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Flores 2019
Flores 2019
Water Research
journal homepage: www.elsevier.com/locate/watres
a r t i c l e i n f o a b s t r a c t
Article history: The objective of this paper is to present the main results of an engineering-research project dealing with
Received 3 December 2018 model-based evaluation of waste streams treatment from a biotech company. This has been extensively
Received in revised form done in domestic treatment systems, but is equally important, and with different challenges in industrial
16 February 2019
wastewater treatment. A new set of biological (activated sludge, anaerobic digestion), physicochemical
Accepted 18 February 2019
(aqueous phase, precipitation, mass transfer) process models and model interfaces are required to
Available online 4 March 2019
describe removal of organics in an upflow anaerobic sludge blanket (UASB) reactor plus either traditional
nitrification/denitrification (A1) or partial nitritation (PN)/anammox (ANX) (A2) processes. Model-based
Keywords:
Anammox
analysis shows that option A1 requires a decrease in digestion energy recovery (Erecovery) in order to have
Bacterial competition enough organic substrate for subsequent post NO3 reduction treatment (95 kWh.kg N1). In contrast, A2
Biofilms in an aerobic granular sludge reactor allows for higher UASB conversion since N removal is carried out
Industrial wastewater autotrophically. The study also reveals that the addition of an aerated pre-treatment unit prior to the PN/
Physico chemical modelling ANX (A2) reactor promotes COD and H2S oxidation, CO2 and CH4 stripping, a pH increase (up to 8.5) and a
reduction of the risk of intra-granular precipitation as well as sulfide inhibition. Simulations indicate
clear differences regarding the microbial distribution/abundance within the biofilm in A2 when
comparing the two operational modes. Final results show the effects of different loading and operational
conditions; dissolved oxygen (DO), Total Suspended Solids (TSSop), energy recovery (Erecovery); on the
overall process performance; N removal, aeration energy (Eaeration), net energy production (Erecovery);
using response surfaces, highlighting the need of integrated approaches to avoid sub-optimal outcomes.
The study shows the benefits of virtual plant simulation and demonstrates the potential of model-based
evaluation when process engineers in industry have to decide between competing options.
© 2019 Elsevier Ltd. All rights reserved.
1. Introduction demands within the treatment facility, and 3) handle a high volu-
metric load with a small spatial footprint (Van Lier, 2015). Never-
Upflow Anaerobic Sludge Blanket (UASB) reactors provide a theless, the effluent of UASB digesters may contain high quantities
sustainable and economic approach to treat high strength domestic of nitrogen, sulfide and methane (Chen et al., 2016a, b). Nitrogen
and industrial wastewaters (Batstone et al., 2015). These systems plays an important role in the eutrophication of the urban catch-
can: 1) substantially reduce the organic load to be in accordance ment and can be toxic for aquatic life (Tchobanoglous et al., 2003).
with the effluent discharge limits, 2) produce biogas that can be Sulfide causes pipe corrosion, health hazards and odour nuisance
converted to energy (heat/electricity) to reduce the power (Zhang et al., 2008). Methane is a potent greenhouse gas with a
warming potential 34 times stronger than that of carbon dioxide
over a 100-year horizon (IPCC, 2013). The transformation/destruc-
tion/capture of nitrogen, sulfide and methane in different forms
* Corresponding author. and qualities should be achieved by adding downstream processes
E-mail address: xfa@kt.dtu.dk (X. Flores-Alsina).
https://doi.org/10.1016/j.watres.2019.02.035
0043-1354/© 2019 Elsevier Ltd. All rights reserved.
