Start-up and steady-state results of a full-scale UASB reactor treating malting wastewater.

An Imhoff tank was reconstructed into a 250 m3 UASB reactor in order to treat a malting plant wastewater. The UASB was inoculated with sludge from an anaerobic lagoon used for slaughterhouse wastewater treatment. After two months of operation the reactor achieved full load with an HRT of 17 h, a COD removal higher than 80% and a biogas production of 300 m3/day (77% average methane content), with an organic loading rate of 3.6 kgCOD/m3.d (0.24 kgCOD/kgVSS.d). A yield coefficient of 0.09 gVSS/gCODrem was found from a mass balance. The fat present in the inoculated sludge (48 mg/gSSV) did not affect the start up performance. Sludge from the inoculum with high content of fat (270 mg/gSSV), was separated by flotation in the first week of operation. The COD removal efficiency was scarcely influenced by the reactor operation temperature (17-25 degrees C).     

On-site treatment of high-strength alcohol distillery wastewater by a pilot-scale thermophilic multi-staged UASB (MS-UASB) reactor.

A pilot-scale multi-staged UASB (MS-UASB) reactor with a working volume of 2.5 m3 was operated for thermophilic (55 degrees C) treatment of an alcohol distillery wastewater for a period of over 600 days. The reactor steadily achieved a super-high rate COD removal, that is, 60 kgCOD m(-3) d(-1) with over 80% COD removal. However, when higher organic loading rates were further imposed upon the reactor, that is, above 90 kgCOD m(-3) d(-1) for barely-based alcohol distillery wastewater (ADWW) and above 100 kgCOD m(-3) d(-1) for sweet potato-based ADWW, the reactor performance somewhat deteriorated to 60 and 70% COD removal, respectively. Methanogenic activity (MA) of the retained sludge in the thermophilic MS-UASB reactor was assessed along the time course of continuous run by serum-vial test using different substrates as a vial sole substrate. With the elapsed time of continuous run, hydrogen-utilizing MA, acetate-utilizing MA and propionate-fed MA increased at maximum of 13.2, 1.95 and 0.263 kgCOD kgVSS(-1) d(-1), respectively, indicating that propionate-fed MA attained only 1/50 of hydrogen-utilizing MA and 1/7 of acetate-utilizing MA. Since the ADWW applied herewith is a typical seasonal campaign wastewater, the influence of shut-down upon the decline in sludge MA was also investigated. Hydrogen-utilizing MA and acetate-utilizing MA decreased slightly by 3/4, during a month of non-feeding period, whereas propionate-fed MA were decreased significantly by 1/5. Relatively low values of propionate-fed MA and its vulnerability to adverse conditions suggests that the propionate degradation step is the most critical bottleneck of overall anaerobic degradation of organic matters under thermophilic condition.     

Pretreatment of silk-dyeing industrial wastewater by UASB reactor.

The objective of this study was to investigate the performance of the upflow anaerobic sludge blanket (UASB) reactor as the pretreatment system for silk-dyeing wastewater. Two laboratory-scale UASB reactors, with working volume of 15.59 I, were used during May 1998 to June 1999. The actual wastewater was diluted to reduce ammonium ion toxicity on anaerobic bacteria. The experiments were conducted at the organic loading rates (OLRs) of 0.52, 1.01, 1.04, 1.54 and 2.56 kgCOD/(m3 x d), treating only wastewater generated from the acid-dye process of mixed-species raw silk. It took approximately 4 1/2 months to reach the steady-state conditions. It was found that the COD removal was in the ranges of 74.1-85.3%, except at OLR 2.56 kgCOD/(m3 x d) where efficiency significantly dropped to 55.2%. The apparent color removal was in the similar trend as COD. During the study periods, wastewater input had various color shades while the effluent generally looked pale yellowish. The methane generation rates ranged from 0.18-0.31 m3/kg COD removed, with methane composition 81.0-88.1% in biogas. The average granule size in the sludge bed had slowly increased to 0.73 mm in the last experiment. It can be concluded that the UASB reactor is suitable as a pretreatment system for silk-dyeing wastewater. An OLR of 1 kgCOD/(m3 x d) and an influent concentration diluted to 2,600 mgCOD/l are suggested while COD and apparent color removal efficiency of 80% and 70%, respectively, can be expected.     

