Winery and distillery wastewater treatment by anaerobic digestion.

Anaerobic digestion is widely used for wastewater treatment, especially in the food industries. Generally after the anaerobic treatment there is an aerobic post-treatment in order to return the treated water to nature. Several technologies are applied for winery wastewater treatment. They are using free cells or flocs (anaerobic contact digesters, anaerobic sequencing batch reactors and anaerobic lagoons), anaerobic granules (Upflow Anaerobic Sludge Blanket--UASB), or biofilms on fixed support (anaerobic filter) or on mobile support as with the fluidised bed. Some technologies include two strategies, e.g. a sludge bed with anaerobic filter as in the hybrid digester. With winery wastewaters (as for vinasses from distilleries) the removal yield for anaerobic digestion is very high, up to 90-95% COD removal. The organic loads are between 5 and 15 kgCOD/m3 of digester/day. The biogas production is between 400 and 600 L per kg COD removed with 60 to 70% methane content. For anaerobic and aerobic post-treatment of vinasses in the Cognac region, REVICO company has 99.7% COD removal and the cost is 0.52 Euro/m3 of vinasses.     

Anaerobic codigestion of waste activated sludge and OFMSW: the experiences of viareggio and treviso plants (Italy).

The paper presents the results of two full-scale applications of the anaerobic co-digestion process of waste activated sludge together with the organic fraction of municipal solid wastes. The experiences were carried out at Viareggio and Treviso wastewater treatment plants (Italy). In the first plant, 3 tons per day of source sorted OFMSW were co-digested with waste activated sludge, increasing the organic loading rate from 1.0 to 1.2 kgTVS/m3d. This determined a 50% increase in biogas production. At Treviso WWTP, which has been working for 2 years, some 10 tons per day of separately collected OFMSW are treated using a low-energy consumption sorting line, which allows the removal of 99% and 90% of metals and plastics respectively. In these conditions, the biogas yield increased from 3,500 up to 17,500 m3/month. Industrial costs were evaluated less than 50 Euro per ton of organic waste, while the payback time was calculated as two years.     

Re-use of winery wastewaters for biological nutrient removal.

The aim of this study was to evaluate the feasibility of the re-use of the winery wastewater to enhance the biological nutrient removal (BNR) process. In batch experiments it was observed that the addition of winery wastewater mainly enhanced the nitrogen removal process because of the high denitrification potential (DNP), of about 130 mg N/g COD, of the contained substrates. This value is very similar to that obtained by using pure organic substrates such as acetate. The addition of winery wastewater did not significantly affect either phosphorus or COD removal processes. Based on the experimental results obtained, the optimum dosage to remove each mg of N-NO3 was determined, being a value of 6.7 mg COD/mg N-NO3. Because of the good properties of the winery wastewater to enhance the nitrogen removal, the viability of its continuous addition in an activated sludge pilot-scale plant for BNR was studied. Dosing the winery wastewater to the pilot plant a significant increase in the nitrogen removal was detected, from 58 to 75%. The COD removal was slightly increased, from 89 to 95%, and the phosphorus removal remained constant.     

Anaerobic co-digestion of sludge with other organic wastes and phosphorus reclamation in wastewater treatment plants for biological nutrients removal.

This paper deals with the performances obtained in full scale anaerobic digesters co-digesting waste activated sludge from biological nutrients removal wastewater treatment plants, together with different types of organic wastes (solid and liquid). Results showed that the biogas production can be increased from 4000 to some 18,000 m3 per month when treating some 3-5 tons per day of organic municipal solid waste together with waste activated sludge. On the other hand, the specific biogas production was improved, passing from 0.3 to 0.5 m3 per kgVS fed the reactor, when treating liquid effluents from cheese factories. The addition of the co-substrates gave minimal increases in the organic loading rate while the hydraulic retention time remained constant. Further, the potentiality of the struvite crystallisation process for treating anaerobic supernatant rich in nitrogen and phosphorus was studied: 80% removal of phosphorus was observed in all the tested conditions. In conclusion, a possible layout is proposed for designing or upgrading wastewater treatment plants for biological nutrients removal process.     

