Enhancement of sewage sludge thickening and energy self-sufficiency with advanced process control tools in a full-scale wastewater treatment plant.

On their path to becoming sustainable facilities, it is required that wastewater treatment plants reduce their energy demand, sludge production, and chemical consumption, as well as increase on-site power generation. This study describes the results obtained from upgrading the sludge line of a full-scale wastewater treatment plant over 6 years (2015-2021) using three advanced process control strategies. The advanced process control tools were designed with the aim of (i) enhancing primary and secondary sludge thickening, (ii) improving anaerobic digestion performance, and (iii) reducing chemical consumption in the sludge line. The results obtained show that the use of advanced process control tools allows for optimising sludge thickening (increasing solids content by 9.5%) and anaerobic digestion (increasing both the removal of volatile solids and specific methane yield by 10%, respectively), while reducing iron chloride and antifoam consumption (by 75% and 53%, respectively). With the strategies implemented, the plant increased its potential energy self-sufficiency from 43% to 51% and reduced de-watered sludge production by 11%. Furthermore, the upgrade required a low investment, with a return of capital expense (CAPEX) in 1.98 years, which presents a promising and affordable alternative for upgrading existing wastewater treatment plants.

Saponification pretreatment and solids recirculation as a new anaerobic process for the treatment of slaughterhouse waste.

Different configurations of anaerobic process, adapted to the treatment of solid slaughterhouse fatty waste, were proposed and evaluated in this study. The tested configurations are based on the combination of anaerobic digestion with/without waste saponification pretreatment (70 °C during 60 min) and with/without recirculation of the digestate solid fraction (ratio=20% w/w). After an acclimation period of substrate pulses-feeding cycles, the reactors were operated in a semi-continuous feeding mode, increasing organic loading rates along experimental time. The degradation of the raw substrate was shown to be the bottleneck of the whole process, obtaining the best performance and process yields in the reactor equipped with waste pretreatment and solids recirculation. Saponification promoted the emulsification and bioavailability of solid fatty residues, while recirculation of solids minimized the substrate/biomass wash-out and induced microbial adaptation to the treatment of fatty substrates.

Modelling inhibitory effects of long chain fatty acids in the anaerobic digestion process.

Mathematical modelling of anaerobic digestion process has been used to give new insights regarding dynamics of the long chain fatty acids (LCFA) inhibition. Previously published experimental data, including batch tests with clay mineral bentonite additions, were used for parameter identification. New kinetics were considered to describe the bio-physics of the inhibitory process, including: i) adsorption of LCFA over granular biomass and ii) specific LCFA substrate (saturated/unsaturated) and LCFA-degrading populations. Furthermore, iii) a new variable was introduced to describe the state of damage of the acetoclastic methanogens in order to account for the loss of cell-functionality (inhibition) induced by the adsorbed LCFAs. The proposed model modifications are state compatible and easy to be integrated into the International Water Association's Anaerobic Digestion Model N°1 (ADM1) framework. Practical identifiability of model parameters was assessed with a global sensitivity analysis, while calibration and model structure validation were performed on independent data sets. A reliable simulation of the LCFA-inhibition process can be achieved, if the model includes the description of the adsorptive nature of the LCFAs and the LCFA-damage over specific biomass. The importance of microbial population structure (saturated/unsaturated LCFA-degraders) and the high sensitivity of acetoclastic population to LCFA are evidenced, providing a plausible explanation of experimental based hypothesis.

Influence of adsorption and anaerobic granular sludge characteristics on long chain fatty acids inhibition process.

The impact of LCFA adsorption on the methanogenic activity was evaluated in batch assays for two anaerobic granular sludges in the presence and absence of bentonite as synthetic adsorbent. A clear inhibitory effect at an oleate (C18:1) concentration of 0.5 g(C18:1) L(-1) was observed for both sludges. Palmitate (C16:0) was confirmed to be the main intermediate of C18:1 degradation in not adapted sludge and its accumulation was further evidenced by fluorescence staining and microscopy techniques. LCFA inhibition could be decreased by the addition of bentonite, reducing the lag-phase and accelerating the kinetics of LCFA degradation, concluding in the importance of the adsorptive nature of the LCFA inhibitory process. Granule morphology and molecular profiling of predominant microorganisms revealed that biomass adaptation to LCFA could modify the intermediates accumulation profiles and process rates.