The efficacy of ozone as a pre- and post-treatment option for UASB-treated food processing wastewaters.

The efficiency of ozone as a pre- and post-treatment to UASB treatment was investigated, followed by a study into UASB reactor performance with ozonated wastewater as substrate. Combinations of pre- and/or post-ozonation with UASB treatment gave better results than ozonation or UASB alone and COD reductions of 53.0-98.9% were achieved for treatment of canning and winery wastewaters. A UASB reactor was fed with pre-ozonated cannery wastewater for over 70 d. COD removal improved from between 58.8 and 64.4% to between 85.3 and 91.8% after pre-ozonated substrate feed commenced. Subsequent increases in organic loading rate (OLR) from 2.4 to 3.4 kgCOD m(-3) x d(-1) did not affect reactor performance. By including a final post-ozonation treatment to this UASB effluent a total COD reduction of 99.2% was achieved.     

UASB treatment of liquid residues from grass bioraffination.

In 2001 the first green biorefinery started operation in Switzerland with a design load of 5,000 tons dm of grass per year and a combined output of fibres (0.4 tons per ton input), protein (160 t/t) and bioenergy (500 kWh/t). Bioenergy was produced in a 570 m3 UASB reactor which has been monitored intensively during its first year of operation. Anaerobic treatment of liquid residues with > 80% degradation of organics was shown up to high f/m ratios and loading rates of 12 -15 kg COD/m3 d and specific biogas production of 0.5-0.65 Nm3 of gas per kg of COD added. A mass flow analysis of solids and pellets leads to the conclusion, that due to a low sludge bed volume of only 16% of the reactor combined with a low actual organic loading of 1.5 kg COD/m3 d there was a restricted adsorption and a low degradation of substrate solids.     

The effects of hydraulic and organic shock loads on the robustness of upflow anaerobic sludge blanket reactors treating sewage.

In this investigation, the robustness and stability of UASB reactors was evaluated on the basis of four indicators: (i) COD removal efficiency; (ii) effluent variability; (iii) pH stability; and (iv) recovery time. The experiments were carried out using six pilot-scale UASB reactors fed with domestic sewage and operated under different operational conditions. After establishment of a "steady-state", organic and hydraulic shock loads (six times the loading rate during six hours) were imposed. The results show that the UASB reactors are robust systems with regards to COD removal efficiency and pH stability when exposed to shock loads. However, this reactor cannot attenuate the imposed fluctuation in the influent COD. A secondary treatment unit is needed to retain the expelled sludge occurring as a result of a hydraulic shock load, or prior to the shock, a sufficient amount of sludge needs to be discharged from the reactor.     

Anaerobic treatment of a medium strength industrial wastewater at low-temperature and short hydraulic retention time: a pilot-scale experience

The aim of this work was to evaluate the performance of a pilot-scale upflow anaerobic sludge blanket (UASB) reactor during the treatment of cereal-processing industry wastewater under low-temperature conditions (17 degrees C) for more than 300 days. The applied organic loading rate (OLR(appl)) was gradually increased from 4 to 6 and 8 kg COD(sol)/m3d by increasing the influent soluble chemical oxygen demand (COD(sol)), while keeping the hydraulic retention time constant (5.2 h). The removal efficiency was high (82 to 92%) and slightly decreased after increasing the influent COD(sol) and the OLR(appl). The highest removed organic loading rate (OLR(rem)) was reached when the UASB reactor was operated at 8 kg COD(sol)/m3d and it was two times higher than that obtained for an OLR(appl) of 4 kg COD(sol)/m3d. Some disturbances were observed during the experimentation. The formation of biogas pockets in the sludge bed significantly complicated the biogas production quantification, but did not affect the reactor performance. The volatile fatty acids in the effluent were low, but increased as the OLR(appl) increased, which caused an increment of the effluent COD(sol). Anaerobic treatment at low temperature was a good option for the biological pre-treatment of cereal processing industry wastewater.     

