Continuous thermal hydrolysis and anaerobic digestion of sludge. Energy integration study

Experimental data obtained from the operation in a pilot plant are used to perform mass and energy balances to a global process combining units of thermal hydrolysis (TH) of secondary sludge, anaerobic digestion (AD) of hydrolysed secondary sludge together with fresh primary sludge, and cogeneration from biogas by using a gas engine in which the biogas produces electricity and heat from the exhaust gases. Three scenarios were compared, corresponding to the three digesters operated: C (conventional AD, 17 days residence time), B (combined TH + AD, same time), and A (TH + AD at half residence time). The biogas production of digesters B and A was 33 and 24% better, respectively when compared with C. In the case of the combined TH + AD process (scenarios A and B), the key factors in the energy balance were the recovery of heat from hot streams, and the concentration of sludge. The results of the balances showed that for 8% DS concentration of the secondary sludge tested in the pilot plant, the process can be energetically self-sufficient, but a fraction of the biogas must by-pass the gas engine to be directly burned. From an economic point of view, scenario B is more profitable in terms of green energy and higher waste removal, while scenario A reduces the digester volume required by a half. Considering a population of 100,000 inhabitants, the economic benefit is 87,600 €/yr for scenario A and 132,373 €/yr for B. This value can be increased to 223,867 €/yr by increasing the sludge concentration of the feeding to the TH unit to a minimum value that allows use of all the biogas to produce green energy. This concentration is 13% DS, which is still possible from a practical point of view. Additional benefits gained with the combined TH + AD process are the enhancement of the digesters rheology and the possibility of getting Class A biosolids. The integration study presented here set the basis for the scale-up to a demonstration plant.     

Continuous thermal hydrolysis and energy integration in sludge anaerobic digestion plants.

A thermal hydrolysis pilot plant with direct steam injection heating was designed and constructed. In a first period the equipment was operated in batch to verify the effect of sludge type, pressure and temperature, residence time and solids concentration. Optimal operation conditions were reached for secondary sludge at 170 degrees C, 7 bar and 30 minutes residence time, obtaining a disintegration factor higher than 10, methane production increase by 50% and easy centrifugation In a second period the pilot plant was operated working with continuous feed, testing the efficiency by using two continuous anaerobic digester operating in the mesophilic and thermophilic range. Working at 12 days residence time, biogas production increases by 40-50%. Integrating the energy transfer it is possible to design a self-sufficient system that takes advantage of this methane increase to produce 40% more electric energy.     

Improvement of anaerobic digestion of sludge.

Anaerobic digestion improvement can be accomplished by different methods. Besides optimization of the process conditions, pretreatment of input sludge and increase of process temperature is frequently used. The thermophilic process brings a higher solids reduction and biogas production, a high resistance to foaming, no problems with odour, better pathogens destruction and an improvement of the energy balance of the whole treatment plant. Disintegration of excess activated sludge in a lysate centrifuge was proved to cause increase of biogas production in full-scale conditions. The rapid thermal conditioning of digested sludge is an acceptable method of particulate matter disintegration and solubilization.     

Effect of biological additives and micronutrients on the anaerobic digestion of physicochemical sludge.

Two additives (lyophilized bacilli and enzymes) and a solution of micronutrients (Fe, Co, Ni and Mo) were tried separately and in combination, in order to assess their effect on the anaerobic digestion of waste sludge from an enhanced primary treatment (EPT) of municipal wastewater. Three batch tests were carried out in serological bottles. In the first test, addition of bacilli increased production of methane from day 11 and at day 1 7 the production was 95% greater than the control. In that experiment, the concentration of volatile fatty acids (VFAs) was 1,391 mg/L, 40% lower than the control. In the second test, the combination of micronutrients with bacilli, reached from the first days a better methane production than the control, 167% higher in day 17. At the end of the experiment, this combination achieved a lower concentration of VFAs and a greater percentage of volatile solid removal than the rest of the treatments. The third test was based on an experimental design in order to statistically determine the best doses of bacilli additive and micronutrients. The anaerobic thermophilic digestion of sludge from aluminium sulfate EPT will be improved with the addition of Fe: 4.5 mg/g VS, Ni: 0.75 mg/g VS, Co: 0.45 mg/g VS, Mo: 0.09 mg/g VS and bacilli additive: 12 mg/g VS.     

Effect of feed/inoculum ratio on anaerobic digestion of sonicated sludge.

In recent years, relevant interest has been devoted to activated sludge disintegration and solubilisation techniques in order to cope with the biological limitations related to particulate degradation. Mechanical disintegration with ultrasound can efficiently transform insoluble organics into a soluble form: the solubilised organic matter is released from the cells to the bulk phase, thus accelerating the hydrolysis step in the digestion process. Experiments were carried out on bench scale anaerobic reactors fed with either untreated or disintegrated excess sludge, added with a biomass inoculum taken from a full scale anaerobic digester. Digestion tests have been carried out at different feed/inoculum ratios (F/I) in the range of 0.1-2, kinetics of VS reduction has been investigated and a beneficial effect of sonication is observed for all the experimental conditions. Similar beneficial results have also been found for biogas production with a maximum gain of 25% at 0.5 F/I ratio.     

