Influence of temperature on the performance of anaerobic fixed-film reactors utilizing screened dairy manure

Thermophilic (55°C) and mesophilic (35°C and 22°C) anaerobic digestions in laboratory scale (4 litre) fixed-film reactors fed with screened dairy manure were successfully operated over a range of hydraulic retention times, from 1 to 20 days. Maximum methane production rates of 1·82, 1·68 and 1·28 litres CH₄ litre⁻¹ day⁻¹ occurred at 1, 1·5 and 1 days HRT for the respective 55°C, 35°C and 22°C reactors. Both thermophilic and mesophilic digestions achieved maximum biodegradation efficiency at 10 days HRT. The thermophilic fixed-film reactor performed better than completely-mixed reactors in terms of methane production at HRTs shorter than 2 days. From the results, mesophilic fixed-film reactor operated at 35°C provided optimum methane production and net energy output between 1 and 5 days HRT.     

Methane production from dairy manure filtrate and supernatants

An anaerobic fixed-film reactor receiving screened dairy manure filtrate and supernatants was operated at 35°C and a hydraulic retention time (HRT) of 1 day. Methane production rates were very similar for both the screened slurry and supernatants. The results indicated that using supernatants from the sedimentation process could simplify the operational procedure in a methane production system. The utilization of a fixed-film reactor in methane production process could accommodate a hydraulically flushed dairy waste treatment system.     

Anaerobic pre-treatment of slaughterhouse wastewater using fixed-film reactors

The aim of this work was to study the performance of anaerobic fixed-film reactors with non-random support, for poultry slaughterhouse wastewater pre-treatment, including the influence of operating conditions. The work was carried out with two lab-scale reactors, one upflow and the other downflow, both equipped with vertical corrugated PVC tubes as support and a recirculation circuit. Both reactors were operated at 35°C.COD removal efficiencies ranging from 85% to 95% were achieved for organic loading rates of 8 kg COD m⁻³ d⁻¹, while the highest organic loading rates (35 kg COD m⁻³ d⁻¹) led to efficiencies of 55–75%. The reactors did not show destabilization after 12 h shock loads of 50 kg COD m⁻³ d⁻¹ .Reactor stability was easily achieved under intermittent operation, with weekend breaks, after which the reactors rapidly returned to their optimal performance. The influences of the hydraulic retention time, temperature, the recirculation ratio and flow direction were also studied.     

Effect of mixing on biogas production during mesophilic anaerobic digestion of screened dairy manure in a pilot plant

The effect of mixing on biogas production of a 1.5‐m³ pilot continuous stirred tank reactor (CSTR) processing screened dairy manure was evaluated. Mixing was carried out by recirculation of reactor content with a mono pump. The experiment was conducted at a controlled temperature of 37±1°C and hydraulic retention times (HRTs) of 20 and 10 days. The effect of continuous and intermittent operation of the recirculation pump on biogas production was studied. At 10 days of HRT, the results showed a minimal influence of recirculation rate on biogas production and that continuous recirculation did not improve reactor performance. At 20 days of HRT, the recirculation rate did not affect reactor performance. Combination of low solid content in feed animal slurry and long HRTs results in minimal mixing requirements for anaerobic digestion.     

Anaerobic dechlorination of pentachlorophenol in fixed-film and upflow anaerobic sludge blanket reactors using different inocula

Longterm performance and stability of two upflow anaerobic sludge blanket (UASB) reactors inoculated with granular sludge and treating a synthetic waste water containing pentachlorophenol (PCP) and phenol were studied. A similar system consisting of two fixed-film reactors inoculated with anaerobic digested sewage sludge were further studied. One reactor in each series received glucose in addition to the phenols. Dechlorination of PCP proceeded via two different dominating pathways in the respective reactor systems, suggesting that two distinct microbial populations were present, probably originating from the different inocula. Dechlorinating activity was maintained for more than 18 months in the UASB reactors and was generally higher than in the fixed-film reactors. In the fixed-film reactors, dechlorination of PCP suddenly decreased after 15.5 months of operation compared to earlier performance. Since no operational parameters had been changed, this indicated that the enriched culture was unstable on a longterm basis. Addition of yeast extract to the medium restored activity. General process stability in both reactor systems was clearly enhanced by the addition of glucose and was superior in the UASB/granular sludge system. The better performance and the higher stability in the UASB/granular sludge reactor highlights the importance of thorough screening of inocular prior to start-up of processes treating waste waters containing xenobiotic compounds.Abbreviations PCP pentachlorophenol - TeCP tetrachlorophenol - TCP trichlorophenol - DCP dichlorophenol - UASB upflow anaerobic sludge blanket - HRT hydraulic retention time     