Optimizing sequencing batch reactor (SBR) reactor operation for treatment of dairy wastewater with aerobic granular sludge

The biological wastewater treatment using aerobic granular sludge is a new and very promising method, which is predominantly used in SBR reactors which have higher volumetric conversion rates than methods with flocculent sludge. With suitable reactor operation, flocculent biomass will accumulate into globular aggregates, due to the creation of increased substrate gradients and high shearing power degrees. In the research project described in this paper dairy wastewater with a high particle load was treated with aerobic granular sludge in an SBR reactor. A dynamic mathematical model was developed describing COD and nitrogen removal as well as typical biofilm processes such as diffusion or substrate limitation in greater detail. The calibrated model was excellently able to reproduce the measuring data despite of strongly varying wastewater composition. In this paper scenario calculations with a calibrated biokinetic model were executed to evaluate the effect of different operation strategies for the granular SBR. Modeling results showed that the granules with an average diameter of 2.5 mm had an aerobic layer in between 65-95 microm. Density of the granules was 40 kgVSS/m3. Results revealed amongst others optimal operation conditions for nitrogen removal with oxygen concentrations below 5 gO2/m3. Lower oxygen concentrations led to thinner aerobic but thicker anoxic granular layers with higher nitrate removal efficiencies. Total SBR-cycle times should be in between 360-480 minutes. Reduction of the cycle time from 480 to 360 minutes with a 50% higher throughput resulted in an increase of peak nitrogen effluent concentrations by 40%. Considering biochemical processes the volumetric loading rate for dairy wastewater should be higher than 4.5 kgCOD/(m3*d). Higher COD input load with a COD-based volumetric loading rate of 9.0 kgCOD/(m3*d) nearly led to complete nitrogen removal. Under different operational conditions average nitrification rates up to 5 gNH/(m3*h) and denitrification rates up to 3.7 gNO/(m3*h) were achieved.     

Influence of effluent-recirculation condition on the process performance of expanded granular sludge bed reactor for treating low strength wastewater.

A 2.0 L volume of EGSB reactor was operated at 20 degrees C for more than 500 days with 0.3-0.4 g COD/L of sucrose base wastewater to investigate the influence of effluent-recirculation on the process performance. At the start up period, the reactor was operated in EGSB mode with 5 m/h upflow velocity by continuous effluent recirculation. The COD loading was set to 7.2-9.6 kg COD/m(3) day with HRT of 1 hour. However, in this mode, EGSB reactor exhibited insufficient COD removal efficiency, i.e., 50-60%. Therefore, UASB mode (without recirculation, 0.7 m/h upflow velocity) was used for 30 minutes in every 40 minutes cycle to increase the COD concentration in the sludge bed. As a result, an excellent process performance was shown. The COD removal efficiency increased from 65% to 91% and the reactor could maintain a good physical property of retained sludge (sludge concentration: 33.4 g VSS/L and SVI: 25 mL/g VSS). Furthermore, retained sludge possessed sufficient level of methanogenic activity at 20 degrees C.     

Biological aerated filtration of municipal wastewater using a low-cost filtration media.

The main objective of this research was to demonstrate that selected natural lava stones can be successfully used for low-cost aerobic biofiltration of municipal wastewater. To demonstrate the procedure a pilot filter was built using 6 mm lava stones as support material. The filter depth was 3.0 m. Provided with sampling ports at different depths analysis of the wastewater could be made for COD, TSS, ammonia and nitrates nitrogen, pH, temperature and Kjeldahl nitrogen. Backwashing was performed every 72 hours. Total and dissolved COD and TSS behaved similarly with the organic load: The highest removal rates were observed with the lowest organic load of 0.8 kgCOD/m3 d. These removal rates decreased to a minimum value at organic loading rates of 1.5 kgCOD/m3 d and then remained without noticeable changes to the highest value of 3.5 kgCOD/m3 d. The highest total and dissolved COD removal values were 81 and 84%, respectively. For TSS the best removal value was 95%. Up to 75% ammonia removal was achieved at the lowest organic load of 0.8 kgCOD/m3 d. Ammonia removal decreased to 36% with a higher organic load of 1.6 kgCOD/m3 d. The Mean Cellular Retention (MCRT) time varied from 1 to 6 days with an average of 3.2 days. This fact proves that the MCRT depends on the backwashing frequency more than of any other factor involved. The bed volume decreased in about 5% after 300 days of operation. Microscopic observations showed that the small stones were rounder after 300 days and that the volume losses were caused when the edges of the stones were cut by the abrasion caused by backwashing.     

