Colloidal Chemistry in Water Treatment: The Effect of Ca2+ on the Interaction between Humic Acid and Poly(diallyldimethylammonium chloride) (PDADMAC)

The complexation of humic acid (HA), as a major component of natural organic matter (NOM) in raw water, with polycations is a key step in the water treatment process. At sufficiently high addition of a polycation, it leads to neutralization of the formed complexes and precipitation. In this work, we studied the effect of the presence of Ca2+ ions on this process, with poly(diallyldimethylammonium chloride) (PDADMAC) as a polycation. This was done by determining the phase behavior and characterizing the structures in solution by light scattering and small-angle neutron scattering (SANS). We observe that with increasing Ca2+ concentration, the phase boundaries of the precipitation region shift to a lower PDADMAC concentration, which coincides well with a shift of the ζ-potential of the aggregates in solution. Light scattering shows the formation of aggregates of a 120-150 nm radius, and SANS shows that Ca2+ addition promotes a compaction in the size range of 10-50 nm within these aggregates. This agrees well with the observation of more densely packed precipitates by confocal microscopy in the presence of Ca2+. Following the precipitation kinetics by turbidimetry shows a marked speeding up of the process already in the presence of rather small Ca2+ concentrations of 1 mg/L. It can be stated that the presence of Ca2+ during the complexation process of HA with a polycation has a marked effect on phase behavior and precipitation kinetics of the formed aggregates. In general, the presence of Ca2+ facilitates the process largely already at rather low concentrations, and this appears to be linked to a compaction of the formed structures in the mesoscopic size range of about 10-50 nm. These findings should be of significant importance for tailoring the flocculation process in water treatment, which is a highly important process in delivering drinking water of sufficient quality to humans.

Forecasting and Optimizing Dual Media Filter Performance via Machine Learning

Four different machine learning algorithms, including Decision Tree (DT), Random Forest (RF), Multivariable Linear Regression (MLR), Support Vector Regressions (SVR), and Gaussian Process Regressions (GPR), were applied to predict the performance of a multi-media filter operating as a function of raw water quality and plant operating variables. The models were trained using data collected over a seven year period covering water quality and operating variables, including true colour, turbidity, plant flow, and chemical dose for chlorine, KMnO₄, FeCl₃, and Cationic Polymer (PolyDADMAC). The machine learning algorithms have shown that the best prediction is at a 1-day time lag between input variables and unit filter run volume (UFRV). Furthermore, the RF algorithm with grid search using the input metrics mentioned above with a 1-day time lag has provided the highest reliability in predicting UFRV with a RMSE and R² of 31.58 and 0.98, respectively. Similarly, RF with grid search has shown the shortest training time, prediction accuracy, and forecasting events using a ROC-AUC curve analysis (AUC over 0.8) in extreme wet weather events. Therefore, Random Forest with grid search and a 1-day time lag is an effective and robust machine learning algorithm that can predict the filter performance to aid water treatment operators in their decision makings by providing real-time warning of the potential turbidity breakthrough from the filters.

Characterizing concrete corrosion below sewer tidal levels at chemically dosed locations

Unexplainable concrete softening below the water line has been observed by Sydney Water in their gravity sewer network, some of which is subjected to corrosion control methods using chemical ferrous chloride (FeCl₂) dosing of the wastewater. We applied a combination of physical and chemical tools to determine the properties of the top 20 mm of concrete cores recovered from sewer pipes. These techniques consist of neutron tomographic imaging, scanning electron microscopy, hardness mapping, and pH profiling. Concrete cores were collected from roof (crown), tidal (wall) and below flow regions of gravity sewer pipes of Sydney Water's wastewater system from locations that received no treatment as well as locations dosed with FeCl₂. All samples showed a degree of softening of the surface exposed to the sewerage with an associated depletion in calcium concentration and reduced pH in the same regions.