Microbial attachment and growth in fixed-film reactors: process startup considerations

Optimal steady-state performance of any biofilm reactor requires a fully developed and mature biofilm. During fixed-film reactor startup phase, biofilm is in process of development and accordingly, process performance is difficult to quantify. Environmental, cellular and surface factors greatly influence the process of biofilm formation during reactor startup. Improved knowledge of nutritional, toxicological and environmental requirements of wastewater degrading microorganisms has helped define optimal microbial growth conditions. In case of anaerobic fixed film reactors the startup is hindered by low microbial growth rates, strict environmental requirements and limited ability of methanogens to adhere and form fixed biofilms. These obstacles could be overcome by proper support media selection and formulation of appropriate inoculation procedures and startup strategies.     

Stability and performance of mesophilic anaerobic fixed-film reactors during organic overloading

The stability of downflow stationary fixed-film (DSFF) reactors was evaluated under extreme organic shock loads. Reactors could handle five- to sevenfold increases in organic loading and recover to normal performance in a relatively short period of time (usually 24-72 h) during treatment of well-buffered sucrose and acetic acid wastewater at 27 and 35 degrees C. Overloading was characterized by elevated volatile-acid concentrations, decreased reactor pH, and excess biofilm sloughing. Reactors could not cope with extreme organic shocks during treatment of poorly buffered sucrose wastewater. The pH of the mixed liquor was observed to be a more important factor than the volatile-acid concentration in determining whether DSFF reactors would recover in a reasonable period of time.     

Continuous-flow biodiesel production using slit-channel reactors

Slit-channel reactors are reactors whose active surface areas are orders of magnitude higher than those of micro-reactors but have low fabrication costs relative to micro-reactors. We successfully produced biodiesel with different degrees of conversion using homogeneous catalyst in the slit-channel reactor. The reactor performance shows that percent conversion of soybean oil to biodiesel increases with channel depth, as expected, due to more efficient mixing. Shallow slit-channels require short average residence times for complete product conversion. Present results show that the slit-channel reactor provides an improved performance over traditional batch reactors using homogeneous sodium alkoxide catalyst. It is aimed to couple the reactors with solid catalysts in converting soybean oil to biodiesel and implementation method is suggested. The cost advantages resulting from the ease of fabrication of slit-channel reactors over micro-reactors and how these factors relate to the oil conversion efficiency to biodiesel are briefly noted and discussed.     

Channel structures in aerobic biofilms of fixed-film reactors treating contaminated groundwater.

Scanning electron microscopy, confocal scanning laser microscopy, and fatty acid methyl ester profiles were used to study the development, organization, and structure of aerobic multispecies biofilm communities in granular activated-carbon (GAC) fluidized-bed reactors treating petroleum-contaminated groundwaters. The sequential development of biofilm structure was studied in a laboratory reactor fed toluene-amended groundwater and colonized by the indigenous aquifer populations. During the early stages of colonization, microcolonies were observed primarily in crevices and other regions sheltered from hydraulic shear forces. Eventually, these microcolonies grew over the entire surface of the GAC. This growth led to the development of discrete discontinuous multilayer biofilm structures. Cell-free channel-like structures of variable sizes were observed to interconnect the surface film with the deep inner layers. These interconnections appeared to increase the biological surface area per unit volume ratio, which may facilitate transport of substrates into and waste products out of deep regions of the biofilm at rates greater than possible by diffusion alone. These architectural features were also observed in biofilms from four field-scale GAC reactors that were in commercial operation treating petroleum-contaminated groundwaters. These shared features suggest that formation of cell-free channel structures and their maintenance may be a general microbial strategy to deal with the problem of limiting diffusive transport in thick biofilms typical of fluidized-bed reactors.     

