Anaerobic Treatment of Industrial Wastewater BioE 202 Iowa State University
Anaerobic Waste Treatment : An Overview Historical development Mainly used for reducing mass of high solids wastes, e.g. h...
Popularity of anaerobic processes Energy crisis in 70 and 80’s- a renewed interest in anaerobic process No. of plants Anae...
Anaerobic treatment within wastewater processing Domestic wastewater (100) Preliminary treatment Bar screen, Comminutor Gr...
Anaerobic treatment of solids How do we achieve high SRT in anaerobic treatment systems? Anaerobic treatment of high solid...
Anaerobic Waste Treatment Anaerobic treatment is a biological process carried out in the absence of O 2  for the stabiliza...
Anaerobic fermentation In anaerobic  fermentation , there is no external electron acceptor. The product generated during t...
O 2  > NO 3 -  > SO 4 2-  > CO 2 Anaerobic respiration Anaerobic  respiration  on the other hand requires external electro...
Advantage of anaerobic processes <ul><li>Less energy requirement as no aeration is needed </li></ul>0.5-0.75 kWh energy is...
<ul><li>Ability to transform several hazardous solvents  including  chloroform,  trichloroethylene  and  trichloroethane t...
Limitations of anaerobic processes 1.  Long start-up time Because of lower biomass synthesis rate, it requires a longer st...
… Limitations of anaerobic processes NH 4 +  + 1.32 NO 2 -   + 0.066CO 2   +  0.13H +      1.02 N 2   +  0.26NO 3 -  + 0....
Comparison  between anaerobic and aerobic processes  Anaerobic    Aerobic Organic loading rate High loading rates:10-40 kg...
Comparison  between anaerobic and aerobic processes  Anaerobic    Aerobic SRT Longer SRT is essential to retain the slow g...
How much methane gas can be generated through  complete anaerobic degradation of 1 kg COD at STP ?   Step 2: Conversion of...
Step 3: CH 4  generation rate per unit of COD removed   From eq. (1) and eq. (2), we have,   => 1 g CH 4     ~ 4 g COD  ~ ...
Methane Carbon dioxide Acetotrophic Methanogenesis Hydrogenetrophic Methanogenesis Organics Conversion in Anaerobic System...
Process Microbiology The anaerobic degradation  of  complex  organic  matter  is carried out by  a series of bacteria and ...
Syntrophic association of acetogenic organisms with methanogenic H 2 - consuming bacteria helps to lower the  concentratio...
Homoacetogenes (3)   Homoacetogenesis has gained much attention in recent years in anaerobic processes due to its final  p...
  Methanogens (4 and 5)   Methanogens are  unique  domain of  microbes classified as  Archeae,  distinguished from  Bacter...
Growth kinetics of  Methanosaeta  and Methanosarcina Methanosaeta Methanosarcina
Essential conditions for efficient anaerobic treatment   <ul><li>Enough nutrients (N & P) and trace metals especially, Fe,...
Best industrial wastewaters for anaerobic treatment <ul><li>Alcohol production </li></ul><ul><li>Brewery and Winery </li><...
Environmental factors <ul><li>Temperature </li></ul><ul><li>Anaerobic processes like other biological processes operate in...
Effect of temperature on anaerobic activity Rule of thumb: Rate of a reaction doubles for every 10  o C rise in temperatur...
pH There exist two microbial domains in terms of pH optima namely acidogens and methanogens.  The best pH range for acidog...
Cont.. pH dependence of methanogens
Cont.. Natural buffering An anaerobic treatment system has its own buffering capacity against pH drop because of alkalinit...
Cont.. COD:N:P = 350:7:1 (for highly loaded system) 1000:7:1 (lightly loaded system) All microbial processes including ana...
Slurry  type  bioreactor, temperature, mixing, SRT or  other  environmental  conditions are not regulated.  Loading of 1-2...
Anaerobic contact process (ACP) Influent Effluent Waste sludge Recycled sludge Completely mixed  reactor Biogas Degassifie...
Cont.. … Anaerobic contact process (ACP) ACP  was  initially  developed  for  the  treatment  of  dilute  wastewater such ...
Anaerobic filter <ul><li>Developed by Young  and  McCarty in  the  late 1960s to treat dilute soluble organic wastes  </li...
Upflow Anaerobic Filter Feeding tank at 4 o C Biogas  Effluent Peristaltic pump Media Perforated Al plate Sampling port He...
Originally,  rocks  were  employed  as  packing  medium  in anaerobic filter.  But due to very low void volume  (40-50%), ...
Cont.. Since anaerobic filters are able to retain  high biomass, a long SRT can be maintained. Typically HRT varies from 0...
Upflow Anaerobic Sludge Blanket (UASB) UASB was developed in 1970s by Lettinga in the Netherlands.  UASB is essentially a ...
Effluent Influent biogas UASB Reactor
Static granular bed reactor (SGBR) <ul><li>Simple in operation with  fewer  moving parts </li></ul><ul><li>Major issue: he...
When the waste contains sulfate, part of COD is diverted to sulfate reduction and thus total COD available for methane  pr...
