Phase II Review Report WWTM-1-Final

8/6/2019 Phase II Review Report WWTM-1-Final

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WWTM Project 1 ARRPET Phase II

A Brief Report on

Wastewater Treatment andManagement Projectin

Asian Regional Research Project in EnvironmentalTechnology (ARRPET) Phase II

Funded by

Swedish International Development Cooperation Agency(SIDA)

Co-coordinated byAsian Institute of Technology

Prepared by:

Saumyen GuhaDepartment of Civil Engineering

Indian Institute of TechnologyKanpur, UP 208016, INDIA

with inputs from the NRIs of WWTM Project

August, 2007


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Table of Contents

Outline of the Report __________________________________________________3

Background _________________________________________________________3

Research ____________________________________________________________4

Networking__________________________________________________________5

Dissemination________________________________________________________6

Capacity Building_____________________________________________________6

Administration _______________________________________________________6

AIT Report: Efficient Processes for Wastewater Nitrogen Removal_____________7

CENTEMA Report: Sustainable Development of Tapioca Processing Industry in

Vietnam____________________________________________________________15

IITK Report: Domestic Wastewater Treatment in India: Optimization of UASB

Reactor ____________________________________________________________25

IITB Report: Characterization of Biosolids fromUASB/Activated Sludge

Process/Fluidized Bed Process _________________________________________32

KMUTT Report:Bioremediation and Reuse of Marine Shrimp Farm Effluent __40


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Outline of the Report

First four pages of this report provide an executive summary of the WWTM project inARRPET Phase II. This is followed by a brief report from each NRI on the progress

and achievement of the individual projects during Phase II.

Background

The main goal of the Wastewater Treatment and Management Project (WWTM) wasto develop cost effective technologies for the region using local resources andexpertise for the treatment of wastewater originating from cities, towns and villages ofthe region. Researchers (NRIs) from several countries work on different projectsegments in order to meet the overall goal of the project. At the inception of the

project in Phase I, there were 7 NRIs from 4 different countries namely India,Thailand, Vietnam and Malaysian. During the transition from Phase I to Phase II, oneof the NRI from India and the NRI from Malaysia were discontinued on the basis ofnon-performance. Five NRIs in Phase II are:

Asian Institute of Technology (AIT), Thailand. e-mail: [email protected] Centre for Environmental Technology and Management (CETEMA), Van

Lang University, Vietnam. e-mail: [email protected] Indian Institute of Technology Kanpur (IITK), India. e-mail: [email protected] Indian Institute of Technology Bombay (IITB), India. e-mail:

[email protected]

King Mongkuts University of Technology (KMUTT), Thailand. e-mail:

[email protected]

In terms of pollutants, the project in Phase II targets carbon and nitrogen removal.The distribution of NRIs according to the pollutants in Phase II is:

Carbon Removal: IITK, IITB and CENTEMA Nitrogen Removal: AIT and KMUTT

Based on the local economy, the wastewater may consist of pure domestic sewage,domestic sewage mixed with small-scale industry wastewater and agro-industrywastewater. The distribution of NRIs according to the wastewater is:

Domestic Wastewater: IITK and IITB Agro Industry Wastewater: CENTEMA Shrimp and Seafood Industry wastewater: AIT and KMUTT

NRIs are working on a diverse range of unit processes such as Upflow AnaerobicSludge Blanket Reactor system for domestic and agro industry wastewater (IITK,IITB and CENTEMA), photo-bio reactor system for shrimp pond wastewater(KMUTT) and nitrogen removal by anaerobic process (AIT). The major researchachievements are summarized in the next section.


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Research

The research in ARRPET consisted of a combination of development of noveltechnology and adaptation of the existing unit processes to local environmental

problems. While developing the technologies, special attention was given to

utilization of low cost and locally available materials and expertise. The researchstarted in Phase I of ARRPET. In Phase II, all the NRIs were conducting laboratoryexperiments with real wastewater and successfully demonstrated the applications inPilot Scale treatment plants. Funding for the pilot plant construction, operation andmaintenance were secured from private partners in most cases. Cost Benefit Analysiswas conducted by each of the NRIs for their respective projects. All the projects were

proved superior compared to the benchmark technologies. Benchmarks were selected based on frequently used technologies used in the area for the target wastewater.Brief outlines of the research achievements of each NRI are presented below:

AIT: A novel process called combined Activated Sludge with Partial Nitrification

(AS/PN) was coupled with Anaerobic Ammonium Oxidation (ANAMMOX) processto remove nitrogen from the wastewater. Target wastewater in this case was effluentafter the secondary treatment of sewage and from seafood industry. Severalexperiments, both in laboratory and pilot plant scale, were conducted to develop thenovel process, which can simultaneously and efficiently remove both organic carbonand nitrogen pollution. In the laboratory experiments, maximum nitrogen removalrate was 1.4 kg N m-3 d-1 at ammonium and nitrite concentrations of around 375 and350 mg N l-1, respectively. The experiments demonstrated that combined AS/PN -ANAMMOX process is stable for wastewater containing high ammonium up to 700mg N/l. Pilot scale experiments with real wastewater from seafood industry alsoshowed satisfactory results.

CENTEMA: Goal of this project was to develop a model for the sustainabledevelopment of tapioca industry at the village level through waste minimization,reprocessing and recycling. Proposed wastewater treatment system consisted of theUASB reactor system combined with an aerobic activated sludge process andstabilization ponds. The treated wastewater was reused for irrigation in the area forcassava cultivation and on the surrounding agricultural land. The wasted sludge fromwastewater treatment plant and cassava root peel was used for composting. Thecompost produced was applied for the cassava and corn cultivations. The fish

produced in the stabilization ponds were edible and was a source of revenue. In this

way, the target was to create a zero waste industrial ecosystem for the tapiocaprocessing villages, where solid waste and wastewater can be gathered and treated atthe central treatment units in the area.

IITK: A field and literature survey during Phase I of ARRPET indicated that theUASB process for the treatment of low strength wastewater suffered from thefollowing shortcomings: longer start-up times, inability to form self-immobilized

bacterial granules and very low bio-gas recovery. Primary objective of the project atIITK was to achieve better granulation in UASB reactors treating low-strengthwastewater. This was achieved using locally available and low cost natural polymeradditives such asReetha seed (Sapindus trifoliata) extract and Chitosan. It was also

shown that the enhanced granules were stable for long period under various shockloading without requiring further doses of the additives. Large granules were


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generated in the reactor using real sewage with COD concentration varying randomly between 100-200 mg/L. More than 80% COD removal could be achieved with anHRT of only 2.5 hours in the sludge bed and 4.5 hours overall including the settlingzone. The 100 m3/day pilot plant has been funded by Vapi Waste and EffluentManagement Co. Ltd. (VWEMCL) and is operated jointly by IITK, IITB and

VWEMCL.

IITB: Enhanced granulation in UASB reactor with low strength wastewater, asdescribed in IITK above was conducted as a collaborative project between IITK andIITB. While the reactor operation and monitoring of chemical and biochemical

parameters were conducted at IITK, the granule examination and characterizationusing Image Analysis (IAS), Environmental Scanning Electron Microscope (ESEM),Electron Probe Micro Analysis (EPMA) and Transmission Electron Microscope(TEM) were conducted at IITB. Close collaboration between the two institutesenabled development of an applicable technology. The pilot plant for the enhancedgranulation is also being operated jointly between IITK, IITB and VWEMCL. In

addition, IITB acted as a hub for bio-solids characterization for all the NRIs inWWTM project and IHWTM project in ARRPET.

KMUTT: This project attempted to develop cost-effective methods for removingammonia nitrogen from shrimp pond water prior to discharge to the environment byutilizing photosynthesis activity of micro-algae developed in shrimp-pond. The keywas to determine the light/dark period and mixing condition for optimum nutrientremoval by green algae (Chlorella sp.). It was observed that the light/dark ratio andmixing are closely related parameters. In a shallow well-mixed tank, the lightrequirement is less compared to a deep tank with less mixing. In the laboratory scaleexperiments, maximum ammonia nitrogen removal rate observed was 0.71-0.98 mg-

N/mg-Chl-a/h. At the pilot scale the nominal ammonia nitrogen removal rate was0.06 to 0.15 mg-N/mg-Chl-a/h which increased substantially to 0.50 mg-N/mg-Chl-a/h with mixing, bringing it close to the laboratory reactor observation. Treatment ofthe sediment from the shrimp pond was considered as the minor issue and preliminaryinvestigations were conducted for biogas production, nutrient leaching and fate ofmicrobial population during the drying process.

Networking

Networking was achieved at three different levels: (i) research networking throughcollaboration between two or more NRIs; (ii) transfer of technology and developmentof expertise through specialized workshops; and (iii) research collaboration between

NRIs and industry partners through pilot scale experiments. NRIs from WWTMproject as well as IHWTM project of ARRPET participated in the first two activities,which lead to healthy interaction and synergy between two projects in ARRPET. Byclose interaction between the NRIs, many research problems were resolved. Some ofthese are: characterization of biosolids, analytical methods for target compounds andmetabolites, analysis of microbial ecology, identification and characterization of

phytochelatins in phytoremediation, etc. The NRIs from two projects meet every yearin a combined regional workshop to foster networking. Eight specialized trainingworkshops have been organized so far for the NRIs in WWTM. Besides, there were 6

more training workshops for the industry partners. Collaboration with industry


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partners through pilot plant opened up the possibility for future transfer of technologydeveloped in ARRPET.