Biomass retention and performance of anaerobic fixed-film reactors treating acetic acid wastewater

An acetic-acid-based synthetic wastewater of different organic concentrations was successfully treated at 35 degrees C in anaerobic downflow fixed-film reactors operated at high organic loading rates and short hydraulic retention times (HRTs). Substrate removal and methane production rates close to theoretical values of complete volumetric chemical oxygen demand (COD) removal and maximum methane conversion were obtained. A high concentration of biofilm biomass was retained in the reactor. Steady-state biofilm concentration increased with increased organic loading rate and decreased HRTs, reaching a maximum of 8.3 kg VFS/m(3) at a loading rate of 17 kg COD/m(3) day. Biofilm substrate utilization rates of up to 1.6 kg COD/kg VFS day were achieved. Soluble COD utilization rates at various COD concentrations can be described by half-order reaction kinetics.     

Biodiesel production in packed-bed reactors using lipase-nanoparticle biocomposite

The development of appropriate reactors is crucial for the production of biodiesel. In this study, a packed-bed reactor system using lipase-Fe(3)O(4) nanoparticle biocomposite catalyst was successfully developed for biodiesel production based on soybean oil methanolysis. Emulsification before methanolysis improved the reaction rate. The lipase-nanoparticle biocomposite showed high activity and stability in the single-packed-bed reactor at an optimal flow rate (0.25 mL min(-1)). After 240 h of reaction, the conversion rate was sustained as high as 45%. The conversion rate and stability achieved using the four-packed-bed reactor were much higher than those achieved using the single-packed-bed reactor. The conversion of biodiesel was maintained at a high rate of over 88% for 192 h, and it only slightly declined to approximately 75% after 240 h of reaction. The packed-bed reactor system, therefore, has a great potential for achieving the design and operation of enzymatic biodiesel production on the industrial scale.     

Methane from coffee pulp juice: Experiments using polyurethane foam reactors

Summary Methanogenic bioreactors packed with polyurethane foams were used for the conversion of acidified coffee pulp juice into a methane-rich biogas. Gas productivities of the order of 3 v/v day were obtained with loads ranging from 9 to 22 kg VS/m³ day.     

Treatment of screened dairy manure by upflow anaerobic fixed bed reactors packed with waste tyre rubber and a combination of waste tyre rubber and zeolite: effect of the hydraulic retention time

Two laboratory-scale anaerobic fixed bed reactors were evaluated while treating dairy manure at upflow mode and semicontinuous feeding. One reactor was packed with a combination of waste tyre rubber and zeolite (R1) while the other had only waste tyre rubber as a microorganism immobilization support (R2). Effluent quality improved when the hydraulic retention time (HRT) increased from 1.0 to 5.5 days. Higher COD, BOD5, total and volatile solids removal efficiencies were always achieved in the reactor R1. No clogging was observed during the operation period. Methane yield was also a function of the HRT and of the type of support used, and was 12.5% and 40% higher in reactor R1 than in R2 for HRTs of 5.5 and 1.0 days, respectively. The results obtained demonstrated that this type of reactor is capable of operating with dairy manure at a HRT 5 times lower than that used in a conventional reactor.     

Succession and convergence of biofilm communities in fixed-film reactors treating aromatic hydrocarbons in groundwater.

