Can a wastewater treatment plant be a powerplant? A case study

Today wastewater treatment plants are evaluated not only in terms of their treatment efficiency but also concerning their energy efficiency. Increasing energy efficiency can be realized either through operational optimisation or by realising an already existing potential for energy generation on-site. The main source of energy at a municipal wastewater treatment plant is the biogas produced in the anaerobic sludge digester. Studies indicate excess digester capacities of about 20% in Germany available for co-fermentation of organic substrates other than sewage sludge. This paper presents an example of a municipal wastewater treatment plant going towards an energy self-sufficient operation and even a surplus energy production as the result of an increasing co-fermentation of sludge from grease skimming tanks. In 2005 on average 113% of the electricity consumed for plant operation was generated on-site in gas engines. Co-fermentation of about 30% (related to the total dry residue input) of grease interceptor sludge in the presented case does not only effect a 4-times increased gas yield, but also an intensified 20% higher anaerobic degradation of the organic matter of the sewage sludge and thus having a positive influence not only on the energy and financial balance but also on the anaerobic sludge stabilisation with respect to the degradation degree of the organic fraction.     

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.     

Plant-wide (BSM2) evaluation of reject water treatment with a SHARON-Anammox process.

In wastewater treatment plants (WWTPs) equipped with sludge digestion and dewatering systems, the reject water originating from these facilities contributes significantly to the nitrogen load of the activated sludge tanks, to which it is typically recycled. In this paper, the impact of reject water streams on the performance of a WWTP is assessed in a simulation study, using the Benchmark Simulation Model no. 2 (BSM2), that includes the processes describing sludge treatment and in this way allows for plant-wide evaluation. Comparison of performance of a WWTP without reject water with a WWTP where reject water is recycled to the primary clarifier, i.e. the BSM2 plant, shows that the ammonium load of the influent to the primary clarifier is 28% higher in the case of reject water recycling. This results in violation of the effluent total nitrogen limit. In order to relieve the main wastewater treatment plant, reject water treatment with a combined SHARON-Anammox process seems a promising option. The simulation results indicate that significant improvements of the effluent quality of the main wastewater treatment plant can be realized. An economic evaluation of the different scenarios is performed using an Operating Cost Index (OCI).     

Comparison of different conditions, substrates and operation modes by dynamic simulation of a full-scale anaerobic SBR plant

Simulation studies for a full-scale anaerobic unit of a wastewater treatment plant (WWTP) were performed using the anaerobic digestion model no. 1 (ADM1). The anaerobic full-scale plant consists of one mesophilic and one thermophilic digester, operated in an anaerobic sequential batch reactor (ASBR) mode, and sludge enrichment reactors (SER) for each digester. The digesters are fed with a mixture of vegetable waste and process wastewater from the food factory. Characteristics such as COD(total), N(total) and NH(4)-N concentrations in the influent and effluent of the digester and SERs were measured and used for input fractionation. Parameters such as level, pH, biogas amount and composition in the digester were measured online and used for calibration. For simulation studies, different temperatures and operation modes with varying chemical oxygen demand (COD) input loads corresponding to feedstocks such as fruits, vegetables and grain were analysed and compared. Higher gas production and digestion efficiency in the thermophilic reactor and in shorter cycles were found and confirmed at full scale. Serial operation mode increased the gas production, but pH inhibition occurred earlier. Feeding only biosolids into digester I and the effluent of digester I together with process water into digester II further improved gas production in serial operation mode.     

Biogas production from anaerobic waste stabilisation ponds treating dairy and piggery wastewater in New Zealand.

New Zealand has over 1000 anaerobic wastewater stabilisation ponds used for the treatment of wastewater from farms and industry. Traditional anaerobic ponds were not designed to optimise anaerobic digestion of wastewater biomass to produce biogas and these uncovered ponds allowed biogas to escape to the atmosphere. This release of biogas not only causes odour problems, but contributes to GHG (greenhouse gas) emissions and is wasteful of energy that could be captured and used. Biogas production from anaerobic stabilisation ponds treating piggery and dairy wastewater was measured using floating 25 m2 HDPE covers on the pond surface. Biogas composition was analysed monthly and gas production was continually monitored. Mean areal biogas (methane) production rates from piggery and dairy anaerobic ponds were 0.78 (0.53) m3/m2/d and 0.03 (0.023) m3/m2/d respectively. Average CH4 content of the piggery and dairy farm biogas were 72.0% and 80.3% respectively. Conversion of the average volume of methane gas that could be captured from the piggery and dairy farm ponds (393.4 m3/d and 40.7 m3/d) to electricity would reduce CO2 equivalent GHG emissions by 5.6 tonnes/d and 0.6 tonnes/d and generate 1,180 kWh/d and 122 kWh/d. These results suggest that anaerobic ponds in New Zealand release considerable amounts of GHG and that there is great potential for energy recovery.     

