Design and start-up of a high rate anaerobic membrane bioreactor for the treatment of a low pH, high strength, dissolved organic waste water.

A Submerged Membrane Anaerobic Reactor (SMAR) is being developed for the treatment of waste water originating in Sasol's coal to fuel synthesis process. The laboratory-scale SMAR uses A4-size submerged flat panel ultrafiltration membranes to induce a 100% solids-liquid separation. Biogas gets extracted from the headspace above the anaerobic mixed liquor and reintroduced through a coarse bubble diffuser below the membranes. This induces a gas scour on the membranes that avoids biomass immobilization and membrane fouling. The substrate is a high strength (18 gCOD/l) petrochemical effluent consisting mostly of C2 to C6 short chain fatty acids with a low pH. Because of this, the pH of the reactor has to be controlled to a pH of 7.1. Organic Loading Rates of up to 25 kgCOD/m3 reactor volume/d has been observed with effluent COD normally <500 mgCOD/l and FSA <50 mgN/l with no particulates >0.45 microm at hydraulic retention times of 17 hours. 98% of the COD is converted to methane and the remainder to biomass. Mixed Liquor (MLSS) concentrations >30 gTSS/l can be maintained without deterioration of membrane fluxes, even though the Diluted Sludge Volume Index (DSVI) indicates that the sludge cannot be settled. No noteworthy deterioration in membrane performance has been observed over the 320 day operational period.

Design and performance of BNR activated sludge systems with flat sheet membranes for solid-liquid separation.

The use of immersed membranes for solid-liquid separation in biological nutrient removal activated sludge (BNRAS) systems was investigated at lab scale. Two laboratory-scale BNR activated sludge systems were run in parallel, one a MBR system and the other a conventional system with secondary settling tanks. Both systems were in 3 reactor anaerobic, anoxic, aerobic UCT configurations. The systems were set up to have, as far as possible, identical design parameters such as reactor mass fractions, recycles and sludge age. Differences were the influent flow and total reactor volumes, and the higher reactor concentrations in the MBR system. The performances of the two systems were extensively monitored and compared to identify and quantify the influence of the membranes on system response. The MBR UCT system exhibited COD, FSA, TKN, TP and TSS removals that were consistently equivalent or superior to the conventional system. Better P removal in the MBR was attributed to lower observed P uptake in the anoxic zone. High nitrate loads to the anoxic reactor appeared to be the determining factor in stimulating P uptake. The MBR UCT system had a greater sludge production than the conventional system. This was partly attributable to the retention of all solids in the MBR reactor. For steady state design this increase is accommodated by increasing the influent unbiodegradable particulate COD fraction. Additionally an attempt was made to determine the Alpha values in the oxygen transfer rate. This paper briefly summarises and compares the results from both systems, and the conclusions that can be drawn from these results.

A general kinetic model for biological nutrient removal activated sludge systems: model evaluation.

Hu et al. (2007) presented a general kinetic model for biological nutrient removal (BNR) activated sludge (AS) systems in general, but for external nitrification (EN) BNRAS (ENBNRAS) systems in particular. In this article, this model is evaluated against a large number of experimental data sets. In this evaluation, the model is first used to simulate a wide variety of conventional internal nitrification (IN) BNRAS systems to evaluate its predictions and also evaluate the model parameters suggested by Hu et al. (2007), and to calibrate those constants for which values are not available in the literature. Simulation results indicate that the model, with appropriately calibrated parameters, is capable of predicting COD removal, nitrification and denitrification and two types of biological excess phosphorus removal (BEPR), namely aerobic and anoxic/aerobic P uptake BEPR. The model is then used to simulate the ENBNRAS systems to evaluate its capacity of simulating the behaviour of this system. Simulation results show that the model is capable of simulating the behaviour of the ENBNRAS systems, including COD, nitrification, denitrification and BEPR, particularly anoxic P uptake BEPR, with the values of kinetic and stoichiometric parameters obtained in modelling conventional BNRAS systems, except for micro(NIT), K(MP), eta(PAO) and eta(H) which required calibration.

A general kinetic model for biological nutrient removal activated sludge systems: model development.

