Incorporating sulfur reactions and interactions with iron and phosphorus into a general plant-wide model

Integrating thermodynamics and mathematical modelling to investigate the stoichiometry and kinetics of sulphide oxidation-nitrate reduction with a special focus on partial autotrophic denitrification

In the present study, the stoichiometry of the Sulphur Oxidizing-Nitrate Reducing (SO-NR) process, with a focus on Partial Autotrophic Denitrification (PAD), has been evaluated through a thermodynamic-based study whereas a model-based approach has been adopted to assess process kinetics. Experimental data on process performance and biomass yields were available from a previous work achieving efficient PAD, where a biomass yield of 0.113 gVSS/gS was estimated. First, the free Gibbs energy dissipation method has been implemented, in order to provide a theoretical framework exploring the boundaries for sulphur oxidizing biomass yields. Second, a screening of available mathematical models describing SO-NR process was conducted and five published models were selected, in order to assess the most suitable model structure for describing the observed PAD kinetics. To the best of our knowledge, none of reported biomass yields are estimated in systems operating PAD as the main process and, analogously, none of the proposed models have been applied to case studies aiming at partial denitrification only. The work showed that the very low biomass yield of 0.117 ± 0.007 gVSS/gS, observed in a PAD system in our previous work, suggests that the conditions applied to achieve partial denitrification resulted in a high energy-dissipating metabolism compared to complete denitrification applications. Models' analysis revealed that nitrite accumulation can be described by a classical Monod kinetics if different μmax are adopted for each intermediate reaction, with Theil Inequality Coefficient values lower than 0.21 for both NO3- and NO2-. Nonetheless, adopting Haldane-type kinetics for nitrite uptake inferred higher identifiability to the model structure, resulting in confidence intervals below ±10% for all the parametric estimations. The thermodynamic and modelling outcomes support the experimental results obtained in the reference study and the critical comparison of model suitability to represent PAD process is believed pivotal to pave the way to its real-scale implementation.

The hybrid MABR process achieves intensified nitrogen removal while N2O emissions remain low

The hybrid membrane aerated biofilm reactor (MABR) process represents a full-scale solution for sustainable municipal wastewater treatment. However, most of the existing hybrid MABR processes retain large aerobic bioreactor volumes for nitrification, which is undesirable for energy and carbon savings. In this study, we used the plant-wide modeling approach with dynamic simulations to examine a novel hybrid MABR configuration with aeration controls that change the anoxic and aerobic fractions of the bioreactor volume. Result showed that the novel hybrid MABR showed "swinging" nitrification and denitrification capacities in response to diurnal loadings, achieving intensified nitrogen removal performance under both warm and cold temperature scenarios. N2O emissions from the hybrid MABR were only 1/5 of the emissions from the conventional activated sludge. The model predicted higher CH4 emissions from the hybrid MABR than the activated sludge process due to the methanogen growth in the oxygen-depleted MABR biofilm layer. Future measurements for CH4 emission are needed to obtain a holistic picture of the carbon footprint of the hybrid MABR process.

Odor emission assessment of different WWTPs with Extended Aeration Activated Sludge and Rotating Biological Contactor technologies in the province of Cordoba (Spain)

In this study, five urban WWTPs (Wastewater Treatment Plant) with different biological treatment (Extended Aeration Activated Sludge - EAAS; Rotating Biological Contactor - RBC), wastewater type (Urban; Industrial) and size, were jointly evaluated. The aim was twofold: (1) to analyze and compare their odor emissions, and (2) to identify the main causes of its generation from the relationships between physico-chemical, respirometric and olfactometric variables. The results showed that facilities with EAAS technology were more efficient than RBC, with elimination yields of organic matter higher than 90%. In olfactometric terms, sludge managements facilities (SMFs) were found to be the critical odor source in all WWTPs compared to the Inlet point (I) or Post primary treatment (PP), and for seasonal periods with ambient temperature higher than 25 °C. Moreover, the global odor emissions quantified in all SMFs revealed that facilities with EAAS (C-WWTP, V-WWTP and Z-WWTP) had a lower odor contribution (19,345, 14,800 and 11,029 ou_E/s·m², respectively) than for those with RBC technology (P-WWTP and NC-WWTP) which accounted for 19,747 ou_E/s·m² and 80,061 ou_E/s·m², respectively. In addition, chemometric analysis helped to find groupings and differences between the WWTPs considering the wastewater (71.27% of total variance explained) and sludge management (64.52% of total variance explained) lines independently. Finally, odor emissions were adequately predicted from the physico-chemical and respirometric variables in the wastewater (r² = 0.8738) and sludge (r² = 0.9373) lines, being pH, volatile acidity and temperature (wastewater line), and pH, moisture, temperature, SOUR (Specific Oxygen Uptake Rate) and OD₂₀ (Cumulative Oxygen Demand at 20 h) (sludge line) the most influential variables.