Effective Separation of CO2 Using Metal-Incorporated rGO Membranes

Graphene-based materials, primarily graphene oxide (GO), have shown excellent separation and purification characteristics. Precise molecular sieving is potentially possible using graphene oxide-based membranes, if the porosity can be matched with the kinetic diameters of the gas molecules, which is possible via the tuning of graphene oxide interlayer spacing to take advantage of gas species interactions with graphene oxide channels. Here, highly effective separation of gases from their mixtures by using uniquely tailored porosity in mildly reduced graphene oxide (rGO) based membranes is reported. The gas permeation experiments, adsorption measurement, and density functional theory calculations show that this membrane preparation method allows tuning the selectivity for targeted molecules via the intercalation of specific transition metal ions. In particular, rGO membranes intercalated with Fe ions that offer ordered porosity, show excellent reproducible N₂ /CO₂ selectivity of ≈97 at 110 mbar, which is an unprecedented value for graphene-based membranes. By exploring the impact of Fe intercalated rGO membranes, it is revealed that the increasing transmembrane pressure leads to a transition of N₂ diffusion mode from Maxwell-Stefan type to Knudsen type. This study will lead to new avenues for the applications of graphene for efficiently separating CO₂ from N₂ and other gases.

Application of a novel molecular technique to characterise the effect of settling on microbial community composition of activated sludge

Activated sludge (AS) and return activated sludge (RAS) microbial communities from three full-scale municipal wastewater treatment plants (denoted plant A, B and C) were compared to assess the impact of sludge settling (i.e. gravity thickening in the clarifier) and profile microorganisms responsible for nutrient removal and reactor foaming. The results show that all three plants were dominated with microbes in the phyla of Proteobacteria, Bacteroidetes, Verrucomicrobia, Actinobacteria, Chloroflexi, Firmicutes, Nitrospirae, Spirochaetae, Acidobacteria and Saccharibacteria. AS and RAS shared above 80% similarity in the microbial community composition, indicating that sludge thickening does not significantly alter the microbial composition. Autotrophic and heterotrophic nitrifiers were present in the AS. However, the abundance of autotrophic nitrifiers was significantly lower than that of the heterotrophic nitrifiers. Thus, ammonium removal at these plants was achieved mostly by heterotrophic nitrification. Microbes that can cause foaming were at 3.2% abundance, and this result is well corroborated with occasional aerobic biological reactor foaming. By contrast, these microbes were not abundant (<2.1%) at plant A and C, where aerobic biological reactor foaming has not been reported.

Long-term hyperalgesia and traumatic neuroma formation in tail-docked lambs

This study aimed to determine if tail-docking induces long-term hyperalgesia, chronic pain and histopathological changes in tail stumps of tail-docked lambs. Fifty male lambs of 45 days of age were randomly allocated in two groups. One group of 25 lambs was tail-docked using a hot cautery iron and a second group of 25 lambs was subjected only to handling as a control group (undocked lambs). Prior to tail-docking and at intervals of 15, 30, 60 and 90 days after the procedure, infra-red thermography (IT) and mechanical nociceptive thresholds (MNTs) tests were carried out in both lambs' tails/stumps, and animals were weighed. In addition, the visual degree of inflammation of tail stumps was evaluated. Finally, animals were slaughtered in a commercial slaughterhouse and tail sections of ten lambs from each group were examined histopathologically. Tail-docking was associated with an inflammatory process according to IT and visual observation in tail stumps at 15 and 30 days post-docking. Tail-docked lambs had lower MNTs than undocked lambs at all evaluated times after tail-docking, indicating the presence of long-term hyperalgesia. Also, traumatic neuroma formation was found in tail stumps of 2/10 tail-docked lambs, and 6/10 presented neuromatous tissue development. It is concluded that tail-docking induces acute and chronic pain in lambs, initially through inflammation, and then via long-term hyperalgesia and traumatic neuroma formation. These long-term findings would have negative implications for the animal welfare of tail-docked lambs.

Impacts of mixing on foaming, methane production, stratification and microbial community in full-scale anaerobic co-digestion process

This study investigated the impact of mixing on key factors including foaming, substrate stratification, methane production and microbial community in three full scale anaerobic digesters. Digester foaming was observed at one plant that co-digested sewage sludge and food waste, and was operated without mixing. The lack of mixing led to uneven distribution of total chemical oxygen demand (tCOD) and volatile solid (VS) as well as methane production within the digester. 16S rRNA gene-based community analysis clearly differentiated the microbial community from the top and bottom. By contrast, foaming and substrate stratification were not observed at the other two plants with internal circulation mixing. The abundance of methanogens (Methanomicrobia) at the top was about four times higher than at the bottom, correlating to much higher methane production from the top verified by ex-situ biomethane assay, causing foaming. This result is consistent with foaming potential assessment of digestate samples from the digester.

