Energy-positive sewage sludge pre-treatment with a novel ultrasonic flatbed reactor at low energy input

Re-flocculation reduces the effectiveness of sewage sludge pretreatment through hydrodynamic disintegration prior to anaerobic digestion

Circular economy model, based on the "make, use, reuse, remake, recycle" approach, is an alternative to progressive depletion of non-renewable fossil fuels. Sewage sludge can be a source of renewable energy obtained through the anaerobic conversion of their organic fraction into biogas. This process is mediated by highly complex microbial communities and its efficiency depends on the availability of substrates to microorganisms. Disintegration of the feedstock in the pre-treatment step may intensify the anaerobic digestion, but re-flocculation of disintegrated sludge (reassembly of the released fractions into larger agglomerates) may result in a reduced availability of the released organic compounds for microbes. Pilot-scale studies on re-flocculation of disintegrated sludge were conducted to select parameters for scaling-up the pre-treatment and intensifying the anaerobic digestion process in two large Polish wastewater treatment plants (WWTPs). Samples of thickened excess sludge from full-scale WWTPs were subjected to hydrodynamic disintegration at three energy density levels of 10 kJ/L, 35 kJ/L and 70 kJ/L. Microscopic analyses of disintegrated sludge samples were carried out twice: i) immediately after the disintegration process at a given energy density level, ii) and after 24-h incubation at 4 °C following the disintegration. Micro-photographs of 30 randomly selected fields of view were taken for each analysed sample. A method of the image analysis was developed as a tool to measure dispersion of sludge flocs to assess the re-flocculation degree. Re-flocculation of the thickened excess sludge occurred within 24 h after hydrodynamic disintegration. This was evidenced by a very high re-flocculation degree, reaching up to 86%, depending on the origin of the sludge and the energy density levels used for the hydrodynamic disintegration.

Stimulating effect of hydrostatic pressure on ultrasonic sewage sludge treatment for COD solubilization and methane production

The performance of ultrasonic treatment was assessed under different hydrostatic pressures for two different waste activated sludges. The impact of pressurized sonication was evaluated based on the degree of disintegration (DD_COD) and the specific methane yield (SMY). An enhancement of DD_COD was observed at an intermediate pressure level (max. 53% at 1.0 bar), but at higher pressure levels (up to 3.5 bar), the enhancement was not as pronounced as for the intermediate ranges (max. 11%). In contrast to DD_COD, SMY increased with increasing pressure for both sludge samples tested (max 17% at 3.5 bar) so that SMY did not show a notable correlation with DD_COD. A positive energy balance (max. 167%) considering the energy input for ultrasonication and the additional methane generated was only achieved in samples treated under elevated hydrostatic pressure. Since this can be achieved with negligible effort, the enhancement can be considered as "methane for free".

Energy-Positive Disintegration of Waste Activated Sludge—Full Scale Study

This study aimed to evaluate the effects of mechanical disintegration of waste activated sludge (WAS) on full scale anaerobic digestion, considering the possibility of obtaining a positive energy balance. The results showed that an increase in energy density (εL) used in disintegration was accompanied by an increase in the release of organic compounds from sludge (SCOD increased from 211 ± 125 mg O2/L for εL = 0 kJ/L to 6292 ± 2860 mgO2/L for εL = 180 kJ/L). Some of them were volatile fatty acids. The percentage share of WAS subject to disintegration was also documented as a crucial parameter affecting the efficiency of biogas production. An increase in the value of this parameter from 25% to 100%, even at much lower εL used in disintegration (therefore with much smaller amounts of organic compounds released from sludge flocs) resulted in an increase in biogas production. Conducting disintegration of the entire stream of WAS directed to the fermentation tank at εL 30 kJ/L resulted in an increase in biogas production by 14.1%. Such a surplus would allow production of approximately 360 kWh/d net electricity. Mechanical disintegration of thickened WAS therefore may be an economically justifiable strategy for the intensification of anaerobic sludge stabilisation.

