Multi-model statistical process monitoring and diagnosis of a sequencing batch reactor

Biological processes exhibit different behavior depending on the influent loads, temperature, microorganism activity, and so on. It has been shown that a combination of several models can provide a suitable approach to model such processes. In the present study, we developed a multiple statistical model approach for the monitoring of biological batch processes. The proposed method consists of four main components: (1) multiway principal component analysis (MPCA) to reduce the dimensionality of data and to remove collinearity; (2) multiple models with a posterior probability for modeling different operating regions; (3) local batch monitoring by the T(2)- and Q-statistics of the specific local model; and (4) a new discrimination measure (DM) to identify when the system has shifted to a new operating condition. Under this approach, local monitoring by multiple models divides the entire historical data set into separate regions, which are then modeled separately. Then, these local regions can be supervised separately, leading to more effective batch monitoring. The proposed method is applied to a pilot-scale 80-L sequencing batch reactor (SBR) for biological wastewater treatment. This SBR is characterized by nonstationary, batchwise, and multiple operation modes. The results obtained for the pilot-scale SBR indicate that the proposed method has the ability to model multiple operating conditions, to identify various operating regions, and also to determine whether the biosystem has shifted to a new operating condition. Our findings show that the local monitoring approach can give more reliable and higher resolution monitoring results than the global model.     

Modeling and optimization of granulation process of activated sludge in sequencing batch reactors

Aerobic granulation is a promising process for wastewater treatment, but this granulation process is very complicated and is affected by many factors. Thus, a mathematical model to quantitatively describe such a granulation process is highly desired. In this work, by taking into account all of key steps including biomass growth, increase in particle size and density, detachment, breakage and sedimentation, an one‐dimensional mathematic model was developed to simulate the granulation process of activated sludge in a sequencing batch reactor (SBR). Discretization methodology was applied by dividing operational time, sedimentation process, size fractions and slices into discretized calculation elements. Model verification and prediction for aerobic granulation process were conducted under four different conditions. Four parameters indicative of granulation progression, including mean radius, biomass discharge ratio, total number, and bioparticle size distribution, were predicted well with the model. An optimum controlling strategy, automatically adjusted of settling time, was also proposed based on this model. Moreover, aerobic granules with a density higher than 120 g VSS/L and radius in a range of 0.4–1.0 mm were predicted to have both high settling velocity and substrate utilization rate, and the corresponding optimum operating conditions were be determined. Experimental results demonstrate that the developed model is appropriate for simulating the formation of aerobic granules in SBRs. These results are useful for designing and optimizing the cultivation and operation of aerobic granule process. Biotechnol. Bioeng. 2013; 110: 1312–1322. © 2012 Wiley Periodicals, Inc.     

Model-based analysis on growth of activated sludge in a sequencing batch reactor

A mathematical model is developed to describe the growth of multiple microbial species such as heterotrophs and autotrophs in activated sludge system. Performance of a lab-scale sequencing batch reactor involving storage process is used to evaluate the model. Results show that the model is appropriate for predicting the fate of major model components, i.e., chemical oxygen demand, storage polymers (X _STO), volatile suspended solid (VSS), ammonia, and oxygen uptake rate (OUR). The influence of sludge retention time (SRT) on reactor performance is analyzed by model simulation. The biomass components require different time periods from one to four times of SRT to reach steady state. At an SRT of 20 days, the active bacteria (autotrophs and heterotrophs) constitute about 57% of the VSS; the remaining biomass is not active. The model established demonstrates its capacity of simulating the reactor performance and getting insight in autotrophic and heterotrophic growth in complex activated sludge systems.     