Dissemination

Knowledge dissemination from ARRPET project was conducted at multiple levels.The technology developed was published in peer-reviewed journals and were

presented at national and international conferences. Twelve articles in peer-reviewedjournals have already been published and 8-10 more are in the process of preparationor review. A total of 14 publications have come out so far in the National andInternational conferences. This enabled technology evaluation by the peer groups atlarge as well as dissemination of the knowledge to technical community. Besides, 4national workshops and were held by the NRIs in order to keep the stake holders and

policy makers informed about the technologies developed at ARRPET. The NRIsfrom WWTM and IHWTM projects published two newsletters every year, which wascirculated widely through internet. These articles were targeted towards the non-

technical community.

Capacity Building

Capacity building activity was mainly targeted towards building technical manpower.To this end, most of the NRIs had large success by guiding Masters and Ph.D.students as part of the project activity. Some laboratory infrastructure was built fromthe funding ofMinor Equipmentin the project.

Administration

Administrative structure of WWTM project consist of a Principal Investigator (PI)designate from amongst the NRIs whose duty is to monitor the NRI projects on aregular basis in consultation with a Swedish expert, give timely feedback to the NRIs,enforce the project requirements and prepare the project reports. The financial matteris handled by AIT. There was a change of PI in the WWTM project in the year 2004and a change of Swedish expert in the year 2006.

Brief reports from the NRIs of individual projects follow.


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AIT Report: Efficient Processes for WastewaterNitrogen Removal

Contact Person:

Prof. Ajit P. AnnachhatreEnvironmental Engineering and ManagementAsian Institute of TechnologyPO Box 4, Klong LuangPathumthani 12120, THAILANDe-mail: [email protected]

Technology Developed Through Research

Technology Developed in ARRPET II

ARRPET Phase I brought out that complete removal of nutrients such as nitrogen andphosphorus from domestic wastewater could not be achieved through UASB process.As a result, UASB effluent needs to be further treated for removal of nutrients.Accordingly, researches were undertaken in ARRPET Phase II for removal ofnitrogen from the UASB effluent. The main objective during ARRPET II researchwas to develop an appropriate and efficient biological nitrogen removal processesfollowing Upflow Anaerobic Sludge Blanket (UASB) process.

Accordingly, the research was initiated with a focus on high strength nitrogen

wastewater with low organic carbon source. Extensive literature review has beencarried out (Khin and Annachhatre, 2004). Several novel biological nitrogen removal

processes were identified including Single reactor system for High AmmoniaRemoval Over Nitrite (SHARON), Anaerobic Ammonium Oxidation (ANAMMOX)and Completely Autotrophic Nitrogen Removal Over Nitrite (CANON). However,these processes require wastewater with very low organic carbon i.e. COD and BODless than 100 mg/l. In reality, effluent from the UASB process rarely achieves thislimit. One of the classical methods is to apply conventional nitrification-denitrification process. However, this requires complete conversion of ammonia tonitrate and from nitrate to nitrogen gas which results in high oxygen demand.Furthermore, addition of external carbon source is required to allow denitrification to

proceed.

An alternative was to use combined SHARON-ANAMMOX process to treat thenitrogen pollution. However, SHARON process was known to be an autotrophic

process, hence, a novel process has to be developed. By careful manipulation of pHand dissolved oxygen level during aeration, a simple activated sludge process (ASP)could actually perform partial nitrification similarly to a SHARON process. Extensiveliterature review as well as laboratory scale experiments have proved this hypothesis(Sinha and Annachhatre, 2006a; Sinha and Annachhatre, 2006b). Hence, a novel

process called combined Activated Sludge with Partial Nitrification (AS/PN) and

ANAMMOX process was developed. Several experiments, both in laboratory and


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pilot plant scale, were conducted to develop novel process which can simultaneouslyand efficiently remove both organic carbon and nitrogen pollution.

Figure 1: Schematic diagram of the developed technology (AS/PN-ANAMMOXprocess)

In essence, the developed technology comprises combined AS/PN-ANAMMOXprocess (Figure 1). Complete organic carbon removal takes place in the first aerationtank as well as partial oxidation of ammonium (only 50-60%) to nitrite. TheAnammox process combines and converts ammonium and nitrite to nitrogen gas witha small amount of nitrate production (Eq. 2).

AS/PN: NH4 + 1.5O2 NO2 + 2H+ + 2H2O Eq. 1

ANAMMOX: NH4 + NO2 N2 + 2H2O Eq. 2

Brief Description of Laboratory Research

Experiments of AS/PN and ANAMMOX processes were carried out with syntheticwastewater (high ammonium with no organic carbon source) in laboratory scalereactors. Several operating conditions (i.e. pH, DO and Temp.) have been tested andoptimized. Effluent from AS/PN with almost equal amount of ammonium and nitritewas produced with the following operating conditions:

pH: 7.5-8.5 Temperature: 35o C (in theory 25 40 o C is acceptable) DO: 0.5 mg/l

The effluent from this reactor was fed into the Anammox reactor. The AS/PN-ANAMMOX process was operated successfully at the laboratory scale experiment.The maximum nitrogen removal rate was 1.4 kg N m-3 d-1 at ammonium and nitriteconcentration of around 375 and 350 mg N l -1. The experiment demonstrated thatcombined partial nitrification-Anammox is suitable for high ammonium wastewaterup to 700 mg N/l. The details of experimental results were included in Annual cumProgress Report 2006.

AS/PN

Settlingtank

Discharge

UASBAnammox

gas-lift

Air

Influent


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Publications

Khin, T. and Annachhatre, A.P. (2004). Novel Microbial Nitrogen RemovalProcesses,Biotechnology Advances, 22 (7): 519-532.

Hanh, D. N., Rajbhandari, B. K. and Annachhatre, A. P. (2005). Bioremediation of

sediments from intensive aquaculture shrimp farms by using slow oxygenrelease agent. Environmental Technology, 26, 581-589.

Sinha, B. and Annachhatre, A. P. (2006a). Assessment of partial nitrification reactorperformance through microbial population shift using quinone profile, FISH andSEM.Bioresource Technology. (In press)

Sinha, B. and Annachhatre, A. P. (2006b). Partial nitrification operational parameters and microorganisms involved. Rev. Environ. Sci. Biotechnol. (Inpress)

Pilot Scale Application

Methodology

Following the successful operation in laboratory scale experiments, pilot plantinvestigation was initiated. Several industries have been contacted, however, nonewas willing to finance and install the developed technology at their plant. Finally, itwas decided to bring wastewater from a seafood processing industry and carry out

pilot plant investigation at AIT.

Experimental setup for the whole pilot plant unit is illustrated in the Figure 2. It

comprises AS/PN and Anammox gas-lift reactors. Details of each unit are describedas follows:

Activated sludge with partial nitrification (AS/PN) reactor setup: The 32 L CSTR wasequipped with DO control as well as a mixer. Biomass was separated from the liquidin a 130 L stainless steel settling tank which has a scraper at the bottom. Effluent fromthis reactor was sent to Anammox process. Start-up and operation of this process wasconducted using the seafood processing industry wastewater. Seed sludge was takenfrom the industry aeration tank. Temperature was not controlled and varied in therange of 27-36 oC.

Figure 2: Process flow diagram of the pilot plant investigation

AS/PNreactor

Wasted

sludge

SettlerEffluent

Anammoxreactor

Industrial

wastewate


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Anammox reactor setup: The gas-lift reactor has a working volume of 32 L with anattached 12 L settler located at the top of the reactor. This reactor will receive effluentfrom AS/PN effluent. Start-up of the Anammox process was performed usingsynthetic wastewater as described previously (Progress Report No. 2). Seeding was

performed by combining active Anammox biomass from previous research (1 L) with

the activated sludge (4 L) from the industry. Anaerobic condition was achieved byflushing with Ar/CO2. Temperature was kept above 30

oC using a temperature controlunit and a hot water coil.

Results and Discussion

Activated sludge with partial nitrification (AS/PN) process was in operation for over140 days. During this period, different DO monitoring and controlling methods wereapplied. It was found that the manual control produced best results at DO of around0.5-0.6 mg/l. During the operation period, steady state was achieved on day 100 150. During this period, COD removal efficiency and concentration in the effluent

were averaged at 90% and 63 mg/l respectively (Figure 3). Hence, the effluent hasvery low organic carbon which is highly suitable for ANAMMOX process.Furthermore, during this period, almost half of ammonium was oxidized andconverted to nitrite. Concentrations of both ammonium and nitrite were fluctuatedaround 100 180 mgN/L (Figure 4). Addition of ammonium chloride was done fromday 82 onwards to compensate for the loss in ammonium concentration in theindustrial wastewater. A small amount of nitrate was produced; however, theconcentration was always less than 30 mg N/L which should not affect ANAMMOX

process. In essence, AS/PN process was stable during the experimental period andsuccessfully produced effluent which highly suited for the ANAMMOX process.

Key results from AS/PN process is illustrated in Figure 3 and 4, while the key resultsfrom the ANAMMOX process is shown in Figure 5.

