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Process Safety and Environmental Protection 1 0 0 ( 2 0 1 6 ) 131141

Contents lists available at ScienceDirect

Process Safety and Environmental Protection

journal homepage: www.elsevier.com/locate/psep

Effect of increasing organic loading rates on the


performance of moving-bed biolm reactors lled
with different support media: Assessing the
activity of suspended and attached biomass
fractions

J.P. Bassin , I.N. Dias, S.M.S. Cao, E. Senra, Y. Laranjeira, M. Dezotti


Federal University of Rio de Janeiro, COPPEChemical Engineering Program, PO Box 68502,
21941-972 Rio de Janeiro, Brazil

a r t i c l e i n f o a b s t r a c t

Article history: In this study, two moving-bed biolm reactors (MBBR1 and MBBR2 ) lled with different car-
Received 12 June 2015 rier media (Kaldnes K1 and Mutag Biochip, respectively) were subjected to increasing organic
Received in revised form 13 loading rates for 700 days. Regardless of the carrier used, both systems could withstand
November 2015 high organic loads up to 3.2 kgCOD/(m3 d), condition under which complete ammonium
Accepted 8 January 2016 removal was achieved. However, the type of media inuenced the quantity and distribution
Available online 14 January 2016 of attached biomass in the support, which in turn affected the activity of specic microbial
functional groups in the biolm. As the chemical oxygen demand (COD) input was grad-
Keywords: ually increased, the biolm got thicker and the surface detachment rates were enhanced.
COD removal Consequently, the amount of suspended solids has increased considerably to levels com-
Nitrication monly found in hybrid bioreactors. Activity batch tests have shown that the contribution
MBBR of the bulk phase biomass to the overall nitrication was very signicant, being more rel-
Carrier media evant as the biolm sloughing events became more intense. At constant organic loading
Organic loading rate rate, the hydraulic retention time (HRT) had a noticeable impact on the nitrication pro-
Specic nitrication rate cess, as it directly inuenced the fraction of ammonium oxidized either by the attached
or suspended biomass. Total nitrogen removal amounted up to 86 and 73% in MBBR1 and
MBBR2 , respectively.
2016 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.

1. Introduction allows for the construction of very compact reactors and pro-
vides an easier separation of the biosolids from the treated
In recent years, the stricter efuent quality requirements efuent. Moreover, in contrast to occulent sludge technolo-
posed by environmental regulations around the world have gies, the retention of biomass in attached growth processes
pushed the development of space- and cost-effective waste- is improved and can be controlled independently of the pre-
water treatment technologies with high performance. In this vailing hydraulic conditions (Lewandowski and Beyenal, 2014).
scenario, biolm processes have increasingly drawn the atten- This particular feature is especially benecial for the estab-
tion of environmental engineers and researchers (Henze et al., lishment and development of slow growing organisms which
2008). The use of attached instead of suspended biomass frequently suffer from washout as a result of hydraulic and


Corresponding author. Tel.: +55 21 25628347; fax: +55 21 25628300.
E-mail address: jbassin@peq.coppe.ufrj.br (J.P. Bassin).
http://dx.doi.org/10.1016/j.psep.2016.01.007
0957-5820/ 2016 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
132 Process Safety and Environmental Protection 1 0 0 ( 2 0 1 6 ) 131141