Cavitation based treatment of industrial wastewater: A critical review focusing on mechanisms, design aspects, operating conditions and application to real effluents

Acoustic cavitation (AC) and hydrodynamic cavitation (HC) coupled with advanced oxidation processes (AOPs) are prominent techniques used for industrial wastewater treatment though most studies have focused on simulated effluents. The present review mainly focuses on the analysis of studies related to real industrial effluent treatment using acoustic and hydrodynamic cavitation operated individually and coupled with H₂O₂, ozone, ultraviolet, Fenton, persulfate and peroxymonosulfate, and other emerging AOPs. The necessity of using optimum loadings of oxidants in the various AOPs for obtaining maximum COD reduction of industrial effluent have been demonstrated. The review also presents critical analysis of designs of various HCRs that have been or can be used for the treatment of industrial effluents. The impact of operating conditions such as dilution, inlet pressure, ultrasonic power, pH, and operating temperature have been also discussed. The economic aspects of the industrial effluent treatment have been analyzed. HC can be considered as cost-efficient approach compared to AC on the basis of the lower operating costs and better transfer efficiencies. Overall, HC combined with AOPs appears to be an effective treatment strategy that can be successfully implemented at industrial-scale of operation.

Sonoprocessing: From Concepts to Large-Scale Reactors

Intensification of ultrasonic processes for diversified applications, including environmental remediation, extractions, food processes, and synthesis of materials, has received attention from the scientific community and industry. The mechanistic pathways involved in intensification of ultrasonic processes that include the ultrasonic generation of cavitation bubbles, radical formation upon their collapse, and the possibility of fine-tuning operating parameters for specific applications are all well documented in the literature. However, the scale-up of ultrasonic processes with large-scale sonochemical reactors for industrial applications remains a challenge. In this context, this review provides a complete overview of the current understanding of the role of operating parameters and reactor configuration on the sonochemical processes. Experimental and theoretical techniques to characterize the intensity and distribution of cavitation activity within sonoreactors are compared. Classes of laboratory and large-scale sonoreactors are reviewed, highlighting recent advances in batch and flow-through reactors. Finally, examples of large-scale sonoprocessing applications have been reviewed, discussing the major scale-up and sustainability challenges.

How to assess the efficiency of the agro waste disintegration process

The objective of the study was to verify whether the method of determining the efficiency of sewage sludge disintegration, i.e. the disintegration degree (DD), can also be used to assess agro-waste disintegration. The following types of agro waste were tested: remains of fruits, sugar beet pulp and sugar beet pulp in the form of pellets. It was shown that DD as used for sewage sludge can also be a useful tool in assessing the disintegration efficiency of agro waste, although it requires the following modifications: (a) a methodology of chemical hydrolysis for each type of agro waste in order to determine the total amount of soluble COD (SCOD) that can be released from the sample and (b) possible changes in the SCOD value that may occur in the sample left in ambient conditions for a time period corresponding to the duration of the disintegration process. DD of agro waste determined according to the formula adopted for sewage sludge resulted in a considerable overestimation of the value in comparison to the formula proposed by the authors, i.e. DD determined for an energy density of 35 kJ L^-1 was higher by 55.9 ± 21.5%, and for an energy density of 140 kJ L^-1 it was higher by as much as 73.8 ± 28.1%. Taking into account the differences in the determined disintegration degree values that result from the methodology of conducting the chemical hydrolysis, it is recommended, in order to assess the efficiency of disintegration of agro waste, to use the efficiency of organic compound release.

Effects of CO2 enrichment on the anaerobic digestion of sewage sludge in continuously operated fermenters

The effect of CO₂ enrichment in sewage sludge anaerobic digestion (AD) as a potential strategy to improve the biogas yield was assessed at increasing organic loading rates (OLR). Effects on process performance and resilience were evaluated in long-term continuous AD experiments at lab-scale. The specific methane production (SMP) was sustainably enhanced in the test digester compared to a control at elevated OLRs, reaching an increase of 6 ± 12% on average at the highest OLR tested (4.0 kg_VS/(m³·d)). The reduction of CO₂ via homoacetogenesis, facilitating acetoclastic CH₄ formation is proposed as the dominant conversion pathway. Results suggest that sufficient load of easily degradable substances is a prerequisite for intrinsic formation of the reduction equivalent H₂ via acidogenesis. The enhanced resilience of the process under CO₂-enriched conditions in response to acid accumulation further qualifies this approach as a viable option for improving AD performance by converting a waste stream into a valuable product.

