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.

Characterization of microbial community dynamics during the anaerobic co-digestion of thermally pre-treated slaughterhouse wastes with glycerin addition.

Microbial community dynamics during the anaerobic co-digestion of pig manure, pasteurized slaughterhouse waste and glycerin were studied in a lab-scale CSTR. The feed composition was optimized through progressive co-substrate additions for enhanced methane production and organic matter removal without accumulation of intermediate compounds. Microbial community structure of biomass samples was studied by means of qPCR and DGGE profiling of 16S rRNA genes (Bacteria and Archaea), and genus-specific qPCR of the methyl coenzyme M reductase gene (mcrA), which encodes for an enzyme universally involved in methanogenesis. The composition of the dominant bacterial populations remained relatively stable, when compared to those in the influent, but the highest changes were observed upon the introduction of glycerin. Biodiversity of archaea was restricted to a few representatives of the genera Methanosaeta and Methanosarcina, but Methanospirillum sp. was detected only when glycerin was introduced in the feeding. Glycerin supplementation coincided with the strongest increase in methane yield (from 0.22 to 0.64 m3CH4 m-3 d-1).

Citrus essential oils and their influence on the anaerobic digestion process: an overview.

Citrus waste accounts for more than half of the whole fruit when processed for juice extraction. Among valorisation possibilities, anaerobic digestion for methane generation appears to be the most technically feasible and environmentally friendly alternative. However, citrus essential oils can inhibit this biological process. In this paper, the characteristics of citrus essential oils, as well as the mechanisms of their antimicrobial effects and potential adaptation mechanisms are reviewed. Previous studies of anaerobic digestion of citrus waste under different conditions are presented; however, some controversy exists regarding the limiting dosage of limonene for a stable process (24-192 mg of citrus essential oil per liter of digester and day). Successful strategies to avoid process inhibition by citrus essential oils are based either on recovery or removal of the limonene, by extraction or fungal pre-treatment respectively.

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.

Biomass adaptation over anaerobic co-digestion of sewage sludge and trapped grease waste.

The feasibility of sewage sludge co-digestion using intermediate waste generated inside a wastewater treatment plant, i.e. trapped grease waste from the dissolved air flotation unit, has been assessed in a continuous stirred lab reactor operating at 35°C with a hydraulic retention time of 20 days. Three different periods of co-digestion were carried out as the grease waste dose was increased. When the grease waste addition was 23% of the volatile solids fed (organic loading rate 3.0 kg(COD)m(-3)d(-1)), an increase in methane yield of 138% was reported. Specific activity tests suggested that anaerobic biomass had adapted to the co-substrate. The adapted inoculum showed higher acetoclastic methanogenic and ß-oxidation synthrophic acetogenic activities but lower hydrogenotrophic methanogenic activity. The results indicate that a slow increase in the grease waste dose could be a strategy that favours biomass acclimation to fat-rich co-substrate, increases long chain fatty acid degradation and reduces the latter's inhibitory effect.

Effects of thermal pre-treatments on solid slaughterhouse waste methane potential.

The effects of thermal pre-treatments on the biogas production potential of two solid slaughterhouse waste types (poultry and piggery slaughterhouse by-products) were assessed by means of batch experiments. Both animal by-products were characterized in terms of fat, protein and carbohydrate concentrations. The selected thermal pre-treatments, pasteurization (70 °C for 60 min) and sterilization (133 °C and 3 bars for 20 min), are included in the current European regulations for the disposal or use of animal by-products. The pre-treatments produced notable improvements in organic matter solubilization, but had different effects on the anaerobic bioavailability of the treated substrates. The methane yield of the initial volatile solids did not increase significantly after pre-treatment when carbohydrate concentration was high, reaching a maximum of 0.48 m(CH4)(3) kg(VS)(-1) for the pasteurized poultry waste. However, this yield increased by up to 52.7% after pasteurization and 66.1% after sterilization for the lower carbohydrate concentration sample (piggery waste), reaching maxima of 0.88 and 0.96 m(CH4)(3) kg(VS)(-1), respectively. The maximum methane production rates, measured as the maximum slope of the accumulated methane production curve, per unit of initial biomass content, were also different. While this rate increased by 52.6% and 211.6% for piggery waste after pasteurization and sterilization, respectively, it decreased by 43.8% for poultry waste after pasteurization with respect to untreated waste. Compounds with low biodegradability that are produced by Maillard reactions during thermal pre-treatment could explain the low bioavailability observed for waste with a high carbohydrate concentration.

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.

A model for the simulation of the SHARON process: pH as a key factor.

