ISSN 0104-6632 Printed in Brazil
www.abeq.org.br/bjche
Vol. 33, No. 04, pp. 733 - 741, October - December, 2016 dx.doi.org/10.1590/0104-6632.20160334s20150288
*To whom correspondence should be addressed
This is an extended version of the work presented at the XI Latin American Symposium on Anaerobic Digestion (DAAL-2014), Havana, Cuba.
Brazilian Journal
of Chemical
Engineering
EVALUATION OF AN INNOVATIVE ANAEROBIC
BIOREACTOR WITH FIXED-STRUCTURED BED
(ABFSB) FOR BREWERY WASTEWATER
TREATMENT
M. M. de Araujo Junior
*, B. O. Gaudencio, D. N. Ayabe and M. Zaiat
Biological Processes Laboratory, Center for Research, Development and Innovation in Environmental Engineering, São Carlos School of Engineering (EESC), University of São Paulo (USP), Engenharia Ambiental, Bloco 4-F, Av. João Dagnone, 1100, Santa Angelina,
13563-120, São Carlos - SP, Brazil. Phone: + 55 16 3416 7110 E-mail: moacir@sc.usp.br
(Submitted: May 5, 2015 ; Revised: October 14, 2015 ; Accepted: November 11, 2015)
Abstract - The aim of this study was to evaluate the application of the anaerobic bioreactor with fixed-structured bed (ABFSB) for brewery wastewater treatment with high volumetric organic loading rate (VOLR) and its comparison with a traditional packed-fixed bed bioreactor. Two different biomass support materials were tested, including polyurethane (PU) and polypropylene (PP) for both configurations. The best global efficiency was reached by the structured-fixed bed reactor with polyurethane as biomass support (SB PU). For a VOLR of 14.0 kg CODt m-3 d-1 (HRT of 8 h) and 20.3 kg CODt m-3 d-1(HRT of 12 h), the SB PU reached the average CODt removal efficiencies (ECOD) of 81% and 71%, respectively. The results show that ABFSB is
a promising technology for high organic matter and solids concentration wastewater treatment, but the type of the biomass support had a big impact on the reactors performance.
Keywords: Brewery wastewater; Fixed-bed reactor; Packed bed; Structured bed; Anaerobic reactor.
INTRODUCTION
Due to its high popularity, beer has an important place in the worldwide economy, being the fifth drink most consumed in the world after tea, soft drinks, milk and coffee (Fillaudeau et al., 2006). As a result of the large production, the brewery industry de-mands high volumes of water and generates large amounts of wastewater. According to Santos (2015), from 4 to 10 L of water are consumed and from 3 to 6 L of wastewater are generated to produce 1 L of beer. In addition, the brewery wastewater has high concentrations of organic matter and suspended
solids; therefore, it has a high potential for environ-mental pollution (Simate et al., 2011).
con-figuration and satisfactory efficiency, UASB reactors demand high hydraulic retention times (over 24 h) and low up-flow velocities (up to 0.7 m h-1). As a result, the reactors become big and need large area to be constructed.
On the other hand, satisfactory removal efficien-cies of organic matter, employing high volumetric organic loading rates (VOLR) and low HRT, can be achieved in fixed bed reactors. Generally, high con-centration of biomass and long cellular retention time are reached by fixed bed reactors (Zaiat et al., 1997). However, the traditional configurations of packed bed reactors are not recommended for waste-water with medium to high solid contents, since hy-drodynamic problems, such as channelling and dead zones, can lead to low efficiencies and even to col-lapse by clogging of the reactor. To overcome this problem, Camiloti et al. (2014) proposed an innova-tive configuration of an anaerobic bioreactor with fixed-structured bed (ABFSB) in which the bed is not randomly packed, thus avoiding accumulation of solids in the interstices and preventing hydrodynamic anomalies.
