Diagnosis and optimization of WWTPs using the PWM library: full-scale experiences.

Given the shift in perception of wastewater treatment plants as water resource recovery facilities, conventional mathematical models need to be updated. The resource recovery perspective should be applied to new processes, technologies and plant layouts. The number and level of models proposed to date give an overview of the complexity of the new plant configurations and provides a wide range of possibilities and process combinations in order to construct plant layouts. This diversity makes the development of standard, modular and flexible tools and model libraries that allow the incorporation of new processes and components in a straightforward way a necessity. In this regard, the plant-wide modelling (PWM) library is a complete model library that includes conventional and advanced technologies and that allows economic and energetic analyses to be carried out in a holistic way. This paper shows the fundamentals of this PWM library that is built upon the above-mentioned premises and the application of the PWM library in three different full-scale case studies.

Add Control: plant virtualization for control solutions in WWTP.

This paper summarizes part of the research work carried out in the Add Control project, which proposes an extension of the wastewater treatment plant (WWTP) models and modelling architectures used in traditional WWTP simulation tools, addressing, in addition to the classical mass transformations (transport, physico-chemical phenomena, biological reactions), all the instrumentation, actuation and automation & control components (sensors, actuators, controllers), considering their real behaviour (signal delays, noise, failures and power consumption of actuators). Its ultimate objective is to allow a rapid transition from the simulation of the control strategy to its implementation at full-scale plants. Thus, this paper presents the application of the Add Control simulation platform for the design and implementation of new control strategies at the WWTP of Mekolalde.

Struvite precipitation in wastewater treatment plants anaerobic digestion supernatants using a magnesium oxide by-product.

Struvite precipitation is a well-known technology to recover and upcycle phosphorus from municipal wastewater as a slow-release fertiliser. However, the economic and environmental costs of struvite precipitation are constrained by using technical-grade reagents as a magnesium source. This research evaluates the feasibility of using a low-grade magnesium oxide (LG-MgO) by-product from the calcination of magnesite as a magnesium source to precipitate struvite from anaerobic digestion supernatants in wastewater treatment plants. Three distinct LG-MgOs were used in this research to capture the inherent variability of this by-product. The MgO content of the LG-MgOs varied from 42 % to 56 %, which governed the reactivity of the by-product. Experimental results showed that dosing LG-MgO at P:Mg molar ratio close to stoichiometry (i.e. 1:1 and 1:2) favoured struvite precipitation, whereas higher molar ratios (i.e. 1:4, 1:6 and 1:8) favoured calcium phosphate precipitation due to the higher calcium concentration and pH. At a P:Mg molar ratio of 1:1 and 1:2, the percentage of phosphate precipitated was 53-72 % and 89-97 %, respectively, depending on the LG-MgO reactivity. A final experiment was performed to examine the composition and morphology of the precipitate obtained under the most favourable conditions, which showed that (i) struvite was the mineral phase with the highest peaks intensity and (ii) struvite was present in two different shapes: hopper and polyhedral. Overall, this research has demonstrated that LG-MgO is an efficient source of magnesium for struvite precipitation, which fits the circular economy principles by valorising an industrial by-product, reducing the pressure on natural resources, and developing a more sustainable technology for phosphorus recovery.

Automatic characterisation of primary, secondary and mixed sludge inflow in terms of the mathematical generalised sludge digester model.

This paper presents the characterisation procedure of different types of sludge generated in a wastewater treatment plant to be reproduced in a mathematical model of the sludge digestion process. The automatic calibration method used is based on an optimisation problem and uses a set of mathematical equations related to the a priori knowledge of the sludge composition, the experimental measurements applied to the real sludge, and the definition of the model components. In this work, the potential of the characterisation methodology is shown by means of a real example, taking into account that sludge is a very complex matter to characterise and that the models for digestion also have a considerable number of model components. The results obtained suit both the previously reported characteristics of the primary, secondary and mixed sludge, and the experimental measurements specially done for this work. These three types of sludge have been successfully characterised to be used in complex mathematical models.

Inclusion of shear rate effects in the kinetics of a discretized population balance model: Application to struvite precipitation.

