Giacomo Bellandi

Experimental investigation of granule size and shape dynamics in twin-screw granulation

A twin-screw granulator (TSG), a promising equipment for continuous high shear wet granulation (HSWG), achieves the desired level of mixing by a combination of the appropriate screw configuration and a suitable set of process settings (e.g. feed rate, screw speed, etc.), thus producing a certain granule size and shape distribution (GSSD). However, the primary sizing and shaping mechanism behind the resulting distribution is not well understood due to the opacity of the multiphase system in the granulator. This study experimentally characterised the GSSD dynamics along the TSG barrel length in order to understand the function of individual screw modules and process settings, as well as their interaction. Particle size analysis of granules collected at the outlet of the TSG suggested significant interaction between the process and screw configuration parameters influencing the heterogeneity in the GSSD. By characterising the samples collected along the screw length, a variable influence of the screw modules at different process conditions was observed. At low liquid-to-solid ratio (L/S), the first kneading module seemed to play a significant role in mixing, whereas the second kneading module was found to be more involved in reshaping the granules. At high L/S and high throughput, aggregation mainly took place in the second kneading module changing the GSSD. The results obtained from this study will be further used for the calibration and validation of a mechanistic model and, hence, support future development of a more detailed understanding of the HSWG process in a TSG.

Monitoring the aeration efficiency and carbon footprint of a medium-sized WWTP: experimental results on oxidation tank and aerobic digester

ABSTRACT The efficiency of aeration systems should be monitored to guarantee suitable biological processes. Among the available tools for evaluating the aeration efficiency, the off-gas method is one of the most useful. Increasing interest towards reducing greenhouse gas (GHG) emissions from biological processes has resulted in researchers using this method to quantify N2O and CO2 concentrations in the off-gas. Experimental measurements of direct GHG emissions from aerobic digesters (AeDs) are not available in literature yet. In this study, the floating hood technique was used for the first time to monitor AeDs. The floating hood technique was used to evaluate oxygen transfer rates in an activated sludge (AS) tank of a medium-sized municipal wastewater treatment plant located in Italy. Very low values of oxygen transfer efficiency were found, confirming that small-to-medium-sized plants are often scarcely monitored and wrongly managed. Average CO2 and N2O emissions from the AS tank were 0.14 kgCO2/kgbCOD and 0.007 kgCO2,eq/kgbCOD, respectively. For an AeD, 3 × 10−10 kgCO2/kgbCOD direct CO2 emissions were measured, while CO2,eq emissions from N2O were 4 × 10−9 kgCO2,eq/kgbCOD. The results for the AS tank and the AeD were used to estimate the net carbon and energy footprint of the entire plant.

Towards advanced aeration modelling: from blower to bubbles to bulk

Aeration is an essential component of aerobic biological wastewater treatment and is the largest energy consumer at most water resource recovery facilities. Most modelling studies neglect the inherent complexity of the aeration systems used. Typically, the blowers, air piping, and diffusers are not modelled in detail, completely mixed reactors in a series are used to represent plug-flow reactors, and empirical correlations are used to describe the impact of operating conditions on bubble formation and transport, and oxygen transfer from the bubbles to the bulk liquid. However, the mechanisms involved are very complex in nature and require significant research efforts. This contribution highlights why and where there is a need for more detail in the different aspects of the aeration system and compiles recent efforts to develop physical models of the entire aeration system (blower, valves, air piping and diffusers), as well as adding rigour to the oxygen transfer efficiency modelling (impact of viscosity, bubble size distribution, shear and hydrodynamics). As a result of these model extensions, more realistic predictions of dissolved oxygen profiles and energy consumption have been achieved. Finally, the current needs for further model development are highlighted.

Detailed off-gas measurements for improved modelling of the aeration performance at the WWTP of Eindhoven.

At wastewater treatment plants (WWTPs), the aerobic conversion processes in the bioreactor are driven by the presence of dissolved oxygen (DO). Within these conversion processes, the oxygen transfer is a rate limiting step as well as being the largest energy consumer. Despite this high importance, WWTP models often lack detail on the aeration part. An extensive measurement campaign with off-gas tests was performed at the WWTP of Eindhoven to provide more information on the performance and behaviour of the aeration system. A high spatial and temporal variability in the oxygen transfer efficiency was observed. Applying this gathered system knowledge in the aeration model resulted in an improved prediction of the DO concentrations. Moreover, an important consequence of this was that ammonium predictions could be improved by resetting the ammonium half-saturation index for autotrophs to its default value. This again proves the importance of balancing sub-models with respect to the need for model calibration as well as model predictive power.