The ABFSB aggregates advantages of both the up-flow anaerobic sludge blanket and fixed-bed reac-tors, such as easy solids separation and sedimenta-tion, high concentration of biomass and high sludge retention time. Nevertheless, the type of support ma-terial used for biofilm reactors influences their bio-mass adhesion and their hydrodynamics, thus affect-ing overall system performance. Many types of sup-port material for fixed bed reactors have been studied in the last decade, including polyurethane foam, plastic rings (polypropylene, polyethylene and PET), plastic plates and ceramic matrix.
Polyurethane (PU) foam as a biomass support has been shown to perform well in anaerobic biofilm reactors (Araujo Junior and Zaiat, 2009; Camiloti et al., 2014). PU foam makes an excellent attached-growth material because of its high surficial area for biomass adhesion and its macroporous structure, promoting a gradient of substrate concentration and electron donors, contributing to establish several anaerobic microorganisms. On the other hand, poly-propylene (PP) rings have been used the most as biomass support in biofilm reactors because of their low price and good mechanical resistance.
In this context, this work considers the applica-tion of an anaerobic bioreactor with fixed-structured bed for brewery wastewater treatment with high VOLR and its comparison with a traditional packed
terials were tested, including polyurethane (PU) and polypropylene (PP) for both configurations.
MATERIAL AND METHODS
Four up-flow fixed bed anaerobic reactors were studied in parallel for brewery wastewater treat-ment. The experimental setup is shown in Figure 1 and the description of each reactor is presented in the following:
PB PU: fixed-packed bed reactor with Biobob® (cylindrical polyurethane foam surrounded by an external frame of polypropylene with diameter of 15 mm and length of 10 mm), made in Brazil by Bio Proj Tecnologia Ambiental Ltda. The characteristics of the polyurethane foam were 95% of void ratio and 28 kg/m³ of density;
PB PP: fixed-packed bed reactor with polypro-pylene rings (diameter of 17 mm, length of 12 mm and surface area of 2621 mm2);
SB PU: fixed-structured bed reactor with lon-gitudinal polyurethane foam strips (7 squared strips 16 mm on a side and 265 mm of length); The charac-teristics of the polyurethane foam were 95% of void ratio and 28 kg/m³ of density;
SB PP: fixed-structured bed reactor with lon-gitudinal bar constructed of polypropylene rings (7 bars 17 mm in diameter, 265 mm in length and sur-face area of 57880 mm2).
The reactors were operated during 181 days at 35 ± 1 °C. They were fed with raw brewery waste-water with increased influent flow rate, with a nomi-nal hydraulic retention time (HRT, estimated from the total reactor liquid volume) of 32 h, 24 h, 18 h, 12 h and 8 h, and flow rates of 0.07 L h-1, 0.11 L h-1, 0.15 L h-1, 0.22 L h-1 and 0.33 L h-1, respectively. Due to variation of the wastewater concentration, the volumetric organic loading rate (VOLR) did not follow the linear flow rate tendency increase and the average values were between 2.0 and 28.6 kg COD m-3 d-1.
o th w ti
er w b p an
ac m te to ch
μ
ti o 2
Eval
To inocula f the UASB he reactors water, remain ion started up
Weekly, th ry industry with mechani
efore feeding H of the equ nd 7.5 with s Samples o ctor were tak methods (APH
ers were eva otal chemic
hemical oxy
μm membran ile suspended
rganic acids 010 (Kyoto,
luation of an Inno
Brazilian
ate the structu sludge was and the vo ning at rest fo
p.
he wastewate and stocked ical mixer t g the reactor ualization tan sodium bicar of the influen ken and anal HA, 2012). S aluated durin al oxygen ygen demand ne), total sus d solids (VS s were perfo Japan) gas c
ovative Anaerobic
Journal of Chem
ured-fixed bed introduced in olume was f for 24 h and
er was taken d at 4 °C in o minimize r. To avoid ac nk was adjust
rbonate. nt and effluen
lyzed accord Several mon ng operation
demand (C d (CODf, filt
spended solid S) and pH. T ormed on a
chromatogra
c Bioreactor with
mical Engineering
Figure 1
d reactors, 1. n the bottom filled with then the ope
from the bre a cooling ta biodegradat cidification, ted between
nt from each ding to stand itoring param n, including CODt), filte tered with a
ds (TSS), vo The analyses Shimadzu G aph with an H
h Fixed-Structure
g Vol. 33, No. 04,
1: Experimen
0 L m of tap
era- ew-ank tion the 6.5
re-dard
me-the ered 1.2 ola-s of
GC-
HP-IN co in Co do chr an um nit
wa ret ing the the the of
d Bed (ABFSB) f
, pp. 733 - 741,
ntal setup.