Effect of the applied organic load rate on biodegradable polymer production by mixed microbial cultures in a sequencing batch reactor

This article studies the operation of a new process for the production of biopolymers (polyhydroxyalkanoates, PHAs) at different applied organic load rates (OLRs). The process is based on the aerobic enrichment of activated sludge to obtain mixed cultures able to store PHAs at high rates and yields. A mixture of acetic, lactic, and propionic acids at different concentrations (in the range 8.5-31.25 gCOD/L) was fed every 2 h in a sequencing batch reactor (SBR). The resulting applied OLR was in the range 8.5-31.25 gCOD/L/day. Even though, as expected, the increase in the OLR caused an increase in biomass concentration (up to about 8.7 g COD/L), it also caused a relevant decrease of maximal polymer production rate. This decrease in polymer production rate was related to the different extent of "feast and famine" conditions, as function of the applied OLR and of the start-up conditions. As a consequence the best performance of the process was obtained at an intermediate OLR (20 gCOD/L/day) where both biomass productivity and PHA storage were high enough. However, at this high OLR the process was unstable and sudden decrease of performance was also observed. The sludge characterized by the highest PHA storage response was investigated by 16S rDNA clone library. The clone library contained sequences mostly from PHA producers (e.g., Alcaligenes and Comamonas genera); however many genera and among them, one of the dominant (Thauera), were never described before in relation to PHA storage response.     

Monitoring of a sequencing batch reactor using adaptive multiblock principal component analysis

Multiway principal component analysis (MPCA) for the analysis and monitoring of batch processes has recently been proposed. Although MPCA has found wide applications in batch process monitoring, it assumes that future batches behave in the same way as those used for model identification. In this study, a new monitoring algorithm, adaptive multiblock MPCA, is developed. The method overcomes the problem of changing process conditions by updating the covariance structure recursively. A historical set of operational data of a multiphase batch process was divided into local blocks in such a way that the variables from one phase of a batch run could be blocked in the corresponding blocks. This approach has significant benefits because the latent variable structure can change for each phase during the batch operation. The adaptive multiblock model also allows for easier fault detection and isolation by looking at the relationship between blocks and at smaller meaningful block models, and it therefore helps in the diagnosis of the disturbance. The proposed adaptive multiblock monitoring method is successfully applied to a sequencing batch reactor for biological wastewater treatment.     

Electricity generation from the treatment of wastewater with a hybrid up‐flow microbial fuel cell

The performance of a prototype up‐flow single‐chambered microbial fuel cell (MFC) for electrical power generation using brewery wastewater as fuel is reported. The designed reactor consisted of three zones, namely a lower anaerobic digestion zone, a central MFC zone, and an upper effluent clarifier zone. Tests were conducted in batch mode using a beer wastewater as the fuel/electron donor (COD concentration: 430 mg/L) and mixed consortia (both sewage microflora and anaerobic sludge) as a source of electrogenic bacteria. A stable current density of ～2,270 mA/m² was generated under continuous polarization with a constant external resistance (0.01 kΩ) and cell polarization gave a peak power density of 330 mW/m² at a current density of 1,680 mA/m². Electrochemical impedance analysis showed that the overall internal resistance of the reactor was quite low, that is, 8.0 Ω. Cyclic voltammetric analysis of the anodic biofilm at low scan rate revealed quite complex processes at the anode, with three redox peaks, at potentials of 116, 214, and 319 mV (vs. NHE). Biotechnol. Bioeng. 2010;107: 52–58. © 2010 Wiley Periodicals, Inc.     

Aerobic granular sludge formation for high strength agro-based wastewater treatment

The present study investigates the formation of aerobic granular sludge in sequencing batch reactor (SBR) fed with palm oil mill effluent (POME). Stable granules were observed in the reactor with diameters between 2.0 and 4.0 mm at a chemical oxygen demand (COD) loading rate of 2.5 kg COD m⁻³ d⁻¹. The biomass concentration was 7600 mg L⁻¹ while the sludge volume index (SVI) was 31.3 mL g SS⁻¹ indicating good biomass accumulation in the reactor and good settling properties of granular sludge, respectively. COD and ammonia removals were achieved at a maximum of 91.1% and 97.6%, respectively while color removal averaged at only 38%. This study provides insights on the development and the capabilities of aerobic granular sludge in POME treatment.     