The ANAMMOX pilot scale unit was in operation for 120 days. Initially, enrichmentwas carried out using synthetic wastewater. On day 89, effluent from AS/PN processwas transferred into the reactor. During 30 days period using industrial wastewater,the ANAMMOX process performance was satisfactory. Nitrogen loading andremoval rates on day 114 were 0.33 and 0.27 kg N m-3 d-1 respectively. Thissuggested that AS/PN effluent was suitable for ANAMMOX bacteria and processcould be performed successfully. Although, the removal rate was not high as in

previous experiments, this could be due to short acclimatization period. Generally,

ANAMMOX process requires around 3-9 months to start-up. Another experiment onlaboratory scale unit showed that removal rate could be up to 0.6 kg N m -3 d-1 withstability (data not shown).


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0

200

400

600

800

1000

1200

0 20 40 60 80 100 120 140

Time (day)

COD(mg/L)

0

20

40

60

80

100

%Removal

COD Inf. COD_Eff. % Removal

Figure 3: COD concentrations and removal efficiency from AS/PN process

0

100

200

300

400

500

1 21 41 61 81 101 121 141

Time (day)

Concentration(mgN/L)

NH4N Inf. NH4N Eff. NO2N Eff. NO3N Eff.

Figure 4: Concentrations for different N species from AS/PN process

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0 20 40 60 80 100 120

Time (day)

kgNm

-3d

-1

NLR NRR

Figure 5: Nitrogen loading rate (NLR) and removal rate (NRR) for ANAMMOX

process


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Networking

Within ARRPETThe networking group was rationalized and re-arranged to reflect the need of each

NRI in this project during the combined regional workshop in Bali (June, 2006). Inthis respect, AIT has actively carried out collaborative researches including:

Microbial population analysis with ARI:AIT has sent Anammox biomass sample toARI for isolation as well as pure culture development. Furthermore, AIT also sentDNA bands from partial nitrification and Anammox reactors to ARI for sequencing.The results from this research will be published under a joint publication.

Biofloc/Bilfilm development and characterization with IIT-B: AIT and IIT-B has

set up a collaborative research on granule characterization of the Anammox inhibitedbiomass. Preliminary experiments were carried out at AIT, and samples were sent toIIT-B for image analysis to determine floc size distribution. The result has showngreat variation between normal and inhibited aggregate size. Thus, furtherinvestigation is necessary and will be conducted within the next 6 months.

Microbial analysis and pilot plant investigation with KMUTT:KMUTT has assistedAIT in setting up of Fluorescence In Situ Hybridization (FISH) laboratory procedureas well as providing connection to the suitable seafood industry.

Outside ARRPET

AIT has undertaken a pilot scale investigation on membrane bioreactor (MBR) withan acrylic fiber industry in Thailand. The collaborative researches include fromcleaner production with a focus on reuse and recycle of treated effluent. Furthermore,investigation of pilot scale unit membrane filtration and MBR was also conducted atthe industry.

Results from the studies have identified various options on reusing of effluent andways to enhance COD removal efficiency of the existing treatment plant. As a result,the industry decided to install a membrane filtration unit to reuse treated effluent fromthe wastewater treatment plant as a make up water in the cooling towers.

DISSEMINATION

Workshops Organized:

Table 1: List of workshop organized by AIT-WWTM

Networking activity Remarks

Training on UASB and ANAMMOXProcess

AIT, Thailand; 21-25 March2005

Training Workshop on MolecularTechniques

AIT, Thailand; 21-25 March2005


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Publications (other than research publication):

Annachhatre, A.P. (2005). Advanced, Appropriate and Affordable Technologies forDomestic Wastewater Treatment and Reuse in Tropical Region, Proceedings of

UNESCO Workshop on Integrated Urban Water Management on HumidTropics, Iguassu Falls, Brazil, 2-3 April 2005.

Khin, T. and Annachhatre, A.P. (2004) Novel Nitrogen Removal Processes presented at the First Thailand-Korea International Symposium onEnvironmental Remediation held at AIT on 20 August 2004.

San Francisco, L.S. and Annachhatre, A.P. (2004). Sustainability of water resources.IWA International Conference, Western Australia, November 2002., 167-174.

Sinha, B. and Annachhatre, A. P. (2005).Inhibition of Nitrite Oxidation duringNitrification. ARRPET Newsletter August 2005.

Lamsam, A. and Annachhatre, A. P. (2005). Cultivation of Anammox Bacteria: Tricksor Treats. ARRPET Newsletter December 2005.

CAPACITY BUILDING

Man- Power:

Miss Le Tuyet Minh - Master student (completed)Miss Mayuree Tonkham Master Student (completed)Mr. Bhaskay Ray Master Student (completed)Mr. Kawin Ruamsuke Master student (completed)Mr. Tharmalingam Suthakar Master Student (completed)

Mr. Apipong Lamsam PhD Student (on-going)Mrs. Banashri Sinha - PhD Student (on-going)Miss Sawanya Laohaoprapanon Master Student (on-going)Mr. Nguyen Phuc Thanh Master Student (on-going)Mr. Nuttapol Tanadehangsaeng Master Student (on-going)Mr. Phrompol Chantrasakdakul Master Student (on-going)Ms. Raquel P. Pedrajas Senior Research Associate

Laboratory Infrastructure:

Major equipment (>50,000 SEK)

Microscope with fluorescence, Program Meta System (Isis FISH) Minor equipment (< 50,000 SEK)

Datalogger ML22, Anammox Gas-lift Reactor (consisting of reactor height 2175 mm,riser height 1700 mm, body made of stainless steel 304 thickness 1.2 mm, cover madeof stainless steel 304 thickness 2 mm, steel plate thickness 6 mm, stainless valve 1/4",steel frame, height 200 mm width 80 mm).

Pilot scale experimental setup consisting of Annamox Gas-lift Reactor, Heater (HCL-19X300-220V-1000W), Temperature sensor (FWP-19A-6.35X100-3M (RTD Pt 100DN), Drive MFLEX, L/S 600 RPM, 115/230V, Pumphead, L/S, Easy-Load 3, SS

Maintenance Kit for Do Sensor (Model: ZBK 600), WTW pH Sensor (Sensolyt


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ECA), O2 4050e wall O2 electrode model, InPro 6050/120, Inlab 413-SG pH probefor Seven-Go pH meter, Computer.

Wall Cabinet, Desk, pH-DO Portable sensor, Micropipette, Incubation oven, HotPlate, Dispensers (2.0-50.0 mL), Partition dark room for FISH analysis, pH meter,

Computers, Printer, UPS, Masterflex pump and accessories, pH Probe, AutomaticBurettes.

Open Issues

Unresolved issues from ARRPET II experiments are as follows:

Dissolved oxygen (DO) control in AS/PN process may require optimization usingautomatic control to enable full scale application.

Combined AS/PN-ANAMMOX should be tested with an industrial wastewaterfollowing a UASB reactor. Furthermore, experiments should be conducted tooptimize both processes under real situation of influent flocculation and varying

temperature in a tropical climate. Maximum capacity of ANAMMOX process in the gas-lift reactor should also be

verified.

Detailed cost-benefit analysis and EIA studies. Characterization of microbial community from efficient AS/PN and ANAMMOX

processes should be conducted.


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CENTEMA Report: Sustainable Development ofTapioca Processing Industry in Vietnam

Contact Person(s):

NGUYEN TRUNG VIET, TRAN THI MY DIEU, HUYNH NGOC PHUONG MAICENTER FOR ENVIRONMENTAL TECHNOLOGY AND MANAGEMENT VAN LANG UNIVERSITY

C4/5-6 DINH BO LINH, BINH THANH DIST., HCMC VIETNAMe-mail: [email protected]

1. TECHNOLOGY DEVELOPED THROUGH RESEARCH

The rapid growth of industrialization and urbanization in Vietnam is putting severe

stress on natural resources and on the environment, forcing the country to face anumber of serious environmental problems, such as water and air pollution,degradation of land resources, soil erosion, over-exploitation of natural resources, andthreats to the ecosystem. Important reasons for the rapid increase in environmental

pollution are mismanagement and limitations in the prevailing level of technologyapplied in industrial production processes and in waste treatment. Tapioca processingindustry is chosen as a case study for our research. Environmental problems from thetapioca processing industry can be divided into specific categories as will be

presented below.

Resource consumption: water consumption for starch extraction process and energy

consumption (coal, petroleum, gas or electricity) for starch drying.

Wastewater: in order to produce 1 ton of starch, a tapioca processing factorydischarges a huge amount (i.e. 15-20 m3) of wastewater, which contents high organicmatters, nutrients, cyanide concentration and very low pH. This is cause serious

problem for the surface and underground water quality in local area.

Solid waste: including root skins and fibrous residues, these may become local sourceof malignant and obnoxious odors during the drying and storing. A portion of thesolid waste is dumped may become environmental pollution.

Air pollution: mainly originates from the combustion of fuel (dust, CO, CO2, SO2,NO2) and comes from the greenhouse gases released from the degradation ofwastewater in anaerobic ponds and from solid waste. Another kind of air pollution isobnoxious odors from degradation of organic matter.

The surveys on tapioca production processes showed that there are severalpossibilities to reduce and reuse non-products (including byproducts and wastes) fromtapioca processing units. Based on that, it is possible to reduce and eliminateenvironmental impacts as well as to improve production efficiencies of tapioca

processing units. Several international literatures show that there are many differentways to get rid of wastes and achieve zero (or close to zero) waste industrial systems.

