Innovative, compact and energy-efficient biofilm process for nutrient removal from wastewater.

Rapid population growth, industrial development and stringent demand for treatment of wastewater require developing and emerging economies to upgrade existing wastewater treatment plants (WWTPs) or planning new WWTPs. In the context of unavailability or unaffordability of land and resources for infrastructure expansion, low cost, small footprint, less energy consumption and product reuse are some of the major factors to be considered when either upgrading or designing new WWTPs in developing and emerging economies. Although the transition from activated sludge to biofilm processes has partly solved these challenges, there are innovations that can make the processes even more compact and more efficient. Newly developed CFIC (continuous flow intermittent cleaning) process is the next generation moving bed biological wastewater treatment system and is an example for addressing these issues. The CFIC pilot studies showed promising performance for biological chemical oxygen demand and nitrogen removal as well as particle separation facilitating wastewater reuse.

Evaluation of moving bed sand filter for denitrification, suspended solids removal and very low effluent total phosphorus concentrations.

Continuously flushing moving bed sand filter was operated in pilot scale for phosphorus (P) and nitrogen removal with simultaneous particle removal. The wastewater tested was either final effluent from a municipal wastewater treatment plant (WWTP) with nitrogen removal in moving bed biofilm reactors (MBBRs) followed by coagulation and dissolved air flotation (DAF) for P and suspended solids (SS) removal, or different mixtures of this final effluent and effluent from the MBBR-stage. The study focused on the applicability to achieve low total phosphorus (TP) concentrations (below 0.1 mg/L) and suspended solids concentrations (below 10 mg SS/L), plus good denitrification (removal rate over 750 g NO3-N/m3-d), by treating wastewater having variable concentrations of TP (from 0.19 to 7.3 mg/L), SS (from 3 to 169 mg/L) and total nitrogen (from 8 to 27 mg/L). The target effluent TP limit was easily achieved when adding coagulant to WWTP effluent. With correct coagulant dose (Al/TP-molar ratio >4) and good particle removal the target effluent TP could also be reached when treating mixed WW with fairly high influent TP. Very high denitrification rates were achieved with adequate influent P concentration and external carbon source. Low denitrification rates were observed when limited by low concentrations of biodegradable carbon and phosphorus.

Pilot-scale study to investigate the impact of rotating belt filter upstream of a MBR for nitrogen removal.

The goal of this study was to investigate what kind of impact the removal of particulate organic matter with 33µm rotating belt filter (RBF) (as a primary treatment) will have on the membrane bioreactor (MBR) performance. Two small MBR pilot plants were operated in parallel, where one train treated 2mm screened municipal wastewater (Train A) and the other train treated wastewater that had passed through a RBF with a 33µm filter cloth (Train B). The RBF was operated without a filter mat on the belt. About one third of the organic matter was removed by the fine mesh filter. The assessment of the overall performance showed that the two pilot plants achieved approximately the same removal efficiencies with regard to total suspended solids (TSS), chemical oxygen demand (COD), total phosphorus and total nitrogen. It was also observed that the system with 33µm RBF as a primary treatment produced more sludge, which could be used for biogas production, and required about 30% less aeration downstream. Transmembrane pressure was significantly lower for the train receiving 33µm primary treated wastewater compared to the control receiving 2mm screened wastewater.

Novel biofilm reactor for denitrification of municipal wastewater.

A pilot-scale CFIC® (continuous flow intermittent cleaning) reactor was run in anoxic conditions to study denitrification of wastewater. The CFIC process has already proven its capabilities for biological oxygen demand removal with a small footprint, less energy consumption and low cost. The present study focused on the applicability for denitrification. Both pre-denitrification (pre-DN) and post-denitrification (post-DN) were tested. A mixture of primary treated wastewater and nitrified wastewater was used for pre-DN and nitrified wastewater with ethanol as a carbon source was used for post-DN. The pre-DN process was carbon limited and removal rates of only 0.16 to 0.74 g NOx-N/m²-d were obtained. With post-DN and an external carbon source, 0.68 to 2.2 g NO3-Neq/m²-d removal rates were obtained. The carrier bed functioned as a good filter for both the larger particles coming with influent water and the bio-solids produced in the reactor. Total suspended solids removal in the reactor varied from 20% to 78% (average 45%) during post-DN testing period and 9% to 70% (average 29%) for pre-DN. The results showed that the forward flow washing improves both the DN function and filtration ability of the reactor.

Rotating belt sieves for primary treatment, chemically enhanced primary treatment and secondary solids separation.

