ISSN 0104-6632 Printed in Brazil

www.abeq.org.br/bjche

Vol. 33, No. 04, pp. 733 - 741, October - December, 2016 dx.doi.org/10.1590/0104-6632.20160334s20150288

*To whom correspondence should be addressed This is an extended version of the work presented at the XI Latin American Symposium on Anaerobic Digestion (DAAL-2014), Havana, Cuba.

Brazilian Journal of Chemical Engineering

EVALUATION OF AN INNOVATIVE ANAEROBIC BIOREACTOR WITH FIXED-STRUCTURED BED

(ABFSB) FOR BREWERY WASTEWATER TREATMENT

M. M. de Araujo Junior*, B. O. Gaudencio, D. N. Ayabe and M. Zaiat

Biological Processes Laboratory, Center for Research, Development and Innovation in

Environmental Engineering, São Carlos School of Engineering (EESC), University of São Paulo (USP), Engenharia Ambiental, Bloco 4-F, Av. João Dagnone, 1100, Santa Angelina,

13563-120, São Carlos - SP, Brazil. Phone: + 55 16 3416 7110 E-mail: moacir@sc.usp.br

(Submitted: May 5, 2015 ; Revised: October 14, 2015 ; Accepted: November 11, 2015)

Abstract - The aim of this study was to evaluate the application of the anaerobic bioreactor with fixed-structured bed (ABFSB) for brewery wastewater treatment with high volumetric organic loading rate (VOLR) and its comparison with a traditional packed-fixed bed bioreactor. Two different biomass support materials were tested, including polyurethane (PU) and polypropylene (PP) for both configurations. The best global efficiency was reached by the structured-fixed bed reactor with polyurethane as biomass support (SB PU). For a VOLR of 14.0 kg CODt m-3 d-1 (HRT of 8 h) and 20.3 kg CODt m-3 d-1(HRT of 12 h), the SB PU reached the average CODt removal efficiencies (ECOD) of 81% and 71%, respectively. The results show that ABFSB is a promising technology for high organic matter and solids concentration wastewater treatment, but the type of the biomass support had a big impact on the reactors performance. Keywords: Brewery wastewater; Fixed-bed reactor; Packed bed; Structured bed; Anaerobic reactor.

INTRODUCTION

Due to its high popularity, beer has an important place in the worldwide economy, being the fifth drink most consumed in the world after tea, soft drinks, milk and coffee (Fillaudeau et al., 2006). As a result of the large production, the brewery industry de-mands high volumes of water and generates large amounts of wastewater. According to Santos (2015), from 4 to 10 L of water are consumed and from 3 to 6 L of wastewater are generated to produce 1 L of beer. In addition, the brewery wastewater has high concentrations of organic matter and suspended

solids; therefore, it has a high potential for environ-mental pollution (Simate et al., 2011).

Much research was carried out to evaluate an-aerobic reactor performance for brewery wastewater treatment (Alvarado-Lassman et al., 2008; Öktem & Tüfekçi, 2006; Parawira et al., 2005; Xiangwen et al., 2008). The results showed that brewery waste-water can be treated efficiently by anaerobic pro-cesses and has a high potential for biogas production. Suspended (or granular) anaerobic biomass processes, mainly up-flow anaerobic sludge blanked reactors (UASB), have been the most used technologies to treat brewery wastewater. In spite of its simple con-

734 M. M. de Araujo Junior, B. O. Gaudencio, D. N. Ayabe and M. Zaiat

Brazilian Journal of Chemical Engineering

figuration and satisfactory efficiency, UASB reactors demand high hydraulic retention times (over 24 h) and low up-flow velocities (up to 0.7 m h-1). As a result, the reactors become big and need large area to be constructed.

On the other hand, satisfactory removal efficien-cies of organic matter, employing high volumetric organic loading rates (VOLR) and low HRT, can be achieved in fixed bed reactors. Generally, high con-centration of biomass and long cellular retention time are reached by fixed bed reactors (Zaiat et al., 1997). However, the traditional configurations of packed bed reactors are not recommended for waste-water with medium to high solid contents, since hy-drodynamic problems, such as channelling and dead zones, can lead to low efficiencies and even to col-lapse by clogging of the reactor. To overcome this problem, Camiloti et al. (2014) proposed an innova-tive configuration of an anaerobic bioreactor with fixed-structured bed (ABFSB) in which the bed is not randomly packed, thus avoiding accumulation of solids in the interstices and preventing hydrodynamic anomalies.

