Combined organic matter and nitrogen removal from a chemical industry wastewater in a two-stage MBBR system

Process innovations and circular strategies for closing the water loop in a process industry

By implementing advanced wastewater treatment technologies coupled with digital tools, high-quality water is produced to be reused within the industry, enhancing process efficiency and closing loops. This paper investigates the impact of three innovation tools (process, circular and digital) in a Solvay chemical plant. Four technologies of the wastewater treatment plant "WAPEREUSE" were deployed, predicting their performance by process modelling and simulation in the PSM Tool. The environmental impact was assessed using Life Cycle Assessment and compared to the impact of the current industrial effluent discharge. The circularity level was assessed through three alternative closed-loop scenarios: (1) conventional treatment and discharge to sea (baseline), (2) conventional and advanced treatment by WAPEREUSE and discharge to sea, (3) conventional and advanced treatment by WAPEREUSE and industrial water reuse through cross-sectorial symbiotic network, where effluents are exchanged among the process industry, municipality and a water utility. Scenario 1 has the lowest pollutants' removal efficiency with environmental footprint of 0.93 mPt/m3. WAPEREUSE technologies decreased COD by 98.3%, TOC by 91.4% and nitrates by 94.5%. Scenario 2 had environmental footprint of 1.12 mPt/m3. The cross-sectorial symbiotic network on the industrial value chain resulted in higher industrial circularity and sustainability level, avoiding effluents discharge. Scenario 3 is selected as the best option with 0.72 mPt per m3, reducing the environmental footprint by 21% and 36% compared to Scenarios 1 and 2, respectively.

Impact of gradually-achieved high phenol loads on the nitrification and COD removal performance of an MBBR fed with synthetic wastewater

Phenol is a noteworthy pollutant, found in effluents of many industrial processes, like oil refining and drugs production, which can impair the treatment efficiency of bioreactors. This study evaluated the performance of phenol, COD, and nitrogen removal of an aerobic bench-scale Moving Bed Biofilm Reactor (MBBR) exposed to gradually increasing phenol content over 233 days. The reactor had Hydraulic Retention Time (HRT) set at 3 h and 40% filling degree (K1 media), and was fed with synthetic wastewater containing phenol (10, 20, 50, 100, 250 and 400 mg/L), glucose (400 mgCOD/L), and 40 mgN-NH3/L. Phenol, COD, and ammoniacal nitrogen removal averages were high - above 88%, 81%, and 82%, respectively -, even when the MBBR was exposed to the greatest phenol loads, indicating that the biofilm was able to acclimate and resist high phenol concentrations. However, the intense EPS production revealed the impact caused by phenol to the biofilm from the concentration of 250 mg/L onwards. Even though, at this concentration, the average removals of COD and phenol were 87.2% and 89.7%. The removal of ammoniacal nitrogen by nitrification was compromised, being 91.6% of the ammoniacal nitrogen removed by assimilation and only 0.35% removed by nitrification. At 400 mg phenol/L, the reactor provided COD and phenol average removals equal 88.6% and 80.9%, respectively. On the last day of operation, the removal of COD dropped to 55.4% and phenol removal was equal 49.0%. Novel microscopical evaluation of the MBBR's biofilm revealed some negative effects of the phenol on the microbiota composition.

A review of ammonia removal using a biofilm-based reactor and its challenges

Extensive growth of industries leads to uncontrolled ammonia releases to environment. This can result in significant degradation of the aquatic ecology as well as significant health concerns for humans. Knowing the mechanism of ammonia elimination is the simplest approach to comprehending it. Ammonia has been commonly converted to less hazardous substances either in the form of nitrate or nitrogen gas. Ammonia has been converted into nitrite by ammonia-oxidizing bacteria and further reduced to nitrate by nitrite-oxidizing bacteria in aerobic conditions. Denitrification takes place in an anoxic phase and nitrate is converted into nitrogen gas. It is challenging to remove ammonia by employing technologies that do not incur particularly high costs. Thus, this review paper is focused on biofilm reactors that utilize the nitrification process. Many research publications and patents on biofilm wastewater treatment have been published. However, only a tiny percentage of these projects are for full-scale applications, and the majority of the work was completed within the last few decades. The physicochemical approaches such as ammonia adsorption, coagulation-flocculation, and membrane separation, as well as conventional biological treatments including activated sludge, microalgae, and bacteria biofilm, are briefly addressed in this review paper. The effectiveness of biofilm reactors in removing ammonia was compared, and the microbes that effectively remove ammonia were thoroughly discussed. Overall, biofilm reactors can remove up to 99.7% ammonia from streams with a concentration in range of 16-900 mg/L. As many challenges were identified for ammonia removal using biofilm at a commercial scale, this study offers future perspectives on how to address the most pressing biofilm issues. This review may also improve our understanding of biofilm technologies for the removal of ammonia as well as polishing unit in wastewater treatment plants for the water reuse and recycling, supporting the circular economy concept.

