Effect of Design Parameters on Oxygen Mass Transfer Coefficient in a Free Jet Bioreactor

The rate of oxygen delivery is a very important factor in aerobic processes. In many cases, this determines the efficiency of processes such as biological wastewater treatment. The availability of oxygen is essential for sustaining the growth of microorganisms necessary for degrading the organic matter. In this work, a continuous, re‐circulation, constant hold‐up plunging free jet‐loop system was designed to study the effects of design parameters on the oxygen mass transfer. This was investigated using three different nozzle diameters 6, 10 and 14 mm. For a fixed value of diameter, the distance between the nozzle mouth and the free liquid surface was varied to cover the range 14–26 cm. The experimental results showed significant effects of these two parameters. The oxygen mass transfer coefficient was found to increase with either increasing the nozzle position or decreasing its diameter.     

Biological treatment of high strength wastewater by fed-batch operation

Biological treatment systems for high strength wastewaters are usually operated in continuous mode such as activated sludge systems. When operated at steady-state, continuous systems result in constant effluent standards. However, in the presence of shock loadings and/or toxic compounds in feed wastewater, system performance drops quite significantly as a result of partial loss of microbial activity. In fed-batch operation, wastewater is fed to the aeration tank with a flow rate determined by effluent standards. In this type of operation, wastewater can be fed to biological oxidation unit intermittently or continuously with a low flow rate without any effluent removal. Feed flow rate is adjusted by measuring COD concentration in the effluent. As a result of intermittent addition of wastewater high COD concentrations and toxic compounds are diluted in large volume of aeration tank and inhibition effects of those compounds are reduced. As a result, biological oxidation of these compounds take place at a much higher rate. In order to show the aforementioned advantage of fed-batch operation, a high strength synthetic wastewater consisting of diluted molasses, urea, KH₂PO₄ and MgSO₄ was treated in an biological aeration tank by fed-batch operation. Organisms used were an active and dominant culture of Zooglea ramigera commonly encountered in activated sludge operations. COD removal kinetics was found to be first order and the rate constant was determined.     

Bubble bed reactor: A reactor design to minimize the damage of bubble aeration on animal cells

A new bubble aeration system was designed to minimize cell killing and cellular damage due to sparging. The residence time of the bubbles in the developed bubble bed reactor was prolonged dramatically by floating them in a countercurrent produced by an impeller. The performance of the new reactor bubble aeration system, implemented in a laboratory reactor, was tested in dynamic aeration experiments with an without cells. An efficiency up to 95% in oxygen transfer could be achieved, which enables a much lower gas flow rate compared with conventional bubble aeration reactors. The low gas flow rate is important to keep cell damage by bubbles as low as possible. A laser light sheet technique used to find the optimal flow pattern in the reactor. The specific power dissipation of the impeller is a good measure to predict cell damage in a turbulent flow. Typical values for the power dissipation measured in the bubble bed reactor were in the range of 0.002 to 0.013 W/kg, which is far below the critical limit for animal cells. The growth of a hybridoma cell line was studied in cell cultivation experiments. A protein-free medium without supplements such as serum or Pluronic F68 was used to exclude any effect of cell-protecting factors, No difference in the specific growth rate and the yield of the antibodies was observed in cell grown in the bubble free surface aeration in the spinner flask. In contrast to the spinner flask, however, the bubble bed reactor design could be scaled up. (c) 1994 John Wiley & Sons, Inc.     

Microbial composition of the activated sludge of Moscow wastewater treatment plants

The contribution of the major technologically important microbial groups (ammonium- and nitrite-oxidizing, phosphate-accumulating, foam-inducing, and anammox bacteria, as well as planctomycetes and methanogenic archaea) was characterized for the aeration tanks of the Moscow wastewater treatment facilities. FISH investigation revealed that aerobic sludge were eubacterial communities; the metabolically active archaea contributed insignificantly. Stage II nitrifying microorganisms and planctomycetes were significant constituents of the bacterial component of activated sludges, with Nitrobacter spp. being the dominant nitrifiers. No metabolically active anammox bacteria were revealed in the sludge from aeration tanks. The sludge from the aeration tanks using different wastewater treatment technologies were found to have differing characteristics. Abundance of the nitrifying and phosphate-accumulating bacteria in the sludge generally correlated with microbial activity in microcosms and with efficiency of nitrogen and phosphorus removal from wastewater. The highest microbial numbers and activity were found in the sludge of the tanks operating according to the technologies developed in the universities of Hannover and Cape Town. The activated sludge from the Novokur’yanovo facilities, where abundant growth of filamentous bacteria resulted in foam formation, exhibited the lowest activity. The group of foaming bacteria included Gordonia spp. and Acinetobacter spp utilizing petroleum and motor oils, Sphaerotilus spp. utilizing unsaturated fatty acids, and Candidatus ‘Microthrix parvicella’. Thus, the data on abundance and composition of metabolically active microorganisms obtained by FISH may be used for the technological control of wastewater treatment.     