The ABFSB aggregates advantages of both the up-flow anaerobic sludge blanket and fixed-bed reac-tors, such as easy solids separation and sedimenta-tion, high concentration of biomass and high sludge retention time. Nevertheless, the type of support ma-terial used for biofilm reactors influences their bio-mass adhesion and their hydrodynamics, thus affect-ing overall system performance. Many types of sup-port material for fixed bed reactors have been studied in the last decade, including polyurethane foam, plastic rings (polypropylene, polyethylene and PET), plastic plates and ceramic matrix.

Polyurethane (PU) foam as a biomass support has been shown to perform well in anaerobic biofilm reactors (Araujo Junior and Zaiat, 2009; Camiloti et al., 2014). PU foam makes an excellent attached-growth material because of its high surficial area for biomass adhesion and its macroporous structure, promoting a gradient of substrate concentration and electron donors, contributing to establish several anaerobic microorganisms. On the other hand, poly-propylene (PP) rings have been used the most as biomass support in biofilm reactors because of their low price and good mechanical resistance.

In this context, this work considers the applica-tion of an anaerobic bioreactor with fixed-structured bed for brewery wastewater treatment with high VOLR and its comparison with a traditional packed bed bioreactor. Two different biomass support ma-

terials were tested, including polyurethane (PU) and polypropylene (PP) for both configurations.

MATERIAL AND METHODS

Four up-flow fixed bed anaerobic reactors were studied in parallel for brewery wastewater treat-ment. The experimental setup is shown in Figure 1 and the description of each reactor is presented in the following:

PB PU: fixed-packed bed reactor with Biobob® (cylindrical polyurethane foam surrounded by an external frame of polypropylene with diameter of 15 mm and length of 10 mm), made in Brazil by Bio Proj Tecnologia Ambiental Ltda. The characteristics of the polyurethane foam were 95% of void ratio and 28 kg/m³ of density;

PB PP: fixed-packed bed reactor with polypro-pylene rings (diameter of 17 mm, length of 12 mm and surface area of 2621 mm2);

SB PU: fixed-structured bed reactor with lon-gitudinal polyurethane foam strips (7 squared strips 16 mm on a side and 265 mm of length); The charac-teristics of the polyurethane foam were 95% of void ratio and 28 kg/m³ of density;

SB PP: fixed-structured bed reactor with lon-gitudinal bar constructed of polypropylene rings (7 bars 17 mm in diameter, 265 mm in length and sur-face area of 57880 mm2).

The reactors were operated during 181 days at 35 ± 1 °C. They were fed with raw brewery waste-water with increased influent flow rate, with a nomi-nal hydraulic retention time (HRT, estimated from the total reactor liquid volume) of 32 h, 24 h, 18 h, 12 h and 8 h, and flow rates of 0.07 L h-1, 0.11 L h-1, 0.15 L h-1, 0.22 L h-1 and 0.33 L h-1, respectively. Due to variation of the wastewater concentration, the volumetric organic loading rate (VOLR) did not follow the linear flow rate tendency increase and the average values were between 2.0 and 28.6 kg COD m-3 d-1.

Before reactor start-up, the biomass supports were inoculated with a full scale UASB sludge treat-ing poultry slaughterhouse wastewater operated at 25 °C and pH 7, with volumetric organic loading rate of 2.0 kg COD m3 d-1. For packed-fixed bed reactors, the biomass supports were submerged in a tank with UASB sludge for 24 h. After this time, the supports were introduced inside the reactors and the volume was filled with tap water and then the operation started up.

othwti

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To inoculaf the UASB he reactors

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Weekly, thry industry

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Samples octor were tak

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Japan) gas c

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Journal of Chem

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Following astewater COtention timesg rates (VOLe operationale influent ane experimentthe main res

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SULTS AND

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HRT (h) VOLR (kg COD m-3 dCODt (mg L-1

WastewaPB PUPB PP SB PUSB PP

CODf (mg L-1

WastewaPB PUPB PP SB PUSB PP

TSS (mg L-1) Wastewa

PB PUPB PP SB PUSB PP

VSS (mg L-1) Wastewa

PB PUPB PP SB PUSB PP

pH Wastewa

PB PUPB PP SB PUSB PP

PB PU: fixed-with longitudin

Tab

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M. M. d

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24

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258±119 2

164±31 141±17 139±18 294±74

1650±86

114±29 84±11 87±18

225±66 - - - - - - - - - -

7.2±0.2 7.5±0.1 7.4±0.1 7.4±0.1 7.3±0.2

or with Biobob®;foam strips; SB P

de Araujo Junior,

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245±38 204±21 5187±28 188±64

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; PB PP: fixed-paP: fixed-structure

B. O. Gaudencio

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main results

18

13.8

10384±355

3707±788 5973±1574

2709±698 4699±819

8562±410 3230±619

5343±1326 2202±646 4234±756

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224±22 605±291

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495±166 465±153

204±23 566±267

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mental time.