Claw horn lesions in mid-lactation primiparous dairy cows under pasture-based systems: Association with behavioral and metabolic changes around calving

The objectives of this study were to describe the lying behavior of primiparous dairy cows under pasture-based systems during the pre- and postcalving period and characterize the association of lying behavior and analytes related to energy metabolism during this period with claw horn disruption lesion development later in lactation. Our convenience sample included 39 primiparous Holstein cows from 3 commercial farms that were assessed for body condition score (BCS; 5-point scale, 0.25-point increments) and had blood collected at wk -3, -2, -1, 1, 2, and 3 relative to calving date. Blood samples were assayed for nonesterified fatty acids, β-hydroxybutyrate (BHB), and cholesterol concentrations. Electronic data loggers (HOBO Pendant G Acceleration, Onset Computer Corporation, Bourne, MA) recorded lying behavior at 1-min intervals from 3 wk before calving to 3 wk after calving. Starting at 4 wk after calving and until 16 wk after calving, cows were examined for claw lesions at approximately 4-wk intervals. Sole lesions and white line lesions were scored on a 0 to 10 scale. Of the 39 primiparous cows, 19 cows scored 0 at all exams during the entire study period and 20 cows had at least 1 severe lesion (score ≥4) between 8 and 16 wk after calving. Time spent lying before calving averaged 10.3 ± 0.3 h/d, but declined to 7.3 ± 0.3 h/d after calving (least squares means ± standard error). At calving, we noted an increase in the number of lying bouts (12.9 ± 0.45 bouts/d) compared with the pre- and postcalving averages of 11.6 (±0.53) and 9.1 (±0.47) bouts, respectively. Cows that developed claw lesions later in mid lactation spent less time lying down than cows without lesions during wk 3 after calving compared with healthy cows (7.29 ± 0.22 vs. 8.51 ± 0.16 h/d). Lesion cows had fewer lying bouts per day, and these bouts were of longer duration than no-lesion cows after calving. Increased odds of lesion were found to be associated with shorter lying times and fewer number of lying bouts during wk 3 (odds ratio = 1.23). Nonesterified fatty acids (747 ± 58 vs. 990 ± 86.85 µmol/L) and BHB (0.77 ± 0.06 vs. 0.60 ± 0.04 mmol/L) concentrations during wk 1 were greater in cows that developed claw lesions relative to cows that did not develop lesions. The BHB concentrations also remained higher in wk 2 for cows that developed claw lesions (0.63 ± 0.04 vs. 0.46 ± 0.03 mmol/L) compared with cows that did not develop any lesions. Cows that developed lesions experienced greater losses in BCS from wk -3 to 3 than cows without lesions (0.74 ± 0.01 and 0.61 ± 0.01 BCS change, respectively). In summary, changes in lying behavior and energy metabolic status after calving were associated with claw horn disruption lesions in mid-lactation primiparous cows under pasture-based systems.

Anaerobic digestion of soft drink beverage waste and sewage sludge

Soft drink beverage waste (BW) was evaluated as a potential substrate for anaerobic co-digestion with sewage sludge to increase biogas production. Results from this study show that the increase in biogas production is proportional to the increase in organic loading rate (OLR) rate due to BW addition. The OLR increase of 86 and 171% corresponding to 10 and 20% BW by volume in the feed resulted in 89 and 191% increase in biogas production, respectively. Under a stable condition, anaerobic co-digestion with BW did not lead to any significant impact on digestate quality (in terms of COD removal and biosolids odour) and biogas composition. The results suggest that existing nutrients in sewage sludge can support an increase in OLR by about 2 kg COD/m³/d from a carbon rich substrate such as soft drink BW without inhibition or excessive impact on subsequent handling of the digestate.

Effects of shearing on biogas production and microbial community structure during anaerobic digestion with recuperative thickening

Recuperative thickening can intensify anaerobic digestion to produce more biogas and potentially reduce biosolids odour. This study elucidates the effects of sludge shearing during the thickening process on the microbial community structure and its effect on biogas production. Medium shearing resulted in approximately 15% increase in biogas production. By contrast, excessive or high shearing led to a marked decrease in biogas production, possibly due to sludge disintegration and cell lysis. Microbial analysis using 16S rRNA gene amplicon sequencing showed that medium shearing increased the evenness and diversity of the microbial community in the anaerobic digester, which is consistent with the observed improved biogas production. By contrast, microbial diversity decreased under either excessive shearing or high shearing condition. In good agreement with the observed decrease in biogas production, the abundance of Bacteroidales and Syntrophobaterales (which are responsible for hydrolysis and acetogenesis) decreased due to high shearing during recuperative thickening.