Experimental study of a ceramic microsparging aeration system in a pilot-scale animal cell culture

The oxygen supply of cell cultures with the aid of free gas bubbles is an efficient process strategy in pharmaceutical production. If the cell-damaging impact of gas bubbles is reduced, direct aeration becomes a practical solution with scale-up potential and comparatively high oxygen transfer rates. In this paper a microsparging aeration system made of porous ceramic was compared with bubble-free membrane aeration. The sparging system was used for the long-term cultivation of mammalian cells in 2- to 100-L scale bioreactors and produced bubble sizes of 100-500 microm in diameter. Using a scale of 2.5 and 30 L, a cell density of 2.6 x 10(6) cells/mL was attained. When a 100-L scale was used, a density of 1.1 x 10(6) cells/mL was achieved, whereas a comparable membrane-aerated system showed a cell density of 2.2 x 10(6) cells/mL. At relatively low agitation rates of less than 70 rpm in the sparged bioreactors, a homogeneous and constant oxygen concentration was kept in the medium. As a result of the different foam-forming tendency caused by the lower gas flow of the ceramic sparger compared to that of the standard aeration systems, we were able to develop an appropriate process control strategy. Furthermore, oxygen transfer measurements for the common stainless steel sparger and the ceramic sparger showed a 3-fold higher oxygen transfer coefficient for the ceramic sparger.     

Performance evaluation of an anoxic/oxic activated sludge system: effects of mean cell residence time and anoxic hydraulic retention time

A laboratory investigation has been undertaken to asses the effects of two operating parameters, mean cell residence time (MCRT) and anoxic hydraulic retention time (HRT), on the performance of an anoxic/oxic activated sludge system. The performance of the system was evaluated in terms of its COD, nitrogen, and biomass characteristics. An activated sludge system is capable of producing a better effluent, in terms of COD and nitrogen characteristics, when it is operated in an anoxic/oxic fashion. A longer MCRT and an adequate anoxic HRT are desirable in the operation of an anoxic/oxic activated sludge system. For the wastewater used in this investigation, the anoxic/oxic unit was capable of producing an effluent with the following characteristics when it was operated at MCRT = 20 days, total system HRT = 10 h, and anoxic HRT = 3-5 h: COD = 15 mg/L; VSS = 10 mg/L; TKN = 1.30 mg/L; NH(3) - N = 0.60 mg/L; and NO(2) + NO(3) - N = 5.0 mg/L. A uniform distribution of biomass is achievable in an anoxic/oxic activated sludge system because of the intensive recirculation/convection maintained. The provision of an anoxic zone in the aeration tank promotes a rapid adsorption of feed COD into the biomass without an immediate utilization for cell synthesis. This, in turn, results in a high microbial activity and a lower observed biomass yield in the system. A tertiary treatment efficiency is achievable in an anoxic/oxic activated sludge system with only secondary treatment operations and costs. A conventional activated sludge system can be easily upgraded by converting to the anoxic/oxic operation with minor process modifications.     

Generation of small bubbles and small bubble-liquid mass transfer in airlift reactors containing highly viscous liquids

The time-dependent gas hold-up is investigated during the aeration of the Saccharomyces cerevisiae suspension, the aqueous saccharose solutions and the glycerol solutions in the external loop airlift reactor. Due to the time-dependent bubble size distribution the fraction of the small bubble hold-up in the total gas hold-up decreases with an increase of the gas flow rate and with a decrease of the viscosity. The course of the accumulation process of the small bubbles is described by the first-order kinetic equation. The small bubble accumulation rate is investigated in the airlift reactor and the bubble column. It is showed that the small bubbles form and disappear exclusively in the riser of the airlift reactor. It is found that the small bubble-liquid mass transfer coefficient is several times larger than the overall oxygen transfer coefficient.     

Overcoming shear stress of microalgae cultures in sparged photobioreactors

In the present work we identified and quantified the effect of hydrodynamic stress on two different microalgae strains, Dunaliella tertiolecta and D. salina, cultivated in bench-scale bubble columns. The cell death rate constant increased with increasing gas-entrance velocity at the sparger. Dunaliella salina was slightly more sensitive than D. tertiolecta. The critical gas-entrance velocities were approximately 50 and 30 m s(-1) for D. tertiolecta and D. salina, respectively. The effects of gas-flow rate, culture height, and nozzle diameter on the death rate constant were also studied. From these results it was concluded that bubble rising and bubble bursting are not responsible for cell death. Regarding nozzle diameter, small nozzles were more detrimental to cells. The bubble formation at the sparger was found to be the main event leading to cell death.     