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2945±120 1481±437 1053±405

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: fixed-structured olypropylene ring

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Journal of Chem

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the experime

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6 18 20

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HRT = 12

for Brewery Was

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of 13.8 kg CODt m-3 d-1(Hre reached b

m as biomased bed reactot than the ph ECOD of 74r each appliof the poly

mass concentd the dead zntributing to

ental time.

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22 24 26

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(ECOD) for

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28 30

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HRTVOL

(kg COD PB PPB PSB PSB P

PB PU: fixed-with longitudin

having a sth a HRT ofefficiency of8 h (13.8 kgfact can be rty in the reaases the mam and substrtion rate (Sadrodynamic ypothesis. FPB PP had

ECOD of 81 ±

and carbon domposition

steps. The hns were not

temporal biane average rational steprespectively.

Table 2: M

T (h) LR m-3 d-1) PU PP PU PP -packed bed reactonal polyurethane f

M. M. d

imilar applif 8 h (14 kgf CODt remog CODt m-3 related to theactor bed foass transfer rate and incrarti et al., 20

test was noor this condbetter perfo

± 5% and 82

dioxide were for all reac

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Figure 5:

Methane co

24

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de Araujo Junior,

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predominantctors during d nitrogen or zero in

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Biogas prod

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; PB PP: fixed-paP: fixed-structure

B. O. Gaudencio

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With the inease in the C

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with polypropyleh longitudinal bar

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erational periween 70% avalue (250 gtabilization actors. the wastewa

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CODt m-3 d-1

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time.

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8

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: fixed-structured olypropylene ring

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luation of an Inno

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R up to 20.3 were alkaline

9 and 28.6 kaded and thegeneration. robic biorea) provides atewater withand solids,

both up-flowf dead zonegh sludge retof biomass s

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Journal of Chem

Figure 6: M

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because it w anaerobic es and bed tention time)support had

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a big impact

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stewater Treatmen

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al time.

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Reactor Configuratio

IFBRa UASB UASB ASBR PB PU PB PP SB PU SB PP

aIFBR: inversebBatch cycle tiPB PU: fixed-with longitudin

The anaeroABFSB) is a

matter and sment. This reime with a fing because ults show thaig impact onad the best ested reactoracked-fixed

For a VOLnd 20.3 kg Ceached the aively. For a Vctors were ov

Table 3

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(kgCOD m10

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e fluidized bed reime: feeding (1 h-packed bed reactonal polyurethane f

CONCL

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of its bed gat the type on the reactort global effirs, but the bed reactors

LR of 14.0 kgCODt m-3 d-1

average ECODVOLR over 2verloaded an

M. M. d

Figure

3: Results o

LR m-3d-1) 0 7 5 5 20.3 20.3 20.3 20.3 eactor h), reacting (6.35 hor with Biobob®;foam strips; SB P

LUSIONS

tor with fixedtechnology fentration wa

motes high slm and low risgeometry. Hf the biomasr performanciciency comSB PP was

s. g CODt m-3 d1 (HRT of 12D of 81% an22.9 kg CODnd the effluen

de Araujo Junior,

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e 8: pH varia

f previous s

HRT (h)

5 84 24 8b

8 / 12 8 / 12 8 / 12 8 / 12

h), settling (0.5 h; PB PP: fixed-paP: fixed-structure

d-structured bfor high orgaastewater treludge retentsk of bed clowever, the

ss support hace. The SB

mpared with similar to

d-1 (HRT of 82 h), the SB nd 71%, respDt m-3 d-1, the nt was acidif

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ECOD (%)

90 95 57 90

79 / 63 82 / 49 81 / 70 75 / 60

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A

The authorsom FAPESP tado de São 2010/20025-

dorno, M. A.A., Developquantify vospace (auto

nd M. Zaiat

rimental tim

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CKNOWLE

s are gratefu(Fundação Paulo, proce-0 2012/1027

REFERE

T., Hirasawapment and valatile acids (C

omatic and m

me.

atment.

Referen

Alvarado-LassmÖktem and Tüfek

arawira et al (2Xiangwen et al (

Current sCurrent sCurrent sCurrent s

: fixed-structured olypropylene ring

centration of ty was sever

EDGMENT

ul for the finde Amparo

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Evaluation of an Innovative Anaerobic Bioreactor with Fixed-Structured Bed (ABFSB) for Brewery Wastewater Treatment 741

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