Certainly, each approach has its strengths and weaknesses and its application oftenworks under specific conditions. Integration of different approaches can overcome the


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weaknesses and shortcomings of individual approaches. The starting point to developsuch a methodology is formed by the material and energy flows in industrial systems.This aims at developing a systematic methodology on how to analyze various optionsto approach a zero waste industrial ecosystem by prevention of waste, minimizationof waste, reuse and recycling within one company and within a wider network of

companies and waste treatment option.

Then, the objective of ARRPET phase 2research is to develop a general model ofzero waste industrial ecosystem for tapioca processing industry in Vietnam. Toachieve the objective, CENTEMA carried-out the research step by step:

Primary surveys and data collection is carried out at 6 tapioca processing villages and3 large-scale tapioca processing companies.

Detailed study is carried out for 2 selected companies. Data from detailed studies todevelop the physical-technological model relate mainly to material and energy flows

within research units and related components of the model. Within research units thedate of input (raw materials, chemicals, energy, water supply, labor) and output(main products, solid waste, byproduct, wastewater, air pollutants) are collectedand studied based on material balances. Besides, the data of related components(wastewater treatment plant, fish culture, cassava culture, livestock feed production,composting plant, biogas plant) also are collected. Based on the data, the researchis carried out and conducted:

Development a methodology

- Assess strengths and weakness of pollution prevention approaches including end-of-pipe treatment, waste reuse and recycling/waste minimization, cleaner

production and industrial ecology;- Utilize strengths of these pollution prevention approaches to develop a method to

move an existing industrial system toward a zero waste industrial ecosystem(physical-technological model development);

- Apply a triad-network of Ecological Modernization Theory to push a physical-technological model of developed zero-waste industrial ecosystem from table towork.

Development an eco-industrial system

- Calculate material balances within tapioca processing factories using the results ofdetailed studies;

- Ascertain waste exchange ability oriented toward eco-industrial system (closedand/or open eco-industrial system);

- Material balances among tapioca processing factories and other components ofindustrial ecosystem;

- Designing physical-technological industrial ecosystems (closed and/or openindustrial ecosystems) including: tapioca processing factory, composting, fishculture, livestock feed production, cassava cultivation, wastewater treatmentsystem.

- Operation (pilot-scale model) including: wastewater treatment system, fishculture, composting plant, plan cultivation.


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- Policy and regulation including: Collection and evaluation of existing environmental policy and regulation Preparation of new policy to support the eco-industrial system.

Fig. 1 Recommended sustainable development for tapioca processing industry.

Based on the results of our research, we can recommend an almost perfect system for thetapioca industry for Vietnam. It combines pollution prevention with energy recovery andresource protection. With the proposed integrated treatment system, which incorporates waste

minimization and reuse of valuable compounds from the waste, a sustainable development ofthe tapioca industry can be achieved. Waste and wastewater can therefore really comprise a

resource instead of a headache. The treated wastewater can be reused in aquaculture or forirrigation in the area. Peel waste can be used for composting, and the compost produced can

be applied for the cassava cultivation or other industrial crops. Fibrous residues can be usedfor animal feed production. In this way, a zero waste industrial ecosystem can be created (see

Fig. 1). This industrial ecosystem can be applied in case of tapioca processing villages, which

solid waste and wastewater can be gathered and treated at the central treatment units in thearea.

List of research publications during ARRPET phase 2 (2004 2007)

a. International conference:

Mai, H.N.P., Duong, H.T., Trang T.T.T. and Viet, N.T. (2004), Sustainable Treatment ofTapioca Processing Wastewater in South Viet Nam. In proceedings: InternationalConference on Wastewater Treatment for Nutrient Removal and Reuse 2004, Asian Instituteof Technology Thailand, 26-29 January 2004, Vol 2, pp. 373-384.

Mai, H.N.P., Duong, H.T., Trang, T.T.T. and Viet, N.T. (2004), UASB Treatment of TapiocaProcessing Wastewater In South Vietnam.In proceedings:International Conference on 10

th

Market Market astewaterastewaterSolid wastes Solid wastes

Tapiocaproduction Tapiocaproduction process process

Cassava harvesting Cassava harvesting

Cassava culturing Cassava culturing

Gas recoveryGas recovery

Watersupply Watersupply

Market Market astewaterastewaterSolid wastes Solid wastes

Composting

Tapiocaproduction Tapiocaproduction process process

Cassava harvesting Cassava harvesting

Cassava culturing Cassava culturing

Fish culturing

Cattle -food

processing

Gas recoveryGas recovery

Waste

sludge

Watersupply Watersupply

Receiving source

CattleBreeding

WWTS


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World Congress Anaerobic Digestion 2004 29th

Aug. to 2nd

Sep, 2004 Montreal, Canada,Vol 4, pp. 2420-2424.

Kragic, D., van Buuren, J.C.L. and Trang, T.T.T (2005). Evaluation of Industrial WastewaterTreatment in Ho Chi Minh City and the Southern Provinces of Vietnam. In proceedings: International Conference on Environmental Management of Urban and Industrial

Infrastructures in Asia. HCMC, Vietnam, 11-12 November, 2005.

b. International papers:

A.P.J. Mol and Tran Thi My Dieu (2006), Analysing and Governing Environmental Flows:the Case of Tra Co Village, Vietnam, NJAS The Wageningen Experience with Research andEducation for Development- Wageningen Journal of Life Sciences, Volume 53, Number 3-4,pp. 301-317.

Dieu, T.T.M. (2006), Greening Food Processing Industries in Vietnam: Opportunities andConstraints, Environmental, Development and Sustainability (2006): 8: 229-249, Springer

2006.

c. Book chapters:

Mai, H.N.P. (2006), Integrated treatment of tapioca processing industrial wastewater Based

on environmental bio-technology. PhD dissertation, Wageningen University. TheNetherlands.

2. PILOT SCALE APPLICATION

Wastewater treatment plant

Fig. 2 Technology for treatment of tapioca processing wastewater, capacity 10m3/d.

A pilot-plant scale version for wastewater treatment with a capacity of 10 m3/d has

already been designed and installed (see Fig. 2). The system start-up was commencedin the middle of December 2005 at KMC Tapioca Starch Factory, Binh Phuoc

GritChamber

FlowEqualization

Neutralization

WASTEWATER

Bar Screen

EFFLUENT

Stabilization pond Stabilization pond

Final settling Activated sludge

Air blower

Return sludgeWaste sludge

Skimming &Settling

Neutralization

OPTION Biogas

SludgeAnimal feed


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Province. The performance data collection show that it is possible to apply thetechnology which aerobic combined anaerobic process for tapioca wastewater withvery high treatment efficiency and the biogas production fluctuates from 320-350 liter

per kilogram COD removal. A successful application of this treatment system cancontribute significantly to a further sustainable development of the tapioca processing

industry in Vietnam by minimizing the environmental pollution.

Based on the results of pilot-scale operation, the estimate shows that the requiredtreatment system with a capacity of 2,000 m3/d will produce 4,200 6,200 m3 biogas

per day (>60 % methane gas), which is equivalent to 2,600 3,800 liters of FO perday. And energy cost savings to the plant are estimated at 850 1,260 US$ per day. If1 m3 biogas (with 60% methane) is equal to 1.7 kWh of electricity (data from the

power plant using biogas of Go Cat landfill, HCMC, Vietnam), then the power plantcan generate 7,100 10,500 kWh per day.

The proposed wastewater treatment system combined with energy recovery can also

benefit from international carbon trading and help support financing projects throughthe Clean Development Mechanism (CDM). In this project based on convertingwastewater to energy and profit - both the technology and the business model arehighly possibility. It also shows how strong returns can be generated for investorsusing CDM.

Besides, for the solid waste treatment, a composting plant and cassava cultivation arecarried out also at pilot-plant scale.

Composting plant

The materials consisting of cassava peel root and activated sludge from the tapiocawastewater treatment system used for the input of composting experiments. Thecomposting method and technical process of composting are presented as Table 1 andFig.3 below.

Cutting

ScreeningMixing withSludge

EM

Residue

Mixing with micro nutrients

etc. (if applicable) COMPOST

- Mixing- Water- EM

Aerobic composting

Curing

Screening

Cassava peel

Fig. 3 Technical process of composting


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Table 1 Introduction of pilot scale of composting experiments

Stage 1

Experiment 1 2 3 4

Composting method Aerated static pile Aerated static pile Periodic turning

pile

Periodic turning

pileMaterial Peel root + sludge Peel root Peel root + sludge Peel root

C/N 25 64 25 64

Blending ratio (peel root : sludge) 3:1 - 3:1 -

Initial weight of the pile (kg) 139 144 139 144

Stage 2

Experiment 1 2 3 4

Composting method Periodic turningpile

Periodic turningpile



Material Peel root + sludge Peel root + sludge Peel root + sludge Peel root + sludge

C/N 30 30 25 25

Blending ratio (peel root : sludge) 2,25:1 2,25:1 1,6:1 1,6:1

Initial weight of the pile (kg) 200 200 200 200

After about 35 days of composting and 10 days for curing, the final compostingproducts were applied for cultivation. The chosen plants for cultivation are corn andcassava presented in following part.

Cultivation of plant

The corn and cassava were chosen as the objects of study on compost application incultivation. Based on the process showing in Fig.4, the pilot scale of corn cultivationexperiments and cassava cultivation experiments were operated and introduced.

Fig. 4 Compost application process for cultivation.