Anaerobic digestion of slaughterhouse waste: main process limitations and microbial community interactions.

Fresh pig/cattle slaughterhouse waste mixtures, with different lipid-protein ratios, were characterized and their anaerobic biodegradability assessed in batch tests. The resultant methane potentials were high (270-300 L(CH4) kg(-1)(COD)) making them interesting substrates for the anaerobic digestion process. However, when increasing substrate concentrations in consecutive batch tests, up to 15 g(COD) kg(-1), a clear inhibitory process was monitored. Despite the reported severe inhibition, related to lipid content, the system was able to recover activity and successfully degrade the substrate. Furthermore, 16SrRNA gene-based DGGE results showed an enrichment of specialized microbial populations, such as ß-oxidizing/proteolitic bacteria (Syntrophomonas sp., Coprothermobacter sp. and Anaerobaculum sp.), and syntrophic methanogens (Methanosarcina sp.). Consequently, the lipid concentration of substrate and the structure of the microbial community are the main limiting factors for a successful anaerobic treatment of fresh slaughterhouse waste.

Long-chain fatty acids inhibition and adaptation process in anaerobic thermophilic digestion: batch tests, microbial community structure and mathematical modelling.

Biomass samples taken during the continuous operation of thermophilic anaerobic digestors fed with manure and exposed to successive inhibitory pulses of long-chain fatty acids (LCFA) were characterized in terms of specific metabolic activities and 16S rDNA DGGE profiling of the microbial community structure. Improvement of hydrogenotrophic and acidogenic (beta-oxidation) activity rates was detected upon successive LCFA pulses, while different inhibition effects over specific anaerobic trophic groups were observed. Bioreactor recovery capacity and biomass adaptation to LCFA inhibition were verified. Population profiles of eubacterial and archaeal 16S rDNA genes revealed that no significant shift on microbial community composition took place upon biomass exposure to LCFA. DNA sequencing of predominant DGGE bands showed close phylogenetic affinity to ribotypes characteristic from specific beta-oxidation bacterial genera (Syntrophomonas and Clostridium), while a single predominant syntrophic archaeae was related with the genus Methanosarcina. The hypothesis that biomass adaptation was fundamentally of physiological nature was tested using mathematical modelling, taking the IWA ADM1 as general model. New kinetics considering the relation between LCFA inhibitory substrate concentration and specific biomass content, as an approximation to the adsorption process, improved the model fitting and provided a better insight on the physical nature of the LCFA inhibition process.

Strategies for recovering inhibition caused by long chain fatty acids on anaerobic thermophilic biogas reactors.

Long chain fatty acids (LCFA) concentrations over 1.0 gL(-1) were inhibiting manure thermophilic digestion, in batch and semi-continuous experiments, resulting in a temporary cease of the biogas production. The aim of the work was to test and evaluate several recovery actions, such as reactor feeding patterns, dilution and addition of adsorbents, in order to determine the most appropriate strategy for fast recovery of the reactor activity in manure based plants inhibited by LCFA. Dilution with active inoculum for increasing the biomass/LCFA ratio, or addition of adsorbents for adsorbing the LCFA and reducing the bioavailable LCFA concentration, were found to be the best recovery strategies, improving the recovery time from 10 to 2 days, in semi-continuously fed systems. Moreover, acclimatization was introduced by repeated inhibition and process recovery. The subsequent exposure of the anaerobic biomass to an inhibitory concentration of LCFA improved the recovery ability of the system, indicated as increasing degradation rates from 0.04 to 0.16 g COD_CH(4)/g VS day. The incubation time between subsequent pulses, or discontinuous LCFA pulses, seems to be a decisive process parameter to tackle LCFA inhibition in manure anaerobic co-digestion.

