From sewage sludge and agri-food waste to VFA: Individual acid production potential and up-scaling.

Volatile fatty acid (VFA) production through anaerobic fermentation may constitute an innovative solution for organic waste management within the context of circular economy. In the present study, the evolution of individual VFA during laboratory-scale fermentation of sewage sludge (SS), winery wastewater (Www) and meat and bone meal (MBM) was assessed, focusing on the effect of pH (5.5 and 10) and temperature (35 and 55 °C). Up-scaling of the fermentation process was evaluated in batch operation. The latter showed that specific VFA could be produced, giving similar individual evolution to lab-scale testing. To be precise, acetic acid percentage ranged within 30-65% and increased up to 5900 mg O2 L-1 during SS fermentation at 55 °C and pH 9. In addition, 60% butyric acid was reached during Www acid fermentation at 55 °C, which corresponded to 6670 mg O2 L-1 concentration in the fermentation broth. Regarding valeric acid, over 20% proportion and 2700 mg O2 L-1 were reached in MBM acid fermentation at 35 °C. Finally, iso-valeric maximum level ranged within 15-17% in SS alkaline fermentation at 55 °C, which represented a concentration close to 2000 mg O2 L-1. Interestingly, co-fermentation of agri-food waste and SS at thermophilic temperature and alkaline pH, boosted the VFA concentration 1.7-2 fold, which suggests that anaerobic co-fermentation of substrates from different nature could give promising outcomes in full-scale operation.

Lessons learnt from the application of a multi-variable controller for nitrogen removal in the Mekolalde wastewater treatment plant: good simulation practices in control.

Although often perceived as tools for use by scientists, mathematical modelling and simulation become indispensable when control engineers have to design controllers for real-life wastewater treatment plants (WWTPs). Nonetheless, the design of effective controllers in the wastewater domain using simulations requires effects, such as the nonlinearity of actuators, the time response of sensors, plant model uncertainties, etc. to have been reproduced beforehand. Otherwise, control solutions verified by simulation can completely underperform under real conditions. This study demonstrates that, when all the above effects are included at the outset, a systematic use of simulations guarantees high quality controllers in a relatively short period of time. The above is exemplified through the Mekolalde WWTP, where a comprehensive simulation study was conducted in order to develop a control product for nitrogen removal. Since its activation in May 2011, the designed controller has been permanently working in the plant which, from this time onwards, has experienced significant improvements in the quality of water discharges combined with a lower utilization of electricity for wastewater treatment.

Combination of extremum-seeking algorithms with effective hydraulic handling of equalization tanks to control anaerobic digesters.

The benefits of upgrading extremum-seeking controllers with an effective exploitation of the buffer capacity of equalization tanks have been investigated and applied to anaerobic digesters. In this respect, a Fuzzy-based supervisory module that monitors the state of the equalization tank has been designed and built on top of an extremum-seeking algorithm in charge of automatically regulating the wastewater fed into the anaerobic digester. The extremum-seeking controller guarantees good disturbance rejection and methane production around an upper limit set-point. The on-top Fuzzy module optimizes the long-term methane production by modifying this upper limit set-point as a function of the state of the equalization tank. A systematic simulation study has been carried out to evaluate the performance of the proposed control solution. Thus, on the basis of existing simulation benchmarks for assessment of control strategies in wastewater treatment plants, a dedicated simulation protocol for anaerobic digesters has been defined and implemented. Simulation results have shown that, compared with manual operation, effluent quality and methane production improvements of 10-15% are achieved using the proposed control approach.

Optimal predictive control of water transport systems: Arrêt-Darré/Arros case study.

This paper proposes the use of predictive optimal control as a suitable methodology to manage efficiently transport water networks. The predictive optimal controller is implemented using MPC control techniques. The Arrêt-Darré/Arros dam-river system located in the Southwest region of France is proposed as case study. A high-fidelity dynamic simulator based on the full Saint-Venant equations and able to reproduce this system is developed in MATLAB/SIMULINK to validate the performance of the developed predictive optimal control system. The control objective in the Arrêt-Darré/Arros dam-river system is to guarantee an ecological flow rate at a control point downstream of the Arrêt-Darré dam by controlling the outflow of this dam in spite of the unmeasured disturbances introduced by rainfalls incomings and farmer withdrawals.

On-line estimation of suspended solids in biological reactors of WWTPs using a Kalman observer.

