Evaluation of sludge reduction and phosphorus recovery efficiencies in a new advanced wastewater treatment system using denitrifying polyphosphate accumulating organisms.

A new biological nutrient removal process, anaerobic-oxic-anoxic (A/O/A) system using denitrifying polyphosphate-accumulating organisms (DNPAOs), was proposed. To attain excess sludge reduction and phosphorus recovery, the A/O/A system equipped with ozonation tank and phosphorus adsorption column was operated for 92 days, and water quality of the effluent, sludge reduction efficiency, and phosphorus recovery efficiency were evaluated. As a result, TOC, T-N and T-P removal efficiency were 85%, 70% and 85%, respectively, throughout the operating period. These slightly lower removal efficiencies than conventional anaerobic-anoxic-oxic (A/A/O) processes were due to the unexpected microbial population in this system where DNPAOs were not the dominant group but normal polyphosphate-accumulating organisms (PAOs) that could not utilize nitrate and nitrite as electron acceptor became dominant. However, it was successfully demonstrated that 34-127% of sludge reduction and around 80% of phosphorus recovery were attained. In conclusion, the A/O/A system equipped with ozonation and phosphorus adsorption systems is useful as a new advanced wastewater treatment plant (WWTP) to resolve the problems of increasing excess sludge and depleted phosphorus.     

Extraction efficiency of phosphate from pre-coagulated sludge with NaHS.

The recovery of phosphorus from sewage and sludge treatment systems is particularly important because it is a limited resource and a large proportion of the phosphorus currently used in Japan must be imported. We have been experimentally evaluating recovery methods with sulphide. In this study, we focussed on the extraction of phosphate from the sludge, and sought to achieve a greater extraction efficiency and to validate the extraction mechanism. We conducted three experiments, i.e. a sludge-type experiment, a coagulant ratio of pre-coagulated sludge experiment, and a concentration of pre-coagulated sludge experiment. Phosphate was extracted not with normal sewage sludge but with pre-coagulated sludge and FePO4 reagent at S/Fe = 1.0-2.0. A coagulant ratio of 23mg Fe L(-1) was required in the precoagulation process to effectively extract phosphate. A high concentration of pre-coagulated sludge was required for the phosphate extraction. The mass balance was calculated, and 44.0% of phosphorus was extracted to supernatant, and 98.5% of iron and 98.3% of sulphur (44.1% of sulphur was sulphide). Thus, phosphate can be selectively separated from iron by the phosphate extraction method with NaHS, and phosphorus and iron can be recovered and reused at sewage treatment plants using ferric chloride as a coagulant.     

Effect of ozonation on sludge reduction in a SBR plant.

This paper provides new insights on the application of the ozonation process for the reduction of activated sludge production in a Sequencing Batch Reactor. The study was performed on two identical lab-scale SBRs plant, fed with domestic sewage: a fraction (1/3 of the working volume) of the activated sludge from one reactor (Exp SBR) was periodically subjected to ozonation for 30 minutes at 0.05 g O(3)/gSS and then recirculated before the beginning of the cycle; the other reactor was used as control and therefore managed at the same sludge retention time but without the application of ozonation. The effects of the recirculation of the ozonated sludge to the Exp SBR were evaluated in terms of biological nitrogen and carbon removal efficiencies, Mixed Liquor Volatile and Suspended Solids (MLSS and MLVSS, respectively) concentrations, effluent quality and sludge settleability. Besides, characterization of the ozonated sludge was carried out for different oxidant dosages (0.05, 0.07 and 0.37 g O(3)/gSS) and durations of the ozonation process (10, 20 and 30 minutes). The results show that at 0.05 g O(3)/gSS and 30 minutes contact time MLVSS as well as MLVSS/MLSS ratio do not change appreciably. Ozone dosage must be increased much further to obtain a relevant effect.     

Development of a process for the recovery of phosphorus resource from digested sludge by crystallization technology.

