Pretreatment of pulp mill secondary sludge for high-rate anaerobic conversion to biogas

Pulp-paper industry sludge waste biorefinery for sustainable energy and value-added products development: A systematic valorization towards waste management

The pulp-paper industry is one of the main industrial sectors that produce massive amounts of residual sludge, constituting an enormous environmental burden for the industries. Traditional sludge management practices, such as landfilling and incineration, are restricted due to mounting environmental pressures, complex regulatory frameworks, land availability, high costs, and public opinion. Valorization of pulp-paper industry sludge (PPS) to produce high-value products is a promising substitute for traditional sludge management practices, promoting their reuse and recycling. Valorization of PPIS for biorefinery beneficiation includes biomethane, biohydrogen, bioethanol, biobutanol, and biodiesel production for renewable energy generation. Additionally, the various thermo-chemical technologies can be utilized to synthesize bio-oil, hydrochar, biochar, adsorbent, and activated carbon, signifying potential for value-added generation. Moreover, PPIS can be recycled as a byproduct by incorporating it into nanocomposites, cardboard, and construction materials development. This paper aims to deliver a comprehensive overview of PPIS management approaches and thermo-chemical technologies utilized for the development of platform chemicals in industry. Substitute uses of PPIS, such as making building materials, developing supercapacitors, and making cardboard, are also discussed. In addition, this article deeply discusses recent developments in biotechnologies for valorizing PPIS to yield an array of valuable products, such as biofuels, lactic acids, cellulose, nanocellulose, and so on. This review serves as a roadmap for future research endeavors in the effective handling of PPIS.

Optimization of anaerobic digestion and solubilization of biosludges from the kraft cellulose industry using thermal hydrolysis as pretreatment

The management of secondary sludge from aerobic treatment of effluents from the cellulose industry is a current problem. The usual ways of disposal do not provide added value to the waste as they assume an economy based on "take-make-waste" (linear economy). In this work, thermal hydrolysis (TH) and anaerobic digestion (AD) are proposed to valorize this biosludge. Based on a Doehlert experimental plan, a response surface methodology (RSM) defined by seven different TH conditions is proposed. After TH, biomethanation potential (BMP) tests were performed to evaluate the AD possibilities. The TH conditions cover a temperature range between 125 °C and 205 °C and a reaction time from 15 min to 45 min. The TH process was successful in enhancing the bioavailability of the waste, increasing the concentration of soluble organic matter quantified by chemical oxygen demand of the soluble fraction (CODs), and decreasing the concentration of volatile suspended solids (VSS). However, response surfaces performed for CODs and VSS revealed the existence of optimums, which demonstrated the adverse effects of the more severe TH conditions. Organic matter solubilization was confirmed by microscopic observations. The amount of suspended organic matter after TH is reduced by two to three times compared to the untreated value. The subsequent BMP of the hydrolyzed waste increases between 100% and 220% compared to the untreated condition, wich had a BMP value of 84 NmL CH4 gVS-1. The response surface determined for the BMP reveals the presence of a maximum point of methane production at 202 °C for 31 min, which differs from the maximum CODs value observed at 196 °C for 40 min.

Improvements in the anaerobic digestion of biological sludge from pulp and paper mills using thermal pretreatment

The current disposal of biosludge generated in wastewater treatment has high costs and causes environmental problems, anaerobic digestion (AD) of solid waste is a promising alternative. Thermal hydrolysis (TH) is an accepted technology to enhance anaerobic biodegradability of sewage sludge, but this technology has not been developed to be used with biological sludge from industrial wastewater treatment. In this work, the improvements to the AD of biological sludge from cellulose industry when thermal pretreatment is carried out were experimentally determined. The experimental conditions for TH were 140 °C and 165 °C for 45 minutes. Batch tests were carried out to quantify methane production evaluated as biomethane potential (BMP), anaerobic biodegradability according to volatile solids (VS) consumption and kinetic adjustments. An innovative kinetic model based on the serial mechanism of fast and slow biodegradation fractions was tested for untreated waste, and parallel mechanism was also evaluated. Increases in BMP and biodegradability values according to VS consumption were determined with increasing TH temperature. The results of 241 NmL CH₄ gVS substrate^-1 for BMP and 65% biodegradability are reported for the 165 °C treatment. AD rate increased for the TH waste compared to the untreated biosludge. Improvements of up to 159% for BMP and 260% for biodegradability according to VS consumption were quantified for TH biosludge compared to untreated biosludge.