The total amount of solids in Wastewater Treatment Plants (WWTPs) and their distribution among the different elements and lines play a crucial role in the stability, performance and operational costs of the process. However, an accurate prediction of the evolution of solids concentration in the different elements of a WWTP is not a straightforward task. This paper presents the design, development and validation of a generic Kalman observer for the on-line estimation of solids concentration in the tank reactors of WWTPs. The proposed observer is based on the fact that the information about the evolution of the total amount of solids in the plant can be supplied by the available on-line Suspended Solids (SS) analysers, while their distribution can be simultaneously estimated from the hydraulic pattern of the plant. The proposed observer has been applied to the on-line estimation of SS in the reactors of a pilot-scale Membrane Bio-Reactor (MBR). The results obtained have shown that the experimental information supplied by a sole on-line SS analyser located in the first reactor of the pilot plant, in combination with updated information about internal flow rates data, has been able to give a reasonable estimation of the evolution of the SS concentration in all the tanks.

Benchmarking of control strategies for ATAD technology: a first approach to the automatic control of sludge treatment systems.

Autothermal Thermophilic Aerobic Digestion (ATAD technology) is a promising alternative to conventional digestion systems. Aeration is a key factor in the performance of these kinds of reactors, in relation to effluent quality and operating costs. At present, the realisation of automatic control in ATADs is in its infancy. Additionally, the lack of robust sensors also makes the control of these processes difficult: only redox potential and temperature sensors are reliable for operation in full-scale plants. Based as it is on the existing simulation protocols for benchmarking of control strategies for wastewater treatment plants (WWTP), this paper presents the definition and implementation of a similar protocol but specifically adapted to the needs of ATAD technology. The implemented simulation protocol has been used to validate two different control strategies for aeration (ST1 and ST2). In comparison to an open-loop operation for the ATAD, simulation results showed that the ST1 strategy was able to save aeration costs of around 2-4%. Unlike ST1, ST2 achieved maximum sludge stabilisation but at the expense of higher aeration costs.

Online monitoring of OUR, K(L)a and OTE indicators: practical implementation in full-scale industrial WWTPs.

Based on on/off aeration strategies, this paper describes all the steps involved in the development and implementation of three identification algorithms aimed at monitoring the oxygen uptake rate (OUR), the oxygen mass-transfer coefficient (K(L)a), and oxygen transfer efficiency (OTE) in aerated biological reactors. Firstly, a detailed explanation of the theoretical background behind every algorithm is given. In addition, practical issues have also been taken into account in order to guarantee the quality of estimations. Finally, the three algorithms have been implemented and validated in a full-scale industrial wastewater treatment plant with satisfactory results. Although short-term noise has been observed in the estimated data (especially at high OURs), the medium and long-term data trajectories have been correctly reproduced.

AqquaScan: design and implementation of an internet-based service for the remote monitoring and management of decentralised WWTPs.

This paper describes the design and implementation of AqquaScan, an Internet-based service for remote monitoring and integrated management of decentralised WWTPs. AqquaScan is a multi-user and multi-WWTP service. It has been built according to criteria such as flexibility, scalability and interoperability with the idea of providing an open environment suited to quickly accommodate future scenarios (e.g. incorporation of new plants or upgrading of existing installations). Both, the management of plant information and users interfaces have been implemented in distributed software components that communicate with one another via web services. The implemented web services can be exploited to develop customised user interfaces for visualising the monitored data. By default, a customised web-based client module has been programmed in order for users to be able to exploit the facilities offered within AqquaScan: (1) real-time monitoring of on-line signals; (2) visualisation of historical data; (3) changing operational parameters; (4) notification of time-event information; and (5) storage of measurements from laboratory analysis. At present, AqquaScan is fully operative and is offering supervision services to eleven industrial WWTPs distributed around Northern Spain.

Integration of equalisation tanks within control strategies for anaerobic reactors. Validation based on ADM1 simulations.

The combination of equalisation tanks and anaerobic digesters represents a typical design scenario within the treatment of industrial wastewaters. In this context, if the hydraulic capacity of the equalisation tanks is effectively handled, significant improvements in the performance of anaerobic digesters can be achieved in terms of process stability and biogas production. This paper presents a rule-based control strategy for anaerobic reactors with the objective of maximising in the long-term the net production of biogas. The control algorithm combines real-time information about the state of the anaerobic digester with on-line measurements about the wastewater volume of the equalisation tank in order to set permanently the appropriate production of biogas. Such a strategy guarantees a continuous influent flow so that emptying and overflowing episodes in the equalisation tank can be prevented. Aiming at a further full-scale implementation, only reliable and cost-effective on-line instrumentation has been considered within the control architecture. The performance of the proposed control approach has been validated for an anaerobic hybrid configuration (AHR) by simulation using the IWA ADM1 model.

Standard signal processing using enriched sensor information for WWTP monitoring and control.

