Anaerobic treatment of complex chemical wastewater in a sequencing batch biofilm reactor: Process optimization and evaluation of factor interactions using the Taguchi dynamic DOE methodology

Catalytic hydrothermal deoxygenation of sugarcane bagasse for energy dense bio-oil and aqueous fraction acidogenesis for biohydrogen production

The study focuses on the effective conversion of sugarcane bagasse (SCB) by catalytic deoxygenation using various alkali and metal-based catalysts under N₂ pressure employing water as solvent. The specific influence of catalyst over bio-crude yields (bio-oil and aqueous fraction) including energy recovery ratio was explored. The optimum catalytic condition (Ru/C) resulted in ∼ 70% of bio-crude and 28% of bio-oil with an improved HHV (31.6 MJ/kg) having 11.6% of aliphatic/aromatic hydrocarbons (C₁₀-C₂₀) which can be further upgraded to drop-in fuels. The biocrude composed of 44% of aqueous soluble organic fraction (HTL-AF). Further, the carbon-rich HTL-AF was valorized through acidogenic fermentation to yield biohydrogen (Bio-H₂). The maximum bio-H₂ production of 201 mL/g of TOC conversion (K₂CO₃ catalyst) was observed with 7.7 g/L of VFA. The SCB was valorized in a biorefinery design with the production of fuels and chemical intermediates in a circular chemistry approach.

Synergy of selective buffering, intermittent pH control and bioreactor configuration on acidogenic volatile fatty acid production from food waste

The production of volatile fatty acids (VFAs) and biohydrogen (bio-H₂) from food waste (FW) by acidogenic process is one of the promising strategies. The present study was performed to evaluate the role of initial (phase I) and intermittent pH (phase II) control strategies utilising combination of sodium hydroxide (NaOH) and sodium carbonate (Na₂CO₃) as buffering/neutralizing agents on VFAs and bio-H₂ production from FW. The study was carried out in two bioreactor configurations (biofilm (UAFBB) and a suspended mode bioreactor (UASB)). Intermittent pH adjustment (phase II) increased hydrolysis and FW acidification compared to the initially adjusted pH (phase I), but had a detrimental influence on bio-H₂ generation in both the studied bioreactor configurations. Combining NaOH and Na₂CO₃ resulted in higher buffering capacity and VFA production. The studied parameters in UAFBB aided in higher VFA (14.05 g/L; 48 h of cycle operation) and bio-H₂ (56%; 12 h of cycle operation) production during phase II and phase I operation, respectively. Overall, the results showed a synergy between the examined parameters, resulting in increased VFA production from FW.

Model-Based Process Optimization for the Production of Macrolactin D by Paenibacillus polymyxa

In this study, we show the successful application of different model-based approaches for the maximizing of macrolactin D production by Paenibacillus polymyxa. After four initial cultivations, a family of nonlinear dynamic biological models was determined automatically and ranked by their respective Akaike Information Criterion (AIC). The best models were then used in a multi-model setup for robust product maximization. The experimental validation shows the highest product yield attained compared with the identification runs so far. In subsequent fermentations, the online measurements of CO2 concentration, base consumption, and near-infrared spectroscopy (NIR) were used for model improvement. After model extension using expert knowledge, a single superior model could be identified. Model-based state estimation with a sigma-point Kalman filter (SPKF) was based on online measurement data, and this improved model enabled nonlinear real-time product maximization. The optimization increased the macrolactin D production even further by 28% compared with the initial robust multi-model offline optimization.

Design Optimization of the Aeronautical Sheet Hydroforming Process Using the Taguchi Method

The aluminium alloy sheet forming processes forging in rubber pad and diaphragm presses (also known as hydroforming processes) are simple and economical processes adapted to aeronautical production. Typical defects of these processes are elastic recovery, necking, and wrinkling, and they present difficulties in control mainly due to property variations of the sheet material that take place during the process. In order to make these processes robust and unresponsive to material variations, a multiobjective optimization methodology based on the Taguchi method is proposed in the present study. The design of experiments and process simulation are combined in the methodology, using the nonlinear finite element method. The properties of sheet material are considered noise factors of the hydroforming process, the objective being to find a combination of the control factors that causes minimal defects to noise factors. The methodology was applied to an AA2024-T3 aluminium alloy sheet of 1 mm thickness stamping process in a diaphragm press. The results allowed us to establish the optimal pressure values, friction coefficient between sheet and block, and friction coefficient between sheet and rubber to reduce the elastic recovery variations and the minimal thickness before noise facts.