Community composition, succession, and performance were compared in three fluidized bed reactors (FBR) operated to test preemptive colonization and the influence of toluene compared with a mixture of benzene, toluene, and p-xylene (BTX) as feeds. One reactor was inoculated with toluene-degrading strains Pseudomonas putida PaW1, Burkholderia cepacia G4, and B. pickettii PKO1. PaW1 outcompeted the other two strains. When groundwater strains were allowed to challenge the steady-state biofilm developed by inoculated strains, they readily displaced the inoculated strains and further reduced the toluene effluent concentration from 0.140 to 0.063 mg/liter for 98% removal. Amplified ribosomal DNA restriction analysis (ARDRA) of reactor community DNA showed a succession of populations to a pattern that was stable for at least 4 months of operation. Parallel reactors fed toluene and BTX but inoculated directly from groundwater had the same treatment performance and the same ARDRA profiles as each other and as the seeded reactor once the groundwater community took over. Convergence and stability of populations were confirmed by genotype analysis of 120 isolates taken from all reactors and at several times. Ninety percent of the isolates were of 4 of the 12 genotypes found, and their ARDRA patterns accounted for most of the community ARDRA patterns. Estimates of the maximum specific growth rates (mu max), half-saturation constants (K(m)), and maximum substrate utilization rates (Vmax) of the 12 genotypes isolated revealed a rather high diversity of toluene use kinetics even though the toluene in the feed was constant. The climax populations, however, generally showed kinetic parameters indicative of greater competitiveness than the inocula. rRNA sequence analysis of three codominant strains showed them to be members of the alpha, beta, and gamma subdivisions of the Proteobacteria. Two were similar to Comamonas and Pseudomonas putida, but the member of the alpha group was somewhat distant from any organism in the rRNA database. The convergence of communities to the same composition from three different starting conditions and their constancy over several months suggests that a rather stable community was selected.     

Bipolar effects of settling time on active biomass retention in anaerobic sequencing batch reactors digesting flushed dairy manure

Active biomass retention is a technical challenge in anaerobic digester treating dilute animal manure that contains solids particles. A strategy was tested using fibers in the dairy manure as biomass carriers by controlling settling time. Settling time ranging from 0.5 to 60 min were applied to eight anaerobic sequencing batch reactors to investigate their effects on active biomass retention in anaerobic digestion of flushed dairy manure. Results revealed that there existed a critical settling time at 2 min at which only minimum amount of active biomass was retained, and as settling time increased or decreased from this threshold, more active biomass could be retained. Gravity settling and selection pressure theories were suggested to account for the results. A model integrating these two effects was developed and verified with the experimental data. Knowledge derived from this study may lead to innovative bacterial retention technology for cost-effective anaerobic digestion of dairy wastes.     

Treatment of dairy manure effluent using freshwater algae: algal productivity and recovery of manure nutrients using pilot-scale algal turf scrubbers

Cultivating algae on nitrogen (N) and phosphorus (P) in animal manure effluents presents an alternative to the current practice of land application. The objective of this study was to determine values for productivity, nutrient content, and nutrient recovery using filamentous green algae grown in outdoor raceways at different loading rates of raw and anaerobically digested dairy manure effluent. Algal turf scrubber raceways (30m(2) each) were operated in central Maryland for approximately 270 days each year (roughly April 1-December 31) from 2003 to 2006. Algal biomass was harvested every 4-12 days from the raceways after daily additions of manure effluent corresponding to loading rates of 0.3 to 2.5g total N (TN) and 0.08 to 0.42g total P (TP) m(-2)d(-1). Mean algal productivity values increased from approximately 2.5g DW m(-2)d(-1) at the lowest loading rate (0.3g TN m(-2)d(-1)) to 25g DW m(-2)d(-1) at the highest loading rate (2.5g TN m(-2)d(-1)). Mean N and P contents in the dried biomass increased 1.5-2.0-fold with increasing loading rate up to maximums of 7% N and 1% P (dry weight basis). Although variable, algal N and P accounted for roughly 70-90% of input N and P at loading rates below 1g TN, 0.15g TP m(-2)d(-1). N and P recovery rates decreased to 50-80% at higher loading rates. There were no significant differences in algal productivity, algal N and P content, or N and P recovery values from raceways with carbon dioxide supplementation compared to values from raceways without added carbon dioxide. Projected annual operational costs are very high on a per animal basis ($780 per cow). However, within the context of reducing nutrient inputs in sensitive watersheds such as the Chesapeake Bay, projected operational costs of $11 per kgN are well below the costs cited for upgrading existing water treatment plants.     

