The cost of a large-scale hollow fibre MBR

A cost sensitivity analysis was carried out for a full-scale hollow fibre membrane bioreactor to quantify the effect of design choices and operational parameters on cost. Different options were subjected to a long term dynamic influent profile and evaluated using ASM1 for effluent quality, aeration requirements and sludge production. The results were used to calculate a net present value (NPV), incorporating both capital expenditure (capex), based on costs obtained from equipment manufacturers and full-scale plants, and operating expenditure (opex), accounting for energy demand, sludge production and chemical cleaning costs.Results show that the amount of contingency built in to cope with changes in feedwater flow has a large impact on NPV. Deviation from a constant daily flow increases NPV as mean plant utilisation decreases. Conversely, adding a buffer tank reduces NPV, since less membrane surface is required when average plant utilisation increases. Membrane cost and lifetime is decisive in determining NPV: an increased membrane replacement interval from 5 to 10 years reduces NPV by 19%. Operation at higher SRT increases the NPV, since the reduced costs for sludge treatment are offset by correspondingly higher aeration costs at higher MLSS levels, though the analysis is very sensitive to sludge treatment costs. A higher sustainable flux demands greater membrane aeration, but the subsequent opex increase is offset by the reduced membrane area and the corresponding lower capex.     

Model-based energy optimisation of a small-scale decentralised membrane bioreactor for urban reuse

The energy consumption of a small-scale membrane bioreactor, treating high strength domestic wastewater for community level wastewater recycling, has been optimised using a dynamic model of the plant. ASM2d was chosen as biological process model to account for the presence of phosphate accumulating organisms. A tracer test was carried out to determine the hydraulic behaviour of the plant. To realistically simulate the aeration demand, a dedicated aeration model was used incorporating the dependency of the oxygen transfer on the mixed liquor concentration and allowing differentiation between coarse and fine bubble aeration, both typically present in MBRs. A steady state and dynamic calibration was performed, and the calibrated model was able to predict effluent nutrient concentrations and MLSS concentrations accurately. A scenario analysis (SCA) was carried out using the calibrated model to simulate the effect of varying SRT, recirculation ratio and DO set point on effluent quality, MLSS concentrations and aeration demand. Linking the model output with empirically derived correlations for energy consumption allowed an accurate prediction of the energy consumption. The SCA results showed that decreasing membrane aeration and SRT were most beneficial towards total energy consumption, while increasing the recirculation flow led to improved TN removal but at the same time also deterioration in TP removal. A validation of the model was performed by effectively applying better operational parameters to the plant. This resulted in a reduction in energy consumption by 23% without compromising effluent quality, as was accurately predicted by the model. This modelling approach thus allows the operating envelope to be reliably identified for meeting criteria based on energy demand and specific water quality determinants.     

Biomass effects on oxygen transfer in membrane bioreactors

Ten biomass samples from both municipal and industrial pilot and full scale submerged membrane bioreactors (MBRs) with mixed liquor suspended solids concentrations (MLSS) ranging from 7.2 to 30.2g L(-1) were studied at six air-flow rates (0.7, 1.3, 2.3, 3, 4.4 and 6m(3)m(-3)h(-1)). Statistical analyses were applied to identify the relative impacts of the various bulk biomass characteristics on oxygen transfer. Of the biomass characteristics studied, only solids concentration (correlated with viscosity), the carbohydrate fraction of the EPS (EPS(c)) and the chemical oxygen demand (COD) concentration of the SMP (SMP(COD)) were found to affect the oxygen transfer parameters k(L)a(20) (the oxygen transfer coefficient) and alpha-factor. The relative influence on k(L)a(20) was MLSS>aeration>EPS(c)>SMP(COD) and on alpha-factor was MLSS>SMP(COD)>EPS(c)>aeration. Both k(L)a(20) and alpha-factor increased with increasing aeration and EPS(c) and decreased with increasing MLSS and SMP(COD). MLSS was found to be the main parameter controlling the oxygen transfer.     

