Controlling effluent suspended solids in the aerobic granular sludge process

Controlling effluent suspended solids in the aerobic granular sludge process

Accepted Manuscript Controlling effluent suspended solids in the aerobic granular sludge process Edward van Dijk, Mario Pronk, Mark van Loosdrecht PII...

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Accepted Manuscript Controlling effluent suspended solids in the aerobic granular sludge process Edward van Dijk, Mario Pronk, Mark van Loosdrecht PII:

S0043-1354(18)30767-X

DOI:

10.1016/j.watres.2018.09.052

Reference:

WR 14102

To appear in:

Water Research

Received Date: 9 July 2018 Revised Date:

19 September 2018

Accepted Date: 26 September 2018

Please cite this article as: van Dijk, E., Pronk, M., van Loosdrecht, M., Controlling effluent suspended solids in the aerobic granular sludge process, Water Research (2018), doi: https://doi.org/10.1016/ j.watres.2018.09.052. This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.

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Effluent

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Stripping phase + Scum baffles

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Effluent

Scum baffle Scum/fatlike particles Biomass

Influent

Floating biomass with attached N2 bubble

Influent

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Controlling effluent suspended solids in the aerobic granular sludge process

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Edward van Dijka,b,1,∗, Mario Pronka,b,1 , Mark van Loosdrechta

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Department of Biotechnology, Delft University of Technology, Van der Maasweg 9, Delft, 2629 HZ, The Netherlands b Royal HaskoningDHV, Laan1914 35, Amersfoort, 3800 AL, The Netherlands

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Abstract

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The main processes contributing to elevated effluent suspended solids in the full-scale aerobic granular sludge process were studied. The two processes found to be most important were (1) rising of sludge due to degasification of nitrogen gas (produced by denitrification) and (2) wash-out of particles that intrinsically do not settle such as certain fats and foams.

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A mathematical model was made to describe the process of degasification of nitrogen gas

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during the feeding phase in an AGS reactor. The process of rising sludge due to degasification could be limited by stripping out the nitrogen gas before starting the settling phase in the

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process cycle. The wash-out of scum particles could be reduced by introducing a vertical scum baffle in front of the effluent weir, similar to weirs in traditional clarifiers. A full-

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scale Nereda® reactor in the municipality of Utrecht, The Netherlands, was operated with a nitrogen stripping phase and scum baffles for 9 months at an average biomass concentration of 10 g L−1 and an average granulation grade of 84 %. In this period the influent suspended solids concentration was 230 ± 118 mg L−1 and the concentration of effluent suspended solids was 7.8 ± 3.8 mg L−1 . 8

Keywords: aerobic granular sludge, denitrification, degasification, nitrogen gas, scum 1

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layer, rising sludge, effluent suspended solids

1. Introduction

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Aerobic Granular Sludge (AGS) technology is a relatively new technology for the treat-

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ment of both domestic and industrial wastewater (Pronk et al., 2015). AGS technology

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was developed at laboratory scale in the late nineties (Heijnen and van Loosdrecht, 1998;

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Morgenroth et al., 1997), a full-scale demonstration installation in Gansbaai was started

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up in 2008 (Giesen et al., 2013) and in 2011 the first full-scale application was reported

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(van der Roest et al., 2011). Effluent requirements for COD, total nitrogen en total phos-

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phorus were easily met, with average suspended solids effluent concentrations reported for

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full-scale applications in the range of 5 mg L−1 to 20 mg L−1 (see table 1).

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Concentration Reference mg L−1 Epe 10 - 20 (van der Roest et al., 2011) Dinxperlo 15 - 20 (van der Roest et al., 2011) Gansbaai <5 (Giesen et al., 2013) Garmerwolde 20 (Pronk et al., 2015) Ryki 13 (Giesen et al., 2016) Vroomshoop 10 (Giesen et al., 2016)

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Table 1: Reported effluent suspended solids concentrations

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Some reports indicate an increase in effluent suspended solids concentrations for AGS

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reactors with increasing granulation (Li et al., 2008; Rockt¨aschel et al., 2015). In most

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laboratory studies the focus is on the granulation process and wasting of sludge for ease of ∗

Corresponding author Email address: [email protected] (Edward van Dijk) 1 Both authors contributed equally to this manuscript

Preprint submitted to Water Research

September 29, 2018

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operation is combined with decanting of the effluent (de Kreuk et al., 2005). As a result,

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biomass is present in the effluent of laboratory reactors. This poses no problem under

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laboratory conditions, but for the full-scale treatment of sewage the removal of suspended

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solids is an integral part of the purification process and is usually limited by law. Since

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hydraulics of laboratory and even pilot plant installations are not representative for full-scale

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conditions, effluent suspended solids can only effectively be studied at full-scale installations.

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In full-scale applications the effluent and sludge withdrawal are separated processes. This

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leads to relatively low suspended solids effluent concentrations, certainly when compared

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to influent values (Pronk et al., 2015). Still, the reported average values of 5 mg L−1 to

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20 mg L−1 are higher than usually reported for conventional activated sludge processes, which

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can be considerably lower than 10 mg L−1 (Parker et al., 2001).