Table 2 Introduction of pilot-scale corn cultivation experiments

1 2Experiment Fertilizing by compost from cassava

hard roots & wood shellsFertilizing by sludge from

stabilization pond 1

Type of plant Corn Corn

Area (m2) 8 m x 9 m = 72 m

28 m x 12 m = 96 m

2

Density of plant (trees/m2) 4 4

Number of plant 288 384

Land/young treepreparation

Planting/

observation

HarvestingFertilizing bycompost


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Table 3 Introduction of pilot-scale cassava cultivation experiments

1 2 3Experiment Fertilizing by compost

from cassava peel &sludge

ertilizing by sludge from

stabilization pond

No fertilizing

Type of plant Cassava Cassava Cassava

Area (m2) 8 m x10 m = 80 m

28 m x 10 m = 80 m

28 m x 10 m = 80 m

2

Density of plant (trees/m2) 2 2 2

Number of plant (trees) 160 160 160

Key results of pilot-scale application

The UASB reactor system combined with an aerobic activated sludge process andstabilization ponds, represents a superior solution for the treatment of high-strength wastewater like tapioca-processing wastewater under Vietnameseconditions, because it enables meeting the severe Vietnamese effluent dischargestandards;

The treated wastewater can be reused for irrigation in the area of cassavacultivation or for agriculture purpose;

The proposed wastewater treatment system combined with energy recovery canbenefit from energy cost saving and CDM program. This is the persuasive reasonsfor industries and financial investors to implement this treatment technology inVietnam.

Sustainable development can be achieved with waste minimization and reusevaluable compounds from waste; To apply the sustainable development for tapioca industry, the study on the

policy/regulation for technical assistance and financial assistance for the factoriesneed to be carried-out;

The wasted sludge from wastewater treatment plant and wasted root peel can bereused as the material for composting;

The compost produced is satisfied Vietnamese standard for compost product andit can be applied for the cassava cultivation or other industrial crops.

3. NETWORKING

Within ARRPET

Networking activity Description

AIT CENTEMA attended the training workshop in AIT on:

UASB and ANAMMOX Processes during 21-25 March, 2005.

Molecular techniques on ANAMMOX bacteria during 21-25 March, 2005.

KMUTT Technology exchange on The Sustainable Shrimp Farming Workshop

from 27-28 June, 2005;

Collaboration in holding theSustainable Aquaculture EngineeringApproach Workshop from 8 9 February, 2007 in Hua Hin, Thailand.


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IITB Research on granulation of sludge from UASB in pilot scale;

Information exchange about agro-industry;

Technology exchange about Advanced Analytical Techniques (attending the

Advanced Analytical Techniques workshop during 2-4 April, 2007).

News letter Responsible for ISSUE 3

Outside ARRPET

Networking activity Description

Dept. of Environmental Technology andManagement Van Lang University

Collaboration in carrying-out the research.

Van Lang Company Collaboration in carrying-out the research.

Department of Natural Resource and

Environment of Tay Ninh province andBinh Phuoc Province

Supporting the investigation of tapioca processing industry

in village and company.

Division of Solid Waste Management DONRE - HCMC

Co-hosting the workshop on Activated Sludge Processoperation and maintenance during 5 -17 July 2004.

KMC tapioca starch Co., Ltd. Vietnam Creating the good condition and extremely support foroperating the wastewater treatment system, pilot of

composting as well as the cultivation.

Vietnam Environment Protection

Agency

Cooperation with CENTEMA in holding the workshop on

Appropriate Criteria for Assessing the Performance of

Waste Treatment Systems in September 30, 2005 in

HCMC, Vietnam.

4. DISSEMINATION

Workshop

No. Workshop Venue Duration

Within ARRPET

1 Training course: UASB operation and maintenance CENTEMA - Vietnam 7-19 June 2004

2 Training course: Activated Sludge Processoperation and maintenance

CENTEMA - Vietnam 5-17 July 2004

3 Training course:The technical skill for

laboratory staffs

CENTEMA - Vietnam 13-24 December2004

4 National workshop: Appropriate Criteria forAssessing the Performance of Waste Treatment

Systems

HCMC, Vietnam September 30th,

2005

5 National workshop: Development of Eco-industrialPark: A Case study of Linh Trung ExportProcessing Zone (supported by Department ofScience and Technology, HCMC)

Department of Science andTechnology, HCMC,Vietnam

July 26th

, 2006

6Sustainable Aquaculture Engineering Approach

(cooperation with KMUTT)

Hua Hin, Thailand8 9 February,

2007


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Outside ARRPET

7Waste Management (supported by DAAD-

Germany)

Van Lang University,

HCMC, Vietnam

14-16 December,

2006

8Sludge Management in HCMC (supported by

Vietnam Australia Environment Joint Stock Co.)

HCMC, Vietnam 23 24 April,

2007

Publication

No. Articles

1. Ecological Transformation Of The Tapioca Processing Industry In VietnamLe Van Khoa* and Tran Thi My Dieu**

*DONRE

** CENTEMA, Van Lang University and Environmental Policy Group, Wageningen University Greening Industrialization in Asian Transitional Economies, Edited by Arthur P. J. Mol and Joost C.L. van Buuren,Lexington Books Publisher, pp. 199-224.

Newsletter No.3

2. Environmental Reform Of Food-Processing Industry:An Industrial Ecology Approach on Bien Hoa 1 Industrial Zone, VietnamTran Thi My Dieu*, Arthur P. J. Mol** and Wim H. Rulkens****CENTEMA, Van Lang University and Environmental Policy Group, Wageningen University

** Environmental Policy Group, Wageningen University

***Environmental Technology Group, Wageningen University

International Journal of Business and Society, Volume 5, Number 1, January 2004, Sarawak,Malaysia, pp. 29-57.

Newsletter No.3

3. Integrated Treatment Of Tapioca Processing Industrial Wastewater - Based

On Environmental Bio-TechnologyHuynh Ngoc Phuong MaiCenter for Environmental Technology and Management, C4/5-6 Dinh Bo Linh, Binh Thanh Dist.,

HCMC, Vietnam.

Extracted from PhD thesis Integrated treatment of tapioca processing industrial wastewater - basedon environmental bio-technology.

Newsletter No.4

Technical report and book chapter

No. Technical report within ARRPET phase 2

1.Model of tapioca processing industrial ecosystem at village level: A Case of Tra Co TapiocaProducing Village (extracted from the appendix of the project progress report in August 2005).

2. Sustainable development of tapioca processing industry: Methodology and Case Studies (extracted

from the appendix of the project annual report in February 2006).

3. EIA report for the project of sustainable development of tapioca processing industry in Vietnam(extracted from the appendix of the project annual report in February 2006).

4. Cost benefits analysis report for sustainable development of tapioca processing industry in Vietnam

5. CAPACITY BUIDING

Within the research, the manpower is reinforced by training and improving for the field of

environmental protection and sustainable development, including: 01 PhD student, 05students and 08 research staffs.

Minor equipments have been purchased during period:

+ For field survey: pH meter, DO meter, gas meter.


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+ For the laboratory: oven, technical balance, distillation apparatus for cyanide,composting reactors, cutting machine for composting.

6. OPEN ISSUES

Results from the research shows that it is possible and good idea to develop a zerowaste emission eco-industrial for tapioca processing industries. This is an innovativestrategy for sustainable development of tapioca processing industry by reducingwaste, reducing the consumption of resources and increasing the recycling ofmaterials and energy. However how to put the theoretical model develops from thisresearch to work is still a question. How to advise the tapioca factories put into their

plant and apply solution from this research to their own factories. Finally, how todeploy this model for the whole country? This oriented questions show the needs offurther research to establish so-called guideline to develop a tapioca eco-industrial

system in general full scale apply.


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IITK Report: Domestic Wastewater Treatment in India:Optimization of UASB Reactor

Contact Person:

Saumyen GuhaDepartment of Civil EngineeringIndian Institute of TechnologyKanpur, UP 208016, INDIAe-mail: [email protected]

1. Technology Developed through Laboratory Research

The advent of high rate anaerobic technology and its proven applicability for thetreatment of high strength wastewater has lead to attempts towards its implementationfor domestic sewage and low-strength wastewater in the countries with warmerclimates. The UASB process, on account of their low installation cost and lowoperation and maintenance overheads, has been installed in some locations in thedeveloping countries, such as, India, Colombia and Brazil etc. The UASB processrelies on anaerobic degradation of organic wastes by combining the advantage of highactive biomass retention with high void volume. Anaerobic microbial granulation,considered as a key parameter for successful operation and stable performance of anUASB reactor, is a natural process under favorable conditions as a result of tendency

of bacteria to self immobilize. The UASB process for the treatment of low strengthwastewater, however, suffers from the following shortcomings: longer start-up times,inability to form self-immobilized bacterial granules and very low bio-gas recovery.

Primary objective of the project at IITK was to achieve better granulation in UASBreactors treating low-strength wastewater, by maintaining appropriate microbialecology as well as physico-chemical environment inside the reactors. In theliterature, many natural and synthetic polymers were reported to enhance granulation

but the reports once again, were mostly limited to high strength wastewater. Thechoice of an additive in the ARRPET project was governed by scientificunderstanding of the process of granulation, low cost and local availability. The

Reetha seed (Sapindus trifoliata) extract was selected as a plant polymer additive.Reetha is cheap and easily available in the region and contains high amounts ofanionic, cationic and non-ionic polymers. For comparison, we chose Chitosan acheap water-absorbing polymer derived from the shells of the crustaceans.