Influence of mixed liquor properties and aeration intensity on membrane fouling in a submerged membrane bioreactor at high mixed liquor suspended solids concentrations

This paper presents the results of 195 days of pilot-scale submerged membrane bioreactor (SMBR) experiments on settled municipal wastewater. Short-term and long-term thickening experiments were performed at a constant membrane flux of 30L/(m(2)h) to determine the impact of the following mixed liquor properties: colloidal material, soluble COD, soluble microbial products, extracellular polymeric substances, and viscosity along with aeration intensity on membrane fouling at high mixed liquor suspended solids (MLSS) concentrations. The normalized permeability declined with increasing MLSS concentrations in all experiments and increasing the coarse bubble aeration intensity increased the permeability at a given MLSS concentration. Using a dynamic approach, this work demonstrates the importance of mixed liquor viscosity, which impacts the efficacy of the coarse bubble aeration, in sustaining membrane permeability. Over an extended thickening time period, a small increase in MLSS concentration and mixed liquor viscosity becomes more prevalent and leads to greater permeability decline at a given MLSS concentration.     

Oxygen transfer in membrane bioreactors treating synthetic greywater

Mass transfer coefficients (k_La) were studied in two pilot scale membrane bioreactors (MBR) with different setup configurations treating 200 L/h of synthetic greywater with mixed liquor suspended solids' (MLSS) concentrations ranging from 4.7 to 19.5 g/L. Besides the MLSS concentration, mixed liquor volatile suspended solids (MLVSS), total solids (TS), volatile solids (VS), chemical oxygen demand (COD) and anionic surfactants of the sludge were measured. Although the pilot plants differed essentially in their configurations and aeration systems, similar α-factors at the same MLSS concentration could be determined. A comparison of the results to the published values of other authors showed that not the MLSS concentration but rather the MLVSS concentration seems to be the decisive parameter which influences the oxygen transfer in activated sludge systems operating at a high sludge retention time (SRT).     

Oxygen transfer and uptake, nutrient removal, and energy footprint of parallel full-scale IFAS and activated sludge processes

Integrated fixed-film activated sludge (IFAS) processes are becoming more popular for both secondary and sidestream treatment in wastewater facilities. These processes are a combination of biofilm reactors and activated sludge processes, achieved by introducing and retaining biofilm carrier media in activated sludge reactors. A full-scale train of three IFAS reactors equipped with AnoxKaldnes media and coarse-bubble aeration was tested using off-gas analysis. This was operated independently in parallel to an existing full-scale activated sludge process. Both processes achieved the same percent removal of COD and ammonia, despite the double oxygen demand on the IFAS reactors. In order to prevent kinetic limitations associated with DO diffusional gradients through the IFAS biofilm, this systems was operated at an elevated dissolved oxygen concentration, in line with the manufacturer’s recommendation. Also, to avoid media coalescence on the reactor surface and promote biofilm contact with the substrate, high mixing requirements are specified. Therefore, the air flux in the IFAS reactors was much higher than that of the parallel activated sludge reactors. However, the standardized oxygen transfer efficiency in process water was almost same for both processes. In theory, when the oxygen transfer efficiency is the same, the air used per unit load removed should be the same. However, due to the high DO and mixing requirements, the IFAS reactors were characterized by elevated air flux and air use per unit load treated. This directly reflected in the relative energy footprint for aeration, which in this case was much higher for the IFAS system than activated sludge.     