Important indicators for monitoring and control of wastewater treatment plants (WWTP) often have to be obtained from the processing of on-line signal trajectories. Therefore, the quality of sensor instantaneous measurements can be improved significantly if they are complemented with valuable information about the geometric features of their trajectories. The present paper describes the design and implementation of a Standard Signal Processing Architecture (SSPA) from which enriched sensor information is generated automatically. The SSPA has been made up of three complementary modules: the pre-processing module, the storage module and the post-processing module. Moreover, the SSPA has been parameterised so as to allow its adaptation to the specifications of every signal. By performing basic calculations on pre-processed signal trajectories, the storage module produces enriched vectors which collect information of the first and second time derivatives, average and variance values, peak values, linear regression parameters, curvature, etc. Then, the enriched information vectors can be exploited to implement customised monitoring and control tools. In this respect, the effectiveness of the SSPA has been demonstrated in three different practical cases: (1) OUR and KLa identification algorithms; (2) processing of measurements for real-time controllers; and, (3) detection of bend-points in on-line signals of SBR processes.

Design and operation of SBR processes for small plants based on simulations.

The paper firstly presents an experimental study in a SBR pilot plant operated at 20 degrees C for nitrogen removal from a very small village wastewater. The plant consisted of only one reactor fed continuously throughout the day and aerated intermittently. Two tests with seven and three intermittences of mixing/aerated phases were conducted and verification of the results by simulations of the activated sludge model (ASM) was also carried out. The experimental results and simulation showed that a wide range of effluent N03-N can be obtained using different numbers of intermittences and values of the oxygen transfer coefficient (K(L)a). At the same time, the paper presents a design procedure for SBR processes based on an iterative process of simulations of the ASM model. After the selection of the cycle time, the mixing/aeration pattern, the initial volume, the solid retention time, and the duration of the phases, the simulation is undertaken, resulting in values for the effluent NH4-N and NO3-N, and the suspended solids before settling. Then, the latter parameters are verified to match the effluent and settling requirements. As an application of the design procedure, the effect on design and operation of different SBR configurations and of several operating conditions are analysed in three case studies.

Optimizing nitrogen removal in the BioDenitro process.

The potential and limits of different configurations of the BioDenitro-alternating process to suit the various design cases that can arise depending on the wastewater characteristics, space necessary and effluent nitrogen requirements were analysed through simulations of the activated sludge model No. 2. The first analysis involved the combination in one cycle of the main phase in the alternating reactors with an aerated phase having the two reactors in aerobic conditions and/or a hydraulic phase using the flow only in the anoxic reactor. This option has been found to have a very high potential for cases with strict requirements concerning effluent total nitrogen, but limited when the requirements are low effluent NH4-N, relatively high effluent total nitrogen and minimum solids and hydraulic retention times. When the latter conditions have to be fulfilled the incorporation of a post-aeration reactor to the alternating reactor was found to be very effective. In addition the configuration is very flexible because multiple combinations of post-aeration reactor volumes and in the duration of the different phases in the alternating reactors can be selected to achieve effluent nitrogen requirements. This flexibility is limited to the use of moderate values in the post-aeration reactor volumes and in the duration of the aerated phase. An experimental trial of the latter configuration was carried out and demonstrated its operational simplicity by achieving the desired nitrogen requirements in the effluent simply by changing the duration of the aerated phase for a given post-aeration reactor volume. From the experimental results an enhanced simultaneous nitrification-denitrification at the start of aeration in the alternating reactors was found and the ASM2 model was shown to have a satisfactory predictive capacity.

Improving the predictions of ASM2d through modelling in practice.

The paper presents the adjustments carried out on the structure and in some default values of the kinetic coefficients of the ASM2d model in order to get an improved prediction for the experimental results obtained in pilot scale plants studies with different activated sludge treatment processes for carbon, nitrogen and phosphorous removal. In order to predict the high effluent filtered COD experimentally observed in high rate processes for carbon removal, a new model structure has been proposed, incorporating into the carbon model a soluble fraction of the slowly biodegradable substrate. Studies with the step feed and the alternating processes showed simultaneous nitrification-denitrification in aerated reactors which was predicted with increased values in the oxygen saturation coefficients for heterotrophic and autotrophic biomass. Both processes also showed loss of the denitrification capacity under unfavourable conditions, such us rains and low anoxic fraction, which required a very large decrease in the value of the reduction factor for denitrification so as to improve the predictions for effluent nitrate experimental results. Regarding phosphorus removal, the ASM2d model showed a satisfactory predictive capacity. For improved predictions of phosphorus release in anaerobic conditions, high values of the rate constant for storage of X(PHA) and low values of the anaerobic hydrolysis reduction factor were used. For phosphorus uptake in aerobic and anoxic conditions satisfactory predictions were obtained using the default values.