Five laboratory scale UASB reactors were run in parallel with same flow rate, influentand environmental conditions. Four of these reactors were augmented with thefollowing additives: (i) BulkReetha seed extract, (ii) Cationic fraction ofReetha seedextract, (iii) Anionic fraction ofReetha seed extract and (iv) Chitosan. No additivewas added in the fifth reactor and it served as the control. Influent and effluentsamples from each reactor were analyzed as follows: for total COD and filtered COD

every alternate days; for pH and alkalinity twice a week; TSS, VSS and VFA twice aweek. Production of methane and total gas were monitored twice a week. Sludge


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samples form the reactors were analyzed for TSS, VSS once a week. Extra-cellular polymers (ECP) and its component sugar, lipids, and protein were analyzed atapproximately 20 days interval. Total and Acetoclastic methanogenic activity testswere conducted once every month. While reactor operation and analyses listed so farwere conducted at IIT Kanpur, a close collaboration was maintained with the NRI of

IIT Bombay throughout the study period for granule examination. Sludge sampleswere fixed and sent to IIT Bombay at a frequency of 15-20 days. They provided uswith the image analysis data showing size distribution. For some select samples,granules were also examined under Environmental Scanning Electron Microscope(ESEM) and Transmission Electron Microscope (TEM).

Initial attempt during the Phase I of ARRPET to enhance granulation using alum ascoagulant failed and the aluminum was found toxic to the microbial population.Thereafter, enhancement in granulation using the natural polymers was achieved inPhase I of ARRPET using synthetic wastewater with an influent COD of 800 mg/L.These two experiences helped us in understanding the mechanism of granulation in

the treatment of low strength wastewater. In Phase II of the ARRPET, the largergranules generated with natural polymer additives were first tested for the stability bysubjecting them to wide variations in flowrate and COD concentration. The largegranules were stable up to influent COD concentration of 250 mg/L and flow ratevariation of 0.5-2 times the design flow. The long term reactor performance andstability of the granules were assessed by running these reactors for 900 days. Basedon the understanding of the process of granulation using synthetic wastewater, theenhanced granulation experiments were designed with real domestic wastewater withinfluent COD concentration varying in the range of 90-200 mg/L during a 24 hr

period and COD/SO42- ratio of < 2. Enhancement of granulation was once again

observed. One key factor in all these studies has been that the seed sludge was

dispersed and did not contain any granules. However, all the reactors reached steadystate in ~60 days. With real domestic wastewater, up to 80% COD removal wasobtained with only 2.6 hr HRT in the sludge zone and an overall HRT of 4.5 hr.Although, the influent COD and the resulting OLR shows large (up to 150%) diurnalvariation, the effluent COD has a variation of only 10%. At present, the reactors withreal domestic wastewater have completed operation for 700 days and the granulescontinue to grow. The granules of size up to 3-4 mm have been observed and nearly60-80% of the sludge bed has undergone granulation leaving very little dispersedsludge in the bed. Such large sizes of granules with low influent COD concentrationin the range of 90-200 mg/L have not been reported. Thus, the additives helped to

maintain larger granules in the sludge bed. This allowed higher flow rate andincreased resilience to shock loading. We have been able to demonstrate that theprotein fraction of the exo-cellular polymeric substances contributes to the structuralintegrity of the granules and that the level of total exo-cellular polymeric substancesdoes not reflect adequately the state of granules.

Domestic wastewater often contain COD/SO42- ratio of < 2. According to literature,

this leads to interference by sulfate reducer and cause reactor failure. We have notobserved any such interference so far although the condition is met. Initialobservations indicate that this may have been averted in our reactor by putting aselection pressure on the sulfate reducers at the initial stages. At present, efforts are

on to confirm and standardize this condition such that UASB reactor can be startedwith unfavourable COD/SO42- ratio.


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During the third year of Phase II, a cost benefit analysis was conducted for thetechnology developed using the activated sludge process as the benchmark. Thetechnology developed in ARRPET was found to be economically beneficial andenvironment friendly.

The experience of operating UASB reactors and many other biological processes inthe ARRPET project showed the importance of monitoring the microbial ecology.This may indicate crucial stages of the reactor performance as well as impendingreactor failure. We made an effort to devise a simple process based on analysis of

phospholipid fatty acids. The method is appealing because the analysis can becompleted in a few hours and reliable estimates are possible. This will enable quickintervention to reactor operation, if required. Although the PLFA analysis are wellestablished in the literature, lack of standard deconvolution strategies make themunusable for routine application to reactors. We have devised and tested a novelapriori approach to deconvolution of the PLFA signature of mixed culture. Theefforts are on to apply it for the routine monitoring of UASB reactor. However, some

more problems remain such as, modification of PLFA-FAME analysis for isoprenoidspresent in archea, standardizedposteriori deconvolution approach, etc.

For the minor issue project, we had demonstrated that it is possible to degrade the azodyes using fixed bed fungal column containingPhenerocheate Chrysporium.

Publications from the project so far are as follows:

Journals (peer reviewed)

Dey, D. K.; Guha, S. (2007) Determination of Community Structure through

Deconvolution of PLFA-FAME Signature of Mixed Population, BiotecnologyBioengineering, V. 96, No. 3, pp409-420.

Tiwari, M. K.; Guha, S.; Harendranath, C. S.; Tripathi, S. (2006) Influence ofExtrinsic Factors on Granulation in UASB Reactor, Applied Microbiology and

Biotecnology, V. 71, No. 2, pp 145- 154.

Tiwari, M. K.; Guha, S.; Harendranath, C. S.; Tripathi, S. (2005) Enhancedgranulation by Natural Ionic Polymer Additives in UASB reactor treating low-strength wastewater, Water Research, V. 39, pp 3801-3810.

Tiwari, M. K.; Guha, S.; Harendranath, C. S. (2004) Enhanced granulation in UASBreactor treating low-strength wastewater by natural polymers, Water Science andTechnology, V. 50, pp 235-240.

Sondhi, A.; Guha, S.; Harendranath, C. S. and Singh, A. Effect of Aluminum onGranulation in UASB Reactor, in preparation.

Singh, R.; Quaff, A. R.; Guha, S. and Harendranath, C. S. Stability of Granules inUASB Reactor Treating Low Strength Wastewater: Flow Variability and Low COD,in review.

Quaff, A. R.; Arockia, V.; Guha, S. and Harendranath, C. S. Population Shift DuringStart-up of UASB Reactor Treating Domestic Wastewater, in preparation.


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Conferences

Singh, R., Quaff, A. R., Guha, S., Harendranath, C. S. Stability of Granules in UASBReactors Treating Low Strength Wastewater: Flow Variability and Low COD,

International Conference on Civil Engineering in New Millennium, CENEM 2007,

Jan 11-14, 2007, Bengal Engineering and Science University, Shibpur, Howrah, WestBengal, India.

Quaff, A. R., Arokia, V. J., Guha, S., Harendranath, C. S. Population Shift DuringStartup of UASB Reactor treating Domestic Wastewater,International Conference onCivil Engineering in New Millennium, CENEM 2007, Jan 11-14, 2007, BengalEngineering and Science University, Shibpur, Howrah, West Bengal, India.

Quaff, A. R., Arokia, V. J., Singh, R., Guha, S., Harendranath, C. S. Startup ofUASB reactor using low strength domestic wastewater, International Workshop on

Biotechnology of Anaerobic Bacteria & Archaea, March 3 & 4, 2006, Agharkar

Research Institute, Pune, India.

Arokia, V. J., Quaff, A. R., Singh, R., Harendranath, C. S., Guha, S. Application ofImage Analysis and Electron Optical Techniques in the Evaluation of AnaerobicProcess,International Workshop on Biotechnology of Anaerobic Bacteria & Archaea,March 3 & 4, 2006, Agharkar Research Institute, Pune, India.

Singh, A, Shetye, B, Guha, S., Harendranath, C. S. Application of ESEM to studygranulation in an UASB reactor treating wastewater, XXVI Annual Conference onElectron Microscopy and Allied Fields, organized by Electron Microscope Society ofIndia at CPRI, Shimla during April 16-18th, 2003 (Best poster Award).

2. Pilot Scale Application

In India, the domestic wastewater treatment is public sector unit and there is nofunding for testing pilot plants. However, the private initiatives have many unitswhich treat composite wastewater from domestic sources and small scale industries.Vapi Waste and Effluent Management Co. Ltd. (VWEMC Ltd.) at Vapi, Gujarat isone such organization. They agreed to built, operate, maintain and monitor a pilotscale reactor based on our design and operation instruction. A 100 cu. m./d UASB

pilot plant was constructed with the joint collaboration of IIT Kanpur, IIT Bombayand VWEMC Ltd. The plant was commissioned in July 2006 to treat composite

wastewater from various industries such as Chemicals, Dyes, Intermediates,Pharmaceuticals, Paper & Paper Board, Cosmetics, Pigments, Paints, Textile, Glass,Engineering etc. mixed with domestic sewage from the twon of Vapi. This mixedwastewater has COD/SO4

2- ~ 1 with COD concentration varying between 800-2200mg/L and 5-day BOD varying between 100-200 mg/L. Wastewater from theequalization tank directly fed to the UASB reactor without any pretreatment.

The reactor was seeded with a mixture of sludge from the dyring bed and freshactivated sludge. The mixing ratio was selected based on VSS/TSS ratio andmethanogenic activity of the sludge. The seed sludge was flocculant in nature and didnot contain any granules. Chitosan was used as additive for enhancement of

granulation. First dose was added at the startup and second dose was added on 170th

day of operation.