Electricity generation using chocolate industry wastewater and its treatment in activated sludge based microbial fuel cell and analysis of developed microbial community in the anode chamber

Feasibility of using chocolate industry wastewater as a substrate for electricity generation using activated sludge as a source of microorganisms was investigated in two-chambered microbial fuel cell. The maximum current generated with membrane and salt bridge MFCs was 3.02 and 2.3 A/m², respectively, at 100 Ω external resistance, whereas the maximum current generated in glucose powered MFC was 3.1 A/m². The use of chocolate industry wastewater in cathode chamber was promising with 4.1 mA current output. Significant reduction in COD, BOD, total solids and total dissolved solids of wastewater by 75%, 65%, 68%, 50%, respectively, indicated effective wastewater treatment in batch experiments. The 16S rDNA analysis of anode biofilm and suspended cells revealed predominance of β-Proteobacteria clones with 50.6% followed by unclassified bacteria (9.9%), α-Proteobacteria (9.1%), other Proteobacteria (9%), Planctomycetes (5.8%), Firmicutes (4.9%), Nitrospora (3.3%), Spirochaetes (3.3%), Bacteroides (2.4%) and γ-Proteobacteria (0.8%). Diverse bacterial groups represented as members of the anode chamber community.     

The effect of bioaugmentation on the performance of sequencing batch reactor and sludge characteristics in the treatment process of papermaking wastewater

In this paper, the differences between reinforced sequencing batch reactor, which was inoculated with superior mixed flora, and conventional sequencing batch reactor were compared in the process of treating papermaking wastewater under similar conditions. The results showed that the addition of superior mixed flora could not only shorten the sludge acclimation time, but also improve the treatment efficiency of reactor as well as make the reactor have higher ability to withstand high volume loading rate; the phenomenon of aerobic granulation only occurred in reinforced sequencing batch reactor, and superior mixed flora were the key reason that aerobic granular sludge could shape; aerobic granular sludge had many advantages over conventional activated sludge such as it possessed compacter microbial structure, better settling performance, and lower water content.     

Effect of vitamins and cell constructions on the activity of microbial fuel cell battery

Construction of efficient performance of microbial fuel cells (MFCs) requires certain practical considerations. In the single chamber microbial fuel cell, there is no border between the anode and the cathode, thus the diffusion of the dissolved oxygen has a contrary effect on the anodic respiration and this leads to the inhibition of the direct electron transfer from the biofilm to the anodic surface. Here, a fed-batch single chambered microbial fuel cells are constructed with different distances 3 and 6?cm (anode- cathode spacing), while keeping the working volume is constant. The performance of each MFC is individually evaluated under the effects of vitamins & minerals with acetate as a fed load. The maximum open circuit potential during testing the 3 and 6?cm microbial fuel cells is about 946 and 791?mV respectively. By decreasing the distance between the anode and the cathode from 6 to 3?cm, the power density is decreased from 108.3?mW?m^?2 to 24.5?mW?m^?2. Thus, the short distance in membrane-less MFC weakened the cathode and inhibited the anodic respiration which affects the overall performance of the MFC efficiency. The system is displayed a maximum potential of 564 and 791?mV in absence & presence of vitamins respectively. Eventually, the overall functions of the acetate single chamber microbial fuel cell can be improved by the addition of vitamins & minerals and increasing the distance between the cathode and the anode.     

A comparison study on the high-rate co-digestion of sewage sludge and food waste using a temperature-phased anaerobic sequencing batch reactor system

Assessing contemporary anaerobic biotechnologies requires proofs on reliable performance in terms of renewable bioenergy recovery such as methane (CH₄) production rate, CH₄ yield while removing volatile solid (VS) effectively. This study, therefore, aims to evaluate temperature-phased anaerobic sequencing batch reactor (TPASBR) system that is a promising approach for the sustainable treatment of organic fraction of municipal solid wastes (OFMSW). TPASBR system is compared with a conventional system, mesophilic two-stage anaerobic sequencing batch reactor system, which differs in operating temperature of 1st-stage. Results demonstrate that TPASBR system can obtain 44% VS removal from co-substrate of sewage sludge and food waste while producing 1.2 m³CH₄/m³_system/d (0.2 m³CH₄/kgVS_added) at organic loading rate of 6.1 gVS/L/d through the synergy of sequencing-batch operation, co-digestion, and temperature-phasing. Consequently, the rapid and balanced anaerobic metabolism at thermophilic stage makes TPASBR system to afford high organic loading rate showing superior performance on OFMSW stabilization.     

