Alexandria Engineering Journal (2021) 60, 1433–1445

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Alexandria University

Alexandria Engineering Journal

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Comparison between the performance of activated

sludge and sequence batch reactor systems for dairy
wastewater treatment under different operating
conditions
Alaa.H. Khalaf a, W.A. Ibrahim a, Mai Fayed a,*, M.G. Eloffy b,c

a
Sanitary Engineering Department, Faculty of Engineering, Alexandria University, Alexandria, Egypt
b
Chemical Engineering Department, Faculty of Engineering, Alexandria University, Alexandria, Egypt
c
National Institute of Oceanography and Fisheries, Alexandria, Egypt

Received 13 January 2019; revised 11 October 2020; accepted 31 October 2020

Available online 11 November 2020

KEYWORDS Abstract The main purpose of this study was to investigate the effect of operating conditions on
Activated sludge (AS); the performance of two methods used for dairy wastewater treatment. First, conventional activated
Biofilm activated sludge sludge (AS). Second, conventional sequencing batch reactor (SBR). On one side, the study included
(BAS); the comparison between the two basic systems. On the other side, it studied the influence of adding
Sequencing batch reactor plastic media on both systems. The modified systems are known as biofilm conventional activated
(SBR); sludge (BAS) and biofilm sequencing batch reactor (BSBR). Four pilot-scale bioreactors, were oper-
Biofilm sequencing batch ated in parallel under different conditions of temperature; 20, 35 and 45 °C. Synthetic dairy wastew-
reactor (BSBR); ater was used with characterizations of COD; 5000 mg/l, NH3-N; 250 mg/l and TP; 50 mg/l. The
Dairy wastewater; results recorded that the optimum temperature was 35 °C where removal efficiencies for COD were
Temperature effects;
(93.52%, 96.63%, 94.74% and 97.79%), (89.01%, 91.14%, 90.45% and 93.22%) for NH3-N, and
GPS-X;
Modeling
the concentration of NO3-N in effluents was (7.56 mg/l, 10.58 mg/l, 8.72 mg/l and 14.12 mg/l) for
AS, BAS, SBR and BSBR respectively. At temperature equals to 45 °C; the oxygen consumption
recorded the highest level of consumption, it was (1.07 mg/l, 1.64 mg/l, 0.98 mg/l and 1.23 mg/l)
for AS, BAS, SBR and BSBR respectively. The results indicated that the sludge settleability was
enhanced with the decrease of temperature. Furthermore GPS-X simulator was employed to pre-
dicting the performances of the biological systems under high COD concentrating reaching up to
17500 mg/l. GPS-X results indicated that SBR effluent could comply with Egyptian standard
NO 2000. An overview, comparing with various treatment systems, it can be concluded that the
SBR was the optimum treatment method for dairy wastewater based on the investigated conditions.
Ó 2020 The Authors. Published by Elsevier B.V. on behalf of Faculty of Engineering, Alexandria
University. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/
licenses/by-nc-nd/4.0/).

