Sludge Mass Reduction Research Articles

Sludge Reduction and Surface Investigation in Electrochemical Machining by Complexing and Reducing Agents

Electrochemical machining (ECM) is widely applied to manufacture parts with complex geometries, used in electronic components and the automotive, military, and aeronautics industries. These parts have a surface shaped by controlled anodic dissolution at high current density levels, using a neutral solution of inorganic salts (i.e., NaCl or NaNO3) as the electrolyte. Such conditions generate a high amount of sludge that deposits onto the surfaces of equipment, devices, cathodes, and working pieces, requiring daily and complicated sludge management during the series production in the industry. Thus, the main goal of the present work is to propose a simple way to reduce sludge generation in the ECM industrial process. To do so, complexing (EDTA) or reducing (ascorbic acid) agents were added to the electrolyte composition, creating parallel reactions to keep the metallic ions from precipitating. The complexing agent EDTA resulted in a 30% reduction in sludge mass, using an alkaline solution (pH > 10.0). The reducing agent, ascorbic acid, resulted in a 90% reduction in sludge mass, using an acidic solution (pH < 5.0). This sludge reduction has the potential to contribute significantly to increasing equipment, devices, and cathode lifetime, as well as reducing costs associated with centrifuge or filter maintenance (sludge removal from electrolyte) and increasing the productivity of industrial ECM processes.

Evaluation of trophic transfer in the microbial food web during sludge degradation based on 13C and 15N natural abundance

Carbon and nitrogen stable isotope ratios (δ13C and δ15N) were determined in activated sludge, which was exposed to endogenous conditions for 36 days and contained a wide diversity of organisms across several trophic levels. The aim of this study was to elucidate the fluctuation of δ13C and δ15N through trophic transfer in the microbial consortia. The sludge was evaluated in view of sludge mass, bacterial community, higher trophic organisms, sludge δ13C and δ15N, and δ15N and δ18O of nitrate. The results show that the activated sludge became more enriched with 15N as degradation proceeded. Eventually, the mixed liquor volatile suspended solid concentrations in the activated sludge decreased from 1610 to 710 mg/L and the δ15N of the sludge increased from 8.3‰ to 10.8‰. In contrast, the δ13C values of the sludge were stable. Microscope observations confirmed that consumers such as Rotifera, Tardigrada and Annelida (Aelosoma sp.) were present in the activated sludge for the entire operational period. The abundance of those organisms drastically changed during the operational periods, and the diversity in bacterial community also changed, resulting in community succession. Changes in biotic community, reduction in sludge mass, and increase in δ15N of the sludge occurred during the sludge degradation processes. This implies that the sludge degradation was partly caused by the trophic conversion of the sludge-derived nitrogen in the food web. The δ15N of the sludge can be used as an indicator of the sludge degradation through trophic transfer in wastewater treatment reactors. These findings provide new insights into understanding trophic transfer during microbial community succession and the effects of the feeding process on sludge degradation.

Enhanced Separation of the Organic Fraction from Paper Mill Effluent for Energy Recovery

In this study pre-treatment of pulp and paper mill sludge was investigated to enhance the energy recovery by anaerobic digestion. Two approaches were followed using hydrolytic enzymes or microbiological treatment at 30 °C. In the first attempt, anaerobic digestion of the whole sludge, no significant improvement of the methane production potential was found. In the second test series only the liquid phase after pre-treatment and solids separation was anaerobically degraded. This option provided up to ten times increased methane production compared to the untreated sample. Sludge mass reduction between 6 and 13 % was achieved after pre-treatment. Moreover this concept can be easily integrated in the established wastewater treatment scheme utilizing an existing upflow anaerobic sludge blanket reactor.

Activated sludge mass reduction and biodegradability of the endogenous residues by digestion under different aerobic to anaerobic conditions: Comparison and modeling

This study was performed to identify suitable conditions for the in-situ reduction of excess sludge production by intercalated digesters in recycle-activated sludge (RAS) flow. The objective was to compare and model biological sludge mass reduction and the biodegradation of endogenous residues (XP) by digestion under hypoxic, aerobic, anaerobic, and five intermittent-aeration conditions. A mathematical model based on the heterotrophic endogenous decay constant (bH) and including the biodegradation of XP was used to fit the long-term data from the digesters to identify and estimate the parameters. Both the bH constant (0.02–0.05d−1) and the endogenous residue biodegradation constant (bP, 0.001–0.004d−1) were determined across the different mediums. The digesters with intermittent aeration cycles of 12h–12h and 5min–3h (ON/OFF) were the fastest, compared to the aerobic reactor. The study provides a basis for rating RAS-digester volumes to avoid the accumulation of XP in aeration tanks.