X. Flores-Alsina et al. / Water Research 156 (2019) 264e276 265
zmax Maximum biofilm thickness (in UASB and aerobic ZCO2 Carbon dioxide (PCM) (kmol.m3)
granular reactors) ZHx S Free hydrogen sulfide (PCM) (kmol.m3)
z Radial distance within the biofilm (m) ZHNO2 Free nitrous acid (PCM) (kmol.m3)
Z Inorganic species (calculated with the PCM) ZNH3 Free ammonia (PCM) (kmol.m3)
when designing Wastewater Treatment Systems (WWTS) (Vela heterotrophic) and the main (bio)chemical processes involving
et al., 2015). methane and sulphur transformations. The entire system
Mathematical models are currently applied in normal water (AD þ post treatment) is simulated simultaneously. The main
engineering practice to evaluate competing design treatment op- novelties of this contribution can be summarized as follows:
tions (Flores-Alsina et al., 2012; Benedetti et al., 2010). In addition,
models can also be used for benchmarking (Copp, 2002; Jeppsson 1) A plant-wide model incorporating a UASB reactor þ two post-
et al., 2007), diagnosing (Rodriguez-Roda et al., 2002), and opti- treatment alternatives within an industrial context. Published
mizing (Rivas et al., 2008; Feldman et al., 2018) water systems, as studies considering plant-wide aspects have focused on virtual
well as for teaching purposes (Hug et al., 2009). Since the publi- case studies (Volcke et al., 2006b; Flores-Alsina et al., 2014).
cation of the International Water Association (IWA) Activated When full-scale facilities were modelled, the type of wastewater
Sludge Models (ASM1, 2d & 3) (Henze et al., 2000) and the was urban (Kazadi-Mbama et al., 2016). Indeed, industrial
Anaerobic Digestion Model No. 1 (ADM1) (Batstone et al., 2002), the wastewater has some drivers and challenges, including elevated
field has been rapidly expanding. Special efforts have been devoted sulfide, high strength inputs and very different system config-
to Plant-Wide Modelling (PWM) in recent years. The main idea in urations, which make state-of-the-art-models for municipal
PWM is that the WWTS should be considered as an integrated wastewater systems less suitable, and often additional exten-
process, where the different units comprising the flow diagram are sions are needed (Feldman et al., 2017).
linked together and need to be operated and controlled not as in- 2) Simultaneous simulation of two types of biofilm systems (anaer-
dividual unit operations, but taking into account all the interactions obic/aerobic). Previous investigations have often been focused
amongst the processes (Skogestad, 2000; Jeppsson et al., 2013). on studying process units (AD, post treatment) separately
One of the most difficult aspects in plant-wide modelling is (Batstone et al., 2015; Chen et al., 2016a, b; Winkler et al., 2014;
prediction and interaction of aquatic chemistry states, which are Castro-Barros et al., 2018) but never combined.
not normally considered in an efficient way in biological models. 3) A biofilm model implementation allowing the consideration of
Recent advances by the IWA Task Group on Physico-Chemical control aspects. This has been a particular drawback when ana-
Modelling (PCM) (Batstone et al., 2012) have boosted this field of lysing aerobic/anaerobic granular systems in the past (Volcke
research, particularly because considering PCM in addition to bio- et al., 2010, 2012; Ni et al., 2009), where the state-of-the-art
logical process models allows predicting the close interactions software used for these studies (Reichert, 2001) did not allow
between the phosphorus (P), sulphur (S) and iron (Fe) cycles (Solon for the inclusion of sophisticated process control elements
et al., 2017). Special aspects, such as model interfacing, have to be (Rosen et al., 2008).
taken into account (Batstone et al., 2015), unless integrated 4) Integration of physico-chemical aspects within (aerobic) biofilms
modelling methodologies are used (Barker and Dold, 1997; Grau systems. Previous works have been focused on granular micro-
et al., 2007; Ekama, 2009; Barat et al., 2013; Ferna ndez-Are valo bial composition (Pe rez et al., 2014; Poot et al., 2016), but there is
et al., 2017). PWM requires elemental mass balance verification no study where rigorous aqueous phase chemistry has been
and continuity checking for all the components comprising the included when modelling aerobic biofilms (Vangsgaard et al.,
model (Volcke et al., 2006a; Zaher et al., 2007; Nopens et al., 2009). 2013).
