Impact of methodological artifact on digested sludge flow curve measurement

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Small-gap-smooth-cup-and-bob is suitable geometry for dilute digested sludge (~2%).

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Small-gap-vane-and-rough cup is preferred for sludge at medium thickness (~3.5%).

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Roughened wide gap geometry is preferred for highly thickened digested sludge (~6%).

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An equilibrium time at each point of flow curve is necessary for sludge measurement.

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Flow curve data requires to visually inspected for instabilities.

Inconsistent experimental procedures have been used to characterize sludge rheology in literature. This often has resulted in proposing different rheological models for sludge as well as non-comparable data. Any collected rheological data needs to be interpreted considering the methodology used for its collection because otherwise they cannot be used by engineers for design and troubleshooting. This paper intends to shed light on the influential parameters during data collection procedure to produce a reliable and reproducible data.

This paper systematically investigates the impact of different geometries, preshear, equilibrium, rest and storage time on flow curve measurement for digested sludge in the range of 2.3 to 6% total solid and recommends a reliable procedure for reproducible sludge flow curve measurements. While the magnitude of impacts is different, we found all factors are significantly dependent on the sludge solid concentration. Besides, the method of the development of the protocol can be utilized to develop appropriate protocols for rheological characterization of any other sludge. The customization highlights are:•

Selecting the geometry according to the sludge solid concentration.

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Allocating an equilibrium time at each point of flow curve according to the sludge solid concentration.

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Flow curve data requires to visually inspected for instabilities.

Rheology improvement in an osmotic membrane bioreactor for waste sludge anaerobic digestion and the implication on agitation energy consumption

Sludge rheology is an essential factor for anaerobic digestion (AD) processes to control the agitation energy consumption. In this study, the sludge rheology was characterized for an osmotic membrane bioreactor and a conventional sludge anaerobic digestion reactor as the solid content being increased from 3.5-3.7% to 7.5-7.7%. The flow curves were fitted using different rheological models and the mechanism was discussed. The sludge from the osmotic membrane bioreactor exhibited obviously better rheological properties than that of the conventional reactor at a solid content of 7.5-7.7%. Larger particles induced by less negative zeta potential and higher extracellular polymeric substances, together with the higher conductivity resulted by reverse salt flux in the osmotic membrane bioreactor, improved the sludge rheology due to reduced interactions between particles. As a result, the agitation energy consumption of the osmotic membrane bioreactor can save up to 34-39% compared with the conventional one at total solid content of 7.5-7.7%.

Interplay between physical cleaning, membrane pore size and fluid rheology during the evolution of fouling in membrane bioreactors

Fouling is one of the most pressing limitations during operation of membrane bioreactors, as it increases operating costs and is the cause of short membrane lifespans. Conducting effective physical cleanings is thus essential for keeping membrane operation above viable performance limits. The nature of organic foulants present in the sludge and the membrane properties are among the most influential factors determining fouling development and thus, efficiency of fouling mitigation approaches. The role of other factors like sludge viscosity on fouling is still unclear, given that contradictory effects have been reported in the literature. In the present study we use a new research approach by which the complex interplay between fouling type, levels of permeate flux, membrane material and feed properties is analyzed, and the influence of these factors on critical flux and membrane permeability is evaluated. A variety of systems including activated sludge and model solutions with distinct rheological behavior has been investigated for two membranes differing in pore size distribution. We present a novel method for assessing the efficiency of fouling removal by backwash and compare it with the efficiency achieved by means of relaxation. Results obtained have proven that backwash delays development of critical fouling as compared with relaxation and reduces fouling irreversibility regardless of fluid rheology. It was shown that backwash is especially effective for membranes for which internal fouling is the main cause of loss in permeability. Nonetheless, we found out that for membranes with tight pores, both relaxation and backwash are equally effective. The critical flux decreases significantly for high-viscosity fluids, such as activated sludge. This effect is mainly caused by an intensified concentration polarization at the feed side rather than by internal fouling events. However, membrane permeability has been proven to rely more on the permeate viscosity than on the feed viscosity: poor rejection of organic fractions showcasing high viscosity causes an acute decline in membrane permeability as a consequence of increased shear stress inside the membrane pores.