Modelling the impacts of operational conditions on the performance of a full-scale membrane aerated biofilm reactor

Membrane Aerated Biofilm Reactors (MABR) are gaining more and more acceptance in the plethora of wastewater process intensification technologies. Mathematical modelling has contributed to show their feasibility in terms of reduced energy consumption and footprint. Nevertheless, most simulation studies published until now are still focused on analyzing MABR as single units and not fully integrated within the flow diagram of the water treatment plant (WWTP). In this paper, the prediction capabilities of an integrated modelling approach is tested using full-scale data from Ejby Mølle WWTP+MABR site (Odense, Denmark). Mass balances, data reconciliation methods, process simulation and the different evaluation criteria were used to adjust influent, effluent and process indicators. Results show 10 % mismatch between flow, COD, N and P predictions and measurements in different plant locations. Using the adopted hydraulic retention time (HRT), nitrogen load (NL), membrane surface area (MA) and oxygen transfer rate (OTR), it was possible to predict nitrification rates (NR) within the interquartile range. This has been done under two different MABR operational conditions: with (#S2) and without (#S1) external aeration (EA) in the bulk liquid. The model provides additional process insights about biofilm structure, substrate gradients, weak acid base chemistry and precipitation potential. More specifically, simulations suggest the potential undesirable effects of sulfate (SRB) and iron reducing bacteria (IRB) on both microbial activity and composition of the biofilm. The latter may have a strong impact on ammonium (NH_x), sulfate (SO_x) and ferrous ion (Fe⁺²) conversion processes. The change of operational strategy in the scenario analysis highlights that the denitrifying activity of phosphorus accumulating organisms (PAOs) can enhance nutrient removal in MABR tanks. In addition, it was possible to assess the chance of success (in terms of energetic cost of nitrogen removal) of adding several MABR units in one tank of the WWTP under study before full-scale implementation.

Formation of vivianite in digested sludge and its controlling factors in municipal wastewater treatment

Engineering solutions to recover phosphorus from municipal wastewater are required to close the anthropogenic phosphorus cycle. After chemical phosphorus elimination by iron, the ferrous iron‑phosphorus mineral vivianite forms in digested sludge, and its separation is being researched at the pilot scale. In this study, sludge samples from 16 wastewater treatment plants (WWTPs) demonstrated that phosphorus bound to biomass and redox-sensitive iron in activated sludge was transformed into other phosphorus binding forms, including vivianite, during digestion. Vivianite quantity was approximated using X-ray diffraction and two sequential extractions. These three independent methods of approximating vivianite quantity were closely related confirming their relationship to the vivianite content in the samples. The digested sludge from three WWTPs exhibited comparatively high levels of vivianite-bound phosphorus approximated between 31 % and 51 % of total phosphorus. The controlling factors of vivianite formation were investigated in order to enhance its formation in digested sludge and increase the amount of phosphorus recoverable as vivianite. They were identified using single and multivariate correlation (MLR), considering the sludge properties, sludge composition, and process parameters within the operating range of the 16 WWTPs. Increasing iron content was verified as the primary predictor of significantly increased vivianite formation (MLR: p < 0.001). In addition, increasing sulphur content was found to be an additional significant factor that decreased vivianite formation (MLR: p < 0.05). Furthermore, a comparison of plants using sulphur-free (FeCl2 and FeCl3) and sulphur-containing (FeSO4 and FeClSO4) precipitants indicated that the latter could increase the sulphur content in digested sludge (one-tailed Welch two-sample t-test: t(14.6) = 2.3, p = 0.02). Thus, by increasing the sulphur content, the use of sulphur-comprising precipitants may counteract vivianite formation, whereas sulphur-free precipitants may facilitate it and, hence, promote vivianite recovery.