The effect of dissolved oxygen on PHB accumulation in activated sludge cultures

Nitrogen removal from wastewater is often limited by the availability of reducing power to perform denitrification, especially when treating wastewaters with a low carbon:nitrogen ratio. In the increasingly popular sequencing batch reactor (SBR), bacteria have the opportunity to preserve reducing power from incoming chemical oxygen demand (COD) as poly-beta-hydroxybutyrate (PHB). The current study uses laboratory experiments and mathematical modeling in an attempt to generate a better understanding of the effect of oxygen on microbial conversion of COD into PHB. Results from a laboratory SBR with acetate as the organic carbon source showed that the aerobic acetate uptake process was oxygen-dependent, producing higher uptake rates at higher dissolved oxygen (DO) supply rates. However, at the lower DO supply rates (k(L)a 6 to 16 h(-1), 0 mg L(-1) DO), a higher proportion of the substrate was preserved as PHB than at higher DO supply rates (k(L)a 30, 51 h(-1), DO >0.9 mg L(-1)). Up to 77% of the reducing equivalents available from acetate were converted to PHB under oxygen limitation (Y(PHB/Ac) 0.68 Cmol/Cmol), as opposed to only 54% under oxygen-excess conditions (Y(PHB/Ac) 0.48 Cmol/Cmol), where a higher fraction of acetate was used for biomass growth. It was calculated that, by oxygen management during the feast phase, the amount of PHB preserved (1.4 Cmmol L(-1) PHB) accounted for an additional denitrification potential of up to 18 mg L(-1) nitrate-nitrogen. The trends of the effect of oxygen (and hence ATP availability) on PHB accumulation could be reproduced by the simulation model, which was based on biochemical stoichiometry and maximum rates obtained from experiments. Simulated data showed that, at low DO concentrations, the limited availability of adenosine triphosphate (ATP) prevented significant biomass growth and most ATP was used for acetate transport into the cell. In contrast, high DO supply rates provided surplus ATP and hence higher growth rates, resulting in decreased PHB yields. The results suggest that oxygen management is crucial to conserving reducing power during the feast phase of SBR operation, as excessive aeration rates decrease the PHB yield and allow higher biomass growth.     

Upflow bio-filter circuit (UBFC): biocatalyst microbial fuel cell (MFC) configuration and application to biodiesel wastewater treatment

A biodiesel wastewater treatment technology was investigated for neutral alkalinity and COD removal by microbial fuel cell. An upflow bio-filter circuit (UBFC), a kind of biocatalyst MFC was renovated and reinvented. The developed system was combined with a pre-fermented (PF) and an influent adjusted (IA) procedure. The optimal conditions were operated with an organic loading rate (OLR) of 30.0 g COD/L-day, hydraulic retention time (HRT) of 1.04 day, maintained at pH level 6.5-7.5 and aerated at 2.0 L/min. An external resistance of circuit was set at 10 k?. The purposed process could improve the quality of the raw wastewater and obtained high efficiency of COD removal of 15.0 g COD/L-day. Moreover, the cost of UBFC system was only US$1775.7/m3 and the total power consumption was 0.152 kW/kg treated COD. The overall advantages of this invention are suitable for biodiesel wastewater treatment.     

Integrated hydrogen production process from cellulose by combining dark fermentation, microbial fuel cells, and a microbial electrolysis cell

Hydrogen gas production from cellulose was investigated using an integrated hydrogen production process consisting of a dark fermentation reactor and microbial fuel cells (MFCs) as power sources for a microbial electrolysis cell (MEC). Two MFCs (each 25 mL) connected in series to an MEC (72 mL) produced a maximum of 0.43 V using fermentation effluent as a feed, achieving a hydrogen production rate from the MEC of 0.48 m³ H₂/m³/d (based on the MEC volume), and a yield of 33.2 mmol H₂/g COD removed in the MEC. The overall hydrogen production for the integrated system (fermentation, MFC and MEC) was increased by 41% compared with fermentation alone to 14.3 mmol H₂/g cellulose, with a total hydrogen production rate of 0.24 m³ H₂/m³/d and an overall energy recovery efficiency of 23% (based on cellulose removed) without the need for any external electrical energy input.     

