The drying of sewage sludge by immersion frying

The objective of this work was to dry sewage sludge using a fry-drying process. The frying experiments were carried out in commercial fryers modified by adding thermocouples to the setup. During frying, typical drying curves were obtained and it was verified that, in relation to the parameters: oil temperature, oil type and shape of the sample, the shape factor the most effect on the drying rate, at least within the range chosen for the variables studied. Oil uptake and calorific value were also analyzed. The calorific value of the samples increased with frying time, reaching values around 24MJ/kg after 600s of frying (comparable to biocombustibles such as wood and sugarcane bagasse). The process of immersion frying showed great potential for drying materials, especially sewage sludge, obtaining a product with a high energy content, thereby increasing its value as a combustible.

Life Cycle Assessment (LCA) Applied to the Design of an Innovative Drying Process for Sewage Sludge

Most adverse environmental impacts result from design decisions made long before manufacturing or usage. In order to prevent this situation, several authors have proposed the application of life cycle assessment (LCA) at the very first phases of the design of a process, a product or a service. The study in this paper presents an innovative thermal drying process for sewage sludge called fry-drying, in which dewatered sludge is directly contacted in the dryer with hot recycled cooking oils (RCO) as the heat medium. Considering the practical difficulties for the disposal of these two wastes, fry-drying presents a potentially convenient method for their combined elimination by incineration of the final fry-dried sludge. An analytical comparison between a conventional drying process and the new proposed fry-drying process is reported, with reference to some environmental impact categories. The results of this study, applied at the earliest stages of the design of the process, assist evaluation of the feasibility of such system compared to a current disposal process for the drying and incineration of sewage sludge.

Heat and mass transfer during fry-drying of sewage sludge

Deep-frying, which consists of immersing a wet material in a large volume of hot oil, presents a process easily adaptable to dry rather than cook materials. A suitable material for drying is sewage sludge, which may be dried using recycled cooking oils (RCO) as frying oil. One advantage is that this prepares both materials for convenient disposal by incineration. This study examines fry-drying of municipal sewage sludge using recycled cooking oil. The transport processes occurring during fry-drying were monitored through sample weight, temperature, and image analysis. Due to the thicker and wetter samples than the common fried foods, high residual moisture is observed in the sludge when the boiling front has reached the geometric center of the sample, suggesting that the operation is heat transfer controlled only during the first half of the process followed by the addition of other mechanisms that allow complete drying of the sample. A series of mechanisms comprising four stages (i.e., initial heating accompanied by a surface boiling onset, film vapor regime, transitional nucleate boiling, and bound water removal) is proposed. In order to study the effect of the operating conditions on the fry-drying kinetics, different oil temperatures (from 120 to 180 degrees C), diameter (D = 15 to 25 mm), and initial moisture content of the sample (4.8 and 5.6 kg water(.)kg(-1) total dry solids) were investigated.

Effects of solids concentration, pH and carbon addition on the production rate and composition of volatile fatty acids in prefermenters using primary sewage sludge

Increasing evidence is emerging that the performance of enhanced biological phosphorus removal (EBPR) systems relies on not only the total amount but also the composition of volatile fatty acids (VFAs). Domestic wastewater often contains limited amounts of VFAs with acetic acid typically being the dominating species. Consequently, prefermenters are often employed to generate additional VFAs to meet the demand for carbon by EBPR and/or denitrification processes. Limited knowledge is currently available on the effects of operational conditions on the production rate and composition of VFAs in prefermenters. In this study, a series of controlled batch experiments were conducted with sludge from a full-scale prefermenter to determine the impact of solids concentration, pH and addition of molasses on prefermentation processes. It was found that an increase in solids concentration enhanced total VFA production with an increased propionic acid fraction. The optimal pH for prefermentation was in the range of 6-7 with significant productivity loss when pH was below 5.5. Molasses addition significantly increased the production of VFAs particularly the propionic acid. However, the fermentation rate was likely limited by the biological activity of the sludge rather than by the amount of molasses added.

The influence of substrate kinetics on the microbial community structure in granular anaerobic biomass

The development of a strong, active granular sludge bed is necessary for optimal operation of upflow anaerobic sludge blanket reactors. The microbial and mechanical structure of the granules may have a strong influence on desirable properties such as growth rate, settling velocity and shear strength. Theories have been proposed for granule microbial structure based on the relative kinetics of substrate degradation, but contradict some observations from both modelling and microscopic studies. In this paper, the structures of four granule types were examined from full-scale UASB reactors, treating wastewater from a cannery, a slaughterhouse, and two breweries. Microbial structure was determined using fluorescence in situ hybridisation probing with 16S rRNA-directed oligonucleotide probes, and superficial structure and microbial density (volume occupied by cells and microbial debris) assessed using scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The granules were also modelled using a distributed parameter biofilm model, with a previously published biochemical model structure, biofilm modelling approach, and model parameters. The model results reflected the trophic structures observed, indicating that the structures were possibly determined by kinetics. Of particular interest were results from simulations of the protein grown granules, which were predicted to have slow growth rates, low microbial density, and no trophic layers, the last two of which were reflected by microscopic observations. The primary cause of this structure, as assessed by modelling, was the particulate nature of the wastewater, and the slow rate of particulate hydrolysis, rather than the presence of proteins in the wastewater. Because solids hydrolysis was rate limiting, soluble substrate concentrations were very low (below Monod half saturation concentration), which caused low growth rates. (C) 2003 Elsevier Ltd. All rights reserved.