Challenges in developing strategies for the valorization of lignin-a major pollutant of the paper mill industry

Apart from protecting the environment from undesired waste impacts, wastewater treatment is a crucial platform for recovery. The exploitation of suitable technology to transform the wastes from pulp and paper industries (PPI) to value-added products is vital from an environmental and socio-economic point of view that will impact everyday life. As the volume and complexity of wastewater increase in a rapidly urbanizing world, the challenge of maintaining efficient wastewater treatment in a cost-effective and environmentally friendly manner must be met. In addition to producing treated water, the wastewater treatment plant (WWTP) has a large amount of paper mill sludge (PMS) daily. Sludge management and disposal are significant problems associated with wastewater treatment plants. Applying the biorefinery concept is necessary for PPI from an environmental point of view and because of the piles of valuables contained therein in the form of waste. This will provide a renewable source for producing valuables and bio-energy and aid in making the overall process more economical and environmentally sustainable. Therefore, it is compulsory to continue inquiry on different applications of wastes, with proper justification of the environmental and economic factors. This review discusses current trends and challenges in wastewater management and the bio-valorization of paper mills. Lignin has been highlighted as a critical component for generating valuables, and its recovery prospects from solid and liquid PPI waste have been suggested.

Effect of ferrate pretreatment on anaerobic digestibility of primary sludge spiked with resin acids

Resin acids are mixtures of high molecular weight carboxylic acids found in tree resins. Due to higher hydrophobicity and low solubility, they tend to adsorb on the suspended solids in pulp and paper (P&P) mill wastewater and accumulate in primary sludge through settling. Anaerobic digestion (AD) is a common practice stabilizing sludge; however, high concentration of resin acids affects the AD process. The aim of this research was mainly to determine the impact of ferrate (Fe (VI)) oxidation on selected resin acids and anaerobic digestibility of ferrate-treated primary sludge (PS) spiked with the resin acids. First, batch control oxidation of model resin acids with Fe (VI) was conducted to identify an optimum dosage, pH and contact time using a Box-Behnken design approach. Thereafter, anaerobic treatability studies of primary sludge spiked with resin acids both under control condition and optimum ferrate pretreatment were conducted. Up to 97% oxidation of resin acids occurred in pure water, while only 44%-62% oxidation of resin acids occurred in PS with an increasing Fe (VI) dosage from 0.034 to 0.137 mg Fe (VI)/mg tCOD_fed. The pretreatment did not affect the anaerobic biodegradability of resin acids; however, it lowered their negative influences on the PS digestibility. About 0.076 mg Fe (VI) dosage/mg tCOD_fed solubilized the sludge increasing the methane production by 40% compared to the untreated digester. The potential benefits of ferrate pretreatment of P&P primary sludge include resin acids oxidation and subsequent toxicity reduction, higher sludge solubilization enhancing methane production and enabling anaerobic digestion at higher COD loading.

Identifying targets for increased biogas production through chemical and organic matter characterization of digestate from full-scale biogas plants: what remains and why?

Background

This study examines the destiny of macromolecules in different full-scale biogas processes. From previous studies it is clear that the residual organic matter in outgoing digestates can have significant biogas potential, but the factors dictating the size and composition of this residual fraction and how they correlate with the residual methane potential (RMP) are not fully understood. The aim of this study was to generate additional knowledge of the composition of residual digestate fractions and to understand how they correlate with various operational and chemical parameters. The organic composition of both the substrates and digestates from nine biogas plants operating on food waste, sewage sludge, or agricultural waste was characterized and the residual organic fractions were linked to substrate type, trace metal content, ammonia concentration, operational parameters, RMP, and enzyme activity.

Results

Carbohydrates represented the largest fraction of the total VS (32–68%) in most substrates. However, in the digestates protein was instead the most abundant residual macromolecule in almost all plants (3–21 g/kg). The degradation efficiency of proteins generally lower (28–79%) compared to carbohydrates (67–94%) and fats (86–91%). High residual protein content was coupled to recalcitrant protein fractions and microbial biomass, either from the substrate or formed in the degradation process. Co-digesting sewage sludge with fat increased the protein degradation efficiency with 18%, possibly through a priming mechanism where addition of easily degradable substrates also triggers the degradation of more complex fractions. In this study, high residual methane production (> 140 L CH₄/kg VS) was firstly coupled to operation at unstable process conditions caused mainly by ammonia inhibition (0.74 mg NH₃-N/kg) and/or trace element deficiency and, secondly, to short hydraulic retention time (HRT) (55 days) relative to the slow digestion of agricultural waste and manure.

Conclusions

Operation at unstable conditions was one reason for the high residual macromolecule content and high RMP. The outgoing protein content was relatively high in all digesters and improving the degradation of proteins represents one important way to increase the VS reduction and methane production in biogas plants. Post-treatment or post-digestion of digestates, targeting microbial biomass or recalcitrant protein fractions, is a potential way to achieve increased protein degradation.

Supplementary Information

The online version contains supplementary material available at 10.1186/s13068-022-02103-3.