Treatment of winery wastewaters in a membrane submerged bioreactor.

Wine production is seasonal, and thus the wastewater flow and its chemical oxygen demand (COD) concentrations greatly vary during the vintage and non-vintage periods, as well as being dependant on the winemaking technologies used, e.g. red, white or special wines production. Due to this seasonal high variability in terms of organic matter load, the use of membrane biological reactors (MBR) could be suitable for the treatment of such wastewaters. MBR offers several benefits, such as rapid start up, good effluent quality, low footprint area, absence of voluminous secondary settler and its operation is not affected by the settling properties of the sludge. A pilot scale hollow fibre MBR system of 220 L was fed by adequately diluting white wine with tap water, simulating wastewaters generated in wineries. The COD in the influent ranged between 1,000 and 4,000 mg/L. In less than 10 days after the start up, the system showed a good COD removal efficiency. The COD elimination percentage was always higher than 97% regardless of the organic loading rate (OLR) applied (0.5-2.2 kg COD/m3 d), with COD concentrations in the effluent ranging between 20 and 100 mg/L. Although the biomass concentration in the reactor increased from 0.5 to 8.6 g VSS/L, the suspended solids concentration in the effluent was negligible. Apparent biomass yield was estimated in 0.14 g VSS/g COD.     

Anaerobic treatment of Hong Kong leachate followed by chemical oxidation.

Landfill leachate of Hong Kong was first treated by the upflow anaerobic sludge blanket (UASB) process. At 37 degrees C, pH 7.1-8.5 and a HRT of 5.1-6.6 days, the process removed 66-90% of COD in the leachate for loading rates of 1-2.4 g-COD/l day depending on the strength of landfill leachate. The final effluent contained 1440-1910 mg-COD/l and 70-91 mg-BOD/l. About 92.5% of the total COD removed was converted to methane and the rest was converted to biomass with an average net growth yield of 0.053 g-VSS/g-COD-removed. The granules developed in the UASB reactor were 0.5-1.5 mm in size and exhibited good settleability. The UASB effluent was then further polished by two oxidation processes. The UASB-ozonation process removed 93.0% of the 12900 mg/l of COD from the raw leachate. The UASB-Fenton-ozonation process improved the COD removal efficiency to 99.3%. The final effluent had only 85 mg/l of COD and 10 mg/l of BOD5. Ozonation was most effectively conducted at pH 7-8 with the addition of 300 mg/l of H2O2 and for the duration of 30 min. Ozonation also significantly improved the biodegradability of the organic residues. Nearly 50% of these residues could be used as carbon source in denitrification.     

Treatment of high loaded swine slurry in an aerobic granular reactor

Aerobic granular sludge grown in a sequential batch reactor was proposed as an alternative to anaerobic processes for organic matter and nitrogen removal from swine slurry. Aerobic granulation was achieved with this wastewater after few days from start-up. On day 140 of operation, the granular properties were: 5 mm of average diameter, SVI of 32 mL (g VSS)(-1) and density around 55 g VSS (L(granule))(-1). Organic matter removal efficiencies up to 87% and nitrogen removal efficiencies up to 70% were achieved during the treatment of organic and nitrogen loading rates (OLR and NLR) of 4.4 kg COD m(-3) d(-1) and of 0.83 kg N m(-3) d(-1), respectively. However, nitrogen removal processes were negatively affected when applied OLR was 7.0 kg COD m(-3) d(-1) and NLR was 1.26 kg N m(-3) d(-1). The operational cycle of the reactor was modified by reducing the volumetric exchange ratio from 50 to 6% in order to be able to treat the raw slurry without dilution.     