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Elevated levels of effluent suspended solids have been intensively studied over the last

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decades in conventional activated sludge systems. Commonly reported issues in these sys-

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tems are bulking sludge and foam formation (Jenkins, 1992). Another reported issue in

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secondary clarifiers is the rising of sludge due to denitrification (Henze et al., 1993). Denitri-

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fication can lead to nitrogen bubble formation (degasification) if over-saturation of nitrogen

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gas in the liquid is reached. The bubbles attach to the sludge flocs which then rise towards

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the top of the clarifier and wash out with the effluent.

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Sludge settling too fast, indicated by a low sludge volume index (SVI), is also reported

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to cause elevated levels of suspended solids in the effluent of conventional activated sludge

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systems, although this effect is doubted by others reporting a strong relation with the

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flocculator design (Parker et al., 2001, 1996; Vitasovic et al., 1997). Since reported SVI 3

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values for full-scale AGS reactors are generally low (35 mL g−1 to 70 mL g−1 ) (Pronk et al.,

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2015; van der Roest et al., 2011) this might also be a potential cause of elevated levels of

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effluent suspended solids.

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Besides a different sludge morphology and likely flocculation behavior, current granular

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sludge plants according to the Nereda® concept deviate also in hydraulics from secondary

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settling tanks. Secondary clarifiers have typical superficial upflow velocities of 0.5 m h−1 to

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1.0 m h−1 , while the complex flow in the clarifier is mainly caused by density currents (Zhou

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et al., 1992). For the Nereda® technology effluent results from pumping influent in the

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bottom of the granular bed. This generates an upward plug flow in the reactor with typical

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superficial velocities in the range of 2 m h−1 to 4 m h−1 through a granular bed with on top of

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that a layer of flocculent sludge. The relatively higher upflow velocities in Nereda® reactors

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might be responsible for the washout of floating sludge and fat-like particles. In contrast

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to conventional activated sludge systems, the mechanisms behind the formation and control

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of effluent suspended solids for full-scale aerobic granular sludge reactors are not yet fully

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understood.

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The aim of this study was to evaluate the main processes leading to effluent suspended

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solids in full-scale AGS reactors, and the options to minimize effluent suspended solids.

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Therefore, a full-scale Nereda® reactor, situated in the municipality of Utrecht, The Nether-

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lands was used to study the mechanisms leading to elevated suspended solids concentrations

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in the effluent. In this study, we focused on both removal of floating material and degasifi-

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cation of nitrogen gas. Hereto, full-scale experiments were performed and a mathematical

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model was developed to describe the degasification of nitrogen gas during the operation of

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the aerobic granular sludge reactor.

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2. Materials and methods

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2.1. Description of the plant

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In 2013 the Dutch water authority Hoogheemraadschap de Stichtse Rijnlanden took a

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1050 m3 aerobic granular sludge reactor in operation. The reactor is located in the munic-

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ipality of Utrecht, The Netherlands and was designed by Royal HaskoningDHV under the

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trade name Nereda® .

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The reactor has a footprint of 150 m2 and a water depth of 7.00 m. The influent pumps

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have a total capacity of 900 m3 h−1 . The influent is pumped directly from a main sewer line

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of the Overvecht district in Utrecht. The sewage consists mainly of domestic wastewater.

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Wastewater characteristics are given in table 2. After screening by a 6 mm perforated plate

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screen, the wastewater is directly pumped into the reactor. During the trial the reactor

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was operated at a MLSS concentration of 8 kg m−3 to 12 kg m−3 , a SVI5 of 34 mL g−1 to

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57 mL g−1 , a SVI30 of 33 mL g−1 to 43 mL g−1 , a volumetric loading rate of 0.6 m3 m−3 d−1

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to 2.7 m3 m−3 d−1 and an average sludge loading rate of 0.08 kgCOD/kgMLSS/d. About

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84 % of the biomass present in the reactor was granulated during the experimental period

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(i.e. granule size larger than 0.2 mm). Average granule size distributions are shown in table

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3. The reactor is equipped with two blowers each with a capacity of 400 m3 h−1 . Air is

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supplied to the reactor using micro bubble diffusors evenly distributed on the floor of the

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tank.

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Table 2: Influent of the aerobic granular sludge wastewater treatment plant in Utrecht, The Netherlands Min mg L−1 442.4 35.0 25.1 5.3 3.2 160.0

Max mg L−1 1007.5 81.7 58.6 11.8 8.2 380.0

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Average mg L−1 707.0 64.0 46.1 8.9 5.6 230.0

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Parameter COD NKj N NH4+ N Total Phosphorus PO43– P Suspended solids

The reactor is operated as a sequencing fed batch process with constant volume, con-

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sisting of a combined feeding and effluent withdrawal step, a reaction phase and a settling

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and sludge withdrawal step. Process conditions are set to target full biological nitrogen and

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phosphorus removal. No possibilities for chemical dosing are present in the reactor. During

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the trial nitrogen removal was established by nitrification and denitrification.

