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Energy Efficiency Optimisation of Wastewater Treatment: Study of ATAD Jaime Rojas Supervisor: Prof. Toshko Zhelev

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Outline       

Our Starting Point Introduction Motivation and Aim Methodology Results Conclusion Future Work

Energy Efficiency Optimisation of Wastewater Treatment: Study of ATAD

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Our Starting Point  Ill-defined problem: energy efficiency improvement – But, how? Where to start? NH3 scrubber

2 Feed Tanks

Sludge from on-site WWTP

Biofilter

Belt Press Reactor Picket Fence Thickener

Reactor

1A

2A

(40-55oC)

(55-65oC)

4 Product Storage tanks

Fig. 1. Simplified flow diagram of the case study ATAD plant (Killarney, Co. Kerry, Ireland).

Fig. 2. Energy breakdown of the case study ATAD Plant.

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Introduction  What is autothermal thermophilic aerobic digestion (ATAD)? Activated sludge process o Stabilisation o Pasteurisation

 How ATAD works (more>>)

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Introduction  What is autothermal thermophilic aerobic digestion (ATAD)? Activated sludge process o Stabilisation o Pasteurisation

 How ATAD works (more>>)  Energy intensive1: 9-15 kWh/m3, 0.3-0.5 kWh/kg  Conflicting reports regarding energy efficiency and cost effectiveness of ATAD systems2

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Motivation and Aim  Operating conditions unexploited • Invariable air supply3 and need for best aeration strategy4 • Influence of volume change frequency on energy requirement, but one single volume change per day: thermophiles’ efficiency not completely exploited5,6 • Sludge pre-heating: shorter reaction times2 • Shorter reaction times: avoidance of oxygen-limited conditions, reduction of thermal shock, and greater realizable load7

 Need to identify optimum operating conditions of ATAD systems4,8 Aim: To minimize the energy requirement of ATAD systems by altering the operating conditions while complying with treatment goals

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Methodology  Dynamic optimisation9,10,11 tf

  P(t ) min E [ x , u ]   m t min  dt u ( t ), t f 0 subject to      f ( x , x , u )  0   x (t0 )  x0

dynamic constraint

0.38  rVS (t f )  0

stabilisation constraint

1  LP (t f )  0    u L  u (t )  uU

pasteurisation constraint

Before solving DO problem: 1.Quantification of treatment goals rVS and LP 2. ATAD model f 3. Selection of optimisation variables u

Em  specific energy use [kWh/kg], cm  specific plant capacity [kg/d], PL  pasteurization lethality [%], rVS  volatile solids reduction [%],   x  state variables , u  optimization variables, P  pasteurization lethality [%], rVS  volatile solids (VS) reduction [%],

VS  desired VS reduction level, t P  pasteurization time [d], X VS (t )  VS solids concentration in the reactor at time t [kg/m 3 ], X VSfeed  VS solids concentration in the feed [kg/m 3 ]

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Methodology  Quantification of treatment goals • Pasteurisation12 D

50070000 for TP  50 o C and D  0.021 days (30 min) 0.14TP 10 t

LP (t ) 

dt ' D t '0

1  LP (t f )  0

 tP

• Stabilisation rVS (t )  1 

X VS (t ) X VSfeed

0.38  rVS (t f )  0

tr  max{ t P , t S }

 tS Energy Efficiency Optimisation of Wastewater Treatment: Study of ATAD

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Methodology  Large Model13 • • •

Volume Mass balance (9 variables) Energy balance

dV  qin  qout dt d(VX i )   vij ρ jV + In(X i )  Out(X i ) dt j dH  In( H l )  Out ( H l )  Pbio  Pmix  Pwall  dt in out ...In( H g )  Out ( H g )  Qlat  Qlat

V – Volume (m3) X i– Mass component i (g/l) H – Enthalpy (MJ)

 Reduced Model14 • •

Mass balance (3 variables) Energy balance

d XB  G  bX B  Q ( X Bfeed  X B ) dt d X   G  b(1  f ) X  Q ( X feed  X ) dt dS  A( S  S )   G  Q ( S feed  S ) dt dT   G  h  Q (T feed  T ) dt

Xs – Biomass (g/l) X – Substrate (g/l)

Energy Efficiency Optimisation of Wastewater Treatment: Study of ATAD

S – Oxygen (mg/l) T – Temperature (°C)

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Table 1. Petersen matrix of extended ASM1 model at thermophilic temperatures13,20

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Methodology  Calculation of specific energy requirements and plant capacity13 tf

Gravimetric

P(t ) dt min

cm 

mVS tr

P(t ) EV   dt Vin t0

cV 

Vin tr

Em   t0 tf

Volumetric

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Results  Simulation and verification – reduced model14

Fig. 6. Simulation of data from a full-scale 300 m3 ATAD reactor during a period of three weeks using the reduced model14: (a) Reactor temperature and (b) volatile solids.

