to improve the modelling of primary sludge solid degradation in anaerobic digesters.     

The bacterial population of piggery-waste anaerobic digesters

A survey was made of the anaerobic and facultatively anaerobic bacteria present in piggery waste, digesting piggery waste and domestic anaerobic sludge sludge used to start a piggery waste digester. An influence of the input waste was shown in that streptococci, the predominant facultatively anaerobic bacteria in the piggery waste, were the predominant bacteria in the digesting waste, and they replaced Enterobacter, predominant in the domestic sludge, when a piggery waste digestion had been established from this latter material. Cellulolytic or methanogenic bacteria could not be detected in the piggery waste but populations of these, and other hydrolytic bacteria, became established at different times during the buildup of digestion by gradual addition of piggery waste to water. The bacteria concerned in degradation of the waste constituents were all anaerobes.Production of methane from H₂/CO₂, formate and butyrate could be detected in mixed cultures from dilutions of digester contents, but the only methanogenic bacterium that could be isolated in pure culture was Methanobacterium formicicum, which uses H₂/CO₂ or formate only.     

Using bioprocess stoichiometry to build a plant-wide mass balance based steady-state WWTP model

Steady-state models are useful for design of wastewater treatment plants (WWTPs) because they allow reactor sizes and interconnecting flows to be simply determined from explicit equations in terms of unit operation performance criteria. Once the overall WWTP scheme is established and the main system defining parameters of the individual unit operations estimated, dynamic models can be applied to the connected unit operations to refine their design and evaluate their performance under dynamic flow and load conditions. To model anaerobic digestion (AD) within plant-wide WWTP models, not only COD and nitrogen (N) but also carbon (C) fluxes entering the AD need to be defined. Current plant-wide models, like benchmark simulation model No 2 (BSM2), impose a C flux at the AD influent. In this paper, the COD and N mass balance steady-state models of activated sludge (AS) organics degradation, nitrification and denitrification (ND) and anaerobic (AD) and aerobic (AerD) digestion of wastewater sludge are extended and linked with bioprocess transformation stoichiometry to form C, H, O, N, chemical oxygen demand (COD) and charge mass balance based models so that also C (and H and O) can be tracked through the whole WWTP. By assigning a stoichiometric composition (x, y, z and a in C_xH_yO_zN_a) to each of the five main influent wastewater organic fractions and ammonia, these, and the products generated from them via the biological processes, are tracked through the WWTP. The model is applied to two theoretical case study WWTPs treating the same raw wastewater (WW) to the same final sludge residual biodegradable COD. It is demonstrated that much useful information can be generated with the relatively simple steady-state models to aid WWTP layout design and track the different products exiting the WWTP via the solid, liquid and gas streams, such as aerobic versus anaerobic digestion of waste activated sludge, N loads in recycle streams, methane production for energy recovery and green house gas (CO₂, CH₄) generation. To reduce trial and error usage of WWTP simulation software, it is recommended that they are extended to include pre-processors based on mass balance steady-state models to assist with WWTP layout design, unit operation selection, reactor sizing, option evaluation and comparison and wastewater characterization before dynamic simulation.     

Fate of pathogens in thermophilic aerobic sludge digestion

The effect of autoheated aerobic thermophilic digestion on the pathogen content of sewage sludges was studied and compared to that of conventional mesophilic anaerobic digestion. Both systems were full scale, continuously-fed facilities operated in parallel and utilized a feed sludge of thickened primary and waste-activated sludge.The relative populations of viruses, Salmonella sp., total and fecal coliforms, fecal streptococci and parasites found before and after digestion were compared. The full scale mesophilic anaerobic digesters were operated at relatively constant conditions, i.e. digester temperature constant at 35°C, and loading rates constant, etc., while the full scale autoheated aerobic digester was operated under a wide range of loading conditions. At all of the conditions studied, the autoheated digester temperature exceeded 45 C. Virus and Salmonella sp. concentrations in the effluent from the aerobic unit were below detectable limits in 10 of 11 samples and 6 of 6 samples, respectively, whereas the anaerobic digester effluent contained detectable numbers of viruses and Salmonella sp. Bacterial indicator counts and parasite concentrations were less in the autoheated digester effluent than in the effluent from the anaerobic digester. It was concluded that the simple autoheated aerobic digestion process could be used to produce a virtually pathogen-free sludge at a cost comparable to that of conventional, mesophilic anaerobic digestion.     