8e  +8H +  +  SO 4 2-      S 2-   +  4H 2 O <ul><li>COD/SO 4 2-   ~  0.67 </li></ul>8e  +8H +  + 2O 2        4H 2 O 2O 2...
Example 2 A UASB reactor has been  employed  to  treat food processing wastewater at 20 o C. The flow rate  is 2 m 3 /day ...
  (7000 x 10 -6 )     Total COD removed =  ----------------- x (2) kg/d   (10 -3 )               =  14 kg/d   From eq. (3...
Cont.. Biogas generation rate   Not all COD (organic matter) is completely degraded. The fate of COD during anaerobic trea...
Cont.. As 10% of the removed COD  has  been  utilized  for  biomass synthesis remaining 90% of the removed COD has thus be...
Cont.. When the waste contains sulfate, part of COD is diverted to sulfate reduction  and thus total  COD  available  for ...
Cont.. Cont..   (5666.67 x 10 -6 )     Total COD available  = ----------------- x  (2) kg/d for CH4 generation   (10 -3 )...
Expanded bed reactor (EBR) <ul><li>Expanded  bed  reactor  is an attached growth system with some suspended biomass. </li>...
Fluidized bed reactor (FBR) <ul><li>FBR is similar to EBR in terms of configuration.  But FBR is truly fixed film reactor ...
Hybrid system: UASB/AF Hybrid system incorporates  both  granular  sludge  blanket (bottom) and anaerobic filter (top). Su...
Biogas Sludge Anaerobic baffled reactor In anaerobic baffled reactor, the wastewater passes  over and  under  the  baffles...
Anaerobic Sequential Bed Reactor
Anaerobic process design Design based on volumetric organic loading rate (VOLR)   S o  . Q  VOLR =  --------- V VOLR : Vol...
S o  and Q can be measured easily and are known upfront VOLR can be selected! How do we select VOLR? <ul><li>Conducting a ...
Design based on hydraulic loading rate   V  =   a  . Q    a  . Q  A  =  -------- H H  :  Reactor height (m)  a   : Allo...
Solids retention time (SRT)  An anaerobic digester  is  a  completely mixed reactor for which solid retention time(SRT) an...
Volatile solids loading rate The size of an anaerobic digester can also be estimated based on volatile solids loading rate...
Green cow power
Methane for power generation The digester uses feeder cattle manure from Amana Farms and industrial and food processing wa...
What happens to the left-overs? Common misconceptions about anaerobic digesters include that anaerobic digestion and the r...
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Anaerobic treatment and biogas (short)

  1. 1. Anaerobic Treatment of Industrial Wastewater BioE 202 Iowa State University
  2. 2. Anaerobic Waste Treatment : An Overview Historical development Mainly used for reducing mass of high solids wastes, e.g. human waste (nightsoil), animal manure, agricultural waste and sludge. <ul><li>Early applications of anaerobic waste treatment include: </li></ul><ul><li>Mouras automatic scavenger - cited in French journal Cosmos in 1881 </li></ul><ul><li>Septic tank- developed by Donald Cameron in 1895 (England) </li></ul><ul><li>Imhoff tank: developed by Karl Imhoff in 1905 (Germany) </li></ul>
  3. 3. Popularity of anaerobic processes Energy crisis in 70 and 80’s- a renewed interest in anaerobic process No. of plants Anaerobic treatment plants for industrial applications (Source: Franklin, 2001)
  4. 4. Anaerobic treatment within wastewater processing Domestic wastewater (100) Preliminary treatment Bar screen, Comminutor Grit chamber etc. Primary sedimentation (100) Primary sludge (35) Aerobic treatment (65) e.g. Activated sludge, Trickling filter, RBC Secondary sedimentation Oxidized to CO 2 (30) Converted to sludge (35) Secondary sludge (25) Effluent (10) Anaerobic digester (60)
  5. 5. Anaerobic treatment of solids How do we achieve high SRT in anaerobic treatment systems? Anaerobic treatment of high solids such as animal manure, biological sludge, nightsoil, etc. is commonly known as “anaerobic digestion” and is carried out in airtight container known as an anaerobic digester (AD). <ul><li>AD is usually a continuous flow stirred tank </li></ul><ul><li>reactor (CFSTR) for which HRT ~ SRT </li></ul><ul><li>Design based on volatile solids (VS) loading rate </li></ul><ul><li>Anaerobic treatment of wastewaters requires a </li></ul><ul><li>long SRT to achieve better treatment efficiency </li></ul><ul><li>The ratio of SRT/HRT ~ 10-100 </li></ul><ul><li>The high ratio allows the slow-growing methanogens to remain </li></ul><ul><li>in the reactor for a longer time </li></ul>
  6. 6. Anaerobic Waste Treatment Anaerobic treatment is a biological process carried out in the absence of O 2 for the stabilization of organic materials by conversion to CH 4 and inorganic end-products such as CO 2 and NH 3 Organic materials + Nutrients CH 4 + CO 2 +NH 3 + Biomass Anaerobic microbes Anaerobic processes Anaerobic fermentation Anaerobic respiration