Start-up strategies of thermophilic anaerobic digestion of sewage sludge.

The aim of the present work was to evaluate two different strategies to convert a continuous mesophilic anaerobic reactor into thermophilic, treating sewage sludge. The compared strategies were a single direct temperature change, from 35 degrees to 55 degrees C, and a multi-step temperature change (35 degrees -43 degrees -50 degrees -55 degrees C). The single direct step strategy was shown to be as effective as the more conservative multi-step strategy, recovering the system efficiency after 20 days in terms of methane yield, although there was a higher volatile fatty acids accumulation and higher propionate/acetate ratio values during the temperature transition. From the results of the multi-step strategy it could be stated that the critical process performance during temperature transition occurred between 43 and 50 degrees C, which should be taken into account to define more accurate future transition strategies. Sewage sludge thermophilic vs mesophilic biodegradability was assessed by means of anaerobic biodegradability tests, and no significant statistical differences in biodegradability or methane yields were found.

Feasibility study of the anaerobic digestion of dewatered pig slurry by means of polyacrylamide.

Liquid livestock waste can be managed by separating liquid and solid fractions then treating each separately by applying best available technology, such as anaerobic digestion for the solid fraction. There is an increasing use of polyacrylamide (PAM) as a flocculant agent to improve solid-liquid separation. In the present work, the anaerobic toxicity of PAM residues and the optimal range of total solids concentration for maximum methane production were studied as a function of PAM dosage. Results showed that dry matter and its volatile solids content increased significantly with increasing PAM dosage. Batch anaerobic tests showed that methane yield decreased linearly with increasing total solids, while the methane production per unit of raw substrate reached a maximum at 16.4% total solids. No PAM toxicity was measured for PAM concentrations below 415 g/kg total solids, but some indirect inhibitory phenomena were observed, such as a limited hydrolysis rate due to particle aggregation, and inhibition of methanogenesis by high ammonia concentration.

Hydrolysis kinetics in anaerobic degradation of particulate organic material: an overview.

The applicability of different kinetics to the hydrolysis of particulate organic material in anaerobic digestion is discussed. Hydrolysis has traditionally been modelled according to the first-order kinetics. For complex substrate, the first-order kinetics should be modified in order to take into account hardly degradable material. It has been shown that models in which hydrolysis is coupled to the growth of hydrolytic bacteria work well at high or at fluctuant organic loading. In particular, the surface-related two-phase and the Contois models showed good fits to experimental data from a wide range of organic waste. Both models tend to the first-order kinetics at a high biomass-to-waste ratio and, for this reason, they can be considered as more general models. Examples on different inhibition processes that might affect the degradation of solid waste are reported. Acetogenesis or methanogenesis might be the rate-limiting stages in complex waste. In such cases, stimulation of hydrolysis (mechanically, chemically or biologically) may lead to a further inhibition of these stages, which ultimately affects hydrolysis as well. Since the hydrolysis process is characterized by surface and transport phenomena, new developments in spatially distributed models are considered fundamental to provide new insights in this complex process.

Identifiability study of the proteins degradation model, based on ADM1, using simultaneous batch experiments.

The objective of the present study is to analyse kinetic and stoichiometric parameter values of gelatine anaerobic degradation at thermophilic range, based on an experiment designed to elucidate if volatile fatty acids (VFA) are inhibitors of the hydrolysis process. Results showed that VFA are not inhibiting the hydrolysis process. The ADM1 model adequately expressed the consecutive steps of hydrolysis and acidogenesis, with estimated kinetic values corresponding to a fast acidogenesis and slower hydrolysis. The hydrolysis was found to be the rate limiting step of anaerobic degradation. Estimation of yield coefficients based on the relative initial slopes of VFA profiles obtained in a simple batch experiment produced satisfactory results. From the identification study, it was concluded that it is possible to determine univocally the related kinetic parameter values for protein degradation if the evolution of amino acids is measured in simultaneous batch experiments, with different initial protein and amino acids concentrations.