Valorization of wastewater to recover value-added products: A comprehensive insight and perspective on different technologies

In recent years, due to rapid globalization and urbanization, the demand for fuels, energy, water and nutrients has been continuously increasing. To meet the future need of the society, wastewater is a prominent and emerging source for resource recovery. It provides an opportunity to recover valuable resources in the form of energy, fertilizers, electricity, nutrients and other products. The aim of this review is to elaborate the scientific literature on the valorization of wastewater using wide range of treatment technologies and reduce the existing knowledge gap in the field of resource recovery and water reuse. Several versatile, resilient environmental techniques/technologies such as ion exchange, bioelectrochemical, adsorption, electrodialysis, solvent extraction, etc. are employed for the extraction of value-added products from waste matrices. Since the last two decades, valuable resources such as polyhydroxyalkanoate (PHA), matrix or polymers, cellulosic fibers, syngas, biodiesel, electricity, nitrogen, phosphorus, sulfur, enzymes and a wide range of platform chemicals have been recovered from wastewater. In this review, the aspects related to the persisting global water issues, the technologies used for the recovery of different products and/or by-products, economic sustainability of the technologies and the challenges encountered during the valorization of wastewater are discussed comprehensively.

Economic, technical, and environmental evaluation of retrofitting scenarios in a full-scale industrial wastewater treatment system

The use of mathematical models is a well-established procedure in the field of (waste) water engineering to "virtually" evaluate the feasibility of novel process modifications. In this way, only options with the highest chance of success are further developed to be implemented at full-scale, while less interesting proposals can be disregarded at an early stage. Nevertheless, there is still lack of studies, where different plant-wide model predictions (effluent quality, process economics, and technical aspects) are comprehensibly verified in the field with full-scale data. In this work, a set of analysis/evaluation tools are used to assess alternative retrofitting options in the largest industrial wastewater treatment plant in Northern Europe. A mechanistic mathematical model is simulated to reproduce process behavior (deviation < 11%). Multiple criteria are defined and verified with plant data (deviation < 5%). The feasibility of three types of scenarios is tested: (1) stream refluxing, (2) change of operational conditions and (3) the implementation of new technologies. Experimental measurements and computer simulations show that the current plant´s main revenues are obtained from the electricity produced by the biogas engine (54%) and sales of the inactivated bio-solids for off-site biogas production (33%). The main expenditures are the discharge fee (39%), and transportation and handling of bio-solids (30%). Selective treatment of bio-solid streams strongly modifies the fate of COD and N compounds within the plant. In addition, it increases revenues (+3%), reduces cost (-9%) and liberates capacity in both activated sludge (+25%) and inactivation reactors (+50%). Better management of the buffer tank promotes heterotrophic denitrification instead of dissimilatory nitrate conversion to ammonia. In this way, 11% of the incoming nitrogen is removed within the anaerobic water line and does not overload the activated sludge reactors. Only a marginal increase in process performance is achieved when the anaerobic granular sludge reactor operates at full capacity. The latter reveals that influent biodegradability is the main limiting factor rather than volume. Usage of either NaOH or heat (instead of CaO) as inactivation agents allows anaerobic treatment of the reject water, which substantially benefits revenues derived from higher electricity recovery (+44%). However, there is a high toll paid on chemicals (+73%) or heat recovery (-19%) depending on the inactivation technology. In addition, partial nitration/Anammox and a better poly-aluminum chloride (PAC) dosage strategy is necessary to achieve acceptable (< 2%) N and P levels in the effluent. The scenarios are evaluated from a sustainability angle by using life cycle impact assessment (LCIA) in form of damage stressors grouped into three categories: human health, ecosystems quality, and resource scarcity. The presented decision support tool has been used by the biotech company involved in the study to support decision-making on how to handle future expansions.

Plant-wide assessment of alternative activated sludge configurations for biological nutrient removal under uncertain influent characteristics

This study presents an extensive plant-wide model-based assessment of four alternative activated sludge (AS) configurations for biological nitrogen (N) and phosphorus (P) removal under uncertain influent loads and characteristics. Zeekoegat wastewater treatment plant (WWTP) in South Africa was chosen as case study due to its flexible design that enables operation in four different AS configurations: 3-stage Bardenpho (A2O), University of Cape Town (UCT), UCT modified (UCTM), and Johannesburg (JHB). A metamodeling based global sensitivity analysis was performed on a steady-state plant-wide simulation model using Activated Sludge Model No. 2d with the latest extension of physico-chemical processes describing the plant-wide P transformations. The simulation results showed that the predictions of effluent chemical oxygen demand (COD), N and P using the proposed approach fall within the interquartile range of measured data. The study also revealed that process configuration can affect: 1) how influent uncertainty is reflected in model predictions for effluent quality and cost related performances, and 2) the parameter rankings based on variance decomposition, particularly for effluent phosphate, sludge disposal and methane production. The results identified UCT and UCTM as more robust configurations for P removal (less propagated uncertainty and less sensitivity to N load) in the expense of incomplete denitrification. Moreover, based on the results of Monte-Carlo based scenario analysis, the balanced SRT for N and P removal is more sensitive to influent load variation/uncertainty for the A2O and JHB configurations. This gives a more operational flexibility to UCT and UCTM, where a narrow SRT range can ensure both N and P removal.