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The cycle time varied between 4 and 8 hours, with 1 hour of anaerobic feeding and

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simultaneous effluent withdrawal, a variable reaction phase and a phase for mixing, setting

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and decanting of sludge of 30 to 60 minutes.

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The reaction phase was stopped when the set points, 2 mg L−1 and 3 mg L−1 for respec-

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tively NH4+ N and NO3– N were reached. During the reaction phase the dissolved oxygen

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concentration was controlled in the range of 1.0 mg L−1 to 2.0 mg L−1 .

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The plant is in operation since the 1st of April 2013. The reactor was started up without

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baffles in front of the overflow weir. At the 3rd of June 2015 vertical baffles were placed in

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front of the effluent weirs, to investigate the effect of scum baffles on the concentration of

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effluent suspended solids.

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2.2. Online measurements The reactor was equipped with probes for dissolved oxygen, redox potential, water level,

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temperature, turbidity, and nitrate. Ammonium and phosphate are continuously measured

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using a filter unit and auto sampling device (Hach Lange; Filtrax, Amtax and Phosphax).

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The filter unit was situated 0.5 meter below the water surface. Sampling was done at an

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interval of 5 minutes. A turbidity sensor (Hach Lange; Solitax) was present in the effluent

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gutter to observe the presence of suspended solids.

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2.3. Sampling

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Samples for analyses of influent and effluent were collected using refrigerated auto sam-

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plers, collecting flow proportional samples for both influent and effluent. Suspended solids

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concentrations of both influent and effluent were measured by filtering 1 L of sample with a

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glass fiber filter, which was dried at 105 ◦C until no weight change was measured.

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Grab samples for MLSS analyses were taken from the top of the reactor after at least 15

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minutes of aeration at full capacity to ensure sufficiently mixed conditions.

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2.4. Physical characteristics of the sludge

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To determine the granule size distribution 1 L of sample was poured over a series of

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sieves with different mesh sizes (200 µm, 400 µm, 630 µm, 1000 µm and 2000 µm). These

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sieve fractions together with 100 mL of unsieved sludge were dried at 105 ◦C. The sludge

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volume index (SVI) was measured by pouring 1000 mL of mixed, undiluted sludge into a

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graduated measuring cylinder. The sludge volumes were measured after 5 and 30 minutes. 7

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Table 3: Average granule size distribution of the sludge in the aerobic granular sludge wastewater treatment plant in Utrecht, The Netherlands

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Percentage % 16 % 3% 2% 4% 31 % 44 % 100 %

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Concentration kg m−3 1.7 0.3 0.2 0.4 3.2 4.6 10.4

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Sieve fraction µm 0 - 200 200 - 400 400 - 600 600 - 1000 1000 - 2000 >2000 Total 2.5. Microscopic analysis

A Leica Microsystems Ltd stereo zoom microscope (M205 FA) in combination with Leica

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Microsystems Qwin (V3.5.1) image analysis software was used to analyze the morphology

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of the sludge.

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2.6. Modelling of N2 stripping

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A mathematical model was developed to calculate the concentrations of dissolved nitro-

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gen gas in the reactor. The solubility of nitrogen gas in water, cs , is dependent on the partial

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pressure of nitrogen gas in the gas phase, p, and is calculated using Henrys law:

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cs = M · kH · p

(1)

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Here kH is the Henrys constant for the solubility of nitrogen gas in water and M is the

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molar mass of nitrogen gas. The Henrys constant is a decreasing function of temperature,

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meaning that the solubility of nitrogen gas in water decreases with an increasing tempera8

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ture. The partial pressure of nitrogen in the gas phase is both dependent on the gas fraction,

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f , and the pressure in the reactor, the latter being the sum of atmospheric pressure, Patm

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and hydrostatic pressure:

p = f · (Patm + h · ρ · g)

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(2)

Here h is the water depth, ρ is the mixture density and g is the gravitational acceleration.

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The transfer of nitrogen gas between the air bubbles and the liquid is calculated by:

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dc = αF · (kL a)N · (cs − c) dt

(3)

Here c is the nitrogen gas concentration in the water phase, kL is the mass transfer

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coefficient and a is the interfacial area of the gas bubbles. The subscripts O and N indicate

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the values for oxygen gas and nitrogen gas. The mass transfer rate is corrected for effects

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of wastewater contaminants, α, and fouling on the membrane aerators, F . The value of the

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product of kL and a for oxygen transfer (kL a)O , is commonly measured during commissioning

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in full-scale wastewater treatment plants and depends on the temperature. For this study,

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a value of (kL a)O including the effects of contaminants and fouling was used. Hereto the

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values for α and F were set to 1.