  7. 7. Anaerobic fermentation In anaerobic fermentation , there is no external electron acceptor. The product generated during the process accepts the electrons released during the breakdown of organic matter. Thus, organic matter acts as both electron donor and acceptor. The process releases less energy and the major portion of the energy is still contained in the fermentative product such as ethanol. Glucose Pyruvate Energy Electron Ethanol Anaerobic fermentation of glucose to ethanol
  8. 8. O 2 > NO 3 - > SO 4 2- > CO 2 Anaerobic respiration Anaerobic respiration on the other hand requires external electron acceptor. The electron acceptors in this case could be SO 4 2- , NO 3 - or CO 2 . The energy released under such a condition is higher than anaerobic fermentation. Glucose Pyruvate Energy Electron CO 2 + H 2 O SO 4 2- CO 2 NO 3 - H 2 S CH 4 N 2 Anaerobic respiration of glucose, preference for electron acceptors
  9. 9. Advantage of anaerobic processes <ul><li>Less energy requirement as no aeration is needed </li></ul>0.5-0.75 kWh energy is needed for every 1 kg of COD removal by aerobic processes 2. Energy generation in the form of methane gas 1.16 kWh energy is produced for every 1 kg of COD fermented in anaerobic process 3. Less biomass (sludge) generation Anaerobic process produces only 20% of sludge compared with aerobic process Soluble BOD 1 kg Aerobic process CO 2 + H 2 O 0.5 kg New biomass 0.5 kg Biodegradable COD 1 kg Anaerobic process CH 4 gas > 0.9 kg New biomass < 0.1 kg
  10. 10. <ul><li>Ability to transform several hazardous solvents including chloroform, trichloroethylene and trichloroethane to an easily degradable form </li></ul>… Advantages of anaerobic processes 4. Less nutrients (N & P) required Lower biomass synthesis rate also implies less nutrients requirement : 20% of aerobic 5. Application of higher organic loading rate Organic loading rates of 5-10 times higher than that of aerobic processes are possible 6. Space saving Higher loading rates require smaller reactor volumes thereby saving on disposal cost
  11. 11. Limitations of anaerobic processes 1. Long start-up time Because of lower biomass synthesis rate, it requires a longer start-up time to attain a biomass concentration 2. Long recovery time If an anaerobic system is subjected to disturbances either due to biomass wash-out, toxic substances or shock loading, it may take longer time for the system to return to normal operating conditions 3. Specific nutrients/trace metal requirements Anaerobic microorganisms, especially methanogens, have specific nutrients e.g. Fe, Ni, and Co requirement for optimum growth 4. More susceptible to changes in environmental conditions Anaerobic microorganisms especially methanogens are prone to changes in conditions such as temperature, pH, redox potential, etc.
  12. 12. … Limitations of anaerobic processes NH 4 + + 1.32 NO 2 - + 0.066CO 2 + 0.13H +  1.02 N 2 + 0.26NO 3 - + 0.066CH 2 O 0.5 N 0.15 5. Treatment of sulfate-rich wastewater The presence of sulfate not only reduces the methane yield due to substrate Competition, but also inhibits the methanogens due to sulfide production 6. Effluent quality of treated wastewater The minimum substrate concentration (S min ) from which microorganisms are able to generate energy for their growth and maintenance is much higher for anaerobic treatment systems. Anaerobic processes may not be able to degrade organic matter to the level to meet the discharge limits for ultimate disposal. 7. Treatment of high protein & nitrogen containing wastewater The anaerobic degradation of proteins produces amines which are no longer be degraded anaerobically. Similarly nitrogen remains unchanged during anaerobic treatment. Recently, a process called ANAMMOX ( ANaerobic AMMonium OXididation) has been developed to anaerobically oxidize NH 4 + to N 2 in presence of nitrite. NH 4 + + NO 2 -  N 2 + 2H 2 O
  13. 13. Comparison between anaerobic and aerobic processes Anaerobic Aerobic Organic loading rate High loading rates:10-40 kg COD/m 3 -day Low loading rates:0.5-1.5 kg COD/m 3 -day (for high rate reactors, e.g. AF,UASB, E/FBR) (for activated sludge process) Biomass yield Low biomass yield:0.05-0.15 kg VSS/kg COD High biomass yield:0.35-0.45 kg VSS/kg COD (biomass yield is not constant but depends on types of substrates metabolized) (biomass yield is fairly constant irrespective of types of substrates metabolized) Specific substrate utilization rate High rate: 0.75-1.5 kg COD/kg VSS-day Low rate: 0.15-0.75 kg COD/kg VSS-day Start-up time Long start-up: 1-2 months for mesophilic : 2-3 months for thermophilic Short start-up: 1-2 weeks
  14. 14. Comparison between anaerobic and aerobic processes Anaerobic Aerobic SRT Longer SRT is essential to retain the slow growing methanogens within the reactor Microbiology Anaerobic processes involve multi-step chemical conversions and a diverse group of microorganisms degrade the organic matter in a sequential order Aerobic process is mainly a one-species phenomenon, except for nutrient-removal processes Environmental factors The process is highly susceptible to changes in environmental conditions SRT of 4-10 days is enough for the activated sludge process The process is more robust to changing environmental conditions