In this article, a kinetic model is developed and presented for biological nutrient removal (BNR) activated sludge (BNRAS) systems in general, but for external nitrification (EN) BNRAS (ENBNRAS) systems in particular. The model is based on the UCTPHO model, but includes some significant modifications, such as anoxic P uptake and associated denitrification by phosphorus accumulating organisms (PAOs). Some key features of the model are described and discussed before the model is presented. Model evaluation will be addressed in another article (Hu et al., 2007).

Using respirometric techniques and fluorescent in situ hybridization to evaluate the heterotrophic active biomass in activated sludge.

The separation and accurate quantification of active biomass components in activated sludge is of paramount importance in models, used for the management and design of waste water (WW) treatment plants. Accurate estimates of microbial population concentrations and the direct, in situ determination of kinetic parameters could improve the calibration and validation of existing models of biological nutrient removal activated sludge systems. The aim of this study was to obtain correlations between heterotrophic active biomass (Z(BH)) concentrations predicted by mathematical models and quantitative information obtained by Fluorescent in situ hybridizations (FISH). Respirometric batch test were applied to mixed liquors drawn from a well-defined parent anoxic/aerobic activated sludge system to quantify the Z(BH) concentrations. Similarly fluorescent labeled, 16S rRNA-targeted oligonucleotide probes specific for ammonia and nitrite oxidizers were used in combination with DAPI staining to validate the Z(BH) active biomass component in activate sludge respirometric batch tests. For the direct enumeration and simultaneous in situ analysis of the distribution of nitrifying bacteria, in situ hybridization with oligonucleotide probes were used. Probes (NSO 1225, NSR 1156, and NIT3) were used to target the nitrifiers and the universal probe (EUB MIX) was used to target all Eubacteria. Deducting the lithoautotrophic population from the total bacteria population revealed the Z(BH) population. A conversion factor of 8.49 x 10(-11) mg VSS/cell was applied to express the Z(BH) in terms of COD concentration. Z(BH) values obtained by molecular probing correlated closely with values obtained from the modified batch test. However, the trend of consistently poor correspondence of measured and theoretical concentrations were evident. Therefore, the focus of this study was to investigate alternative technology, such as FISH to validate or replace kinetic parameters which are invariably incorporated into models.

Biodegradability of activated sludge organics under anaerobic conditions.

From an experimental and theoretical investigation of the continuity of activated sludge organic (COD) compounds along the link between the fully aerobic or N removal activated sludge and anaerobic digestion unit operations, it was found that the unbiodegradable particulate organics (i) originating from the influent wastewater and (ii) generated by the activated sludge endogenous process, as determined from response of the activated sludge system, are also unbiodegradable under anaerobic digestion conditions. This means that the activated sludge biodegradable organics that can be anaerobically digested can be calculated from the active fraction of the waste activated sludge based on the widely accepted ordinary heterotrophic organism (OHO) endogenous respiration/death regeneration rates and unbiodegradable fraction. This research shows that the mass balances based steady state and dynamic simulation activated sludge, aerobic digestion and anaerobic digestion models provide internally consistent and externally compatible elements that can be coupled to produce plant wide steady state and dynamic simulation WWTP models.

Tracking influent inorganic suspended solids through wastewater treatment plants.

From an experimental and theoretical investigation of the continuity of influent inorganic suspended solids (ISS) along the links connecting the primary settling tank (PST), fully aerobic or N removal activated sludge (AS) and anaerobic and aerobic sludge digestion unit operations, it was found that the influent wastewater (fixed) ISS concentration is conserved through primary sludge anaerobic digestion, activated sludge and aerobic digestion unit operations. However, the measured ISS flux at different stages through a series of wastewater treatment plant (WWTP) unit operations is not equal to the influent ISS flux, because the ordinary heterotrophic organisms (OHO) biomass contributes to the ISS flux by differing amounts depending on the active fraction of the VSS solids at that stage.

The effects of hydraulic retention time and feed COD concentration on the rate of hydrolysis of primary sewage sludge under methanogenic conditions.