Therefore, COD, C, N, P, Fe and S need to be balanced across the 5) A holistic evaluation approach using net energy balances (UASB
interface (Flores-Alsina et al., 2016). The main advantage of using recovery e post treatment energy demand) that are applied under
an interface-based approach with respect to other integrated different operational conditions. This is closely linked to the first
methodologies is that the original model structure can be used, point, where there is a lack of full-scale studies using integrated
thus there is no need to consider all the state variables for each models and global criteria (Solon et al., 2017; Ferna ndez-Are valo
simulated unit process, with a reduction of the required compu- et al., 2017).
tational power and better overall model transparency (Grau et al.,
2009). The paper details the development of the new PWM developed
In this paper, we present a model-based feasibility study of for this study by presenting sequentially the elements of which it is
different anaerobic digestion post-treatment options in a biotech- comprised as well as highlighting the integration/interfacing as-
nology company using a PWM. The main motivation of the study is pects. The capabilities/potentials of the proposed approach are
to analyse how the selected technologies may affect the fate of illustrated by means of several simulated scenario analyses. Lastly,
nitrogen, methane and sulfide compounds leaving an industrial AD opportunities and limitations that arise from utilization of the new
system. Special aspects such as energy expenditures and potential models are discussed in detail.
(energy) recovery through the entire flow diagram will be
accounted for. This will be done using a previously published multi- 2. Methods
scale mathematical model approach describing the competition
between sulfate reducing bacteria and methanogens, the addition Sections 2.1.1 and 2.1.2 describe the processes and state variables
of ethanol as a separate model component, the effect of ionic included in both the Anaerobic Digestion (ADM) and the Activated
strength/activity corrections and the formation of multiple mineral Sludge (ASM) models, respectively. Additional aspects, with special
precipitates (Feldman et al., 2017). The above is linked to two emphasis on linking the ADM and ASM with a Physico-Chemical
different reactor designs (activated sludge/granular) representing Model (PCM) (Section 2.2), are described in Section 2.3 (Model
two post treatment options where a new model is developed. This integration). Implementation details for different types of reactor
model describes nitrification, denitrification (autotrophic/ designs: UASB, activated sludge and aerobic granular, are detailed
X. Flores-Alsina et al. / Water Research 156 (2019) 264e276 267
Fig. 1. Schematic representation of the system under investigation: UASB reactor þ two digestion post treatment options. A1 ¼ conventional nitrification/denitrification system,
A2 ¼ PN/ANX system (with pre-treatment).
Fig. 1 for details). The multi-scale approach described in Feldman assuming a response time of 4 min for the blowers. More info about
et al. (2017) is used to describe reactor hydrodynamics using mul- sensor and actuator models can be found elsewhere (Rieger et al.,
tiple Continuous Stirred Tank Reactors (CSTRs), a granule size dis- 2003; Rosen et al., 2008).
tribution and biofilm growth. More specifically, the biofilm model is
based on the one-dimensional approach reported in Wanner et al. 2.4.4. Aerobic granular sludge reactor model
(2006). The model contains both soluble (S) and particulate (X) A similar approach as described in Section 2.4.2 is used to
state variables. The mass balance assumes that the transport of describe the aerobic granular sludge reactor (A2). For simplicity
soluble compounds is governed solely by (homogenous) diffusion, purposes, the REAC is modelled by assuming one single CSTR and
whereas movement of particulate compounds takes place by con- one single granule size (zmax) type (additional information in
vection (Saravanan and Sreekrishnan, 2006). Biofilm thickness (L) is Vansgaard et al. (2012)). The exact same strategy as described
given as the radial distance (z) from the centre to the surface of the above predicts competition for substrate/space within the biofilm
granule and varies due to two phenomena: 1) the net growth of the by the different microorganisms accounted for by the ASM. An ideal
particulate species and 2) detachment from the biofilm surface separator (SEP) avoids that the granules leave REAC. An aerated
(Lackner et al., 2008). The resulting system of partial differential tank (PRE) and a splitting unit (SPLIT) are added before REAC, and
equations (PDEs) is solved using the method of lines (Press et al., act as a pre-treatment using the ASM as in the conventional N/DN
2007). reactor (Jeppsson et al., 2007) (see Fig. 1 for details). The objective of
PRE is to adjust COD/N ratios þ pH as well get rid of potentially
2.4.3. Conventional N/DN reactor model troublesome compounds (H2S) that can hinder Anammox biomass
The first configuration (A1) is based on a modified Ludzack- activity. Literature values were used to determine the hydraulic
Ettinger (MLE) design. The plant is described as 5 CSTRs in series retention time (HRT) and TSSop (Lackner et al., 2014). A default
and one secondary sedimentation tank (SEC) (see Fig. 1 for details). strategy based on a simple PI DO loop with similar sensor/actuator
The behaviour of the SEC is approximated by using the double- characteristics (noise, delay, response time) as described in Section
exponential settling function proposed in Tak acs et al. (1991). 2.4.3 is implemented (set-point ¼ 0.25 g (-COD).m3). Note the
Tanks 1 and 2 are anoxic (ANOX1, 2). Tanks 3, 4 and 5 (AER1, 2 and difference between REAC (physical unit where PN/ANX takes place)
3) are aerobic. All reactors are assumed to have the same volume. and A2 (alternative comprising both PRE þ REAC).