GISCOD: General Integrated Solid Waste Co-Digestion model

This paper views waste as a resource and anaerobic digestion (AD) as an established biological process for waste treatment, methane production and energy generation. A powerful simulation tool was developed for the optimization and the assessment of co-digestion of any combination of solid waste streams. Optimization was aimed to determine the optimal ratio between different waste streams and hydraulic retention time by changing the digester feed rates to maximize the biogas production rate. Different model nodes based on the ADM1 were integrated and implemented on the Matlab-Simulink^® simulation platform. Transformer model nodes were developed to generate detailed input for ADM1, estimating the particulate waste fractions of carbohydrates, proteins, lipids and inerts. Hydrolysis nodes were modeled separately for each waste stream. The fluxes from the hydrolysis nodes were combined and generated a detailed input vector to the ADM1. The integrated model was applied to a co-digestion case study of diluted dairy manure and kitchen wastes. The integrated model demonstrated reliable results in terms of calibration and optimization of this case study. The hydrolysis kinetics were calibrated for each waste fraction, and led to accurate simulation results of the process and prediction of the biogas production. The optimization simulated 200,000 days of virtual experimental time in 8 h and determined the feedstock ratio and retention time to set the digester operation for maximum biogas production rate.     

The effect of sludge digestion on virus infectivity

The rate of inactivation of coxsackievirus B3 during anaerobic sludge digestion was found to be 2 log units in 24 h at pH 7.0 and 35°C. The rate indicates that virus inactivating factor(s) were produced in the digestion. The virus inactivation was enhanced if the digester sludge was pasteurized at 60°C for 1 h. The reason why digesters at sewage treatment plants do not completely inactivate virus is discussed in terms of the continuous nature of digester operation.     

Modified ADM1 disintegration/hydrolysis structures for modeling batch thermophilic anaerobic digestion of thermally pretreated waste activated sludge

Anaerobic digestion disintegration and hydrolysis have been traditionally modeled according to first-order kinetics assuming that their rates do not depend on disintegration/hydrolytic biomass concentrations. However, the typical sigmoid-shape increase in time of the disintegration/hydrolysis rates cannot be described with first-order models. For complex substrates, first-order kinetics should thus be modified to account for slowly degradable material. In this study, a slightly modified IWA ADM1 model is presented to simulate thermophilic anaerobic digestion of thermally pretreated waste activated sludge. Contois model is first included for disintegration and hydrolysis steps instead of first-order kinetics and Hill function is then used to model ammonia inhibition of aceticlastic methanogens instead of a non-competitive function. One batch experimental data set of anaerobic degradation of a raw waste activated sludge is used to calibrate the proposed model and three additional data sets from similar sludge thermally pretreated at three different temperatures are used to validate the parameters values.     

Combined anaerobic and aerobic digestion for increased solids reduction and nitrogen removal

A unique sludge digestion system consisting of anaerobic digestion followed by aerobic digestion and then a recycle step where thickened sludge from the aerobic digester was recirculated back to the anaerobic unit was studied to determine the impact on volatile solids (VS) reduction and nitrogen removal. It was found that the combined anaerobic/aerobic/anaerobic (ANA/AER/ANA) system provided 70% VS reduction compared to 50% for conventional mesophilic anaerobic digestion with a 20 day SRT and 62% for combined anaerobic/aerobic (ANA/AER) digestion with a 15 day anaerobic and a 5 day aerobic SRT. Total Kjeldahl nitrogen (TKN) removal for the ANA/AER/ANA system was 70% for sludge wasted from the aerobic unit and 43.7% when wasted from the anaerobic unit. TKN removal was 64.5% for the ANA/AER system.     

