An accurate and robust method for intensification of wastewater sludge pipe flow.

Globally, environmental impacts and population growth are driving the process intensification of wastewater treatment plants (WWTPs) via transition from conventional (2-3 wt% solids) to highly concentrated (4-6 wt% solids) wastewater sludges (HCWS). This presents an industrial challenge as HCWS are complex, non-Newtonian materials whose viscosity increases nonlinearly with solids concentration. This viscosity increase is particularly relevant for sludge pipe flow as it leads to considerable pumping pressure that ultimately limits the feasibility of pipe flow transportation. Hence, process intensification demands accurate prediction of HCWS turbulent pipe flow to design and optimise pumping infrastructure and piping systems. Such prediction requires accurate rheological characterisation of HCWS and numerical prediction of HCWS turbulent pipe flow, neither of which has been achieved to date due to respective limitations associated with benchtop rheometry and numerical turbulence models. We address these challenges by first developing accurate methods for rheological characterisation of HCWS via laminar flow of digested sludge at various solids concentrations (2-5 %) in a fully instrumented pipe loop facility at a large-scale WWTP. These rheological parameters are used in direct numerical simulation (DNS) computations (that avoid turbulence models) of turbulent pipe flow of HCWS. These predictions are then validated against turbulent flow pipe loop data. This method yields accurate (2-15 % error) predictions of HCWS turbulent pipe flow, compared with up to ∼75 % error for conventional pipe flow correlations. This validation highlights the need for accurate rheological characterisation and numerical simulation to predict HCWS pipe flow and provides a sound basis for the intensification and optimisation of WWTP pipeline systems.

Constitutive modelling and pipeline flow of thixotropic viscoplastic wastewater sludge.

Due to the inherent rheological complexity of wastewater sludges, conventional sludge pipeline design based on simplified rheological models can result in inefficient sludge transportation systems. These inefficiencies are further exacerbated by a global need for the processing of more concentrated wastewater sludges that have a more pronounced non-Newtonian character, and hence require greater energy for transportation. However, the complex rheology of these materials (typically visco-elastic and thixotropic) requires sophisticated methods for constitutive modelling that are impractical to implement for complex materials such as sewerage sludges. We address this challenge by developing a novel viscoplastic thixotropic constitutive model that exploits the separation of timescales between the thixotropic and viscoelastic processes, leading to simpler and more robust experimental methods, parameter estimation and process simulation methods. This constitutive model combines a kinetic model for thixotropic degradation and agglomeration via a classical structural parameter (λ) approach coupled nonlinearly with a Herschel-Bulkley model to yield a thixotropic viscoplastic model of sludge rheology. Experimental data for thickened digested sludge between 3 and 4.9% solids were collected to validate the assumption for the separation of viscoelastic and thixotropic responses. The fitting procedure was found to be robust and efficient, and several rheological parameters were found to be invariant with solids concentration. Simplified energy calculations for a typical sludge pipeline showed that the pumping energy could be significantly under- or overestimated without considering thixotropy. These simple and robust constitutive models and fitting methods can accurately predict (and hence design and optimise) sludge behaviour over a wide range of wastewater processes.

Impact of methodological artifact on digested sludge flow curve measurement.

Inconsistent experimental procedures have been used to characterize sludge rheology in literature. This often has resulted in proposing different rheological models for sludge as well as non-comparable data. Any collected rheological data needs to be interpreted considering the methodology used for its collection because otherwise they cannot be used by engineers for design and troubleshooting. This paper intends to shed light on the influential parameters during data collection procedure to produce a reliable and reproducible data. This paper systematically investigates the impact of different geometries, preshear, equilibrium, rest and storage time on flow curve measurement for digested sludge in the range of 2.3 to 6% total solid and recommends a reliable procedure for reproducible sludge flow curve measurements. While the magnitude of impacts is different, we found all factors are significantly dependent on the sludge solid concentration. Besides, the method of the development of the protocol can be utilized to develop appropriate protocols for rheological characterization of any other sludge. The customization highlights are:•Selecting the geometry according to the sludge solid concentration.•Allocating an equilibrium time at each point of flow curve according to the sludge solid concentration.•Flow curve data requires to visually inspected for instabilities.