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This empirical value of (kL a)O can be used to derive a value for nitrogen gas by using

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Higbies penetration theory (Higbie, 1935). Based on this model the following relation be-

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tween the kL a for oxygen gas and nitrogen gas and the diffusion coefficient for oxygen gas

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(DO ) and nitrogen gas (DN ) for can be derived: 9

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(kL a)O = (kL a)N

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DO DN

(4)

Both the diffusion coefficient and the Henry coefficient need to be corrected for temper-

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ature. For the diffusion coefficient this is based on the Stokes-Einstein equation (Einstein,

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1905). In this equation the diffusion coefficient D is related to the temperature T and the

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dynamic viscosity µT :

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T µ0 T0 µ T

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D(T ) = D0

(5)

The viscosity is also depending on temperature according to equation the Vogel-Fulcher-

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Tammann equation (Dagdug, 2000), in which parameters A, B and C are empirical param-

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eters:

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B

µ(T ) = eA+ C+T

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(6)

The Henry coefficient is corrected for temperature using the van ’t Hoff equation (van’t

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Hoff, 1884), in which kH0 is the Henry coefficient at reference temperature, T0 is the reference

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temperature and Hc is the temperature correction factor:

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kH (T ) = kH0 e

−kHc ( T1 − T1 ) 0

(7)

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The stripping of nitrogen gas is done by aeration of the reactor with fine bubble aera-

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tion. This leads to transport of dissolved nitrogen gas through the reactor. A simple axial 10

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dispersion model can be used to describe the liquid backmixing of dissolved nitrogen gas in

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the reactor (Degaleesan and Dudukovic, 1998), in which x is the reactor depth.

dc d2 c = Dax,1 2 dt dx

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(8)

The axial dispersion coefficient, Dax,1 , is a lumped coefficient, containing the effect of

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both turbulent dispersion and global convective recirculation in the reactor. Molecular

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diffusion in this case is neglected due to an expected limited impact. A tracer experiment

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with NH4+ was used to determine the value of Dax,1 .

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To describe the transfer of nitrogen gas between the air bubbles and the water phase,

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equation 4 is substituted in equation 3. If this equation is combined with the transport

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of nitrogen gas in the water phase according equation 8 a description for the stripping of

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nitrogen in a 1D bubble column is constructed:

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DN · (cs (x) − c) DO

(9)

The saturation concentration for nitrogen gas according to equation 1 can be combined

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d2 c dc = Dax,1 2 + αF · (kL a)O dt dx

with the actual concentration to calculate the nitrogen gas deficit in the bulk liquid, cd .

cd = cs − c

(10)

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When over-saturation occurs during aeration (i.e. the actual concentration c is bigger

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than cs at ambient pressure and temperature), it is assumed that N2 gas bubbles are formed 11

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immediately and efficiently stripped out of the bulk liquid. This is modelled by artificially

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increasing the local kL a with an order of magnitude.

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2.7. Modelling of mixing during imperfect plug-flow feeding

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During feeding the bulk liquid in the reactor is pushed up towards the top of the reactor

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where the overflow weirs are situated. To describe the transport of nitrogen gas during

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feeding, the same axial dispersion model of equation 8 is used with a different value for

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Dax . Also an additional term is added to describe the transport of nitrogen gas through

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convection. Here, v is the upflow velocity of the liquid in the reactor. The value of Dax,2

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was experimentally established by measuring a step response curve with NH4+ as a tracer.

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(11)

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dc d2 c dc = Dax,2 2 + v dt dx dx

The influent is fed from the bottom of the reactor. It is assumed that the influent con-

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centration of dissolved nitrogen is equal to the equilibrium concentration of nitrogen gas at

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atmospheric pressure. During the feeding phase denitrification can take place. The denitri-

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fication rate depends on many parameters, but in this case a lumped specific denitrification

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rate, r, is used. The specific denitrification rate was measured in the reactor in the days be-

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fore the experiment, by measuring the decrease of the NO3– concentration during an anoxic

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phase in the cycle. This rate is multiplied by the MLSS concentration, X, which is a function

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of the reactor depth. The sludge bed is assumed to be in steady state and thus invariable

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in time. In the simulations it was assumed that the sludge bed occupies the lower 4 meters

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of the reactor and that the sludge is evenly distributed. We can then write equation 11 as

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follows:

dc d2 c dc = Dax,2 2 + v + rX(x) dt dx dx

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(12)

In this model the water in the reactor can get over-saturated with nitrogen gas. This

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means that the local concentration of nitrogen gas, c, becomes larger than the local satu-

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ration concentration according to equation 1. It is assumed that nitrogen gas bubbles are

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formed immediately after over-saturation. Most likely supersaturation of nitrogen gas can

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occur, but the effect is assumed to be limited (Henze et al., 1993).

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4.

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3. Results

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3.1. Reactor operation

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To solve the model a Python code was written. All model parameters are given in table

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The data were collected between June 2015 and May 2016. In this period the reactor

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was run stable and without interruption with average effluent values of COD of 41 mg L−1 ,

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Nkj N of 4.05 mg L−1 , NH4+ N of 1.29 mg L−1 , NO3– N of 3.72 mg L−1 , Ptot of 0.51 mg L−1

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and PO43– P of 0.26 mg L−1 , showing an highly efficient N and P removal of respectively

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94 % and 91 %. The average granule size distribution is reported in table 3. The sludge in

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the reactor mainly consisted of smooth granules bigger than 1 mm, which is also shown by

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the microscopic image of the sludge in figure 1A. The water temperature was in the range

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of 9 ◦C to 23 ◦C.