Impact of suspended solids concentration on sludge filterability in full-scale membrane bioreactors

The relation between activated sludge filterability and mixed liquor suspended solids (MLSS) concentration in membrane bioreactors (MBRs) is framed in a single hypothesis, explaining results seemingly contradictory. A total of 44 activated sludge samples were collected and analyzed on a variety of parameters, i.e. filterability, MLSS concentration, soluble microbial products (SMP) concentrations and particle size distribution in the range of 2–100μm and of 0.4–5.0μm. The sludge filterability was assessed by using the Delft Filtration Characterization method (DFCm). In order to investigate the impact of MLSS concentration, identical samples were diluted with permeate. Results showed that dilution of the samples led to an increased activated sludge filterability, but only when the starting MLSS concentration was below the apparent critical value of 10.5g/L. As opposed, the filterability of sludge with MLSS concentrations above 10.5g/L, and which was characterized by a moderate to good filtration quality, i.e. ΔR20<1 [×1012m−1], worsened when diluted. The specific resistance times the particle concentration of a cake layer obtained when filtrating sludge of moderate to good filterability and MLSS concentration above the apparent critical value was 5.5 times smaller compared to the cake layer of sludge with MLSS concentration below the critical value. Results from SMP assessment and particle counting in the range 2–100µm showed that reduction in sludge mass and de-flocculation occurred, upon dilution of all samples. However, when diluting sludge samples with MLSS concentrations exceeding 10.5g/L and which were characterized by a moderate to good filtration characteristics, there was also release of particles below 0.4µm, opposite to dilutions of samples with MLSS concentrations below 10.5g/L. We postulate that sludge, which is characterized by a moderate to good filterability, having an MLSS concentration above the apparent critical value of 10.5g/L, is likely to retain particles smaller than 0.4μm in its mass, as opposed to sludge with MLSS concentration below the apparent critical value. Our work indicates that there are optimal MLSS concentration ranges in MBR technology, to promote good filterable sludge quality in order to avoid fouling.

Assessment of physiological state of microorganisms in activated sludge with flow cytometry: application for monitoring sludge production minimization

Many sludge reduction processes have been studied for the minimization of sludge production in biological wastewater treatment. The investigations on most of these processes have monitored the increase of the soluble chemical oxygen demand, the sludge mass reduction, or the decrease of the floc size, but little information has been obtained on cell lysis and the change of the biological cell activity. However, employing any strategy for reducing sludge production may have an impact of microbial community in biological wastewater treatment process. This impact may influence the sludge characteristics and the quality of effluent. The objective of this study concerns the determination of the physiological state of activated sludge microorganisms during a sludge minimization process. A thermal treatment at 80 degrees C for 5, 20, 40 and 60 min was chosen in this study. Staining bacteria with CTC and SYTOX green was used to evaluate biological cell activity and viability of cell types contained in activated sludge, respectively. The monitoring of cell activity and viability was performed using flow cytometry (FCM) analysis before and after thermal treatment of activated sludge. Results indicated an increase in the number of permeabilized cells and a decrease in the number of active cells, subsequent to the thermal treatment. The study also confirms the potential of FCM to successfully evaluate the physiological heterogeneity of an activated sludge bacterial population. Moreover, the experimentally observed correlations between the FCM results and the organic matter solubilization in activated sludge samples during thermal treatment revealed that the increase in the soluble organic matter concentration was predominantly due to an intracellular material release. Identifying the increase in activated sludge hydrolysis requires a precise knowledge of the involved mechanisms, and this study indicated that the FCM, used in conjunction with specific probes, could be a useful tool.