Single-stage fermentation process for high-value biohythane production with the treatment of distillery spent-wash

The current communication reports the development of a single-stage biosystem for biohythane production from wastewater treatment. A semi-pilot scale bioreactor with 34 L capacity was used for this study. Maximum biohythane production of 147.5 ± 2.4 L was observed after five cycles of operation with production rate of 4.7 ± 0.1L/h. The biohythane composition (H2/(H2+CH4)) varied from 0.60 to 0.23 during stabilized fifth cycle of operation. During each cycle of operation, higher H2 fraction was noticed within 12h of cycle period followed by CH4 production for rest of operation (36 h). During biohythane production, COD removal efficiency of 60 ± 5% (SDR, 29.0 ± 1.9 kg CODr/m(3)-day) was also achieved. The synergistic function of volatile fatty acids (VFA) production and consumption during process in hybrid biosystem played vital role on the composition of biohythane. The single-stage biosystem facilitates production of high valued and cost efficient biofuel (biohythane) with fewer controls than individual acidogenic and methanogenic processes.

High rate biomethanation technology for solid waste management and rapid biogas production: An emphasis on reactor design parameters

A high rate biomethanation digester was designed and fabricated to study its real field treatment efficiency and simultaneous biogas generation. The major design parameters like self mixing, delinking hydraulic retention time and solid retention time etc. were considered for efficient performance. It was operated with an organic loading rate (OLR) of 1.5kg/m(3)d(-1) with composite food waste for about one year. The maximum treatment efficiency achieved with respect to total solid (TS) reduction and volatile solids (VS) reduction was 94.5% and 89.7%, respectively. Annual mean biogas of about 0.16m(3)/kgVSd(-1) was observed with methane content varying from 56% to 60% (v/v). The high competence of high rate digester is attributed to its specific design features and intermittent mixing of the digester contents and also due to the hydrodynamic principles involved in its operation.

Enhancement of biodiesel production from marine alga, Scenedesmus sp. through in situ transesterification process associated with acidic catalyst

The aim of this study was to increase the yield of biodiesel produced by Scenedesmus sp. through in situ transesterification by optimizing various process parameters. Based on the orthogonal matrix analysis for the acidic catalyst, the effects of the factors decreased in the order of reaction temperature (47.5%) > solvent quantity (26.7%) > reaction time (17.5%) > catalyst amount (8.3%). Based on a Taguchi analysis, the effects of the factors decreased in the order of solvent ratio (34.36%) > catalyst (28.62%) > time (19.72%) > temperature (17.32%). The overall biodiesel production appeared to be better using NaOH as an alkaline catalyst rather than using H₂SO₄ in an acidic process, at 55.07 ± 2.18% (based on lipid weight) versus 48.41 ± 0.21%. However, in considering the purified biodiesel, it was found that the acidic catalyst was approximately 2.5 times more efficient than the alkaline catalyst under the following optimal conditions: temperature of 70°C (level 2), reaction time of 10 hrs (level 2), catalyst amount of 5% (level 3), and biomass to solvent ratio of 1 : 15 (level 2), respectively. These results clearly demonstrated that the acidic solvent, which combined oil extraction with in situ transesterification, was an effective catalyst for the production of high-quantity, high-quality biodiesel from a Scenedesmus sp.

Optimization of critical factors to enhance polyhydroxyalkanoates (PHA) synthesis by mixed culture using Taguchi design of experimental methodology

Optimizing different factors is crucial for enhancement of mixed culture bioplastics (polyhydroxyalkanoates (PHA)) production. Design of experimental (DOE) methodology using Taguchi orthogonal array (OA) was applied to evaluate the influence and specific function of eight important factors (iron, glucose concentration, VFA concentration, VFA composition, nitrogen concentration, phosphorous concentration, pH, and microenvironment) on the bioplastics production. Three levels of factor (2(1) × 3(7)) variation were considered with symbolic arrays of experimental matrix [L(18)-18 experimental trails]. All the factors were assigned with three levels except iron concentration (2(1)). Among all the factors, microenvironment influenced bioplastics production substantially (contributing 81%), followed by pH (11%) and glucose concentration (2.5%). Validation experiments were performed with the obtained optimum conditions which resulted in improved PHA production. Good substrate degradation (as COD) of 68% was registered during PHA production. Dehydrogenase and phosphatase enzymatic activities were monitored during process operation.