AER3 and ANOX1 are linked by means of an internal recycle (QINTR).
Literature values were used to determine the hydraulic retention 2.4.5. Evaluation criteria
time (HRT) and TSSop (Tchobanoglous et al., 2003). A PI controller To assess the performance of the different treatment options, a
regulating the airflow (Qair) to maintain a constant dissolved oxy- set of evaluation criteria is necessary (Jeppsson et al., 2013). Different
gen (DO) concentration (set-point ¼ 2 g (-COD).m3) is imple- effluent quality criteria, such as Total Kjeldahl Nitrogen (TKN) and
mented in AER2. Proportional controllers are used to determine Qair Total Nitrogen (TN), are calculated from ASM state variables (Henze
in AER1 and AER3 (see Gernaey et al., 2014) according to AER2. The et al., 2000) to assess the pollution removal efficiency of the system.
DO sensor response time (1 min), sensor delay and white noise are Energy recovery (Erecovery) in the UASB is calculated by using the
included in the sensor/actuator models in order to avoid creating a energy content of the methane gas (50.014 MJ (kg CH4)1) and
simulation of unrealistic ideal control applications. Finally, the assuming a 43% efficiency for electricity generation. Aeration energy
aeration system (Qair), is defined with significant dynamics, (Eaeration) is calculated imposing an energy expenditure equal to
X. Flores-Alsina et al. / Water Research 156 (2019) 264e276 269
more expensive compared to A2 (Enet is up to 146.5 MWh.d1). XDAMO1 / XDAMO2 in SCH4 conversion for A2. Similar results were
Dynamic simulations show again the differences in N removal reported in Daelman et al. (2014) and Winkler et al. (2014).
performance and how option A1 is not capable to remove SNO3 / Regarding SHx S , this compound is (bio)chemically re-oxidated to
SNO2 due to insufficient available carbon source (see Fig. 2, row II). XS0 / SSOx (see row 6) in both A1 and A2. The relatively high oper-
There are substantial differences in SO2 levels for both options. In ational pH (see Table 1) ensures a relatively low ZH2 S stripping, i.e.
option A1, all SNHx has to be transformed to SNO3 . Therefore, the SO2 the equilibrium is moved towards ZHS (Stumm and Morgan, 1996).
demand is very high. In option A2, only a part of the incoming SNHx
is oxidized to SNO2 thereby reducing the aeration requirements 3.1.2. Modification of the UASB reactor conversion efficiency
substantially (see Eaeration in Table 2). It is important to notice the In this section, the balance between organics conversion within
effect of the defined noise/delay level in the sensor and actuator the UASB reactor versus energy consumption and N removal in both
model. These model additions, e.g. the sensor models, provide a aerobic reactors (A1 & A2) is studied in more detail. In order to do
more realistic PI response and hence contribute to avoiding having this, an increase/decrease of conversion efficiency is imposed by
unrealistic (¼ideal) control actions in the simulation (see Fig. 2, row changing the UASB reactor volume. A pH control ensured the same
I). Both A1 and A2 options achieve almost complete removal of SCH4 acid-base conditions. This modified conversion efficiency, com-
and SHx S at the end of the treatment (>99% removal) (see rows 4 bined with alternatives A1 and A2 respectively, is simulated using
and 5). Stripping is the main mechanism for SCH4 removal in the two the PWM presented in this paper (see Table 1). Fig. 3a and b shows
evaluated options. Stripping in A1 takes place in the AER section, the changes in the quantity of SS leaving the reactor (from 240 to
while in A2 it is in the PRE section. The predicted activity of XMOB is 100 kg h1) and the quantity of methane produced (from 9500 to
zero for A1 and A2. Nevertheless, there is a minor contribution of 11,400 m3 d1). The latter is used to calculate the potential Erecovery
Fig. 2. UASB influent (column I), effluent (column II), data/model predictions and simulation results of the proposed post-digestion treatment options (columns III & IV).