The role of hydrodynamic conditions and pH on algal-rich water fouling of ultrafiltration

The aim of this paper was to study the membrane fouling phenomena by eutrophic water using Microcystis aeruginosa under various operational conditions (flux and air flow rate) and solution chemistry (pH). All the experiments were performed in a lab scale employing the polyvinyl chloride ultrafiltration membrane with nominal cut-off of 10 kDa. A slight fouling appeared at the flux not more than 10 L/m²/h, and the trend of trans-membrane pressure (TMP) development varied as a function of flux from linear to exponential with the increase of cell concentration. This paper also studied an important consideration of aeration in algal fouling: shear force. Besides alleviating membrane fouling, the shear produced by the bubbling should take responsible for the breakup of cells and the release of intracellular organic matters which caused the rate of the TMP increase closed to that without aeration. The optimum aeration intensity was observed to be 2.5 m³/m²/h in this experimental condition. As another important parameter considered in the study, the pH value of the raw water changed the physical and chemical reaction between the membrane and foulants or themselves. The results showed that the final TMP reduced with the pH increase due to the electro-static repulsion strengthening between the macromolecules which developed a looser gel. The most severe fouling was obtained at pH 5.0 near to the iso-electric point of algal solution, where electrostatic repulsion between algal cells was weakest. Furthermore, low pH value had a negative impact on cell integrity which gave rise to much more dissolved algogenic organic matter in the solution. It also played a part role on the membrane fouling.     

Identification of wastewater sludge characteristics to predict critical flux for membrane bioreactor processes

The effects of sludge characteristics on critical flux were examined using a submerged membrane bioreactor pilot plant operated under different process conditions to treat municipal wastewater. The sludge in the membrane tank was characterized by measuring colloidal particle concentration, extracellular polymeric substances (EPS), mixed liquor suspended solids (MLSS), temperature, time to filter (TTF) and diluted sludge volume index (DSVI). The colloidal particle concentration was represented by the colloidal total organic carbon (TOC), which is the TOC difference between the filtrate passing through a 1.5 microm pore size filter and the permeate collected from pilot ultrafiltration membrane modules with a pore size of 0.04 microm. The results showed that the critical flux measured by the stepwise flux method was almost solely related to the colloidal TOC despite different sludges tested. In contrast, MLSS was shown to have little impact on the critical flux within the range examined. Neither TTF nor DSVI could be used to reliably predict the critical flux. Furthermore, colloidal TOC can be attributed to soluble EPS, but not bound EPS. Therefore, it is suggested that colloidal TOC be used as a new filterability index for MBR processes in wastewater treatment.     

The influence of aeration intensity on predation and EPS production in membrane bioreactors

Shear, in the form of vigorous aeration, is used to control fouling in membrane bioreactor (MBR) systems. However, shear also influences the physicochemical and biological properties of MBR biomass. The current study examines the relationship between the aeration intensity and extracellular polymeric substance (EPS) production in MBRs. Two identical submerged MBRs were operated in parallel but the aeration rate was three times greater in one of the MBRs. The concentrations of floc-associated and soluble EPS were monitored for the duration of the experiment. Microscopic images and floc-size measurements were also collected regularly. The membrane fouling potential of the biomass was quantified using the flux-step method. Increased aeration did not have a direct effect on soluble or floc-associated EPS production in the microfiltration MBRs. However, aeration intensity had a significant effect on predatory organisms. Large aquatic earthworms, Aeolosoma hemprichi, proliferated under lower shear conditions but were never observed in the high shear reactor. Predation by A. hemprichi resulted in increased floc-associated and soluble EPS production. Thus, the mixing conditions in the low shear MBR indirectly resulted in increased soluble EPS concentrations and higher fouling potential. This research suggests that predation can have a significant impact on the production rates of floc-associated and soluble EPS - key parameters driving membrane fouling in MBRs.     