Post-aeration of anaerobically digested sewage sludge for advanced COD and nitrogen removal: results and cost-benefit analysis at large-scale.

At a large Austrian municipal wastewater treatment plant enhanced stabilisation of anaerobically digested sewage sludge was required in order to get a permit for landfill disposal of the dewatered stabilized sludge. By implementing a post-aeration treatment after anaerobic digestion the organic content of the anaerobically well digested sludge can be decreased by 16%. Investigations at this plant showed that during digested sludge post-aeration anoxic phases are needed to provide stable process conditions. In this way the pH value can be kept in a more favourable range for micro-organisms and concrete structures. Additionally, under the process conditions applied nitrite accumulation would inhibit the stabilisation process if denitrification is not adequately applied. By optimising the aeration/pause ratio approximately 45% of total nitrogen in digested sludge can be removed. NH4-removal occurs through nitrification and denitrification with an efficiency of 98%. This significantly improves nitrogen removal efficiency at the wastewater treatment plant. The costs/benefit analysis shows that post-aeration of digested sludge results in an increase of total annual costs for wastewater treatment of only 0.84%, corresponding to 0.19 Euro/pe/a. Specific costs for nitrogen removal (0.32 Euro/kgN) are comparable with other biological processes for N-removal in reject water.     

Treatment of winery wastewater in a full-scale fixed bed biofilm reactor.

The treatment of winery wastewater was performed at full-scale applying a two-stage fixed bed biofilm reactor (FBBR) system for the discharge in the sewerage. The results of the first year of operation at the full-scale plant are presented. Values of removed organic loads and effluent concentrations were interpreted on the basis of the COD fractionation of influent wastewater assessed through respirometric tests. The average removal efficiency of total COD was 91 %. It was not possible to reach an higher efficiency because of the unbiodegradable soluble fraction of COD (about 10% of total COD on average during the whole year), that cannot be removed by biological process or settling. Due to the high empty space offered by the plastic carriers, FBBRs did not require backwashing during the seasonal operationing period of the plant (September-March). In comparison with other treatment systems the FBBR configuration allows one to ensure a simple management, to obtain high efficiency also in the case of higher fluctuations of flow and loads and to guarantee a good settleability of the sludge, without bulking problems.     

Evaluation of the reject waters from co-digestion of solid wastes from agro-industries in a municipal WWTP.

Overcapacities of anaerobic digesters at municipal WWTPs are frequently used for the treatment of organic wastes in order to increase the biogas production. However, "co-digestion" of organic wastes leads to additional nitrogen loading and to additional loads of non-biodegradable COD. The effects of (co-) digestion of organic wastes from agro-industries (slaughterhouses, dairies and leather industry) on the wastewater cycle have been evaluated in full-scale investigations at Leoben WWTP with a capacity of 90,000 pe where the methane production was increased from 700 to more than 1700 Nm3 CH4 per day. For this evaluation, mass balances for COD and nitrogen have been applied to estimate the fluxes of these substances. Application of this method is described in detail. As the additional loadings, it was found that related to methane production less nitrogen is released from the organic wastes than from the waste sludge. While the ammonia nitrogen load in the effluent from sludge digestion was about 100 g NH4-N per Nm3 of CH4 produced, in the effluent from the digestion of organic wastes only 70 g NH4-N/Nm3 CH4 were found. The decrease in the COD removal efficiency after digestion of the organic wastes started was not regarded as significant enough to be seen as a consequence of the treatment of external substrate.     