Aerobic granulation in a mechanical stirred SBR: treatment of low organic loads

Aerobic granular sludge was produced in a sequencing batch reactor (SBR) characterized by a height to diameter ratio of 2.5 and the use of mechanical stirring. Compact and regular aerobic granules of up to 1.75 mm of average diameter were formed in the reactor with an organic loading rate of 1.75 kg COD/(m3 d). Settling properties of the obtained aggregates were: sludge volumetric index of 30-40 mL/g VSS and settling velocity higher than 8 m/h. The effects of different carbon to nitrogen ratios (TOC/N) in the feeding on the organic matter oxidation and nitrification process were studied. The concentration of organic matter in the feeding was stepwise reduced (from 190.0 to 37.5 mg TOC/L) and ammonium increased (from 25 to 50 mg NH4+ -N/L). TOC/N ratios of 7.50, 3.00, 1.50 and 0.75 g/g in the feeding were tested. The TOC removal percentage was around 80-95% during the whole operational period and the N removal percentages obtained in the reactor were up to 40%, however, physical properties of the granules were not maintained.     

Enhanced granulation in UASB reactor treating low-strength wastewater by natural polymers.

Reetha (Sapindus trifoliata) seed extract and Chitosan were used as additives in the sludge bed of a UASB reactor treating low strength wastewater to enhance granulation. Five parallel laboratory scale UASB reactors were operated for 250 days with synthetic wastewater feed containing COD in the range of 600-800 mg/L. The reactors were seeded with spent sludge from a full-scale 5MLD UASB treatment plant at Jajmau, Kanpur, India. The seed sludge contained little or no granules. Different additives in the five reactors were as follows: control with no additive, cationic part of Reetha extract as additive, anionic part of Reetha extract as additive, bulk Reetha extract as additive and Chitosan as additive. The granulation rapidly increased in all the reactors beyond the 90th day of operation. The mean granule sizes as well as the fraction of granular sludge (particle size > or = 100 microm) were more in the presence of some of the additives compared to the control reactor. Chitosan significantly enhanced granulation followed by the cationic and anionic fractions of the Reetha extract. The bulk Reetha extract did not show enhancement of granulation. The ESEM/EDAX results showed that the bigger granules (3-4 mm) had porous structure and appeared as conglomerates of smaller granules.     

A novel process for organic acids and nutrient recovery from municipal wastewater sludge.

In this paper, a novel process for organic acids and nutrient recovery from municipal sludge was introduced and evaluated based on laboratory-scale studies. An economical estimation for its practical application was also performed by mass balance in a full-scale plant (Q=158,000 m3 d(-1)). This novel process comprises an upflow sludge blanket-type high performance elutriated acid fermenter (5d of SRT) for organic acids recovery followed by an upflow-type crystallisation (3 h of HRT) reactor using waste lime for nutrient recovery. In the system, the fermenter is characterised by thermophilic (55 degrees C) and alkaline conditions (pH 9), contributing to higher hydrolysis/acidogenesis (0.18 g VFA(COD) g(-1) VSS(COD), 63.3% of VFA(COD)/COD produced, based on sludge characteristics of the rainy season) and pathogen-free stabilised sludge production. It also provides the optimal condition for the following crystallisation reactor. In the process, the waste lime, which is an industrial waste, can be used for pH control and cation (Ca and Mg) sources for crystallisation reaction. A cost estimation for full-scale application demonstrates that this process has economic benefits (about 67 dollars per m3 of wastewater except for the energy expense) even in the rainy season.     

An innovative technology based on aerobic granular biomass for treating municipal and/or industrial wastewater with low environmental impact.

