Project Number: EVE-DDB-1415 THE ACTIVITY OF IMMOBILIZED ANAEROBIC BACTERIA IN THE TREATMENT OF INDUSTRIAL WASTEWATER A Major Qualifying Project Proposal submitted to the Faculty of Worcester Polytechnic Institute in partial fulfillment of the requirements for the Degree of Bachelor of Science By _________________________ Martha Gray Date: December 20, 2008 Approved: _________________________________________ Professor D. DiBiasio, Major Advisor 1. anaerobic bacteria 2. immobilization 3. wastewater treatment i ABSTRACT The objectives of this project were to determine the start-up time and optimal running conditions for an upflow anaerobic sludge bed reactor using imbedded bacteria, and to upgrade a current wastewater treatment system used in the fiber industry. Using information collected from activity tests and daily data from the reactor, conclusions were drawn about the use of imbedded bacteria and process design. From the results an efficient treatment design was developed and the optimal operating conditions were found. ii ABSTRACT Anaerobic treatment has been considered one of the most effective and economical methods in treating industrial wastewater, especially high strength industrial wastewater. However, the major drawback of anaerobic treatment is its extremely long start-up period due to the low growth rate of the anaerobic bacteria. The start up period generally requires 3 to 8 months. This project looked to reduce the start-up time by embedding bacteria in cubes of a dense polymer. The objectives of this project were to: Determine the start-up time and optimal running conditions for a UASB reactor using raw wastewater from the fiber industry Assess the activity of the imbedded bacteria over the running period and height of the reactor Establish the effect of the glucose on the degradation of the PTA wastewater components Utilize the information collected to develop an effective design to upgrade a current PTA wastewater treatment system To obtain these objectives an upflow anaerobic sludge bed reactor was run over a 137 day period. Data was recorded daily from the reactor and tests were conducted to determine the daily chemical oxygen demand and volatile fatty acids concentration. Samples were taken over the running period and height of the reactor to be used in activity measurements. The samples were first analyzed using a glucose analysis to measure the activity of the fermentative bacteria. A glucose substrate was added to the samples and the change in glucose was measured over time. The resin glucose was calculated by measuring the absorption and compared to a standard to determine the activity of the bacteria. After the glucose analysis the activity of the methanogens was measured using acetic acid. An acetic acid substrate was added to the samples. Samples were taken when biogas was produced. The concentration of acetic acid was measured using gas chromatography. Gas chromatography-mass spectroscopy was used to determine the major components in the influent and the effluent. The chromatographic peaks were identified by comparison with two reference mass spectral libraries utilized through the program Turbomass version 4.1.1. From the data it was found that the startup of the anaerobic reactor using the imbedded bacteria took 62 days. At this time the PTA wastewater was no longer diluted. The proper hydraulic retention time was 3-4 days and the organic loading rate was 2 kg COD/m3∙d. The hydraulic retention time did not vary greatly over the running period. These conditions allowed the COD removal rate of to reach 70-80% consistently. The increase of the fermentative bacteria during the startup phase coincided with the increase in the efficiency of the reactor. For this information, it can be inferred that the fermentative bacteria were the rate limiting step in the anaerobic metabolism. The activity of the methanogens decreased after the startup period. Methanogenic bacteria are more sensitive to changes in their environment than the fermentative bacteria. Crystals were found at the base of the reactor and were believed to have been formed by the buildup of inorganic materials. These inorganics had a negative affect on the sensitive methanogenic bacteria in the reactor. There was an increase in activity with the height of the reactor for both types of bacteria. This similarity shows that there was a balance between the fermentative bacteria and the methanogens that was iii consistent throughout the reactor. The most active bacteria were at the top of the reactor, while the least active were near the entrance of the influent. The addition of glucose to the influent allowed for greater degradation of more complex molecules. Glucose was only added to the reactor when necessary. It added an additional cost to the treatment, but the benefits of the glucose were easily recognizable by comparing the two effluents. A new treatment system was designed, in which the two anaerobic filters were replaced by five upflow anaerobic sludge bed reactors (UASB) that contained no media for the bacteria to grow on. The new design reduced costs by not employing the expensive media. The UASB system eliminated the need for settling tanks and allowed the reactors to be maintained more effectively. Overall, the activity of the bacteria was not hindered by the immobilization technique. The use of the imbedded bacteria increased the start-up time of the bacteria and led to greater stability of the reactor, as seen through the high organic loading rates. The addition of glucose led to greater degradation of the refractory materials and inorganics in the wastewater. The enhanced design of the wastewater treatment increased safety and longevity of the system, while reducing the cost. iv ACKNOWLEDGEMENTS I would like to thank the following people and institutions: Shanghai Jiao Tong University Professor Weili Zhou, STJU Advisor Wu Bingtao Guo Tingting Wu Xiaoyi Cheng Xuehang Worcester Polytechnic Institute Professor David DiBiasio, Primary Advisor Professor Susan Zhou, Secondary Advisor Without your help I would not have been able to come to China and have this wonderful, unique, and successful MQP experience! v CAPSTONE DESIGN STATEMENT As a Major Qualifying Project, this report fulfills the Capstone Design experience. The Capstone Design requires that the project address issues related to the real world implementation of the chosen design. The aspects of design that must be addressed to fulfill the capstone requirement include: Economic Sustainability Manufacturability Health and Safety Ethical Social Political Despite the fact that some of these issues are not wholly relevant in the context of this project, it is my goal to address these issues as directly as possible throughout the course of this report. While prices of labor and materials vary greatly between China and other countries, one of the overall goals of the treatment plant design was to reduce costs. This was done by using local materials that are manufactured in China, as well as local labor. The cost of supplies and labor vary throughout China and these numbers are not readily available to foreigners. This made it difficult to find actual numbers on the cost of construction. The modeling software