A1 ¼ conventional nitrification/denitrification system, A2 ¼ PN/ANX system (including pre-treatment).
X. Flores-Alsina et al. / Water Research 156 (2019) 264e276 271
Fig. 3. UASB capacity analysis (a,b) and effect on the denitrification efficiency of the two evaluated options (c,d). A1 ¼ conventional nitrification/denitrification system, A2 ¼ PN/ANX
system (with pre-treatment). On the two top plots, also experimental data (plant measurements) are included (marked with x). The bar centred on the figure, represents the default
operational conditions (see Table 2). Bars to the right and to the left of the default condition bars represent an increase and decrease of the AD conversion efficiency, respectively.
(see section 2.4.5). Fig. 3c and d shows the nitrogen removal effi- 3.2. Effect of pre-treatment on PN/ANX performance
ciency for the two evaluated options considering the different UASB
reactor capacities. It is important to highlight that in all cases, the 3.2.1. PN/ANX influent characteristics
total quantity of nitrogen to treat is the same (80 kg N.h1). This section describes the effect on the overall process perfor-
When the UASB reactor volume is lowered, higher N removal mance when the aerated pre-treatment (PRE) unit is utilised (or
rates were achieved in the option A1 (up to þ 67% of the total not) before the PN/ANX reactor (options A2,1 and A2,2) (see Section
incoming N). This is attributed to the higher quantity of organics 2.4). The PRE consists of a CSTR with a residence time of 8 h, which
arriving from the AD to the MLE plant, and therefore more carbon is aerated (see Table 1). Fig. 4 shows the UASB influent (see Section
source is available for the traditional denitrification process. As a 2.4.1), the effluent (see Section 2.4.2.) and the PRE (see Section
direct result, there is a decrease of 11% in the Erecovery. When the 2.2.4) model predictions as well as the measured data (when these
UASB reactor conversion is higher (up to þ 5% in Erecovery) by were available). Computer simulations show that adding the PRE
increasing its volume it has negative effects (¼ not sufficient electron promoted a COD decrease (organic matter and H2S oxidation) in the
donor) on nitrogen removal due to denitrification failure (down to UASB effluent, CH4/CO2 stripping and a pH increase (up to pH 8.5).
34% N removal). Using the numbers generated in this case study, we High pH also promotes the formation of inorganic precipitates
can conclude that each additional kg of nitrogen removed in the post (XCaCO3 and XCa3 ðPO4 Þ2 ), which decreases the quantity of soluble Ca
treatment will require a decrease in the digester performance and P in the effluent. Since compounds containing Mg are present
equivalent to 95 kWh.kg N1. More details are provided in Fig. 3c. in under-saturated conditions, no precipitates of Mg compounds
Regarding option A2, simulation results show that a higher are formed (reflected as struvite in Fig. 4.
destruction of organics in the UASB reactor brings many benefits to
the overall plant performance. Firstly, the quantity of energy re-
covery is higher (up to þ 5% in Erecovery). Secondly, Eaeration in REAC 3.2.2. P/ANX effluent characteristics and granule structure/
is slightly lower due to a minor decrease of the oxygen demand properties
required to remove the arriving COD (Eaeration changes from 1200 to Fig. 5 reveals that the most immediate effect of PRE is a sub-
1100 kWh.d1) (Cao et al., 2017). As a result Enet is more favourable stantial reduction of the H2S inhibition (and consequently SNHx
(from 146.5 to 153.9 MWh.d1). Thirdly, the quantity of nitrogen conversion). Both A2,1 and A2,2 show that the centre of the granule
removed is slightly increased (from 80 to 84%) due to a lower is inactive due to the high concentration of inert material (XI )
competition with XOHO giving advantage to XANX (Ni et al., 2009). resulting from biomass death. The biomass (Xbio ) and organics
More details are provided in Fig. 3d. (Xorg ) concentrations increase for an increasing radial distance (z),
i.e. the closer to the surface, the higher the biomass concentration.