Enhanced lignocellulosic component removal and biomethane potential from chestnut shell by a combined hydrothermal-alkaline pretreatment

This study proposes new perspectives for the management and biorefinery of wastes deriving from the agri-food sector such as chestnut shell (CS), which was here used as an organic feedstock for biomethane production through anaerobic digestion (AD). 1-5% alkaline (i.e. NaOH and KOH), hydrothermal (i.e. at 100 °C) and combined hydrothermal-alkaline pretreatments were employed to enhance the CS biodegradability prior to biochemical methane potential (BMP) tests conducted under mesophilic conditions. The hydrothermally-pretreated CS with 3% NaOH achieved the highest biomethane yield of 253 (±9) mL CH₄·g VS^-1 coupled to a volatile solid reduction of 48%. The hydrothermal-alkaline pretreatment positively affected both delignification and hemicellulose polymerization, promoting an approximately 2.4-fold higher substrate biodegradability compared to the untreated CS, which only reached a CH₄ production of 104 (±5) mL CH₄·g VS^-1. AD proceeded via volatile fatty acid accumulation, subsequently followed by methane production that was effectively simulated via the modified Gompertz kinetic having a R² of 0.974-0.999. Among the physical-chemical parameters characterizing the CS, the soluble chemical oxygen demand (sCOD) was highly correlated with the BMP showing a Pearson coefficient of 0.952. The cumulative biomethane yield, the sCOD and the cellulose, hemicellulose and lignin amount of CS were also processed through the least square method, obtaining a useful regression equation to predict the BMP. The economic assessment indicated that the hydrothermal-alkaline pretreatment is a cost-effective method to improve the BMP of CS, also for future full-scale applications.

Anaerobic digestibility of resin acids in primary sludge: Effect of ozone pretreatment

Resin acids in pulp and paper mills wastewater are potentially partitioned in the solids in post-primary clarification due to higher hydrophobicity with log K_ow ∼1.74-5.80. They are known to adversely affect anaerobic digestion (AD) process, although the effect has not been quantified deterministically in control studies. The objective of the present work was to determine the effect of untreated and ozonated spiked resin acids on AD of primary sludge. Batch adsorption tests were conducted to determine the solid-liquid partition coefficient (K_d) of resin acids on the primary sludge. Higher K_d was obtained at pH 4; however, it was decreased by 78-98% at pH 8. Thereafter, batch AD of model resin acids in primary sludge using food to microorganism ratio (S₀/X) of 0.5gtCOD/gVSSindicated only 15-20% removal of resin acids in the liquid phase anaerobically. While, ozonation in pure water using 0.74-1.48 mg O₃/mg tCOD showed >90% reduction of the test resin acids, an ozone dose of 0.52 mg O₃/mg tCOD reduced 50-70% spiked resin acids' load to the digester. However, no further removal of resin acids occurred during AD over 30 days. About 42% reduction in methane production compared to the control digestor occurred in the presence of 150 mg/L of resin acids. When treated with 0.52 mg O₃/mg tCOD, methane production improved and was comparable to the control digestor, indicating that resin acids may not be detrimental to AD at a concentration range of 45-75 mg/L.

Viscosity dynamics and the production of extracellular polymeric substances and soluble microbial products during anaerobic digestion of pulp and paper mill wastewater sludges

The production processes of the pulp and paper industry often run in campaigns, leading to large variations in the composition of wastewaters and waste sludges. During anaerobic digestion (AD) of these wastes, the viscosity or the production of extracellular polymeric substances (EPS) and soluble microbial products (SMP) may be affected, with the risk of foam formation, inefficient digester mixing or poor sludge dewaterability. The aim of this study was to investigate how viscosity and production of EPS and SMP during long-term AD of pulp and paper mill sludge is affected by changes in organic loading rate (OLR) and hydraulic retention time (HRT). Two mesophilic lab-scale continuous stirred tank reactors (CSTRs) were operated for 800 days (R1 and R2), initially digesting only fibre sludge, then co-digesting fibre sludge and activated sludge. The HRT was lowered, followed by an increase in the OLR. Reactor fluids were sampled once a month for rheological characterization and analysis of EPS and SMP. The production of the protein fraction of SMP was positively correlated to the OLR, implicating reduced effluent qualities at high OLR. EPS formation correlated with the magnesium content, and during sulphate deficiency, the production of EPS and SMP increased. At high levels of EPS and SMP, there was an increase in viscosity of the anaerobic sludges, and dewatering efficiency was reduced. In addition, increased viscosity and/or the production of EPS and SMP were important factors in sludge bulking and foam formation in the CSTRs. Sludge bulking was avoided by more frequent stirring.