A series of completely mixed methanogenic anaerobic digesters have been operated to determine the rate of hydrolysis of primary sewage sludge. The hydraulic retention time was reduced from 60 d to when the system failed (approximately 5 d), while the feed COD concentration was 40, 25, 13 and 2 gCOD/L. A steady state model based on first order kinetics was developed to simulate the hydrolysis rate at each retention time and feed concentration. With the mean value for the hydrolysis rate constant (0.992 +/- 0.492 d(-1)), this model was able to accurately predict the effluent COD for all steady state operating conditions. However, the effluent COD concentration was relatively insensitive to the exact value for this constant. The model provides a framework for analysis of anaerobic digestion experimental data, to enable meaningful comparisons.

Integrated chemical, physical and biological processes modelling of anaerobic digestion of sewage sludge.

The biological kinetic processes for anaerobic digestion (AD) are integrated into a two phase subset of a three phase mixed weak acid/base chemistry kinetic model. The approach of characterising sewage sludge into carbohydrates, lipids and proteins, as is done in the International Water Association (IWA) AD model No 1 (ADM1), requires measurements that are not routinely available on sewage sludges. Instead, the sewage sludge is characterised with the COD, carbon, hydrogen, oxygen and nitrogen (CHON) composition and is formulated in mole units, based on conservation of C, N, O, H and COD. The model is calibrated and validated with data from laboratory mesophilic anaerobic digesters operating from 7 to 20 d sludge age and fed a sewage primary and humus sludge mixture. These digesters yielded COD mass balances between 107-109% and N mass balances between 91-99%, and hence the experimental data is accepted as reasonable. The sewage sludge COD is found to be 32-36% unbiodegradable (depending on the kinetic formulation selected for the hydrolysis process) and to have a C3.5H7O2N0.196 composition. For the selected hydrolysis kinetics of surface mediated reaction (Contois), with a single set of kinetic and stoichiometric constants, for all retention times good correlation is obtained between predicted and measured results for: (i) COD; (ii) free and saline ammonia (FSA); (iii) short chain fatty acids (SCFA); (iv) H2CO3 * alkalinity; (v) pH of the effluent stream; (vi) CO2; and (vii) CH4 gases in the gas stream. The measured composition of primary sludge from two local wastewater treatment plants ranged between C3.38H7O1.91 N0.21 and C3.91H7O2.04N0.16. The predicted composition based on mass balances is therefore within 5% of the average measured composition providing persuasive validation of the model.

Tracking the inorganic suspended solids through biological treatment units of wastewater treatment plants.

From an experimental and theoretical investigation of the continuity of influent inorganic suspended solids (ISS) along the links connecting the primary settling tank (PST), fully aerobic or N removal activated sludge (AS) and anaerobic and aerobic digestion (AerD) unit operations, it was found that (i) the influent wastewater (fixed) ISS concentration is conserved through primary sludge anaerobic digestion, and AS and AerD unit operations. However, the measured ISS flux at different stages through a series of WWTP unit operations is not equal to the influent ISS flux because the ordinary heterotrophic organisms (OHO) biomass contributes to the ISS flux by differing amounts depending on the OHO (active) fraction of the VSS solids at that stage.

Integrated chemical--physical processes kinetic modelling of multiple mineral precipitation problems.

A three-phase (aqueous/gas/solid) mixed weak acid/base chemistry kinetic model is applied to evaluate the processes operative in the aeration treatment of swine wastewater (SWW) and sewage sludge anaerobic digester liquor (ADL). In both applications, with a single set of constants (except for the aeration rates which are situation specific), close correlation could be obtained between predicted and measured data, except for the Ca concentration-time profile in the SWW. For this wastewater, the model application highlighted an inconsistency in the measured Ca data which could not be resolved; this illustrates the value of a mass balance-based model in evaluating experimental data. From the model applications, in both wastewaters the dominant minerals precipitating are struvite and amorphous calcium phosphate (ACP), which precipitate simultaneously competing for the same species, P. The absolute and relative masses of the two precipitants are governed by the initial solution state (e.g. total inorganic C (C(T)), Mg, Ca and P concentrations), their relative precipitation rates (struvite > ACP) and the system conditions imposed (aeration rates and time applied). It is concluded that the kinetic model is able to predict correctly the time-dependent weak acid/base chemistry reactions and final equilibrium state for situations where multiple minerals competing for the same species precipitate simultaneously or sequentially, a deficiency in traditional equilibrium chemistry-based algebraic models.

