Aspen Plus process-simulation model: Producing biogas from VOC emissions in an anaerobic bioscrubber.

A process-simulation model for a novel process consisted of an anaerobic bioscrubber was developed in Aspen Plus®. A novel approach was performed to implement the anaerobic reactor in the simulation, enabling it to be connected to the scrubber. The model was calibrated and validated using data from an industrial prototype that converted air emissions polluted with volatile organic compounds with an average daily concentration of 1129 mgC Nm-3 into bioenergy for more than one year. The scrubber, which showed a removal efficiency within 83-93%, was successfully predicted with an average absolute relative error of 5.2 ±â€¯0.08% using an average height-to-theoretical-plate value of 1.05 ±â€¯0.08 m and 1.37 ±â€¯0.11 m for each of the two commercial packing materials used, respectively. The anaerobic reactor, which treated up to 24 kg of chemical oxygen demand m-3 d-1 with efficiencies of about 93%, was accurately simulated, both in effluent-stream characteristics and in the biogas stream. For example, the average absolute error between the experimental biogas production and the model values was 19.6 ±â€¯18.9%. The model proved its capability as a predictive tool and an aid in design, resulting in savings of time and money for practitioners. In addition, the approach proposed can be expanded to other bioprocesses that include unit operations.

Control of VOCs from printing press air emissions by anaerobic bioscrubber: Performance and microbial community of an on-site pilot unit.

A novel process consisted of an anaerobic bioscrubber was studied at the field scale for the removal of volatile organic compounds (VOCs) emitted from a printing press facility. The pilot unit worked under high fluctuating waste gas emissions containing ethanol, ethyl acetate, and 1-ethoxy-2-propanol as main pollutants, with airflows ranging between 184 and 1253 m3 h-1 and an average concentration of 1126 ± 470 mg-C Nm-3. Three scrubber configurations (cross-flow and vertical-flow packings and spray tower) were tested, and cross-flow packing was found to be the best one. For this packing, daily average values of VOC removal efficiency ranged between 83% and 93% for liquid to air volume ratios between 3.5·10-3 and 9.1·10-3. Biomass growth was prevented by periodical chemical cleaning; the average pressure drop was 165 Pa m-1. Rapid initiation of anaerobic degradation was achieved by using granular sludge from a brewery wastewater treatment plant. Despite the intermittent and fluctuating organic load, the expanded granular sludge bed reactor showed an excellent level of performance, reaching removal efficiencies of 93 ± 5% at 25.1 ± 3.2 °C, with biogas methane content of 94 ± 3% in volume. Volatile fatty acid concentration was as low as 200 mg acetic acid L-1 by treating daily average organic loads up to 3.0 kg COD h-1, equivalent to 24 kg COD m-3 bed d-1. The denaturing gradient gel electrophoresis (DGGE) results revealed the initial shift of the domains Archaea and Bacteria associated with the limitation of the carbon source to a few organic solvents. The Archaea domain was more sensitive, resulting in a drop of the Shannon index from 1.07 to 0.41 in the first 123 days. Among Archaea, the predominance of Methanosaeta persisted throughout the experimental period. The increase in the proportion of Methanospirillum and Methanobacterium sp. was linked to the spontaneous variations of operating temperature and load, respectively. Among Bacteria, high levels of ethanol degraders (Geobacter and Pelobacter sp.) were observed during the trial.

Abatement of styrene waste gas emission by biofilter and biotrickling filter: comparison of packing materials and inoculation procedures.

The removal of styrene was studied using two biofilters packed with peat and coconut fibre (BF1-P and BF2-C, respectively) and one biotrickling filter (BTF) packed with plastic rings. Two inoculation procedures were applied: an enriched culture with strain Pseudomonas putida CECT 324 for BFs and activated sludge from a municipal wastewater treatment plant for the BTF. Inlet loads (ILs) between 10 and 45 g m(-3) h(-1) and empty bed residence times (EBRTs) from 30 to 120 s were applied. At inlet concentrations ranging between 200 and 400 mg Nm(-3), removal efficiencies between 70 % and 95 % were obtained in the three bioreactors. Maximum elimination capacities (ECs) of 81 and 39 g m(-3) h(-1) were obtained for the BF1-P and BF2-C, respectively (IL of 173 g m(-3) h(-1) and EBRT of 60 s in BF1-P; IL of 89 g m(-3) h(-1) and EBRT of 90 s in BF2-C). A maximum EC of 52 g m(-3) h(-1) was obtained for the BTF (IL of 116 g m(-3) h(-1), EBRT of 45 s). Problems regarding high pressure drop appeared in the peat BF, whereas drying episodes occurred in the coconut fibre BF. DGGE revealed that the pure culture used for BF inoculation was not detected by day 105. Although two different inoculation procedures were applied, similar styrene removal at the end of the experiments was observed. The use as inoculum of activated sludge from municipal wastewater treatment plant appears a more feasible option.