Ex situ slurry phase bioremediation of chrysene contaminated soil with the function of metabolic function: process evaluation by data enveloping analysis (DEA) and Taguchi design of experimental methodology (DOE)

Bioremediation of chrysene in soil matrix was evaluated in soil slurry phase bioreactor in conjugation with metabolic functions (aerobic, anoxic and anaerobic), microenvironment (single and mixed) conditions and nature of mixed consortia (native/resident mixed microflora and bioaugmented inoculum). Twelve experiments were operated independently in agitated-batch reactor keeping all other operating conditions constant (substrate loading rate--0.084 g chrysene/kg soil-day; soil loading rate--10 kg soil/m(3)-day (3:25 soil water ratio); operating temperature--35+/-2 degrees C). Data envelopment analysis (DEA) procedure was employed to analyze the performance of experimental variations in terms of chrysene degradation and pH. The efficacy of anoxic metabolism over the corresponding aerobic and anaerobic metabolic functions was documented. Aerobic metabolic function showed effective degradation capability under mixed microenvironment after augmentation with anaerobic inoculum. Anaerobic metabolic function showed lowest degradation potential. Application of bioaugmentation showed positive influence on the chrysene degradation rate. Design of experimental methodology (DOE) by Taguchi approach was applied to evaluate the effect of four selected factors (native soil microflora, microenvironment, metabolic function and bioaugmentation) on the chrysene degradation process. The optimized factors derived from analysis depicted the requirement of native soil microflora under anoxic metabolic function using mixed microenvironment after augmenting with anaerobic inoculum for achieving effective chrysene degradation efficacy.

Assessment of aerosol (PM10) and trace elemental interactions by Taguchi experimental design approach

An attempt has been made to assess the trace elemental interactions of atmospheric aerosol through Taguchi orthogonal array (OA) experimental design (DOE) approach. Seven toxic trace metals (Cu, Cd, As, Pb, Cr, Co and Ni) along with aerosol mass (PM(10)) at three different concentration levels were considered for this study. The annual mean concentrations of PM(10) and its trace components observed at Tirupati, southern peninsular India, and 50% lower and 50% higher values to the permissible exposure limit (PEL) of each factor in air were considered for level 1, level 2, and level 3 respectively. Interactions between the factors have been estimated by orthogonal array design of experiments with eighteen sets of experimental trial (L18) and varied combinations of factor levels.

Bioelectricity production from wastewater treatment in dual chambered microbial fuel cell (MFC) using selectively enriched mixed microflora: Effect of catholyte

The performance of aerated and ferricyanide catholytes on the bioelectricity production was evaluated in dual chambered microbial fuel cell (MFC) (mediatroless anode; graphite electrodes) employing selectively enriched H(2) producing mixed consortia as anodic inoculum. Two MFCs with aerated catholyte (MFC(AC)) and ferricyanide catholyte (MFC(FC)) were operated separately to elucidate the difference in power generation potential and carbon removal efficiency under similar operating conditions [ambient pressure; room temperature (28+/-2 degrees C); acidophilic microenvironment (pH 6)]. The experimental data demonstrated the feasibility of in situ bioelectricity generation along with wastewater treatment. Effective power generation and substrate removal efficiency was documented in the fuel cell operated with ferricyanide catholyte (586 mV; 2.37 mA; 0.559 kg COD/m(3) day) than aerated catholyte (572 mV; 1.68 mA; 0.464 kg COD/m(3) day). Maximum power yield (0.635 W/kg COD(R) and 0.440 W/kg COD(R)) and current density (222.59 mA/m(2) and 190.28 mA/m(2)) was observed at 100 Omega resistor with ferricyanide and aerated catholytes, respectively. The study documented both wastewater treatment and electricity production through direct conversion of H(2) in a single system.

Bioslurry phase remediation of chlorpyrifos contaminated soil: process evaluation and optimization by Taguchi design of experimental (DOE) methodology

Design of experimental (DOE) methodology using Taguchi orthogonal array (OA) was applied to evaluate the influence of eight biotic and abiotic factors (substrate-loading rate, slurry phase pH, slurry phase dissolved oxygen (DO), soil water ratio, temperature, soil microflora load, application of bioaugmentation and humic substance concentration) on the soil bound chlorpyrifos bioremediation in bioslurry phase reactor. The selected eight factors were considered at three levels (18 experiments) in the experimental design. Substrate-loading rate showed significant influence on the bioremediation process among the selected factors. Derived optimum operating conditions obtained by the methodology showed enhanced chlorpyrifos degradation from 1479.99 to 2458.33microg/g (over all 39.82% enhancement). The proposed method facilitated systematic mathematical approach to understand the complex bioremediation process and the optimization of near optimum design parameters, only with a few well-defined experimental sets.