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Figure 1: Biomass in the aerobic granular sludge plant in Utrecht, The Netherlands: (A)

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granules in the reactor, (B) light microscopic picture of effluent suspended solids, (C) scum

3.2. Degasification of nitrogen gas

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on top of the reactor after installation of the baffles, (D) biomass from the top of the reactor

Due to denitrification and upward transport of liquid (decreasing local pressure) over-

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saturation of the water phase with nitrogen gas can occur, leading to gas bubble formation

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in the feeding/decanting period. To confirm that over-saturation of nitrogen gas is present

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during parts of the cycle an experiment was performed. Two comparable batches were fed

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to the reactor. The batch sizes are given as volumetric exchange ratio (VER), which is

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the ratio between the batch size (f.e. 400 m3 ) and the volume of the reactor (1000 m3 ).

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Before the first batch (batch 1) the reactor was intensely aerated before feeding the reactor,

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while in the second batch (batch 2) this stripping phase was omitted. The gas stripping

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period was 30 minutes long, with an air flow of 800 m3 h−1 . This high value was chosen

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to strip a maximum amount of nitrogen gas. The process conditions in the two batches

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were comparable (batch 1: volumetric exchange ratio 40 %, nitrogen removed in previous

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batch 13.8 mg L−1 , average temperature 13.6 ◦C; batch 2: volumetric exchange ratio 40 %,

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nitrogen removed in previous batch 13.9 mg L−1 , average temperature 13.5 ◦C). The effect

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of a stripping phase is clearly illustrated in figure 2, showing the effluent turbidity for both

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batches. Batch 1 showed an overall lower level effluent turbidity with a turbidity slightly

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decreasing over the batch, with an average value of 4.9 FNU. The turbidity in batch 2 was

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overall higher than in batch 1, with an average value of 21.0 FNU. At a volumetric exchange

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ratio of 30 % the effluent turbidity started to increase up to a value of 48.5 FNU at the end

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of batch 2. In figure 3 photographs recorded by a security camera are showing the gradual

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formation of a scum layer due to degasification during batch 2.

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Turbidity [FNU]

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batch 1 batch 2

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10 15 20 25 30 Volumetric Exchange Ratio [%]

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Figure 2: turbidity of the effluent in a batch with gas stripping (batch 1) and without gas stripping (batch 2)

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Figure 3: Degasification and the resulting floatation of biomass during feeding in a batch

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without stripping: (A) VER = 0 % (B) VER = 20 % (C) VER = 40 %

3.3. Stripping of nitrogen gas

Dissolved nitrogen gas can be stripped out by aerating right before the feeding phase in

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order to prevent rising of biomass as is shown above. Equation 9, together with equation

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1 and 2 for pressure correction, equation 5, equation 6 and equation 7 for temperature

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correction and equation 4 for the conversion of the kL a can be used to evaluate the effect of

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the stripping period on the dissolved N2 concentration in the reactor.

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In figure 4 the effect of stripping of an initially fully N2 saturated situation in the reactor

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is shown at a temperature of 20 ◦C. The dissolved nitrogen gas concentration in the reactor

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(top at 0 m, bottom at 7 m) is shown. The figure shows three colored zones: the green

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zone marks the area where the nitrogen gas concentration is lower than the equilibrium

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concentration for air (i.e. no degasification expected). The red zone marks the area where

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the nitrogen gas concentration is higher than the equilibrium concentration for pure nitrogen

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gas (i.e. degasification expected). The white zone marks the area where only a partial

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nitrogen gas deficit exists. The boundary between the green area and the white area is

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calculated according to equation 1 and equation 2 with a gas fraction of nitrogen gas in

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air at ambient water pressure and temperature (f = 78 %). The boundary between the

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white and the red area is calculated in a similar manner, but with pure nitrogen gas bubbles

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(f = 100 %).

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The mixing of the reactor has a large impact on the effect of the stripping phase. Dis-

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solved nitrogen gas is convectively transported through the reactor, leading to an over-

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saturated situation near the top of the reactor and an undersaturated situation near the

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bottom of the reactor. When the aeration continues, the nitrogen gas is slowly stripped out

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of the reactor and a N2 deficit is created at the bottom of the tank. After 15 minutes, due

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to the mixing, the N2 concentration near the bottom of the reactor is lower than the air

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equilibrium concentration at 7 meters water depth. However, near the top of the reactor

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the N2 concentration is still over-saturated. Even after 60 minutes of aeration the nitrogen

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concentration is still at saturation concentration near the top of the reactor due to upmixing

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of dissolved N2 gas. Note that for operational conditions over-saturation at the top of the

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reactor is not important since there is no sludge bed/blanket near the top of the reactor

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during effluent withdrawal.