NNOWAX (3 lumn (Agilen
each reacto ounter and th one with a Sh
romatograph d Carboxen mn, with det trogen and m
RES
Following astewater CO tention times g rates (VOL e operational e influent an e experiment the main res
for Brewery Was
October - Decem
0 m × 0.25 nt Technolog or was measu he analyses o
himadzu GC h with a ther 1010 PLOT tection of h methane.
SULTS AND
the real va ODt concent
s (HRT) and LR) were app l period. Fig nd effluent o tal time. Tab sults for each
stewater Treatmen
mber, 2016
mm × 0.25 gies). The bi sured by a R of biogas com C-2010 (Kyo
rmal conduc T (30 m x 0 hydrogen, ca
D DISCUSSI
ariation of tration, diffe d volumetric
plied in the r gure 2 shows
of the reacto ble 1 presen h operational
nt 7
μm) capilla iogas flow ra Ritter Millig mposition we oto, Japan) g ctivity detect 0.53 mm) co arbon dioxid
ION
the industri erent hydraul organic loa reactors durin
s the CODt ors througho nts a summa
l step.
735
ary ate gas ere gas tor ol-de,
ial lic
HRT (h) VOLR (kg COD m-3 d CODt (mg L-1
Wastewa PB PU PB PP SB PU SB PP CODf (mg L-1 Wastewa PB PU PB PP SB PU SB PP TSS (mg L-1)
Wastewa PB PU PB PP SB PU SB PP VSS (mg L-1)
Wastewa PB PU PB PP SB PU SB PP pH
Wastewa PB PU PB PP SB PU SB PP
PB PU:
fixed-Tab
d-1) 1
)
ater 2 U
U
1 ) ater U U
ater U U
ater U U
ater U U
-packed bed reacto
Fig
ble 1: Summ
24
2.3
258±119 2 164±31 141±17 139±18 294±74 1650±86 114±29 84±11 87±18 225±66
- - - - - - - - - - 7.2±0.2 7.5±0.1 7.4±0.1 7.4±0.1 7.3±0.2
or with Biobob®;
ure 2: CODt
mary of the m
18
2.9
2201±135 1 245±38 204±21 5 187±28 188±64 1471±105 142±30 119±19 5 113±23 129±39
- - - - - - - - - - 7.2±0.3 7.6±0.1 7.6±0.2 7.7±0.2 7.7±0.2
; PB PP: fixed-pa
t throughout
main results
18
13.8
10384±355 3707±788 5973±1574 2709±698 4699±819 8562±410 3230±619 5343±1326 2202±646 4234±756
- - - - - - - - - - 7.1±0.4 7.8±0.7 7.7±0.8 8.2±0.5 8.0±0.7
acked bed reactor
t the experim
s for each op
12
20.3
10050±623 3703±813 5112±1094 3087±722 4013±962 8120±582 3377±831 4733±1138 2754±645 3702±958 1902±230 517±166 493±158 224±22 605±291 1658±198 495±166 465±153 204±23 566±267 7.6±0.3 8.2±0.1 8.1±0.1 8.2±0.1 8.2±0.1
with polypropyle
mental time.
perational st
8
14.0
4641±372 988±391 836±285 891±238 1139±220 2733±103 728±380 625±276 564±79 815±283 1191±102 456±60 487±110 546±0 527±0 986±89 388±61 435±124 538±0 - 7.9±0.3 7.8±0.1 7.8±0.1 7.7±0.1 7.7±0.1
ene rings; SB PU: tep.