Effects of ultrasonic reactor design on sewage sludge disintegration

The impact of ultrasound (US) reactor design on cavitation intensity distribution and disintegration efficiency was studied for sewage sludge pre-treatment, using a US flatbed reactor of variable reaction chamber height (RCH, 20-100 mm). Mapping of cavitation intensity and treatment effects was conducted using (i) hydrophone measurements, (ii) aluminum foil tests, and (iii) soluble chemical oxygen demand (COD) analyses. The overall disintegration efficiency was evaluated based on average COD solubilization. The impact of flow on treatment (in)homogeneity was additionally examined using computational fluid dynamics (CFD). Results of all measurement techniques suggest that small RCHs (20 mm, for instance) enable uniform and intense treatments, while large RCHs, which are subjected to strong sound wave attenuation, entail inhomogeneous treatments where large fractions of substrate are no longer exposed to notable cavitation activity. For instance, COD solubilization (relative to alkaline hydrolysis) measured in the channel center dropped from 6.4% to zero as RCH widened from 20 mm to 100 mm. Flow-through sonication further aggravates treatment inhomogeneity due to the high flow rates in the low-cavitation channel centers. Overall disintegration efficiency declined with increasing RCH, showing a drop in average COD solubilization by 73% from RCH = 20 mm to RCH = 100 mm. The drop correlated with average cavitation noise levels (R² = 0.82), indicating that hydrophone measurements may be a suitable tool for US reactor design optimization. Overall, results suggest that reactor geometry has a critical impact on both treatment (in)homogeneity and treatment efficiency and that equal specific energy inputs do not imply equal US treatments.

Measurement of Biochemical Methane Potential of Heterogeneous Solid Substrates: Results of a Two-Phase French Inter-Laboratory Study

Biochemical methane potential (BMP) is essential to determine the production of methane for various substrates; literature shows important discrepancies for the same substrates. In this paper, a harmonized BMP protocol was developed and tested with two phases of BMP tests carried out by eleven French laboratories. Surprisingly, for the three same solid tested substrates (straw; raw mix and dried-shredded mix of potatoes, maize, beef meat and straw; and mayonnaise), the standard deviations of the repeatability and reproducibility inter-laboratory were not enhanced by the harmonized protocol (average of about 25% depending on the substrate), as compared to a previous step where all laboratories used their own protocols. Moreover, statistical analyses of all the results, after removal of the outliers (about 15% of all observations), did not highlight significant effect of the operational effect on BMP (stirring, automatic or manual gas quantification, use of trace metal, uses a bicarbonate buffer, inoculum to substrate ratio) at least for the tested ranges. On the other hand, the average intra-laboratory repeatability was low, about 7%, whatever the protocol, the substrate and the laboratory. It also appears that drying the SA substrate, which contained proteins, carbohydrates, lipids and fibers, does not impact its BMP.

Reactional ultrasonic systems and microwave irradiation for pretreatment of agro-industrial waste to increase enzymatic activity

Pretreatment of keratinous residues using an ultrasonic reaction system provides greater enzymatic production in less time. This is a promising technology for measuring enzyme activity and microwave processes. In the present work, an ultrasonic probe reaction system was used to evaluate the potential of swine hair pretreatment. The pretreated material was submerged with non-pretreated residues for 9 days to obtain the enzyme. Enzyme activity was measured in the extracts obtained using the ultrasonic probe, ultrasonic bath, and microwave. We also used the enzymatic concentration technique with NaCl and acetone. Homemade enzymatic extracts were evaluated for their ability to degrade swine hair and chicken feathers by comparing them with the activities commercial enzymes. Macrobeads gave greater energy dissipation in less time, providing greater enzyme activity (50.8 U/mL over 3 days). In terms of waste degradation, non-pretreated swine hair was more promising. The ultrasonic probe reaction system had the potential to evaluate increased enzyme activity (38.4% relative activity) and the enzyme concentration increased activity by 53.5%. The homemade enzymatic extract showed promise for degradation of keratinous residues.