Influence of ground tire rubber on the transient loading response of a peat biofilter.

The effect of using ground tire rubber (GTR) as an adsorptive material in the removal of a 2:1:1 weight mixture of n-butyl acetate, toluene and m-xylene by using a peat biofilter under different intermittent conditions was investigated. The performance of two identical size biofilters, one packed with fibrous peat alone and the other with a 3:1 (vol) fibrous peat and GTR mixture, was examined for a period of four months. Partition coefficients of both materials were measured. Values of 53, 118 and 402 L kg(-1) were determined for n-butyl acetate, toluene and m-xylene in peat, respectively; and values of 40, 609 and 3035 L kg(-1) were measured for the same compounds in GTR. Intermittent load feeding of 16 h per day, 5 days per week working at an EBRT of 60 s and an inlet VOC concentration of 0.3 g C m(-1), resulted in removal efficiencies higher than 90% for both biofilters, indicating that the addition of GTR did not adversely affect the behavior of the bioreactor. Full removal of n-butyl acetate was obtained for both biofilters. GTR improved the removal of the aromatics in the first part of the biofilter, facilitating lower penetration of the toluene and m-xylene into the bed. A 31-day starvation period was applied and intermittent operation subsequently restarted. In both biofilters, high removal efficiencies after a re-acclimation period of two days were achieved. A shock loading test related to 1-h peaks of three- and four-fold increases in its baseline concentration (0.30 g C m(-3)) was applied in both biofilters. For the biofilter packed with the peat and GTR mixture, attenuation greater than 60% was observed in the maximum outlet concentration when compared to the biofilter packed with peat alone.

Biofiltration of ethylbenzene vapours: influence of the packing material.

In order to investigate suitable packing materials, a soil amendment composed of granular high mineralized peat (35% organic content) locally available has been evaluated as carrier material for biofiltration of volatile organic compounds in air by comparison with a fibrous peat (95% organic content). Both supports were tested to eliminate ethylbenzene from air streams in laboratory-scale reactors inoculated with a two-month conditioned culture. In pseudo-steady state operation, experiments at various ethylbenzene inlet loads (ILs) were carried out. Maximum elimination capacity of about 120 g m(-3) h(-1) for an IL of 135 g m(-3) h(-1) was obtained for the fibrous peat. The soil amendment reactor achieved a maximum elimination capacity of about 45 g m(-3) h(-1) for an inlet load of 55 g m(-3) h(-1). Ottengraf-van den Oever model was applied to the prediction of the performance of both biofilters. The influence of gas flow rate was also studied: the fibrous peat reactor kept near complete removal efficiency for empty bed residence times greater than 1 min. For the soil amendment reactor, an empty bed residence time greater than 2 min was needed to achieve adequate removal efficiency. Concentration profiles along the biofilter were also compared: elimination occurred in the whole fibrous peat biofilter, while in the soil amendment reactor the biodegradation only occurred in the first 65% part of the biofilter. Results indicated that soil amendment material, previously selected to increase the organic content, would have potential application as biofilter carrier to treat moderate VOC inlet loads.

Granulation and microbial community dynamics in the chitosan-supplemented anaerobic treatment of wastewater polluted with organic solvents.

The effect of chitosan on the development of granular sludge in upflow anaerobic sludge blanket reactors (UASB) when treating wastewater polluted with the organic solvents ethanol, ethyl acetate, and 1-ethoxy-2-propanol was evaluated. Three UASB reactors were operated for 219 days at ambient temperature with an organic loading rate (OLR) of between 0.3 kg COD m-3 d-1 and 20 kg COD m-3 d-1. One reactor was operated without the addition of chitosan, while the other two were operated with the addition of chitosan doses of 2.4 mg gVSS-1 two times. The three reactors were all able to treat the OLR tested with COD removal efficiencies greater than 90%. However, the time required to reach stable operation was considerably reduced in the chitosan-assisted reactors. The development of granules in the reactors with chitosan was accelerated and granules larger than 2000 µm were only observed in these reactors. In addition, these granules exhibited better physicochemical characteristics: the mean particle diameter (540 and 613 µm) was approximately two times greater than in the control reactor (300 µm), and the settling velocities exceeded 35 m h-1. The extracellular polymeric substances (EPS) in the reactors with the chitosan was found to be higher than in the control reactor. The protein-EPS content has been correlated with the granule size. The analyses of the microbial communities, performed through denaturing gradient gel electrophoresis and high-throughput sequencing, revealed that the syntrophic microorganisms belonging to genus Geobacter and the hydrogenotrophic methanogen Methanocorpusculum labreanum were predominant in the granules. Other methanogens like Methanosaeta species were found earlier in the chitosan-assisted reactors than in the control reactor.

