Aspen Plus simulation for effluent reuse in thermomechanical pulp mills.

The objective of this study was to evaluate the closing of the water circuit and reusing the treated effluent in the production of TMP, using simulations performed with the Aspen Plus®. The treated effluent was reused to replace 50, 75 and 100% of the well water. An adaptation of the Aspen Plus® program simulating the TMP production process and a dynamic simulation test to verify the accumulation of non-process elements (NPEs) in industrial processes at different proportions of reuse were evaluated. The quality of the final product was assessed in laboratory bleaching tests for pulp brightness and brightness reversion. The concentrations of the NPE were 0.00097, 0.00122 and 0.00145 kmol/h for Mn2+, 0.012929, 0.018368 and 0.023595 kmol/h for Fe2+ and 0.000542, 0.000722 and 0.000948 kmol/h for Cu2+, with the recycling of the treated effluent of 50, 75 and 100%, respectively. The brightness and brightness reversion of the pulp were similar with the different proportions of effluent reuse and with the use of fresh industrial water, with values ranging from 83.37 to 83.97% ISO and 5.43 to 6.38 ISO units, respectively. The use of treated effluent did not affect the pulp quality, which could diminish the water use a pulp mil.

Characteristics and treatment of Brazilian pulp and paper mill effluents: a review.

Pulp and paper industries are very important for developing the Brazilian economy. During production processes, many effluents are generated with high polluting potential. The objective of this study is to conduct an extensive literature review on the characteristics of effluents and treatment forms adopted by Brazilian mills in this industrial sector. Most consulted studies address raw (without treatment) and secondary (after biological treatment) effluents, considering their main characteristics like pH, chemical and biochemical oxygen demands (COD and BOD, respectively), color, solids, organochlorines, toxicity, estrogenic activity, and phenols. Raw effluents differ considerably in composition, depending on the type of paper produced, the pulping process employed, and other steps, like pulp bleaching. Raw effluent characteristics indicate that this effluent cannot be directly disposed of into water bodies, because it does not comply with federal and state disposal standards. Secondary effluents normally comply with Brazilian legislations, although some studies have reported COD and total phenol concentrations higher than disposal standards, suggesting that additional treatments are necessary. Treated effluent reuse was verified in some Brazilian mills, while its disposal in eucalyptus plantations has been considered a promising alternative for irrigation purposes.

Pulp mill sludge-derived carbon activated with an alternative source of chemicals and its application in wastewater treatment - An approach for byproducts valorization.

The purpose of this study was to investigate pulp mill by-products valorization through activated carbon (AC) production and its application in wastewater treatment. Bio-sludge is a known promising precursor for AC production. The mill's chemical recovery stage generates an effluent (electrostatic precipitator ash leachate - EPAL) with high levels of potassium and sodium, which motivate studies regarding its viability as a chemical source for carbon activation. Bio-sludge and EPAL are problematic by-products and this research line would allow their return to the productive chain, as an adsorbent for the wastewater treatment. Two carbonization heating rates (3.5, 15 °C/min), three activation agents (NaOH, KOH, EPAL) and two activator:bio-sludge ratios (1:1, 2:1) were used for AC production. The best ACs in terms of surface area were those produced at 3.5 °C/min, with KOH or EPAL in 2:1 proportion. ACs produced under these conditions and commercial activated carbon (CAC) were used in adsorption tests with industrial wastewater. For color removal, KOH-activated carbon presented the greatest efficiency (80.45 %), followed by CAC (76.74 %) and EPAL-activated carbon (70.13 %). For COD removal, EPAL-activated carbon presented greater efficiency (53.49 %), followed by CAC (40.84 %) and KOH-activated carbon (36.86 %). Freundlich's model best described the experimental adsorption data. The KOH results were expected to be satisfactory, since KOH is proven to be effective for carbon activation. The EPAL-activated carbon results were remarkable, especially for COD removal, showing that EPAL can be used as an activator and that the by-products have potential for valorization according to the circular economy principles.

Effect of the gradual increase of salt on stability and microbial diversity of granular sludge and ammonia removal.

Two sequential batch reactors were operated, aiming at forming aerobic granular sludge and studying the effects of the gradual increase of the NaCl concentration on the granule. structure and microbial diversity, and on the efficiency of ammonia removal. The reactors were fed with ammonia-enriched synthetic effluent and 5 g L-1 of NaCl per week were applied. A decrease in the size of the granules was observed until they were completely disintegrated as the salt concentration increased up to 10 g L-1. However, the ammonia removal efficiency remained high in all the salinities applied. By sequencing the 16S rRNA amplicon gene, the microbial community structure allowed the verification of the presence of several genera affiliated with the bacteria that perform both heterotrophic nitrification and aerobic denitrification, besides those involved in the conventional nitrification and denitrification and the ANAMMOX process. Salinity affected the microbial population related to the formation and stability of the granules.

Ammonium removal from high-salinity oilfield-produced water: assessing the microbial community dynamics at increasing salt concentrations.