Pre-treatment Strategies for Value Addition in Poultry Litter

We studied different pre-treatments of poultry litter aiming to add economic value to this residue. Strategies were applied to extract ammonium nitrogen with the aim of allowing its further use as fertilizer, and to promote the hydrolysis and solubilization of lignocellulosic components with the aim of facilitating its subsequent conversion to biogas. Ammonia extraction was performed by solubilization in water in a one-step process and by successive extraction steps (3 times 60 min). Successive extractions presented greater removal of total ammonia nitrogen than did one-step extraction, solubilizing about 36% of the ammonia in water. In parallel pre-treatment using ultrasound was performed to increase carbon bioavailability for anaerobic digestion. Using this tool, 24.7 g kg⁻¹ of total organic carbon and 13.0 g kg⁻¹ of total reducing sugars were solubilized, employing 10% dry mass sample amount, 100% amplitude ultrasound at frequency of 20 kHz amplitude and 2.5 min of treatment (energy input of 299 ± 7 kJ L⁻¹; 3,822 ± 95 kJ kg⁻¹). Anaerobic digestion of ultrassound pre-treated biomass was evaluated using a biological biogas production assay, and an increase of 10% of biogas production was obtained compared to untreated samples (147.9 and 163.0 mL g⁻¹ for crude and pre-treated PL, respectively). The findings suggest that these are environmentally friendly and sustainable strategies to add economic value to poultry litter, reducing the environmental impacts of improper disposal.

Assessment of sonotrode and tube reactors for ultrasonic pre-treatment of two different sewage sludge types

The effectiveness of tube and sonotrode reactors for the sonication of sewage sludge under identical conditions was compared for the first time. Despite the considerable structural differences, sonication with each ultrasonic reactor led to an accelerated degradation rate and an increased methane production within the first five days for the majority of the sewage sludge samples tested. On closer examination, however, it becomes clear that the investigated sonication systems are not equally suitable for the substrates considered. While the use of a sonotrode proved to be particularly advantageous for the treatment of waste activated sludge (+25% methane yield at 300 kJ/kg_TS), the use of a 2-inch tube reactor achieved the highest enhancement for low-intensity sonication in digested sludge (+22% methane yield at 300 kJ/kg_TS). With increasing energy input, more chemical oxygen demand was solubilized, but this did not result in an increase in methane yield for all samples. Sonication of waste activated sludge led to a significant reduction in viscosity of up to 50%, and a reduction of up to 60% was observed after sonication of digested sludge with low energy inputs. The study, therefore, demonstrates that the choice of the most suitable sonication system essentially depends on the properties of the sludge to be sonicated.

Effect of hydrodynamic disintegration on the solubilisation and bioavailability of thickened excess sludge

The main objective of the study was the verification whether conducting the hydrodynamic disintegration (HD) of thickened excess sludge (TES) before the anaerobic hydrolysis (AH) can cause an increase in the efficiency of the hydrolysis process, and therefore a reduction in its duration, or allow for complete omission of the stage before the anaerobic digestion (AD). For this purpose, the HD (conducted in five levels of energy density (E_L): 140, 280, 420, 560 and 700 kJ/L) of TES was carried out, and then all sludges (before and after disintegration) were subjected to the AH. The obtained results confirmed that the process of HD can be an effective method of increasing the solubilisation and bioavailability of TES. In the process of HD, the maximum increase in ΔVFA (308-428 mg VFA/L), was reported when E_L was increased from 140 to 280 kJ/L (the solubilisation degree increased from approximately 2 to 8%). The obtained results also showed that the ΔSTN and ΔSTP were related to solubilisation degree. The most intensive increase in the ΔSTN was determined for solubilisation degree in a range of 15-20%. In the case of ΔSTP, constant intensity of release of the compounds to the sludge liquid was observed. The obtained results also confirmed that conducting the process of AH of disintegrated TES proved to change the SCOD value when contrasted with the value of this indicator at the start of the experiment (before hydrolysis): (i) the E_L equal to 140 and 280 kJ/L allowed for a higher SCOD value; (ii) at E_L higher or equal to 560 kJ/L it caused a decrease in the SCOD value.