Integration of biological pre-treatment methods for increased energy recovery from paper and pulp biosludge

The paper and pulp industry (PPI) produces high quantities of solid and liquid discharge and is regarded as the most polluting industry in the world causing adverse effects to environments and human beings. Hence changes in the way PPI sludge and waste materials are treated is urgently required. Nearly, 10 million tons of waste is generated per year, however PPI waste is enriched with many organic chemicalscontaining a high percentage of lignin, cellulose, and hemicellulose which can be used as valuable raw materials for the production of bioenergy and value-added chemicals. Pretreatment of complex lignocellulosic materials of PPI waste is difficult because of the cellulose crystallinity and lignin barrier. At present most of this waste is recycled in a conventional treatment approach through biological and chemical processes, incurring high cost and low returns. Henceefficient pretreatment techniques are required by which complete conversion of PPI waste is possible. Therefore, the present chapter provides the scope of integration of pretreatment methods through which bioenergy recovery is possible during the PPI waste treatment. Detailed information is presented on the various pre-treatment techniques (chemical, mechanical, enzymatic and biological) in order to increase the efficiency of PPI waste treatment and energy recovery from PPI waste. Along with acid and alkali based efficient chemical treatment process, physical methods (i.e. shearing, high-pressure homogenization, etc.), biochemical techniques (whole cell-based and enzyme-based) and finally biological techniques (e.g. aerobic and anaerobic treatment) are discussed. During each of the treatment processes, scope of energy recovery and bottlenecks of the processes were elaborated. The review thus provides systemic insight into developing efficient pretreatment processes which could increase carbon recovery and treatment efficiency of PPI waste.

Pretreatment with rumen fluid improves methane production in the anaerobic digestion of paper sludge

Because paper sludge discharged from the waste paper recycling process contains high levels of lignin and ash, it is not hydrolyzed effectively during anaerobic digestion. In this study, we investigated the effects of pretreatment with rumen fluid on paper sludge and on the methane fermentation process. Paper sludge was pretreated with rumen fluid at 37 °C for 6 h. Following pretreatment, 4.5% of the total solids in paper sludge were degraded and converted, and the dissolved chemical oxygen demand and volatile fatty acid concentration increased. Batch methane fermentation was conducted at 37 °C for 20 days. During methane fermentation, the degradation and hydrolysis of paper sludge were enhanced by pretreatment with rumen fluid. The amounts of total methane production from pretreated paper sludge (excluding methane generated from rumen fluid), rumen fluid and untreated paper sludge were 650.4, 819.9 and 190.8 ml, respectively. The volume of methane gas produced from pretreated paper sludge was 3.4 times larger than that from untreated paper sludge. These results indicate that pretreatment with rumen fluid enhances methane production from paper sludge.

Electrohydrolysis pretreatment for enhanced methane production from lignocellulose waste pulp and paper mill sludge and its kinetics

A novel electrohydrolysis pretreatment enhances methane production from lignocellulose material during anaerobic digestion. A biochemical methane potential assay was carried out to determine the effect of direct current and the efficacy of electrohydrolysis pretreatment on biogas production. Methane yield was increased by 13.8%, to 301 ± 3 mL CH₄/g VS, when lignocellulosic waste was pretreated with electrohydrolysis. A net energy gain of 13,224 kJ was realized after electrohydrolysis pretreatment, which was 1.51 times higher than reported for thermal pretreatment. In addition, two kinetic models were used, including the modified Gompertz model to reproduce the experimental data. These finding support the potential for increased methane recovery from lignocellulosic waste using electrohydrolysis as a pretreatment.

Ultrasound assisted biogas production from co-digestion of wastewater sludges and agricultural wastes: Comparison with microwave pre-treatment

This study investigates the effect of ultrasonication and microwave sludge disintegration/pre-treatment techniques on the anaerobic co-digestion efficiency of wastewater sludges with olive and grape pomaces. The effects of both co-digestion and sludge pre-treatment techniques were evaluated in terms of the organic removal efficiency and the biogas production. The "co-digestion" of wastewater sludge with both types of pomaces was revealed to be a much more efficient way for the biogas production compared to the single (mono) sludge digestion. The ultrasonication and microwave pre-treatments applied to the sludge samples caused to a further increase in biogas and methane yields. Based on applied specific energies, ultrasonication pre-treatment was found much more effective than microwave irradiation. The specific energy applied in microwave pre-treatment (87,000kj/kgTS) was almost 9 times higher than that of used in ultrasonication (10,000kj/kgTS), resulting only 10-15% increases in biogas/methane yield. Co-digestion of winery and olive industry residues with pre-treated wastewater sludges appears to be a suitable technique for waste management and energy production.