Anaerobic treatment of complex chemical wastewater in a sequencing batch biofilm reactor: process optimization and evaluation of factor interactions using the Taguchi dynamic DOE methodology

The Taguchi robust experimental design (DOE) methodology has been applied on a dynamic anaerobic process treating complex wastewater by an anaerobic sequencing batch biofilm reactor (AnSBBR). For optimizing the process as well as to evaluate the influence of different factors on the process, the uncontrollable (noise) factors have been considered. The Taguchi methodology adopting dynamic approach is the first of its kind for studying anaerobic process evaluation and process optimization. The designed experimental methodology consisted of four phases--planning, conducting, analysis, and validation connected sequence-wise to achieve the overall optimization. In the experimental design, five controllable factors, i.e., organic loading rate (OLR), inlet pH, biodegradability (BOD/COD ratio), temperature, and sulfate concentration, along with the two uncontrollable (noise) factors, volatile fatty acids (VFA) and alkalinity at two levels were considered for optimization of the anae robic system. Thirty-two anaerobic experiments were conducted with a different combination of factors and the results obtained in terms of substrate degradation rates were processed in Qualitek-4 software to study the main effect of individual factors, interaction between the individual factors, and signal-to-noise (S/N) ratio analysis. Attempts were also made to achieve optimum conditions. Studies on the influence of individual factors on process performance revealed the intensive effect of OLR. In multiple factor interaction studies, biodegradability with other factors, such as temperature, pH, and sulfate have shown maximum influence over the process performance. The optimum conditions for the efficient performance of the anaerobic system in treating complex wastewater by considering dynamic (noise) factors obtained are higher organic loading rate of 3.5 Kg COD/m3 day, neutral pH with high biodegradability (BOD/COD ratio of 0.5), along with mesophilic temperature range (40 degrees C), and low sulfate concentration (700 mg/L). The optimization resulted in enhanced anaerobic performance (56.7%) from a substrate degradation rate (SDR) of 1.99 to 3.13 Kg COD/m3 day. Considering the obtained optimum factors, further validation experiments were carried out, which showed enhanced process performance (3.04 Kg COD/m3-day from 1.99 Kg COD/m3 day) accounting for 52.13% improvement with the optimized process conditions. The proposed method facilitated a systematic mathematical approach to understand the complex multi-species manifested anaerobic process treating complex chemical wastewater by considering the uncontrollable factors.     

Granular activated carbon single-chamber microbial fuel cells (GAC-SCMFCs): A design suitable for large-scale wastewater treatment processes

As an emerging biotechnology capable of removing contaminants and producing electricity, microbial fuel cells (MFCs) hold a promising future in wastewater treatment. However, several main problems, including the high internal resistance (R_in), low power output, expensive material, and complicated configuration have severely hindered the large-scale application of MFCs. The study targeted these challenges by developing a novel MFC system, granular activated carbon single-chamber MFC, termed as GAC-SCMFC. The batch tests showed that GAC was a good substitute for carbon cloth and GAC-SCMFCs generated high and stable power outputs compared with the traditional two-chamber MFCs (2CMFCs). Critical operational parameters (i.e. wastewater substrate concentrations, GAC amount, electrode distance) affecting the performance of GAC-SCMFCs were examined at different levels. The results showed that the R_in gradually decreased from 60 Ω to 45 Ω and the power output increased from 0.2 W/m³ to 1.2 W/m³ when the substrate concentrations increased from 100 mg/L to 850 mg/L. However, at high concentrations of 1000–1500 mg/L, the power output leveled off. The R_in of MFCs decreased 50% when the electrode distance was reduced from 7.5 cm to 1 cm. The highest power was achieved at the electrode distance of 2 cm. The power generation increased with more GAC being added in MFCs due to the higher amount of biomass attached. Finally, the multi-anode GAC-SCMFCs were developed to effectively collect the electrons generated in the GAC bed. The results showed that the current was split among the multiple anodes, and the cathode was the limiting factor in the power production of GAC-SCMFCs.     