8
28.6
9475±993 5784±632 6299±503 6757±1313 5649±1504 6239±560 5203±707 5448±465 5326±866 4455±1320 3310±198 1674±630 1216±557 1438±357 988±1303 2945±120 1481±437 1053±405 1400±0 1470±0 7.6±0.3 6.8±0.2 6.8±0.2 6.3±0.5 6.7±0.5
: fixed-structured
8
22.9
7574±241 4267±1051 4784±303 4330±82 4573±451 4923±160 3484±1001 4034±392 3477±438 3787±257
- - - - - - - - - - 7.1±0.5 7.1±0.3 6.8±0.2 6.7±0.2 6.9±0.2
H u st re in b sa ti la C ex
d tw
Eval The first s HRT of 32 h a
sed to acclim tart-up of th eaching ECOD noculation. O
ed reactors ame perform ion. This fact ation proced CODt remov xperimental The ECOD f -1) was simila ween 90% a
luation of an Inno
Brazilian
step of react and VOLR o matize the bi he packed-fix
D higher than On the other had a slow mance after
t was due to dure done fo val efficienc
time are pre for low VOL ar for all reac and 94%. Fi
20 30 40 50 60 70 80 90 100
ECO
D
(%
)
ovative Anaerobic
Journal of Chem
tor operation of 2.0 kg CO iomass to the
xed bed rea n 90% after 2 r hand, the s wer start up,
15 days fro the differen or each con ies (ECOD) sented in Fig LR (2.0 and 2 ctors, with av igure 4 show
Fig
Fig
0 2 4
HR
c Bioreactor with
mical Engineering
n (15 days w ODt m-3 d-1) w
e substrate. T actors was fa 2 days from structured-fix , achieving
m the inocu t type of ino figuration. T throughout gure 3. 2.3 kg CODt
verage ECOD ws the avera
gure 3: ECOD
gure 4: ECOD 6 8 10
V PB PU
HR RT = 24 - 18 h
h Fixed-Structure
g Vol. 33, No. 04,
with was The fast, the xed the ula- ocu-The
the
m-3 be-rage
CO VO
an for ure str mo (PB spe pe the be co pe
D throughout
D as a functio 12 14 16 VOLR (kg COD
PB PP SB
RT = 18 h HRT = 8 h
d Bed (ABFSB) f
, pp. 733 - 741,
ODt remova OLR.
For VOLR d 20.3 kg CO rmances wer ethane foam ructured-fixe ore efficient B PU), with ectively, for rficial area e fixed biom d minimized nditions con rformance.
the experime
on of the VOL 6 18 20 D m-3d-1)
PU SB PP
HRT = 12
for Brewery Was
October - Decem
l efficiency
of 13.8 kg C ODt m-3 d-1(H
re reached b m as biomas ed bed reacto
t than the p h ECOD of 74 r each appli of the poly mass concent d the dead z ntributing to
ental time.
LR. 22 24 26
2 h
HRT = 8 h H
stewater Treatmen
mber, 2016
(ECOD) for CODt m-3 d-1
HRT of 12 h by the reacto ss support. tor (SB PU)
packed-fixed 4 ± 7% and ied VOLR. yurethane fo ntration and
zones in the o the increa
28 30
HRT = 8 h
nt 7 each applie
(HRT of 18 h) the best pe
ors with pol However, th
was over 9 d bed react 70 ± 6%, r The high s oam increase
the structure e reactor, bo
ase in react 737
ed
h)
er- y-he
% tor
op h at ac st w tw st a p S an ti th op co b an fo an Although peration wit ad a better e tion with 18 ctors. This f titial velocit which decrea ween biofilm
trate utilizat specific hyd rove this hy B PU and P n average E ively.