The effect of mixing in the modelling of processes based on mass transfer phenomena is commonly ignored in wastewater treatment industry. In this contribution, the effect of the average shear rate in the nucleation and growth rates of struvite is analyzed by combining experimental data with simulation results obtained with a previously presented mass-based discretized population balance model. According to the obtained results, the effect of the average shear rate is identifiable for the selected data and mechanisms. Therefore, it should be considered when a detailed modelling of the process is needed. Consequently, in this contribution, the average shear rate has been decoupled from the kinetic constants. In addition, kinetic rates where it is explicitly included as a power law function have been proposed. The exponents in these power law functions for the primary homogeneous nucleation and growth are 1.3 and 0.3, respectively. Considering shear rate effects allowed to see in the simulation outputs experimentally observed effects: a faster pH decay and smaller particle distribution for increasing mixing intensities.

A comparative analysis of different approaches for integrated WWTP modelling.

In this paper a comparative analysis of the most important approaches for integrated WWTP modelling is presented. After an introductory presentation of the most important drawbacks and challenges for plant wide modelling, the fundamentals of three different approaches to construct integrated models are presented: "Interfaces" "Standard Supermodel" and "Tailored Supermodel". Afterwards, a comparative analysis of these approaches from different points of view (difficulties for the model end user, characterization of the process in the plant, flexibility or adaptability for each case of study, simulation platform requirements and computational costs) is carried out. From this comparison, some important conclusions about the suitability of each alternative depending on the simulation case study are extracted.

On-line estimation of suspended solids in biological reactors of WWTPs using a Kalman observer.

The total amount of solids in Wastewater Treatment Plants (WWTPs) and their distribution among the different elements and lines play a crucial role in the stability, performance and operational costs of the process. However, an accurate prediction of the evolution of solids concentration in the different elements of a WWTP is not a straightforward task. This paper presents the design, development and validation of a generic Kalman observer for the on-line estimation of solids concentration in the tank reactors of WWTPs. The proposed observer is based on the fact that the information about the evolution of the total amount of solids in the plant can be supplied by the available on-line Suspended Solids (SS) analysers, while their distribution can be simultaneously estimated from the hydraulic pattern of the plant. The proposed observer has been applied to the on-line estimation of SS in the reactors of a pilot-scale Membrane Bio-Reactor (MBR). The results obtained have shown that the experimental information supplied by a sole on-line SS analyser located in the first reactor of the pilot plant, in combination with updated information about internal flow rates data, has been able to give a reasonable estimation of the evolution of the SS concentration in all the tanks.

Optimal predictive control of water transport systems: Arrêt-Darré/Arros case study.

This paper proposes the use of predictive optimal control as a suitable methodology to manage efficiently transport water networks. The predictive optimal controller is implemented using MPC control techniques. The Arrêt-Darré/Arros dam-river system located in the Southwest region of France is proposed as case study. A high-fidelity dynamic simulator based on the full Saint-Venant equations and able to reproduce this system is developed in MATLAB/SIMULINK to validate the performance of the developed predictive optimal control system. The control objective in the Arrêt-Darré/Arros dam-river system is to guarantee an ecological flow rate at a control point downstream of the Arrêt-Darré dam by controlling the outflow of this dam in spite of the unmeasured disturbances introduced by rainfalls incomings and farmer withdrawals.

Model-based opti mization of phosphorus management strategies in Sur WWTP, Madrid.

Phosphorus has been considered as a pollutant to be removed from the wastewater. In the last years, however, it has been considered a valuable asset that needs to be recovered due to its shortage in nature. The study of optimum phosphorus management in wastewater treatment plants is not straightforward, due to the complexity of technologies and configurations that may be applied for phosphorus removal and recovery. In this context, plant-wide mathematical modelling and simulation tools are very useful for carrying out these studies. This paper introduces a study carried out at the Sur WWTP (Madrid) to assess optimum phosphorus management strategies based on the PWM. The mathematical model made it possible to describe the phosphorus flux and its characterization throughout the plant. Finally, an exploration by simulation with WEST™ was carried out to analyse different plant configurations and different operational strategies to optimize phosphorus management strategies in the Sur WWTP.

A New Mass-Based Discretized Population Balance Model for Precipitation Processes: Application to Struvite Precipitation.

Mathematical models describing precipitation processes in one step need to be upgraded. Particle size distribution is a crucial variable and its inclusion in the modelling libraries is necessary if the technology wants to be optimized through simulation. With this objective, a mass based population balance model is presented in this contribution. The model has been constructed using a stoichiometric matrix and a kinetic vector and using mass as the internal coordinate, as it is usually done in wastewater treatment modelling. Identifiability of the parameters of the model was evaluated using a sensitivity and a collinearity analysis for six simulation case studies of struvite precipitation. In addition, parameters in the model were calibrated to represent data from two batch tests in the laboratory. The results of the analysis showed that the identifiability of the parameters depends on the available experimental data and explored scenarios. Identifiability of the parameters could be the reason behind the shifting parameter values describing mechanisms of precipitation in the literature. This contribution helps to understand the possibilities and limitations that the population balance model approach offer.