A combined UASB-MBR with shortcut nitrification-denitrification for energy reduction in wastewater reclamation

Shortcut nitrification has been successfully applied in a laboratory scale nitrification-denitrification process consisting of an up-flow anaerobic sludge blanket (UASB) and an aerobic membrane bioreactor (MBR) in treating synthetic and municipal wastewater to simultaneously remove organic carbon and nitrogen. For the treatment of synthetic wastewater, the combined system exhibited a high TOC removal of 98% with a steady ammonia removal efficiency of about 98% in the MBR and a total nitrogen (TN) removal efficiency of 90%. In treating municipal wastewater, due to its low COD concentration, removal efficiencies of TOC, ammonia and TN were 70%, 98% and 60%, respectively. The biogas production was around 76.4 L/m3 wastewater when treating synthetic wastewater. However, little biogas was produced when treating municipal wastewater which was the result of low organic carbon loading to the UASB. Energy analysis has demonstrated that this novel shortcut nitrification process could consume less energy than a conventional process and have the potential of bio-energy generation via biogas production thus helping to achieve a more favorable energy balance.     

Benchmarking of BAF plants: operational experience on 40 full-scale installations in Germany.

For some years, bio-filtration has been used in municipal wastewater treatment as a relatively new method. Within a German DWA research project, the method of benchmarking was used to compile and scientifically evaluate performance data and operation experiences with this technology on municipal wastewater treatment plants in Germany. This report presents selected partial results from the project. Generally, it becomes apparent that bio-filters as supplementary technology allow for additional improvements in regard to the COD and nitrogen effluent values. Bio-filtration is a compact method which combines biological purification processes with the filtration process. Apart from sound results in regard to the operation costs, operational problems (MSR technology, filter material losses) are described. In terms of energy balances, dimensions of the biological main stages can be compared to other biological purification methods. In regard to the sludge production, further research is necessary.     

Treatment and valorisation of winery wastewater by a new biophysical process (ECCF).

Taking account of the high specificity of the organic load of winery effluents, a new biophysical treatment using the stripping of ethanol combined with a final concentration by evaporation has been studied. Two options are proposed: full treatment and pre-treatment. The study of the composition of winery wastewater has shown the large, dominant part of ethanol in the organic load (75 to 99% of the COD). According to a linear correlation between COD and ethanol concentration, the determination of ethanol concentration can be used to estimate the organic load of winery wastewater. Full treatment by stripping and concentration at a pilot plant allows the separation of the wastewater into highly purified water (COD elimination > 99%), a concentrated alcoholic solution usable as bio-fuel and a concentrated by-product. Stripping alone represents an advantageous pre-treatment of winery wastewater. The purification rate reaches 78 to 85% and ethanol is recovered. The process facilitates discharge into a sewage system in view of treatment with domestic effluents and can also improve the efficiency of overloaded or old purification plants. The economical approach of this method demonstrates its competitiveness in comparison with biological treatments: low energy consumed, no sludge.     

Operation of a full-scale pumped flow biofilm reactor (PFBR) under two aeration regimes

A novel technology suitable for centralised and decentralised wastewater treatment has been developed, extensively tested at laboratory-scale, and trialled at a number of sites for populations ranging from 15 to 400 population equivalents (PE). The two-reactor-tank pumped flow biofilm reactor (PFBR) is characterised by: (i) its simple construction; (ii) its ease of operation and maintenance; (iii) low operating costs; (iv) low sludge production; and (v) comprising no moving parts or compressors, other than hydraulic pumps. By operating the system in a sequencing batch biofilm reactor (SBBR) mode, the following treatment can be achieved: 5-day biochemical oxygen demand (BOD5), chemical oxygen demand (COD) and total suspended solids (TSS) reduction; nitrification and denitrification. During a 100-day full-scale plant study treating municipal wastewater and operating at 165 PE and 200 PE (Experiments 1 and 2, respectively), maximum average removals of 94% BOD5, 86% TSS and 80% ammonium-nitrogen (NH4-N) were achieved. During the latter part of Experiment 2, effluent concentrations averaged: 14 mg BOD5/l; 32 mg COD(filtered)/l; 14 mg TSS/l; 4.4 mg NH4-N/l; and 4.0 mg NO3-N/l (nitrate-nitrogen). The average energy consumption was 0.46-0.63 kWh/m3(treated) or 1.25-1.76 kWh/kg BOD5 removed. No maintenance was required during these experiments. The PFBR technology offers a low energy, minimal maintenance technology for the treatment of municipal wastewater.     

