Influence of the operating conditions of the intermediate thermal hydrolysis on the energetic efficiency of the sludge treatment process.

The application of steam explosion between two stages of anaerobic digestion may improve energy recovery from sludge while increasing organic matter removal. The influence of the operating conditions of the thermal process: temperature (130-210 °C), retention time (5-45 min) and TS concentration (5.4-10.8%), on the efficiency of VS removal, the biochemical methane potential of hydrolysed sludge and the kinetic constant of the degradation were evaluated using a Taguchi design. Increasing temperature and time increased the removal of VS and the potential of methane production but the kinetic constant was higher at lower temperatures. An optimal operating scheme was found at 170 °C (6 barg), 25 min at the greatest TS concentration in the feeding. Under such conditions, the thermal energy obtained from biogas combustion in a CHP covered the requirements for vapour generation and a profit of 3.54 € m-3 of sludge was estimated.

Traceability of organic contaminants in the sludge line of wastewater treatment plants: A comparison study among schemes incorporating thermal hydrolysis treatment and the conventional anaerobic digestion.

The traceability of conventional pollutants and 10 organic microcontaminants in the sludge line of a wastewater treatment plant (WWTP) was evaluated. The application of thermal hydrolysis (TH) as pre-treatment to anaerobic digestion (AD) or as inter-treatment (between two AD stages) was considered and compared with the conventional digestion scheme. TH scenarios reduced the mass flow rate of biosolids (40-60%) as well as the ratio of solids (50-100%), organic matter (5-26%) and nitrogen (8-13%) destined to biosolids. Micropollutants showed a strong tendency to accumulate in the solid phase (more than 90% were sorbed) in spite of thermal and dewatering processes, but TH scenarios exhibited greater removal efficiency (80%) in comparison to conventional AD (50%), reducing the ratio of micropollutants destined to biosolids from a conventional 48% to 7-8%. These findings reveal that TH could increase the value of biosolids from sewage sludge treatment because of greater removal of pollutants and dewaterability.

Anaerobic co-digestion of coffee husks and microalgal biomass after thermal hydrolysis.

Residual coffee husks after seed processing may be better profited if bioconverted into energy through anaerobic digestion. This process may be improved by implementing a pretreatment step and by co-digesting the coffee husks with a more liquid biomass. In this context, this study aimed at evaluating the anaerobic co-digestion of coffee husks with microalgal biomass. For this, both substrates were pretreated separately and in a mixture for attaining 15% of total solids (TS), which was demonstrated to be the minimum solid content for pretreatment of coffee husks. The results showed that the anaerobic co-digestion presented a synergistic effect, leading to 17% higher methane yield compared to the theoretical value of both substrates biodegraded separately. Furthermore, thermal hydrolysis pretreatment increased coffee husks anaerobic biodegradability. For co-digestion trials, the highest values were reached for pretreatment at 120 °C for 60 min, which led to 196 mLCH4/gVS and maximum methane production rate of 0.38 d-1.

Enhancement of methane production in mesophilic anaerobic digestion of secondary sewage sludge by advanced thermal hydrolysis pretreatment.

Studies on the development and evolution of anaerobic digestion (AD) pretreatments are nowadays becoming widespread, due to the outstanding benefits that these processes could entail in the management of sewage sludge. Production of sewage sludge in wastewater treatment plants (WWTPs) is becoming an extremely important environmental issue. The work presented in this paper is a continuation of our previous studies with the aim of understanding and developing the advanced thermal hydrolysis (ATH) process. ATH is a novel AD pretreatment based on a thermal hydrolysis (TH) process plus hydrogen peroxide (H2O2) addition that takes advantage of a peroxidation/direct steam injection synergistic effect. The main goal of the present research was to compare the performance of TH and ATH, conducted at a wide range of operating conditions, as pretreatments of mesophilic AD with an emphasis on methane production enhancement as a key parameter and its connection with the sludge solubilization. Results showed that both TH and ATH patently improved methane production in subsequent mesophilic BMP (biochemical methane potential) tests in comparison with BMP control tests (raw secondary sewage sludge). Besides other interesting results and discussions, a promising result was obtained since ATH, operated at temperature (115 °C), pretreatment time (5 min) and pressure (1 bar) considerably below those typically used in TH (170 °C, 30 min, 8 bar), managed to enhance the methane production in subsequent mesophilic BMP tests [biodegradability factor (fB) = cumulative CH4production/cumulative CH4production (Control) = 1.51 ± 0.01] to quite similar levels than conventional TH pretreatment [fB = 1.52 ± 0.03].

Simplified mechanistic model for the two-stage anaerobic degradation of sewage sludge.

Two-phase anaerobic systems are being increasingly implemented for the treatment of both sewage sludge and organic fraction of municipal solid waste. Despite the good amount of mathematical models in anaerobic digestion, few have been applied in two-phase systems. In this study, a three-reaction mechanistic model has been developed, implemented and validated by using experimental data from a long-term anaerobic two-phase (TPAD) digester treating sewage sludge. A sensitivity analysis shows that the most influential parameters of the model are the ones related to the hydrolysis reaction and the activity of methanogens in the thermophilic reactor. The calibration procedure highlights a noticeable growth rate of the thermophilic methanogens throughout the evaluation period. Overall, all the measured variables are properly predicted by the model during both the calibration and the cross-validation periods. The model's representation of the organic matter behaviour is quite good. The most important disagreements are observed for the biogas production especially during the validation period. The whole application procedure underlines the ability of the model to properly predict the behaviour of this bioprocess.