Settling behavior of activated sludge from an effluent treatment plant of a petrochemical industry: Involvement of biofactor in sludge bulking

Poor sludge settling was observed occasionally during the treatment of effluent from acrylonitrile and acrylates manufacturing plants using an extended aeration activated sludge process. Sludge settled excellently when suspended in water or a filtrate obtained by passing aeration tank supernatant through granular activated charcoal (GAC) column. A biofactor consisting of 52% lipid, 10% protein, and 11% carbohydrate was isolated from the supernatant obtained after removal of suspended solids from aeration tank wastewater. Addition of biofactor in water or GAC filtrate adversely affected the sludge settling.     

Treatment of lipid-containing wastewater using bacteria which assimilate lipids

Bacteria which grew in a medium containing olive oil as a sole source of carbon were isolated from two meat plants in the Sendai district of Japan. All of the isolates tested assimilated beef tallow, lard, olive oil and used salad oil as a sole carbon source in shaking cultures. One of the isolates, strain 351, digested lipids most efficiently, as shown by the amount of n-hexane extracts that remained. This bacterium was identified as Bacillus sp. A new and efficient laboratory-scale apparatus for the biological treatment of lipid-containing wastewater was devised using strain 351. The apparatus consisted of a water circulation system for the primary treatment of the water, in which strain 351 was inoculated, and an ordinary aeration tank using activated sludge as a secondary treatment. Lipids in the wastewater could be almost completely removed by this apparatus without physical treatment. On the other hand, an ordinary aeration system in the laboratory using an air stone and air pump resulted in the floating of lipids, and was not successful in digesting lipids even in the presence of strain 351.     

The ejector-loop fermenter: Description and performance of the apparatus

A novel fermentation unit, the ejector-loop fermenter (ELF), consisting of an outer-loop tower fermenter, a centrifugal pump, a plate-heat exchanger, and a gas-liquid ejector, was designed and constructed. Aeration was achieved by continuously recirculating the fermentation medium through two different nozzle devices instead of using the traditional expensive air compressor. By carrying out a whey fermentation with Kluyveromyces fragilis as the test organism, either in the ELF or in conventional stirred fermenter, it was possible to confirm that the high sheat streses and mixing shock occurring in the ejector nozzle and diffuser sections did not affect microbial growth. Within the range of experimental power consumption per unit volume (-0.1-5 kW/m(3)), the oxygen transfer capability of the ELF per unit power input was found to vary from 1 to 2.5 kg O(2) kW(-1)h(-1). Moreover, it is shown that there is suficient room for improvement in the performance of the ELF unit by care fully designing the aeration device. In fact, at constant volumetric oxygen transfer coefficient, the power consumpotion per unit volume in a 4-mm nozzle was found to be about 40% less than that in a 6-mm nozzle.     

Characteristics of aerobic granular sludge in a sequencing batch reactor with variable aeration

Aerobic granules can be used for the treatment of industrial or municipal wastewater, but high aeration rate is required for the stable operation of the granular sludge system. Therefore, the aim of this research was to reduce aeration rate greatly to decrease the energy consumption for the technology of aerobic granules. Based on the characteristics of sequencing batch reactor with distinct feast and famine periods, aeration rate was reduced from 1.66 to 0.55 cm s⁻¹ in the famine period after granules were formed. It was found that the settleability of aerobic granules in reactor R1 with reduced aeration was the same as that of aerobic granules in reactor R2 with constant aeration rate of 1.66 cm s⁻¹. However, the outer morphology of aerobic granules gradually changed from round shape to long shape, and minor population showed certain shift after aeration rate was reduced in the famine period. Since good settleability is the most essential feature of aerobic granules, it can be said that reducing aeration rate in famine period did not influence the stable operation of aerobic granular sludge system. Furthermore, the experimental results indicated that aeration rate in feast period was much more important to the stable operation of aerobic granules than that in famine period.     