Biodegradation of the endogenous residue of activated sludge

This study evaluated the potential biodegradability of the endogenous residue in activated sludge subjected to batch digestion under either non-aerated or alternating aerated and non-aerated conditions. Mixed liquor for the tests was generated in a 200 L pilot-scale aerobic membrane bioreactor (MBR) operated at a 5.2 days SRT. The MBR system was fed a soluble and completely biodegradable synthetic influent composed of sodium acetate as the sole carbon source. This influent, which contained no influent unbiodegradable organic or inorganic materials, allowed to generate sludge composed of essentially two fractions: a heterotrophic biomass X_H and an endogenous residue X_E, the nitrifying biomass being negligible (less than 2%). The endogenous decay rate and the active biomass fraction of the MBR sludge were determined in 21-day aerobic digestion batch tests by monitoring the VSS and OUR responses. Fractions of X_H and X_E: 68% and 32% were obtained, respectively, at a 5.2 days SRT. To assess the biodegradability of X_E, two batch digestion units operated at 35 °C were run for 90 days using thickened sludge from the MBR system. In the first unit, anaerobic conditions were maintained while in the second unit, alternating aerated and non-aerated conditions were applied. Data for both units showed apparent partial biodegradation of the endogenous residue. Modeling the batch tests indicated endogenous residue decay rates of 0.005 d⁻¹ and 0.012 d⁻¹ for the anaerobic unit and the alternating aerated and non-aerated conditions, respectively.     

Investigation of the sludge reduction mechanism in the anaerobic side-stream reactor process using several control biological wastewater treatment processes

To investigate the mechanism of sludge reduction in the anaerobic side-stream reactor (SSR) process, activated sludge with five different sludge reduction schemes were studied side-by-side in the laboratory. These are activated sludge with: 1) aerobic SSR, 2) anaerobic SSR, 3) aerobic digester, 4) anaerobic digester, and 5) no sludge wastage. The system with anaerobic SSR (system #2) was the focus of this study and four other systems served as control processes with different functions and purposes. Both mathematical and experimental approaches were made to determine solids retention time (SRT) and sludge yield for the anaerobic SSR process. The results showed that the anaerobic SSR process produced the lowest solids generation, indicating that sludge organic fractions degraded in this system are larger than other systems that possess only aerobic or anaerobic mode. Among three systems that involved long SRT (system #1, #2, and #5), it was only system #2 that showed stable sludge settling and effluent quality, indicating that efficient sludge reduction in this process occurred along with continuous generation of normal sludge flocs. This observation was further supported by batch anaerobic and aerobic digestion data. Batch digestion on sludges collected after 109 days of operation clearly demonstrated that both anaerobically and aerobically digestible materials were removed in activated sludge with anaerobic SSR. In contrast, sludge reduction in the aerobic SSR process or no wastage system was achieved by removal of mainly aerobically digestible materials. All these results led us to conclude that repeating sludge under both feast/fasting and anaerobic/aerobic conditions (i.e., activated sludge with anaerobic SSR) is necessary to achieve the highest biological solids reduction with normal wastewater treatment performance.     

Anaerobic digestion of seven different sewage sludges: A biodegradability and modelling study

Seven mixed sewage sludges from different wastewater treatment plants, which have an anaerobic digester in operation, were evaluated in order to clarify the literature uncertainty with regard to the sewage sludge characterisation and biodegradability. Moreover, a methodology is provided to determine the Anaerobic Digestion Model No. 1 parameters, coefficients and initial state variables as well as a discussion about the accuracy of the first order solubilisation constant, which was obtained through biomethane potential test. The results of the biomethane potential tests showed ultimate methane potentials from 188 to 214 mL CH₄ g⁻¹ COD_fed, COD removals between 58 and 65% and two homogeneous groups for the first order solubilisation constant: (i) the lowest rate group from 0.23 to 0.35 day⁻¹ and (ii) the highest rate group from 0.27 to 0.43 day⁻¹. However, no statistically significant relationship between the ultimate methane potential or the disintegration constant and the sewage sludge characterisation was found. Next, a methodology based on the sludge characterisation before and after the biomethane potential test was developed to calculate the biodegradable fraction, the composite concentration and stoichiometric coefficients and the soluble COD of the sewage sludge; required parameters for the implementation of the Anaerobic Digestion Model No. 1. The comparison of the experimental and the simulation results proved the consistency of the developed methodology. Nevertheless, an underestimation of the first order solubilisation constant was detected when the experimental results were simulated with the solubilisation constant obtained from the linear regression experimental data fitting. The latter phenomenon could be related to the accumulation of intermediary compounds during the biomethane potential assay.     

