Performance and life cycle assessment of moving-bed biofilm and integrated fixed-film reactors to upgrade activated sludge systems

Abstract

Upgrading the capacity of existing wastewater treatment plants (WWTPs) is hindered by the limited space for extension. This matter is particularly crucial in developing countries where dense urban areas experience unexpectedly growing populations. Herein, we study the capacity upgrading of a WWTP working by a conventional activated sludge (CAS) system from 180,000 m3/d to 240,000 and 300,000 m3/d. The WWTP case study focuses on a large plant in Mansoura, Egypt, requiring capacity upgrades to accommodate population growth. For this purpose, we used mathematical modeling to simulate current and suggested WWTP designs. Moving bed biofilm reactor (MBBR) and integrated fixed film-activated sludge (IFAS) systems were designed to increase the WWTP capacity to 240,000 and 300,000 m3/d by the addition of plastic biofilm carrier to 25% and 50% of the aeration basins, respectively. IFAS outperformed conventional and MBBR systems in terms of BOD, COD, TSS, NH4, TP, and PO4, in addition to increased capacity. We moreover used life cycle assessment (LCA) to comprehend the environmental favorability of upgrading scenarios. The most affected environmental categories are global warming and eutrophication due to the operation stage (especially electricity). Global warming potential for CAS, MBBR, and IFAS (300,000 m3/d) are 2.19, 1.69, and 1.73 kg CO2 eq respectively. Eutrophication potential for CAS, MBBR, and IFAS (300,000 m3/d) are 0.0025, 0.0022, and 0.0017 kg PO4- eq respectively. We also estimated the amortization and running costs for various upgrading scenarios, providing an integrated analysis for decision-making purposes.