* Corresponding author.
E-mail addresses: walid.elbarki@alexu.edu.eg (W.A. Ibrahim), mai.fayed@alexu.edu.eg (M. Fayed), manal_eloffy@yahoo.com (M.G. Eloffy).
Peer review under responsibility of Faculty of Engineering, Alexandria University.
https://doi.org/10.1016/j.aej.2020.10.062
1110-0168 Ó 2020 The Authors. Published by Elsevier B.V. on behalf of Faculty of Engineering, Alexandria University.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
1434
1. Introduction
The dairy industry is one of the manufactories that generates
great quantities of wastewater, that contribute to the environ-
ment pollution not just from the produced sewage amount, but
also from where its complicated characteristics. It produces
about 0.2–10 l of wastewater for every liter of processed milk
[1]. Dairy wastewater contains high concentrations of chemical
oxygen demand (COD) and biological oxygen demand (BOD)
and nutrients (Nitrogen and phosphorus). It also contains sig-
nificant amounts of sodium, chlorine, potassium, iron, copper,
manganese, nickel, and magnesium. High concentration pres-
ence of sodium and chlorine is appropriate to the use of great
quantities of alkaline cleaners in the dairy plant [2–4].
Generally, dairy wastewater faces several problems, such as
treatment, disposal, and reuse. The improper discharge of
dairy wastewater provider negative impact on the receiving
aquatic environment and soil structure. Also, it could subject
toxic effects on the groundwater being discharged to the land.
This necessitates prompt and adequate treatment of the
wastewater before its disposal [3,5,6]. Dairy wastewater are
generally treated using physico-chemical and biological meth-
ods such as activated sludge process, trickling filters, aerated
lagoons, sequencing batch reactor, etc. [1,7]. In addition, aer-
ated electrocoagulation combined with phytoremediation
treatment was used in dairy industry wastewater [8]. The treat-
ment of dairy wastewater using traditional wastewater treat-
ment plants such as the activated sludge is not feasible, as it
will require high-energy rate to provide the required oxygen
[9].
Dairy wastewater characterized by its relatively high tem-
perature so it is treated with high-temperature system (ther-
mophilic) which is one of the available choices and
considered a biological treatment for each of the sewage water
or industrial sludge using biological reactors that operate at
high temperature. This is one of the methods which helps to
digest organic loadings at high speed, and consequently
reduces the amount of the produced sludge and improves the
qualities of how rid of it. It is a common method in the United
States of America and Europe in dealing with the high concen-
tration sewage water or the produced sludge from the biolog-
ical sewage water stations [10]. Activated sludge process (ASP)
is an uninterrupted treatment that uses a combination of
microbes suspended in the wastewater in aeration tank to
digest and disintegration the organic pollutants. A portion of
the organic installation will be entirely oxidized to innocuous
end products and other inorganic substances to equipping
energy to sustain the microbial growth and the forming of bio-
mass (flocs). Numerous reports show that ASP has been used
successfully to treat dairy wastewater. Found that COD
removal more than 90% and 65% decreases in total nitrogen
could be obtained with a dairy wastewater [11]. SBR system
after 1980 onwards became a very good alternative for the con-
stant flow. This system aims to dispose of continuous flow
method of the activated sludge. SBR system works without
the need to a secondary sedimentation basin contrary to the
activated sludge which cannot operate without Secondary sed-
imentation basin. Also, there is no sludge return to the aera-
tion basin in the system of SBR as it is in AS system. SBR
system considers as a suitable system for treating dairy
wastewater for this system ability to eliminate nitrogen com-
A.H. Khalaf et al.
pounds to nitrification and denitrification [12–14]. In the last
years, the integration of activated sludge and biofilm wastew-
ater treatment processes has been significantly used all over
the world which demonstrated its efficiency in removing the
nitrogen and the organic material [14]. SBR might be consid-
ered as the most important cost choice for treating dairy
sewage water, where its removal efficiency reaches (91–97%).
The SBR efficiency for the treatment of wastewater from small
cheese-making dairies with treatment levels of >97% being
obtained at a loading rate of 0.50 kg COD/day [11,15]. Tem-
perature effect on biological treatment is considered one of
the most important factors affecting microbial growth and sur-
vival. Microbial growth can occur at temperatures varying
from below freezing to more than 100 °C. Optimum tempera-
tures for bacterial activity are in the range from 25 to 35 °C
[16–18].
Kossay K. et al. (2012) compared the performance of acti-
vated sludge systems at Mesophilic and Thermophilic modes in
treating synthetic dairy wastewater (influent). In this research,
two activated sludge experimental laboratory systems were
operated for raw wastewater (influent). One of these systems
was operated at thermophilic reactor, whereas the other one
were operated at a constant temperature of mesophilic reactor.
The results showed that the organic removal efficiency of
mesophilic reactor it was higher than the thermophilic reactor
[10]. Song Z. et al. (2009) studied the temperature effect on
removing efficiency COD, NH3- N and TP by using sequenc-
ing batch reactor. The research results had shown removing
efficiency of NH3- N increase of 68.5% to 87.5% at tempera-
ture increase of 25 °C to 35 °C, also found the highest remov-
ing efficiency for COD and TP was 97% and 75%
consecutively at 30 °C [19]. Also, Masoud M. et al. (2012)
investigated the effect of temperature on the probative acti-
vated sludge from their capability of the flocculation and Sed-
imentation. It has noted that the increase of temperature
resulted in significant deterioration of sludge settle-ability.
Increasing temperature from 15 °C to 35 °C has been found
it cause the increase to (SVI) and the suspended solids from
40 to 130 ml/g MLSS and from 43 to 67 ml/l respectively
[20]. Britz et al. (2005) studied the purification of milk effluents
by SBR system and observed reductions in COD (91–97%), TS
(63%), volatile solids (VS) (66%), TKN (75%), and total
nitrogen (TN) (38%) [15]. Abdulgader et al. (2019) fabricated
a single stage flexible fiber biofilm reactor (SS-FFBR) to treat
(MPW) under different CODin and HRTs. From the results
obtained, the optimum removal efficiency was found at HRT
of 8 h, CODin of 3922 mg/L and OLR of 11.67 kg COD/m3/
d [21]. In another study, researchers have modified SBR by
added eight bundles of flexible fiber as a supporting media
for microorganisms’ growth in the reactor to treat milk-
processing wastewater (MPW).
The result demonstrated the sequencing batch flexible fiber
biofilm reactor SB-FFBR can be considered as a promising
technology to treat high strength wastewaters [22]. GPS-X is
a unit, multi-purpose modeling environment for the simulation
of domestic and industrial WWTPs. It is the world’s premier
WWTP simulator. GPS-X uses a sophisticated graphical user
interface to simplification dynamic modeling and simulation
there is no another software for modeling and simulation of
wastewater treatment processes equips the power and elasticity
obtainable with GPS-X. It is state-of-the-art technology, using
Comparison between the performance of activated sludge and sequence batch reactor systems for dairy wastewater
the most recent advances in process modeling, simulation tech-
nology, graphics and a host of productivity tools that simplify
model construction, simulation and interpretation of results.
The ASM1 model was used for biological processes, and the
BOD-based influent model was applied for influent character-
ization. Default values for all kinetic and stoichiometric
parameters in the ASM1 model were used for the simulations
[23]. The International association of Water Pollution
Research and Control (IAWPRC) task group realized that
due to the long solids retention times and low growth rates
of the bacteria, the actual effluent substrate concentrations
between different activated sludge treatment plants did not
vary greatly. What were significantly different were the levels
of MLSS and electron acceptor (oxygen or nitrate). Thus,
the focus of the Activated Sludge Model No. 1 (called ASM
1 in GPS-X) is the prediction of the amount and change of
the solids and electron acceptor. The dairy industry is the main
food-processing sector in Egypt that utilizes high water quan-
tity and generates high quantities of dairy wastewater.
In Egypt, increasing the population reflects increasing con-
sumption and production of dairy products especially milk
production. The major problem faces dairy wastewater how
to treat it and achieve high performance of treatment effi-
ciency, cost-efficient, and sustainable treatment and that can
be realized by biological treatment. To date, no studies have
been emphasized on comparison between the performance of
activated sludge and sequence batch reactor systems for dairy
wastewater treatment under different conditions such as add-
ing suspended media and increasing the temperature. There-
fore, this study was conducted to: (1) Performance of AS,
BAS, SBR and BSBR systems at temperature 20, 35, 45 °C,
(2) Comparison between the treatment capability of AS and
BAS. Also between SBR and BSBR to investigate the opti-
mum treatment of dairy wastewater based on the condition
and (3) Predicting the performance of AS and SBR at different
scenarios use GPS-X simulation.
2. Materials and methods
2.1. Dairy wastewater characteristics
To study the performance of different proposed treatment
methods, synthetic wastewater has been used as influent for
activated sludge (AS), biofilm activated sludge (BAS),
sequence batch reactor (SBR) and biofilm sequence batch reac-
tor (BSBR) with different chemical compositions as shown in
Table1. The synthetic dairy wastewater characterizations were
estimated referring to the common specifications of raw dairy
wastewater and according to the previous work mostly used to
study the treatment methods [3,24,25].
2.2. Pilot-scale bioreactor
2.2.1. Activated sludge (AS) and biofilm activated sludge
(BAS) pilot systems
The activated sludge system consists of two sections as shown
in Fig. 1a. The first basin was operated as a rectangular aera-
tion tank (length = 45 cm, width = 40 cm, height = 35 cm
and depth of water = 25 cm); the total volume of aeration
tank was 45 l. The second basin was operated as a final settling
1435
Table 1 Chemical characterizations of raw and synthetic
dairy wastewater [26,27].
Parameter Range Influent synthetic wastewater
COD (mg/l) 5000–10,000 5000
BOD5 (mg/l) 3000–5000 –
Oil & grease (mg/l) 70–500 –
NH3-N (mg/l) – 250
pH ± 0.02 4–7 –
TP (mg/l) 50–70 –
tank; the total volume settler was 45.58 l. The aeration tank
was modified by provided it with plastic media Fig. 1b.
2.2.2. Sequence batch reactor (SBR) and biofilm sequence batch
reactor (BSBR) systems
The SBR pilot system composed of aeration tank; length,
width, height and water depth dimensions were respectively
(45, 40, 35 and 25 cm) and final settling tank as shown in
Fig. 1c. Biofilm sequence batch reactor (BSBR) pilot system
was installed by equipped the aeration tank with plastic media
as drawn in Fig. 1d
2.3. Experimental procedures
Two pilot units were constructed in the laboratory of Sanitary
Engineering Department, a college of Engineering, and
Alexandria University. It has been constructed two treatment
systems which were operated in parallel; the first is activated
sludge (AS) system and the second is sequencing batch reactor
(SBR) system, as shown in Fig. 1. In this study, three different
temperature values were applied and the feasibility of using
free-floating media (plastic suspended media) was studied;
plastic suspended media was supplied from ornamental fish
shop. Properties of the media showed in Fig. 2 and Table 2.
The two systems were provided by two peristaltic manual
pumps) Master Flex - U.S.A, Cole - Parmer Instrument Com-
pany (. Air was supplied by an air compressor (DARI –DEC
100/280 – HP 2 – Kw 1.5 – Volt 220, 50 Hz). Heaters were used
to control the desired temperature values.
2.4. Operation of AS, BAS, SBR and BSBR systems
From aeration tank of El-Dekeela wastewater treatment plant,
the reactors were seeded with the wastewater. Through the
startup period, the stability of effluent COD concentration
was used as a primary indicator of steady-state conditions.
The operation parameters of both activated sludge and
sequence batch reactor systems shown in Table 3. The two
pilot units were fed with prepared synesthetic sewage with
characterizations of COD; 5000 mg/l, NH3-N; 250 mg/l and
TP; 50 mg/l and operated side by side under the same physical
and chemical condition.
2.5. Analytical analysis
The daily operation producer, the two systems were inspected
for any malfunction that may have occurred overnight.
1436 A.H. Khalaf et al.