272 X. Flores-Alsina et al. / Water Research 156 (2019) 264e276
Fig. 4. UASB influent (row I), data (circles)/model predictions and simulation (solid lines) results obtained when including a PRE unit (rows II and III). A2,1 ¼ PN/ANX þ pre-
treatment, A2,2 ¼ PN/ANX without pre-treatment. Since the scenario A2,2 does not include pre-treatment, the influent of the PN/ANX is in that case exactly the same as the effluent
of the UASB reactor (where measurements were available).
More specifically, a high portion of XANX is placed in the inner zone granule size (Feldman et al., 2017). In this particular case, the flat pH
and this fraction decreases as the radius of the granule increases. profiles can be justified due to the relatively low SNO2 concentra-
The presence of XAOB and XOHO is comparatively higher in the outer tions and the high buffer capacity of the system.
layers of the biofilm. This distribution corresponds to the degree of
SO2 penetration within the biofilm. 3.3. Variation in loading/operational conditions
The main differences between A2,1 and A2,2 rely on the relative
presence of XOHO , XDAMO and XSOB . This is attributed to the fact that 3.3.1. DO set-point, TSSop and Erecovery
part of the COD, H2S and CH4 is removed in the PRE. Finally, PRE has Response surfaces depicted in Fig. 6 show the effect of changing
an effect on the weak acid-base chemistry of both the bulk and the the operational conditions on: 1) N removal (effluent SNHx /N
granule. As a consequence of including the PRE, the risk of having denitrified), 2) aeration energy (Eaeration), and 3) net energy balance
intra-granular precipitation for calcite (SIcalc) and calcium phos- (Enet) when both UASB reactor þ A2 (PN/ANX þ pre-treatment) are
phate (SICaP) is reduced. In both cases, the system is under- simulated simultaneously. Computer results show that optimal DO
saturated for struvite. Surprisingly, no pH gradient between the levels for N removal ranges from 0.25 > DO < 0.5 g m3. At lower
biofilm and the bulk phase is predicted while some authors values (DO < 0.25 g m3) there is a failure in nitritation efficiency,
observed otherwise (Lemaire et al., 2009). Other simulation studies and there is no conversion of SNHx to SNO2 (Fig. 6b and f). At higher
have shown that pH gradients are increased as function of the DO values, XNOB have a competitive advantage compared to XANX .
Fig. 5. Intra-granule model prediction for option A2 when PRE is active (A2,1 ¼ PN/ANX þ pre-treatment) or not active (A2,2 ¼ PN/ANX without pre-treatment). In the plot,
0 represents the centre of the granule and 0.5 the surface of the granule that is in contact with the liquid phase.
X. Flores-Alsina et al. / Water Research 156 (2019) 264e276 273
Fig. 6. Local (DO set-point and TSSop in REAC) and Global/plant-wide (Erecovery in UASB and DO set-point in REAC) modifications of the operational settings (1st and 2nd row,
respectively) and their effects on TKN, TN, Eaeration and Enet for option A2 (PRE þ PN/ANX). In this case A2 includes PN/ANX þ pre-treatment.
