Enhancement of sewage sludge thickening and energy self-sufficiency with advanced process control tools in a full-scale wastewater treatment plant.

On their path to becoming sustainable facilities, it is required that wastewater treatment plants reduce their energy demand, sludge production, and chemical consumption, as well as increase on-site power generation. This study describes the results obtained from upgrading the sludge line of a full-scale wastewater treatment plant over 6 years (2015-2021) using three advanced process control strategies. The advanced process control tools were designed with the aim of (i) enhancing primary and secondary sludge thickening, (ii) improving anaerobic digestion performance, and (iii) reducing chemical consumption in the sludge line. The results obtained show that the use of advanced process control tools allows for optimising sludge thickening (increasing solids content by 9.5%) and anaerobic digestion (increasing both the removal of volatile solids and specific methane yield by 10%, respectively), while reducing iron chloride and antifoam consumption (by 75% and 53%, respectively). With the strategies implemented, the plant increased its potential energy self-sufficiency from 43% to 51% and reduced de-watered sludge production by 11%. Furthermore, the upgrade required a low investment, with a return of capital expense (CAPEX) in 1.98 years, which presents a promising and affordable alternative for upgrading existing wastewater treatment plants.

The effect of magnesium as activator and inhibitor of anaerobic digestion.

Anaerobic digestion stands as a key technology in the emerging green energy economy. Mg(2+) has been identified as an important element to improve digesters methane production; however the inhibition risk that high Mg(2+) concentrations can cause to the AD process must also be considered when dosing Mg reagents and wastes containing Mg(2+). Despite its importance, Mg(2+) stimulation and inhibition mechanisms as well as threshold values are scarce in the literature. This research paper investigates the impact (stimulation and inhibition) of Mg(2+) on pig manure anaerobic digestion. Mathematical modelling was used to better understand the interaction between substrate, inoculum and magnesium, where Mg(2+) inhibition was modelled by a n-component non-competitive inhibition function. Modelling was done on absolute curves rather than specific methane productions curves (new approach) to account for the lower background methane production of the inoculum as the Mg(2+) concentration increased. Results showed that no stimulation or inhibition occurred between 40 (native concentration) and 400mgMg(2+)L(-1), while minor and major inhibition were observed at 750 and 1000mgMg(2+)L(-1), and at 2000 and 4000mgMg(2+)L(-1), respectively. Mg(2+) half maximal inhibition concentration was estimated at 2140mgMg(2+)L(-1) with an inhibition order of 2. The latter indicates that Mg(2+) inhibition is a progressive rather than a steep inhibition mechanism.

Reagent use efficiency with removal of nitrogen from pig slurry via struvite: A study on magnesium oxide and related by-products.

Controlled struvite formation has been attracting increasing attention as a near mature technology to recover nutrients from wastewater. However, struvite feasibility is generally limited by the high cost of chemical reagents. With the aim to understand and control reagent use efficiency, experiments and equilibrium model simulations examined inorganic nitrogen (TAN) removal from pig manure via struvite with added magnesium and phosphate reagents. Four industrial magnesium oxide (MgO), a commercial product and three by-products from magnesite calcination, were tested with phosphate added as a highly soluble potassium salt. TAN removal extents with the MgOs ranged from 47 to 72%, with the highest grade MgO providing the greatest extent of TAN removal. However, model analysis showed that all the MgO reagents were poorly soluble (only about 40% of added magnesium actually dissolved). The model results suggested that this poor dissolution was due to kinetic limitations, not solubility constraints. A further set of additional reagents (termed stabilization agents) were prepared by pre-treating the MgO reagents with phosphoric acid, and were tested separately as a source of both magnesium and phosphate. Results showed that acid pre-treatment of moderate to highly reactive MgOs (soft to medium-burnt) primarily formed bobierrite as the stabilizing agent, whereas the pre-treatment of very low reactivity MgOs (dead-burnt) mostly formed newberyite. The newberyite stabilizing agents achieved very high TAN removal extents of about 80%, which is significant, considering that these were formed from dead-burnt/low-grade MgOs. However, the bobierrite stabilizing agents achieved a substantially lower TAN removal extent than their medium-to-high reactivity precursor MgOs. Again, model analysis showed that the bobierrite stabilizing agents were poorly soluble, due to kinetic limitations, not solubility constraints. In contrast, the model suggested that the newberyite stabilizing agents almost completely dissolved to very effectively form struvite. A mechanism was proposed by which conditions near a dissolving reagent particle surface causes unwanted struvite nucleation onto and overgrowth of the reagent particle, inhibiting further dissolution and markedly reducing reagent efficiency. The findings of the study could have implications for reagent efficiency with struvite in general, even when using other solid reagents such as magnesium hydroxide or other MgOs.