Bacteriophage MS-2 removal by submerged membrane bioreactor

A membrane bioreactor (MBR) may serve as a pre-disinfection or disinfection unit, in addition to its solid/liquid separation and biological conversion functions, to produce sewage effluent of high quality. This bench-scale pilot study focuses on investigating the performance of a submerged MBR in pathogen removal and the factors affecting the removal, using a 0.4-microm hollow-fiber membrane module submerged in an aeration tank and bacteriophage MS-2 as the indicator organism. Removal of the MS-2 phage was found to be contributed by physical filtration by the membrane itself, biomass activity in the aeration tank and bio-filtration achieved by the biofilm developed on the membrane surface. The membrane alone gave poor virus removal (0.4+/-0.1 log) but the overall removal increased substantially with the presence of biomass and the membrane-surface-attached biofilm. The contributions of the suspended biomass and attached biofilm to the phage removal are dependent on the inter-related parameters including the concentration of mixed liquor suspended solids (MLSS), the sludge retention time (SRT) and the food to mass (F/M) ratio. The correlations between effluent flux/trans-membrane pressure and virus removal give evidence that phage removal in the MBR is most likely susceptible to both biological and physical factors including the quantity and property of the biomass and the biofilm and the membrane pore size reduction.     

自生动态膜生物反应器处理城市污水

采用自生动态膜生物反应器（SFDMBR）处理城市污水，结果表明，在整个试验期间反应器对COD的平均去除率为81％，在稳定运行期间，对氨氮的平均去除率为87％，对总磷的平均去除率为70％；两边侧向曝气的效果明显优于单边侧向曝气，它不仅能够加大膜片间的错流流速，而且还能使错向流更加均匀；自生动态膜的形成较恢复快，且恢复速度随运行时间的延长呈递增趋势；出水水头、污泥浓度、膜通量、混合液粘度、膜面错流流速等对膜阻力有影响。     

The Development and Use of Hybrid Aeration Processes

Requirements to improve effluent quality have led to the establishment of better design procedures for activated-sludge plants. The recognition that activated-sludge aeration is responsible for a large proportion of the energy used in sewage treatment has resulted in the specification of energy-efficient aeration systems as part of such design procedures. Fine-bubble diffused-air techniques are potentially more efficient than mechanical surface-aeration systems, but low oxygen-transfer efficiency is often observed in practice under conditions of high aeration tank solids loading. Surface-aeration systems appear to be able to operate at reasonable aeration efficiencies under conditions of high loading, but they are not as effective as diffused-air systems in low-rate processes.
There is evidence that a properly designed combination of the two types of aeration system in the same process (hybrid aeration) can result in optimum energy use and good effluent quality. The paper describes the development of this concept, showing the long-term performance of three full-scale plants utilizing hybrid aeration.     

Control of the aeration volume in an activated sludge process using supervisory control strategies

In this paper, a simulation benchmark of a pre-denitrifying activated sludge process is utilized in order to evaluate a supervisory aeration volume control strategy. The aeration volume control strategy has also been evaluated in a pilot plant at Hammarby Sj?stad in Stockholm, Sweden. The main idea has been to let the dissolved oxygen (DO) concentration in some of the aerated compartments be determined by a higher level controller driven by the DO concentration in other compartments. In this way, only sensors for measuring the DO concentrations are needed for the decision of time varying DO set-points. The high reliability of such sensors implies robust input values for the proposed control strategy. Moreover, it is known that the respiration rate is affected by the content of substrate and nitrogen in the compartments; therefore, the suggested manipulations of the DO set-points are indirectly determined by the current load into the plant. Compared to constant DO control and a supervisory DO set-point control strategy based on ammonium measurements in the last aerobic compartment, the suggested aeration volume control strategy could reduce the effluent nitrate and ammonium concentrations significantly without increasing the aeration energy.     

Effects of aeration patterns on the flow field in wastewater aeration tanks

Due to the high energy input of aeration, the spatial distribution of air diffusers largely determines the flow field in aeration tanks. This has consequences on the efficiency of the aeration system, the performance of the aeration tank and on tank operation and control. This paper deals with these effects applying both Computational Fluid Dynamics (CFD) enhanced with a biokinetic model and full scale validation using velocity and reactive tracer measurements with high temporal and spatial resolution. It is shown that small changes in the diffuser arrangement drastically change the overall flow field. Using different aeration patterns in the same tank may lead to large scale instabilities in the flow field that lower plant performance and produce strong variations in concentration signals impeding their use for plant control. CFD is a valuable tool to analyze the interaction of flow field and aeration and their effects on plant performance and operation. But, in complex flow situations experimental validation is needed and strongly suggested.     