Comparative power demand of mechanical and aeration imposed shear in an immersed membrane bioreactor

The power demanded for the application of mechanically-imposed shear on an immersed flat sheet (iFS) membrane bioreactor (MBR) has been compared to that of conventional membrane air scouring. Literature correlations based on the Ostwald model were used to define the rheological characteristics of an MBR sludge. The correlation of specific power demand (P^'¯, in Watts per m² membrane area) with shear rate γ in s^-1 was developed from first principles through a consideration of the force balance on the system in the case of mechanically-imposed shear. The corresponding aeration imposed shear correlation was interpreted from literature information. The analysis revealed the energy required to impose a shear mechanically through oscillation (or reciprocation) of the membrane to be between 20 and 70% less than that demanded for providing the same shear by conventional aeration of the immersed membrane. The energy saving increases with decreasing shear in accordance with a power demand ratio (aeration:mechanical) of 1400γ^-1.4 for a specific sludge rheology. Whilst the absolute P^'¯ value is dependent on the sludge rheology, the aeration:mechanical power demand ratio is determined by the difference in the two exponents in the respective correlations between P^'¯ and γ. Consequently, aeration-imparted shear becomes energetically favoured beyond some threshold shear rate value (∼180 s^-1, based on the boundary conditions applied in the current study). The outcomes qualitatively corroborate findings from the limited practical measurement of energy demand in MBRs fitted with reciprocating immersed membranes.

Numerical simulation of bubble induced shear in membrane bioreactors: effects of mixed liquor rheology and membrane configuration

A CFD model, incorporating an empirically determined rheology model and a porous media model, was developed to simulate bubble induced surface shear in membrane bioreactors configured with hollow fibre membranes with outer diameters ranging from 1.3 to 2.4 mm, arranged in vertically orientated modules with packing density from 200 to 560 m(2)/m(3). The rheology model was developed for mixed liquor suspended solids (MLSS) concentrations of 3 to 16 gL(-1) in the presence and absence of coagulant (generated by addition of a ferrous salt) for shear rates ranging from 0 to 500 s(-1). Experimentally determined particle relaxation times for the biological flocs in the mixed liquor, both in the absence and presence of iron, were negligible, consistent with an environment where positive buoyancy forces were greater than negative settling forces thereby allowing the sludge mixture to be modelled as a single continuous phase. The non-Newtonian behaviour of the mixed liquor was incorporated into the CFD simulations using an Ostwald-de Waele rheology model. Interactions between mixed liquor and hollow fibre membranes of different fibre size and packing density were described using a porous media model that was calibrated by empirical measurement of inertial loss coefficients over a range of viscosities (0.8 × 10(-3) to 2.1 × 10(-3) Pa.s) and velocities (0 to 0.35 m/s) typically encountered in full scale MBRs. Experimental results indicated that addition of iron salts resulted in an increase in MLSS and sludge viscosity. Shear stress is affected by both velocity and viscosity. The increase in sludge viscosity resulted in an increase in resistance to flow through the hollow fibre membrane bundles and, as a result, decreased the liquid flow velocities. CFD simulations provided insight on the effects of point of coagulant addition and MLSS concentration on bubble-induced shear over a range of industrially relevant conditions. A 12% increase in shear stress was observed when ferrous salts were added to the membrane filtration zone compared to addition to the primary anoxic zone. The presence of iron salts also improved the distribution of shear stress especially at the lower zone of the membrane module. The CFD models developed here were validated using Particle Image Velocimetry (PIV) with the average difference between simulated liquid velocities and PIV measured velocities found to be 5.5%.

CFD simulation of anaerobic digester with variable sewage sludge rheology

A computational fluid dynamics (CFD) model that evaluates mechanical mixing in a full-scale anaerobic digester was developed to investigate the influence of sewage sludge rheology on the steady-state digester performance. Mechanical mixing is provided through an impeller located in a draft tube. Use is made of the Multiple Reference Frame model to incorporate the rotating impeller. The non-Newtonian sludge is modeled using the Hershel-Bulkley law because of the yield stress present in the fluid. Water is also used as modeling fluid to illustrate the significant non-Newtonian effects of sewage sludge on mixing patterns. The variation of the sewage sludge rheology as a result of the digestion process is considered to determine its influence on both the required impeller torque and digester mixing patterns. It was found that when modeling the fluid with the Hershel-Bulkley law, the high slope of the sewage stress-strain curve at high shear rates causes significant viscous torque on the impeller surface. Although the overall fluid shear stress property is reduced during digestion, this slope is increased with sludge age, causing an increase in impeller torque for digested sludge due to the high strain rates caused by the pumping impeller. Consideration should be given to using the Bingham law to deal with high strain rates. The overall mixing flow patterns of the digested sludge do however improve slightly.