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N2 concentration

0

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2

over saturated

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max deficit

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3 4 5 reactor depth [m]

max deficit

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N2 concentration

over saturated

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max deficit

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N2 concentration

over saturated

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over saturated

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36 34 32 30 28 26 24 22 20 18 16 36 34 32 30 28 26 24 22 20 18 16

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N2 concentration

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Figure 4: Stripping of N2 gas from fully saturated situation (A) and after 5 minutes (B),

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15 minutes (C) and 60 minutes of stripping (D) at 20 ◦C. Black solid line: the actual N2 concentration, red area: N2 concentration above saturation, green area: N2 concentration below equilibrium with air, boundary between red area and white area: N2 concentration at equilibrium with pure nitrogen gas at ambient water pressure, boundary between green area and white area: N2 concentration at equilibrium with air at ambient water pressure.

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Table 4: Model parameters

3.4. Degasification during feeding

Unit mol m−3 Pa−1 K g mol−1 Pa kg m3 m s−2 h−1 m2 s−1 m2 s−1 m2 s−1 m2 s−1

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Value 6.4 × 10−6 1300 28 0.78 101,325 1000 9.81 1 1 5.5 2.10 × 10−9 1.88 × 10−9 -10.6265 578.919 -137.546 1.0 × 10−4 1.0 × 10−2

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Symbol kh khc M f Patm ρ g α F (kL a)O DO DN A B C Dax,1 Dax,2

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Parameter Henry’s constant for N2 (25 ◦C) Temperature coefficient N2 Molar mass N2 Gas fraction of N2 in air Atmospheric pressure Density of water Gravity acceleration Alpha factor Fouling factor Gas transfer rate for oxygen Diffusion coefficient O2 (25 ◦C) Diffusion coefficient N2 (25 ◦C) Empirical coefficient A Empirical coefficient B Empirical coefficient C Axial dispersion during feeding Axial dispersion during aeration

The effect of denitrification during feeding on degasification of nitrogen gas was also

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evaluated by extending the model according to equation 12. In figure 5 an example is shown

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for a batch comparable with the previously described batch 1 in which a stripping phase of

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30 minutes is applied, with T = 13.5 ◦C, r = 0.25 mg g−1 d−1 .

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The model shows limited over-saturation during the feeding period of 1 hour, but the

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over-saturation only occurs above the sludge blanket so rising of sludge due to bubble for-

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mation is not likely to happen.

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N2 concentration MLSS concentration

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biomass concentration [g L 1]

N2 concentration MLSS concentration

over saturated

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B

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N2 concentration MLSS concentration

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Figure 5: effect of feeding after a stripping phase on the dissolved nitrogen gas concentration

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from the start (A), after 15 minutes (B), after 30 minutes (C) and after 50 minutes (D). T = 13.5 ◦C, r = 0.25 mg g−1 d−1 . Black solid line: the actual N2 concentration, gray solid line: biomass concentration, red area: N2 concentration above saturation, green area: N2 concentration below equilibrium with air, boundary between red area and white area: N2 concentration at equilibrium with pure nitrogen gas at ambient water pressure, boundary between green area and white area: N2 concentration at equilibrium with air at ambient water pressure. 20

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If the stripping phase is reduced to 5 minutes, again with T = 13.5 ◦C, r = 0.25 mg g−1 d−1 ,

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a situation comparable with the above described batch 2 experiment can be modelled. The

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results are shown in figure 6. The water in the vicinity of the sludge blanket is almost

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immediately slightly over-saturated with nitrogen gas. After 30 minutes the top of the

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sludge blanket is fully over-saturated with nitrogen gas, which most likely will lead to rising

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sludge as the escaping nitrogen bubbles get caught by small flocs near the supernatant

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sludge interface.

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N2 concentration MLSS concentration

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N2 concentration MLSS concentration

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B

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N2 concentration MLSS concentration

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Figure 6: effect of feeding without a prior stripping phase on the dissolved nitrogen gas

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concentration from the start (A), after 15 minutes (B), after 30 minutes (C) and after 50 minutes (D). T = 13.5 ◦C, r = 0.25 mg g−1 d−1 . Black solid line: the actual N2 concentration, gray solid line: biomass concentration, red area: N2 concentration above saturation, green area: N2 concentration below equilibrium with air, boundary between red area and white area: N2 concentration at equilibrium with pure nitrogen gas at ambient water pressure, boundary between green area and white area: N2 concentration at equilibrium with air at ambient water pressure. 22

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3.5. Identification of suspended solids in the effluent The suspended solids present in the effluent were examined under a stereo-zoom micro-

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scope to determine the characteristics and possible origin. Figure 1b and 1d show that the

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suspended solids in the effluent are small dense light brown flocs. No filamentous organisms

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like Thiothrix spp. or Microthrix spp. were observed that would normally be associated

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with bad settling sludge (figure 1d). It was also observed that after light shaking of the sam-

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ple flask the suspended solids quickly settled to the bottom indicating that the suspended

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solids were able to settle well.

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3.6. Effect of the vertical baffle

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During the first experimental period (between April 2013 and May 2015) the average sus-

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pended solids effluent concentration was 30 mg L−1 with a 50-percentile value of 19.8 mg L−1 .