Mechanism of water transport in graphene oxide laminates

The water transport mechanisms recently proposed by various researchers suggest that membranes composed of graphene oxide laminates could be regarded as an assembly of many tiny carbon nanotubes stacked together with attached functional groups as spacers.

It is understood that nano-channels of graphene oxide membranes have a water flow mechanism which is similar to the water flow inside carbon nanotube pores. The water transport mechanisms recently proposed by various researchers suggest that membranes composed of graphene oxide laminates could be regarded as an assembly of many tiny carbon nanotubes stacked together with attached functional groups as spacers.

Effects of sludge retention time on oxic-settling-anoxic process performance: Biosolids reduction and dewatering properties

In this study, the effect of sludge retention time (SRT) on oxic-settling-anoxic (OSA) process was determined using a sequencing batch reactor (SBR) attached to external aerobic/anoxic reactors. The SRT of the external reactors was varied from 10 to 40d. Increasing SRT from 10 to 20d enhanced volatile solids destruction in the external anoxic reactor as evidenced by the release of nutrients, however, increasing the SRT to 40d did not enhance volatile solids destruction further. Relatively short SRT (10-20d) favoured the conversion of destroyed solids into inert products. The application of an intermediate SRT (20d) of the external reactor showed the highest sludge reduction performance (>35%). Moreover, at the optimum SRT, OSA improved sludge dewaterability as demonstrated by lower capillary suction time and higher dewatered cake solids content.

Biosolids reduction by the oxic-settling-anoxic process: Impact of sludge interchange rate

The impact of sludge interchange rate (SIR) on sludge reduction by oxic-settling-anoxic (OSA) process was investigated. The sludge yield of an OSA system (a sequencing batch reactor, SBR, integrated with external anoxic reactors) was compared to that of a control (an SBR attached to a single-pass aerobic digester). SIR (%) is the percentage by volume of sludge returned from the external reactor into the main bioreactor of the OSA, and was varied from 0% to 22%. OSA achieved greater sludge reduction when fed with unsettled sewage (sCOD=113mg/L) rather than settled sewage (sCOD=60mg/L). The SIR of 11% resulted in the highest OSA performance. At the optimum SIR, higher volatile solids destruction and nitrification/denitrification (i.e., conversion of destroyed volatile solids into inert forms) were observed in the external anoxic and intermittently aerated (i.e., aerobic/anoxic) reactors, respectively. Denitrification in the aerobic/anoxic reactor was inefficient without SIR. Effluent quality and sludge settleability of the main SBR were unaffected by SIR.

Impact of reduced water consumption on sulfide and methane production in rising main sewers

Reduced water consumption (RWC), for water conservation purposes, is expected to change the wastewater composition and flow conditions in sewer networks and affect the in-sewer transformation processes. In this study, the impact of reduced water consumption on sulfide and methane production in rising main sewers was investigated. Two lab-scale rising main sewer systems fed with wastewater of different strength and flow rates were operated to mimic sewers under normal and RWC conditions (water consumption reduced by 40%). Sulfide concentration under the RWC condition increased by 0.7-8.0 mg-S/L, depending on the time of a day. Batch test results showed that the RWC did not change the sulfate-reducing activity of sewer biofilms, the increased sulfide production being mainly due to longer hydraulic retention time (HRT). pH in the RWC system was about 0.2 units lower than that in the normal system, indicating that more sulfide would be in molecular form under the RWC condition, which would result in increased sulfide emission to the atmosphere as confirmed by the model simulation. Model based analysis showed that the cost for chemical dosage for sulfide mitigation would increase significantly per unit volume of sewage, although the total cost would decrease due to a lower sewage flow. The dissolved methane concentration under the RWC condition was over two times higher than that under the normal flow condition and the total methane discharge was about 1.5 times higher, which would potentially result in higher greenhouse gas emissions. Batch tests showed that the methanogenic activity of sewer biofilms increased under the RWC condition, which along with the longer HRT, led to increased methane production.

Is H2S a suitable process indicator for odour abatement performance of sewer odours?

