Mathematical modelling and comparative analysis of treatment technologies for upgrading wastewater treatment plants: A case study of biofilm reactors in El-Gouna, Egypt.

In recent years, Moving Bed Biofilm Reactors (MBBRs) have been preferred to conventional processes with suspended biomass. The main reason for this preference is that it can achieve better removal efficiencies than conventional systems with smaller footprints. However, unlocking the full potential of MBBRs in large-scale WWTPs remains challenging in real life. In this study, the performance of three different treatment technologies, Extended Aeration Activated Sludge (EAAS), Hybrid Fixed Bed Biofilm Reactor (HFBBR), and Hybrid Moving Bed Biofilm Reactor (HMBBR), was investigated over a year in a WWTP located in El-Gouna, Egypt. The COD removal efficiencies of the three systems were comparable, with the EAAS achieving 93.5%, HFBBR 94%, and HMBRR 95%. Nevertheless, the NH4 removal efficiency of the EAAS was slightly lower (97.5%) than that of the HFBBR and the HMBBR, that achieved a removal efficiency of 98%. BioWin Software was able to mimic the real case of the WWTP of El-Gouna and critically defined all plant limitations and operational data. Different simulations were modeled to test the hydraulic and organic loading capacities of the three systems under different scenarios and operating conditions. The HMBBR system failed to withstand the increase in organic load because of the biomass sloughing effect and subsequently high TSS loads in the settlers. Biomass sloughing overloaded the settlers and lead to biomass loss in the effluent. As the settleability of the HMBBR sludge was significantly lower than for the HFBBR the TSS loss in the effluent happened that much earlier that the moving carrier application had an adverse effect contradicting with the primary purpose of adding media carriers. Model simulations and data analysis findings were used to recommend the most suitable configuration for upgrading an existing system using the attached growth technique with all kinetic parameters and operational conditions. The recommended configuration focuses mainly on the separation of plastic media in a compartment with a very low hydraulic retention time to absorb the incoming shock load.

Assessment of hybrid fixed and moving bed biofilm applications for wastewater treatment capacity increase - In situ tests in El-Gouna WWTP, Egypt.

This paper provides a procedure for comparing the performance of different biofilm carrier medias and their surrounding suspended biomass through oxygen uptake rate (OUR) tests. For in situ (oxygen uptake rate (OUR) measurements, three identical lab scale biofilm reactors were set up at the El Gouna wastewater treatment plant (WWTP). In this setup, two options of media for moving-bed biofilm reactors (MBBR) and one media for fixed-bed biofilm reactors (FBBR) were compared. The WWTP also used the same carrier in a real scale hybrid application to analyze how the interactions between the carrier type and the suspended biomass influences the overall performance. The in situ OUR approach is recommended to measure the contribution of the biofilm fixed biomass under site specific conditions. Specifically, settleability and diffusion limitations are the two opposite poles that cannot be predicted adequately for mild climate conditions based on the literature. A biofilm carrier application can add but actually can also reduce the capacity in a hybrid activated sludge system: The added MBBR-media was able to grind down the sludge flocs forming a poorly settleable suspended biomass. The added FBBR-media can lead to extracellular polymeric substances (EPS) rich biofilms that contribute very little as substrate and oxygen are unavailable for the microorganisms present in the biofilm. In this application of the comparison procedure, Kaldnes K1 like MBBR media was compared with a recycling MBBR carrier option (poly propylene bottle caps) and Jäger Envirotech "BioCurlz™" FBBR media. The study showed higher average rates for the MBBR but decreased settleability. The FBBR showed higher peak rates when flushed to break up the biofilm and well settleable sludge. The determination of OUR per g of volatile solids (SOUR) showed comparable results for all the carriers and in warm conditions, only the capacity to accommodate biomass determines the contribution of the carrier.

Semi-continuous Production of 2-Ethyl Hexyl Ester in a Packed Bed Reactor: Optimization and Economic Evaluation.

The aim of this work was to investigate the technical as well as the economic feasibility of producing 2-ethyl hexyl oleate (2-EHO), a non-phthalate plasticizer in a solvent free medium. The esterification reaction between oleic acid and 2-ethyl hexyl alcohol was carried out in a packed bed reactor (PBR) using Candida antarctica lipase B (Novozym 435; Novozymes; Copenhagen-Denmark) as biocatalyst. RSM was employed to optimize the esterification reaction conditions. The optimum reaction conditions were found to be flow rate of 1.5 mL/min, No. of cycles of 12 and molar ratio of 4:1 2-ethyl hexanol to oleic acid. The maximum experimental and predicated conversions were found to be 95.8% and 95.61% respectively. Formation of 2-EHO was approved by FTIR, 1HNMR and 13CNMR. From the economic prospective, PBR was capable of producing 2-EHO with a purity of more than 94% over 480 h without remarkable reduction of enzyme activity. This revealed an economic production of 2-EHO at a yield of 2 tons kg-1 lipase. The manufacturing cost was found to be $ 1.88 /kg 2-EHO, this contributed to a profit of about 30% compared to the commercial price of 2-EHO. Such results approve the technical and economic feasibility for this sustainable method in esters production.

Kinetics and Gibbs Function Studies on Lipase-Catalyzed Production of Non-Phthalate Plasticizer.

Petroleum based phthalate plasticizers encounter enormous claims to prohibit their production due to their harmful health impacts when they are mixed with plastics. That is why efforts are being done to find safer natural alternatives. We have investigated the reaction kinetics of the esterification epoxidation of oleic acid and 2-ethylhexanol in the presence of hydrogen peroxide catalyzed using Candida antarctica lipase (Novozym 435, Novozymes, Kobenhavn, Denmark). The product of this reaction is epoxidized 2-ethylhexyl oleate, a non-phthalate green plasticizer. The kinetic model for this reaction follows a multi-substrate PingPong Bi-Bi mechanism with competitive inhibition by the alcohol. The reaction's kinetic parameters were found to be 0.76 M, 0.37 M, 0.08 M, and 37.20 mM/min for Michalis-Menten constant for oleic acid (Kmo), Michalis-Menten constant for alcohol (Kma), alcohol inhibition constant (Kia), and maximum reaction velocity (Vmax), respectively. Then the Gibbs function analysis of the transition state based on the Arrhenius and Eyring equations was carried out. The internal diffusional limitations were found to be negligible as the effectiveness factor took the value of almost unity. While the external mass transfer resistance had no effect on the reaction due to operating at relatively high agitation speed and high temperature. This investigation confirms that this reaction was only kinetically controlled.