A comparison of BNR activated sludge systems with membrane and settling tank solid-liquid separation.

Installing membranes for solid-liquid separation into biological nutrient removal (BNR) activated sludge (AS) systems makes a profound difference not only to the design of the membrane bio-reactor (MBR) BNR system itself, but also to the design approach for the whole wastewater treatment plant (WWTP). In multi-zone BNR systems with membranes in the aerobic reactor and fixed volumes for the anaerobic, anoxic and aerobic zones (i.e. fixed volume fractions), the mass fractions can be controlled (within a range) with the inter-reactor recycle ratios. This zone mass fraction flexibility is a significant advantage of MBR BNR systems over BNR systems with secondary settling tanks (SSTs), because it allows changing the mass fractions to optimise biological N and P removal in conformity with influent wastewater characteristics and the effluent N and P concentrations required. For PWWF/ADWF ratios (fq) in the upper range (fq approximately 2.0), aerobic mass fractions in the lower range (f(maer) < 0.60) and high (usually raw) wastewater strengths, the indicated mode of operation of MBR BNR systems is as extended aeration WWTPs (no primary settling and long sludge age). However, the volume reduction compared with equivalent BNR systems with SSTs will not be large (40-60%), but the cost of the membranes can be offset against sludge thickening and stabilisation costs. Moving from a flow unbalanced raw wastewater system to a flow balanced (fq = 1) low (usually settled) wastewater strength system can double the ADWF capacity of the biological reactor, but the design approach of the WWTP changes away from extended aeration to include primary sludge stabilisation. The cost of primary sludge treatment then has to be offset against the savings of the increased WWTP capacity.

Measurement and modelling of ordinary heterotrophic organism active biomass concentrations in anoxic/aerobic activated sludge mixed liquor.

Ordinary heterotrophic organism (OHO) active biomass (ZBH) is a key parameter in models for activated sludge systems, which defines quantitatively the kinetic rates of relevant processes. However, ZBH has not been measured directly with consistent success: a simple respirometric batch test has provided varying correspondence between measured and theoretical concentrations. In this paper, the batch test is applied to mixed liquors drawn from well defined anoxic/aerobic parent systems at 10 and 20 d sludge ages, with consistent but poor correspondence between measured and theoretical values. In contrast, aerobic digestion batch tests on the same mixed liquors give good correspondences. It is concluded that the differences between theoretical and batch test measured values are due to the batch test method itself and its interpretation. It is found that the batch test conditions (particularly the substrate/ZBH ratio) influence the kinetic constants derived from the data, and hence the ZBH estimate. Two kinetic models with two competing OHO populations, a fast and a slow grower, are developed and applied to the batch tests and parent systems. The first model is based on kinetic selection only, while the second includes additional metabolic selection. Both models can account for the observations in the batch tests, but the second provides greater consistency between simulations of the parent systems and batch tests.

Impact of membrane solid-liquid separation on design of biological nutrient removal activated sludge systems.

Installing membranes for solid-liquid separation into biological nutrient removal (BNR) activated sludge (AS) systems makes a profound difference not only in the design of the BNR system itself, but also in the design approach for the whole wastewater treatment plant (WWTP). In multizone BNR systems with membranes in the aerobic reactor and fixed volumes for the anaerobic, anoxic, and aerobic zones (i.e., fixed volume fractions), the mass fractions can be controlled (within a range) with the interreactor recycle ratios. This zone mass fraction flexibility is a significant advantage in membrane BNR systems over conventional BNR systems with SSTs, because it allows for changing of the mass fractions to optimize biological N and P removal in conformity with influent wastewater characteristics and the effluent N and P concentrations required. For PWWF/ADWF ratios in the upper range (f(q) approximately 2.0), aerobic mass fractions in the lower range (f(maer) < 0.60), and high (usually raw) wastewater strengths, the indicated mode of operation of MBR BNR systems is as extended aeration WWTPs. Although the volume reduction compared with equivalent conventional BNR systems with secondary settling tanks is not as large (40% to 60%), the cost of the membranes can be offset against sludge thickening and stabilization costs. Moving from a flow-unbalanced raw wastewater system to a flow-balanced (f(q) = 1), low (usually settled) wastewater strength system can double the ADWF capacity of the biological reactor, but the design approach of the WWTP changes from extended aeration to include primary sludge stabilization. The cost of primary sludge treatment then has to be paid from the savings from the increased WWTP capacity.