Odour abatement units are typically designed and maintained on H(2)S concentrations, but operational failures are reported in terms of overall odour removal, suggesting a wide range of malodorous compounds emitted from sewers that may not be efficiently removed by existing odour abatement processes. Towards providing greater insight into this issue, several activated carbon filters and biofilters treating odorous emissions from sewer systems in Sydney (Australia) were monitored by collecting and analysing gas samples before and after treatment. The monitoring studies were conducted by both olfactometric measurements and gas-chromatography-based chemical analysis. Single H(2)S assessment often failed to indicate the odour abatement performance for treatment systems in the abatement units studied, particularly when the incoming H(2)S concentrations were in the sub-ppm range (i.e. below H(2)S odour threshold). Chemical analysis indicated that some non-H(2)S odorous compounds were not removed efficiently during odour treatment. Additionally, when odour eliminations were correlated with the removal of individual compounds (Pearson's correlations) it was observed that the correlation (with a coefficient of 0.79) was best when the overall removal of all the measured odorous compounds that exceeded their odour threshold values was used for the analysis. These findings may help to further advance the design and operation of odour abatement processes to address the treatment of sewer odour emissions.

Reduced sulfur compounds in the atmosphere of sewer networks in Australia: geographic (and seasonal) variations

The management of odorous emissions from sewer networks has become an important issue for sewer system operators resulting in the need to better understand the composition of reduced sulfur compounds (RSCs). Gaseous RSCs including hydrogen sulfide (H2S), methanethiol (MeSH), dimethyl sulfide (DMS), carbon disulfide (CS2), dimethyl disulfide (DMDS) and dimethyl trisulfide (DMTS) were measured in the atmosphere of selected sewer networks in two major Australian cities (Sydney and Melbourne) during 2011-2012. The RSC concentrations in the sewer air were detected in a highly variable range. H2S and MeSH were found at the highest concentrations, followed by DMS (39.2-94.0 μg/m(3)), CS2 (18.3-19.6 μg/m(3)), DMDS (7.8-49.6 μg/m(3)) and DMTS (10.4-35.3 μg/m(3)). Temporal trends in the occurrence of targeted RSCs were observed and the highest sulfur concentration occurred either in summer or spring, which are typically regarded as the warmer seasons. Statistical significant difference in the magnitude of targeted RSCs was found between samples collected in Sydney and Melbourne.

Surface neutralization and H(2)S oxidation at early stages of sewer corrosion: influence of temperature, relative humidity and H(2)S concentration

While the involvement of a range of environmental factors in sewer corrosion is known, a comprehensive understanding of the processes involved and the exact role of individual environmental factors in sewer corrosion is still lacking. The corrosion of concrete in sewer systems is reported to be initiated through chemical reactions (involving H(2)S and CO(2)) that lower the surface pH to a level then conducive for biological activity. However, the specific influence of environmental variables, such as H(2)S level, temperature, and relative humidity etc. remains unclear; although, they are expected to control these initial surface reactions of the concrete sewer pipe. We examined changes in the surface chemistry of concrete during the early stages of corrosion by exposing concrete coupons to thirty-six independent conditions in well-controlled laboratory chambers that simulated conditions typically found in various sewer environments across Australia. The conditions employed were combinations of six H(2)S levels, three gas-phase temperatures and two relative humidity levels. Our results indicate that the role of CO(2) on initial surface pH reduction is insignificant when compared to the influence of H(2)S. Within the first 12 months, a decrease in surface pH by 4.8 units was observed for coupons exposed to 30 °C and 50 ppm H(2)S, while significantly lower pH reductions of 3.5 and 1.8 units were detected for coupons exposed to 25 °C and 18 °C respectively, and 50 ppm H(2)S. Elemental sulphur was found to be the major oxidation product of H(2)S and elevated concentrations were detected at the higher levels of H(2)S, temperature and relative humidity. More significantly, the data obtained from the controlled chamber experiments correlated with those obtained from the field-exposed coupons. Hence, these findings can be extended to real sewer corrosion processes.