Continuous power generation and microbial community structure of the anode biofilms in a three-stage microbial fuel cell system

A mediator-less three-stage two-chamber microbial fuel cell (MFC) system was developed and operated continuously for more than 1.5 years to evaluate continuous power generation while treating artificial wastewater containing glucose (10 mM) concurrently. A stable power density of 28 W/m³ was attained with an anode hydraulic retention time of 4.5 h and phosphate buffer as the cathode electrolyte. An overall dissolved organic carbon removal ratio was about 85%, and coulombic efficiency was about 46% in this MFC system. We also analyzed the microbial community structure of anode biofilms in each MFC. Since the environment in each MFC was different due to passing on the products to the next MFC in series, the microbial community structure was different accordingly. The anode biofilm in the first MFC consisted mainly of bacteria belonging to the Gammaproteobacteria, identified as Aeromonas sp., while the Firmicutes dominated the anode biofilms in the second and third MFCs that were mainly fed with acetate. Cyclic voltammetric results supported the presence of a redox compound(s) associated with the anode biofilm matrix, rather than mobile (dissolved) forms, which could be responsible for the electron transfer to the anode. Scanning electron microscopy revealed that the anode biofilms were comprised of morphologically different cells that were firmly attached on the anode surface and interconnected each other with anchor-like filamentous appendages, which might support the results of cyclic voltammetry. Electronic supplementary material  The online version of this article (doi:) contains supplementary material, which is available to authorized users.     

Competition between two microbial populations in a sequencing fed-batch reactor: theory, experimental verification, and implications for waste treatment applications

Competition between two microbial populations for a single pollutant (phenol) was studied in a sequencing fed-batch reactor (SFBR). A mathematical model describing this system was developed and tested experimentally. It is based on specific growth rate expressions revealed from pure culture batch experiments. The species employed were Pseudomonas putida (ATCC 17514) and Pseudomonas resinovorans (ATCC 14235). It was found that both species biodegrade phenol following inhibitory kinetics which can be described by Andrews' expression. The model predicts that the dynamics of a SFBR, and the kinetics of biodegradation, result in a complex set of operating regimes in which neither species, only one species, or both species can survive at steady cycle. The model also predicts the existence of multiple outcomes, achievable from different start-up conditions, in some domains of the operating parameter space. Experimental results confirmed the model predictions. There was excellent agreement between predicted and measured concentrations of phenol, total biomass, and the biomass of each individual species. This study shows how serious discrepancies can arise in scale-up of biodegradation data if population dynamics are not taken into account. It also further confirms experimentally the theory of microbial competition in periodically forced bioreactors. (c) 1993 John Wiley & Sons, Inc.     

Effect of influent nutrient ratios and hydraulic retention time (HRT) on simultaneous phosphorus and nitrogen removal in a two-sludge sequencing batch reactor process

A laboratory-scale anaerobic–anoxic/nitrification sequencing batch reactor (A₂N-SBR) fed with domestic wastewater was operated to examine the effect of varying ratios of influent COD/P, COD/TN and TN/P on the nutrient removal. With the increased COD/P, the phosphorus removals exhibited an upward trend. The influent TN/P ratios had a positive linear correlation with the phosphorus removal efficiencies, mainly because nitrates act as electron acceptors for the phosphorus uptake in the A₂N-SBR. Moreover, it was found that lower COD/TN ratio, e.g. 3.5, did not significantly weaken the phosphorus removal, though the nitrogen removal first decreased greatly. The optimal phosphorus and nitrogen removals of 94% and 91%, respectively were achieved with influent COD/P and COD/TN ratios of 19.9 and 9.9, respectively. Additionally, a real-time control strategy for A₂N-SBR can be undertaken based on some characteristic points of pH, redox potential (ORP) and dissolved oxygen (DO) profiles in order to obtain the optimum hydraulic retention time (HRT) and improve the operating reliability.