A predictive model for the reactor inorganic suspended solids concentration in activated sludge systems.

A simple predictive model for the activated sludge reactor inorganic suspended solids (ISS) concentration (excluding that from chemical precipitant dosing) is presented. It is based on the accumulation of influent ISS in the reactor and an ordinary heterotrophic organism (OHO) ISS content (fiOHO) of 0.15 mg ISS/mg OHO organic (volatile) suspended solids (VSS) and a variable phosphate accumulating organism (PAO) ISS content (fiPAO) proportional to their P content (fXBGP). Organism ISS content is conceptualized as the uptake of dissolved inorganic solids by active organisms, which when dried in the total suspended solids (TSS) test procedure, precipitate and manifest as ISS. The model is validated with data from 22 investigations conducted over the past 15 years on 30 aerobic and anoxic-aerobic nitrification-denitrification (ND) systems and 18 anaerobic-anoxic-aerobic ND biological excess P removal (BEPR) systems variously fed artificial and real wastewater, and operated from 3 to 20 days sludge age. The predicted reactor VSS/TSS ratio reflects the observed relative sensitivity to sludge age, which is low, and to BEPR, which is high. To use the model for design, two parameters need to be known: (1) the influent ISS concentration, which is not commonly measured in wastewater characterization analyses and (2) the P content of PAOs (fXBGP), which can vary considerably depending on the extent of anoxic P uptake BEPR that takes place in the system. Some guidance on the measurement of influent ISS concentration and selection of the PAO P content to calculate the mixed liquor VSS/TSS ratio for design is given.

Control of corrosion and aggression in drinking water systems.

Corrosion and/or aggression are common problems arising in pipelines transporting terrestrial waters. The kinetics and severity of such events depend on both the quality of the water being transported and the material properties of the pipeline. Irrespective of the nature of the problem, its solution (or at least its minimisation) is strongly linked to control of pH, calcium concentration and carbonate chemistry of the water (stabilisation). However, application of such chemistry to water treatment problems is complex and time consuming. Various numerical, graphical and computer techniques have been developed to address this, but these are either of insufficient accuracy, too time consuming or lacking in generality. In this paper algorithms are presented for solving a broad spectrum of problems related to control of mineral precipitation/aggression, pH and chemical dosing in water treatment. These have been incorporated into a computer software package, STASOFT, which offers the requisite framework for use in water treatment. Various stabilisation problems pertinent to water supply are addressed.

Modelling multiple mineral precipitation in anaerobic digester liquor.

Mineral precipitation problems have been experienced with the conveyance and treatment of anaerobically digested primary and waste activated sludge blends. This paper describes an experimental investigation into mineral precipitation in anaerobic digester liquor (ADL) from the Cape Flats (CF) Wastewater Treatment Plant (WWTP) (Cape Town, South Africa), and application of the three-phase (aqueous/solid/gas) physical and chemical processes kinetic model developed by Musvoto et al. (Water Res. 34 (2000) 1857; Water Res. 34 (2000) 1868; Water SA 26(4) (2000) 417) to the experimental data. From the experimental investigation and theoretical modelling, it is concluded inter alia that: (i) there is a close correlation between experimental measured and theoretically predicted data, (ii) the dominating mineral that precipitates is struvite, with small amounts of amorphous calcium phosphate and negligible newberyite, calcite and magnesite, (iii) the precipitation of struvite is governed by the increase in pH when CO2 is lost from the ADL, (iv) the ADL is initially undersaturated with respect to struvite, but becomes supersaturated at pH > 7.3-7.7, (v) the rate and mass of struvite precipitation are controlled by the rate of pH increase and the initial Mg concentration and (vi) the three-phase kinetic model is able to simulate accurately the time dependent precipitation data for multiple minerals competing for the same species and allows determination of specific precipitation rates for a number of minerals simultaneously in an integrated manner from a single batch test. Some operational strategies to minimise struvite precipitation are proposed.

Modelling biological nutrient removal activated sludge systems - a review.