Fig. 1 a, b, c and d. Different operating systems; AS, BAS, SBR and BSBR.

Fig. 2 (a) Shape of Individual suspended media ‘‘Bio-Balls”. (b) Set of media.
Comparison between the performance of activated sludge and sequence batch reactor systems for dairy wastewater 1437

dizing agent (K2Cr2O7). The mixture is then refluxed (boiled

Table2 Properties of the plastic suspended media ‘‘Bio-Balls”.
and re-condensed) for two hours at 150 °C to ensure maximum
Properties Value oxidation. The COD is determined by measuring the amount
Diameter/ball (mm ± 0.1 mm) 25 of potassium dichromate remaining after the reflux period.
Volume/ball (mm3) 4,600 This is accomplished by colorimetric method using spec-
Net volume/ball (mm3) 2,370 trophotometer (DR2010 Colorimeter Hach, USA made). The
Surface area/ball (mm2) 5,520.6 COD of the sample is directly measured by inserting the stan-
Surface area (m2/m3) 1200 dard 10-ml ampoules that are used in this test in the suitable
Porosity 94.1% COD spectrophotometer after adjusting the COD spectropho-
Weight/ball (gm ± 0.1gm) 4.40
tometer with the blank sample at zero reading.
Number of balls in reactor (ball) 400
Total surface area of balls (m2) 2.208
Percentage of media volume/Reactor volume 4% 2.5.2. Sludge volume index (SVI)
Total weight of media in reactor (gm ± 0.1gm) 1,760 The sludge volume index (SVI) is the volume in milliliters
occupied by one gram of a suspension after 30 min settling.
SVI typically is used to monitor settling characteristics of acti-
vated sludge and other biological suspension. To determine the
Samples from the feed and the effluent were withdrawn and sludge volume index (SVI), the MLSS and sludge settle ability
analyzed for chemical oxygen demand COD, Soluble ammonia volume (SV) should be measuring first. Usual in any wastewa-
nitrogen (NH3-N), and Nitrate nitrogen (NO3-N) concentra- ter treatment plant, the settled volume SV of biological suspen-
tions. Mixed-liquor suspended solids MLSS and SV from the sion and, the mixed liquor suspended solids MLSS are useful
two reactors were measured at the end of the react stage. in routine monitoring of biological process. The value of
The temperature (°C) was measured and recorded three times sludge volume index is responding the characteristics of the
daily. Dissolved oxygen (DO) was maintained at the start of sludge and its settle ability.
the react stage within the desired limits (0.7–1) mg/l and mea- The SV is determined as follows:
sured at the end of the react stage as an indicator of oxygen
consumptions. For each parameter, the reading recorded, mea- – Collect a sample of MLSS from the biological reactor.
sured minimum three times daily to calculated the average of – Fill a standard one-lite graduated cylinder to the one-liter
the reading that causes any systematic error due to other fac- mark.
tors is randomly distributed across your measurements [28]. – Allow the sample to settle for 30 min without any
The chosen techniques and calculations for the determination disturbance.
of parameters using standard methods for the examination of – Read the volume occupied by the settled sludge (settle
water and wastewater are described below [29]: sludge volume).