A plant-wide model describing GHG emissions and nutrient recovery options for water resource recovery facilities

In this study, a plant-wide model describing the fate of C, N and P compounds, upgraded to account for (on-site/off-site) greenhouse gas (GHG) emissions, was implemented within the International Water Association (IWA) Benchmarking Simulation Model No. 2 (BSM2) framework. The proposed approach includes the main biological N₂O production pathways and mechanistically describes CO₂ (biogenic/non-biogenic) emissions in the activated sludge reactors as well as the biogas production (CO₂/CH₄) from the anaerobic digester. Indirect GHG emissions for power generation, chemical usage, effluent disposal and sludge storage and reuse are also included using static factors for CO₂, CH₄ and N₂O. Global and individual mass balances were quantified to investigate the fluxes of the different components. Novel strategies, such as the combination of different cascade controllers in the biological reactors and struvite precipitation in the sludge line, were proposed in order to obtain high plant performance as well as nutrient recovery and mitigation of the GHG emissions in a plant-wide context. The implemented control strategies led to an overall more sustainable and efficient plant performance in terms of better effluent quality, reduced operational cost and lower GHG emissions. The lowest N₂O and overall GHG emissions were achieved when ammonium and soluble nitrous oxide in the aerobic reactors were controlled and struvite was recovered in the reject water stream, achieving a reduction of 27% for N₂O and 9% for total GHG, compared to the open loop configuration.

Sulfur transformations during two-stage anaerobic digestion and intermediate thermal hydrolysis

The formation of hydrogen sulfide (H₂S) during anaerobic digestion (AD) imposes constraints on the valorisation of biogas. So far, inorganic sulfur compounds -mainly sulfate - have been considered as the main contributors to H₂S formation, while the contribution of organic sulfur compounds is mostly neglected. This study investigates the fate of organic and inorganic sulfur compounds during two-stage anaerobic digestion with intermediate thermal hydrolysis for treatment of primary and secondary sludge in a WWTP treating domestic wastewater. The results of a seven-week monitoring campaign showed an overall decrease of organic sulfur compounds in both stages of anaerobic digestion. Further fractionation of organic sulfur revealed a high conversion of the particulate organic fraction during the first digestion stage and of the soluble organic fraction during the second digestion stage. The decrease of soluble organic sulfur during the second digestion stage was attributed to the solubilisation and hydrolysis of sulfur-containing organic compounds during thermal hydrolysis. In both digestion stages, more organic sulfur was taken up than particulate inorganic sulfur (metal sulfide) was produced, indicating the formation of other reduced sulfur forms (e.g. H₂S). Further batch experiments confirmed the role of organic sulfur uptake in the formation of H₂S during anaerobic digestion as sulfate reduction only partly explained the total sulfide formed (H₂S in biogas and precipitated FeS). Overall, the conversion of organic sulfur was demonstrated to play a major role in H₂S formation (and thus the biogas quality), especially in case of thermal hydrolysis pretreatment.

Impacts of aluminum- and iron-based coagulants on municipal sludge anaerobic digestibility, dewaterability, and odor emission

Although aluminum- and iron-based chemicals have been broadly used as the two most common types of coagulants for wastewater treatment, their impacts on the performance of downstream sludge management can be quite different and have not been well understood. This work reviewed and analyzed their similarities and differences in the context of the anaerobic digestion performance, dewaterability of digested sludge, and odor emission from dewatered biosolids. In short, iron-based coagulants tend to show less negative impact than aluminum-based coagulants. This can be attributed to the reduction of ferric to ferrous ions in the course of anaerobic digestion, which leads to a suite of changes in protein bioavailability, alkalinity and hydrogen sulfide levels, and in turn the sludge dewaterability and odor potential. Whether these observations still hold true in the context of thermally hydrolyzed sludge management remains to be studied. PRACTITIONER POINTS: The impacts of aluminum-/iron-based coagulant addition on municipal sludge anaerobic digestibility, dewaterability, and odor emission are reviewed. Iron-based coagulants show less negative impact on the sludge digestibility than aluminum-based coagulants. Conclusions may aid practitioners in selecting coagulants in practice and better understanding the mechanisms behind the phenomena.