Two-stage thermophilic-mesophilic anaerobic digestion of waste activated sludge from a biological nutrient removal plant.

A two-stage thermophilic-mesophilic anaerobic digestion pilot-plant was operated solely on waste activated sludge (WAS) from a biological nutrient removal (BNR) plant. The first-stage thermophilic reactor (HRT 2 days) was operated at 47, 54 and 60 degrees C. The second-stage mesophilic digester (HRT 15 days) was held at a constant temperature of 36-37 degrees C. For comparison with a single-stage mesophilic process, the mesophilic digester was also operated separately with an HRT of 17 days and temperature of 36-37 degrees C. The results showed a truly thermophilic stage (60 degrees C) was essential to achieve good WAS degradation. The lower thermophilic temperatures examined did not offer advantages over single-stage mesophilic treatment in terms of COD and VS removal. At a thermophilic temperature of 60 degrees C, the plant achieved 35% VS reduction, representing a 46% increase compared to the single-stage mesophilic digester. This is a significant level of degradation which could make such a process viable in situations where there is no primary sludge generated. The fate of the biologically stored phosphorus in this BNR sludge was also investigated. Over 80% of the incoming phosphorus remained bound up with the solids and was not released into solution during the WAS digestion. Therefore only a small fraction of phosphorus would be recycled to the main treatment plant with the dewatering stream.     

Reduction of sludge production from WWTP using thermal pretreatment and enhanced anaerobic methanisation.

The objective of the study presented here was to investigate the performance of an enhanced two-step anaerobic process for the treatment of WWTP sludge. This process was developed to answer the urgent need currently faced by WWTP operators to reduce the production of biosolids, for which disposal pathways are facing increasing difficulties. A pilot plant was operated on a full-scale WWTP (2,500 p.e.) over a period of 4 months. It consisted of a thermal pre-treatment of excess sludge at 175 degrees C and 40 min, followed by dewatering and methanisation of the centrate in a fixed-film reactor. The thermal lysis had a two-fold enhancing effect on sludge reduction efficiency: firstly, it allowed a decrease of the HRT in the methaniser to 2.9 days and secondly, it yielded biosolids with a high dewaterability. This contributed to further reductions in the final volume of sludge to be disposed of. The two-step process achieved a sludge reduction efficiency of 65% as TSS, thus giving an interesting treatment option for WWTP facing sludge disposal problems.     

Analysis of microbial community structure and diversity in the thermophilic anaerobic digestion of waste activated sludge.

The microbial community structures in the thermophilic anaerobic digestion (TAD) of waste activated sludge (WAS) and WAS were analyzed with molecular biological techniques including real-time polymerase chain reaction (PCR) and cloning. The microbial community of TAD had less diversity than that of WAS, and the sequences obtained in WAS were not present in TAD by the cloning analysis. In the TAD bacterial clone library, 97.5% of total clones were affiliated with the phylum Firmicutes and 73.1% with the genus Coprothermobacter. Real-time PCR and cloning analysis revealed that the number of Methanosarcina thermophila, which is an acetoclastic methanogen, is larger than that of Methanoculleus thermophilus, which is a hydrogenotrophic methanogen, in terms of the numbers of copies of 16S ribosomal DNA (rDNA).     

Effect of low power ultrasound on aerobic/anoxic digestion of activated sludge

The effect of low power ultrasound on aerobic/anoxic digestion of activated sludge was investigated. First, dehydrogenate activity (DHA) and special oxygen uptake rate (SOUR) were detected to indicate the change of biological activity of sludge induced by ultrasound. Single-factor experiments showed that when the ultrasonic frequency was 28 kHz, the optimal ultrasonic density and exposure time were 0.15 W/mL and 10 min, respectively. Through orthogonal tests, the optimal ultrasonic parameters for aerobic/anoxic digestion were found to be a ultrasonic density of 0.15 W/mL, ultrasonic exposure time of 10 min and interval time of 12 h. The aerobic/anoxic digestion was improved by ultrasonic pretreatment, the VSS reduction at the optimal conditions was increased by 35.73%, compared with the control. It can be concluded that low power ultrasonic pretreatment is a valid method for improving aerobic/anoxic biodegradability of activated sludge.     

Membrane-coupled anaerobic digestion of municipal sewage sludge.