Anaerobic waste activated sludge co-digestion with olive mill wastewater

Co-digestion of waste activated sludge (WAS) with agro-industrial organic wastewaters is a technology that is increasingly being applied in order to produce increased gas yield from the biomass. In this study, the effect of olive mill wastewater (OMW) on the performance of a cascade of two anaerobic continuous stirred tank (CSTR) reactors treating thickened WAS at mesophilic conditions was investigated. The objectives of this work were (a) to evaluate the use of OMW as a co-substrate to improve biogas production, (b) to determine the optimum hydraulic retention time that provides an optimised biodegradation rate or methane production, and (c) to study the system stability after OMW addition in sewage sludge. The biogas production rate at steady state conditions reached 0.73, 0.63, 0.56 and 0.46 l(biogas)/l(reactor)/d for hydraulic retention times (HRTs) of 12.3, 14, 16.4 and 19.7 d. The average removal of soluble chemical oxygen demand (sCOD) ranged between 64 and 72% for organic loading rates between 0.49 and 0.75 g sCOD/l/d. Reduction in the volatile suspended solids ranged between 27 and 30%. In terms of biogas selectivity, values of 0.6 l(biogas)/g tCOD removed and 1.1 l(biogas)/g TVS removed were measured.     

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.     

Three stages MBR (methanogenic, aerobic biofilm and membrane filtration) for the treatment of low-strength wastewaters

The use of a new three stages MBR process with a first methanogenic UASB stage, a second stage with aerobic biofilm growing on small carrier elements maintained in suspension and third stage with membrane filtration module is presented. The objective of the first methanogenic chamber is to diminish COD of the raw wastewater, producing a biogas rich in methane, and decrease the sludge production. In the second stage, the remaining soluble biodegradable COD is oxidized by heterotrophs. In the third stage, the membrane modules could be operated at higher fluxes than those reported for AnMBR systems, and similar to those obtained in aerobic MBRs. In this sense, the concept of these three stages MBR is to join the advantages of the methanogenic and aerobic membrane bioreactor processes, by reducing energy requirements for aeration, producing biogas with high methane percentage and a permeate with very low COD content. A synthetic wastewater was fed to the three stages MBR. COD in the influent was between 200 and 1,200 mg/L, ammonium ranged from 10 to 35 mg/L and phosphorous concentration was 8 mg/L. OLR in-between 1 and 3 kg COD/(m3 d) and a HRT of 13-21 h were applied. Temperature was between 17.5 and 23.2 degrees C. During the whole operating period the COD removal efficiencies were in the range of 90 and 96% of which in between 40 and 80% was removed in the first methanogenic chamber. Biogas production with methane content between 75 and 80% was observed. With regard to membrane operation, average permeabilities around 150 L/(m2 h bar) were achieved, operating with fluxes of 11-15 L/(m2 h).     

Potentials and limits of anaerobic digestion of sewage sludge: energy self-sufficient municipal wastewater treatment plant?

Anaerobic digestion is the only energy-positive technology widely used in wastewater treatment. Full-scale data prove that the anaerobic digestion of sewage sludge can produce biogas that covers a substantial amount of the energy consumption of a wastewater treatment plant (WWTP). In this paper, we discuss possibilities for improving the digestion efficiency and biogas production from sewage sludge. Typical specific energy consumptions of municipal WWTPs per population equivalent are compared with the potential specific production of biogas to find the required/optimal digestion efficiency. Examples of technological measures to achieve such efficiency are presented. Our findings show that even a municipal WWTP with secondary biological treatment located in a moderate climate can come close to energy self-sufficiency. However, they also show that such self-sufficiency is dependent on: (i) the strict optimization of the total energy consumption of the plant, and (ii) an increase in the specific biogas production from sewage sludge to values around 600 L per kg of supplied volatile solids.     

Start-up and steady-state results of a full-scale UASB reactor treating malting wastewater.

An Imhoff tank was reconstructed into a 250 m3 UASB reactor in order to treat a malting plant wastewater. The UASB was inoculated with sludge from an anaerobic lagoon used for slaughterhouse wastewater treatment. After two months of operation the reactor achieved full load with an HRT of 17 h, a COD removal higher than 80% and a biogas production of 300 m3/day (77% average methane content), with an organic loading rate of 3.6 kgCOD/m3.d (0.24 kgCOD/kgVSS.d). A yield coefficient of 0.09 gVSS/gCODrem was found from a mass balance. The fat present in the inoculated sludge (48 mg/gSSV) did not affect the start up performance. Sludge from the inoculum with high content of fat (270 mg/gSSV), was separated by flotation in the first week of operation. The COD removal efficiency was scarcely influenced by the reactor operation temperature (17-25 degrees C).     