Water generated during oil exploration is chemically complex and contains high concentrations of ammonium and, in some cases, high salinity. The most common way to remove ammonium from effluent is a biological process, which can be performed by different routes and different groups of microorganisms. However, the presence of salts in the effluents could be an inhibiting factor for biological processes, interfering directly with treatment. This study aimed to evaluate changes in the profile of a microbial community involved in the process of ammonium removal when subjected to a gradual increase of salt (NaCl), in which the complete inhibition of the ammonium removal process occurred at 125 g L-1 NaCl. During the sludge acclimatization process, samples were collected and submitted to denaturing gradient gel electrophoresis (DGGE) and massive sequencing of the 16S ribosomal RNA (rRNA) genes. As the salt concentration increased in the reactor, a change in the microbial community was observed by the DGGE band profiles. As a result, there was a reduction in the presence of bacterial populations, and an increase in archaeal populations was found. The sequencing data suggested that ammonium removal in the reactor was carried out by different metabolic routes by autotrophic nitrifying bacteria, such as Nitrosococcus, Nitrosomonas, Nitrosovibrio, Nitrospira, and Nitrococcus; ammonium-oxidizing archaea Candidatus nitrosoarchaeum; ANAMMOX microorganisms, such as Candidatus brocadia, Candidatus kuenenia, and Candidatus scalindua; and microorganisms with the potential to be heterotrophic nitrifying, such as Paracoccus spp., Pseudomonas spp., Bacillus spp., Marinobacter sp., and Alcaligenes spp.

Effects of electrostatic precipitators ash leachate (EPAL) from recovery boilers on the biological treatment of effluent of kraft pulp mills.

The electrostatic precipitators ash leachate (EPAL) from recovery boilers of kraft pulp mills is generated in processes dedicated to the removal of potassium and chloride salts seeking to avoid fouling and corrosion in pipes and equipment. However, the EPAL is rich in salts and has high electrical conductivity. Whenever it is sent to the effluent treatment plant (ETP), it can cause negative impacts to the biological process. It may jeopardize particularly the microbial community and the sludge bio-flocculation, causing sludge losses in the secondary clarifiers, reducing the overall efficiency of the effluent treatment plant. The objective of this research was to evaluate the influence of EPAL from the recovery boilers added to a typical effluent from a bleached eucalyptus kraft pulp mill in gradually increased doses and in sudden doses (shock loads) in the efficiency of the biological treatment. Three biological sequential batch reactors (R1, R2, R3) with a volume of 1000 ml each were tested. The Reactor R1 was operated as a reference and fed only with typical effluent from the pulp mill; Reactor R2 was fed with mill effluent with gradually increased doses of EPAL in fixed proportions until reaching a real industrial condition; Reactor R3 was fed with mill effluent and with sudden doses of EPAL. The reactors were operated in similar conditions, i.e., the concentration of dissolved oxygen (DO) was always kept higher than 2 mg L-1, COD:N:P ratio equal to 250:5:1 and hydraulic retention time of 12 h. Depending on the dose which was applied, the EPAL inhibited microbiological activity, reduced the efficiency of COD removal of the biological treatment (10% when EPAL was gradually applied and 15% in sudden doses) and increased the sludge carryover in the sedimentation phase (148% when EPAL was gradually applied and 170% in sudden dosages). Furthermore, the reduced efficiency and suspended solid carryover were more significant when sudden doses were applied compared to the application of gradual doses of the EPAL.

Thermal drying of industrial sludge using forced aeration.

This study investigated an industrial biosludge drying system using hot gases from a coal furnace, seeking to increase the solids content of the biosludge above 50% (w.b.), considered suitable for combustion in biomass boilers. Biosludge was collected from a paper mill activated sludge plant. Biosludge mixtures with eucalyptus chips and eucalyptus bark in two different proportions (15% and 25%) were placed into a drying chamber. Hot gases generated by the furnace, with a flowrate of 0.64 ± 0.02 m3 s-1 at 100 ± 20°C, were applied to the piles through a blowing system. The results demonstrated that the 75% biosludge/25% eucalyptus bark mixture achieved the best drying ratio, increasing the total solids content from 31% to 72%, over a 5-h drying period. Nevertheless, all other treatments involving the addition of a bulking agent achieved solids content above 50%, confirming the positive effect of adding dried material to the sludge. These results indicate a potential use of hot gases that are currently available and released into the atmosphere by paper mills.

A multi-criteria decision analysis of management alternatives for anaerobically digested kraft pulp mill sludge.

The Multi-Criteria Decision Analysis (MCDA) procedure was used to compare waste management options for kraft pulp mill sludge following its anaerobic digestion. Anaerobic digestion of sludge is advantageous because it produces biogas that may be used to generate electricity, heat and biofuels. However, adequate management of the digested sludge is essential. Landfill disposal is a non-sustainable waste management alternative. Kraft pulp mill digested sludge applied to land may pose risks to the environment and public health if the sludge has not been properly treated. This study is aimed to compare several recycling alternatives for anaerobically digested sludge from kraft pulp mills: land application, landfill disposal, composting, incineration, pyrolysis/gasification, and biofuel production by algae. The MCDA procedure considered nine criteria into three domains to compare digested sludge recycling alternatives in a kraft pulp mill: environmental (CO2 emission, exposure to pathogens, risk of pollution, material and energy recovery), economic (overall costs, value of products) and technical (maintenance and operation, feasibility of implementation). The most suitable management options for digested sludge from kraft pulp mills were found to be composting and incineration (when the latter was coupled with recycling ash to the cement industry). Landfill disposal was the worst option, presenting low performance in feasibility of implementation, risk of pollution, material and energy recovery.