Removal of 2-butoxyethanol gaseous emissions by biotrickling filtration packed with polyurethane foam.

The removal of 2-butoxyethanol from gaseous emissions was studied using two biotrickling filters (BTF1 and BTF2) packed with polyurethane foam. Two different inoculum sources were used: a pure culture of Pseudomonas sp. BOE200 (BTF1) and activated sludge from a municipal wastewater treatment plant (BTF2). The bioreactors were operated at inlet loads (ILs) of 130 and 195 g m(-3) hour(-1) and at an empty bed residence time (EBRT) of 12.5s. Under an IL of ∼130 g m(-3) hour(-1), BTF1 presented higher elimination capacities (ECs) than BTF2, with average values of 106±7 and 68±8 g m(-3) hour(-1), respectively. However, differences in ECs between BTFs were decreased by reducing the irrigation intervals from 1 min every 12 min to 1 min every 2 hours in BTF2. Average values of EC were 111±25 and 90±7 g m(-3) hour(-1) for BTF1 and BTF2, respectively, when working at an IL of ∼195 g m(-3) hour(-1). Microbial analysis revealed a significant shift in the microbial community of BTF1 inoculated with Pseudomonas sp. BOE200. At the end of the experiment, the species Microbacterium sp., Chryseobacterium sp., Acinetobacter sp., Pseudomonas sp. and Mycobacterium sp. were detected. In BTF2 inoculated with activated sludge, the denaturing gradient gel electrophoresis (DGGE) technique showed a diverse microbial community including species that was able to use 2-butoxyethanol as its carbon source, such as Pseudomonas aeruginosa and Pseudomonas putida as representative species. Although BTF1 inoculated with Pseudomonas sp. BOE200 and higher gas velocity (probably greater gas/liquid mass transfer rate) showed a slight improvement in performance, the use of activated sludge as inoculum seems to be a more feasible option for the industrial application of this technology.

Performance of a composite membrane bioreactor for the removal of ethyl acetate from waste air.

Ethyl acetate removal from an air stream was carried out by using a flat composite membrane bioreactor. The composite membrane consisted of a dense polydimethylsiloxane top layer with an average thickness of 0.3 µm supported in a porous polyacrylonitrile layer (50 µm). The membrane bioreactor (MBR) was operated during 3 months, and a maximum elimination capacity of 225 g m⁻³ h⁻¹ at an empty bed residence time of 60s was observed. Removal efficiencies higher than 95% were obtained for inlet loads lower than 200 g m⁻³ h⁻¹ and empty bed residence times as short as 15 s. The estimated yield coefficient, determined from the carbon dioxide production, resulted in 0.82 g dry biomass synthesized per gram of ethyl acetate degraded. No data of ethyl acetate treatment in MBR have been found in the literature, but the results illustrate that membrane bioreactors can potentially be a good option for its treatment.

Bacterial community analysis of a gas-phase biotrickling filter for biogas mimics desulfurization through the rRNA approach.

The bacterial composition of a lab-scale biotrickling filter (BTF) treating high loads of H(2)S was investigated by the rRNA approach. Two 16S rRNA gene clone libraries were established 42 and 189 d after reactor startup, while fluorescent in-situ hybridization (FISH) with DNA probes was performed throughout 260d of reactor operation. Diversity, community structure and metamorphosis were studied from reactor startup to fully-established pseudo-steady state operation at near neutral pH and at an inlet H(2)S concentration of 2000 ppmv (load of 55.6g H(2)S m(-3)h(-1)). In addition, FISH was used for assessing the spatial distribution of sulfur-oxidizing bacteria (SOB) along the length of the reactor under pseudo-steady state operation. A major shift in the diversity of the community was observed with the operating time, from a well-diverse community at startup to pseudo-steady state operation with a majority of retrieved sequences affiliated to SOB of the sulfur cycle including Thiothrix spp., Thiobacillus spp., and Sulfurimonas denitrificans. Although aerobic species were predominant along the BTF, a vertical stratification was encountered, in which facultative anaerobes had a major relative abundance in the inlet part of the BTF, where the sulfide to oxygen ratio was higher. The observed changes were related to the trophic properties of the community, the DO concentration, the accumulation of elemental sulfur and the operation at neutral pH.