The paper reports the results of an investigation carried out at lab scale to assess the effectiveness of an innovative technology (SUPERBIO) for treating municipal and/or industrial wastewater. When this technology was applied for treating municipal wastewater, the results showed that even at maximum organic load (i.e. 7 kg COD m(-3) d(-1)), the COD in the treated effluent was lower than 50 mg L(-1). In addition, both ammonia and TKN removal efficiencies resulted in higher than 87% up to an organic load of 5.7 kg COD m(-3) d(-1) corresponding to a nitrogen load of 0.8 kg TKN m(-3) d(-1). Very satisfactory process performances also resulted during tannery wastewater treatment, when a chemical oxidation step (i.e. ozonation) was inserted in the treatment cycle of SUPERBIO. In such an instance, at organic and nitrogen loadings of 3 kgCOD m(-3) d(-1) and 0.20 kg N m(-3) d(-1), COD, NH4+ -N and TSS average removals were 96, 99 and 98%, respectively. Finally, during the whole experimentation, SUPERBIO was always characterised by a very low sludge production. Such a result was ascribed mainly to the characteristics of biomass that grew in the form of very dense granules (i.e. 130 gVSS L(Biomass)(-1) allowing a biomass concentration as high as 50-60 gTSS l(bed)(-1) to be achieved.     

Effect of the pH influent conditions in fixed-film reactors for anaerobic thermophilic treatment of wine-distillery wastewater.

In anaerobic treatments, the pH conditions affect the efficacy and operation of the process. The main purpose of this research is to compare the effect of the pH influent on the performance of a high rate technology at laboratory scale, upflow anaerobic fixed-film reactor, treating distillery wastewater (wine vinasses) in thermophilic conditions. The results obtained shown that the pH influent influences the performance of the biodegradation process: the depurative efficiency is higher for the operation with alkaline influent. The operation with acid influent allows us to operate at organic loading rates (OLR) around 5.6 kgCOD/m3/d (hydraulic retention time: 1.5 days), maintaining total Chemical Oxygen Demand removals (CODr) of 77.2%; the operation with alkaline influent allows total CODr of 76.8% working at OLR around 10.5 kgCOD/m3/d. The greatest efficiency of substrate removal was 87.5% for OLR 3.2 kgCOD/m3/d and hydraulic retention time of 4.0 days operating with alkaline influent. Therefore, the operation with alkaline influent implicates senior levels of purifying efficiency for similar organic load rate.     

Granulation of Anammox microorganisms in up-flow reactors.

Experimental studies were performed to evaluate the feasibility of granulation of Anammox microorganisms for biomass retention in up-flow reactors. Two experimental studies, one using a 6.4-L lab-scale reactor with synthetic medium and the other using a 200-L pilot-scale reactor with half-nitrified reject water from a sludge digester were conducted. To enhance the granulation process, seed granules from a UASB reactor were added to both experimental reactors. Granulation of Anammox microorganisms was observed using both the synthetic medium and the reject water. The core of a large proportion of Anammox granules retained part of the original seed biomass. The Anammox granules had a slightly lower density than the seed granules from the UASB process, but the size and other physical properties were comparable. The successful granulation of the Anammox microorganisms led to a stable nitrogen removal performance. The maximum nitrogen removal rate of the lab-scale reactor was observed to be 2.9 kg/(m3 x d) after 173 days of operation and that of the pilot-scale reactor was 6.4 kg/(m3 x d) after 12 months of operation.     

Evaluation of sludge properties in a pilot-scale UASB reactor for sewage treatment in a temperate region

In this study, continuous operation of a pilot-scale upflow anaerobic sludge blanket (UASB) reactor for sewage treatment was conducted for 630 days to investigate the physical and microbial characteristics of the retained sludge. The UASB reactor with a working volume of 20.2 m(3) was operated at ambient temperature (16-29 °C) and seeded with digested sludge. After 180 days of operation, when the sewage temperature had dropped to 20 °C or lower, the removal efficiency of both total suspended solids (TSS) and total biochemical oxygen demand (BOD) deteriorated due to washout of retained sludge. At low temperature, the cellulose concentration of the UASB sludge increased owing to the rate limitation of the hydrolytic reaction of suspended solids in the sewage. However, after an improvement in sludge retention (settleability and concentration) in the UASB reactor, the process performance stabilized and gave sufficient results (68% of TSS removal, 75% of total BOD removal) at an hydraulic retention time (HRT) of 9.7 h. The methanogenic activity of the retained sludge significantly increased after day 246 due to the accumulation of Methanosaeta and Methanobacterium following the improvement in sludge retention in the UASB reactor. Acid-forming bacteria from phylum Bacteroidetes were detected at high frequency; thus, these bacteria may have an important role in suspended solids degradation.