Oxygen transfer and uptake, nutrient removal, and energy footprint of parallel full-scale IFAS and activated sludge processes

Abstract

Integrated fixed-film activated sludge (IFAS) processes are becoming more popular for both secondary and sidestream treatment in wastewater facilities. These processes are a combination of biofilm reactors and activated sludge processes, achieved by introducing and retaining biofilm carrier media in activated sludge reactors. A full-scale train of three IFAS reactors equipped with AnoxKaldnes media and coarse-bubble aeration was tested using off-gas analysis. This was operated independently in parallel to an existing full-scale activated sludge process. Both processes achieved the same percent removal of COD and ammonia, despite the double oxygen demand on the IFAS reactors. In order to prevent kinetic limitations associated with DO diffusional gradients through the IFAS biofilm, this systems was operated at an elevated dissolved oxygen concentration, in line with the manufacturer’s recommendation. Also, to avoid media coalescence on the reactor surface and promote biofilm contact with the substrate, high mixing requirements are specified. Therefore, the air flux in the IFAS reactors was much higher than that of the parallel activated sludge reactors. However, the standardized oxygen transfer efficiency in process water was almost same for both processes. In theory, when the oxygen transfer efficiency is the same, the air used per unit load removed should be the same. However, due to the high DO and mixing requirements, the IFAS reactors were characterized by elevated air flux and air use per unit load treated. This directly reflected in the relative energy footprint for aeration, which in this case was much higher for the IFAS system than activated sludge.