Influence of pretreatment techniques on anaerobic digestion of pulp and paper mill sludge: A review

Pulp and paper industry is one of the most polluting, energy and water intensive industries in the world. Produced pulp and paper mill sludge (PPMS) faces a major problem for handling and its management. An anaerobic digestion has become an alternative source. This review provides a detailed summary of anaerobic digestion of PPMS - An overview of the developments and improvement opportunities. This paper explores the different pretreatment methods to enhance biogas production from the PPMS. First, the paper gives an overview of PPMS production, and then it reviews PPMS as a substrate for anaerobic digestion with or without pretreatment. Finally, it discuss the optimal condition and concentration of organic and inorganic compounds required for the anaerobic metabolic activity. Future research should focus on the combination of different pretreatment technologies, relationship between sludge composition, reactor design and its operation, and microbial community dynamics.

Enhanced methane production and its kinetics model of thermally pretreated lignocellulose waste material

The objective of the study was to assess the effect of substrate concentration by specific methanogenic activity (SMA) of thermally pretreated pulp and paper mill sludge. Different substrate concentration through food to microorganism ratio varied from 1.0 to 3.0 was carried out in a mesophilic condition as biochemical methane potential assay. Experimental results offered that cellulose removal rate spikes up to 60.2%. The specific methane gas production and biodegradability were increased up to 303mL of CH₄/g VS and 73% respectively. By increasing the substrate concentration, SMA was significantly improved in a linear manner. The net energy of 8735kJ was gained after thermal pretreatment. In addition to that three kinetics model were used, among that the modified Gompertz and logistic function models represent and reproduce the experimental data, while the earlier has the better fit.

Prerequisite - An electrohydrolysis pretreatment for anaerobic digestion of lignocellulose waste material

This novel work is focused on evaluating the electrohydrolysis pretreatment conditions (applied voltage and time) and anaerobic digestion process for the biological bioconversion of pulp and paper mill sludge into biogas in batch assay. The pretreatment at 15V for 45min shows highest impact on sludge solubilization. The XRD and FT-IR spectroscopic characterization shows the development of aliphatic, unsaturated and carbonyl carbon functionalities in the pretreated samples. FESEM picture also qualities the change in alteration of structure after pretreatment. Batch anaerobic bioreactor was carried out to determine the efficacy of electrohydrolysis pretreated and untreated pulp and paper mill sludge. The methane production potential was increased from 274±5 to 301±4mL CH₄/g VS after electrohydrolysis pretreatment.

Mesophilic anaerobic digestion of pulp and paper industry biosludge-long-term reactor performance and effects of thermal pretreatment

The pulp and paper industry wastewater treatment processes produce large volumes of biosludge. Limited anaerobic degradation of lignocellulose has hindered the utilization of biosludge, but the processing of biosludge using anaerobic digestion has recently regained interest. In this study, biosludge was used as a sole substrate in long-term (400 d) mesophilic laboratory reactor trials. Nine biosludge batches collected evenly over a period of one year from a pulp and paper industry wastewater treatment plant had different solid and nutrient (nitrogen, phosphorus, trace elements) characteristics. Nutrient characteristics may vary by a factor of 2-11, while biomethane potentials (BMPs) ranged from 89 to 102 NL CH4 kg(-1) VS between batches. The BMPs were enhanced by 39-88% with thermal pretreatments at 105-134 °C. Despite varying biosludge properties, stable operation was achieved in reactor trials with a hydraulic retention time (HRT) of 14 d. Hydrolysis was the process limiting step, ceasing gas production when the HRT was shortened to 10 days. However, digestion with an HRT of 10 days was feasible after thermal pretreatment of the biosludge (20 min at 121 °C) due to enhanced hydrolysis. The methane yield was 78 NL CH4 kg(-1) VS for untreated biosludge and was increased by 77% (138 NL CH4 kg(-1) VS) after pretreatment.

Enhancing pulp and paper mill biosludge dewaterability using enzymes

There have been limited studies on the potential use of enzymes for enhancing the dewaterability of biosludge. The mechanisms for such enhancement have not been investigated despite the environmental advantages of using enzymes over synthetic polymers for biosludge conditioning. In order to find enzymes with this potential, a screening of commercially available enzymes was carried out using capillary suction time to assess biosludge dewaterability. The only enzyme that showed dewatering improvements in the screening tests was a lysozyme which reduced the capillary suction time by 36% and increased the cake solids content from 5.6 to 8.9 DS%. Lysozyme aided in the flocculation of particles reducing the polymer demand from 11% to 6%. Active and inactive lysozyme exhibited a similar ability for enhancing sludge dewatering, indicating that the conditioning mechanism of lysozyme is similar to that of a flocculant.