  15. 15. How much methane gas can be generated through complete anaerobic degradation of 1 kg COD at STP ? Step 2: Conversion of CH 4 mass to equivalent volume Based on the ideal gas law, 1 mole of any gas at STP (Standard Temperature and Pressure) occupies a volume of 22.4 L    1 Mole CH 4 ~ 22.4 L CH 4    16 g CH 4 ~ 22.4 L CH 4    1 g CH 4 ~ 22.4/16 = 1.4 L CH 4 ---------- (2) Step 1: Calculation of COD equivalence of CH 4   CH 4 + 2O 2  CO 2 + 2H 2 O   16 g 64g  16 g CH 4 ~ 64 g O 2 (COD)    1 g CH 4 ~ 64/16 = 4 g COD ------------ (1)
  16. 16. Step 3: CH 4 generation rate per unit of COD removed   From eq. (1) and eq. (2), we have,   => 1 g CH 4 ~ 4 g COD ~ 1.4 L CH 4   => 4 g COD ~ 1.4 L CH4   => 1 g COD ~ 1.4/4 = 0.35 LCH 4   or 1 Kg COD ~ 0.35 m 3 CH 4 ----------- (3)   Complete anaerobic degradation of 1 kg COD produces 0.35 m 3 CH 4 at STP
  17. 17. Methane Carbon dioxide Acetotrophic Methanogenesis Hydrogenetrophic Methanogenesis Organics Conversion in Anaerobic Systems 72 28 COMPLEX ORGANIC MATTER Proteins Carbohydrates Lipids Amino Acids, Sugars Fatty Acids, Alcohols hydrolysis INTERMEDIARY PRODUCTS (C>2; Propionate, Butyrate etc) acidogenesis Acetate Hydrogen, Carbon dioxide Homoacetogenesis acetogenesis methanogenesis 1 1 1 1 1 2 3 5 4
  18. 18. Process Microbiology The anaerobic degradation of complex organic matter is carried out by a series of bacteria and archeae as indicated in the figure (with numbers). There exists a coordinated interaction among these microbes. The process may fail if a certain of these organisms are inhibited.   Fermentative bacteria (1) This group of bacteria is responsible for the first stage of anaerobic digestion - hydrolysis and acidogenesis . These bacteria are either facultative or strict anaerobes. The anaerobic species belonging to the family of Streptococcaceae and Enterobacteriaceae and to the genera of Bacteroides , Clostridium, Butyrivibrio , Eubacterium , Bifidobacterium and Lactobacillus are most common .
  19. 19. Syntrophic association of acetogenic organisms with methanogenic H 2 - consuming bacteria helps to lower the concentration of H 2 below inhibitory level so that propionate degrading bacteria are not suppressed by excessive H 2 level H 2 partial pressure 10 -2 (100 ppm)   This group of bacteria metabolizes propionate and other organic acids (>C-2), alcohols and certain aromatic compounds (i.e. benzoate) into acetate and CO 2 Hydrogen producing acetogenic bacteria (2) CH 3 CH 2 COO -  CH 3 COO - + CO 2 + H 2
  20. 20. Homoacetogenes (3) Homoacetogenesis has gained much attention in recent years in anaerobic processes due to its final product: acetate, which is the important precursor to methane generation. The bacteria are, H 2 and CO 2 users. Clostridium aceticum and Acetobacterium woodii are the two homoacetogenic bacteria isolated from the sewage sludge. Homoacetogenic bacteria have a high thermodynamic efficiency; as a result there is no accumulation H 2 and CO 2 during growth on multi-carbon compounds . CO 2 + H 2  CH 3 COOH + 2H 2 O
  21. 21.   Methanogens (4 and 5) Methanogens are unique domain of microbes classified as Archeae, distinguished from Bacteria by a number of characteristics, including the possession of membrane lipids, absence of the basic cellular characteristics (e. g. peptidoglycan) and distinctive ribosomal RNA. Methanogens are obligate anaerobes and considered as a rate-limiting species in anaerobic treatment of wastewater. Moreover, methanogens co-exist or compete with sulfate-reducing bacteria for the substrates in anaerobic treatment of sulfate-laden wastewater. Two classes of methanogens that metabolize acetate to methane are: <ul><li>Methanosaeta (old name Methanothrix ): Rod shape, low K s , high affinity </li></ul><ul><li>Methanosarcina (also known as M. mazei ): Spherical shape, high K s , </li></ul><ul><li>low affinity </li></ul>
  22. 22. Growth kinetics of Methanosaeta and Methanosarcina Methanosaeta Methanosarcina
  23. 23. Essential conditions for efficient anaerobic treatment <ul><li>Enough nutrients (N & P) and trace metals especially, Fe, Co, Ni, etc. </li></ul><ul><li>COD:N:P = 350:7:1 (for highly loaded system) 1000:7:1 (lightly </li></ul><ul><li>loaded system) </li></ul><ul><li>Avoid excessive air/O 2 exposure </li></ul><ul><li>No toxic/inhibitory compounds present in the influent </li></ul><ul><li>Maintain pH between 6.8 –7.2 </li></ul><ul><li>Sufficient alkalinity present (mainly bicarbonates) </li></ul><ul><li>Low volatile fatty acids (VFAs) </li></ul><ul><li>Temperature around mesophilic range (30-38 o C) </li></ul><ul><li>SRT/HRT >>1 (use high rate anaerobic reactors) </li></ul>