Removal and recovery of phosphorus from sewage in form of MAP (magnesium ammonium phosphate) have attracted attention from the viewpoint of eutrophication prevention and phosphorus resource recovery as well as scaling prevention inside digestion tanks. In this work, phosphorus recovery demonstration tests were conducted in a 50 m3/d facility having a complete mixing type reactor and a liquid cyclone. Digested sludge, having 690 mg/L T-P and 268 mg/L PO4-P, was used as test material. The T-P and PO4-P of treated sludge were 464 mg/L and 20 mg/L achieving a T-P recovery efficiency of 33% and a PO4-P crystallization ratio of 93%. The reacted phosphorus did not become fine crystals and the recovered MAP particles were found to be valuable as a fertilizer. A case study in applying this phosphorus recovery process for treatment of sludge from an anaerobic-aerobic process of a 21,000 m3/d sewage system, showed that 30% of phosphorus concentration can be reduced in the final effluent, recovering 315 kg/d as MAP.     

Process performance and change in sludge characteristics during anaerobic digestion of sewage sludge with ozonation.

A new process configuration combining anaerobic digestion with ozonation, and operated at long SRT, was studied with the objective of on-site reduction in sludge quantity and improving biogas recovery. The process performance with respect to solid reduction efficiency and other important process parameters like accumulation of inorganic solids, changes in sludge viscosity and dewatering characteristics were evaluated from the data of long term pilot scale continuous experiments conducted using a mixture of primary and secondary municipal sewage sludge. Due to sludge ozonation and long SRT, high VSS degradation efficiency of approximately 80% was achieved at a reactor solid concentration of 6.5%. A high fraction of inorganic solid (>50%) consisting mainly of acid insoluble and iron compounds was found to accumulate in the reactor. The high inorganic content accumulated in the digested sludge did not, however, contribute to the observed increase in sludge viscosity at high solid concentration. The sludge viscosity was largely found to depend on the organic solid concentration rather than the total solid content. Moreover, higher inorganic content in the digested sludge resulted in better sludge dewaterability. For a quick assessment of the economic feasibility of the new process, an economic index based on the unit cost of digested sludge disposal to unit electric cost is proposed.     

Anaerobic digestion with partial ozonation minimises greenhouse gas emission from sludge treatment and disposal.

A novel anaerobic digestion process combined with partial ozonation on digested sludge was demonstrated for improving sludge digestion and biogas recovery by full-scale testing for 2 years and its performance was compared with a simultaneously operated conventional anaerobic digestion process. The novel process requires two essential modifications, which are ozonation for enhancing the biological degradability of sludge organics and concentrating of solids in the digester through a solid/liquid separation for extension of SRT. These modifications resulted in high VSS degradation efficiency of ca. 88%, as much as 1.3 times of methane production and more than 70% reduction in dewatered sludge cake production. Based on the performance, its energy demands and contribution for minimisation of greenhouse gas emission was evaluated throughout an entire study of sludge treatment and disposal schemes in a municipality for 130,000 p.e. The analysis indicated that the novel process with power generation from biogas would lead to minimal greenhouse gas emission because the extra energy production from the scheme was expected to cover all of the energy demand for the plant operation, and the remarkable reduction in dewatered sludge cake volumes makes it possible to reduce N2O discharge and consumption of fossil fuel in the subsequent sludge incineration processes.     

Full-scale application of anaerobic digestion process with partial ozonation of digested sludge.

For improving sludge digestion and biogas recovery, a new anaerobic digestion process combined with ozonation was tested at a full-scale unit for 2 years and its performance was compared with a simultaneously operated conventional anaerobic digestion process. The new process requires two essential modifications, which includes ozonation for enhancing the biological degradability of sludge organics and concentrating of solids in the digester through a solid/liquid separation for extension of SRT. These modifications resulted in high VSS degradation efficiency of ca. 88%, as much as 1.3 times of methane production and more than 70% reduction in dewatered sludge cake production. Owing to accumulation of inorganic solids in the digested sludge, water content of the dewatered sludge cake also reduced from 80% to 68%. An energy analysis suggested that no supplemental fuel was necessary for the subsequent incineration of the cake from the new process scheme. The process is suitable to apply to a low-loaded anaerobic digestion tank, where power production is used.     

Potential of activated sludge ozonation.