Optimized Operating Conditions for a Biological Treatment Process of Industrial Residual Process Brine Using a Halophilic Mixed Culture

Residual process brine is a sustainable raw material for chlor-alkali electrolysis processes. This study investigates the influence of critical process parameters on the performance of a continuous treatment process for residual process brine using halophilic microorganisms. The goal of the bioprocess is an efficient degradation of the organic impurities formate, aniline, phenol, and 4,4′-methylenedianline from this residual stream. It was shown that formate could be degraded with high efficiencies (89–98%) during the treatment process. It was observed that formate degradation was influenced by the co-substrate glycerol. The lowest residual formate concentrations were achieved with specific glycerol uptake rates of 8.0–16.0 × 10−3 g L−1 h−1 OD600−1. Moreover, a triple-nutrient limitation for glycerol, ammonium, and phosphate was successfully applied for continuous cultivations. Furthermore, it was shown that all aromatic impurities were degraded with an efficiency of 100%. Ultimately, this study proposed optimized operating conditions, allowing the efficient degradation of organics in the residual process brine under various process conditions. Future optimization steps will require a strategy to prevent the accumulation of potential intermediate degradation products formed at high aniline feed concentrations and increase the liquid dilution rates of the system to achieve a higher throughput of brines.

Treatment of a slaughterhouse wastewater by anoxic-aerobic biological reactors followed by UV-C disinfection and microalgae bioremediation

In this study, removal of organic matter and nitrogen from a cattle slaughterhouse wastewater was investigated in a two-stage anoxic-aerobic biological system, followed by UV-C disinfection. Ecotoxicity of the raw, biotreated, and disinfected wastewater against the microalgae Scenedesmus sp. was evaluated in short-term tests, while the potential of the microalgae as a nutrient removal step was addressed in long-term experiments. Throughout 5 operational phases, the biological system was subjected to gradual reduction of the hydraulic retention time (8-1.5 day), increasing the organic (0.21-1.11 kgCOD·m^-3 ·day^-1 ) and nitrogen (0.05-0.28 kgN·m^-3 · day^-1 ) loading rates. COD and total ammoniacal nitrogen (TAN) removal ranged within 83%-97% and 83%-99%, respectively. While providing alkalinity source, effluent TAN concentrations were below 5 mg·L^-1 . Nitrate was the main nitrification product, while nitrite levels remained low (<1 mgN·L^-1 ). Upon supplementation of external COD as ethanol, total nitrogen removal reached up to 90% at the highest load (0.28 kgN·m^-3 ·day^-1 ). After UV-C treatment, 3-log reduction of total coliforms was attained. The 96-hr ecotoxicity tests showed that all non-diluted samples tested (raw, biologically treated and UV-C irradiated wastewater) were toxic to microalgae. Nevertheless, these organisms were able to acclimate and grow under the imposed conditions, allowing to achieve nitrogen and phosphorous removal up to 99.1% and 43.0%, respectively. PRACTITIONER POINTS: The treatment of a slaughterhouse wastewater in an anoxic-aerobic biological system followed by a UV-C disinfection step was assessed. The pre-denitrification system showed efficient simultaneous removal of organic matter and nitrogen from the wastewater under increasing applied loads. UV-C disinfection worked effectively in reducing coliforms from the biotreated effluent, boosting the performance of microalgae on nutrients removal. Despite the toxicity to microalgae, they were capable to acclimate to the aqueous matrices tested, reducing efficiently the nutrients content. The combined stages of treatment presented great capacity for depleting up to 97% COD, 99% nitrogen, and 43% phosphorous.