organic shock loadings (Hu et al., 2011) and/or insufcient organic matter input (Figueroa and Silverstein, 1992), evalu-
solids retention time (Head and Oleszkiewicz, 2005). ating the activity of nitriers in the bulk and biolm phases
The moving-bed biolm reactor (MBBR) is a growing biolm at different organic loading rates is important to understand
technology which has gained much attention in the waste- how nitrifying bacteria respond to load variations and predict
water treatment sector in the last 20 years (Barwal and nitrication performance under different COD/N ratios.
Chaudhary, 2014). It is based on the use of freely moving In the light of this background, this work attempts to eval-
plastic carrier elements with density a little lighter than that uate the impact of increasing organic loading rates on COD
of water in which microorganisms form biolms (degaard, and nitrogen conversions in two lab-scale MBBRs operated on
2006). Given the advantages shown by the MBBR process such a long-term basis (700 days). In order to observe the inuence
as compactness, exibility and high quality efuent produc- of the support media on the overall treatment performance as
tion, a rapidly growing market for this technology has been well as on the dynamics of suspended and adhered biomass
established worldwide. In this context, many different types throughout the experiment, each reactor was lled with a par-
of commercial media have been developed for specic applica- ticular type of biomass-supporting carrier differing in size,
tions (van Haandel and van der Lubbe, 2012) and this biolm structure and shape. The distribution of the biolm grown
process has been extensively used for the treatment of syn- in the different media was characterized by image analysis
thetic (Bassin et al., 2012a; Hoang et al., 2014), domestic (Bassin whereas the nitrifying activity of the different biomass frac-
et al., 2011; Caldern et al., 2012) and industrial wastewaters tions and their relative importance to the overall nitrication
(Bassin et al., 2011; Dvork et al., 2014). process were monitored at all experimental conditions.
Part of the applications of the MBBR technology is focused
on the treatment of high organic load waste streams, as inves- 2. Material and methods
tigated previously (Rusten et al., 1998; Melin et al., 2005; Aygun
et al., 2008; Javid et al., 2013). Under such conditions, the 2.1. Operational conditions of the MBBR systems
development of fast-growing heterotrophs which outcompete
nitrifying bacteria for oxygen and space in biolm systems The experiments were conducted in two lab-scale MBBR sys-
is favoured (Figueroa and Silverstein, 1992), whereas nitri- tems (MBBR1 and MBBR2 ) with a volume of 1 L, which were
cation functionality may be hindered. Thus, investigating run in a continuous mode for 700 days. Throughout this
how nitrication behaves in MBBR systems subjected to high study, the reactors were subjected to six different experimen-
COD input is important to predict their overall treatment per- tal conditions, presented in Table 1. The volumetric organic
formance. Furthermore, as the carrier material employed in loading rate was gradually increased from runs 14. Sub-
MBBR processes has been reported to inuence the attach- sequently (runs 46), both the inuent COD and the HRT
ment and distribution characteristics of the biolm (Chu et al., were proportionally decreased in order to keep the organic
2014), it is interesting to understand how the type of sup- loading rate constant. This procedure was conducted to eval-
port media will affect the activity of nitriers in situations uate the effect of the HRT on the dynamics of attached and
where overgrowth of heterotrophs takes place. Such informa- suspended biomass fractions and their corresponding nitri-
tion may potentially be used in the selection of suitable biolm fying activities. Both reactors were inoculated with 100 mL
carriers for MBBRs treating high loaded wastewaters. So far, of activated sludge from a municipal wastewater treatment
studies addressing the impact of the carrier material on the plant (CEDAEAlegria, Rio de Janeiro, Brazil) designed for
operation of MBBR have been restricted to low to medium COD removal and nitrication. To ensure controlled sub-
organic load applications (Chu and Wang, 2011a,b; Chu et al., strate concentrations, laboratory prepared wastewater was
2014). used as inuent for the MBBRs. Sodium acetate (NaAc) and
MBBR systems are often characterized by low suspended ammonium chloride (NH4 Cl) were used as organic carbon
solids content (Barwal and Chaudhary, 2014). Hence, their and nitrogen source, respectively. The inuent synthetic
design and operation is usually based on surface loading rates, medium (modied from Bassin et al., 2012b) was prepared
which are intrinsically dependent on the activity of the media- with demineralized water and had the following composi-
attached biomass (degaard et al., 2000). On the other hand, tion: 1028.4 g/L NaAc3H2 O (for inuent COD of 400 mg/L),
the suspended biomass activity is usually neglected. However, 382.14 mg/L NH4 Cl (for inuent ammonium of 100 mgN/L),
depending on the hydraulic and organic load conditions, the 55.5 mg/L KH2 PO4 (12 mgP/L), 53 mg/L MgSO4 , 222.5 mg/L NaCl,
amount of solids in the bulk phase arising from either biolm and 589.3 mg/L NaHCO3 . Depending on the experimental con-
detachment or growth in suspension can be signicant (Kwok dition, the medium composition was varied in order to obtain
et al., 1998). This exchange of biomass between the liquid and the desired inuent COD and ammonium-nitrogen concen-
solid media phases underlines the need of taking into consid- trations. Alkalinity (supplied as NaHCO3 ) and phosphorus
eration both the suspended and attached biomass fractions in source (provided as KH2 PO4 ) were also correspondingly dosed
the design and modelling of biolm systems (Boltz et al., 2009; according to the bacterial nutrition requirements in each
Masic and Eberl, 2014). Recently, Piculell et al. (2014) conducted experimental stage. A trace elements solution whose compo-
a comprehensive study addressing the removal of organic sition was described previously (Bassin et al., 2012a) was added
matter in MBBRs subjected to varying operational conditions. in a proportion of 0.5 mL/L of medium. The inuent wastewa-
This particular work provided insightful ndings regarding the ter was stored under refrigeration (4 C) at a pH of 7.58.0 until
heterotrophic activity of free-growing and attached biomass being fed to the reactors. To evaluate the effect of different
fractions and their contribution to the overall COD removal types of support media on the treatment process, MBBR1 was
under different hydraulic retention times (Piculell et al., 2014). lled with Kaldnes K1 carriers whereas MBBR2 was lled with
However, information on the nitrifying activity of suspended Mutag BiochipTM media (see Fig. S1, Supplementary material).
and attached biomass in MBBR systems subjected to increas- These two carriers present a specic surface area for biomass
ing organic loads is poorly addressed in literature. Given that adhesion of 500 and 3000 m2 /m3 , respectively. Further infor-
nitrication in biolm systems is highly inuenced by the mation about the characteristics of the support materials can
Process Safety and Environmental Protection 1 0 0 ( 2 0 1 6 ) 131141 133