Quality of brackish aquaculture sludge and its suitability for anaerobic digestion and methane production in an upflow anaerobic sludge blanket (UASB) reactor

Intensive recirculating aquaculture systems (RAS) produce high volumes of biosolid waste. The high salinity of brackish/marine sludge limits its use in landfill sites and waste outflows and it is a source of pollution. A reduction in sludge mass would therefore minimize the potential environmental hazard and economic burden stemming from its disposal. The aims of the current study were: 1) to characterize brackish aquaculture sludge (BAS) from three RAS in order to test for potentially suitable treatments, and 2) to test the BAS's suitability for anaerobic digestion in an upflow anaerobic sludge blanket reactor (UASB). Brackish sludge from three intensive RAS was collected periodically and analyzed for a variety of physical and chemical parameters. The mean sludge electrical conductivity and pH values ranged from 4.0 to 8.6 mS cm − 1 and 7.0 to 7.7, respectively. A low sludge redox potential averaging − 80 mV and dissolved oxygen concentrations of less than 1 mg l − 1 indicated the existence of anaerobic conditions. Volatile solids comprised 56 to 76% of the dry weight and the sludge volume index ranged from 44 to 69 ml g − 1 . High concentrations of total nitrogen and total carbon were also observed, resulting in a C:N ratio ranging between 8.1 and 10.3. Toxic and/or inhibitory compounds for methanogenesis such as nitrites, nitrates and sulfides were almost absent. Sludge BOD 5 ranged from 10 to 30% dry weight. These data suggest that BAS may be used in anaerobic digestion and methanogenesis without pretreatment. This concept was tested by digesting aquaculture sludge in UASB reactors. Despite the high sulfate and phosphate concentrations in the BAS, these were found not to be inhibitory to methanogenesis. Up to 70% sludge-mass reduction and an average of 40% methane production were demonstrated.

Ultrasonic treatment of biological sludge: Floc disintegration, cell lysis and inactivation

The aim of this work was to study the effect of ultra sound treatment on the solid content of sludge and biological activity, and the increase in the soluble chemical oxygen demand (SCOD), proteins and nucleic acids concentrations during sonication. The results showed that sonication effectively degraded and inactivated the sludge. The sludge disintegration and cell lysis occurred continuously while sludge inactivation mainly occurred in the second stage (10–30 min) during sonication. The SCOD, supernatant proteins and nucleic acids concentrations, and sludge mass reduction and inactivation degrees increased with the sonication time and power density increases. Higher energy ultrasound was more efficient than lower energy ultrasound for the sludge treatment.

Sludge minimization technologies - an overview

The management of wastewater sludge from wastewater treatment plants represents one of the major challenges in wastewater treatment today. The cost of the sludge treatment amounts to more than the cost of the liquid in many cases. Therefore the focus on and interest in sludge minimization is steadily increasing. In this paper an overview is given for sludge minimization (sludge mass reduction) options. It is demonstrated that sludge minimization may be a result of reduced production of sludge and/or disintegration processes that may take place both in the wastewater treatment stage and in the sludge stage. Various sludge disintegration technologies for sludge minimization are discussed, including mechanical methods (focusing on stirred ball-mill, high-pressure homogenizer, ultrasonic disintegrator), chemical methods (focusing on the use of ozone), physical methods (focusing on thermal and thermal/chemical hydrolysis) and biological methods (focusing on enzymatic processes).

Sludge treatment by ozonation Ð evaluation of full-scale results

Ozonation of industrial and sewage sludge is a suitable process for minimizing the sludge production of activated sludge processes. The ozonation has the advantage for complete oxidation of volatile suspended solids (VSS) of combining partial sludge oxidation with subsequent biological oxidation. This paper describes the evaluation of two full-scale sewage sludge ozonation investigations for subsequent aerobic stabilisation as well as for subsequent anaerobic stabilisation compared to different sludge treatment processes. For both the anaerobic and aerobic application, sludge liquefying by release of 110 and 160 mg COD per g total suspended solids (TSS) has been reached at specific ozone consumption of 0.03 and 0.06 kg O3 per kg TSS, respectively. The subsequent biological treatment has reached a mass reduction of 20-35% for the aerobic and 19% for the anaerobic stabilisation. For both applications the specific ozone consumption was about 0.05 kgO3 per kg TSS to be treated. A comparison with mechanical and thermo-chemical sludge mass reduction methods shows that the mass reduction potential of ozonation is presently higher. Even though costs for sludge ozonation are higher compared to other methods, the optimisation potential for cost reduction of sludge ozonation is obvious from the results presented in this paper.