Evaluation of rapid methods for in-situ characterization of organic contaminant load and biodegradation rates in winery wastewater.

Rapid methods for the in-situ evaluation of the organic load have recently been developed and successfully implemented in municipal wastewater treatment systems. Their direct application to winery wastewater treatment is questionable due to substantial differences between municipal and winery wastewater. We critically evaluate the use of UV-VIS spectrometry, buffer capacity testing (BCT), and respirometry as rapid methods to determine organic load and biodegradation rates of winery wastewater. We tested three types of samples: actual and treated winery wastewater, synthetic winery wastewater, and samples from a biological batch reactor. Not surprisingly, respirometry gave a good estimation of biodegradation rates for substrate of different complexities, whereas UV-VIS and BCT did not provide a quantitative measure of the easily degradable sugars and ethanol, typically the main components of the COD in the influent. However, our results strongly suggest that UV-VIS and BCT can be used to identify and estimate the concentration of complex substrates in the influent and soluble microbial products (SMP) in biological reactors and their effluent. Furthermore, the integration of UV-VIS spectrometry, BCT, and mathematical modeling was able to differentiate between the two components of SMPs: substrate utilization associated products (UAP) and biomass associated products (BAP). Since the effluent COD in biologically treated wastewaters is composed primarily by SMPs, the quantitative information given by these techniques may be used for plant control and optimization.     

An innovative technology based on aerobic granular biomass for treating municipal and/or industrial wastewater with low environmental impact.

The paper reports the results of an investigation carried out at lab scale to assess the effectiveness of an innovative technology (SUPERBIO) for treating municipal and/or industrial wastewater. When this technology was applied for treating municipal wastewater, the results showed that even at maximum organic load (i.e. 7 kg COD m(-3) d(-1)), the COD in the treated effluent was lower than 50 mg L(-1). In addition, both ammonia and TKN removal efficiencies resulted in higher than 87% up to an organic load of 5.7 kg COD m(-3) d(-1) corresponding to a nitrogen load of 0.8 kg TKN m(-3) d(-1). Very satisfactory process performances also resulted during tannery wastewater treatment, when a chemical oxidation step (i.e. ozonation) was inserted in the treatment cycle of SUPERBIO. In such an instance, at organic and nitrogen loadings of 3 kgCOD m(-3) d(-1) and 0.20 kg N m(-3) d(-1), COD, NH4+ -N and TSS average removals were 96, 99 and 98%, respectively. Finally, during the whole experimentation, SUPERBIO was always characterised by a very low sludge production. Such a result was ascribed mainly to the characteristics of biomass that grew in the form of very dense granules (i.e. 130 gVSS L(Biomass)(-1) allowing a biomass concentration as high as 50-60 gTSS l(bed)(-1) to be achieved.     

A pilot study on a step-feeding anoxic/oxic activated sludge system.

A four stage pilot plant of step-feed biological nutrient removal (BNR) was employed to investigate reactor performance and process stability. The results obtained showed that step-feed BNR is efficient and cost-effective for nitrogen and carbonaceous removal from municipal wastewater. The total average removal efficiencies of COD, NH3-N, TN and TP could reach as high as 89.5, 97.8, 73 and 75%, respectively, with 50% of return activated sludge (RAS), 9 h of hydraulic retention time (HRT) and 20 d of sludge retention time (SRT). Step-feed BNR is an alternative and effective technology of nutrient removal for municipal wastewater treatment.     

Winery wastewater treatment by constructed wetlands and the use of treated wastewater for cash crop production.