Local overall volumetric gas-liquid mass transfer coefficients in gas-liquid-solid reversed flow jet loop bioreactor with a non-Newtonian fluid

The local overall volumetric gas-liquid mass transfer coefficients at the specified point in a gas-liquid-solid three-phase reversed flow jet loop bioreactor (JLB) with a non-Newtonian fluid was experimentally investigated by a transient gassing-in method. The effects of liquid jet flow rate, gas jet flow rate, particle density, particle diameter, solids loading, nozzle diameter and CMC concentration on the local overall volumetric gas-liquid mass transfer coefficient (K(L)a) profiles were discussed. It was observed that local overall K(L)a profiles in the three-phase reversed flow JLB with non-Newtonian fluid increased with the increase of gas jet flow rate, liquid jet flow rate, particle density and particle diameter, but decreased with the increase of the nozzle diameter and CMC concentration. The presence of solids at a low concentration increased the local overall K(L)a profiles, and the optimum of solids loading for a maximum profile of the local overall K(L)a was found to be 0.18x10(-3)m(3) corresponding to a solids volume fraction, varepsilon(S)=2.8%.     

Sewage treatment by a low energy membrane bioreactor

A new membrane bioreactor (MBR) was developed for treatment of municipal wastewater. The MBR was mainly made up of an activated sludge reactor and a transverse flow membrane module, with an innovative configuration being in application between them. As a result, the transverse flow membrane module and low recirculation flow rate created advantages, such as lower energy consumption and more resistance to membrane fouling. The total energy consumption in the whole system was tested as 1.97+/-0.74 kWh/m(3) (permeate) while using periodical backwash with treated water and backflush with mixed liquor daily, being in the same level as a submerged membrane bioreactor, reported to be 2.4 kWh/m(3) (permeate). Energy consumption analysis in the system shows that the membrane module was more energy consuming than the other four parts listed as pump, aeration, pipe system and return sludge velocity lose, which consumed 37.66-52.20% of the total energy. The effluent from this system could be considered as qualified for greywater reuse in China, showing its potential application in the future.     

Modeling and simulation of oxygen-limited partial nitritation in a membrane-assisted bioreactor (MBR)

Combination of a partial nitritation process and an anaerobic ammonium oxidation process for the treatment of sludge reject water has some general cost-efficient advantages compared to nitrification-denitrification. The integrated process features two-stage autotrophic conversion of ammonium via nitrite to dinitrogen gas with lower demand for oxygen and no external carbon requirement. A nitrifying membrane-assisted bioreactor (MBR) for the treatment of sludge reject water was operated under continuous aeration at low dissolved oxygen (DO) concentrations with the purpose of generating nitrite accumulation. Microfiltration was applied to allow a high sludge retention time (SRT), resulting in a stable partial nitritation process. During start-up of the MBR, oxygen-limited conditions were induced by increasing the ammonium loading rate and decreasing the oxygen transfer. At a loading rate of 0.9 kg N m(-3) d(-1) and an oxygen concentration below 0.1 mg DO L(-1), conversion to nitrite was close to 50% of the incoming ammonium, thereby yielding an optimal effluent within the stoichiometric requirements for subsequent anaerobic ammonium oxidation. A mathematical model for ammonium oxidation to nitrite and nitrite oxidation to nitrate was developed to describe the oxygen-limited partial nitritation process within the MBR. The model was calibrated with in situ determinations of kinetic parameters for microbial growth, reflecting the intrinsic characteristics of the ammonium oxidizing growth system at limited oxygen availability and high sludge age. The oxygen transfer coefficient (K(L)a) and the ammonium-loading rate were shown to be the appropriate operational variables to describe the experimental data accurately. The validated model was used for further steady state simulation under different operational conditions of hydraulic retention time (HRT), K(L)a, temperature and SRT, with the intention to support optimized process design. Simulation results indicated that stable nitrite production from sludge reject water was feasible with this process even at a relatively low temperature of 20 degrees C with HRT down to 0.25 days.     

Anaerobic ammonium oxidation (Anammox) in immobilized activated sludge biofilms during the treatment of weak wastewater

This work studied the formation of molecular nitrogen by the microbial population of immobilized activated sludge of the domestic wastewater treatment plants (WWTP) that employ the technology developed by ZAO ECOS Company. The technology includes physicochemical water pretreatment and treated water recycling. A hard flexible fibrous brush carrier is used for the immobilization of microorganisms. The presence of both aerobic and anaerobic microorganisms and functioning of the methanogenic microbial community was shown in the biofilms developing on the carrier fibers and in suspended sludge. The high efficiency of nitrogen removal at a low C/N ratio was established to be due to the conjugated nitrification, denitrification, and anammox processes, whose functioning was demonstrated by laboratory cultivation methods and by studying the processes in batch and continuous reactors. Fluorescence in situ hybridization with 16S rRNA-targeted oligonucleotide probes (FISH) revealed bacteria belonging to the order Planctomycetales, particularly their anammox group. This work is the first evidence of the important role of the anammox process in the combined system of physicochemical and biological treatment of weak wastewater (BCDEAMOX).     