Membrane-coupled anaerobic digestion utilizes a concept of simultaneous sludge digestion and thickening. Membranes may successfully be applied to eliminate the need for thickening polymers and avoid their likely inhibitory effect on anaerobic biomass. A 550 L completely mixed anaerobic digester was operated under mesophilic conditions (35 degrees C). Two ultrafiltration membrane systems were evaluated for their potential in membrane-coupled anaerobic digestion: vibrating and cross flow. A volatile solids reduction of 590% was achieved at an average mixed liquor suspended solids concentration of 1.8%. The substrate utilization rate was 1.3 d(-1). The vibrating membrane operated at a flux of 1.6-2.0 m3/m2-d and the tubular membrane fluxes in the range 3.4-3.6 m3/m2-d.     

Ultrasonic sludge treatment for enhanced anaerobic digestion.

Ultrasound is the term used to describe sound energy at frequencies above 20 kHz. High-powered ultrasound can be applied to a waste stream via purpose-designed tools in order to induce cavitation. This effect results in the rupture of cellular material and reduction of particle size in the waste stream, making the cells more amenable to downstream processing. sonix is a new technology utilising high-powered, concentrated ultrasound for conditioning sludges prior to further treatment. This paper presents recent results from a number of demonstration and full-scale plants treating thickened waste activated sludge (TWAS) prior to anaerobic digestion, therefore enhancing the process. The present studies have proved that the use of ultrasound to enhance anaerobic digestion can be achieved at full scale and effectively result in the TWAS (typically difficult to digest) behaving, after sonication, as if it were a "primary" sludge. The technology presents benefits in terms of increased biogas production, better solids reduction, improved dewatering characteristics of the digested sludge mixture and relatively short payback periods of two years or less subject to the site conditions and practices applicable at that time.     

Impact of sludge thickening on energy recovery from anaerobic digestion.

This paper presents energy balances for various digestion systems, which include single mesophilic digestion, single thermophilic digestion, two-stage thermophilic-mesophilic digestion system and systems at elevated solids content in sludge. On the basis of a sludge flow containing 30 tons TS/day (equivalent to a 100 ML/d WWTP plant) it was shown that a two-stage thermophilic-mesophilic digestion system generated more available energy than single mesophilic digestion and single thermophilic digestion systems. Sludge thickening offered the greatest amount of available energy; however that energy surplus was offset by the cost of thickening. After the cost of thickening was converted into equivalent energy units it was shown that the price of energy is important in calculation of equivalent energy units related to operation of the thickening plant. Sludge thickening may be beneficial from energy view point compared to conventional mesophilic digestion when price of energy exceeds dollars 0.08 CAN kW-hr.     

Application of the IWA anaerobic digestion model (ADM1) for simulating full-scale anaerobic sewage sludge digestion.

A steady-state implementation of the IWA Anaerobic Digestion Model No. 1 (ADM1) has been applied to the anaerobic digesters in two wastewater treatment plants. The two plants have a wastewater treatment capacity of 76,000 and 820,000 m3/day, respectively, with approximately 12 and 205 dry metric tons sludge fed to digesters per day. The main purpose of this study is to compare the ADM1 model results with full-scale anaerobic digestion performance. For both plants, the prediction of the steady-state ADM1 implementation using the suggested physico-chemical and biochemical parameter values was able to reflect the results from the actual digester operations to a reasonable degree of accuracy on all parameters. The predicted total solids (TS) and volatile solids (VS) concentration in the digested biosolids, as well as the digester volatile solids destruction (VSD), biogas production and biogas yield are within 10% of the actual digester data. This study demonstrated that the ADM1 is a powerful tool for predicting the steady-state behaviour of anaerobic digesters treating sewage sludges. In addition, it showed that the use of a whole wastewater treatment plant simulator for fractionating the digester influent into the ADM1 input parameters was successful.     

Maximising biogas in anaerobic digestion by using engine waste heat for thermal hydrolysis pre-treatment of sludge.

Dublin's Ringsend WWTP was designed to serve a population of approximately 1.2 million p.e. with a sludge production of 37,000 dry tonnes per year after upgrading to full secondary treatment. Several technical solutions were put forward as part of a design, build, finance and operate (DBFO) competition, with the chosen solution being a proposal by Black and Veatch for a combination of sequencing batch reactor (SBR) technology and anaerobic digestion with Cambi thermal hydrolysis pre-treatment (THP). The THP plant was built by Cambi and handed over to B&V in 2002. The plant is now operated by Celtic Anglian Water. In September 2004 a test was carried out on the mass and energy balance of the plant following 2 years of operation and is detailed in this paper. The process enables digestion at very high dry solids feed and low hydraulic retention time. The plant was built with three digesters of 4250 m3 each and is fed with hydrolysed sludge at 11% DS. There are four no. 1 MW Jenbacher engines operating mainly on biogas. Each pair of engines is fitted with a waste heat boiler with a capacity of one tonne steam per hour. These boilers have sufficient capacity to provide 80% of the steam required for the THP, which in turn provides all the heat for the subsequent digestion in the form of hydrolysed feed. There are two main biogas boilers for top up steam and other uses of the biogas including thermal oxidation of concentrated odours.     