CAPCOST was used in conjunction with technical data to find the construction costs of both plants in U.S. dollars. By comparing the new design and the current system, it was clear which system would be more cost effective. By reducing the dependence on overseas companies, the manufacturability and sustainability of the reactors was increased. Using a simple reactor design requires less training for employees and creates a sustainable product that can be maintained by the treatment plant. The reactors were designed so that maintenance could be performed at regular intervals, to ensure the longevity of the treatment system. The health and safety issues are closely related to the political, social and ethical aspects of water treatment. When companies produce chemicals such as purified terephthalic acid, vi governmental standards must be followed for the treatment of the wastewater. This ensures the health of the environment and society. The safety of the treatment process was increased by reducing the dependence on each individual reactor. Instead of using two large reactors, five reactors will be used. This allows for a reduced environmental impact if a reactor needs to be drained in an emergency. High strength industrial wastewater poses major health and environmental problems if not treated properly. The use of these new reactors is aimed at increasing the treatment efficiency so that environmental standards set by the government can be met. This project addresses many of the major aspects required by the capstone design. The proposed design wholly reflects the considerations that were made in regards to safety, costs, sustainability, and manufacturability. The project and design also touch on other aspects such as ethical and social issues associated with the wastewater treatment. This project fulfills the capstone design experience. vii TABLE OF CONTENTS Abstract ........................................................................................................................................................................ ii Abstract ....................................................................................................................................................................... iii Acknowledgements .................................................................................................................................................. v Capstone Design Statement ................................................................................................................................ vi List of Figures ............................................................................................................................................................. x List of Tables ............................................................................................................................................................. xi List of Acronyms .................................................................................................................................................... xii Executive Summary ............................................................................................................................................. xiii Background ........................................................................................................................................................ xiii Methods ............................................................................................................................................................... xiii Results .................................................................................................................................................................. xiv Conclusions.......................................................................................................................................................... xv 1 Introduction ........................................................................................................................................................... 1 2 Background ............................................................................................................................................................ 3 2.1 Anaerobic vs. Aerobic Treatment ......................................................................................................... 3 2.2 Parameters related to Running Conditions ...................................................................................... 4 2.3 Anaerobic Bacteria ...................................................................................................................................... 5 2.4 Anaerobic Treatment ................................................................................................................................. 7 2.4.1 Suspended Growth Systems ........................................................................................................... 7 2.4.2 Fixed Film Systems ............................................................................................................................. 9 2.5 Purified Terephthalic Acid (PTA) ....................................................................................................... 10 2.5.1 Production ........................................................................................................................................... 10 2.5.2 Current Treatment Systems ......................................................................................................... 12 2.6 Background Conclusions ........................................................................................................................ 15 3 Methodology ........................................................................................................................................................ 17 viii 3.1 Running Performance of UASB Reactor ........................................................................................... 17 3.1.1 Measurement of Volatile Fatty Acids (VFA) ........................................................................... 20 3.1.2 Measurement of Chemical Oxygen Demand (COD) ............................................................ 21 3.2 Activity of Immobilized Bacteria ......................................................................................................... 22 3.2.1 Preparing Samples with Glucose Substrate ........................................................................... 22 3.2.2 Conducting Glucose Analysis ........................................................................................................ 25 3.2.3 Preparing Samples with Acetic Acid Substrate ..................................................................... 25 3.2.4 Conducting Acetic Acid Analysis ................................................................................................. 26 3.3 Major Wastewater Constituents .......................................................................................................... 27 3.4 Design of Wastewater Treatment System ....................................................................................... 