Towards improved accuracy in modeling aeration efficiency through understanding bubble size distribution dynamics

Aeration is the largest energy consumer in most water and resource recovery facilities, which is why oxygen transfer optimization is fundamental to improve energy efficiency. Although oxygen transfer is strongly influenced by the bubble size distribution dynamics, most aeration efficiency models currently do not include this influence explicitly. In few cases, they assume a single average bubble size. The motivation of this work is to investigate this knowledge gap, i.e. a more accurate calculation of the impact of bubble size distribution dynamics on oxygen transfer. Experiments were performed to study bubble size distribution dynamics along the height of a bubble column at different air flow rates for both tap water and solutions that mimic the viscosity of activated sludge at different sludge concentrations. Results show that bubble size is highly dynamic in space and time since it is affected by hydrodrynamics and the viscosity of the liquid. Consequently, oxygen transfer also has a dynamic character. The concept of a constant overall volumetric oxygen transfer coefficient, KLa, can thus be improved. A new modeling approach to determine the KLa locally based on bubble size distribution dynamics is introduced as an alternative. This way, the KLa for the entire column is calculated and compared to the one measured by a traditional method. Results are in good agreement for tap water. The modeled KLa based on the new approach slightly overestimates the experimental KLa for solutions that mimic the viscosity of activated sludge. The difference appears to be lower when the air flow rate increases. This work can be considered as a first step towards more accurate and rigorous mechanistic aeration efficiency models which are based on in-depth mechanism knowledge. This is key for oxygen transfer optimization and consequently energy savings.

A New Plant Wide Modelling Approach for the Reduction of Greenhouse Gas Emission from Wastewater Treatment Plants

Recent studies about greenhouse gas (GHG) emissions show that sewer collection systems and wastewater treatment plants (WWTPs) are anthropogenic GHG potential sources. Therefore, they contribute to the climate change and air pollution. This increasing interest towards climate change has led to the development of new tools for WWTP design and management. This paper presents the first results of a research project aiming at setting-up an innovative mathematical model platform for the design and management of WWTPs. More specifically, the study presents the project’s strategy aimed at setting-up a plant-wide mathematical model which can be used as a tool for reducing/controlling GHG from WWTP. Such tool is derived from real data and mechanicistic detailed models (namely, Activated Sludge Model’s family). These latter, although are a must in WWTP modelling, hamper a comprehensive and easy application due to complexity, computational time burdens and data demanding for a robust calibration/application. This study presents a summary of the results derived from detailed mechanistic models which have been applied to both water and sludge line of a WWTP: primary treatment, biological reactor, secondary settler, membrane bioreactor, sludge digester etc. The project is organized in overall four research units (RUs) which focus each on precise WWTP units.

Multi-point monitoring of nitrous oxide emissions in three full-scale conventional activated sludge tanks in Europe

The large global warming potential of nitrous oxide (N2O) is currently of general concern for the water industry, especially in view of a new regulatory framework concerning the carbon footprint of water resource recovery facilities (WRRFs). N2O can be generated through different biological pathways and from different treatment steps of a WRRF. The use of generic emission factors (EF) for quantifying the emissions of WRRFs is discouraged. This is due to the number of different factors that can affect how much, when and where N2O is emitted from WRRFs. The spatial and temporal variability of three WRRFs in Europe using comparable technologies is presented. An economically feasible and user-friendly method for accounting for the contribution of anoxic zones via direct gas emission measurements was proven. The investigation provided new insights into the contribution from the anoxic zones versus the aerobic zones of biological WRRF tanks and proved the unsuitability of the use of a single EF for the three WRRFs. Dedicated campaigns for N2O emissions assessment are to be advised. However, similarities in the EF magnitude can be found considering treatment strategy and influent water composition.

A Novel Comprehensive Procedure for Estimating Greenhouse Gas Emissions from Water Resource Recovery Facilities

The emissions of the major greenhouse gases (GHGs), i.e. carbon dioxide (CO2), methane (CH4), and nitrous oxide (N2O) from water resource recovery facilities (WRRFs) are of increasing concern in the water industry. In order to produce useful and comparable information for monitoring, assessing, and reporting GHG emissions from WRRFs, there is a need for a generally accepted methodology for their quantification. This paper aims at proposing the first protocol for monitoring and accounting for GHG emissions from WRRFs, taking into account both direct and indirect internal emissions and focusing the attention on plant sections known to be primarily responsible for GHG emissions (i.e. oxidation tanks and sludge digestors). The main novelties of the proposed protocol are: (i) measurement of direct internal emissions ascribed to aeration devices; (ii) estimation of indirect internal emissions derived from field measurement; (iii) GHG emission offset due to biogas energy recovery quantified by monitoring biogas composition in case of anaerobic digestion. Finally, the proposed methodology enables and allows the gathering of useful information on plants (e.g. energetic efficiency of the aeration device system and composition of biogas produced in anaerobic digestion) to address potential strategies for improving the plants’ performance.

Multi-point monitoring of nitrous oxide emissions and aeration efficiency in a full-scale conventional activated sludge tank

In this work the biological tank of a WRRF in Italy was monitored placing five floating hoods on a plug-flow-like biological aerated tank surface in order to capture emission dynamics in both time and space domains. The five hoods report which location is more responsible for N2O production at a certain moment of the day. Moreover, with this experimental investigation, a spatial shift in N2O production towards the end of the biological tank could be detected. This provides important insights in the changes in biological dynamics especially with varying incoming load.

Towards mechanistic models for activated sludge flocculation under different conditions based on inverse problems

Experimental data of Ca-induced activated sludge flocculation under different conditions of temperature and dissolved oxygen are investigated in order to model the influence of changing physical and chemical factors. However, current kernel structures for collision frequency and efficiency are unable to describe activated sludge flocculation data. Therefore, an earlier developed methodology based on an inverse problem is applied, yielding empirical models, to find out how flocculation is affected by these different environmental conditions. This contribution shows the useful application of inverse problems to improve the understanding of complex aggregation mechanisms.