Effects of Thickened Excess Sludge Pre-Treatment Using Hydrodynamic Cavitation for Anaerobic Digestion

The main purpose of this study was the assessment of the possibility of increasing the production of biogas through the pre-treatment of thickened excess sludge (TES) by means of the hydrodynamic cavitation (HC) conducted at different levels of energy density (EL) i.e., 70, 140 and 210 kJ/L. The experiments were performed on a pilot scale, and a mixture of thickened primary sludge (TPS) and TES was used as digester feed. The results documented that an important parameter determining the possibility of obtaining an enhanced methane production is the value of energy input in the HC process. This parameter determines the changes occurring in sludge as a result of disintegration (i.e., sludge floc deagglomeration, lysis of cells, re-flocculation process and the related release of compounds susceptible to biodegradation from sludge flocs). The maximum increase in methane yield (MY) of 152% was obtained for EL = 140 kJ/L. In this case, HC mainly caused sludge floc deagglomeration. An increase in MY was also recorded when TES was subject to the disintegration process at EL = 210 kJ/L. However, it was 4.3 times lower than that observed for EL = 140 kJ/L. Pre-treatment of TES at EL = 70 kJ/L did not contribute to an increase in methane production.

Removal of heavy metals from leaching effluents of sewage sludge via supported liquid membranes

Heavy metal content of sewage sludge is one of the factors preventing its agricultural use. Leaching processes have been used to solubilize heavy metals and thus reduce metal content of the sludge through chemical or biological routes. Subsequent to leaching processes, metal removal from the supernatant is attractive in terms of decreasing metal content of the effluent and recovering metals. This paper investigates application of supported liquid membrane (SLM) technology for metal removal from leaching effluents. SLM system was first optimized using synthetic metal mixtures. Optimized system was then used for the anaerobic bioleaching and chemical leaching effluents and metal removal efficiencies of 27.1 ± 1.3% and 46.0 ± 4.3% were obtained, respectively. Considering integrated leaching and membrane separation processes, metal removal efficiencies obtained in this study are valuable as it will decrease the metal content of sludge and increase the metal solubilization during leaching process. Future integration of metal leaching and removal technologies would make it possible to develop a sustainable system involving heavy metal removal from sewage sludge, land application of the sludge with a low metal content, and metal recovery.

Impact of ultrasound-induced cavitation on the fluid dynamics of water and sewage sludge in ultrasonic flatbed reactors

The fluid dynamics of water, thickened waste activated sludge (WAS, total solids concentration 4.4%) and digested sludge (DS, total solids concentration 2.5%) within a lab-scale ultrasonic flatbed reactor were experimentally investigated. For a visual observation of the opaque sludge flow, sewage sludges were approximated by transparent xanthan solutions with identical flow behavior. The visualization of the flow was realized by use of an ultrasonic reactor with a transparent panel and dye streams injected into the flow. Without ultrasonic treatment, xanthan solutions showed distinct laminar flow behavior (generalized Reynolds numbers < 1), at a flow rate of 100 L/h. In water, dye streams remained coherent as well, but with slightly unsteady features (Reynolds number ∼ 350). Activation of the ultrasound reactor caused strong fluid dynamic disturbance in the water flow and dye streams were dissolved instantly, thus indicating turbulent mixing. For the xanthan solutions, however, mixing was considerably less pronounced. The dye streams in the DS substitute (0.5% xanthan solution) remained overall in laminar shape, but exhibited an eruption-like branching and an increase in diameter with advancing treatment duration. For the solution resembling WAS (2.0% xanthan solution), only weak dye stream disruption was observed, thus indicating that WAS flow in flatbed reactors is nearly laminar during ultrasonic treatment.