Table 1 Operational conditions of the MBBR systems.


Run Inuent COD Inuent HRT Volumetric organic Surface organic Volumetric nitrogen Surface organic Time of
(mg/L) ammonium (h) loading rate loading rate loading rate loading rate operation
(mgN/L) (kgCOD/(m3 d)) (gCOD/(m2 d)) (kgNH4 + N/(m3 d)) (gNH4 + N/(m2 d)) (days)

1 400 100 12 0.8 3.2 0.2 0.8 112a


2 800 100 12 1.6 6.4 0.2 0.8 112
3 1200 100 12 2.4 9.6 0.2 0.8 142
4 1600 100 12 3.2 12.8 0.2 0.8 134
5 800 100 6 3.2 12.8 0.4 1.6 100
6 400 50 3 3.2 12.8 0.4 1.6 103

a
The rst experimental run comprised a start-up phase for biolm development, which lasted 20 and 30 days in MBBR1 and MBBR2 , respectively.

be found in Table S1. In order to have the same surface area for and therefore the conversions would not be only attributed
biolm development in both reactors, the lling fraction, i.e., to the biolm but also to the bulk phase biomass activity.
the amount of support per volume of reactor (Vsupport /Vreactor ) Similarly to the previous experiment, the volumetric ammo-
was chosen to be 50% and 8.3% for the MBBR1 and MBBR2 , nium removal rate obtained with each type of biomass fraction
respectively. Hence, the specic surface area corresponded to was estimated by linear regression of the ammonium con-
250 m2 /m3 . Taking into account the volume of the reactors centration over time. The contribution of suspended biomass
(1 L), the total area available for establishment of the biolm to the overall ammonium removal, expressed in percentage,
was 0.25 m2 . Air was introduced to the reactors through porous was estimated by dividing the volumetric ammonium removal
diffusers, placed at the bottom of each tank. The air ow was rate obtained in the experiments performed without carriers
kept constant at around 4 L/min in order to have the same by that obtained with both attached (biolm) and suspended
hydraulic conditions in all experimental runs. The distribu- solids. The remaining amount (calculated by subtracting the
tion of air bubbles allowed to keep the carriers in suspension percentage attributed to suspended solids from 100%) was
and provided satisfactory oxygen transfer into the bulk liquid. credited to attached biomass activity. Biomass-specic ammo-
The dissolved oxygen (DO) concentration varied within the nium removal rates (here also referred to as specic nitrifying
range of 45 mg/L. Ambient temperature was around 22 4 C activity) obtained with either attached or suspended biomass
and pH was maintained between 6.8 and 7.5 by adding either was determined by the ratio between the volumetric ammo-
1 M NaOH or 1 M HCl. nium removal rate obtained with each fraction of biomass and
the corresponding amount of solids (either VAS or VSS).