Application of hydrothermal treatment to affect the fermentability of Pinus radiata pulp mill effluent sludge

A hybrid technique incorporating a wet oxidation stage and secondary fermentation step was used to process Pinus radiata pulp mill effluent sludge. The effect of hydrothermal oxidation at high temperature and pressure on the hydrolysis of constituents of the waste stream was studied. Biochemical acidogenic potential assays were conducted to assess acid production resulting from anaerobic hydrolysis of the wet oxidised hydrolysate under acidogenic conditions. Significant degradation of the lignin, hemicellulose, suspended solids, carbohydrates and extractives were observed with wet oxidation. In contrast, cellulose showed resistance to degradation under the experimental conditions. Extensive degradation of biologically inhibitory compounds by wet oxidation did not show a beneficial impact on the acidogenic or methanogenic potential compared to untreated samples.

Chemically coupled microwave and ultrasonic pre-hydrolysis of pulp and paper mill waste-activated sludge: effect on sludge solubilisation and anaerobic digestion

The effects of alkali-enhanced microwave (MW; 50-175 °C) and ultrasonic (US) (0.75 W/mL, 15-60 min) pretreatments, on solubilisation and subsequent anaerobic digestion efficiency of pulp and paper mill waste-activated sludge, were investigated. Improvements in total chemical oxygen demand and volatile suspended solids (VSS) solubilisation were limited to 33 and 39 % in MW pretreatment only (175 °C). It reached 78 and 66 % in combined MW-alkali pretreatment (pH 12 + 175 °C), respectively. Similarly, chemical oxygen demand and VSS solubilisation were 58 and 37 % in US pretreatment alone (60 min) and it improved by 66 and 49 % after US-alkali pretreatment (pH 12 + 60 min), respectively. The biogas yield for US 60 min-alkali (pH 12)-pretreated sludge was significantly improved by 47 and 20 % over the control and US 60 reactors, respectively. The biogas generation for MW (150 °C)-alkali (pH 12)-pretreated sludge was only 6.3 % higher than control; however, it was 8.3 % lower than the MW (150 °C) reactor, which was due to the inhibition of anaerobic activity under harsh thermal-alkali treatment condition.

Transformation and removal of wood extractives from pulp mill sludge using wet oxidation and thermal hydrolysis

In order to remove wood extractive compounds from pulp mill sludge and thereby enhancing anaerobic digestibility, samples were subjected to either oxidative hydrothermal treatment (wet oxidation) or non-oxidative hydrothermal treatment (thermal hydrolysis). Treatments were carried out at 220 °C with initial pressure of 20 bar. More than 90% destruction of extractive compounds was observed after 20 min of wet oxidation. Wet oxidation eliminated 95.7% of phenolics, 98.6% fatty acids, 99.8% resin acids and 100% of phytosterols in 120 min. Acetic acid concentration increased by approximately 2 g/l after 120 min of wet oxidation. This has potential for rendering sludge more amenable to anaerobic digestion. In contrast thermal hydrolysis was found to be ineffective in degrading extractive compounds. Wet oxidation is considered to be an effective process for removal of recalcitrant and inhibitive compounds through hydrothermal pre-treatment of pulp mill sludge.

Effect of microwave hydrolysis on transformation of steroidal hormones during anaerobic digestion of municipal sludge cake

Fate and removal of 16 steroidal (estrogenic, androgenic and progestogenic) hormones were studied during advanced anaerobic digestion of sludge cake using microwave (MW) pretreatment. Effect of pretreatment temperature (80, 120, 160 °C), operating temperature (mesophilic at 35 ± 2 °C, thermophilic at 55 ± 2 °C) and sludge retention time (SRT: 20, 10, 5 days) were studied employing eight lab-scale semi-continuously fed digesters. To determine the potential effect of MW hydrolysis, hormones were quantified in total (sorbed + soluble) and supernatant (soluble) phases of the digester influent and effluent streams. Seven of 16 hormones were above the method reporting limit (RL) in one or more of the samples. Hormone concentrations in total phase of un-pretreated (control) and pretreated digester feeds ranged in <157-2491 ng/L and <157-749 ng/L, respectively. The three studied factors were found to be statistically significant (95% confidence level) in removal of one or more hormones from soluble and/or total phase. MW hydrolysis of the influent resulted in both release (from sludge matrix) and attenuation of hormones in the soluble phase. Accumulation of estrone (E1) as well as progesterone (Pr) and androstenedione (Ad) in most of the digesters indicated possible microbial transformations among the hormones. Compared to controls, all pretreated digesters had lower total hormone concentrations in their influent streams. At 20 days SRT, highest total removal (E1+E2+Ad +Pr) was observed for the thermophilic control digester (56%), followed by pretreated mesophilic digesters at 120 °C and 160 °C with around 48% efficiency. In terms of conventional performance parameters, relative (to control) improvements of MW pretreated digesters at a 5-d SRT ranged in 98-163% and 57-121%, for volatile solids removal and methane production, respectively.