The cost of a package plant membrane bioreactor

The capital and operating costs associated with a small package plant MBR for small-scale domestic duty has been appraised based on a medium-strength municipal wastewater. The three main membrane configurations were considered, these being multi-tube, hollow fibre and flat sheet, with the most appropriate plant design chosen for each configuration. The analysis proceeded via a consideration of the estimated amortised capital costs of the plant individual components and their installation, coupled with operating costs based largely on energy demand and residuals management. Energy demand was calculated from aeration and pumping costs, with aeration based on a combination of empirical relationships for membrane aeration and mass balance, and the modified Activated Sludge Model version 2 used for estimating tank size and sludge generation. Results indicate that it is possible to produce a single household MBR at a capital cost similar to the current market cost for package treatment plants. Desludging and maintenance of these plants is similar but power requirements for an MBR are around 4 times that associated with more conventional package plants. Economies of scale exist from 6-20 p.e. plants but above 20 p.e. there is little cost difference per head, due to the design assumptions made. CAPEX and OPEX are to some extent interchangeable; reductions in CAPEX are associated with an increase in OPEX and vice versa. Whilst costs are high, the market for package MBRs is significantly influenced by the recycling potential of the effluent produced.     

Influence of filtration conditions on membrane fouling and scouring aeration effectiveness in submerged membrane bioreactors to treat municipal wastewater

Membrane fouling and scouring aeration effectiveness were studied using three large pilot-scale submerged membrane bioreactors (MBRs) operated at a series of permeate fluxes, scouring aeration intensities and cyclic aeration frequencies to treat municipal wastewater. The results showed that when operated at the sustainable conditions, the MBRs had a stable reversible fouling resistance. At unsustainable conditions, the reversible fouling resistance increased exponentially as filtration progressed. For each of above two cases, the fouling ratios newly defined by Eqs. (7) and (8) were calculated from the transmembrane pressure increases to compare the relative reversible fouling rates. With the range of sustainable filtration conditions, the fouling ratios at the same reference scouring aeration intensity were found to be proportional to permeate flux. Similarly, the fouling ratios calculated with the same reference permeate flux decreased exponentially with increasing scouring aeration intensity. Moreover, the effects of scouring aeration intensity and permeate flux on the fouling ratios were found to be independent of one another. As a result, an empirical relationship was derived to relate the stable reversible fouling resistance to sustainable permeate fluxes and scouring aeration intensities. Its application was demonstrated by constructing transmembrane pressure contours overlaid with scouring aeration effectiveness contours to aid in the selection of optimal MBR filtration conditions.     

Calibration of a model for an A + B acivated sludge pilot plant treating industrial wastewater

A mathematical model has been developed and calibrated for a two-stage (A + B) activated sludge pilot plant treating wastewater from a chemical-pharmaceutical industry. Two series of simulations have been performed: (a) by using typical values for the parameters of the model from the bibliography, which remain constant with time, and (b) by using, for some parameters, values which are variable with time, and are determined following a specific methodology. The calibration is constrained to be exactly consistent with daily observations of COD from the effluent and reactor suspended solids (MLSS). Three internal parameters of the system were thus obtained in their daily variation: MLSS growth rate, specific substrate removal rate and concentration factor in the settling tank. Mean values obtained for MLSS growth rate were 0.73 d⁻¹ and 0.022 d⁻¹ for reactors A and B respectively, and the average observed biomass yield coefficient was 0.38 (reactor A) and 0.21 (reactor B). The model infered the evolution of the COD and MLSS with a fairly good accuracy, proving that the method used to obtain the parameters does not have internal inconsistencies and may be used in other situations.     