Extracellular biological organic matters in sewage sludge during mesophilic digestion at reduced hydraulic retention time

To operate an anaerobic digester at low hydraulic retention time (HRT) is welcome in practice. This study characterized the extracellular biological organic matter (EBOM) and supernatant organics for a sewage sludge digested in a lab-scale mesophilic digester (5 l) running at an HRT of 20, 15 or 10 d. The hydrophilic and hydrophobic acid fractions were the principal components in the sludge EBOM. The hydrolysis rates for hydrophobic acid fraction related EBOM at 10 d HRT and that of hydrophilic fraction related proteins in supernatant at 20 d HRT limited the anaerobic processes. Improved hydrolysis of soluble hydrophilic fraction assisted improving digester performance at 20 d HRT. To shorten digestion HRT, efficiency of hydrophobic acid fraction hydrolysis has to be practiced.     

Operating Experiences of Sludge Disinfection and Stabilization at Colburn Sewage Treatment Works, Yorkshire

A NEW integrated sludge treatment plant was installed at Colburn sewage treatment works (STW) in 1986. The plant comprises a number of novel features including a continuous gravity thickener features including a continuous gravity thickener, a pasteurization unit using submerged combustion of digester gas for sludge heating, a peat-bed odour control system, and a 'pump-our/pump-in'prefabricated anaerobic digester. Plant operation is controlled automatically by a computer system The performance of the thickener has been in accordance with predictions and has achieved at least a halving of raw sludge volume. The submerged combustion plant has consistently heated the sludge to 70°C with high efficiency of gas utilization before the anaerobic digestion stage. Some problems were experienced with the continuity of supply of the raw sludge but overall the plant has performed very satisfactorily with the production of a high quality disinfected and stabilized sludge for use by local farmers.     

CFD simulation of anaerobic digester with variable sewage sludge rheology

A computational fluid dynamics (CFD) model that evaluates mechanical mixing in a full-scale anaerobic digester was developed to investigate the influence of sewage sludge rheology on the steady-state digester performance. Mechanical mixing is provided through an impeller located in a draft tube. Use is made of the Multiple Reference Frame model to incorporate the rotating impeller. The non-Newtonian sludge is modeled using the Hershel–Bulkley law because of the yield stress present in the fluid. Water is also used as modeling fluid to illustrate the significant non-Newtonian effects of sewage sludge on mixing patterns. The variation of the sewage sludge rheology as a result of the digestion process is considered to determine its influence on both the required impeller torque and digester mixing patterns. It was found that when modeling the fluid with the Hershel–Bulkley law, the high slope of the sewage stress-strain curve at high shear rates causes significant viscous torque on the impeller surface. Although the overall fluid shear stress property is reduced during digestion, this slope is increased with sludge age, causing an increase in impeller torque for digested sludge due to the high strain rates caused by the pumping impeller. Consideration should be given to using the Bingham law to deal with high strain rates. The overall mixing flow patterns of the digested sludge do however improve slightly.     

The behaviour of nitrilotriacetic acid during the anaerobic digestion of sewage sludge

In laboratory simulations of the anaerobic sludge digestion process, the impact of the detergent builder nitrilotriacetic acid (NTA) on digester efficiency has been studied. It was concluded that NTA at concentrations up to 30 mg l⁻¹ had no adverse effect on anaerobic digestion. However, analysis of the digested sludge indicated that only 29–45% of the influent NTA was removed during treatment. To differentiate between biological and physical processes of removal, biological activity in the digesters was arrested by the addition of sodium azide. Effluent NTA concentration did not increase indicating that biological activity was not responsible for the removal observed.Batch experiments undertaken to evaluate NTA solubility in digested sludge (containing azide) at two solids concentrations indicated a decrease in soluble NTA with increasing solids concentration.It is concluded that the removal of NTA observed during anaerobic digestion was not biological and in part was the result of adsorption onto the solid phase.     

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