Characterization of a pilot plant airlift tower loop reactor: III. Evaluation of local properties of the dispersed gas phase during yeast cultivation and in model media

The local properties of the dispersed gas phase (gasholdup, bubble diamater, and bubble velocity) were measured and evaluated at different positions in the riser and downcomer of a pilot plant reactor and, for comparison, in a laboratory reactor. These were described in Parts I and II of this series of articles during yeast cultivation and with model media. In the riser of the pilot plant reactor, the local gas holdup and bubble velocities varied only slightly in axial direction. The gas holdup increased considerably, while the bubble velocity increased only slightly with aeration rate. The bubble size diminished with increasing distance from the aerator in the riser, since the primary bubble size was larger than the equilibrium bubble size. In the downcomer, the mean bubble size was smaller than in the riser. The mean bubble size varied only slightly, the bubble velocity was accelerated, and the gas holdup decreased from top to bottom in the downcomer. In pilot plant at constant aeration rate, the properties of the dispersed phase were nearly constant during the batch cultivation, i.e., they depended only slightly on the cell concentration. In the laboratory reactor, the mean bubble sizes were much larger than in the pilot plant reactor. In the laboratory reactor, the bubble velocities in the riser and downcomer increased, and the mean gas holdup and bubble diameter in the downcomer remained constant as the aeration rate was increased.     

Effect of sludge flocs on the aeration performance of suction-impellers

The authors have investigated a special aspect of the transfer of oxygen: the aeration performance of small-scale suction-impellers in a suspension of activated sludge floes and a performance comparison with clear water. The principle of the impellers is, that in order to disperse air bubbles into the aforementioned liquids, all that we need do is a simple stirring. Due to the impellers the authors could not show a reduction of the oxygen transfer coefficient in the presence of sludge flocs. Former comparative studies of oxygen transfer, using a fixed orifice, did show a reduction in the presence of sludge flocs. Therefore, it seems probable that the effect of activated sludge flocs on the transfer coefficient is linked with the manner in which air is dispersed, i.e., depends on whether an orifice is fixed or moved. The experimental results allow presumption that by developing a high intensity of shear near the location where air bubbles are produced, we are able to minimize the effect of sludge flocs on the process of bubble formation.     

Dynamic behavior of a complete-mixing activated sludge system

The dynamic behavior of a laboratory-scale activated sludge biological waste treatment process with recycle and wasting of sludge was investigated by subjecting the system to step changes in the influent waste concentration, the recycle flow rate, or the sludge wasting rate. The dynamic behavior of the system was examined by measuring adenosine triphosphate (ATP) in addition to dissolved chemical oxygen demand (COD) and cell dry weight in the aeration tank. Cell dry weight of the recyle flow and effluent COD were also measured. Analysis of the results and estimation of time constants assuming first order responses showed that the time constants characterizing the dynamic responses of the sludge were directly related to the sludge mean residence time. The time constants estimated from dissolved COD measurements were of the same order of magnitude as the fluid residence time in the aeration tank. The ATP transient response was frequently different from that of the cell dry weight in the aeration tank.     

Different bioreactor configurations for the decolourisation of the azo dye reactive black 5 by Geotrichum sp. CCMI 1019

Decolourisation of the azo dye Reactive Black 5 by Geotrichum sp. CCMI 1019 was studied using stirred tank reactors (STR) and two types of bubble columns (porous plate (PP) bubble column and aeration tube (AT) bubble column). For the bubble columns, the k_La increased with the gas fractional hold-up (ε_G) and the aeration rate. A linear relationship between ε_G and superficial gas velocity was obtained for all reactors. At same aeration rates, the PP bubble columns showed higher k_La and hold-up values than the AT bubble column. In the STRs, large and dense aggregates were formed which adhered to surfaces whereas bubble columns gave smaller and less compact pellets.

Manganese peroxidase and laccase were detected in the extracellular media in all reactors. However, laccase was only detected after the onset of decolourisation, suggesting that additional enzymes may be involved. Mn peroxidase activity was detected (about 46 U/ml) in both the STRs and AT bubble columns but higher values (110 U/ml) were obtained with the PP bubble columns.

Out of the three reactor systems studied, the AT bubble columns gave the most favourable results for Reactive Black 5 decolourisation. Rapid and complete colour removal was obtained throughout the visible spectrum. Bubble columns are simple in design as well as operation and may be useful for the bioremediation of textile wastewater.