Revegetation strategies for bauxite refinery residue: A case study of Alcan Gove in Northern Territory, Australia

Alumina extraction from bauxite ore with strong alkali produces waste bauxite refinery residue consisting of residue sand and red mud. The amount and composition of refinery residue depend on the purity of the bauxite ore and extraction conditions, and differs between refineries. The refinery residue is usually stored in engineered disposal areas that eventually have to be revegetated. This is challenging because of the alkaline and sodic nature of the residue. At Alcan Gove's bauxite refinery in Gove, Northern Territory, Australia, research into revegetation of bauxite residue has been conducted since the mid-1970s. In this review, we discuss approaches taken by Alcan Gove to achieve revegetation outcomes (soil capping of refinery residue) on wet-slurry disposal areas. Problems encountered in the past include poor drainage and water logging during the wet season, and salt scalding and capillary rise during the dry season. The amount of available water in the soil capping is the most important determinant of vegetation survival in the seasonally dry climate. Vegetation cover was found to prevent deterioration of the soil cover by minimising capillary rise of alkalinity from the refinery residue. The sodicity and alkalinity of the residue in old impoundments has diminished slightly over the 25 years since it was deposited. However, development of a blocky structure in red mud, presumably due to desiccation, allows root penetration, thereby supplying additional water to salt and alkali-tolerant plant species. This has led to the establishment of an ecosystem that approaches a native woodland.

Modelling of two-stage anaerobic digestion using the IWA Anaerobic Digestion Model No. 1 (ADM1)

The aim of the study presented was to implement a process model to simulate the dynamic behaviour of a pilot-scale process for anaerobic two-stage digestion of sewage sludge. The model implemented was initiated to support experimental investigations of the anaerobic two-stage digestion process. The model concept implemented in the simulation software package MATLAB(TM)/Simulink(R) is a derivative of the IWA Anaerobic Digestion Model No.1 (ADM1) that has been developed by the IWA task group for mathematical modelling of anaerobic processes. In the present study the original model concept has been adapted and applied to replicate a two-stage digestion process. Testing procedures, including balance checks and 'benchmarking' tests were carried out to verify the accuracy of the implementation. These combined measures ensured a faultless model implementation without numerical inconsistencies. Parameters for both, the thermophilic and the mesophilic process stage, have been estimated successfully using data from lab-scale experiments described in literature. Due to the high number of parameters in the structured model, it was necessary to develop a customised procedure that limited the range of parameters to be estimated. The accuracy of the optimised parameter sets has been assessed against experimental data from pilot-scale experiments. Under these conditions, the model predicted reasonably well the dynamic behaviour of a two-stage digestion process in pilot scale. (C) 2004 Elsevier Ltd. All rights reserved.

Integration of sulphate reduction, autotrophic denitrification and nitrification to achieve low-cost excess sludge minimisation for Hong Kong sewage

An integrated anaerobic-aerobic treatment system of sulphate-laden wastewater was proposed here to achieve low sludge production, low energy consumption and effective sulphide control. Before integrating the whole system, the feasibility of autotrophic denitrification utilising dissolved sulphide produced during anaerobic treatment of sulphate rich wastewater was studied here. An upflow anaerobic sludge blanket reactor was operated to treat sulphate-rich synthetic wastewater (TOC = 100 mg/L and sulphate = 500 mg/L) and its effluent with dissolved sulphide and external nitrate solution were fed into an anoxic biofilter. The anaerobic reactor was able to remove 77-85% of TOC at HRT of 3 h and produce 70-90 mg S/L sulphide in dissolved form for the subsequent denitrification. The performance of anoxic reactor was stable, and the anoxic reactor could remove 30 mg N/L nitrate at HRT of 2 h through autotrophic denitrification. Furthermore, sulphur balance for the anoxic filter showed that more than 90% of the removed sulphide was actually oxidised into sulphate, thereby there was no accumulation of sulphur particles in the filter bed. The net sludge productions were approximately 0.15 to 0.18 g VSS/g COD in the anaerobic reactor and 0.22 to 0.31 g VSS/g NO3--N in the anoxic reactor. The findings in this study will be helpful in developing the integrated treatment system to achieve low-cost excess sludge minimisation.