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Results

0.65

0.65

0.6

0.6

0.55

0.55

0.5

0.5

Em [kWh/m 3]

Em [kWh/m 3]

 Sensitivity analysis13

0.45 0.4

0.45 0.4

0.35

0.35

0.3

0.3

0.25

3

3.5 4 4.5 Aeration flowrate [vvh]

5

0.25 50

100

150 200 Loading time [min]

250

Fig. 8. Results from the sensitivity analysis for 1000 scenarios under different operating conditions and reactor volumes for a single reactor system showing effect of several variables on the energy requirement: (a) aeration flowrate, (b) loading time, (c) percent of volume replaced, and (d) reactor volume.

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Results  Sensitivity analysis13 (a)

(b)

Fig. 9. Results from the sensitivity analysis for 1000 scenarios under different operating conditions and reactor volumes for a single reactor system displaying (a) the volumetric energy requirement as a function of plant capacity, and (b) the stabilization time vs. pasteurization time.

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Results  Preliminary optimization results – Case study I Table 2. Design and operating parameters of . case study 1 (Killarney, Ireland). Parameter

Value

No. of reactors in series (-)

2

Reactor volume (m3)

100

Energy requirement (kWh/kg VS)

1.3

Daily load (m3/day)

20-35

Batch time (hours)

24

Hydraulic retention time (days)

7-10

Specific power (W/m3)

100

Aeration flowrate (vvh)

3-4

Influent VS concentration (g/l)

40

Influent temperature (°C)

10-17

Temperature in first reactor (°C)

40-50

Temperature in second reactor (°C)

50-65

Fig. 10. Optimal trajectories of state variables for case study 1 for nb-value of seven: (a) oxygen concentration, (b ) readily biodegradable substrate concentration, (c) thermophilic biomass concentration, and (d) temperature.

→ f* = 0.86 kWh/kg (33% improvement) Energy Efficiency Optimisation of Wastewater Treatment: Study of ATAD

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Results  Preliminary optimization results – Case study II Table 3. Design and operating parameters of case study 2 (Navarra, Spain). Parameter

Value

No. of reactors in series (-)

1

Reactor volume (m3)

300

Energy requirement (kWh/kg VS)

2

Daily load (m3/day)

25-60

Batch time (hours)

24

Hydraulic retention time (days)

5-12

Specific power (W/m3)

120

Aeration flowrate (vvh)

0.8-1.4

Influent VS concentration (g/l)

30-37

Influent temperature (°C)

10-17

Reactor temperature (°C)

45-65

Fig. 11. Optimal trajectories of state variables for case study 2: (a) reactor temperature, (b) biomass concentration, (c) substrate concentration, and (d) oxygen concentration.

→ f* = 1.2 kWh/kg (40% improvement) Energy Efficiency Optimisation of Wastewater Treatment: Study of ATAD

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Conclusion  Two ATAD models13,14 • Simulation studies • Verification  Sensitivity analysis: identification of significant variables13 (reactor volume, aeration and sludge flowrate, and reaction time) • Reaction limited by stabilization • Substantial scope for improvement in terms of energy requirement and plant capacity by altering operating conditions  General formulation and implementation of energy efficiency optimisation of ATAD systems • Case study I: 33% improvement • Case study II: 40% improvement

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Future Work  Implementation of optimisation problem using global optimisation techniques15,16  Formulation and implementation of a general scheduling and structural optimisation problem of ATAD systems17

