Multi-zone bioreactor with packing media for sludge reduction
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Solution Overview
Problem
Biological wastewater treatment processes generate excess sludge, leading to increased operational and disposal costs, and environmental pollution, while existing technologies fail to effectively reduce sludge production and odor while maintaining high treatment efficiency.
Innovation Solution
A multi-zone bioreactor process with Super Aerators and unique packing media that enhances attached microbial growth, allowing for efficient aeration and turbulence to reduce sludge production, odor, and increase nitrogen removal, capable of being used standalone or in combination with other processes to enhance treatment capacity and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If biological treatment is used to remove organic pollutants from wastewater, then treatment effectiveness is improved, but excess sludge production increases
Solution Approach 1:
The bioreactor is divided into multiple zones (aerobic zone with packing media for attached growth, anoxic zone for denitrification, and anaerobic zone for phosphorus release) to simultaneously achieve pollutant removal and sludge reduction through different biological processes in each zone
Solution Approach 2:
The system changes environmental parameters (oxygen concentration, nitrate levels) across different zones to control microbial metabolism, creating conditions that maximize pollutant removal while minimizing excess sludge production through endogenous respiration
2Use of energy by moving object
If conventional aeration systems are used, then oxygen supply is provided, but energy consumption increases and mixing efficiency decreases
Solution Approach 1:
The system transitions from conventional bulk aeration to surface aeration using packing media, creating a two-dimensional air-water interface that dramatically increases oxygen transfer efficiency while reducing the energy required for mixing and aeration
3Loss of substance
If sludge production is reduced through biological processes, then operational costs decrease, but treatment capacity may be compromised
Solution Approach 1:
Packing media serves as an intermediary substrate that supports attached microbial growth, providing a large surface area for biomass attachment while maintaining low suspended solids in the effluent, thus achieving both sludge reduction and high treatment capacity
Solution Approach 2:
The packing media uses porous structures to provide extensive surface area for microbial attachment, enabling high biomass concentration on the media surface while keeping the bulk liquid clear, thereby maintaining treatment capacity without increasing sludge production
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process effectively reduces or eliminates excess biological sludge and odor, while improving nitrogen removal and treatment capacity, offering a cost-effective solution for wastewater treatment plants by promoting high-energy production and microbial growth on large surface areas.
Implementation Method 1
The upper zone of the treatment system operates under alternatively aerobic and anoxic conditions controlled by the on-off operation of an air blower that introduces air through air diffusers placed at the bottom of the upper zone
Implementation Method 2
Within the volume of upper aerobic zone and lower oxygen-depleted zones, loose carrier material or stationary objects are disposed to support the attachment of microbial biomass and the formation of microbial biofilm
Implementation Method 3
If Nitrate is present then the first zone at the bottom will be anoxic where Nitrate is getting utilized by microorganisms along with carbon sources thus N2 gas is generated
Implementation Method 4
After all Nitrates are consumed, due to lack of Oxygen anaerobic zone is formed
Implementation Method 5
The aerobic section of this process can use Super Aerators as aeration units that cover with high efficiency a large area of the bioreactor
Data Source
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AI summary
A wastewater treatment method and process returns the whole excess sludge mixes it with the influent wastewater. The mixed flow is introduced in distributed in the bottom of a treatment tank. High turbulence aeration is done in the middle or upper parts of the treatment tank. Anoxic, anaerobic, facultative and aerobic zones are formed while the mixed flow is travelling from bottom of the treatment tank to the top. Due to futile cycle around the aeration and facultative zone right beneath the aeration the excess biological sludge production is eliminated. This process also can remove odor and can denitrify nitrate. There is a new type of packing media with high specific surface area without clogging that has been introduced and described in this invention. The present invention can be used for different application including domestic or industrial wastewater treatment, large or small. The described packing media can be used in different wastewater treatment plants or in aquaculture and cooling, contact or stripping towers.