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The plant at present is removing 20 % COD and 40-50 % BOD with a total HRT of10 hr. It may be noted that the influent contains difficult to degrade substrates fromthe industrial effluent. A standard UASB reactor operating for more than a year with19 hr HRT and effluent recycle gives inferior performance compared to the ARRPETreactor. The pH and VFA level have stabilized within 90 days. The VSS/TSS of

sludge has also stabilized at 0.5. The color removal is 30% and TSS removal is 40%.Continuously increasing Methanogenic activity shows that the Methanogens areestablishing in the reactor and the gas production has started at 94 L/day. A TEMresult shows that Methanosarcina has established in the reactor. The exocellular

polymeric substances are increasing with its protein fraction indicating healthygranules. Granules size is increasing continuously. Particles greater than 0.1 mmstands at 70% and are growing larger. The particles greater than 0.3 mm are about 21% and increasing.

The VFA level and conversion of the harder to degrade substrates to easily degradablesubstrates shows significant scope of improvement and need for research in that

direction. Considering that 87 such combined effluent treatment plants (CETPs) arealready operational in the country and the government subsidy towards setting upmore such plants, there is a need to evolve an appropriate technology in the countryfor treating composite wastewater. At this point, plan is to demonstrate thetechnology in the pilot plant for pure domestic wastewater and consider the problemof the composite wastewater in Phase III of ARRPET.

3. Networking

One of the key goal of the ARRPET Phase II was to form close network amongst the NRIs and solve the mutual problems through networked research. We maintained a

close collaboration with the NRI at IIT Bombay for the granule characterization of theUASB reactors. The effort yielded many a fruitful insight into the processes. Withthe help of transmission electron micrographs from IIT Bombay and the biochemical

parameters measured at IIT Kanpur, we were able to notice a change in microbialecology during the first 100 days of the start of the UASB reactors with real domesticwastewater. The microbial ecological shift was crucial for start of the formation ofthe granules.

A networking with ARI Pune and IIT Bombay are on to establish detailed microbialecology of the UASB reactor using genetic methods such as DGGE, PCR, FISH.This will then be compared with the results obtained using PLFA based method

designed at IIT Kanpur.

We also had a networking with the NRI from UoM, Sri Lanka. They were studyingmetal uptake in the water hyacynth. We at IIT Kanpur were able to isolate andcharacterize the phytochelatins responsible for metal binding in water hyacynth plant.With the help of IITB, we were able to locate the metal chelated phytochelatins invarious parts of the plant. We demonstrated that the metal is initially bound by

phytochelatins of smaller molecular weight and later transferred to larger molecules.

Pilot plant is being operated in collaboration between IITK, IITB and VWEMCL.


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4. Dissemination

In addition to the technical publications in peer-reviewed journals, internationalconferences and national conferences listed in item 1, we also organized workshops,delivered invited lectures and contributed to the newsletter. Some are listed below:

Combined Regional Workshop of WWTM and HWTM was held on 11-12 th March,2005. A Report is available at,http://www.arrpet.ait.ac.th/wwtm/newsletter1/index.html.

Delivered invited lecture at the training workshops at ARI, Pune (IHWTM NRI) andIIT Bombay.

A special training workshop on Statistical Data Analysis for the NRIs of IHWTM andWWTM to be held in 2007.

Close contact is being maintained with industries in Vapi, state pollution control board and Central Pollution Control Board so that the developed technology inARRPET remains available to the stake holders.

5. Capacity Building

Present Project Staff:

Abdur Rahman Quaff (Ph.D. Student)Richa Parasher (Project Associate)Anoop Agnihotri (Project Assistant)

Completed M.Tech. Theses (Available online through IITK Library):

Patel, N. K. (2006). Characterization of Phytochelatins Produced by Water Hyacinth,M.Tech. Dissertation, IIT Kanpur.

Dey, D. K. (2005). Determination of Community Structure through Deconvolution ofPLFA-FAME Signature of Mixed Population, M.Tech. Dissertation, IIT Kanpur.

Singh, R. (2004). Effect of Variable Flow Rate and Low COD on the Stability ofGranules in UASB Reactor, M.Tech. Dissertation, IIT, Kanpur.

Tiwari, M. K. (2003). Enhancement of Granulation in UASB Reactor by Natural

Polymer Additives, M.Tech. Dissertation, IIT, Kanpur.

Sondhi, A. (2002). Effect of Aluminum Chloride on the Performance of UASBReactors Treating Low Strength Wastewater, M.Tech. Dissertation, IIT, Kanpur.

Equipments Procured from ARRPET II fund:

Hereus Biofuge Stratos R, Coy Laboratories Anaerobic Glove Box, Laminar FlowHood, PC.

6. Open Issues

The following are the open issues from ARRPET Phase II:


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Deveopment of appropriate technology for the treatment of compositewastewater: The CETP concept is widely given preference by thegovernmental agencies. There are 96 CETPs already established and thenumber is increasing every year. Majority of the plants are based on powerconsuming activated sludge process that generates a large amount of toxic

sludge. Development of anaerobic technology in this direction will not onlycut down on power consumption but also recover valuable methane. Ourresults in Phase II shows that there is ample scope for the development of sucha process.

Low cost Pretreatment and Post treatment options for composite wastewater:It is established in the literature that some non-specific eukaryotic enzymes areable to degrade the difficult to degrade substrates to some extent. A high rateand low cost pre-treatment unit has the potential to increase the performanceof the anaerobic reactor to a large extent in a CETP.

Routine Monitoring of Microbial Ecology of Bioreactors: In all the biologicalreactors operated in different countries during Phase II, one critical issue forreactor maintenance and detection of impending reactor failure was ability tomonitor the microbial ecology and intervene in a timely fashion.Development of a fast, reliable and simple to use technology in this directionwill go a long way in maintaining biological reactors in the developingcountries. Our efforts in this direction have yielded encouraging resultsduring Phase II. The method still needs to be tested widely and comparedwith the genetic tools.


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IITB Report: Characterization of BiosolidsfromUASB/Activated Sludge Process/Fluidized Bed

Process

Contact Person:

C. S. HarendranathRegional Sophisticated Instrument CenterIndian Institute of TechnologyMumbai, Maharashtra, Pin. 400076, INDIAe-mail: [email protected]

IIT Bombay participated in ARRPET II in two ways:

1. Collaboration with IITK in the development of UASB for Domestic wastewater

treatment.2. Application of Advanced Imaging and Image Analysis techniques to other

biosolids from other NRIs

1. Technology Developed through Research

The Technology developed, in collaboration with IITK, was the UASB process as atreatment option for low strength Domestic wastewater. The difficulties usuallyassociated in achieving granulation while faced with low strength wastewaters have beensuccessfully overcome and the UASB, with appropriate additives, has been demonstratedto successfully treat Domestic wastewater. The novelty of the Technology is the use ofchitosan and naturally occurring reetha seed extracts as additives while treating lowstrength Domestic wastewater. The reactors with chitosan and anionic fraction of reethaseed extracts have shown superior granulation and reactor performance.

The specific research component involved assessment and evaluation, using advancedimaging [Transmission Electron Microscopy (TEM), Environmental Scanning ElectronMicroscopy (ESEM) and Electron probe microanalysis(EPMA)] and Image analysistechniques, of the process of granulation (GranuleGeneration/degeneration/regeneration) in UASB reactor treating low strength Domestic

wastewater, and its susceptibility to shock loads. The Key objectives are theestablishment of granular sludge with low strength Domestic wastewater, underfluctuating OLR; use of additives for enhancement of granulation and associated reactorperformance; and the promotion of granular stability.

Electron microscopic (TEM, ESEM, EPMA) and Image analysis protocols wereestablished and periodically corrected taking into account sludge/biosolids variabilityfrom time to time. Granulation, a key element in UASB operation/performance, wascontinuously monitored, assessed and evaluated throughout the 3 year study period andcorrelated with reactor operation and performance. The reactors operation andperformance are divided in to four phases -- Start up/steady state and the other threephases correspond to the periods between the successive introduction of additives.

Phase I was characterized by growth of residual aggregates to microaggregates; A shift inmicrobial population from Methanosaeta to Methanosarcina and back to Methanosaeta ;


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corresponding changes in mean aggregates size, sludge wash out, volatile fatty acidconcentration and COD variations. However the reactors achieved steady state andstability during this period.Averaged OLR over the steady state period was ~1.2 Kg-COD/m3/d and HRT was 4.8h.

During phase II, all the reactors performed similarly and agglomerate sizes larger than 0.3mm and 0.5 mm started growing. Corresponding COD removal efficiency of about 70-80% was achieved in all the reactors in spite of wide fluctuations in influent COD.During Phase III and IV, reactors with chitosan and anionic fractions of reetha extractshowed significant enhancement in granulation (Macroaggregates/granules) andcorresponding improvements in COD removal efficiency, ECP concentration andMethanogenic activity. Cost Benefit Analysis of the technology developed was carriedout, in collaboration with IITK, using activated sludge as the bench mark.

Complete list of Research publications :

Tiwari M K, Guha S, Harendranath CS, Tripathi S. (2006) Influence of extrinsicfactors on granulation in UASB reactor. Appl Microbiol Biotechnol. 71:145-54.

