Validation and implementation of model based control strategies at an industrial wastewater treatment plant.

In this paper, the practical implementation and validation of advanced control strategies, designed using model based techniques, at an industrial wastewater treatment plant is demonstrated. The plant under study is treating the wastewater of a large pharmaceutical production facility. The process characteristics of the wastewater treatment were quantified by means of tracer tests, intensive measurement campaigns and the use of on-line sensors. In parallel, a dynamical model of the complete wastewater plant was developed according to the specific kinetic characteristics of the sludge and the highly varying composition of the industrial wastewater. Based on real-time data and dynamic models, control strategies for the equalisation system, the polymer dosing and phosphorus addition were established. The control strategies are being integrated in the existing SCADA system combining traditional PLC technology with robust PC based control calculations. The use of intelligent control in wastewater treatment offers a wide spectrum of possibilities to upgrade existing plants, to increase the capacity of the plant and to eliminate peaks. This can result in a more stable and secure overall performance and, finally, in cost savings. The use of on-line sensors has a potential not only for monitoring concentrations, but also for manipulating flows and concentrations. This way the performance of the plant can be secured.

Adequate model complexity for scenario analysis of VOC stripping in a trickling filter.

Two models describing the stripping of volatile organic contaminants (VOCs) in an industrial trickling filter system are developed. The aim of the models is to investigate the effect of different operating conditions (VOC loads and air flow rates) on the efficiency of VOC stripping and the resulting concentrations in the gas and liquid phases. The first model uses the same principles as the steady-state non-equilibrium activated sludge model Simple Treat, in combination with an existing biofilm model. The second model is a simple mass balance based model only incorporating air and liquid and thus neglecting biofilm effects. In a first approach, the first model was incorporated in a five-layer hydrodynamic model of the trickling filter, using the carrier material design specifications for porosity, water hold-up and specific surface area. A tracer test with lithium was used to validate this approach, and the gas mixing in the filters was studied using continuous CO2 and O2 measurements. With the tracer test results, the biodegradation model was adapted, and it became clear that biodegradation and adsorption to solids can be neglected. On this basis, a simple dynamic mass balance model was built. Simulations with this model reveal that changing the air flow rate in the trickling filter system has little effect on the VOC stripping efficiency at steady state. However, immediately after an air flow rate change, quite high flux and concentration peaks of VOCs can be expected. These phenomena are of major importance for the design of an off-gas treatment facility.