Analysis of very-high surface area 3D-printed media in a moving bed biofilm reactor for wastewater treatment

Optimization of moving bed biofilm reactors for the treatment of municipal wastewater

The properties of biocarriers significantly influence the performance of a moving bed-biofilm reactor (MBBR). This study aimed to assess the impact of media type, filling ratio, and hydraulic retention time (HRT) on biofilm formation and MBBR performance in both batch and continuous setups using real municipal wastewater. Two different media, high-density polyethylene (HDPE) and polypropylene (PPE), with varying surface area and properties were used. Biofilm growth and MBBR performance were monitored and optimized using response surface methodology. The effect of different media was investigated for three filling ratios of 20%, 40% and 60% and HRT of 4, 6 and 8 h. Results depicted a better biofilm growth on HDPE media in comparison to PPE carriers due to difference in media structure and surface properties. At all the conditions tested, HDPE media showed comparatively better performance for the removal of organic matter and nutrients than PPE media. The maximum organic matter removal efficiency was found as 77% and 75% at an HRT of 6 h and filling ratio of 40% for HDPE and PPE media, respectively. The ammonia removal was also found better for HDPE media due to its geometry and structure favoring the anoxic conditions with maximum removal of 89% achieved at 6-h HRT and 40% filling ratio. Overall, the system with HDPE media indicated more stability in terms of reactor performance than PPE carriers with variations in the operating conditions.

3D-Printed Materials for Wastewater Treatment

The increasing levels of water pollution pose an imminent threat to human health and the environment. Current modalities of wastewater treatment necessitate expensive instrumentation and generate large amounts of waste, thus failing to provide ecofriendly and sustainable solutions for water purification. Over the years, novel additive manufacturing technology, also known as three-dimensional (3D) printing, has propelled remarkable innovation in different disciplines owing to its capability to fabricate customized geometric objects rapidly and cost-effectively with minimal byproducts and hence undoubtedly emerged as a promising alternative for wastewater treatment. Especially in membrane technology, 3D printing enables the designing of ultrathin membranes and membrane modules layer-by-layer with different morphologies, complex hierarchical structures, and a wide variety of materials otherwise unmet using conventional fabrication strategies. Extensive research has been dedicated to preparing membrane spacers with excellent surface properties, potentially improving the membrane filtration performance for water remediation. The revolutionary developments in membrane module fabrication have driven the utilization of 3D printing approaches toward manufacturing advanced membrane components, including biocarriers, sorbents, catalysts, and even whole membranes. This perspective highlights recent advances and essential outcomes in 3D printing technologies for wastewater treatment. First, different 3D printing techniques, such as material extrusion, selective laser sintering (SLS), and vat photopolymerization, emphasizing membrane fabrication, are briefly discussed. Importantly, in this Perspective, we focus on the unique 3D-printed membrane modules, namely, feed spacers, biocarriers, sorbents, and so on. The unparalleled advantages of 3D printed membrane components in surface area, geometry, and thickness and their influence on antifouling, removal efficiency, and overall membrane performance are underlined. Moreover, the salient applications of 3D printing technologies for water desalination, oil-water separation, heavy metal and organic pollutant removal, and nuclear decontamination are also outlined. This Perspective summarizes the recent works, current limitations, and future outlook of 3D-printed membrane technologies for wastewater treatment.

Parametric optimization of additive manufactured biocarrier submerged in sequencing batch reactor for domestic wastewater treatment

The high nutrient concentration in domestic wastewater effluent can endanger the aquatic life via eutrophication. Thus, research have been carried out to prevent harm to aquatic life. In regard biofilm reactors have been successful by far with few limitations. Bio-carrier fabrication of desired shape is one of the limitations. Recently, the invention of additive manufacturing (AM) of object made it feasible to fabricate the desired shape. In this study additive manufactured bio‒carrier (AMB) was printed using AM technique, with high surface area to volume ratio as well as density higher than water. The submerged attach growth sequencing batch biofilm reactor (SAGSBBR) for organic and nutrient removal from domestic wastewater (DWW) was conducted to determine the optimum bio‒carrier filling ratio (FR) and cycle time (CT) by using response surface methodology (RSM) with CT ranging between 12 h and 24 h and FR ranging between 0 and 20%. The maximum chemical oxygen demand (COD), ammonia-nitrogen (NH₄ ⁺‒N), and total phosphorus (TP) removal was 96.8 mg/L, 93.32 mg/L, and 88.89 mg/L respectively, which was achieved in submerged attached growth sequential biofilm batch reactor with 10% FR (SAGSBBR‒10). The optimization study determined the optimal solution of CT and FR to be 17.07 h and 12.38% respectively, with desirability of 0.987. The predicted mean of responses for the optimal solution were 96.64%, 94.40% and 89.94% for COD removal, NH₄ ⁺‒N removal and TP removal, respectively. The rate of biomass attachment at the first stage in SAGSBBR‒10 and SAGSBBR‒20 was about 11.39 mg/carrier.d and 8.64 mg/carrier.d, whereas the highest accumulation achieved was 98.27 mg/carrier and 80.15 mg/carrier respectively. Thus, this study can assist us to achieve sustainable development goal (SDG) 6.