Fine mesh rotating belt sieves (RBS) offer a very compact solution for removal of particles from wastewater. This paper shows examples from pilot-scale testing of primary treatment, chemically enhanced primary treatment (CEPT) and secondary solids separation of biofilm solids from moving bed biofilm reactors (MBBRs). Primary treatment using a 350 microns belt showed more than 40% removal of total suspended solids (TSS) and 30% removal of chemical oxygen demand (COD) at sieve rates as high as 160 m³/m²-h. Maximum sieve rate tested was 288 m³/m²-h and maximum particle load was 80 kg TSS/m²-h. When the filter mat on the belt increased from 10 to 55 g TSS/m², the removal efficiency for TSS increased from about 35 to 60%. CEPT is a simple and effective way of increasing the removal efficiency of RBS. Adding about 1 mg/L of cationic polymer and about 2 min of flocculation time, the removal of TSS typically increased from 40-50% without polymer to 60-70% with polymer. Using coagulation and flocculation ahead of the RBS, separation of biofilm solids was successful. Removal efficiencies of 90% TSS, 83% total P and 84% total COD were achieved with a 90 microns belt at a sieve rate of 41 m³/m²-h.

Impact of fine mesh sieve primary treatment on nitrogen removal in moving bed biofilm reactors.

The purpose of this project was to investigate the effect of selective particle removal during primary treatment on nitrogen removal in moving bed biofilm reactors (MBBRs). Two small MBBR pilot plants were operated in parallel, where one train treated 2 mm screened municipal wastewater and the other train treated wastewater that had passed through a Salsnes Filter SF1000 rotating belt sieve (RBS) with a 33 µs sieve cloth. The SF1000 was operated without a filter mat on the belt. The tests confirmed that, for the wastewater characteristics at the test plant, Salsnes Filter primary treatment with a 33 µs RBS and no filter mat produced a primary effluent that was close to optimum. Removal of organic matter with the 33 µs sieve had no negative effect on the denitrification process. Nitrification rates improved by 10-15% in the train with 33 µs RBS primary treatment. Mass balance calculations showed that without RBS primary treatment, the oxygen demand in the biological system was 36% higher. Other studies have shown that the sludge produced by RBS primary treatment is beneficial for biogas production and will also significantly improve sludge dewatering of the combined primary and biological sludge.

Effect of selective organic fractions on denitrification rates using Salsnes Filter as primary treatment.

The purpose of this project was to investigate the effect of selective particle removal during primary treatment on downstream biological nutrient removal processes. Bench-scale Salsnes Filter fine mesh sieves were used as a primary treatment to obtain different organic fractions to test the effect on denitrification. Activated sludge and moving bed biofilm reactor anoxic tests were performed on municipal wastewater collected from two full-scale wastewater treatment plants located around the Oslo region (Norway). About 43% of the suspended solids in the wastewater was less than 18 µm, and 14% was between 18 and 150 µm. The effect of particulate chemical oxygen demand (COD) removal on denitrification rates was very minor.

Evaluation and testing of fine mesh sieve technologies for primary treatment of municipal wastewater.

Fine mesh sieve technologies were tested in full scale at several municipal wastewater treatment plants. A screening test was used to characterize wastewater and establish the design criteria for the sieves. To achieve high removal efficiencies it was crucial to operate the sieves with a filter mat. Rotating belt sieves performed best in the full-scale tests. A small dose of cationic polymer and a static flocculator ahead of a rotating belt sieve achieved excellent results on a wastewater that was originally found unsuitable for primary treatment with fine mesh sieves. Simple screw presses dewatered the sludge from the sieves to typically 25-30% total solids. Using fine mesh sieves with <500 microns openings was found to normally be the most economical process for primary treatment.

Increasing the capacity for treatment of chemical plant wastewater by replacing existing suspended carrier media with Kaldnes Moving Bed media at a plant in Singapore.

The Kaldnes biomedia K1, which is used in the patented Kaldnes Moving Bed biofilm process, has been tested along with other types of biofilm carriers for biological pretreatment of a complex chemical industry wastewater. The main objective of the test was to find a biofilm carrier that could replace the existing suspended carrier media and at the same time increase the capacity of the existing roughing filter-activated sludge plant by 20% or more. At volumetric organic loads of 7.1 kg COD/m3/d the Kaldnes Moving Bed process achieved much higher removal rates and much lower effluent concentrations than roughing filters using other carriers. The Kaldnes roughing stage achieved more than 85% removal of organic carbon and more than 90% removal of BOD5 at the tested organic load, which was equivalent to a specific biofilm surface area load of 24 g COD/m2/d. Even for the combined roughing filter-activated sludge process, the Kaldnes carriers outperformed the other carriers, with 98% removal of organic carbon and 99.6% removal of BOD5. The Kaldnes train final effluent concentrations were only 22 mg FOC/L and 7 mg BOD5/L. Based on the successful pilot testing, the full-scale plant was upgraded with Kaldnes Moving Bed roughing filters. During normal operation the upgraded plant has easily met the discharge limits of 100 mg COD/L and 50 mg SS/L. For the month of September 2002, with organic loads between 100 and 115% of the design load for the second half of the month, average effluent concentrations were as low as 9 mg FOC/L, 51 mg COD/L and 12 mg SS/L.