Feasibility of using a chlorination step to reduce excess sludge in activated sludge process

The ultimate disposal of excess sludge generated from activated sludge processes has been one of the most challenging problems for wastewater treatment utilities. Previous work has shown that excess sludge can be minimized successfully by using sludge ozonation to dissolve it into substrates to be oxidized in the aeration tank. However, this approach is a costly option. Therefore, as an alternative solution, we propose to use chlorination to replace ozonation in excess sludge minimization in the light of operational cost. To investigate the feasibility of this low cost approach, this paper mainly focuses on the effect of chlorination on sludge reduction rate, formation of trihalomethanes, sludge settleability, and effluent quality. Two identical activated sludge membrane bioreactors were continuously operated with synthetic wastewater under the same operation conditions for several months. During this period, one pilot unit was used as the reference system without chlorination of excess sludge, while another served as a testing unit, where excess sludge was taken out for conducting chlorination at a dose of 133mg/g MLSS every day and the chlorinated liquor was then returned to the aeration tank. The sludge production rate and the water quality of both the units were analyzed daily. It was observed that the sludge production could readily be reduced by 65% once the chlorination treatment was involved. However, the chlorination treatment also resulted in poor sludge settleability as well as significant increase of soluble chemical oxygen demand in the effluent, which creates potential difficulties in the operation of a conventional treatment plant with gravity clarifiers. However, it has been demonstrated that by integrating the immersed membrane into the activated sludge process these difficulties can be overcome effectively.     

The optimum operational condition of membrane bioreactor (MBR): cost estimation of aeration and sludge treatment

A methodology to obtain the most economical operational condition of membrane bioreactor (MBR) is developed. In order to achieve the optimum design parameters of MBR with which operational costs are minimized, aeration and sludge treatment costs were estimated for various operational conditions. Generally sludge treatment cost and aeration cost were inversely proportional to each other, which means sludge treatment cost is minimized when aeration cost is maximized and vice versa. Therefore, there might exist an optimum point between the two extreme cases. However, sludge treatment cost turned out to overwhelm the aeration cost over the reasonable operational conditions. Therefore, sludge minimization was considered to be a key for the economical operation of MBR. In the case of typical municipal wastewater of which COD was 400mgL(-1), steady-state MLSS was expected to increase from 11,000 to 15,000mg/L without sludge removal when HRT was decreasing from 16 to 12h. For the range of operational conditions considered in this study, economically optimum HRT and target MLSS were turned out to be 16h and 11,000mg/L, respectively. Under this condition, aeration for the biodegradation of organic matters would be 13.3m(3) air/min when influent was 1000m(3)/day.     

A bench-scale aeration study using batch reactors on swine manure stabilization to control odour in post treatment storage

A bench-scale study on swine manure stabilization for odour control was conducted using batch aeration reactors. In trial 1, two aeration lengths, i.e., 0.5 and 4.0 day, were used under uncontrolled ambient temperature that increased gradually over the experimental period. While in trial 2, a 16.0-day aeration scheme was employed under constant 17 degrees C. An airflow rate of 1.2L/s/m(3) was used for both trials to aerate batch reactors containing finishing pig manure with initial total solids (TS) levels ranging from 0.5 to 4.0%. Manure stabilization during the 90-day post-treatment storage was evaluated by the changes in organic materials, nitrogen and volatile fatty acids (VFA). The odour generation potential in the treated manure was determined by the changes in VFA. Up to 827 mL of liquid was lost due to aeration related foaming. The reductions in total volatile solids (TVS), 5-day biochemical oxygen demand (BOD(5)), total Kjeldahl nitrogen (TKN) and VFA during storage were improved when aeration length increased. Low solids levels offered a more advantageous circumstance for manure stabilization and odour control. Biodegradation of organic matter, removal of nitrogen, and breakdown of VFA would increase with increasing ambient temperature. VFA removals in manure under 16.0-day aeration were higher than those under 0.5- and 4.0-day aeration; however, VFA regeneration started to exceed its consumption on day 20 (4 days after the aeration treatment). BOD(5) was the best estimate of VFA concentration in the aerated manure during storage. The 4.0-day aeration scheme was sufficient to stabilize manure to effectively assuage odour generation potential during the 90-day storage under increasing ambient temperature conditions.