  24. 24. Best industrial wastewaters for anaerobic treatment <ul><li>Alcohol production </li></ul><ul><li>Brewery and Winery </li></ul><ul><li>Sugar processing </li></ul><ul><li>Starch (barley, corn, potato, wheat, tapioca) and desizing </li></ul><ul><li>waste from textile industry. </li></ul><ul><li>Food processing </li></ul><ul><li>Bakery plant </li></ul><ul><li>Pulp and paper </li></ul><ul><li>Dairy </li></ul><ul><li>Slaughterhouse </li></ul><ul><li>Petrochemical waste </li></ul>
  25. 25. Environmental factors <ul><li>Temperature </li></ul><ul><li>Anaerobic processes like other biological processes operate in certain temperature ranges </li></ul><ul><li>In anaerobic systems: three optimal temperature ranges: </li></ul><ul><ul><li>Psychrophilic (5 - 15 o C) </li></ul></ul><ul><ul><li>Mesophilic (35 – 40  C) </li></ul></ul><ul><ul><li>Thermophilic (50-55 o C) </li></ul></ul>The successful operation of anaerobic reactor depends on maintaining the environmental factors close to the comfort of the microorganisms involved in the process.
  26. 26. Effect of temperature on anaerobic activity Rule of thumb: Rate of a reaction doubles for every 10 o C rise in temperature up to an optimum and then declines rapidly
  27. 27. pH There exist two microbial domains in terms of pH optima namely acidogens and methanogens. The best pH range for acidogens is 5.5 – 6.5 and for methanogens is 7.8 – 8.2. The operating pH for combined cultures is 6.8-7.4 with neutral pH being the optimum. Since methano-genesis is considered as a rate limiting step, it is necessary to maintain the reactor pH close to neutral. Low pH reduces the activity of methanogens causing accumulation of VFA and H 2 . At higher partial pressure of H 2 , propionic acid degrading bacteria will be severely inhibited thereby causing excessive accumulation of higher molecular weight VFAs such as propionic and butyric acids and the pH drops further. If the situation is left uncorrected, the process may eventually fail. This condition is known as going “SOUR” or STUCK”. Remedial measures: Reduce the loading rates and supplement chemicals to adjust the pH: alkaline chemicals such as NaHCO 3 , NaOH, Na 2 CO 3 , quick lime (CaO), slaked lime [Ca(OH) 2 ], limestone (or softening sludge) CaCO 3 , and NH 3 can be used.
  28. 28. Cont.. pH dependence of methanogens
  29. 29. Cont.. Natural buffering An anaerobic treatment system has its own buffering capacity against pH drop because of alkalinity produced during waste treatment: e.g. the degradation of protein present in the waste releases NH 3 , which reacts with CO 2 forming ammonium carbonate as alkalinity. NH 3 + H 2 O + CO 2  NH 4 HCO 3 The degradation of salt of fatty acids may produce some alkalinity. CH 3 COONa + H 2 O  CH 4 + NaHCO 3 Sulfate and sulfite reduction also generate alkalinity. CH 3 COO - + SO 4 2-  HS - + HCO 3 - + 3H 2 O When pH starts to drop due to VFA accumulation, the alkalinity present within the system neutralizes the acid and prevents further drop in pH. If the alkalinity is not enough to buffer the system pH, we need external additions.
  30. 30. Cont.. COD:N:P = 350:7:1 (for highly loaded system) 1000:7:1 (lightly loaded system) All microbial processes including anaerobic require macro (N, P and S) and micro (trace metals) nutrients in sufficient concentration to support biomass synthesis. Anaerobic micro-organisms, especially methanogens, have specific requirements of trace metals such as Ni, Co, Fe, Mo, Se etc. The nutrients and trace metals requirements for anaerobic process are much lower as only 4 - 10% of the COD removed is converted to biomass. Nutrients and trace metals Inhibition/Toxicity The toxicity is caused by substances present in the influent waste or byproducts of metabolic activities. Heavy metals, halogenated compounds, and cyanide are examples of the former type whereas sulfide and VFAs belong to latter . Ammonia from either group
  31. 31. Slurry type bioreactor, temperature, mixing, SRT or other environmental conditions are not regulated. Loading of 1-2 kg COD/m 3 -day Able to retain very high concentration of active biomass in the reactor. Thus extremely high SRT could be maintained irrespective of HRT. Load 5-20 kg COD/m 3 -d COD removal efficiency : 80-90% Types of anaerobic reactors Low-rate anaerobic reactors High-rate anaerobic reactors Anaerobic pond Septic tank Standard rate anaerobic digester Imhoff tank Anaerobic sequencing batch reactor (ASBR) Anaerobic contact process Anaerobic filter (AF) Upflow anaerobic sludge blanket (UASB) Fluidized bed reactor Hybrid reactor: UASB/AF
  32. 32. Anaerobic contact process (ACP) Influent Effluent Waste sludge Recycled sludge Completely mixed reactor Biogas Degassifier Biogas Settling tank Anaerobic contact process is essentially an anaerobic activated sludge process. It consists of a completely mixed reactor followed by a settling tank. The settled biomass is recycled back to the reactor. Hence ACP is able to maintain high concentration of biomass in the reactor and thus high SRT irrespective of HRT. Degasifier allows the removal of biogas bubbles (CO 2 , CH 4 ) attached to sludge which may otherwise float to the surface. .