Biochemical methane potential of two-phase olive mill solid waste: influence of thermal pretreatment on the process kinetics

The effect of thermal pretreatment on two-phase olive mill solid waste was evaluated by chemical oxygen demand solubilisation and biochemical methane potential (BMP) tests. Temperatures of 100, 120, 160 and 180°C were applied during 60, 120 and 180 min for each temperature studied. The highest chemical oxygen demand solubilisation after pretreatment (42%) was found for 120 and 180°C during 180 min in both cases. These two conditions were selected for the BMP tests. BMP tests showed two different stages: a first exponential stage and a sigmoidal zone after a lag period. No influence of the pretreatment was observed on the kinetic constant of the first-stage. Clear difference was observed in the maximum methane production rate of the second stage, 76.8 mL CH4/(g VS day) was achieved after pretreatment at 180°C (180 min), value 22% and 40% higher than that obtained for the untreated and pretreated OMSW at 120°C, respectively.

Effect of microwave pretreatment in presence of NaOH on mesophilic anaerobic digestion of thickened waste activated sludge

This work experimentally determined the effect of microwave irradiation with NaOH pretreatment on anaerobic digestion of thickened waste activated sludge in semi-continuous mesophilic digesters at hydraulic retention times (HRT) of 15, 10, 7, and 5 days. The degree of substrate solubilization was 18 times higher in pretreated sludge (53.2%) than in raw sludge (3.0%). Removal efficiency of volatile solid in digesters fed with raw (control) and pretreated sludges (PD) decreased as HRT reduced. The highest relative improvement of properties compared with the control occurred at 5 day HRT. Improvements in biogas production compared with the control increased in the PD as HRT was reduced to 5 days (205% higher at 5 days). However, digested sludges in the control and PD increased capillary suction time compared with raw sludge. The results show that microwave irradiation combined with alkali pretreatment is effective in increasing mesophilic anaerobic biodegradability of sewage sludge.

Evaluation of a microwave-heating anaerobic digester treating municipal secondary sludge

This work experimentally determined the effect of microwave irradiation on the anaerobic digestion of municipal secondary sludge in semi-continuous mesophilic digesters at hydraulic retention times (HRT) of 15, 10 and 5 days when microwaves were used as a heating source. A microwave-heating anaerobic digester (MHAD) was compared with a water-heating reactor (control). Biogas production increased in both digesters as the HRT decreased except for the control with a HRT of 5 days. Improvement in removal efficiency of volatile solid and biogas production of the MHAD relative to the control increased as the HRT decreased. The results show that the MHAD was more effective than the control in increasing mesophilic anaerobic biodegradability and biogas production treating secondary sludge.

Thermophilic anaerobic digestion of pulp and paper mill primary sludge and co-digestion of primary and secondary sludge

Anaerobic digestion of pulp and paper mill primary sludge and co-digestion of primary and secondary sludge were studied for the first time in semi-continuously fed continuously stirred tank reactors (CSTR) in thermophilic conditions. Additionally, in batch experiments, methane potentials of 210 and 230 m³CH₄/t volatile solids (VS)(added) were obtained for primary, and 50 and 100 m³CH₄/tVS(added) for secondary sludge at 35 °C and 55 °C, respectively. Anaerobic digestion of primary sludge was shown to be feasible with organic loading rates (OLR) of 1-1.4 kgVS/m³d and hydraulic retention times (HRT) of 16-32 d resulting in methane yields of 190-240 m³CH₄/tVS(fed). Also the highest tested OLR of 2 kgVS/m³d and the shortest HRT of 14-16 d could be feasible, if pH stability is confirmed. Co-digestion of primary and secondary sludge with an OLR of 1 kgVS/m³d and HRTs of 25-31 d resulted in methane yields of 150-170 m³CH₄/tVS(fed). In the digestion processes, cellulose and hemicellulose degraded while lignin did not. pH adjustment and nitrogen deficiency needs to be considered when planning anaerobic digestion of pulp and paper mill wastewater sludges.

Thermal and thermo-chemical pre-treatment of four waste residues and the effect on acetic acid production and methane synthesis

In this study four diverse solid waste substrates (coal, Kraft pulp solids, chicken feathers and chicken processing waste) were thermally pre-treated (70, 140 and 200 °C), under an inert (nitrogen) or oxidative (oxygen) atmosphere, and then anaerobically digested. Membrane inlet mass spectrometry during the thermal and thermo-chemical reactions was successfully used to establish oxygen and carbon dioxide gas fluxes and product formation (acetic acid). There was significant solids hydrolysis pre-treatment at 200 °C under an oxidative atmosphere, as indicated by a decrease in the volatile suspended solids and an increase in dissolved organic carbon. Greater concentrations of volatile fatty acids were produced under oxidative conditions at higher temperatures. The methane yield more than tripled for feathers after pre-treatment at 140 °C (under both atmospheres), but decreased after oxidative pre-treatment at 200 °C, due to the destruction of available carbon by the thermo-chemical reaction. Methane yield more than doubled for the Kraft pulp solids with the 200 °C pre-treatment under oxidative conditions. This study illustrated the power of wet oxidation for solids destruction and its potential to improve methane yields generated during anaerobic digestion.