2.5.1. Chemical oxygen demand (COD) The SVI calculated as follows:

The chemical oxygen demand (COD) is used as a measure of
SV  1000
the oxygen equivalent of the organic matter content of a sam- SVI in ml=g ¼
MLSS
ple that is susceptible to oxidation by strong chemical oxidant.
It measures those organic materials that can be oxidized by a where;
strong chemical oxidizing agent as potassium dichromate.
The units of measurement of COD are in terms of mg/l of oxy- SVI = sludge volume index, ml/g.
gen involved in the oxidation reaction. SV = settle sludge volume in 30 min, ml/l.
In this test, the sample is mixed with sulfuric acid (H2SO4), MLSS = Mixed liquor suspended solids, mg/l.
silver sulfate (Ag2SO4) reagent and potassium dichromate oxi-
The value of sludge volume index is responding the charac-
teristics of the sludge and its settleability. The sludge volume
Table 3 Operation parameters of AS, BAS, SBR and BSBR index (mg/l) of excellent settled sludge is less than 50, the
systems: SVI of very good settled sludge is from 50 to 100, SVI of good
Operation parameters of AS Operation parameters of SBR and
settled sludge is from 100 to 150, and the SVI of poor settled
and BAS plants BSBR plants sludge is more than 150.
 Influent flow rate  Cycle length = 24 h (1
2.5.3. Dissolved oxygen (DO), temperature (°C)
Qin = 30 l/d. cycle/day).
 Return sludge flow rate,  (Fill up = 2 h, Aeration = 19 h, Dissolved oxygen (DO) represents the amount of oxygen dis-
Qr = 15 l/d (50% 0f Settling 2 h Draw & Idle 1 h). solved in a sample at the time of the test. The dissolved oxygen
Qin).  Influent flow rate Qin = 15 l/d. (DO) levels in natural and wastewater depend on the physical,
 Detention time in the aer-  Hydraulic detention time chemical and biochemical activities in the water body. The
ation tank = 8 h. HRT = 3 days. analysis for the dissolved oxygen (DO) is a key test in water
 Hydraulic detention time  Sludge age hc = 10 days. pollution and wastewater process control. The DO was mea-
HRT = 3 days.  F/M ratio = (0.29 to 0.32)
sured using the electrometric method with the oximeter for
 Sludge age hc = 10 days. l/day.
oxygen (YSI Model 57 Oxygen Meter Yellow Spring In. Co.,
 F/M ratio = (0.5 to 0.62)
l/day USA). The temperature was determined using the same elec-
trode of the oxygen meter The DO meter was calibrated by
1438
using standard DO solutions. The method of measurement was
as follows:
– put the electrode of the DO meter in the water sample.
– turn the operation key of the DO meter to temperature
mode and then read the water sample temperature.
– Turn the operating key of the DO meter to DO mode and
then read the DO of the water sample.
2.5.4. Nitrogen, ammonia
This test was performed outside of environmental laboratory-
Faculty of engineering- Alexandria University. Ammonia test
was performed in the environmental laboratory of ‘‘The
National Institute of Oceanography and Fisheries” according
to the standard methods for the examination of water and
wastewater (APHA, 1999). Ammonia compounds combine
with chlorine to form monochloramine. Monochloramine
reacts with salicylate to form 5-aminosalicylate. The 5 aminos-
alicylate is oxidized in the presence of a sodium nitrioprusside
catalyst to form a blue colored compound. The blue color is
masked by the yellow color from the excess reagent present
to give a green solution. This is accomplished by colorimetric
method using spectrophotometer.
2.5.5. Nitrate
Cadmium metal reduces nitrates present in the sample to
nitrite. The nitrite ion reacts in an acidic medium with sul-
fanilic acid to form an intermediate diazonium salt which cou-
ples to gentisic acid to form an amber-colored product. This is
accomplished by colorimetric method using spectrophotome-
ter (DR 2010 Colorimeter Hach, USA made).
2.5.6. Mixed liquor suspended solids (SS), MLSS
Suspended Solids (SS) are those solids that can be trapped on a
standard filter paper. The suspended solids of effluent treated
water indicate the efficiency of the settling process in the sys-
tem. The suspended solids concentration in the aeration tank
during the aeration period was called mixed liquor suspended
solids (MLSS). A well-mixed sample (100 ml) is filtered
through a weighed filter paper and washed with about 10 ml
of distilled water, allowing complete drainage. The residue
retained on the filter paper is dried to constant weight at 103
to 105 °C in drying oven and then allowed to cool in a desecra-
tor. The increase in weight of the filter paper represents the
total suspended solids in sample. The suspended solids were
calculated as follows:
A  B  1000
SS ðmg=lÞ ¼
Sample volume; ml
where
A = Weight of filter paper plus dried residue, mg.
B = Weight of filter paper, mg.
2.6. GPS-X simulation
Simulations were performed on the two reactors (AS and SBR)
using modular program GPS-X aims to assure the compatibil-
A.H. Khalaf et al.
ity between the results obtained in the laboratory at a temper-
ature 20 °C to those calculated from the model for BOD,
COD, TSS, and Total Kjeldahl Nitrogen (TKN). Table 4
shows model calibration used for both AS and SBR plants.
All scenarios simulated in this work used the ASM 1 model.
3. Results and discussion
3.1. Performance of AS and BAS systems at temperature
20 °C ± 0.2 °C
This scenario shows the performance and comparison between
AS and BAS systems at an aerobic treatment of synthetic dairy
wastewater at the temperature 20 °C. Figs. 3 and 4 showed that
the average of the effluent during the steady-state for the efflu-
ent COD, NH3-N and NO3-N concentration of the AS system
were (411.86, 41.82 and 3.03) mg/l respectively. Also, Figs. 3
and 4 clarifies the performance of the system BAS for concen-
tration effluent COD, NH3-N and NO3-N of the system were
(322.25, 29.50 and 8.41) mg/l respectively. Fig. 5 has also
shown performance and comparison between AS and BAS sys-
tems from where the Dissolved Oxygen Residual (DOres) in the
aeration tank. This shows that the average concentration of
DOres in steady state is 3.31 mg/l for AS while the concentra-
tion of DOres in the reactor for BAS in steady state is 5.36 mg/
l. The figure also shows sludge volume index for AS and BAS
systems were the average value 55.54 and 43.62 ml/gMLSS
respectively.
3.2. Performance of SBR and BSBR systems at temperature
20 ± 0.2 °C
In this section, depicts the performance and comparison
between SBR and BSBR systems at an aerobic treatment of
synthetic dairy wastewater at the temperature 20 °C. Fig. 6
illustrates the average of the effluent during the steady-state
for the effluent COD for SBR and BSBR (379.87 and
252.25) mg/l respectively. Whereas Fig. 7 shows the average
of the effluent NH3-N and NO3-N concentration of the SBR
and BSBR systems where was effluent NH3-N and NO3-N at
SBR 38.44 mg/l and 4.25 mg/l respectively whereas at BSBR
was 23.69 mg/l and 11.16 mg/l respectively. Fig. 8 has also
shown performance and comparison between SBR and BSBR
from where the DOres in the aeration tank. This figure has
Table 4 Model calibration used for both AS and SBR plants.
Parameter AS SBR
BOD: Total carbonaceous BOD5 (gO2/m ) 3
3500 3500
COD : Total COD (gCOD/m3) 5000 5000
X: Total suspended solids (TSS) (g/m3) 20 20
TKN: Total TKN (gN/m3) 186 186
Si: Soluble inert organic material (gCOD/m3) 15 20
Salk: Alkalinity (mole/m3) 7 7
Fss: Soluble substrate/BODultimate 0.1 0.29
Fbod: BOD5/BODultimate ratio 0.72 0.82
Ivt: VSS/TSS ratio (gVSS/gTSS) 0.8 0.8
Ixbn: N content of active biomass (gN/gCOD) 0.06 0.086
T: Temperature (°C) ± 0.2 °C 20 20
Comparison between the performance of activated sludge and sequence batch reactor systems for dairy wastewater 1439