Thermal pretreatment and hydraulic retention time in continuous digesters fed with sewage sludge: assessment using the ADM1.

Thermal pretreatment is an interesting technique not only for increasing sludge biodegradability, leading to higher methane productivity, but also for improving degradation rates, allowing full-scale plants to reduce the size of digesters. In this study, the Anaerobic Digestion Model No. 1 (ADM1) was used as a tool to assess the effects of thermal pretreatment and hydraulic retention time (HRT) on the performance of three pilot-scale digesters fed with mixed sludge with/without pretreatment applied to the waste activated sludge fraction. Calibration procedures using batch tests showed an increase of up to five times in the model disintegration coefficient due to the pretreatment, and the validations performed presented good accuracy with the experimental data, with under/overestimation lower than 15% in both average and global accumulated CH4 productions. Therefore, the ADM1 demonstrated its feasibility and usefulness in predicting and assessing the behavior of the digesters under these conditions.

Long-term hydrolytic capacity evaluation of a thermophilic anaerobic digester treating sewage sludge.

This study presents an evaluation of the hydrolytic activity of a continuous thermophilic anaerobic reactor in long-term operation. The hydrolytic coefficient was estimated by fitting a three-reaction model of the anaerobic digestion process with experimental data obtained from a pilot thermophilic digester operated for about 2 years. The model fitting and the cross-validation indicate that this model can represent the behavior of the system in a proper way; moreover, the results show a variation of the hydrolytic capacity of the system throughout the evaluation period. The increase in the hydrolytic coefficient is in agreement with the increase in the organic load applied to the reactor, which shows the capacity of the continuous reactor to select populations according to the input conditions of the system.

Advanced thermal hydrolysis: optimization of a novel thermochemical process to aid sewage sludge treatment.

The aim of this work was to study in depth the behavior and optimization of a novel process, called advanced thermal hydrolysis (ATH), to determine its utility as a pretreatment (sludge solubilization) or postreatment (organic matter removal) for anaerobic digestion (AD) in the sludge line of wastewater treatment plants (WWTPs). ATH is based on a thermal hydrolysis (TH) process plus hydrogen peroxide (H(2)O(2)) addition and takes advantage of a peroxidation/direct steam injection synergistic effect. On the basis of the response surface methodology (RSM) and a modified Doehlert design, an empirical second-order polynomial model was developed for the total yield of: (a) disintegration degree [DD (%)] (solubilization), (b) filtration constant [F(c) (cm(2)/min)] (dewaterability), and (c) organic matter removal (%). The variables considered were operation time (t), temperature reached after initial heating (T), and oxidant coefficient (n = oxygen(supplied)/oxygen(stoichiometric)). As the model predicts, in the case of the ATH process with high levels of oxidant, it is possible to achieve an organic matter removal of up to 92%, but the conditions required are prohibitive on an industrial scale. ATH operated at optimal conditions (oxygen amount 30% of stoichiometric, 115 °C and 24 min) gave promising results as a pretreatment, with similar solubilization and markedly better dewaterability levels in comparison to those obtained with TH at 170 °C. The empirical validation of the model was satisfactory.

The influence of the energy absorbed from microwave pretreatment on biogas production from secondary wastewater sludge.

In this study, microwave treatment is analyzed as a way to accelerate the hydrolysis in anaerobic digestion of municipal wastewater sludge. The influence of the absorbed energy, power and athermal microwave effect on organic matter solubilization and biogas production has been studied. In addition, a novel method that considers the absorbed energy in the microwave system is proposed, in order to obtain comparable experimental results. The absorbed energy is calculated from an energy balance. The highest solubilization was achieved using 0.54 kJ/ml at 1000 W, where an increment of 7.1% was observed in methane production, compared to the untreated sample. Using a higher energy value (0.83 kJ/ml), methane production further increased (to 15.4%), but solubilization decreased. No power influence was found when 0.54 kJ/ml was applied at 1000, 600 and 440 W. Microwave heating was compared to conventional heating in two different experimental setups, providing similar methane yields in all cases.

Hydrothermal multivariable approach: full-scale feasibility study

A process configuration combining thermal hydrolysis (TH) and anaerobic digestion (AD) of sludge has been studied with the objective of analysing the feasibility of the technology for full scale installations. The study has been performed through pilot scale experiments and energy integration considerations, and a scheme of the most profitable option is presented: thermal hydrolysis unit fed with 7 percent total solids (TS) secondary sludge, anaerobic digestion of the hydrolysed sludge together with fresh primary sludge, and a cogeneration unit to produce green electricity and provide hot steam for the thermal hydrolysis process. From a technical and practical point of view, the process scheme proposed is considered to be feasible. Based on the results of the pilot plant performance and the laboratory studies, the process has proven to operate successfully at a concentration of 7-8 percent TS. After the thermal hydrolysis, sludge viscosity becomes radically smaller, and this favours the digesters mixing and performance (40 percent more biogas can be obtained in nearly half the residence time compared to the conventional digestion). From an economic point of view, the key factors in the energy balance are: the recovery of heat from hot streams, and the concentration of sludge. The article presents the main energy integration schemes and defines the most profitable one: an energetically self-sufficient process, with a cogeneration unit. The scheme proposed has proven to need no additional energy input for the sludge hydrolysis, generates more that 1 MW green electricity (246 kW surplus with respect to the conventional process), and produces 58 percent less volume of Class A biowaste. The study and balances here presented set the basis for the scale-up to a demonstration plant (hydrolysis + anaerobic digestion + cogeneration unit).