A 45 m long, 4 m wide and 1 m deep wetland was constructed at Goudini in 2002 to treat distillery and winery effluent. After the plants were fully established, the wastewater with an average chemical oxygen demand (COD) of 14,000 mg/l was introduced to the wetland system at a rate of 4,050 litres per day. After treatment, wastewater at the outlet had an average COD of 500 mg/l, indicating more than 90% COD removal. After treatment, the wastewater was used to irrigate cash crops as part of poverty alleviation for farm workers. The experiment consisted of four treatment: clean irrigation water with fertilizer applied (B1); clean irrigation water without fertilizer applied (B2); wastewater irrigation with fertilizer applied (B3); and wastewater irrigation without fertilizer applied (B4). These were replicated seven times. Cabbage was cultivated as a cash crop. The results indicated that cabbage could be irrigated with winery wastewater treated by wetlands. The study found that there was significant difference between treatments that were fertilized compared with those that were not fertilized. The results indicated that wastewater irrigation improved the nutritional status of the soil.     

Technological transfer to demonstrative scale of sequencing batch biofilter granular reactor (SBBGR) technology for municipal and industrial wastewater treatment

The paper reports the results of an experimental investigation aimed at transferring to demonstrative scale an innovative technology (SBBGR-Sequencing Batch Biofilter Granular Reactor) for the treatment of municipal and industrial wastewater by financial support of the EU Life programme. When this technology was applied for treating municipal wastewater, the results showed that the system was able to remove 80-90% of COD, total suspended solids and ammonia independently of the hydraulic residence time investigated (i.e., from 12 to 4 h). In the case of tannery wastewater, chosen as representative of concentrated industrial wastewater, SBBGR technology was suitable for removing 80-90% of the COD, suspended solids and ammonia content up to organic loading values of 3.5 kg COD/m3.d. During both periods, the process was characterised by a very high sludge age value (theta(c) approximately 150 d) that led to a biomass concentration as high as 35 gTSS/L(bed) and a sludge production much lower (5-6 times lower) that than commonly reported for conventional treatment plants.     

Upgrading of Florence wastewater treatment plant: co-digestion and nitrogen autotrophic removal.

In recent years a completely autotrophic nitrogen removal process based on Anammox biomass has been tested in a few European countries in order to treat anaerobic supernatant and to increase the COD/N ratio in municipal wastewater. This work reports experimental results on a possible technical solution to upgrade the S. Colombano treatment plant which treats wastewater from the Florentine urban area. The idea is to use 50% of the volume of the anaerobic digester in order to treat external sewage sludge (as septic tank sludge) together with waste activated sludge and to treat the resulting effluent on a SHARON-ANAMMOX process in order to remove nitrogen from the anaerobic supernatant. Anaerobic co-digestion, tested in a 200 L pilot plant, enables low cost treatment of septic tank sludge and increases biogas production; however, it also increases the nitrogen load re-circulated to the WWTP, where nitrogen removal efficiency is already low (<50%), due to the low COD/N ratio, which limits predenitrification efficiency. Experimental results from a SHARON process tested in a lab-scale pilot plant show that nitrite oxidising bacteria are washed-out and steady nitrite production can be achieved at retention times in the range 1 - 1.5 days, at 35 degrees C. In a lab-scale SBR reactor, coupled with a nitration bioreactor, maximum specific nitrogen removal rate under nitrite-limiting conditions (with doubling time equal to about 26 days at 35 degrees C) was equal to 0.22 kgN/kgSSV/d, about 44 times the rate measured in inoculum Anammox sludge. Finally, a cost analysis of the proposed upgrade is reported.     