AS BAS SBR BSBR

450 400
430
COD eff. (mg/l)

375
410

COD eff. (mg/l)

350
390
370 325
350 300
330 275
310
250
290
1 2 3 4 5 6 7 8 225
Time (day) 200
1 2 3 4 5 6 7 8
Fig. 3 The COD of the effluents for AS and BAS at temperature
Time (day)
20 °C.
Fig. 6 COD of the effluents for SBR and BSBR at temperature.
20 °C.

NH3-N eff at AS NH3-N eff at BAS

50 NO3-N eff at AS NO3-N eff at BAS 25 NH3-N eff at SBR NH3-Neff at BSBR
45 NO3-N eff at SBR NO3-Neff at BSBR
45 30
NH3-N eff. (mg/l)

40 20 NO3-N eff. (mg/l)

40

NH3-N eff. (mg/l)

NO3-N eff. (mg/l)

35 25
35
30 15
30 20
25
20 10 25
15
15 20
10 5 15 10
5 10
0 0 5
5
2 3 4 5 6 7 8 9
0 0
Time (day) 2 3 4 5 6 7 8 9
Time (day)
Fig. 4 NH3N and NO3N concentrations in the effluent for AS
and BAS at (20 °C). Fig. 7 NH3-N and NO3-N concentrations of the effluent for
SBR and BSBR at 20 °C.

SVI at AS SVI at BAS DO at AS DO at BAS SVI at SBR SVI at BSBR

70 12 DO at SBR DO at BSBR
60 10
60 10 9
SVI (ml/gMLSS)

50
SVI (mg/gMLSS)

8
50
DOres. (mg/l)

DOres (mg/l)
8 7
40
40 6
6
30 5
30
4 4
20 20 3
10 2 10 2
1
0 0 0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
Time (day) Time (day)

Fig. 5 Residual Dissolved Oxygen and SVI for AS and BAS at Fig. 8 Residual Dissolved Oxygen and SVI for SBR and BSBR
temperature. 20 °C. at temperature. 20 °C.

shown that the concentration of DOres in steady state is

3.02 mg/l for SBR while the concentration of DOres in the reac- 3.3. Performance of AS and BAS systems at temperature
tor for BSBR in steady state is 5.05 mg/l. The figure also shows (35 ± 0.2 °C)
sludge volume index for SBR and BSBR system were 47.9 and
36.94 ml/g MLSS; respectively. The conventional activated This scenario has clarified the performance AS and BAS sys-
sludge process such as SBR can be upgraded to handle high tems for the effluent concentrations at the temperature
organic loads by adding packed media to the reactor. Higher 35 °C. Figs. 9 and 10 has shown that the average has shown
COD removal efficiency at BSBR can be explained by higher in aerobic treatment of synthetic dairy wastewater at that the
total biomass, attached growth on carrier in addition to sus- average of the effluent during the steady-state for the effluent
pended growth and anaerobic, anoxic and aerobic bacteria concentration COD (324.25 and 168) mg/l, NH3-N (27.47
growth in the same time at BSBR [22] and 21.61) mg/l and NO3- N (7.56 and 10.58) mg/l for AS
1440 A.H. Khalaf et al.

and BAS respectively. Fig. 11 has shown dissolved oxygen AS BAS

400
Residual in AS and BAS systems. Where was the DOres
1.93 mg/l and at AS, whereas DOres 2.45 mg/l at BAS, the fig- 350

COD eff. (mg/l)

ure also shows SVI for AS and BAS systems was the average 300
SVI 70.27 ml/gMLSS at AS and 55.22 ml/g MLSS at BAS. 250