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References [1] USEPA (1990) ‘Environmental regulations and technology: Autothermal thermophilic aerobic digestion of municipal wastewater sludge’. Technical report, United States Environmental Protection Agency, Office of Research and Development, Washington, D.C. [2] Layden, N. M., Kelly, H. G., Mavinic, D. S., Moles, R. and Barlet, J. (2007b) 'Autothermal thermophilic aerobic digestion (ATAD) -- Part II: Review of research and full-scale operating experiences'. Journal of Environmental Engineering and Science, 6(6), 679-690. [3] Scisson, J. P. (2003) 'ATAD, The Next Generation: Design, Construction, Start-up and Operation of the First Municipal 2nd Generation ATAD', Joint Residuals and Biosolids Managament Conference and Exhibition 2003. [4] LaPara, T. M. and Alleman, J. E. (1999) 'Thermophilic aerobic biological wastewater treatment'. Water Research, 33(4), 895-908. [5] Ponti, C., Sonnleitner, B. and Fiechter, A. (1995a) 'Aerobic thermophilic treatment of sewage sludge at pilot plant scale. 1. Operating conditions'. Journal of Biotechnology, 38(2), 173-182. [6] Ponti, C., Sonnleitner, B. and Fiechter, A. (1995b) 'Aerobic thermophilic treatment of sewage sludge at pilot plant scale. 2. Technical solutions and process design'. Journal of Biotechnology, 38(2), 183-192. [7] Csikor, Z., Mihaltz, P., Hanifa, A., Kovacs, R. and Dahab, M. F. (2002) 'Identification of Factors Contributing to Degradation in Autothermal Thermophilic Sludge Digestion'. Water Science and Technology, 46(10), 131-8. [8] Layden, N. M., Kelly, H. G., Mavinic, D. S., Moles, R. and Barlet, J. (2007a) 'Autothermal thermophilic aerobic digestion (ATAD) -- Part I: Review of origins, design, and process operation'. Journal of Environmental Engineering and Science, 6(6), 665-678. [9] Pontryagin, L. S. (1964) ‘Mathematische Theorie Optimaler Prozesse’, Oldenbourg Verlag, Wien. [10] J.R. Banga, E. Balsa-Canto, C.G. Moles (2003), Dynamic optimization of bioreactors – a review, Proc. Ind. Natl. Sci. Acad. 69A, pp. 257-265. [11] D. Bonvin, S. Palanki and, B. Srinivasan (2003) Dynamic Optimization of Batch Processes: I. Characterization of the nominal solution, Computers and Chemical Engineering, vol. 27, pp. 1–26. [12] Toledo R T. (1991) ‘Fundamentals of Food Process Engineering’, 2nd ed. Chapman and Hall: New York. [13] Rojas, J., Zhelev, T., & Bojarski, A. D. (2010a) 'Modelling and Sensitivity Analysis of ATAD', Computers and Chemical Engineering, vol. 34, issue 5, pp. 802-811. doi:10.1016/j.compchemeng.2009.11.019 [14] Rojas, J., Burke, M., Chapwanya, M., Doherty, K., Hewitt, I., Korobeinikov, A., McCarthy, S ., Meere, M., Tuoi, V., O’Brien, M., Winstanley, H., Zhelev. T. (2010b) 'Modeling of autothermal thermophilic aerobic digestion' Mathematics-in-Industry Case Studies (MICS) Journal. vol. 2, pp. 34-63. [15] Rojas, J., Zhelev, T., Graells, M. ‘Energy efficiency optimization of wastewater treatment: study of ATAD’ Accepted for the 20th European Symposium of Computer Aided Process Engineering [16] Rojas, J. and Zhelev, T. ‘Taylor-made energy efficiency optimization of an ATAD plant’ Accepted for the 23rd International Conference on Efficiency, Cost, Optimization, Simulation and Environmental Impact of Energy Systems. [17] Capon-Garcia, E., Rojas, L., Zhelev, T., Graells, M., ‘Operation Scheduling of Batch Autothermal Thermophilic Aerobic Digestion Processes’ Accepted for the 20th European Symposium of Computer Aided Process Engineering [18] Gomez, J., de Gracia, M., Ayesa, E. and Garcia-Heras, J. L. (2007) 'Mathematical modelling of autothermal thermophilic aerobic digesters'. Water Research, 41(5), 959-968. [19] Kambhu, K. and Andrews, J. F. (1969) 'Aerobic Thermophilic Process for the Biological Treatment of Wastes - Simulation Studies'. Journal - Water Pollution Control Federation, 41(127-143. [20] Kovacs, R. and Mihaltz, P. (2005) 'Untersuchungen der Kinetik der aerob-thermophilen Klaerschlammstabilisierung - Einfluss der Temperatur', 17. Fruehlingsakademie und Expertentagung, Balatonfuered, Germany, May 2005.

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