The disposal of sewage sludge and the agricultural use of stabilised sludge are decreasing due to more stringent regulations in Europe. An increasing fraction of sewage sludge must therefore be dewatered, dried, incinerated and the ashes disposed of in landfills. These processes are cost-intensive and also lead to the loss of the valuable phosphate resources incorporated in the sludge ash. The implementation of processes that could reduce excess sludge production and recycle phosphate is therefore recommended. Partial ozonation of the return sludge of an activated sludge system significantly reduces excess sludge production, improves the settling properties of the sludge and reduces bulking and scumming. The solubilised COD will also improve denitrification if the treated sludge is recycled to the anoxic zone. However, ozonation partly kills nitrifiers and could therefore lead to a decrease of the effective solid retention time of the nitrifier, thus reducing the safety of the nitrification. This paper discusses the effect of ozonation on sludge reduction, the operating stability of nitrification, the improvement of denitrification and also presents an energy and cost evaluation.     

Application of excess activated sludge ozonation in an SBR Plant. Effects on substrate fractioning and solids production

This paper provides new insights on the application of the ozonation process for the reduction of the activated sludge production in a sequencing batch reactor (SBR). The study was performed in two identical lab-scale SBRs plant, one for experimental activities (Exp SBR) and one used as control (Control SBR), both fed with domestic sewage. A fraction of the activated sludge collected from the Exp SBR at the end of the aerobic react phase was periodically subjected to ozonation for 30 minutes at three different specific dosages (0.05, 0.07 and 0.37 g O(3)/gSS) and then recirculated before the beginning of the following cycle.Recirculation of the ozonated sludge to the Exp SBR did not appreciably affect the efficiency of the biological nitrogen and carbon removal processes. Nonetheless, an improvement of the denitrification kinetic was observed. Mixed liquor volatile and suspended solids (MLSS and MLVSS, respectively) concentrations in the reactor decreased significantly with time for long term application of the ozonation treatment. Kinetic batch tests on unstressed sludge taken from Control SBR indicated that the different oxidant dosages (0.05, 0.07 and 0.37 g O(3)/gSS) and durations of the ozonation process (10, 20 and 30 minutes) used remarkably affected chemical oxygen demand (COD) and organic nitrogen fractioning. In particular, soluble and biodegradable fractions seemed to be higher at lower dosage and longer contact time.     

Recovery of phosphorus and aluminium from sewage sludge ash by a new wet chemical elution process (SESAL-Phos-recovery process)

The potential of a new wet chemical process for phosphorus and aluminium recovery from sewage sludge ash by sequential elution with acidic and alkaline solutions has been investigated: SESAL-Phos (sequential elution of sewage sludge ash for aluminium and phosphorus recovery). Its most innovative aspect is an acidic pre-treatment step in which calcium is leached from the sewage sludge ash. Thus the percentage of alkaline soluble aluminium phosphates is increased from 20 to 67%. This aluminium phosphate is then dissolved in alkali. Subsequently, the dissolved phosphorus is precipitated as calcium phosphate with low heavy metal content and recovered from the alkaline solution. Dissolved aluminium is recovered and may be reused as a precipitant in wastewater treatment plants.     

Potentials of using nanofiltration to recover phosphorus from sewage sludge.

Due to the depletion of mineral phosphorus resources there is an increasing demand for efficient phosphorus recovery technologies. In this study the potential of nanofiltration to recover phosphorus from pre-treated sewage sludge is investigated. The efficiency of three commercial nanofiltration membranes (Desal 5DK, NP030; MPF34) was tested using model solutions. Desal 5DK showed the best selectivity for phosphorus. A pH of lower than 1.5 was found to be most suitable. Desal 5DK was used on four different sewage sludge ash eluates and on one sewage sludge. In these experiments it was shown that a separation of phosphorus from undesired components such as heavy metals was possible with significant variations in the efficiency for the different ash and sludge types. Additionally the achievable product recovery was investigated with model solutions. A product recovery of 57.1% was attained for pH 1 and 41.4% for pH 1.5.     