Basic and procedural requirements for energy potential from biogas of sewage treatment plants

The objective of this study is to evaluate the potential for electricity generation in the State of São Paulo (SP) from the sewage treatment. A sewage treatment plant (STP) with domain in the production of biogas from wastewater treatment plant (WWTP) is the basis for this case study. The basic premise is that the very generation of electricity in STPs is advantageous for companies in the sanitation sector in Brazil, resulting in cost reductions of the treatment process. Gains at the end of the process are found in two levels, namely: (i) economic, by generating 165% of electricity from biogas burning in relation to the expend; (ii) energy, by adding a new sustainable and storable energy source equivalent to 4% of natural gas offered in the State of SP and 0,5% of electricity produced from biogas burning in relation to electricity consumption. In conclusion, the potential of electricity production linked to the biogas at STPs is capable of supply its domestic demand and export the surplus to other segments of the state and national economy.

Nanoferrosonication: A novel strategy for intensifying the methanogenic process in sewage sludge

In this work, the effect of coupling ultrasonic pretreatment with dosing of zero-valent iron nanoparticles (nanoferrosonication, "NFS") to improve the anaerobic digestion of sewage sludge was studied. Biochemical methane potential tests were conducted at 15,000 and 25,000 kJ/kg_TS and their combinations with 2 and 7 mgFe⁰/g_VS. The biogas yield increased from 106 (control) to 143 (25,000 kJ/kg_TS) and 308 mL/g_VS with NFS (7 mgFe⁰/g_VS + 15,000 kJ/kg_TS). The methane content increased from 55.6 to 66%, and the maximum VS removal was 11.5% at 7 mgFe⁰/g_VS + 15,000 kJ/kg_TS. The results demonstrated that NFS was effective in intensifying the process.

The Effects of Ultrasonic Disintegration as a Function of Waste Activated Sludge Characteristics and Technical Conditions of Conducting the Process-Comprehensive Analysis

A comprehensive analysis of the effects obtained in the process of ultrasonic disintegration (UD) of waste activated sludge (WAS), was conducted. Sludge samples were collected periodically from Central Wastewater Treatment Plant (WWTP) in Gliwice (Poland) and disintegrated in the two ultrasonic devices of different construction and technical parameters, i.e., WK-2010 (A) and ultrasonic washer (B). The experiments were performed under a constant energy supply per sludge volume E_V = 160 kWh·m⁻³. The direct and technological effects, i.e., after UD and anaerobic digestion (AD) were investigated, respectively. Statistical analysis showed that characteristics and parameters of the WAS, which affects the magnitude of the direct effects create the following sequence: TS (total solids), VS (volatile solids), ΔT (temperature increase) > EPS (extracellular polymeric substances) > SCOD (soluble chemical oxygen demand) > CST (capillary suction time) > N_{TOT (}total nitrogen), P_TOT (total phosphorus) > pH. Whereas, in the case of technological effects, the above sequence was as follows: TS, VS > CST > N_TOT, P_TOT > pH. Ultrasonic disintegration of WAS prior to AD increased total biogas production (from 13.0% to 19.7%) and reduced the content of TS (from 4.1% to 8.2%) and VS (5.8% to 9.5%) in comparison to the control sample. This confirms the usefulness of ultrasonic disintegration as an effective method of sludge digestion intensification. The obtained results showed that changes in the characteristics of WAS have a significant impact on the magnitude of the effects of ultrasonic disintegration, especially TS, VS, ΔT, EPS, SCOD and CST. Concluding, it can be inferred that the most promising conditions for ultrasonic pretreatment conducted under constant energy supply per sludge volume, are: low power, long sonication time, large surface area of the emitter, and high increase of sludge temperature while conducting the process.