Assessing the impact of synthetic estrogen on the microbiome of aerated submerged fixed-film reactors simulating tertiary sewage treatment and isolation of estrogen-degrading consortium

17α-ethinylestradiol (EE2) is a synthetic estrogen that can cause harmful effects on animals, such as male feminization and infertility. However, the impact of the EE2 contamination on microbial communities and the potential role of bacterial strains as bioremediation agents are underexplored. The aim of this work was to evaluate the impact of EE2 on the microbial community dynamics of aerated submerged fixed-film reactors (ASFFR) simulating a polishing step downstream of a secondary sewage treatment. For this purpose, the reactors were fed with a synthetic medium with low COD content (around 50 mg l^-1), supplemented (reactor H) or not (reactor C) with 1 μg l^-1 of EE2. Sludge samples were periodically collected during the bioreactors operation to assess the bacterial profile over time by 16S rRNA gene amplicon sequencing or by bacterial isolation using culture-dependent approach. The results revealed that the most abundant phyla in both reactors were Proteobacteria and Bacteroidetes. At genus level, Chitinophagaceae, Nitrosomonas and Bdellovibrio predominated. Significant effects caused by EE2 treatment and bioreactors operating time were observed by non-metric multidimensional scaling. Therefore, even at low concentrations as 1 μg l^-1, EE2 is capable of influencing the bioreactor microbiome. Culture-dependent methods showed that six bacterial isolates, closely related to Pseudomonas and Acinetobacter genera, could grow on EE2 as the sole carbon source under aerobic conditions. These organisms may potentially be used for the assembly of an EE2-degrading bacterial consortium and further exploited for bioremediation applications, including tertiary sewage treatment to remove hormone-related compounds not metabolized in secondary depuration stages.

Feasibility of applying intermittent aeration and baffles for achieving granular nitritation in a continuous short-cut denitrifying phosphorus removal system

It was difficult to obtain a stable and efficient short-cut denitrification and phosphorus removal process for domestic sewage treatment, therefore, the possibility of using granulation technology of nitritation sludge and intermittent aeration was evaluated to resolve the difficulty. Results showed that the nitrogen and phosphorus removal efficiencies of the system were 72% and 93%, respectively, under the condition of mode 3 (a period of 10 min with aeration 8 min and stop 2 min) with aeration energy consumption decreasing 20%. Microbial community revealed that Rhodocyclales was the dominant short-cut denitrifying phosphorus removing bacteria in the process, closely related to the performance of short-cut denitrifying phosphorus removal. Furthermore, Thauera and Denitratisoma belonging to the Rhodocyclales play a significant role of short-cut denitrifying phosphorus removal in the process. In addition, Aeromonas improved the performance of short-cut denitrifying phosphorus removal. Finally, nutrient removal efficiency was improved 8% in intermittent aeration mode 3 based on short-cut denitrifying phosphorus removal.

Soft Sensor-Based Monitoring and Efficient Control Strategies of Biomass Concentration for Continuous Cultures of Haloferax mediterranei and Their Application to an Industrial Production Chain

Continuous bioprocessing using cell retention allows the achievement of high space-time yields for slow-growing organisms such as halophiles. However, the lack of efficient methods for monitoring and control limits the application of biotechnological processes in the industry. The aim of this study was to implement a control and online monitoring strategy for biomass in continuous cultures. For the first time, a feedforward cultivation strategy in a membrane-based cell retention system allowed to control the biomass concentration of the extreme halophilic Haloferax mediterranei at defined levels. Moreover, soft sensor-based biomass estimation allowed reliable monitoring of biomass online. Application of the combined monitoring and control strategy using industrial process water containing formate, phenol, aniline and 4,4′-methylenedianiline could for the first time demonstrate high throughput degradation in this extremophilic bioremediation process, obtaining degradation efficiencies of up to 100%. This process demonstrates the usefulness of continuous halophilic cultures in a circular economy application.

Modeling and dynamic simulation of a two-stage pre-denitrification MBBR system under increasing organic loading rates

Biofilm-based wastewater treatment systems have become attractive due to their numerous advantages when compared to other suspended growth processes. However, the mathematical modeling of these reactors is relatively complex, since it has to consider a wide range of phenomena to accurately describe the process behavior. This work deals with the modeling of a two-stage MBBR system run in pre-denitrification mode for the removal of organic matter and nitrogen from wastewater. The model development took into account diffusive phenomena and kinetics in a homogeneous biofilm composed of different bacterial functional groups (namely heterotrophs and nitrifiers). The thickness of the biofilm was treated as a variable, given that detachment of adhered biomass took place. The suspended biomass fraction was also considered to remove the pollutants by means of Monod-type kinetics associated with the activated sludge model. The dynamic behavior of the components involved in the system and their spatial distribution in the biofilm obtained from simulated data showed good agreement with those reported in the literature, demonstrating the reproducibility of the model and encouraging future applications in full-scale MBBR plants.