The use of immersed membranes for upgrading wastewater treatment plants

Membranes can be installed in the clarifier (or aeration tank) of an existing activated sludge plant to enhance the biomass separation function of the system, thereby effectively overcoming any operating constraints associated with sludge settleability. The resulting upgraded plant can be operated at high biomass concentrations (10–20 gMLSS/L), leading to an increase in its treatment capacity. The membranes also ensure a treated water consistently free of suspended solids and a superior disinfection performance. The system offers an enhanced operating flexibility, and allows to operate at high sludge ages leading to a low excess sludge production.Such an immersed membrane activated sludge process (BIOSEP^®) has been developed and applied to the treatment of raw sewage. When treating screened raw sewage with this process, with a sludge concentration of 15 gMLSS/L and a volumetric loading of 1.2 kgCOD/m³/d, a 96% COD reduction and a 95% Total Kjeldahl Nitrogen (TKN) reduction have been obtained. The disinfection performance of the system was over 6 Log removal for fecal coliforms. The resulting production of sludge was 0.20 kgMLSS/kgCOD.Two desk case studies are given for 900 m³/day upgraded plants. In one case, the primary objective was to increase the treatment efficiency and develop nutrient removal for the original plant, while in the other case the primary objective was to increase the capacity of the original 460 m³/day plant.     

Partial ozonation of activated sludge to reduce excess sludge, improve denitrification and control scumming and bulking.

Disposal of sewage sludge is forbidden and agricultural use of stabilized sludge will be banned in 2005 in Switzerland. The sludge has to be dewatered, dried, incinerated and the ashes disposed in landfills. These processes are cost intensive and lead also to the loss of valuable phosphate resources incorporated in the sludge ash. The implementation of processes that could reduce excess sludge production and recycle phosphate is therefore recommended. Partial ozonation of the return sludge of an activated sludge system reduces significantly excess sludge production, improves settling properties of the sludge and reduces bulking and scumming. The solubilized COD will also improve denitrification if the treated sludge is recycled to the anoxic zone. But ozonation will partly inhibit and kill nitrifiers and might therefore lead to a decrease of the effective solid retention time of the nitrifier, which reduces the safety of the nitrification. This paper discusses the effect of ozonation on sludge reduction, the operation stability of nitrification, improvement of denitrification and gives also an energy and cost evaluation.     

Pilot scale evaluation of SANI process for sludge minimization and greenhouse gas reduction in saline sewage treatment

This study reports on a pilot trial of the SANI process (Sulfate reduction, Autotrophic denitrification and Nitrification Integrated process) in Hong Kong. A pilot-scale SANI plant treating saline sewage at 10 m3/day was scaled-up from a lab-scale system treating synthetic saline sewage. The plant consisted of a sulfate reduction up-flow sludge bed (SRUSB), an anoxic bioreactor (BAR1) for autotrophic denitrification utilizing dissolved sulfide produced by the SRUSB and an aerobic bioreactor (BAR2) for nitrification. The SANI pilot plant was successfully operated for 225 days and achieved average COD, TSS, TN removal of 87, 87, and 57%, respectively. The ratio of MLVSS to MLSS in the SRUSB was stable at 0.7 and the average sludge volume index (SVI) was constantly below 110 ml/g. No sludge was purposely withdrawn from the plant during 225-day plant operation. This was attributed to a very low observed sludge yield (0.02 kgVSS/kgCOD removed) of the SRUSB reactor. DNA extraction, PCA amplification results revealed that no methanogens were detected in the SRUSB. SANI can reduce 90% sludge production, 35% energy and 36% GHG compared to conventional biological nutrient removal (CBNR) process.     

Minimization of greenhouse gas emission by application of anaerobic digestion process with biogas utilization.

To assess the impact on greenhouse gas emission, different process schemes for municipal sludge treatment were evaluated based on the data from pilot-scale experiments and review of annual operation reports. A modified anaerobic digestion process with partial ozonation of digested sludge to improve biological degradability and the conventional anaerobic digestion process were compared with respect to the energy demand in each process schemes. Options for beneficial use of biogas included (1) application of biogas for power production and (2) recovery as an alternative to natural gas utilization. The analysis indicated that the partial ozonation process with power production led to minimal greenhouse gas emission because the extra energy production from this scheme was expected to cover all of the energy demand for the plant operation. Moreover, the final amount of dewatered sludge cake was only 40% of that expected from the conventional process, this significantly minimizes the potential for greenhouse gas emission in the subsequent sludge incineration processes.     