Efficiency of various biofilm carriers and microbial interactions with substrate in moving bed-biofilm reactor for environmental wastewater treatment

In a moving bed-biofilm reactor (MBBR), the fluidization efficiency, immobilization of microbial cells, and treatment efficiency are directly influenced by the shape and pores of biofilm carriers. Moreover, the efficacy of bioremediation mainly depends on their interaction interface with microbes and substrate. This review aims to comprehend the role of different carrier properties such as material shapes, pores, and surface area on bioremediation productivity. A porous biofilm carrier with surface ridges containing spherical pores sizes > 1 mm can be ideal for maximum efficacy. It provides diverse environments for cell cultures, develops uneven biofilms, and retains various cell sizes and biomass. Moreover, the thickness of biofilm and controlled scaling shows a significant impact on MBBR performance. Therefore, the effect of these parameters in MBBR is discussed detailed in this review, through which existing literature and technical strategies that focus on the surface area as the primary factor can be critically assessed.

Enhancement of wastewater treatment performance using 3D printed structures: A major focus on material composition, performance, challenges, and sustainable assessment

In order to enhance the performance and sustainability of wastewater treatment technologies, researchers are showing keen interest in the development of novel materials which can overcome the drawbacks associated with conventional materials. In this context, 3D printing gained significant attention due to its capability of fabricating complex geometrics using different material compositions. The present review focuses on recent advancements of 3D printing applications in various physicochemical and biological wastewater treatment techniques. In physicochemical treatment methods, substantial research has been aimed at fabricating feed spacers and other membrane parts, photocatalytic feed spacers, catalysts, scaffolds, monoliths, and capsules. Several advantages, such as membrane fouling mitigation, enhanced degradation efficiency, and recovery and reusability potential, have been associated with the aforementioned 3D printed materials. While in biofilm-based biological treatment methods, the use of 3D printed bio-carriers has led to enhanced mass transfer efficiency and microbial activities. Moreover, the application of these bio-carriers has shown better removal efficiency of chemical oxygen demand (∼90%), total nitrogen (∼73%), ammonia nitrogen (95%), and total phosphorous (∼100%). Although the removal efficiencies were comparable with conventional carriers, 3D printed carriers led to ∼40% reduction in hydraulic retention time, which could significantly save capital and operational expenditures. This review also emphasizes the challenges and sustainability aspects of 3D printing technology and outlines future recommendations which could be vital for further research in this field.

Manufacturing and Application of 3D Printed Photo Fenton Reactors for Wastewater Treatment

Additive manufacturing (AM) or 3D printing offers a new paradigm for designing and developing chemical reactors, in particular, prototypes. The use of 3D printers has been increasing, their performance has been improving, and their price has been reducing. While the general trend is clear, particular applications need to be assessed for their practicality. This study develops and follows a systematic approach to the prototyping of Advanced Oxidation Processes (AOP) reactors. Specifically, this work evaluates and discusses different printable materials in terms of mechanical and chemical resistance to photo-Fenton reactants. Metallic and ceramic materials are shown to be impracticable due to their high printing cost. Polymeric and composite materials are sieved according to criteria such as biodegradability, chemical, thermal, and mechanical resistance. Finally, 3D-printed prototypes are produced and tested in terms of leakage and resistance to the photo-Fenton reacting environment. Polylactic acid (PLA) and wood-PLA composite (Timberfill^®) were selected, and lab-scale raceway pond reactors (RPR) were printed accordingly. They were next exposed to H2O2/Fe(II) solutions at pH = 3 ± 0.2 and UV radiation. After 48 h reaction tests, results revealed that the Timberfill^® reactor produced higher Total Organic Carbon (TOC) concentrations (9.6 mg·L^-1) than that obtained for the PLA reactor (5.5 mg·L^-1) and Pyrex^® reactor (5.2 mg·L^-1), which suggests the interference of Timberfill^® with the reaction. The work also considers and discusses further chemical and mechanical criteria that also favor PLA for 3D-printing Fenton and photo-Fenton reactors. Finally, the work also provides a detailed explanation of the printing parameters used and guidelines for preparing prototypes.