27 4 Results .................................................................................................................................................................... 29 4.1 Running Performance of UASB Reactor ........................................................................................... 29 4.1.1 Analysis of PTA Wastewater ........................................................................................................ 29 4.1.2 Running Conditions .......................................................................................................................... 30 4.1.3 Volatile Fatty Acids ........................................................................................................................... 32 4.1.3 Chemical Oxygen Demand ............................................................................................................. 33 4.2 Activity of Immobilized Bacteria ......................................................................................................... 35 4.3 Major Wastewater Constituents .......................................................................................................... 41 4.4 Design of Wastewater Treatment System ....................................................................................... 43 5 Conclusions ........................................................................................................................................................... 48 5.1 Running Performance of Reactor ........................................................................................................ 48 5.2 Activity of Bacteria .................................................................................................................................... 48 5.3 Major Wastewater Constituents .......................................................................................................... 49 5.4 Wastewater Treatment System ........................................................................................................... 49 Bibliography............................................................................................................................................................. 51 Appendix A: Equations ........................................................................................................................................ 53 Appendix B: Data From Reactor Run ............................................................................................................. 54 ix LIST OF FIGURES Figure 1: Steps of Anaerobic Metabolism ...................................................................................................................... 6 Figure 2: The Upward-Flow Anaerobic Sludge bed (UASB) Reactor Concept ................................................................ 8 Figure 3: The Expanded Granular Sludge Bed (EGSB) Reactor Concept ......................................................................... 9 Figure 4: Oxidation of P-Xylene in the Production of PTA ............................................................................................ 10 Figure 5: Terephthalic Acid Production by Catalytic, Liquid-Phase Air Oxidation of P-Xylene ..................................... 11 Figure 6: Impurities (top) and Purification (below) of CTA to Form the Desired PTA ................................................... 11 Figure 7: Current Design of PTA Wastewater Treatment Plant at Yangzi Petrochemical Company in Nanjing, China ..................................................................................................................................................................................... 12 Figure 8: Equalization Tank at Yangzi Petrochemical Company Wastewater Plant in Nanjing, China ........................ 13 Figure 9: Anaerobic Filter at Yangzi Petrochemical Company Wastewater Plant in Nanjing, China ........................... 13 Figure 10: Primary Settling Tank at Yangzi Petrochemical Company Wastewater Plant in Nanjing, China ................ 14 Figure 11: Primary Aeration Tank at Yangzi Petrochemical Company Wastewater Plant in Nanjing, China .............. 14 Figure 12: Media Used in Anaerobic Filters at Yangzi Petrochemical Company Wastewater Plant in Nanjing, China15 Figure 13: Reactor Setup.............................................................................................................................................. 18 Figure 14: Location of Ports along Reactor .................................................................................................................. 19 Figure 15: Setup of VFA Concentration Procedure ....................................................................................................... 20 Figure 16: SHZ-88 Reciprocating Waterbath Constant Temperature Shaker .............................................................. 24 Figure 17: Influent and Effluent pH .............................................................................................................................. 31 Figure 18: Volatile Fatty Acids in Effluent .................................................................................................................... 33 Figure 19: Influent and Effluent COD ........................................................................................................................... 34 Figure 20: Percentage of COD removed ....................................................................................................................... 35 Figure 21: Activity of Fermentative Bacteria ............................................................................................................... 36 Figure 22: Activity of the Methanogens....................................................................................................................... 37 Figure 23: Activity of Bacteria over the Running Period .............................................................................................. 38 Figure 24: Activity of Fermentative Bacteria (Left) and Methanogens (Right) over the Height of the Reactor........... 39 Figure 25: Activity of Bacteria over Height of Reactor ................................................................................................. 40 Figure 26: Spectra of (from Top) PTA Raw Wastewater, Effluent with Glucose, and Effluent without Glucose .......... 41 Figure 27: Chemical Structure of Major Constituents .................................................................................................. 42 Figure 28: Proposed Treatment System Design ........................................................................................................... 43 Figure 29: Design of UASB Reactor .............................................................................................................................. 47 Figure 30: Organic Loading Rate ................................................................................................................................. 54 Figure 31: Hydraulic Retention Time............................................................................................................................ 54 x