Long-term effects of the ozonation of the sludge recycling stream on excess sludge reduction and biomass activity at full-scale

This paper presents a full-scale experience of sludge minimization by means of short contact time ozonation in a wastewater treatment plant (WWTP) mainly fed on textile wastewater. The WWTP performance over a 3-year operational data series was analysed and compared with a two-year operation with sludge ozonation. Lab-scale respirometric tests were also performed to characterize biomass activity upstream and downstream of the ozone contact reactor. Results suggest that sludge ozonation: (1) is capable of decreasing excess sludge production by 17%; (2) partially decreases both N removal, by lowering the denitrification capacity, and P removal, by reducing biomass synthesis; (3) increases the decay rate from the typical value of 0.62 d(-1) to 1.3 d(-1); (4) decreases the heterotrophic growth yield from the typical value of 0.67 to 0.58 gCOD/gCOD.     

Application of vibration milling for advanced wastewater treatment and excess sludge reduction

As a new sludge reduction technology with a phosphorus removal mechanism, a vibration milling technology that uses iron balls have been applied to the wastewater treatment process. Three anaerobic-aerobic cyclic activated sludge processes: one without sludge disintegration; one disintegrated sludge by ozonation; and the other disintegrated sludge with the vibrating ball mill were compared. Ozonation achieved the best sludge reduction performance, but milling had the best phosphorus removal. This is because iron was mixed into the wastewater treatment tank due to abrasion of the iron balls, leading to settling of iron phosphates. Thus, the simple means of using iron balls as the medium in a vibrating ball mill can achieve both a sludge reduction of half and excellent phosphorus removal. Material balances in the processes were calculated and it was found that carbon components in disintegrated sludge were more resistant to biological treatment than nitrogen.     

Potentially toxic element release by fenton oxidation of sewage sludge.

The presence, in sewage sludge, of excess levels of the potentially toxic elements (PTE) copper, zinc, chromium, cadmium, nickel, lead and mercury, could impact on our ability to recycle these residues in the future. Far stricter limits on the levels of PTEs are likely in proposed legislation. A method involving the dosing of Fenton's reagent, a mixture of ferrous iron and hydrogen peroxide, under acidic conditions was evaluated for its potential to reduce metal levels. The [Fe]:[H2O2] (w/w) ratio was found to give a good indication of the percentage copper and zinc elution obtainable. Sites with no iron dosing as part of wastewater treatment required extra iron to be added in order to initiate the Fenton's reaction. A significant reduction, in excess of 70%, of the copper and zinc was eluted from both raw primary and activated sludge solid fractions. Cadmium and nickel could be reduced to below detection limits but elution of mercury, lead and chromium was less than 40%. The iron catalyst concentration was found to be a crucial parameter. This process has the potential to reduce the heavy metal content of the sludge and allow the recycling of sludge to continue in a sustainable manner.     

Development of MBR with reduced operational and maintenance costs.

To reduce MBR O&M costs, a new MBR process that conducts efficient simultaneous biological nitrogen and phosphorus removal (BNR) was developed. In the development of this process, various approaches were taken, including reduction of power demand, chemical consumption and sludge disposal costs. To address power demand reductions, air supply requirements for membrane cleaning were reduced. The process adopted an improved membrane that requires less air for cleaning than conventional membranes. It also introduced cyclic aeration, which alternately supplies washing air to the two series of membrane units. Adoption of biological phosphorus removal eliminated chemical costs for phosphorus removal and contributed to the reduction of sludge disposal costs. By combining these technologies, compared to conventional MBR processes, an approximately 27% reduction in O&M costs was achieved.     

Towards a complete recycling of phosphorus in wastewater treatment--options in Germany

Global reserves of mineral phosphorus are finite and the recycling of phosphorus from wastewater, a significant sink for phosphorus, can contribute to a more sustainable use. In Germany, Switzerland, and the Netherlands, an increasing percentage of municipal sewage sludge is incinerated and the contained phosphorus is lost. This paper reviews current technologies and shows that a complete phosphorus recovery from wastewater is technically feasible. Depending on the composition of the sewage sludge ash (SSA), there are various options for phosphorus recovery that are presented. Iron-poor SSAs can be used directly as substitute for phosphate rock in the electrothermal phosphorus process. SSAs with low heavy metal contents can be used as fertilizer without prior metal elimination. Ashes not suitable for direct recycling can be processed by thermal processes. Operators of wastewater treatment plants can additionally influence the ash composition via the selection of precipitants and the control of (indirect) dischargers. This way, they can choose the most suitable phosphorus recovery option. For sewage sludge that is co-incinerated in power plants, municipal waste incinerators or cement kilns phosphorus recovery is not possible. The phosphorus is lost forever.