200
3.4. Performance of SBR and BSBR systems at temperature
(35 ± 0.2 °C) 150

100

This scenario has clarified the performance of SBR and BSBR 50

1 2 3 4 5 6 7 8
systems for the effluent concentrations at the temperature
Time (day)
35 °C. Figs. 12 and 13 has shown that the average of the efflu-
ent during the steady-state for the effluent concentration COD Fig. 10 NH3N and NO3N concentrations in the effluent for AS
(262.25 and 110.38) mg/l, NH3-N (23.87 and 16.95) mg/l and and BAS at temperature. 35 °C.
NO3- N (8.72 and 14.12) mg/l for SBR and BSBR respectively.
Fig. 14 has shown dissolved oxygen consumption in SBR and
BSBR systems. Where was the DOres 1.76 mg/l at SBR, NH3-N at AS NH3-N at BAS
whereas DOres 2.32 mg/l at BSBR, the figure also shows SVI 35 NO3-N at AS NO3-N at BAS 25
for SBR and BSBR systems were the average value 61.73

NO3-N eff. (mg/l)

30

NH3H eff. (mg/l)

20
and 47.28 ml/g MLSS; respectively. 25
20 15
3.5. Performance of AS and BAS systems at temperature
15
(45 ± 0.2 °C). 10
10
5
5
This scenario shows the performance the AS and BAS systems
for the effluent concentrations at the temperature 45 °C. 0 0
1 2 3 4 5 6 7 8 9
Figs. 15 and 16 has shown that the average of the effluent Time (day)
COD, NH3-N and NO3-N concentration of the AS system
were 590, 51.35 and 1.77 mg/l respectively. The Figs. 15 and Fig. 11 Residual Dissolved Oxygen and SVI for AS and BAS at
16 also clarifies the performance of the system BAS for concen- temperature. 35 °C.
tration effluent COD, NH3-N and NO3-N of the system were
512.25, 46.75 and 2.85 mg/l respectively. Also, Fig. 17 illus-
SBR BSBR
trates concentration oxygen Residual consumption (DOres) in
300
AS and BAS systems. Figure has shown that the average con-
280
COD eff. (mg/l)

centration of DOres in steady state is 1.07 mg/l for AS while the 260
concentration of DOres in the reactor for BAS in steady state is 240
1.64 mg/l. The figure also shows SVI for AS and BAS systems 220
were the average value 90.12 and 78.81 ml/g MLSS 200
respectively. 180
160
140
3.6. Performance of SBR and BSBR systems at temperature 120
(45 ± 0.2 °C) 100
1 2 3 4 5 6 7 8 9
Time (day)
This Section illustrates the performance and comparison
between the SBR and BSBR systems for the effluent concen- Fig. 12 The COD of effluents for SBR and BSBR at temper-
ature. 35 °C.
SVI at AS SVI at BAS
90
DO at AS DO at BAS 6
trations at the temperature 45 °C. Fig. 18 shows the average
80
5 of the effluent during the steady-state for the effluent COD
SVI (ml/gMLSS)

70
DOres. (mg/l)

60 4 for SBR and BSBR (541.5 and 458.5) mg/l respectively.

50 Whereas Fig. 19 shows the average of the effluent NH3-N
3
40 and NO3-N concentration of the SBR and BSBR systems
30 2 where was effluent NH3-N and NO3-N at SBR 45.96 and
20
1
2.64 mg/l respectively whereas at BSBR was 41.24 and
10 4.34 mg/l respectively. Fig. 20 illustrates concentration (DOres)
0 0 in SBR and BSBR where was concentration of DOres 0.98 mg/l
0 1 2 3 4 5 6 7 8 9
Time (day) for SBR while the concentration of DOres in the reactor for
BSBR in steady state is 1.23 mg/l. The figure also shows SVI
Fig. 9 COD of the effluents for AS and BAS at temperature. for SBR and BSBR system were 81.03 and 69.46 ml/gMLSS
35 °C. respectively.
Comparison between the performance of activated sludge and sequence batch reactor systems for dairy wastewater 1441

NH3-N at SBR NH3-N at BSBR NH3-N at AS NH3-N at BAS

NO3-N at SBR NO3-N at BSBR NO3-N at AS NO3-N at BAS
30 30
55 8

NH3-N eff. (mg/l)

NO3-N eff. (mg/l)
25 25 7
NH3-N eff. (mg/l)

50

NO3-N eff. (mg/l)

45 6
20 20
5
40
15 15 4
35
3
10 10 30 2
25 1
5 5
20 0
0 0 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
Time (day) Time (day)

Fig. 13 NH3N and NO3N concentrations in the effluents of SBR Fig. 16 NH3N and NO3N in the effluent concentration for AS
and BSBR at temperature. 35 °C. and BAS at 45 °C.

SVI at SBR SVI at BSBR SVI at AS SVI at BAS DO at AS DO at BAS

DO at SBR DO at BSBR 100 5
70 6
90

SVI (ml/gMLSS)
SVI ml/gMLSS

60 5 4
80
DOres. (mg/l)

DOres (mg/l)
50 70
4 3
40 60
3 50 2
30
2 40
20 1
30
10 1
20 0
1 2 3 4 5 6 7 8
0 0
0 1 2 3 4 5 6 7 8 9 Time (day)
Time (day)

Fig. 17 Residual Dissolved Oxygen and SVI for AS and BAS at

Fig. 14 Residual Dissolved Oxygen and SVI for SBR and BSBR
temp. 45 °C.
at temp. 35 °C.

SBR BSBR
AS BAS 600
625
575
COD eff. (mg/l)

600
COD eff. (mg/l)

550
575
525
550 500
525 475
500 450
475 425

450 400
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Time (day)
Time (day)
Fig. 18 The COD of effluents for SBR and BSBR at temp. 45 °C.
Fig. 15 The COD of effluents for AS and BAS at temp. 45 °C.