Impacts of morphological, physical and chemical properties of sludge flocs on dewaterability of activated sludge

This study examined how the floc characteristics affect dewaterability of activated sludge. The floc properties were characterized by morphological parameters (floc size distribution, fractal dimension and filament index), physical properties (flocculating ability, surface charge, relative hydrophobicity and viscosity), and chemical constituents in sludge and extracted extracellular polymeric substances (EPS), including the polymeric compounds protein, humic substances, carbohydrates and the ions Ca2+, Mg2+, Fe3+ and Al3+. The dewaterability was defined in terms of the bound water content and capillary suction time (CST). The bound water and CST corresponded to a similar indication with respect to dewaterability of activated sludge. The floc physical parameters were the most important factors which effect significantly on the water binding ability of the sludge flocs. The morphological characteristics had relatively weak impact on the dewaterability. The polymeric components protein and carbohydrate had a significant contribution to enhance the water binding ability of the sludge flocs. The effect of humic substances in the sludge on the dewaterability was, however, insignificant. The CST had good statistical correlations with the polymeric constituents measured in both sludge and the extracted EPS, and the bound water was only correlated well with the individual polymers measured in the sludge. High concentration of Ca2+, Mg2+, Fe3+ and Al3+ had significant improvement for dewaterability. (C) 2003 Elsevier B.V. All rights reserved.

Piggery pond sludge as a nitrogen source for crops. 1. Mineral N supply estimated from laboratory incubations and field application of stockpiled and wet sludge

Piggery pond sludge (PPS) was applied, as-collected (Wet PPS) and following stockpiling for 12 months ( Stockpiled PPS), to a sandy Sodosol and clay Vertosol at sites on the Darling Downs of Queensland. Laboratory measures of N availability were carried out on unamended and PPS-amended soils to investigate their value in estimating supplementary N needs of crops in Australia's northern grains region. Cumulative net N mineralised from the long-term ( 30 weeks) leached aerobic incubation was described by a first-order single exponential model. The mineralisation rate constant (0.057/week) was not significantly different between Control and PPS treatments or across soil types, when the amounts of initial mineral N applied in PPS treatments were excluded. Potentially mineralisable N (N-o) was significantly increased by the application of Wet PPS, and increased with increasing rate of application. Application of Wet PPS significantly increased the total amount of inorganic N leached compared with the Control treatments. Mineral N applied in Wet PPS contributed as much to the total mineral N status of the soil as did that which mineralised over time from organic N. Rates of CO2 evolution during 30 weeks of aerobic leached incubation indicated that the Stockpiled PPS was more stabilised (19-28% of applied organic C mineralised) than the Wet PPS (35-58% of applied organic C mineralised), due to higher lignin content in the former. Net nitrate-N produced following 12 weeks of aerobic non-leached incubation was highly correlated with net nitrate-N leached during 12 weeks of aerobic incubation (R-2 = 0.96), although it was

Eliminating non-renewable CO2 emissions from sewage treatment: An anaerobic migrating bed reactor pilot plant study

The aim of this work was to demonstrate at pilot scale a high level of energy recovery from sewage utilising a primary Anaerobic Migrating Bed Reactor (AMBR) operating at ambient temperature to convert COD to methane. The focus is the reduction in non-renewable CO2 emissions resulting from reduced energy requirements for sewage treatment. A pilot AMBR was operated on screened sewage over the period June 2003 to September 2004. The study was divided into two experimental phases. In Phase 1 the process operated at a feed rate of 10 L/h (HRT 50 h), SRT 63 days, average temperature 28 degrees C and mixing time fraction 0.05. In Phase 2 the operating parameters were 20 L/h, 26 days, 16 degrees C and 0.025. Methane production was 66% of total sewage COD in Phase 1 and 23% in Phase 2. Gas mixing of the reactor provided micro-aeration which suppressed sulphide production. Intermittent gas mixing at a useful power input of 6 W/m(3) provided satisfactory process performance in both phases. Energy consumption for mixing was about 1.5% of the energy conversion to methane in both operating phases. Comparative analysis with previously published data confirmed that methane supersaturation resulted in significant losses of methane in the effluent of anaerobic treatment systems. No cases have been reported where methane was considered to be supersaturated in the effluent. We have shown that methane supersaturation is likely to be significant and that methane losses in the effluent are likely to have been greater than previously predicted. Dissolved methane concentrations were measured at up to 2.2 times the saturation concentration relative to the mixing gas composition. However, this study has also demonstrated that despite methane supersaturation occurring, microaeration can result in significantly lower losses of methane in the effluent (< 11% in this study), and has demonstrated that anaerobic sewage treatment can genuinely provide energy recovery. The goal of demonstrating a high level of energy recovery in an ambient anaerobic bioreactor was achieved. An AMBR operating at ambient temperature can achieve up to 70% conversion of sewage COD to methane, depending on SRT and temperature. (c) 2006 Wiley Periodicals, Inc.