  33. 33. Cont.. … Anaerobic contact process (ACP) ACP was initially developed for the treatment of dilute wastewater such as meat packing plant which had tendency to form a settleable flocs. ACP is suitable for the treatment of wastewater containing suspended solids which render the microorganisms to attach and form settleable flocs. The biomass concentration in the reactor ranges from 4-6 g/L with maximum concentration as high as 25-30 g/L depending on settleability of sludge. The loading rate ranges from 0.5 – 10 kg COD/m 3 -day. The required SRT could be maintained by controlling the recycle rate similar to activated sludge process.
  34. 34. Anaerobic filter <ul><li>Developed by Young and McCarty in the late 1960s to treat dilute soluble organic wastes </li></ul><ul><li>The filter was filled with rocks similar to the trickling filter </li></ul><ul><li>Wastewater distributed across the bottom and the flow was in the upward direction through a bed of rocks </li></ul><ul><li>Whole filter submerged completely </li></ul><ul><li>Anaerobic microorganisms accumulate within voids of media </li></ul><ul><li>(rocks or other plastic media) </li></ul><ul><li>The media retain or hold the active biomass within the filter </li></ul><ul><li>The non-attached biomass within the interstices forms bigger </li></ul><ul><li>flocs of granular shape due to rising gas bubble/liquid </li></ul><ul><li>Non-attached biomass contributes significantly to waste treatment </li></ul><ul><li>Attached biomass not be a major portion of total biomass </li></ul><ul><li>64% attached and 36% non-attached </li></ul>
  35. 35. Upflow Anaerobic Filter Feeding tank at 4 o C Biogas Effluent Peristaltic pump Media Perforated Al plate Sampling port Heater Constant temperature recirculation line Water bath Peristaltic pump Sludge wastage
  36. 36. Originally, rocks were employed as packing medium in anaerobic filter. But due to very low void volume (40-50%), serious clogging problems were witnessed. Now, many synthetic packing media are made up of plastics; ceramic tiles of different configuration have been used in anaerobic filters. The void volume in these media ranges from 85-95 %. Moreover, these media provide high specific surface area, typically 100 m 2 /m 3 , or above, which enhances biofilm growth. Cont.. Anaerobic Filter Packing
  37. 37. Cont.. Since anaerobic filters are able to retain high biomass, a long SRT can be maintained. Typically HRT varies from 0.5 – 4 days and the loading rates vary from 5 - 15 kg COD/m 3 -day. Biomass wastage is generally not needed and hydrodynamic conditions play an important role in biomass retention within the void space. Anaerobic Filters Downflow anaerobic filters are similar to a trickling filter in operation. DAF is closer to fixed film reactor as loosely held biomass/sludge within the void spaces is potentially washed out of the reactor. The specific surface area of media is more important in DAF than UAF. There is less of a clogging problem and wastewater with some SS concentration can be treated using DAF. Downflow anaerobic filter (DAF)
  38. 38. Upflow Anaerobic Sludge Blanket (UASB) UASB was developed in 1970s by Lettinga in the Netherlands. UASB is essentially a suspended growth system in which proper hydraulic and organic loading rate is maintained in order to facilitate the dense biomass aggregation known as granulation. The size of granules is about 1-3 mm diameter. Since granules are bigger in size and heavier, they will settle down and be retained within the reactor. The concentration of biomass in the reactor may become as high as 50 g/L. Thus a very high SRT can be achieved even at a very low HRT of 4 hours. The granules consist of hydrolytic bacteria, acidogen/acetogens and methanogens. Carbohydrate degrading granules show layered structure with a surface layer of hydrolytic/fermentative acidogens. A mid-layer comprising of syntrophic colonies and an interior with acetogenic methanogens.
  39. 39. Effluent Influent biogas UASB Reactor
  40. 40. Static granular bed reactor (SGBR) <ul><li>Simple in operation with fewer moving parts </li></ul><ul><li>Major issue: head loss due to build-up of solids </li></ul><ul><li>Developed at Iowa State University by Drs. Ellis and Kris Mach </li></ul><ul><li>Just opposite to UASB; flow is from top to bottom and the bed </li></ul><ul><li>is static </li></ul><ul><li>No need of three-phase separator or flow distributor </li></ul>Effluent
  41. 41. When the waste contains sulfate, part of COD is diverted to sulfate reduction and thus total COD available for methane production would be reduced greatly. Effect of sulfate on methane production Sulfide will also impose toxicity on methanogens at a concentration of 50 to 250 mg/L as free sulfide.