Rheological characterization of thermal hydrolysed waste activated sludge.

Rheological properties are important in the design and operation of sludge-handling process. Despite this, the rheology of sludge in thermal hydrolysis processes (TH) is not well described. In-situ measurements were performed to characterize the flow behaviour of various concentrations (7-13 wt%) of waste activated sludge (WAS) at TH conditions. Equations were presented for predicting in-situ rheological parameters (high-shear viscosity, η∞,i, consistency index, ki, and yield stress, σc,i) under various treatment conditions, which are useful for design of process units. The equations enable convenient estimation of in-situ properties based on ambient rheological measurements. Results suggested that the proportion of sludge solubilization and its rate were unaffected by varying sludge concentration. Thermally treated sludge still exhibited gel-like, viscoelastic characteristics similar to untreated sludge; however, the storage (G') and loss (G") moduli decreased with higher treatment temperatures. Frequency and creep responses were described by a fractional derivatives Kelvin-Voigt (FKV) model, which showed increasing viscous characteristics of treated sludge. These equations can be utilised in CFD models. Results obtained from oscillatory measurements can also approximate steady-shear behaviour by comparing dynamic viscosity, η'(ω), and steady-shear viscosity, η(γ̇), whose values were very similar. This enables convenient estimation of steady-shear behaviour of sludge from oscillatory measurements, which is found to be a non-destructive technique for measuring flow behaviour of highly concentrated sludge. Yield stress can also be predicted from the product of modified Cox-Merz shift factors and storage modulus (G'). Practical engineering implications of the rheological observations were discussed.

Comparison between classical Kelvin-Voigt and fractional derivative Kelvin-Voigt models in prediction of linear viscoelastic behaviour of waste activated sludge.

Appropriate sewage sludge rheological models are essential for computational fluid dynamic simulation of wastewater treatment processes, in particular aerobic and anaerobic digestions. The liquid-like behaviour of sludge is well documented but the solid-like behaviour remains poorly described despite its importance for dead-zone formation. In this study, classical Kelvin-Voigt model, commonly used for sludge in literature, were compared with fractional derivative Kelvin-Voigt model regarding their predictive ability for describing the solid-like behaviour. Results showed that the fractional Kelvin-Voigt model best fitted the experimental data obtained from creep and frequency sweep tests. Whereas, classical Kelvin-Voigt could not fit the frequency sweep data as this model is not a function of angular velocity. Also, the Kelvin-Voigt model was unable to predict the creep data at low stresses.

Net positive energy wastewater treatment plant via thermal pre-treatment of sludge: A theoretical case study.

In a wastewater treatment process, energy is mainly used in sludge handling and heating, while energy is recovered by biogas production in anaerobic digestion process. Thermal pre-treatment of sludge can change the energy balance in a wastewater treatment process since it reduces the viscosity and yield stress of sludge and increases the biogas production. In this study, a calculation based on a hypothetical wastewater treatment plant is provided to show the possibility of creating a net positive energy wastewater treatment plant as a result of implementing thermal pre-treatment process before the anaerobic digester. The calculations showed a great energy saving in pumping and mixing of the sludge by thermal pre-treatment of sludge before anaerobic digestion process.

Rheological characterisation of thermally-treated anaerobic digested sludge: impact of temperature and thermal history.

This study investigated the partially irreversible effect of thermal treatment on the rheology of digested sludge when it was subjected to temperature change between 20 °C and 80 °C and then cooled down to 20 °C. The yield stress, infinite viscosity and liquor viscosity of sludge were measured at 20 °C for different thermal histories and were compared to the evolution of the solubilised chemical oxygen demand (COD) of sludge liquor. The results showed that thermal history irreversibly affects sludge rheology as the yield stress of sludge which was heated to 80 °C then cooled down to 20 °C was 68% lower than the initial yield stress at 20 °C. This decrease was due to the irreversible solubilisation of solid matter during heating as underlined by soluble COD data which did not reach its original level after thermal treatment. Measured soluble COD of sludge which was heated and cooled down was much higher than the soluble COD of initial sludge. We found a proportionality of the increase of soluble COD with the decrease of the yield stress as well as increase of infinite viscosity.