As a result, there is a decrease in the overall N removal efficiency mentioned in the introduction, previous studies including biofilm
due to the substantial amount of SNO3 that is formed in the aqueous reactors did not include sophisticated control elements mainly due
phase. This can be compensated by increasing the TSSop (and to software limitations of the platform on which these simulations
thereby the ratio of Vbiofilm to Vreactor) or increasing the quantity of were executed (Reichert, 2001). The biofilm model presented here,
organics coming from the digester. Nevertheless, this practice has a while carrying a high development overhead, offers a number of
negative effect on the entire energy balance in the plant. (Eaeration, advantages over classic lumped parameter implementations
Erecovery and Enet). (which normally rely on increased solids retention time, Batstone
et al., 2002). This includes inherent incorporation of diffusional
3.3.2. Importance of plant-wide approaches to avoid suboptimal limitations, consideration of how specific gaps will be selectively
outcomes retained, and in-biofilm interactions. Many of these factors are
The potential N removal and Enet maximization in REAC by quite important to short term dynamics, which in turn, impact
modifying TSSop and DO setpoint is a clear example of sub- control strategies. The implementation presented in this paper has
optimization. For example, it was possible to get better Enet shown that the computational demand is manageable. This
values when the UASB and REAC where modified together (see implementation (which will be freely distributed) will allow users
Fig. 6, second row) instead of making local changes in REAC (up to to develop/simulate control strategies using the most common on-
155 MWh.d1 compared to 148 MWh.d1 while N removal effi- line sensors, such as pH, DO, NH4, NO3, NO2 and conductivity
ciency is maintained). The mass and energy balances provided by (Lackner et al., 2014). Implementation of pH has been especially
the PWM can be very useful to suggest ways of better managing the challenging due to the numerical problems that this variable causes
different industrial streams within the factory, and achieving better (Batstone et al., 2012). Some of these implemented sensors might
operational process solutions. In addition, the optimization exam- have considerable noise, response time and delay (Rieger et al.,
ples depicted in Fig. 6 could be combined with other approaches, 2003). The same applies for actuators. Therefore, such elements
such as pH and sulfide production control in the AD. In this regard, should be included in order to evaluate controllers realistically
previous studies (Feldman et al., 2018) have demonstrated that a (Rosen et al., 2008). The special numerical routines implemented in
good pH control could reduce the operational cost of the digester by these models allowed simulating these elements without problems
up to 45% without risking the overall process performance. Another (Flores-Alsina et al., 2015; Feldman et al., 2017).
interesting example is reported in Irizar et al. (2018), where
advanced software sensors are applied to a similar type of UASB 4.2. Generation of alternatives
reactor to ensure stable operating conditions.
The options evaluated in this case study have been systemati-
4. Discussion cally generated, but they are based on general process knowledge.
The combination of plant-wide models (Ekama, 2009; Barat et al.,
4.1. Evaluation of (realistic) control strategies in biofilm systems 2013; Solon et al., 2017, Ferna ndez-Are valo et al., 2017) with envi-
ronmental decision support systems (EDSS) for suggesting process
The PN/ANX model developed during this study will allow flow sheets (Poch et al., 2004; Garrido-Baserba et al., 2012; Castillo
multiple possibilities, thus opening a new field of research. As et al., 2016) is a promising line of research. Indeed, the combination
274 X. Flores-Alsina et al. / Water Research 156 (2019) 264e276
of process heuristics with mixed integer non-linear programming implemented in two reactor designs (activated sludge/aerobic
could yield a good set of technologies to be further evaluated using granular sludge). Sensor and actuator models were included to
dynamic process models. There is a bright future if both tools go avoid unrealistic control actions and allow future control pos-
hand in hand when retrofitting an existing plant during the tran- sibilities. The PWM was simulated and the performance of the
sition from WWTPs to Water Resource Recovery Facilities (Daigger, different flow diagrams evaluated in terms of pollution removal
2011). (nitrogen, CH4, H2S), energy production (Erecovery), energy con-
sumption (Eaeration/Epumping) and net energy balance (Enet).