The external nitrification (EN) biological nutrient removal (BNR) activated sludge (ENBNRAS) system shows considerable promise for full-scale implementation. As an aid for this implementation, a mathematical simulation model would be an invaluable tool. To develop such a model, a study was conducted to select the most suitable simulation model to serve as a starting point for further development. For this, the existing available simulation models for BNRAS systems are compared with one another and evaluated against experimental observations in the literature and on ENBNRAS systems. One process immediately apparent to be crucially important is the anoxic growth of phosphorus accumulating organisms (PAOs), with associated PAO denitrification and anoxic P uptake for polyP formation. These linked processes are lacking in the earlier kinetic simulation models for BNRAS systems, which were based on aerobic PAO growth and P uptake only, but have been incorporated into the more recent kinetic models. This provides a substantive body of information on modelling this aspect. Other processes of significance identified to require consideration are anaerobic slowly biodegradable COD (SBCOD) hydrolysis to readily biodegradable COD (RBCOD), and COD loss. Both processes have significant impact on the predicted BEPR performance. Due to the uncertainties associated with the mechanisms and quantification of these two processes, it is concluded that the most extensively validated kinetic simulation model should be selected for development, and that the omissions in this model should be addressed progressively, using the relevant information drawn from the existing models, the literature and observations on ENBNRAS systems.

Experimental investigation of the external nitrification biological nutrient removal activated sludge (ENBNRAS) system.

A systematic lab-scale experimental investigation is reported for the external nitrification (EN) biological nutrient removal (BNR) activated sludge (ENBNRAS) system, which is a combined fixed and suspended medium system. The ENBNRAS system was proposed to intensify the treatment capacity of BNR-activated sludge (BNRAS) systems by addressing two difficulties often encountered in practice: (a) the long sludge age for nitrification requirement; and (b) sludge bulking. In the ENBNRAS system, nitrification is transferred from the aerobic reactor in the suspended medium activated sludge system to a fixed medium nitrification system. Thus, the sludge age of the suspended medium activated sludge system can be reduced from 20 to 25 days to 8 to 10 days, resulting in a decrease in reactor volume per ML wastewater treated of about 30%. Furthermore, the aerobic mass fraction can also be reduced from 50% to 60% to <30% and concommitantly the anoxic mass fraction can be increased from 25% to 35% to >55% (if the anaerobic mass fraction is 15%), and thus complete denitrification in the anoxic reactors becomes possible. Research indicates that both the short sludge age and complete denitrification could ameliorate anoxic aerobic (AA) or low food/microorganism (F/M) ratio filamentous bulking, and hence reduce the surface area of secondary settling tanks or increase the treatment capacity of existing systems. The lab-scale experimental investigations indicate that the ENBNRAS system can obtain: (i) very good chemical oxygen demand (COD) removal, even with an aerobic mass fraction as low as 20%; (ii) high nitrogen removal, even for a wastewater with a high total kjeldahl nitrogen (TKN)/COD ratio, up to 0.14; (iii) adequate settling sludge (diluted sludge volume index [DSVI] <100 mL/g); and (iv) a significant reduction in oxygen demand.

The effect of residual ammonia concentration under aerobic conditions on the growth of Microthrix parvicella in biological nutrient removal plants.

It is demonstrated with two parallel single reactor intermittently aerated nitrification denitrification systems fed municipal wastewater as influent, that Microthrix parvicella bulking can be stimulated and cured by manipulating the ammonia concentration in the aerobic period (by inhibiting the nitrifiers) to high and low values respectively. The proliferation or not of M. parvicella is hypothesized to be due to their requirement for ammonia as a nitrogen source for growth. In terms of this hypothesis, if nitrification is rapid and complete, ammonia is not freely available and will limit M. parvicella growth. If nitrification is not complete for whatever reason, ammonia is available for the growth of the slow growing M. parvicella, enabling their proliferation to cause a bulking sludge. This hypothesis does not overturn or replace the anoxic-aerobic (AA, or low Food/Microorganism, F/M, ratio) filament bulking hypothesis of Casey et al. (Water SA 25(4) (1999) 425) but appears to be additional to it. Future research will focus on determining how elements of both hypotheses superimpose on the conditions in BNR systems, to produce an AA filament bulking sludge or not.