  42. 42. 8e +8H + + SO 4 2-  S 2- + 4H 2 O <ul><li>COD/SO 4 2- ~ 0.67 </li></ul>8e +8H + + 2O 2  4H 2 O 2O 2 / SO 4 2- = 64/96 ~ 0.67 Theoretically, 1 g of COD is needed to reduce 1.5 g of sulfate Stoichiometry of sulfate reduction
  43. 43. Example 2 A UASB reactor has been employed to treat food processing wastewater at 20 o C. The flow rate is 2 m 3 /day with a mean soluble COD of 7,000 mg/L. Calculate the maximum CH 4 generation rate in m 3 /day. What would be the biogas generation rate at 85% COD removal efficiency and 10% of the removed COD is utilized for biomass synthesis. The mean CH 4 content of biogas is 80%. If the wastewater contains 2.0 g/L sulfate, theoretically how much CH 4 could be generated? Solution: Maximum CH 4 generation rate: The complete degradation of organic matter in the waste could only lead to maximum methane generation and is also regarded as theoretical methane generation rate .
  44. 44.   (7000 x 10 -6 )  Total COD removed = ----------------- x (2) kg/d (10 -3 )             = 14 kg/d   From eq. (3) in example 1, we have   1 Kg COD produces 0.35 m 3 CH 4 at STP   14 Kg COD produces ~ 0.35 x 14 = 4.9 m 3 CH 4 /d at STP   At 20  C, the CH 4 gas generation = 4.9 x(293/273) = 5.3 m 3 /d   The maximum CH 4 generation rate = 5.3 m 3 /d Cont.. :
  45. 45. Cont.. Biogas generation rate   Not all COD (organic matter) is completely degraded. The fate of COD during anaerobic treatment process can be viewed as           Residual COD (in effluent)          COD converted to CH 4 gas           COD diverted to biomass synthesis          COD utilized for sulfate reduction (if sulfate is present) (7000 x 10 -6 ) Total COD removed = ------------- x (2) x 0.85 kg/d (10 -3 )   = 11.9 kg/d :
  46. 46. Cont.. As 10% of the removed COD has been utilized for biomass synthesis remaining 90% of the removed COD has thus been converted to CH 4 gas.   COD utilized for CH 4 generation = 11.9 x 0.9 kg/d   = 10.71 kg/d   From eq. (3) in example 1, we have:   1 Kg COD produces 0.35 m 3 CH 4 at STP   10.71 Kg COD produces ~ 0.35 x 10.71 = 3.75 m 3 CH 4 /d at STP   At 20  C, the CH 4 gas generation = 3.75 x (293/273) = 4.02 m 3 /d   The bio-gas generation rate is larger as it also contains CO 2 and H 2 S 4C.02/0.80 = 5.03 m 3 /d
  47. 47. Cont.. When the waste contains sulfate, part of COD is diverted to sulfate reduction and thus total COD available for methane production would be reduced greatly. Sulfate-reducing bacteria   Organic matter + Nutrients + SO 4 2-  H 2 S + H 2 O + HCO 3 - + New biomass Theoretically, 1 g COD is required for reduction of 1.5 g sulfate. In this problem, there is 2 g/L sulfate. Total COD consumed in sulfate reduction = 1.33g = 1330 mg COD available for methane production = (7000 –1330) mg/L = 5670 mg/L Methane generation rate when sulfate is present
  48. 48. Cont.. Cont..   (5666.67 x 10 -6 )  Total COD available = ----------------- x (2) kg/d for CH4 generation (10 -3 )            = 11.33 kg/d   From eq. (3) in example 1, we have:   1 kg COD produces 0.35 m 3 CH 4 at STP   11.33 kg COD produces ~ 0.35 x 11.33 = 3.97m 3 CH 4 /d at STP   At 20  C, the CH 4 gas generation = 3.97 x(293/273) = 4.3 m 3 /d The CH 4 generation rate when sulfate is present = 4.3 m 3 /d Presence of sulfate reduces methane yield by about 19% However, total biogas will now contain more H 2 S, adding volume
  49. 49. Expanded bed reactor (EBR) <ul><li>Expanded bed reactor is an attached growth system with some suspended biomass. </li></ul><ul><li>The biomass gets attached on bio-carriers such as sandman, pulverized polyvinyl chloride, shredded tire beads. </li></ul><ul><li>The bio-carriers are expanded by the upflow velocity of influent wastewater and recirculated effluent. </li></ul><ul><li>In the expanded bed reactor, sufficient upflow velocity is maintained to expand the bed by 15-30%. </li></ul><ul><li>The expanded bed reactor has less clogging problems and better substrate diffusion within the biofilm. </li></ul><ul><li>The biocarriers are partly supported by fluid flow and partly by contact with adjacent biocarriers, which retain the same relative position within the bed. </li></ul>
  50. 50. Fluidized bed reactor (FBR) <ul><li>FBR is similar to EBR in terms of configuration. But FBR is truly fixed film reactor as suspended biomass is washed–out due to high upflow velocity. </li></ul><ul><li>The bed expansion is 25-300% of the settled bed volume, which requires much higher upflow velocity (10-25 m/hr). </li></ul><ul><li>The bio-carriers are supported entirely by the upflow liquid velocity and therefore able to move freely in the bed. </li></ul><ul><li>The fluidized bed reactor is free from clogging problem short-circuiting and better substrate diffusion within the biofilm. </li></ul>
  51. 51. Hybrid system: UASB/AF Hybrid system incorporates both granular sludge blanket (bottom) and anaerobic filter (top). Such approach prevents wash-out of biomass from the reactor. Further additional treatment at the top bed due to the retention of sludge granules that escaped from the bottom sludge bed. UASB reactor facing a chronic sludge wash-out problem can be retrofitted using this approach. Hybrid system may be any combi-nation of two types of reactor
  52. 52. Biogas Sludge Anaerobic baffled reactor In anaerobic baffled reactor, the wastewater passes over and under the baffles. The biomass accumulates in Between the baffles which may in fact form granules with time. The baffles present the horizontal movement of of biomass in the reactor. Hence a high concentration of biomass can be maintained within the reactor.