4.3. Outlook, limitations and future research directions Model-based evaluation revealed that PN/ANX (option A2)
demanded lower aeration rates (Eaeration ¼ 1.75 kWh/kg Nre-
It is important to highlight that only the ADM section of the in- moved) and potentially allowed more energy recovery in the
tegrated approach presented in this study has been validated UASB reactor (Erecovery ¼ up to 156.7 MWh.d1) since the
experimentally with full-scale data. Process equations and kinetic Anammox bacteria in charge of denitrification did not need
and stoichiometric parameters for the ASM part have been extracted organics as electron donor. As a result, the Enet
from literature based on validated case studies. The N removal part (¼153.9 MWh.d1) was potentially higher. Conventional N/DN
using a granular system has been tested in Vangsgaard et al. (2013). (option A1) as post-treatment of UASB effluent required higher
Methane and sulfide process equations were taken from previous aeration rates (Eaeration/Epumping ¼ 3.95 kWh/kg Nremoved) to
studies dealing with a similar type of wastewater (Winkler et al., convert the NHþ 4 all the way to NO3, and lower conversion in the
2014; Chen et al., 2016a, b). pH predictions and precipitation equa- AD (Erecovery is down to 132.8 MWh.d1) to allow denitrification,
tions are validated in Kazadi-Mbamba et al. (2015a, b). Therefore, the i.e. resulting in a considerably lower net energy production Enet
results from the simulation study seem to be correct and reliable, (¼127.1 MWh.d1). Calculations show that 95 kWh.d1 is lost in
within the normal uncertainty range of simulation studies of terms of energy production per extra kg N.d1 removed. These
wastewater treatment systems. It is interesting to note that, as a results are in agreement with the well-known advantages of PN/
result of this study, the company involved will implement alterna- ANX process over the conventional nitrification/denitrification
tive PRE þ PN/ANX at full scale as a post-digestion treatment tech- process.
nology. The potential better results in Enet were the key issue to tip The addition of an aeration pre-treatment tank (PRE) before the
the scale towards selection of this option. PN/ANX reactor increases COD/H2S oxidation, CH4/CO2 strip-
Last but not least, the reader should be aware that the PWM ping, Ca precipitation and increases pH. These processes change
presented in this case study shows a good compromise between the wastewater influent composition, and due to the presence of
model complexity and prediction capabilities. Nevertheless, the list XDAMO and XSRB this ends up changing the granule microbial
of relevant processes is far from being complete. PN processes (or distribution. pH variation and risk of precipitation are also
systems in general where there is NO 2 accumulation) are well- predicted by the model.
known for producing relatively high quantities of N2O emissions. The modification of the UASB conversion efficiency þ DO set-
N2O is a powerful greenhouse gas that is 300 times stronger than CO2 point in the PN/ANX reactor rendered better results (Enet) than
(IPCC, 2013). CH4 stripping is an important contribution to green- the local (TSSop þ DO set-point) optimization of the PN/ANX
house gas formation as well. As a consequence, a more integrated operational settings. In this way, it was possible to take full
assessment should include a compromise between effluent quality, advantage of the interactions amongst the different units and
operational cost and greenhouse gas emissions (Flores-Alsina et al., hence avoid sub-optimal outcomes.
2014; Ni and Yuan 2015). Other important factors not included in The study has shown the potential of using simulations for
this study when evaluating PN/ANX systems is the variation of the virtually evaluating competing options before full-scale imple-
size of the granular sludge (Volcke et al., 2010, 2012) and the effects mentation. Relevant information about the general mass and
of intra-granular precipitation (Johansson et al., 2017; Feldman et al., energy balances will yield additional information that will help
2018). Sulfide inhibition should also be better represented in the the process engineer to take the right decision in terms of
model. In this study, an arbitrarily high value was defined to account treatment option to be selected.
for the S effect on biomass growth. Nevertheless, there are numerous
studies that report quite complex interactions between XANX and
XSRB (Jin et al., 2012, 2013). The present study could be com- 6. Software availability
plemented with more thorough energy balances (Ferna ndez-
Arevalo et al., 2017; Longo et al 2018) or life cycle assessment The Matlab/Simulink implementation of the UASB reactor
(Corominas et al., 2013). Uncertainty/risk analysis, a central concept model, the N/DN reactor model and the PN/ANX reactor model plus
for model-based evaluation of alternatives (Belia et al., 2009), is an model interfaces are available on request. The code is fully docu-
important issue that should be considered as well. The consideration mented and presented results can be reproduced. To express an
of uncertainty/risk factors within the evaluation procedure can interest, please contact Dr. Xavier Flores-Alsina (xfa@kt.dtu.dk) or
substantially change the evaluation results, and preliminary Professor Krist V. Gernaey (kvg@kt.dtu.dk) at the Department of
selected technologies might come up as less desirable while other Chemical and Biochemical Engineering at the Technical University
options retain a higher chance of success under uncertainty. of Denmark.
The main findings of this study can be summarized in the Supplementary data to this article can be found online at
following points: https://doi.org/10.1016/j.watres.2019.02.035.
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