Aerobic biological treatment of thermophilically digested sludge

Aerobic biological treatment of digested sludge was studied in a continuously operated laboratory set-up. An aerated reactor was filled with thermophilically digested sludge from the Moscow wastewater treatment plant and inoculated with special activated sludge. It was then operated at the chemostat mode at different flow rates. Processes of nitrification and denitrification, as well as dephosphatation, occurred simultaneously during biological aerobic treatment of thermophilically digested sludge. Under optimal conditions, organic matter degradation was 9.6%, the concentrations of ammonium nitrogen and phosphate decreased by 89 and 83%, respectively, while COD decreased by 12%. Dewaterability of digested sludge improved significantly. The processes were found to depend on hydraulic retention time, oxygen regime, and temperature. The optimal conditions were as follows: hydraulic retention time 3-4 days, temperature 30-35 degrees C, dissolved oxygen levels 0.2-0.5 mg/L at continuous aeration or 0.7-1 mg/L at intermittent aeration. Based on these findings, we propose a new combined technology of wastewater sludge treatment. The technology combines two stages: anaerobic digestion followed by aerobic biological treatment of digested sludge. The proposed technology makes it possible to degrade the sludge with conversion of approximately 45% volatile suspended solids to biogas, to improve nitrogen and phosphorus removal in reject water from sludge treatment units, and to achieve removal of malodorous substances after 8-9 days of anaerobic-aerobic sludge treatment.     

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.     

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.     

A promising approach of reject water treatment using a tidal flow constructed wetland system employing alum sludge as main substrate

This study examined a novel reuse of alum sludge, an inescapable by-product of drinking water treatment process when aluminium salt is added as a coagulant, as the main medium in a laboratory-scale multi-stage constructed wetland (CW) system for reject water treatment. Such reject water is a main concern in municipal wastewater treatment plant (MWWTP) for increasing the organic and nutrient loading. A 'tidal flow' strategy was employed to enhance the wetland aeration to stimulate organic matters (OM) and ammoniacal-nitrogen (N) oxidation while the 'step feed' operation was adopted to supply the necessary amount of carbon source for denitrification. The results reveal that alum sludge acting as P adsorbent can secure the P removal. Meanwhile, high removals of N and OM can also be obtained due to the active bacteria growth on the alum sludge surface. The results show that average removal efficiencies of 65.4 +/- 12.3% for chemical oxygen demand (COD), 67.8 +/- 9.2% for five-day biochemical oxygen demand (BOD5), 33.6 +/- 17.0% for N and 99.5 +/- 0.49% for P can be achieved over a period of 190 days. This indicates that novel reuse of alum sludge as medium in CW system can provide a promising approach for reject water treatment. Therefore, it will significantly reduce the amount of pollutant feedback through reject water recycling in a MWWTP.     

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.     

Confectionery industry: a case study on treatability-based effluent characterization and treatment system performance

Source-based wastewater characterization and stream segregation provide effective management of industrial wastewaters. The characterization of wastewater sources from a confectionery factory was presented and performance of the wastewater treatment plant was evaluated in this study. All of the wastewater sources in the factory, except the vacuum water line, can be characterized by high concentrations of soluble pollutants and low pH. High organic content of the wastewater generated from the confectionery industry promoted the application of anaerobic technology as a pre-treatment before the conventional aerobic treatment. The average chemical oxygen demand (COD) removal and biogas production for expanded granular sludge bed reactor were 88% and 1,730 Nm(3)/day, respectively. The effluent from the investigated facility can be used for irrigation provided that conductivity values are within acceptable limits.     

Life cycle assessment of an intensive sewage treatment plant in Barcelona (Spain) with focus on energy aspects

Life Cycle Assessment was used to evaluate environmental impacts associated to a full-scale wastewater treatment plant (WWTP) in Barcelona Metropolitan Area, with a treatment capacity of 2 million population equivalent, focussing on energy aspects and resources consumption. The wastewater line includes conventional pre-treatment, primary settler, activated sludge with nitrogen removal, and tertiary treatment; and the sludge line consists of thickening, anaerobic digestion, cogeneration, dewatering and thermal drying. Real site data were preferably included in the inventory. Environmental impacts of the resulting impact categories were determined by the CLM 2 baseline method. According to the results, the combustion of natural gas in the cogeneration engine is responsible for the main impact on Climate Change and Depletion of Abiotic Resources, while the combustion of biogas in the cogeneration unit accounts for a minor part. The results suggest that the environmental performance of the WWTP would be enhanced by increasing biogas production through improved anaerobic digestion of sewage sludge.     

我国城市污水处理厂污泥产沼气的前景分析

污泥厌氧消化具有稳定污泥和回收能量以及处理后污泥可作农肥的突出优点.我国城市污水处理厂污泥多,污泥厌氧消化的推广空间巨大.污泥厌氧消化推广的主要问题是规模较小、投资高、技术复杂、维修量大等,而沼气利用不理想大大削弱了该工艺的优势.必须降低投资、简化运行和提高沼气利用的效益,加速研究配套政策,才能改变投入高、产出低的现状,才能使污泥厌氧消化成为污泥处理的首选工艺.     

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.