  53. 53. Anaerobic Sequential Bed Reactor
  54. 54. Anaerobic process design Design based on volumetric organic loading rate (VOLR) S o . Q VOLR = --------- V VOLR : Volumetric organic loading rate (kg COD/m 3 -day) S o : Wastewater biodegradable COD (mg/L) Q : Wastewater flow rate (m 3 /day) V : Bioreactor volume (m 3 )
  55. 55. S o and Q can be measured easily and are known upfront VOLR can be selected! How do we select VOLR? <ul><li>Conducting a pilot scale studies </li></ul><ul><li>Find out removal efficiency at different VOLRs </li></ul><ul><li>Select VOLR based on desired efficiency </li></ul>VOLR Efficiency, %
  56. 56. Design based on hydraulic loading rate V =  a . Q  a . Q A = -------- H H : Reactor height (m)  a : Allowable hydraulic retention time (hr) Q : Wastewater flow rate (m 3 /h) A : Surface area of the reactor (m 2 ) Permissible superficial velocity (V a ) V a = H/  For dilute wastewater with COD < 1,000 mg/L
  57. 57. Solids retention time (SRT) An anaerobic digester is a completely mixed reactor for which solid retention time(SRT) and hydraulic retention time (HRT) is the same. V, m 3 Influent flow rate (Q), m 3 /day HRT, days = Volume V (m 3 ) = day Flow rate Q (m 3 /day) For a given SRT (HRT), the size of reactor can be easily determined since flow rate (Q) is known to us Digester volume, V (m 3 ) = Flow rate (Q) x SRT (  C )
  58. 58. Volatile solids loading rate The size of an anaerobic digester can also be estimated based on volatile solids loading rate expressed as kg VS/m 3 -day. V, m 3 Influent VS kg/day Volatile solids loading rate, (kg VS/m 3 - day) Influent VS (kg/day) Reactor volume (m 3 ) = For a given volatile solids loading rate, the size of reactor can be easily determined since influent VS (kg/day) is known to us. Influent VS (kg/day) Digester volume, V (m 3 ) = Volatile solids loading rate,(kg VS/m 3 - day)
  59. 59. Green cow power
  60. 60. Methane for power generation The digester uses feeder cattle manure from Amana Farms and industrial and food processing waste from such industries as Genencor International, Cargill and International Paper’s Cedar River Mill in Cedar Rapids. The $4.9 million facility near West Amana produces methane biogas that powers four electric generators. The system produces about 2.6 MW of power or 15% of Amana Service Co.’s base load electricity in winter and 10% in summer.
  61. 61. What happens to the left-overs? Common misconceptions about anaerobic digesters include that anaerobic digestion and the resulting biogas production will reduce the quantity of manure and the amount of nutrients that remain for utilization or disposal. An anaerobic digester DOES NOT MAKE MANURE DISAPPEAR! Often the volume of material (effluent) handled from a digester increases because of required dilution water for satisfactory pumping or digester operation. On average, only 4% of the influent manure is converted to biogas. None of the water! The remaining 96% leaves the digester as an effluent that is stable, rich in nutrients, free of weed seed, reduced or free of pathogens, and nearly odorless. This means that a farm loading 1,000 gallons per day into a digester can expect to have 960 gallons of material (effluent) to store and ultimately utilize. Depending on digester design and operation, solids can also settle out in the bottom of the digester and/or form a floating scum mat. Both the scum mat and the solids will eventually need to be mechanically removed from the digester to assure desired performance. When evaluating the actual performance and operation of a digester, it is important to determine and account for the amount and type of material retained in the digester and the cost of lost digester volume and ultimate cleaning. More anaerobic digester information can be found at: www.biogas.psu.edu Author: Patrick A. Topper, Pennsylvania State University
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