Tiwari, M. K.; Guha, S.; Harendranath, C. S.; Tripathi, S. (2005) Enhancedgranulation by Natural Ionic Polymer Additives in UASB reactor treating low-strength wastewater, Water Research, 39: 3801-3810.

Tiwari, M. K.; Guha, S.; Harendranath, C. S. (2004) Enhanced granulation inUASB reactor treating low-strength wastewater by natural polymers, Water Scienceand Technology, 50: 235-240.

Singh, R., Quaff, A. R., Guha, S., Harendranath, C. S. Stability of Granules in UASB

Reactors Treating Low Strength Wastewater: Flow Variability and Low COD, International Conference on Civil Engineering in New Millennium, CENEM 2007,Jan 11-14, 2007, Bengal Engineering and Science University, Shibpur, Howrah, WestBengal, India.

Quaff, A. R., Arokia, V. J., Guha, S., Harendranath, C. S. Population Shift DuringStartup of UASB Reactor treating Domestic Wastewater,International Conference onCivil Engineering in New Millennium, CENEM 2007, Jan 11-14, 2007, BengalEngineering and Science University, Shibpur, Howrah, West Bengal, India.

Quaff, A. R., Arokia, V. J., Singh, R., Guha, S., Harendranath, C. S. Startup of

UASB reactor using low strength domestic wastewater, International Workshop on Biotechnology of Anaerobic Bacteria & Archaea, March 3 & 4, 2006, AgharkarResearch Institute, Pune, India.

Arokia, V. J., Quaff, A. R., Singh, R., Harendranath, C. S., Guha, S. Application ofImage Analysis and Electron Optical Techniques in the Evaluation of AnaerobicProcess,International Workshop on Biotechnology of Anaerobic Bacteria & Archaea,March 3 & 4, 2006, Agharkar Research Institute, Pune, India.

Singh, A, Shetye, B, Guha, S., Harendranath, C. S. Application of ESEM to studygranulation in an UASB reactor treating wastewater, XXVI Annual Conference on

Electron Microscopy and Allied Fields, organized by Electron Microscope Society ofIndia at CPRI, Shimla during April 16-18th, 2003 (Best poster Award).


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Physiochemical Parameters and Bioprocessoptimization IITK

UASB reactors treating low strength wastewater

Particle size distribution

Arithmetic MeanGeometric meanCoefficiency of uniformityParticles greater than 300 umParticles greater than 500 um

Biosolids Characterization - IITB

Fraction of smaller agglomerates(micro aggregates)

Size distribution Measurement -

Fraction of larger agglomerates

(macro aggregates).

Microaggregate formationMutual auto attachments of microbes

Comparative analysis of elemental contents

Porosity and Gas passage

Presence of inert organic and inorganicparticles in the sludge

Microbial Composition

Sludge samples Regular monitoring

Early stage of granule degeneration

Organization and morphological changesin microbes

Spatial distribution of microbes

Ruptured cell wall, Cell debris and

morphological changes like clumps to

single cells - granule disintegration

IAS ESEM and EPMA TEM

Image Capturing, optimization,segmentation, processing, Measurement

Community compositionMicrobial Dynamics Competition

between Metahnosaeataand Methanosarcina

Surface Morphology

Statistical Analysis

Early stage of granulation

Structure of granules

Ecological examination of granules


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2. Pilot scale application

A 100 cu.m./day UASB pilot plant was designed, fabricated and commissioned atVapi, state of Gujarat, India, in June 2006, in collaboration with IITK and VAPIWaste and Effluent Management Co. Ltd (VWEMCL), and is in operation now. The

location where the pilot plant has been commissioned is indicated in the adjoiningmap. The CETP at Vapi receives effluents from paper pulp, ink, chemical precursors,

pesticide manufacturing, fertilizer manufacturing and dye manufacturing industries.The pilot plant was started with above mixed wastewater in addition to the sewagewastewater.

Being a joint effort, the roles of IITB, IITK and Vapi are also indicated in the flowdiagram. Regular visits to the pilot plant was coordinated by IITB for assessing thereactor performance. A continuous interaction was also maintained with the plant andlaboratory personnel at Vapi, and IITK, through regular exchanges of email / couriermail and telephonic conversations. At every 20 days interval, sludge from the reactorswas continuously monitored and characterized for its aggregation/granulation, surfacemorphology, chemistry, community composition and ecological associations.

The plant was started with unaltered mixed wastewater from the industrial town ofVAPI. The reactor was seeded with a mixture of 60% sludge drying bed and 40% of

activated sludge. After the first dose of chitosan addition, there was sudden increasein the arithmetic mean size and the percentage of granules greater than 300 and 500

IITB IITK Vapi

IAS

ESEM

EPMA

TEM

DGGE

Methanogenic Activity

TSS/ECP/Protein-Sugar-

Lipid

Reactor Operation &

Maintainence

Physiochemical analysis

Total Height -7.850m

Internal Diameter -3.175mWater depth - 6.850mSludge bed depth- 2.5m

O.1 MLD UASB

Sludge, Influent and effluent sample was

Continuously monitored and assessed

Granule

characterization

Physicochemical Analysis


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um. Targeted Flow rate (4170L/hr) was achieved in about 40 days and the OLR was ~2.5 Kg-COD/d/m3. Stepped up flow rate from 800 4170 L/h in the reactor showed agradual decrease in the mean aggregate size which indicated a need for flow ratereduction. Soon after the flow rate reduction to 1000 L/h, a gradual increase in themean granule size was noticed until 136 days. Sudden/drastic drop in percentage of

granules greater than 300 and 100 um prompted addition of second dose of chitosan.

A steady COD removal efficiency of 20 % (corresponding BOD removal efficiencyof 30- 35%), attainment of steady and appropriate VFA and pH levels, presence ofactively dividing biomass, increased methanogenic activity indicated that the plantwas stabilized within three months of reactoroperation.

TEM studies revealed the presence of various morphotypes reflecting the complexsubstrate involved and the presence of Methanogens in the sludge samples.Methanogenic Activity and Methane gas production have been noticed. TEM studiesalso specified that the sludge aggregates in the pilot plant was healthy. Although the

UASB reactor seems to be performing better than the existing treatment system at theCETP, Vapi, in view of some of the difficulties faced with the UASBoperation/performance, a switch over to Domestic wastewater instead of the complexwastewater has been planned and steps are being examined to enhance the pilot plant

performance. This is further addressed in the open issues section.

3. Networking

IITB initiated and carried out networking with the following NRIs within the WWTMand IHWTM groups:

1. Center for Environmental Technology and Management - Vietnam2. De La Salle University -Philippines3. University of Morotua - Srilanka4. Asian Institute of Technology- Bangkok5. Centre of Paper and Pulp Research Institute Indonesia6. Indian Institute of Technology Kanpur- India7. Agarkhar Research Institute

The focus of networking activity was related to extension of application of TEM,ESEM, EPMA and Advanced Image Analysis techniques to other biosolids.

Networking with UoM:

The problem was to evaluate the performance of up flow anaerobic attached growthreactor to remove Fe and Mn from synthetic textile effluents. TEM study helped inthe selection of seed sludge for reactor start

up. Our studies confirmed that the metal removal, particularly Fe, was mainly due todismillatory sulfate reduction carried out by SRB. The proliferation of SRB is due togeneration of H2S in the reactor. The results of these studies corroborated well withthe performance of maximum sulfate and COD reduction. Networking pertaining to

wetland studies is in progress.


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Networking with AIT:

The objective of the experiments was to investigate effect of nitrite nitrogen inhibitionon the Anammox granule as well as microbial population. IAS and TEM studies,demonstrating effect of nitrite nitrogen

concentration on anammox floc /aggregation and presence/ absence ofanammoxosome, correlated well with FISH and DGGE results. Further work in thisarea is in progress.

Networking With DLSU :

The main aim of this work was to select suitable biofilm with appropriate subtrate forChlordane degradation.

Networking with CENTEMA:

The essential features of the networking was to characterize and evaluate granulationin UASB and SRB reactors treating different wastewater

Networking with CPP:

The main aim of this work was to asses granulation process in UASB reactors treatingAOX.

Networking with IITK and UoM-----Characterization of Phytochelatins

IITB was a member of networking group on Characterization of Phytochelatins. The

specific role of IITB was to locate and quantify the cadmium concentration in waterhyacinth. ICP and EPMA studies confirmed and demonstrated the presence ofcadmium in root hair and root tip. The concentration in the root hair is comparativelyhigher in root hair than in root tip. This was correlated with IITKs result.

Networking with ARI

TEM investigations on sludge samples from AOX treating reactor was carried out

Networking outside ARRPET

Pilot plant activity was carried out and is in progress with the VAPI Waste andEffluent Management Co. Ltd (VWEMCL). The pilot plant activity has been partiallyfunded by VWEMCL, VAPI in particular the fabrication, installation and day to dayoperations. In addition networking was carried out with various industries likeMaharashtra oil Extractions pvt limited; Reliance dyeing works; Chemtech

processors, Soneji food industries, Mumbai; Rajashree sugars and chemicalindustries, Tamilnadu; Bangalore Dairy; Parle products private limited, Mumbai andTNPCB, Tamilnadu with respect to the survey on agrobased industry effluenttreatment plant.

Networking with Indira Gandhi centre for Atomic Research (IGCAR) and

Madurai Kamaraj University to explore application of confocal laser scanningmicroscopy and Atomic force microscopy.


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Networking also involved interaction with Central pollution control board,

Documents

Phase II Review Report WWTM-1-Final