Stable operation during pilot-scale anaerobic digestion of nutrient-supplemented maize/sugar beet silage

Biogas production from maize/sugar beet silage was studied under mesophilic conditions in a continuous stirred tank reactor pilot-scale process. While energy crop mono-digestion is often performed with very long hydraulic retention times (HRTs), the present study demonstrated an efficient process operating with a 50-day HRT and a corrected total solids (TS(corr)) based organic loading rate of 3.4 kg/m(3)d. The good performance was attributed to supplementation with both macro- and micronutrients and was evidenced by good methane yields (318 m(3)/ton TS(corr)), which were comparable to laboratory maximum expected yields, plus low total volatile fatty acid concentrations (<0.8 g/L). A viscoplastic and thixotropic digester fluid behaviour was observed, and the viscosity problems common in crop mono-digestion were not seen in this study. The effluent also complied with Swedish certification standards for bio-fertilizer for farmland application. Nutrient addition thus rendered a stable biogas process, while the effluent was a good quality bio-fertilizer.

Anaerobic treatment of activated sludge from Swedish pulp and paper mills--biogas production potential and limitations

The methane potential of activated sludge from six Swedish pulp and paper mills was evaluated. The methane production potential of sludge samples ranged from 100-200 NmL CH4 g(-1) volatile solids (VS) and for four of the six sludge samples the potential exceeded 170 NmL CH4 g(-1) VS. The effects of sludge age and dewatering on the methane production potential were evaluated. The effects of enzymatic and ultrasonic pre-treatment on the digestibility of sludge were also investigated, but energy or enzyme inputs in viable ranges did not exert a detectable, positive effect. Long-term, semi-continuous trials with sludge from two of the mills were also conducted in attempts to develop stable biogas production at loading rates up to 4 g VS L(-1). Cobalt addition (0.5 mg L(-1)) was here found to positively affect the turnover of acetate. High viscosity was a problem in all the experimental reactors and this limited the organic loading rate.

Microwave, ultrasonic and chemo-mechanical pretreatments for enhancing methane potential of pulp mill wastewater treatment sludge

Microwave (2450 MHz, 1250 W), ultrasonic (20 kHz, 400 W) and chemo-mechanical (MicroSludge® with 900 mg/L NaOH followed by 83,000 kPa) pretreatments were applied to pulp mill waste sludge to enhance methane production and reduce digester sludge retention time. The effects of four variables (microwave temperature in a range of 50-175°C) and sonication time (15-90 min), sludge type (primary or secondary) and digester temperature (mesophilic and thermophilic) were investigated. Microwave pretreatment proved to be the most effective, increasing specific methane yields of WAS samples by 90% compared to controls after 21 days of mesophilic digestion. Sonication solubilized the sludge samples better, but resulted in soluble non-biodegradable compounds. Based on the laboratory scale data, MicroSludge® was found the least energy intensive pretreatment followed by sonication for 15 min alternative with net energy profits of 1366 and 386 kWh/tonne of total solids (TS), respectively. Pretreatment benefits were smaller for thermophilic digesters.

The effect of electrodialytic treatment and Na2H2EDTA addition on methanogenic activity of copper-amended anaerobic granular sludge: treatment costs and energy consumption

The effect of electrodialytic treatment in terms of a current density, pH and Na(2)H(2)EDTA addition on the methanogenic activity of copper-amended anaerobic granular sludge taken from the UASB reactor from paper mill was evaluated. Moreover, the specific energy consumption and simplified operational and treatment costs were calculated. Addition of Na(2)H(2)EDTA (at pH7.7) to copper-amended sludge resulted in the highest microbial activity (62 mg CH(4)-COD g VSS(-1)day(-1)) suggesting that Na(2)H(2)EDTA decreased the toxic effects of copper on the methanogenic activity of the anaerobic granular sludge. The highest methane production (159 %) was also observed upon Na(2)H(2)EDTA addition and simultaneous electricity application (pH7.7). The energy consumption during the treatment was 560, 840, 1400 and 1680 kW h m(-3) at current densities of 0.23, 0.34, 0.57 and 0.69 mA cm(-2), respectively. This corresponded to a treatment costs in terms of electricity expenditure from 39.2 to 117.6 € per cubic meter of sludge.