Methane a he biogas co
perational s oncentration iogas. The nd the metha or each oper nd Table 2, r
HRT VOL (kg COD PB P PB P SB P SB P
PB PU: fixed-with longitudin
having a s th a HRT of efficiency of 8 h (13.8 kg fact can be r ty in the rea ases the ma m and substr tion rate (Sa drodynamic ypothesis. F
PB PP had ECOD of 81 ± and carbon d omposition steps. The h ns were not
temporal bi ane average rational step respectively.
Table 2: M
T (h) LR
m-3 d-1) PU
PP PU PP
-packed bed reacto nal polyurethane f
imilar appli f 8 h (14 kg f CODt remo g CODt m-3 related to the
actor bed fo ass transfer rate and incr arti et al., 20 test was no or this cond better perfo ± 5% and 82
dioxide were for all reac hydrogen an significant iogas produc
concentratio p are present
Figure 5: Methane co 24 2.3 86±3 88±2 88±3 91±1
or with Biobob®; foam strips; SB P
ed VOLR, CODt m-3 d oval than op
d-1) for all e highest int or 8 h of HR
resistance b reases the su 001). Howev
t carried out dition, both ormances, w ± 6%, resp
predominant ctors during d nitrogen
or zero in ction flow r on in the bio
ted in Figure
Biogas prod ncentration 18 2.9 91±1 90±2 89±3 90±1
; PB PP: fixed-pa P: fixed-structure
the d-1) per- re- ter-RT, be- ub-ver, t to the with pec-nt in all gas the rate gas re 5 cre qu the du ag sto den tiv flu var var rea ev act an con ing op tio sen duction throu
n (%) in the
18 13.8 79±13 77±16 83±13 89±6
acked bed reactor ed bed reactor with
With the in ease in the C uent decrease e methane yi uring the ope e values bet oichiometric ncing the s vity for all rea
Because of uent concentr riation durin riation, the actors for VO
idencing the tivity. Howev d 28.6 kg C ncentration w g the predom perational ste on (TOA) thr nted in Figur
ughout the ex
biogas for e
12 20.3 88±3 90±1 90±2 92±2 with polypropyle h longitudinal bar
ncrease of th CODt remov e of the biog
eld (YCH4) di erational peri ween 70% a value (250 g tabilization actors.
the wastewa ration of tota ng the reacto organic acid OLR less th e predomina ver, for VOL CODt m-3 d-1 was higher t minance of ac
eps. The tota roughout the re 7. xperimental t each operati 8 14.0 81±2 80±2 82±2 83±5
ene rings; SB PU: r constructed of po
he VOLR, th val efficiency gas producti did not chang riod (Figure and 90% of g CH4 kg-1CO
of the meth
ater characte al organic aci ors operation ds were con han 20.3 kg ance of the LR of 22.9 kg
1 the effluen than the infl cidogenic ac al organic ac e experiment time. ional step. 8 28.6 70±7 69±6 69±7 74±6 : fixed-structured olypropylene ring
here was a d y and a cons ion. Howeve ge significant
6), with ave the maximu ODremoved), ev hanogenic a
eristics, the i ids had a larg n. Despite th nsumed by a CODt m-3 d
methanogen g CODt m-3 d nt organic ac
uent, eviden ctivity in the cid concentr tal time is pr
re-p V w o
b m g v (l fi ev
Eval
For VOLR H values w VOLR of 22.9 were overloa
rganic acid g The anaer ed (ABFSB) ment of wast anic matter antages of b low risks of ixed-bed (hig ver, the type
luation of an Inno
Brazilian
R up to 20.3 were alkaline 9 and 28.6 k aded and the generation.