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In the same period, many values below 10 mg L−1 were also recorded with a 25-percentile

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value of 9.3 mg L−1 . On the 3rd of June 2015 vertical baffles were installed in front of the

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overflow weirs. Composite samples of the effluent of the reactor were taken in the period

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immediately before and after the baffles were installed; i.e. under similar operational and

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sludge characteristics. Figure 7 shows the effluent suspended solids in this period. In the

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period immediately before installation of the baffles the average effluent suspended solids

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concentration was 23 mg L−1 , which is 10 % of the influent suspended solids concentration.

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In the period directly after installation of the baffles only 1 sample was above 10 mg L−1

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with a total average of 7.2 mg L−1 . In the period June 2015 to May 2016, 175 composite

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influent and effluent samples were taken by the local water authority. The suspended solids

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pended solids was 7.8 ± 3.8 mg L−1 with a 95-percentile value of 13.6 mg L−1 . The average

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removal efficiency of suspended solids was 97 %. After installation of the baffles a thin layer

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of scum was present in most batches during feeding (figure 1c), but in this period no built

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up of scum was observed. The thin layer of scum always disappeared in the first few minutes

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of the reaction phase of the cycle.

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concentration in the influent was 230 ± 118 mg L−1 and the concentration of effluent sus-

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Figure 7: Suspended solids concentration in the effluent before and after installation of

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vertical baffle in front of the overflow weirs

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4. Discussion

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4.1. Comparison of AGS reactors with activated sludge systems

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In this study we examined the main processes for production of effluent suspended solids

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in full-scale aerobic granular sludge reactors. The problem of rising sludge is known from

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both continuously fed activated sludge systems (Henze et al., 1993) as from sequencing batch 24

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reactors (Tor`a et al., 2011). Comparison of the flow patterns in a secondary clarifier and the

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AGS reactor reveals some important differences (figure 8). The outflow from an aeration

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tank towards a secondary clarifier generally flows over a weir making the water pressure

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almost atmospheric and generating a lot of turbulence. This is an effective way to remove

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at least part of the dissolved nitrogen gas. Subsequently, the water from the aeration tank

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flows into the secondary clarifier through the center well were the water pressure is close to

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atmospheric pressure again. In the clarifier the flow splits into effluent and return sludge.

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The return sludge is removed from the bottom of the clarifier. During dry weather conditions

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a limited amount of sludge is present in the clarifier and this sludge will be near the bottom

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of the clarifier at a water pressure well above atmospheric pressure. If the water pressure

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increases at higher water depth, automatically the nitrogen gas deficit increases. Thus, if

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nitrogen gas is formed in a clarifier due to denitrification this will mainly take place at

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the bottom of the clarifier, where a relatively high nitrogen gas deficit is present. This is

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probably why degasification in a clarifier is not a very common problem and is only known

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from high loaded systems at high temperatures with high denitrification rates (Sarioglu and

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Horan, 1996) or when the inflow to the clarifier is not degassed at an overflow weir. In the

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AGS reactor the influent is fed from the bottom of the reactor, pushing the with nitrogen gas

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saturated water in the reactor upwards to lower water pressure. This process is comparable

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with the process occurring in a sequencing batch reactor, where degasification can occur

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while decanting the effluent and thereby decreasing the water pressure. Thus, while feeding

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the reactor, the upwards moving liquid gets a lower saturation concentration for nitrogen

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gas, while in a clarifier it gets increased. In the AGS reactor during feeding, denitrification of

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remaining NO3– on storage polymers by GAO and PAO like organisms, built up in previous

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cycles, can occur (Kuba et al., 1996). The combination of a lower nitrogen gas deficit due

334

to pressure decrease and an higher denitrification potential make the AGS reactor more

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susceptible for degasification of nitrogen gas in comparison to a clarifier. Therefore washout

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of suspended solids due to degasification of nitrogen gas is less common in clarifiers than in

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AGS reactors.

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Effluent

Scum/fatlike particles Biomass

Floating biomass with attached N2 bubble Effluent

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Return sludge

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AGS Reactor

Aeration tank + clarifier

Figure 8: Comparison of flow in an AGS reactor and flow in a conventional aeration tank and clarifier

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4.2. Effect of N2 stripping Rising of sludge due to degasification of dissolved N2 gas can cause elevated levels of

340

suspended solids in the effluent of activated sludge and AGS plants. Experimentally it was

341

shown that a nitrogen gas stripping phase just before the influent feeding phase was effective

342

to prevent rising of sludge in the AGS process. The developed mathematical model shows

343

that a limited amount of N2 gas deficit can be reached by applying a stripping phase. When

344

the water is pushed up during the feeding phase almost immediate over-saturation occurs

345

when no stripping phase is applied.