Effect of Ce(3+) on soluble microbial products production in anaerobic granular sludge digestion

Upflow anaerobic sludge bed reactors fed on glucose were used to investigate the effects of Ce(3+) on soluble microbial products (SMP) production, which is the majority of the residual chemical oxygen demand present in the effluent. It was found that Ce(3+) concentration of 0.05 mg/L had no significant effect on the amount of SMP production, whereas that of 1 mg/L led to the increase in SMP production. The molecular-weight distribution and carbohydrate analysis indicated that an increase in SMP production may be partly attributed to the release of extracellular polymeric substances (EPS) into the bulk solution resulted from cerium toxicity, and the nucleic acids analysis suggested that increased cell lysis also contributed to SMP accumulation in the presence of Ce(3+). The increase in SMP production in the presence of Ce(3+) is possibly a consequence of the release of EPS and increased cell lysis due to cerium toxicity.     

Minimisation of excess sludge production in a WWTP by coupling thermal hydrolysis and rapid anaerobic digestion.

In many cases, reducing sludge production could be the solution for wastewater treatment plants (WWTP) that here difficulty evacuating the residuals of wastewater treatment. The aim of this study was to test the possibility of minimising the excess sludge production by coupling a thermal hydrolysis stage and an anaerobic digestion with a very short HRT. The tests were carried out on a 2,500 p.e. pilot plant installed on a recycling loop between the clarifier and the actived sludge basin. The line equipped with the full scale pilot plant produced 38% TSS less than the control line during a 10 week period. Moreover, the rapid anaerobic digestion removed, on average, more than 50% of the total COD load with a hydraulic retention time (HRT) of 3 days. Lastly, the dryness of the remaining excess sludge, sanitised by the thermal hydrolysis, was more than 35% with an industrial centrifuge. This combination of thermal hydrolysis and rapid anaerobic digestion equally permits a significant gain of compactness compared to traditional anaerobic digesters.     

大型污泥厌氧消化系统的启动与运行调控

北京小红门污水处理厂建有5座单体容积12 300m3的卵形污泥厌氧消化设施,设计沼气产量30 000m3/d。以运行数据为基础,总结了大型厌氧消化系统的启动、运行与调控经验,分析大型污泥厌氧消化系统的启动与运行特点。提出建议与措施,并提出系统优化的具体目标。     

Effect of H2O2 dose on the thermo-oxidative co-treatment with anaerobic digestion of excess municipal sludge.

Thermo-oxidative treatment, applied at moderate temperatures below the boiling point of water and using hydrogen peroxide as oxidant, has been shown to enhance anaerobic digestion of excess municipal sludge. Due to the high economic impact of chemical addition on the process, a balance between process performance and economic cost has to be established. The effect of three low hydrogen peroxide dosages (0.1, 0.25 and 0.5 gH2O2/gVSSinfluent) applied at 90 degrees C was evaluated. Increases in solids destruction of 13.9, 18.9 and 25.6% with respect to a control were observed when the thermo-oxidative co-treatment was operated at 0.1, 0.25 and 0.5 gH2O2/gVSSinfluent, respectively.     

碱-热法预处理改善污泥厌氧消化性能的试验研究

用传统热化学法(简称同步法)促进污泥水解,将污水厂浓缩污泥预先用NaOH处理24 h,然后再进行热处理(简称碱-热法)。以生物化学甲烷势(BMP)试验后污泥的溶解性化学需氧量(SCOD)去除率和产气量来评价碱-热法预处理对污泥厌氧消化性能的影响。BMP试验结果表明:经碱-热法处理的污泥,SCOD去除率是同步法预处理污泥SCOD去除率的1.06~1.31倍,产气量是同步法预处理污泥产气量的1.08~1.31倍。可见,碱-热法能有效提高污泥中有机物的可生化性,减少厌氧消化后污泥的剩余SCOD浓度,提高生物气产量。     

污水污泥高温与中温厌氧消化对比研究

研究了不同HRT条件下污泥高温(50℃)厌氧消化效果,并与中温(35℃)厌氧消化效果进行对比分析。结果表明,与中温条件相比,高温厌氧消化对有机物的去除率显著提高;高温厌氧消化沼气产量高于中温,但沼气产率差异并不明显(1.13~1.25L/gVS去除);高温和中温厌氧消化系统运行稳定性良好,挥发酸/碱度比值仅为0.02~0.03;高温和中温厌氧消化出泥的毛细吸水时间(CST)均增加,并且高温消化污泥的CST高于中温消化污泥,厌氧消化过程可能导致污泥脱水性能变差。