Antibody production in packed bed reactors using serum-free and protein-free medium

The present work demonstrates the utility of packed bed reactors for the production of monoclonal antibody. We present data from a continuous process run for the production of over 100 grams of antibody, using serum-free medium. An additional pilot run also demonstrates the potential for continued antibody production under protein-free conditions, using a standard basal medium.     

Methane emission factors from cattle manure in Mexico

Factors responsible for methane emission from cattle manure representing diverse climates, systems and functions of cattle production are presented. These factors were obtained by means of an experimental methodology developed for this project. It was considered that the temperature, moisture, handling of manure and the animals' feed ration affect methane production. Drying conditions and fermentation of manure in cool, temperate and warm climates were simulated in the laboratory. Cattle manure was obtained from animals in intensive, semi-intensive and extensive production systems; for dairy, non-dairy and double purpose cattle production functions. Also handling of manure in dry lot, pasture and solid storage was considered. Results suggest that the dominant factor in methane emissions is the feed ration, followed by fermentation temperature and the excreta moisture content. The emission factors obtained in this work are at least a factor of five smaller than those proposed in the revised 1996 IPCC Guidelines for National Greenhouse Gas Inventories for countries like Mexico.     

Nitrogen and phosphorus removal rates using small algal turfs grown with dairy manure

Conservation and reuse of nitrogen (N) and phosphorus (P) from animalmanure is increasingly important as producers try to minimize transport ofthesenutrients from farms. An alternative to land spreading is to grow crops ofalgaeon the N and P present in the manure. The general goal of our research is toassess nutrient recovery from animal manure using attached algae. The specificobjective of this study was to evaluate the use of small subsections of algalturfs for determining N and P removal rates by attached algae under differentloading rates of dairy manure. Algae were grown in a laboratory–scalealgal turf scrubber (ATS) operated by recycling wastewater and adding manureeffluent daily. Replicate subsections (0.032 m²) ofalgal turf screens were removed and treated with five different loadings ofanaerobically digested dairy manure containing 5 to 80 mgL^–1 NH₄-N and 1 to 20 mgL^–1 PO₄-P over a 2-h incubationperiod. NH₄-N removal rates were biphasic with a fast initial ratefollowed by a slower rate. Biphasic rates were more pronounced for the lowestloading rates but less so for the higher ones. PO₄-P removal rateswere linear throughout the incubation period for all loading rates. N and Premoval rates increased with increasing loading rate and biomass. Inincubationsusing 1% dairy manure NH₄-N and PO₄-P removal ratesaveraged 0.72 and 0.33 g m^–2d^–1,respectively. These rates were approximately 5 to 8-fold lower than ratesmeasured on laboratory-scale ATS units using undisturbed turfs.     

Enhancing anaerobic hydrolysis of cattle manure in leachbed reactors

In this study, it is hypothesized that anaerobic hydrolysis of organic solid wastes (OSWs) in leachbed reactors can be enhanced by two approaches: (1) by increasing the porosity of the leachbed; and (2) by seeding the bed with brown-rot fungi or anaerobically digested residues. The hypothesis is verified using cattle manure as a model OSW and pistachios-half-shell as an inert additive to increase the porosity of the leachbed. The enhancement was quantified in terms of volatile fatty acid (VFA) generation and soluble COD generation. Results of this study showed that 15% more VFAs and 8% more soluble COD can be obtained at higher bed porosities and with brown-rot fungi or digested residues as the seed. Compared to a leachbed without any recirculation, porosity enhancement, nor seed addition, the VFA yield (g VFA/g manure) in a leachbed with pistachios-half-shell as porosity enhancers was 193% higher; that in a leachbed with leachate recirculation (of 4 L/day), pistachios-half-shell as porosity enhancers, and brown-rot fungi or digested sludge as seed was 230% higher.