Standard signal processing using enriched sensor information for WWTP monitoring and control.

Important indicators for monitoring and control of wastewater treatment plants (WWTP) often have to be obtained from the processing of on-line signal trajectories. Therefore, the quality of sensor instantaneous measurements can be improved significantly if they are complemented with valuable information about the geometric features of their trajectories. The present paper describes the design and implementation of a Standard Signal Processing Architecture (SSPA) from which enriched sensor information is generated automatically. The SSPA has been made up of three complementary modules: the pre-processing module, the storage module and the post-processing module. Moreover, the SSPA has been parameterised so as to allow its adaptation to the specifications of every signal. By performing basic calculations on pre-processed signal trajectories, the storage module produces enriched vectors which collect information of the first and second time derivatives, average and variance values, peak values, linear regression parameters, curvature, etc. Then, the enriched information vectors can be exploited to implement customised monitoring and control tools. In this respect, the effectiveness of the SSPA has been demonstrated in three different practical cases: (1) OUR and KLa identification algorithms; (2) processing of measurements for real-time controllers; and, (3) detection of bend-points in on-line signals of SBR processes.

AqquaScan: design and implementation of an internet-based service for the remote monitoring and management of decentralised WWTPs.

This paper describes the design and implementation of AqquaScan, an Internet-based service for remote monitoring and integrated management of decentralised WWTPs. AqquaScan is a multi-user and multi-WWTP service. It has been built according to criteria such as flexibility, scalability and interoperability with the idea of providing an open environment suited to quickly accommodate future scenarios (e.g. incorporation of new plants or upgrading of existing installations). Both, the management of plant information and users interfaces have been implemented in distributed software components that communicate with one another via web services. The implemented web services can be exploited to develop customised user interfaces for visualising the monitored data. By default, a customised web-based client module has been programmed in order for users to be able to exploit the facilities offered within AqquaScan: (1) real-time monitoring of on-line signals; (2) visualisation of historical data; (3) changing operational parameters; (4) notification of time-event information; and (5) storage of measurements from laboratory analysis. At present, AqquaScan is fully operative and is offering supervision services to eleven industrial WWTPs distributed around Northern Spain.

Validation of a multi-phase plant-wide model for the description of the aeration process in a WWTP.

This paper introduces a new mathematical model built under the PC-PWM methodology to describe the aeration process in a full-scale WWTP. This methodology enables a systematic and rigorous incorporation of chemical and physico-chemical transformations into biochemical process models, particularly for the description of liquid-gas transfer to describe the aeration process. The mathematical model constructed is able to reproduce biological COD and nitrogen removal, liquid-gas transfer and chemical reactions. The capability of the model to describe the liquid-gas mass transfer has been tested by comparing simulated and experimental results in a full-scale WWTP. Finally, an exploration by simulation has been undertaken to show the potential of the mathematical model.

Mathematical modelling of autothermal thermophilic aerobic digesters.

This paper presents a new mathematical model for Autothermal Thermophilic Aerobic Digesters. The reactor has been modelled as two completely mixed volumes to separately predict the behaviour of the liquid and gaseous phases as well as the interrelation between them. The model includes biochemical transformations based on the standard Activated Sludge Models of IWA, as well as physico-chemical transformations associated with the chemical equilibria and the mass transfer between the liquid and the gaseous phases similar to those proposed in the ADM1 of IWA. An energy balance has also been included in the model in order to predict the temperature of the system. This thermal balance takes into account all those biochemical and physico-chemical transformations that entail the most relevant heat interchanges. Reactor performance has been explored by simulation in two different scenarios: in the first where it acts as the initial stage in a Dual system, and in the second where it acts as a single-stage treatment. Each scenario enabled the identification of the relevance of the different parameters.

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.

BSM2 Plant-Wide Model construction and comparative analysis with other methodologies for integrated modelling.

In this paper, a new methodology for integrated modelling of the WWTP has been used for the construction of the Benchmark Simulation Model N degrees 2 (BSM2). The transformations-approach proposed in this methodology does not require the development of specific transformers to interface unit process models and allows the construction of tailored models for a particular WWTP guaranteeing the mass and charge continuity for the whole model. The BSM2 PWM constructed as case study, is evaluated by means of simulations under different scenarios and its validity in reproducing water and sludge lines in WWTP is demonstrated. Furthermore the advantages that this methodology presents compared to other approaches for integrated modelling are verified in terms of flexibility and coherence.