NH3-N at SBR NH3-N at BSBR

3.7. Comparison between AS, BAS, SBR and BSBR under
NO3-N at SBR NO3-N at BSBR
different temperatures 50 8
NO3-N eff. (mg/l)
NH3-N eff. (mg/l)

7
45
6
A comparison was conducted to show the COD removal effi- 40
5
ciency for synthetic dairy wastewater at AS, BAS, SBR and
35 4
BSBR systems, and show the effect of changing the tempera-
3
tures for all scenarios. Fig. 21 Shows the effect of temperatures 30
2
on all systems and comparison between AS, AS, SBR and 25
1
BSBR on COD removal. The results record that the average
20 0
removal efficiency of COD during the temperatures 20 °C 1 2 3 4 5 6 7 8 9
was (91.76%, 93.55%, 92.40% and 94.95%), temperature Time (day)
35 °C was (93.52%, 96.63%, 94.74% and 97.79%) and temper-
ature 45 °C (88.2%, 89.76%, 89.11% and 90.83%) for AS, Fig. 19 NH3N and NO3N concentrations in the effluents of SBR
BAS, SBR and BSBR respectively. This can be explained by and BSBR at 45 °C.
1442 A.H. Khalaf et al.

SVI at SBR SVI at BSBR AS BAS SBR BSBR

90 DO at SBR DO at BSBR 4

5.36

5.05
SVI (ml/gMLSS)

80
3

DO res (mg/l)
DOres (mg/l)
70

3.31

3.02
60 2

2.45

2.32
1.93

1.76

1.64
50

1.23
1

1.07

0.98
40

30 0
1 2 3 4 5 6 7 8
20 35 45
Time (day) Temperature °C

Fig. 20 Residual Dissolved Oxygen and SVI for SBR and BSBR Fig. 22 DOres (mg/l) for AS, BAS, SBR and BSBR at different
at 45 °C. temperatures.

the fact that the total bio-sludge mass of the BAS and BSBR
systems was higher than that of the AS and SBR systems
due to the increased amount of biofilm mass on the media of
the BAS and BSBR systems [30–32]. In general, BSBR dis-
played superior performance in terms of removal COD,
ammonium and phosphorus efficiencies when compared to
SBR [33]
Another overall comparison was conducted to show the
DOres for AS, BAS, SBR and BSBR at temperatures 20 °C,
35 °C, 45 °C. Fig. 22 Shows that the temperature increase leads
to the consumption of DO. On one side, It is noted the highest
oxygen consumption of (1.07, 1.64, 0.98 and 1.23) mg/l for AS,
BAS, SBR and BSBR at a temperature 45 °C. On other side, a
temperature 35 °C recorded (1.93, 2.45, 1.76 and 2.32) mg/l
and temperature 20 °C recorded (3.31, 5.36, 3.o2 and 5.05)
mg/l for AS, BAS, SBR and BSBR respectively. It can be
noted that increasing the temperature causes increasing the
growth rate of bacteria and that leads to consumption of
DO [6,12,32].
Also, another overall comparison was conducted to show
the SVI for AS, BAS, SBR and BSBR in all temperatures.
Fig. 23 has shown that the average of the SVI during the
steady-state at temperatures 20 °C was (55.04, 43.62, 47.9
and 36.94) ml/gMLSS, temperatures 35 °C was (70.27, 55,
22, 61.73 and 47.28) ml/gMLSS and temperatures 45 °C was
(90.12, 78.81, 81.03 and 69.46) ml/gMLSS for AS, BAS,
SBR and BSBR respectively. High temperature causes poor
floc formation and that led to a significant deterioration of
SVI, this is according to [34,35].
A comparison between AS, BAS, SBR and BSBR for all
scenarios was conducted and show the effect of changing the
AS
temperature on NH3-N removal and NO3-N removal.
Fig. 24 shows an effect the temperature on NH3-N removal
for all systems, the average of the effluent during the steady-
state for the effluent concentration NH3-N at AS, BAS, SBR
and BSBR was (41.82, 29.5, 38.44 and 23.69) mg/l respectively
at a temperature of 20 °C. Beside the effluent concentration
NH3-N a temperature of 35 °C was (27.47, 21.61, 23.87 and
16.95) mg/l, and (51.35, 46.75, 45.96 and 41.24) mg/l at a tem-
perature of 45 °C for AS, BAS, SBR and BSBR respectively.
The result note that at temperature 35 °C enhances the
removal efficiency of NH3-N. Beside the NH3-N removal effi-
ciencies in BSBR is the highest, the reason is to increase the
growth rate of bacteria at temperature 35 °C and thus increas-
ing the rate of consumption of nutrients, and this is according
to [19,34]. The Fig. 25 also shows effluent Nitrate concentra-
tions for all scenarios. The average of the effluent concentra-
tion NO3-N for AS, BAS, SBR and BSBR at temperature
20 °C was (3.03, 8.41, 4.24 and 11.16) mg/l, at temperature
35 °C was (7.56, 10.58, 8.72 and 14.12) mg/l and at tempera-
ture 45 °C was (1.77, 2.85, 2.64 and 4.32) mg/l respectively.
The result shows the minimum effluent NO3-N concentration
recorded at temperature 45 °C from AS system. Also, nitrifica-
tion decreased dramatically at a temperature 45 °C this is
according to [18].
3.8. Result of modeling
3.8.1. Model validation
Model validation aims to assure the compatibility between the
results obtained in the laboratory at a temperature (20 °C).
BAS SBR BSBR
97.79

90.12
96.63

AS BAS SBR BSBR

81.03
94.74
94.69

78.81
Efficiency Removal %

93.56

93.52

70.27

69.46
92.4
91.76

61.73
90.83

SVI (ml/gMLSS)

55.25
55.04
89.72
89.11

47.28
47.9
43.62
88.2

36.94

20 35 45 20 35 45
Temperature °C Temperature OC

Fig. 21 COD removal efficiencies for AS, BAS, SBR and BSBR Fig. 23 SVI (ml/gMLSS) for AS, BAS, SBR and BSBR at
in all scenarios. different temperatures.
Comparison between the performance of activated sludge and sequence batch reactor systems for dairy wastewater 1443

AS BAS SBR BSBR AS measured AS simulation

51.35
SBRmeasured SBR simulation

46.75
430

45.96
41.82

41.24
420
NH3-N eff. (mg/l)

38.44

COD eff. (mg/l)

410
400
29.5

27.47

23.87
23.69 390

21.61

16.95
380
370
360
350
1 2 3 4 5 6 7 8
Time (day)
20 35 45
Temperature OC
Fig. 26 COD measured in the effluent, and simulation effluent
Fig. 24 NH3-N concentration in the effluent of BAS and BSBR concentrations for AS and SBR.
at different temperatures.