robic biorea ) provides a tewater with and solids, both up-flow f dead zone gh sludge ret
of biomass s
ovative Anaerobic
Journal of Chem
Figure 6: M
Figure
kg CODt m -e (Figur-e 8) g CODt m-3 e effluent w
actor with f a good altern h high conce because it w anaerobic es and bed tention time)
support had
c Bioreactor with
mical Engineering
Methane yiel
e 7: TOA thr
3 d-1the efflu . However, d-1, the react as acidified
fixed-structu native for tre entration of aggregates sludge blan
clogging) a reactors. Ho a big impact
h Fixed-Structure
g Vol. 33, No. 04,
ld (YCH4) thro
roughout the
uent for tors by
ured
eat- or- ad-nket
and ow-t on
the glo bu rea be tha thi be as
3), SB rem
d Bed (ABFSB) f
, pp. 733 - 741,
oughout the e
experimenta
e reactor pe obal efficien ut the SB PP actors. Due d reactor has an the packe is fact, the bi d reactor has in the polyu
Compared w , in spite of B PU had sat moval for bre
for Brewery Was
October - Decem
experimental
al time.
rformance. T ncy compared P was simila
to its geom s a smaller v
d-fixed bed r iomass suppo s to present h rethane foam with previou
the higher V tisfactory eff
ewery wastew
stewater Treatmen
mber, 2016
al time.
The SB PU d with all te ar to the pac metry, the st volume of su reactor. Thu ort for the st high superfi m.
usly studied r VOLR and lo ficiency for o
water treatm
nt 7
U had the be ested reactor cked-fixed be
tructured-fixe upport materi
s, to minimi tructured-fixe
cial area, suc
reactors (Tab ower HRT, th
organic matt ment.
739
est rs, ed ed ial ze ed ch
(A m m ti g su b h te p
an re ti ac
Reactor Configuratio
IFBRa UASB UASB ASBR PB PU PB PP SB PU SB PP aIFBR: inverse bBatch cycle ti
PB PU: fixed-with longitudin
The anaero ABFSB) is a matter and s ment. This re
ime with a f ing because ults show tha ig impact on ad the best ested reactor
acked-fixed For a VOL nd 20.3 kg C eached the a ively. For a V
ctors were ov
Table 3
n
VOL (kgCOD m
10 7 12.5 5 14.0/ 2 14.0 / 2 14.0 / 2 14.0 / 2
e fluidized bed re ime: feeding (1 h -packed bed reacto nal polyurethane f
CONCL
obic bioreact a promising t solids conce eactor prom fixed-biofilm of its bed g at the type o n the reactor t global effi rs, but the
bed reactors LR of 14.0 kg CODt m-3 d-1 average ECOD VOLR over 2 verloaded an
Figure
3: Results o
LR m-3d-1) 0 7 5 5 20.3 20.3 20.3 20.3
eactor
h), reacting (6.35 h or with Biobob®; foam strips; SB P
LUSIONS
tor with fixed technology f entration wa motes high sl m and low ris geometry. H
f the biomas r performanc iciency com
SB PP was s.
g CODt m-3 d 1 (HRT of 12 D of 81% an 22.9 kg COD nd the effluen
e 8: pH varia
f previous s
HRT (h)
5 84 24 8b 8 / 12 8 / 12 8 / 12 8 / 12
h), settling (0.5 h ; PB PP: fixed-pa P: fixed-structure
d-structured b for high orga astewater tre ludge retent sk of bed cl owever, the ss support ha ce. The SB mpared with
similar to
d-1 (HRT of 8 2 h), the SB nd 71%, resp Dt m-3 d-1, the nt was acidif
ation through
studies for b
ECOD (%) 90 95 57 90 79 / 63 82 / 49 81 / 70 75 / 60
h), decanting (0.15 acked bed reactor ed bed reactor with
bed anic eat-tion
log- re-ad a
PU all the
8 h) PU
pec- re-fied
by so
fro
Es
0,
Ad
hout the expe
rewery wast
Temp (°C)
35 35 37 33 35 35 35 35
5 h)
with polypropyle h longitudinal bar
y the increase the methano
A
The authors om FAPESP
tado de São
2010/20025-dorno, M. A. A., Develop quantify vo space (auto
rimental tim
tewater trea
p.
A Ö Pa X
ene rings; SB PU: r constructed of po
e of the conc ogenic activit
CKNOWLE
s are gratefu (Fundação Paulo, proce -0 2012/1027
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