Anaerobic treatment of a medium strength industrial wastewater at low-temperature and short hydraulic retention time: a pilot-scale experience

The aim of this work was to evaluate the performance of a pilot-scale upflow anaerobic sludge blanket (UASB) reactor during the treatment of cereal-processing industry wastewater under low-temperature conditions (17 degrees C) for more than 300 days. The applied organic loading rate (OLR(appl)) was gradually increased from 4 to 6 and 8 kg COD(sol)/m3d by increasing the influent soluble chemical oxygen demand (COD(sol)), while keeping the hydraulic retention time constant (5.2 h). The removal efficiency was high (82 to 92%) and slightly decreased after increasing the influent COD(sol) and the OLR(appl). The highest removed organic loading rate (OLR(rem)) was reached when the UASB reactor was operated at 8 kg COD(sol)/m3d and it was two times higher than that obtained for an OLR(appl) of 4 kg COD(sol)/m3d. Some disturbances were observed during the experimentation. The formation of biogas pockets in the sludge bed significantly complicated the biogas production quantification, but did not affect the reactor performance. The volatile fatty acids in the effluent were low, but increased as the OLR(appl) increased, which caused an increment of the effluent COD(sol). Anaerobic treatment at low temperature was a good option for the biological pre-treatment of cereal processing industry wastewater.     

Anaerobic reactor/high rate pond combined technology for sewage treatment in the Mediterranean area.

Two high-rate, anaerobic/aerobic units were used to treat the sewage of the Institut Agronomique st Vétérinaire Hassan II (Morocco) campus in a 1,100 m2-plant designed for 1,500 e.p. and receiving 63 m3 per day. The anaerobic pre-treatment consisted of a two-step up-flow anaerobic reactor (TSUAR) comprising two reactors and one external settler all in series. The aerobic line, or post-treatment, consisted of a high-rate algal pond (HRAP) and one maturation pond in series. The system totalized a hydraulic retention time (HRT) of 9 days. A gravel filter (GF) was constructed behind the TSUAR to trap low-density particles. The TSUAR removed 80% of COD and 90% of SS within 48 h. Solids retention time in the reactors averaged 32 d with a specific sludge production of 0.28 g SS g(-1) COD removed. Almost 93% of the sludge evacuated from the settler was stabilized. Specific biogas production from both reactors was 0.25m3 kg(-1) COD removed. Used in this configuration, the HRAP lost its BOD removal activity and increased its nutrients and pathogens removal capabilities (tertiary treatment). Results showed that 85% of total nitrogen and 48% of total phosphorus were removed by the HRAP. Land area requirement of this combination was less than 1 m2 per capita and filtered final effluent was of excellent quality (COD, 82 mg/l; TKN, 8.3 mg/l; total P, 2.7 mg/l, faecal coliforms, 2.4 10(3)/100 ml and zero helminths eggs).     

Occurrence of benzothiazoles in municipal wastewater and their fate in biological treatment.

A number of 2-substituted benzothiazoles that are known to be used as fungicides, corrosion inhibitors and vulcanization accelerators in industry have been analyzed in municipal wastewater and the effluents of activated sludge and membrane bioreactor (MBR) treatment over a three month period. All six analytes were regularly detected in the municipal wastewater by liquid chromatography-mass spectrometry and amount to a total concentration of 3.4 microg/L. Of these compounds benzothiazole-2-sulfonic acid (1,700 ng/L), benzothiazole (850 ng/L) and 2-hydroxybenzothiazole (500 ng/L) were most prominent. The source of the benzothiazole emission is yet unknown. Activated sludge treatment did not reduce total benzothiazole concentration significantly. Removals of the individual compounds ranged from 90% for 2-mercaptobenzothiazole and 70% for hydroxybenzothiazole to 40% for benzothiazole. The concentration of benzothiazole-2-sulfonic acid increased by 20%, whereas 2-methylthiobenzothiazole increased by 160% during activated sludge treatment, likely due to the methylation of mercaptobenzothiazole. Total benzothiazole removal in two parallely operated MBRs was significantly better (43%) than in the conventional activated sludge treatment. Namely benzothiazole and benzothiazole-2-sulfonic acid were more effectively removed. This first systematic study on the occurrence of benzothiazoles in municipal wastewater has shown that this is a relevant class of trace contaminants in municipal wastewater which is only incompletely removed in biological wastewater treatment. Emission from sewage treatment is dominated by the most polar benzothiazole-2-sulfonic acid. MBR treatment may reduce but cannot avoid this emission.