Assessment of alkaline stabilization processes in industrial waste streams using a model-based approach

Chemical conditioning prior to disposal is a common practice in biotech companies to stabilize the biological waste generated during production. Nevertheless, the state of the art models used to analyze management strategies in water treatment systems (WTS) do not include the effect of high alkaline conditions during bio-solids processing. In this paper, the prediction capabilities of a novel model-based approach describing the effect of quicklime addition (CaO) on the waste streams of an industrial WTS is assessed. Two measuring campaigns were carried out taking samples of TSS, VSS and total/soluble COD, N, P, S and multiple metals before and after chemical stabilization, and dewatering under and overflow. Mass balances were set up and Sankey diagrams were generated to represent the occurrence, transformation and fate of the major compounds within the studied facility. A simulation model was used to predict plant at different locations. Next, a scenario analysis was carried out in order to assess potential alternatives to the current operational practice. The resulting mass balances show a mismatch between the system's input and output up to 17%. It was also possible to identify different types of compound-behavior depending on the effect that high pH induced on the soluble and particulate fractions: hydrolysis, precipitation and unaltered. Model predictions and measurements differed 9.6% (steady state) and 12.4% (dynamic state) respectively. Finally, in the scenario analysis, the model suggested that the change from quicklime to sodium hydroxide (NaOH) would increase the quantity of organics in the dewatered cake (+23%), but with a considerable increase in chemical consumption (+50%). The selective stabilization of the incoming streams has the lowest use of chemicals (-30%) and reduces the load of CODsol (-13%) and TNsol (-14%) recirculated to the water line of the WWTP.

Assessment of sludge management strategies in wastewater treatment systems using a plant-wide approach

The objective of this paper is to use plant-wide modeling to assess the net impacts of varying sludge management strategies. Special emphasis is placed on effluent quality, operational cost and potential resource recovery (energy, nutrients). The study is particularly focused on a centralized bio-solids beneficiation facility (BBF), which enables larger, more capital intensive sludge management strategies. Potential barriers include the ability to process reject streams from multiple donor plants in the host plant. Cape Flats (CF) wastewater treatment works (WWTW) (Cape Town, South Africa) was used as a relevant test case since it is currently assessing to process sludge cake from three nearby facilities (Athlone, Mitchells Plain and Wildevoelvlei). A plant-wide model based on the Benchmark Simulation Model no 2 (BSM2) extended with phosphorus transformations was adapted to the CF design / operational conditions. Flow diagram and model parameters were adjusted to reproduce the influent, effluent and process characteristics. Historical data between January 2014 and December 2019 was used to compare full-scale measurements and predictions. Next, different process intensification / mitigation technologies were evaluated using multiple criteria. Simulation values for COD, TSS, VSS/TSS ratio, TN, TP, NH₄⁺/NH₃, H_xPO4^3-x, NO_x alkalinity and pH fall within the interquartile ranges of measured data. The effects of the 2017 severe drought on influent variations and biological phosphorus removal are successfully reproduced for the entire period with dynamic simulations. Indeed, 80% of all dynamically simulated values are included within the plant measurement uncertainty ranges. Sludge management analysis reveals that flow diagrams with thermal hydrolysis pre-treatment (THP) result in a better energy balance in spite of having higher heat demands. The flow diagram with THP is able to i) increase biodegradability/solubility, ii) handle higher sludge loads, iii) change methanogenic microbial population and iv) generate lower solids volumes to dispose by improving sludge dewaterability. The study also reveals the importance of including struvite precipitation and harvesting (SPH) technology, and the effect that pH in the AD and the use of chemicals (NaOH, MgO) may have on phosphorus recovery. Model-based results indicate that the current aerobic volume in the water line (if properly aerated) would be able to handle the returns from the sludge line and the contribution of a granular partial nitritation/Anammox (PN/ANX) reactor on the overall nitrogen removal would be marginal. However autotrophic N denitrification generates a much lower sludge production and therefore increases AD treatment capacity. The study shows for the very first time in Africa how the use of a (calibrated) plant-wide model could assist water utilities to decide between competing plant layouts when upgrading a WWTW.