The SHARON process allows partial nitrification of wastewaters with high ammonium content and, when coupled with the Anammox process, represents a more sustainable alternative for N-removal than a conventional nitrification-denitrification. In this work, a mathematical model describing a continuously aerated SHARON reactor is presented. Special attention was given to the pH, because it affects substrates availability and inhibition phenomena, implementing an algorithm for its calculation. Since ammonium-oxidizing and nitrite-oxidizing organisms are inhibited by their own substrates, ammonia and nitrous acid respectively, Haldane kinetics was used in both nitrification steps. A preliminary evaluation of the model using historical experimental data generated in a lab-scale SHARON reactor, fed with synthetic substrate, is also presented, corroborating that the quality of the obtained effluent is highly dependent on pH.

Anaerobic digestion of solid material: multidimensional modeling of continuous-flow reactor with non-uniform influent concentration distributions.

A new multidimensional (3 and 2D) anaerobic digestion model for cylindrical reactor with non-uniform influent concentration distributions was developed to study the way in which mixing intensity affects the efficiency of continuous-flow anaerobic digestion. Batch experiments reported and simulated earlier by Vavilin and Angelidaki (2005) were used to modernize a kinetic scheme and to obtain the corresponding kinetic coefficients. In the new models, hydrolytic microorganisms were included using Contois kinetics for the hydrolysis/acidogenesis degradation of municipal solid waste (MSW). Monod kinetics was applied for description of methanogenesis. Both hydrolytic and methanogenic microorganisms were assumed to be inhibited by high volatile fatty acids (VFA) concentration. According to the new distributed models, the mixing level reduction expressed by increasing dimensionless Peclet number may improve the continuous flow reactor performance at the relatively low influent methanogenic biomass concentration. In the continuously stirred tank reactor (CSTR) there are two steady states with and without methane production at slightly different values of initial methanogenic biomass concentration. In the system, the threshold methanogenic biomass concentration existed because of inhibition by high VFA concentration. High methanogenic biomass concentration is required for efficient anaerobic digestion of MSW in order to avoid possible inhibition due to high VFA build-up. Thus, CSTR configuration might have unstable dynamics at high organic loading as shown in earlier experiments carried out by Stroot et al. (2001). A gradual increase of organic loading during the start up of a completely mixed digester causing an accumulation of methanogenic biomass is a solution to prevent a probable digester failure. According to the distributed models a plug-flow reactor with non-uniform influent concentration distributions where methanogenic and hydrolytic microorganisms are separated has significant methane production and solids removal at the relatively low influent methanogenic biomass concentration.

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.

Environmental engineering education in Spain.

There is a growing demand for engineers and technologists who show multidisciplinary expertise to deal with environmental issues. As a result of this demand, most countries are adapting their old university programs on environmental engineering education. In Spain an official environmental engineering degree does not yet exist, but the Council of Universities is working to present a proposal, based on Bologna agreement concepts. The paper summarizes not only the future perspectives of environmental engineering education in Spain, but also the evolution of the approach during the last decades, which includes the role of the private initiative, the environmental sciences degree, and the intensification in different traditional engineering degrees. Finally, the paper briefly details and compares the syllabus developed in the only four Spanish universities where environmental engineering is offered as a non-official post-graduate course lasting two years.

A method for livestock waste management planning in NE Spain.

A method of decision-making on livestock wastes management in areas with nutrient surplus due to high livestock density is applied in Catalonia (NE Spain). Nutrient balance is made considering soil nitrogen application as the limiting factor. Special attention is paid to the centralized treatment option. The method presented consists of: 1. minimizing livestock waste generation (at farm scale) as a step previous to any other, both in amount and limiting components, 2. applying the nitrogen balance method at regional and municipal scale and providing enough storage capacity in order to apply wastes in an agronomically correct way, 3. spatially refining the results of the nitrogen balance by a proposed method that allows precisely pinpointing the hotspots of livestock waste generation, where centralized treatment might be an interesting option, and 4. deciding on the waste treatment objectives, provided that treatments be necessary. Knowledge about the wastes, meeting the interests and merging the efforts of the various actors, as well as an adequate budget are necessary ingredients for the success of any waste management plan.

Concentration of pig slurry by evaporation: anaerobic digestion as the key process.

Nutrient redistribution between areas with a structural pig slurry surplus and those with a shortage, is limited by the high cost of transportation and spreading, due to the high water content in slurry (more than 90%) and its relative low nutrient concentration. Water can be removed from slurry by evaporation, through the application of waste heat from a power plant or from other processes. Apart from obtaining a concentrate with an obviously higher nutrient concentration than the original slurry, another objective is to obtain clean water as condensate. The objective of this work was to study the batch vacuum evaporation of pig slurry liquid fraction, to evaluate the economic feasibility and to evaluate condensate quality as a function of both pH (4, 5 and 6) and pig slurry type (fresh slurry and anaerobically digested slurry). Results showed that condensate characteristics (ammonia nitrogen, VFA, COD) were strongly dependent on these variables. Previous anaerobic digestion presented clear advantages: it provided a fraction of the required energy and it removed organic matter, preventing its volatilisation in the evaporation process and providing higher quality condensates. These advantages make the combined treatment strategy economically more feasible than the evaporation process alone.