New mathematical procedure for the automatic estimation of influent characteristics in WWTPs.

This paper proposes a new methodology for the automatic characterization of the influent wastewater in WWTP. With this methodology, model components are automatically estimated by means of optimization algorithms combining a-priori knowledge of the expected wastewater composition with experimental information from the available measurement data. The characterization is carried out based on an extended model components list in which components are described by means their elemental mass fractions. This allows an easy establishment of relationships between model components with experimental data and also, to obtain a general methodology applicable to any model used for wastewater biological treatments. The characterization of the wastewater influent of Galindo-Bilbao according this methodology has demonstrated its validity and the easy application to the ASM1 model influent characterization.

Algebraic solution of the mass balanced ADM1 to predict the steady state and to optimise the design of the anaerobic digestion of sewage sludge.

This paper proposes an algebraic solution of the mass and charge balanced ADM1 model to predict the steady state performance of an anaerobic digester for sewage sludge treatment. The algebraic solution consists of three sequential stages: a kinetic stage that considers only the slowest transformations of the model, a stoichiometric stage based on the complete mass fluxes of the biological process and a physicochemical stage from which some digester outputs are calculated. The predictive capacity and the applicability of this model solution are corroborated by its comparison to the differential equation's model solution and the experimental data of a real case study. The algebraic solution is used to explore the digester response under different operational conditions. An example of application is used to verify the potential of the algebraic solution to be used, together with optimisation algorithms, for optimising the design of the digester and the operational conditions for specified performance criteria, such as effluent quality.

Quantitative assessment of energy and resource recovery in wastewater treatment plants based on plant-wide simulations.

The growing development of technologies and processes for resource treatment and recovery is offering endless possibilities for creating new plant-wide configurations or modifying existing ones. However, the configurations' complexity, the interrelation between technologies and the influent characteristics turn decision-making into a complex or unobvious process. In this frame, the Plant-Wide Modelling (PWM) library presented in this paper allows a thorough, comprehensive and refined analysis of different plant configurations that are basic aspects in decision-making from an energy and resource recovery perspective. In order to demonstrate the potential of the library and the need to run simulation analyses, this paper carries out a comparative analysis of WWTPs, from a techno-economic point of view. The selected layouts were (1) a conventional WWTP based on a modified version of the Benchmark Simulation Model No. 2, (2) an upgraded or retrofitted WWTP, and (3) a new Wastewater Resource Recovery Facilities (WRRF) concept denominated as C/N/P decoupling WWTP. The study was based on a preliminary analysis of the organic matter and nutrient energy use and recovery options, a comprehensive mass and energy flux distribution analysis in each configuration in order to compare and identify areas for improvement, and a cost analysis of each plant for different influent COD/TN/TP ratios. Analysing the plants from a standpoint of resources and energy utilization, a low utilization of the energy content of the components could be observed in all configurations. In the conventional plant, the COD used to produce biogas was around 29%, the upgraded plant was around 36%, and 34% in the C/N/P decoupling WWTP. With regard to the self-sufficiency of plants, achieving self-sufficiency was not possible in the conventional plant, in the upgraded plant it depended on the influent C/N ratio, and in the C/N/P decoupling WWTP layout self-sufficiency was feasible for almost all influents, especially at high COD concentrations. The plant layouts proposed in this paper are just a sample of the possibilities offered by current technologies. Even so, the library presented here is generic and can be used to construct any other plant layout, provided that a model is available.

ADM1-based methodology for the characterisation of the influent sludge in anaerobic reactors.

This paper presents a systematic methodology to characterise the influent sludge in terms of the ADM1 components from the experimental measurements traditionally used in wastewater engineering. For this purpose, a complete characterisation of the model components in their elemental mass fractions and charge has been used, making a rigorous mass balance for all the process transformations and enabling the future connection with other unit-process models. It also makes possible the application of mathematical algorithms for the optimal characterisation of several components poorly defined in the ADM1 report. Additionally, decay and disintegration have been necessarily uncoupled so that the decay proceeds directly to hydrolysis instead of producing intermediate composites. The proposed methodology has been applied to the particular experimental work of a pilot-scale CSTR treating real sewage sludge, a mixture of primary and secondary sludge. The results obtained have shown a good characterisation of the influent reflected in good model predictions. However, its limitations for an appropriate prediction of alkalinity and carbon percentages in biogas suggest the convenience of including the elemental characterisation of the process in terms of carbon in the analytical program.