The effluent’s actual results from the laboratory were com-
pared to the modeled effluent results for COD, BOD and
TSS and it was noted that the simulation results showed good
agreement with the actual results from the laboratory. Fig. 26
Shown the simulation under COD influent concentrations
were 5000 mg/l, in activated sludge were average COD mea-
sured effluent 411.86 mg/l, and COD simulation effluent
413.7 mg/l, While SBR were average COD measured effluent
379.87 mg/l, and COD simulation effluent 376.1 mg/l. It was
noted that the simulation results showed good agreement with
the actual results from the laboratory. After using the model
through the GPS-X results drawing by program Excel, Word
2010 to clarify the results better.
Model scenarios
After validation a simulation was conducted to the wastew-
ater treatment plant (WWTP) under different conditions to
know the performance of AS and SBR under these conditions.
Where has been studied three different scenarios, First sce-
nario was changing organic loads, the Second scenario was
changing HRT and the third scenario was organic shock load.
All cases run for 8 days of operation except for the third sce-
nario were 10 days.
Scenario 1:
In this scenario, influent different concentrations from
COD on AS and SBR system to know the ultimate concentra-
tion that treated in AS system and SBR, which it has been trea-
ted according the Egyptians specifications for the year 2000
which states that the possible limits discharge on the sewer sys-
AS BAS
tem (1100 mg/l), Fig. 27 shows that SBR system when input
COD concentration 12500 mg/l. be the treatment COD out
of limits allowed. While SBR is off limits when input the
COD concentration 17500 mg/l. From this we conclude that
SBR system is the best system for treating the high-level
concentrations.
Scenario 2:
In this scenario, a comparison between AS and SBR for the
different HRT was conducted to show the effect of changing
the HRT as shown in Fig. 28. When influent COD concentra-
tions 5000 (mg/l), the figure shows that HRT effect on COD
removal clearly. The figure shows that average COD removal
increased clearly by increasing the HRT.
Scenario 3:
In this scenario, the effect of a shock load on the AS and
SBR systems has been studied. Fig. 29 Shows organic shock
load in the second day the COD concentration has been
increased from 5000 mg/l to 10000 mg/l, After the second
day was the focus returns to 5000 mg/l concentration, where
AS system has been noticed that it is returned to the stability
condition after 6 days, while SBR needed 4 days to return to
stability condition.
4. Conclusions
This study has highlighted the treatment performance of Acti-
vated sludge and Sequencing batch reactor for dairy wastewa-
ter under different conditions. Besides, the effect of adding
plastic media on both reactors has been investigated on the
removal efficiencies. From a comparison between the four sys-
SBR BSBR
AS SBR
1590.1
14.12

1372.6
NO3-N eff. (mg/l)

11.16

1165.7
1140.9
10.58

COD eff. (mg/l)

8.72
8.41

7.56

805.3

783.7

846
655.9
609.1
518.3
4.32
4.25

413.7
3.03

376.1
2.85
2.64
1.77

20 35 45
Temperature 5000 7500 10000 12500 15000 17500
Influent COD (mg/l)
Fig. 25 NO3-N concentration in the effluent of BAS and BSBR
in different temperatures. Fig. 27 COD in the effluents of AS and SBR.
1444 A.H. Khalaf et al.

AS SBR  Based on the investigated conditions, we can summarize

524.2
493.7
that SBR was the optimum treatment of dairy wastewater.

413.7
376.1
Moreover, GPS-X model simulation showed good agree-
COD eff. (mg/l)

349.5
ment with the measured data for both AS and SBR systems.

305.5
294.1

273.3
Conclusions drawn from simulations were similar to experi-

243.5

208.9
mental results. SBR showed higher COD removal efficiencies
and greater ability to maintain stability under all cases of oper-
ation compared to conventional SBR. When we increase the
COD influent reduces the efficiency of COD removal when
input COD concentration 12500 mg/l on AS and SBR be the
treatment COD out of limits that discharge on the sewer sys-
2 3 4 5 6
HRT tem at AS according to the Egyptians specifications for the
no 2000. While SBR is off limits when input the COD concen-
Fig. 28 COD in the effluents of AS and SBR at the different tration 17500 mg/l. when was Increasing the HRT leads to a
HRT. clear change the performance of both AS and SBR increases
from efficiency COD removal. There was a large variation in
COD values in organic shock loads concentrations, however,
1400
11000
SBR showed a faster recovery of its stability compared to
1200
AS. It can be concluded that SBR was the optimum treatment
Effluent COD (mg/l)

1000 9000
of dairy wastewater. This study investigated the performance
800 7000
600
of treatment on a pilot scale. Our future scope is to examine
5000
400 the full scale in the field with developed SBR to achieve opti-
200 3000 mize treatment. Besides, further studies are required to pro-
1 2 3
0
4 5 6 7 8 9 10
1000 duce cost-effective, and to demonstrate new industrially
influent COD

CODeff at AS 413.7 620.9 530 467.2 437.5 424.6 419.3 415.8 413.1 412.5 applicable methods to treat high strength dairy wastewater
(mg/l)

CODeff at SBR 376.1 584.4 496.9 443.3 406.3 376.8 376.5 372.1 371.7 371.9 and to recycle the treated water in the dairy industrial process.
COD in 5000 10000 5000 5000 5000 5000 5000 5000 5000 5000

Declaration of Competing Interest

Fig. 29 COD in and COD eff. for BAS and BSBR under organic
shock load. The authors declare that they have no known competing
financial interests or personal relationships that could have
appeared to influence the work reported in this paper.
tems (AS, BAS, SBR and BSBR) which operated under differ-
ent temperature; 20, 35, 45 OC, we can summarize that:
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