Taguchi approach significantly increases bioremediation process efficiency: a case study with Hg (II) removal by Pseudomonas aeruginosa

AIM

Optimization of process parameters for mercury removal by an Hg (II)-reducing Pseudomonas aeruginosa strain.

METHODS AND RESULTS

A strain of Ps. aeruginosa was found to reduce 10 mg l(-1) Hg (II) to Hg0 with 70% efficiency in 24 h. To optimize process performance, a statistical tool--Taguchi design of experiments (DOE)--was used to carry out 18 well-defined experiments (L18 Orthogonal array) with eight variable parameters (viz. agitation, temperature, pH, carbon source, medium volume: flask volume ratio and concentrations of Hg (II), ammonium sulfate and yeast extract). When data obtained were analyzed using specialized software for Taguchi design, Qualitek-4 (Nutek Inc., MI, USA), Hg (II) reduction efficiency was predicted to be 95% in 24 h under the optimized process parameters (also suggested by the software). In the validation experiment, Hg (II) removal of 99.29% in 24 h was indeed obtained.

CONCLUSIONS

Using Taguchi DOE, Hg (II) reduction (and hence its removal) using Ps. aeruginosa could be improved by 29.3%.

SIGNIFICANCE AND IMPACT OF THE STUDY

Taguchi approach could be employed as an efficient and time-saving strategy for parameter optimization in bioremediation processes.

Biohydrogen production from chemical wastewater treatment in biofilm configured reactor operated in periodic discontinuous batch mode by selectively enriched anaerobic mixed consortia

Molecular hydrogen (H(2)) production with simultaneous wastewater treatment was studied in biofilm configured periodic discontinuous/sequencing batch reactor using chemical wastewater as substrate. Anaerobic mixed consortia was sequentially pretreated with repeated heat-shock (100 degrees C; 2 h) and acid (pH-3.0; 24 h) treatment procedures to selectively enrich the H(2) producing mixed consortia prior to inoculation of the reactor. The bioreactor was operated at mesophilic (room) temperature (28+/-2 degrees C) under acidophilic conditions with a total cycle period of 24 h consisting of FILL (15 min), REACT (23 h), SETTLE (30 min) and DECANT (15 min) phases. Reactor was initially operated with synthetic wastewater (SW) at OLR of 4.8 kg COD/m(3)-day and subsequently operated using composite chemical wastewater (CW) at OLR of 5.6 kg COD/m(3)-day by adjusting pH to 6.0 prior to feeding to inhibit the methanogenic activity. H(2) evolution rate differed significantly with the nature of wastewater used as substrate [SW--volumetric H(2) production rate--12.89 mmol H(2)/m(3)-min and specific H(2) production rate--0.0084 mmol H(2)/min-g COD(L) (0.026 mmol H(2)/min-g COD(R)); CW--volumetric H(2) production rate--6.076 mmol H(2)/m(3)-min and specific H(2) production rate--0.0089 mmol H(2)/min-g COD(L) (0.033 mmol H(2)/min-g COD(R))]. Relatively rapid progress towards higher H(2) yield (2 h) was observed with SW compared to the CW (10 h). Substrate (COD) reduction of 32.4% (substrate degradation rate (SDR)--1.55 kg COD/m(3)-day) and 26.7% (SDR-1.49 kg COD/m(3)-day) was observed with SW and CW, respectively. The system showed rapid stabilization tendency (SW--37 days; CW--40 days) with respect to H(2) generation and COD reduction. H(2) evolution showed relatively good correlation with VFA concentration in the case of SW (R(2)-0.961) compared to CW (R(2)-0.912). A surge in pH values from 5.87 to 4.23 (SW) and 5.93 to 4.62 (CW) was observed during the cycle operation. Integration of biofilm configuration with periodic discontinuous batch operation under the defined operating conditions showed potential to influence the microbial system by selectively enriching the specific group of microflora capable of producing H(2).