Fate of cyanobacteria and their metabolites during water treatment sludge management processes

Cyanobacteria and their metabolites are an issue for water authorities; however, little is known as to the fate of coagulated cyanobacterial-laden sludge during waste management processes in water treatment plants (WTPs). This paper provides information on the cell integrity of Anabaena circinalis and Cylindrospermopsis raciborskii during: laboratory-scale coagulation/sedimentation processes; direct filtration and backwashing procedures; and cyanobacterial-laden sludge management practices. In addition, the metabolites produced by A. circinalis (geosmin and saxitoxins) and C. raciborskii (cylindrospermopsin) were investigated with respect to their release (and possible degradation) during each of the studied processes. Where sedimentation was used, coagulation effectively removed cyanobacteria (and intracellular metabolites) without any considerable exertion on coagulant demand. During direct filtration experiments, cyanobacteria released intracellular metabolites through a stagnation period, suggesting that more frequent backwashing of filters may be required to prevent floc build-up and metabolite release. Cyanobacteria appeared to be protected within the flocs, with minimal damage during backwashing of the filters. Within coagulant sludge, cyanobacteria released intracellular metabolites into the supernatant after 3d, even though cells remained viable up to 7d. This work has improved the understanding of cyanobacterial metabolite risks associated with management of backwash water and sludge and is likely to facilitate improvements at WTPs, including increased monitoring and the application of treatment strategies and operational practices, with respect to cyanobacterial-laden sludge and/or supernatant recycle management.

Fate of toxic cyanobacterial cells and disinfection by-products formation after chlorination

Drinking water sources in many regions are subject to proliferation of toxic cyanobacteria (CB). Chlorination of source water containing toxic cyanobacterial cells for diverse treatment purposes might cause cell damage, toxin release and disinfection by-products (DBP) formation. There is limited information available on chlorination of different toxic CB cells and DBP formation potentials. This work: (1) determines the extent of lysis and toxins/taste and odor compound release in chlorinated natural water from CB cells (Anabaena circinalis, Microcystis aeruginosa, Cylindrospermopsis raciborskii, and Aphanizomenon issatsckenka) from laboratory cultures and natural blooms; (2) assesses the rates of oxidation of toxins by free chlorine under environmental conditions; (3) studies the DBP formation associated with the chlorination of CB cell suspensions. With chlorine exposure (CT) value of <4.0 mg min/L >60% cells lost viability causing toxin release. Cell membrane damage occurred faster than oxidation of released toxins. Kinetic analysis of the oxidation of toxins in natural water revealed significant differences in their susceptibility to chlorine, saxitoxins being the easiest to oxidize, followed by cylindrospermopsin and microcystin-LR. Furthermore, concentrations of trihalomethanes and haloacetic acids (<40 μg/L) and N-nitrosodimethylamine (<10 ng/L) as chlorination by-products were lower than the guideline values even at the highest CT value (220 mg min/L). However, the DBP concentrations in environmental bloom conditions with very high cell numbers were over the guideline values.

Application of powdered activated carbon for the adsorption of cylindrospermopsin and microcystin toxins from drinking water supplies

Cylindrospermopsin (CYN) and microcystin are two potent toxins that can be produced by cyanobacteria in drinking water supplies. This study investigated the application of powdered activated carbon (PAC) for the removal of these toxins under conditions that could be experienced in a water treatment plant. Two different PACs were evaluated for their ability to remove CYN and four microcystin variants from various drinking water supplies. The removal of natural organic material by the PACs was also determined by measuring the levels of dissolved organic carbon and UV absorbance (at 254 nm). The PACs effectively removed CYN and the microcystins from each of the waters studied, with one of the PACs shown to be more effective, possibly due to its smaller particle diameter. No difference in removal of the toxins was observed using PAC contact times of 30, 45 and 60 min. Furthermore, the effect of water quality on the removal of the toxins was minimal. The microcystin variants were adsorbed in the order: MCRR > MCYR > MCLR > MCLA. CYN was found to be adsorbed similarly to MCRR.

Effect of film thickness and filler properties on sulphuric acid permeation in various commercially available epoxy mortar coatings

The performance of various commercially available epoxy mortar coatings was compared by measuring their sulphuric acid diffusivity. Apparent diffusivities, which were measured gravimetrically, were found to be dependent on coating tortuosity. In composite materials like epoxy mortars, the tortuosity was determined by filler properties and polymer alignment. Tortuosity was found to depend on the filler size, their dispersion, filler aspect ratio and concentration. The order and greater alignment of polymer aggregates, which characterises thinner coatings effects higher tortuosity and thus lower permeabilities. The result is that sulphuric acid diffusivities were observed to increase with coating thickness, which challenges the notion that greater coating thicknesses provide greater protection or environmental barrier. The effect of film thickness and filler properties observed in this study has significant implications to the current selection of coatings and sewer protection.