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The model presented by Henze et al. (Henze et al., 1993) only showed a steady state

347

N2 gas deficit in an unmixed situation. This model was extended to show the effect of non-

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steady state aeration and feeding. A convection/dispersion term was added to the model

349

to describe both mixing due to aeration of the reactor and the plug flow behaviour of the

350

AGS reactor during feeding. The model shows that the local dissolved N2 gas concentration

351

changes over time and depth of the reactor. The maximum deficit for N2 gas depends highly

352

on the temperature, as do the denitrification rates. The model can easily be extended to

353

calculate the risk of rising sludge based on temperature, batch size and aeration history

354

of the reactor. Denitrification rates increase with temperature and the N2 gas deficit will

355

decrease with temperature. At temperatures above 20 ◦C the need for a stripping phase

356

increases. It should be realized that for the denitrification during the settling/feeding phase

357

mainly residual COD from the previous cycles is used. The COD containing influent is

358

replacing the nitrate containing liquid in the reactor. Therefore influent COD and nitrate

359

will only mix after the feeding phase when the aeration is switched on.

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4.3. Effect of the scum baffle Introduction of the vertical scum baffles in front of the effluent weir lowered the effluent

362

suspended solids concentration from 23 mg L−1 to 7 mg L−1 . Analyses of the suspended

363

solids in the effluent before installation of the baffles did not show any significant presence

364

of granules or filamentous bacteria. Microscopic analyses only revealed the presence of small

365

sludge flocs. The thin layer of sludge present on the surface of the reactor during feeding,

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observed after installation of the baffles apparently was the result of the blocking of wash-out

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of floating sludge by the baffles. The same effect is known from clarifiers in activated sludge

368

systems (Metcalf and Eddy, 2014).

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It was shown that at a MLSS concentration of 10.1 g L−1 and an influent suspended solids

370

of 230 mg L−1 an effluent suspended solids concentration below 10 mg L−1 were obtained over

371

long term operation. The flocs present in the layer on top of the reactor are assumed to

372

be grown in the reactor. Apparently not all biomass grown in the reactor is granular.

373

The flocculent mass likely consists of non biodegradable inert COD from the influent and

374

detached biomass from the granules. This is also shown by the fractionation of the sludge

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showing an average 16 % of mass smaller than 200 µm.

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The influent of the reactor contained an average of 230 mg L−1 of TSS after screening.

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Since the only pre-treatment of the reactor was a 6 mm perforated plate screen, some floating

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material from the sewerage will end up in the reactor. Although the influent consists merely

379

of domestic wastewater, the sewage of the Overvecht district is known to contain relatively

380

large fraction of fat. Some fatlike particles were observed in the reactor, but in the period of

381

10 months in which the experiment was run, no build up of scum or fat on the reactor was 28

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observed. Apparently the fat particles were converted or removed with the excess sludge. The reported values of effluent suspended solids of 20 mg L−1 for the Garmerwolde plant

384

(Pronk et al., 2015) are comparable with the levels measured in this study before installation

385

of the vertical baffles in front of the effluent weirs. Since the Garmerwolde plant mainly treats

386

domestic sewage and also the pre-treatment of the wastewater is comparable, these levels of

387

effluent suspended solids are to be expected. Also reported values for other plants (table 1)

388

were in the range of 10 mg L−1 to 20 mg L−1 and thus comparable with the values measured

389

in this study before installation of the vertical baffle. This value is to be expected from

390

a full-scale aerobic granular sludge reactor on domestic wastewater if no baffle is present.

391

The Gansbaai plant is the exception, with a value of 5 mg L−1 , but detailed information

392

is not available. Baffles have proven to be an effective and economic way to keep effluent

393

suspended solids below 10 mg L−1 , similar to well operated secondary clarifier effluents.

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5. Conclusions

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In this study, two main processes have been identified that can contribute to elevated

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suspended solids concentration in the effluent of the aerobic granular sludge process in prac-

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tice. These processes also play an important role in suspended solids control in secondary

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clarifiers of activated sludge plants. Two solutions known from operation of secondary clar-

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ifiers could successfully be incorporated into the AGS process leading to low concentration

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of suspended solids in the effluent. The implementation of nitrogen stripping, before the

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settling period, avoids gas bubble formation during feeding and thus the floatation of lighter

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biomass. A mathematical model describing degasification was developed that explains the

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observations of higher suspended solids concentrations in the effluent when treating sewage.

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Introduction of a vertical baffle in front of the effluent weir showed to be an effective measure

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to keep floating sludge and fat-like particle in the reactor, resulting in an effluent suspended

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solids concentration lower than 10 mg L−1 with an average influent suspended solids concen-

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tration of 230 mg L−1 . This was achieved with high biomass concentrations (10 g L−1 ) and a

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high granulation grade (84 %).

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6. Acknowledgements

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The authors wish to thank Mark Stevens, Jan Cloo and Tim van Erp for their end-

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less dedication to this project. This work was supported by Royal HaskoningDHV, The

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Netherlands.

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ACCEPTED MANUSCRIPT * Mechanisms for production of effluent suspended solids in AGS reactors unravelled * Stripping of nitrogen gas prevents rising sludge * Vertical baffle prevents washout of fat-like particles and scum

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* Mathematical model of rising sludge describes stripping of nitrogen gas