2.2. Additional experiments for assessment of


nitrifying activity 2.3. Scanning electron microscopy (SEM) analysis of
the attached biomass
In order to determine the maximum specic nitrifying activ-
ity of both attached and suspended biomass and estimate the The properties of the biomass attached to the carrier elements
amount of ammonium oxidized by each biomass fraction in (e.g., biolm thickness) of both MBBR systems were evaluated
the different experimental runs, two types of batch tests were by SEM. This analysis was carried out during run 4, condi-
conducted from runs 2 to 6. In this set of trials, the reactor tion in which the volumetric organic loading rate reached the
feeding was stopped and a pulse of a concentrated stock solu- maximum value (Table 1). For visualization of the adhered
tion of ammonium chloride was added in the beginning of biomass, a piece of the Kaldnes K1 (MBBR1 ) and Mutag Biochip
the test in order to achieve initial ammonium concentrations (MBBR2 ) carriers was cut by means of a razor blade. This
similar to that of the reactor inuent, i.e., 100 mgN/L. Samples procedure was performed very carefully to keep the biolm
were collected every 15 to 30 min for 6 h (360 min) for deter- structure unchanged. The preparation of the sample (i.e., x-
mination of the ammonium concentration. The volumetric ation, post-xation, dehydration, washing and drying) can be
ammonium removal rate was calculated by linear regression found elsewhere (Bassin et al., 2012a). The prepared specimen
of ammonium concentration over time whereas the biomass- was further attached to supports (aluminium stubs) with the
specic ammonium removal rate was determined by dividing aid of silver glue and nally coated with gold powder in a
the volumetric ammonium removal rate by the total amount Balzers FL-9496 metalizer for observation in a Jeol JSM-6340F
of biomass (i.e., volatile total solids (VTS) = volatile attached microscope. The biomass thickness could then be determined
(VAS) + suspended (VSS) solids) in the corresponding reactor. by the tools provided by the microscope software.
The approach used to discriminate between the amount of
ammonium nitried by the attached and suspended biomass 2.4. Analytical measurements and calculation
was a bit different. Given the fact that this information can- procedures
not be assessed under normal operating conditions as both
attached and suspended solids are present within the sys- COD, ammonium, total suspended solids (TSS) and volatile
tems, it was decided to remove one of the biomass fractions. suspended solids (VSS) were determined according to
Hence, it was opted to remove all the plastic carriers from the Standard Methods (Apha, 2005). Nitrite and nitrate were mea-
two reactors and therefore keep only the suspended biomass. sured by analytical test kits provided by Hach Co. (Loveland,
Otherwise, if the test was performed only with the supports Colorado, USA). The biomass concentration in the carrier
by removing the suspended solids, detachment of biomass media, expressed as total (TAS) and volatile (VAS) attached
from the carriers would eventually occur over the experiment solids, was measured according to the procedure described
134 Process Safety and Environmental Protection 1 0 0 ( 2 0 1 6 ) 131141

previously (Bassin et al., 2012a), with minor modications.


Three representative carriers of each reactor were collected
and placed in a falcon tube. A known volume of a 1 N NaOH
solution was then added to the tubes to aid the removal
of the attached biomass from the carrier materials. Subse-
quently, the detached biomass present in the aqueous solution
was quantied following the same procedure used to deter-
mine the suspended solids concentration (Apha, 2005). The
amount of NaOH solids remaining after the biomass deter-
mination procedure was subtracted from the total amount of
solids in the sample aliquot. In order to extrapolate the results
obtained in this determination for the entire reactor and there-
fore calculate the TAS and VAS concentrations (g/L), the total
number of plastic carriers within the MBBRs and the volume Fig. 1 Inuent () (equal for both reactors) and efuent
of the bioreactors were taken into account. The sum of volatile COD over the continuous operation of MBBR1 () and MBBR2
attached (VAS) and suspended solids (VSS) was designated as (). The grey shaded area within Run 1 refers to the start-up
total volatile solids (VTS). Dissolved oxygen levels were reg- phase (20 and 30 days for MBBR1 and MBBR2 ), period
ularly monitored with a WTW DO meter (model Oxi 7310). during which the biolm was formed in the freely moving
Temperature and pH were measured by means of a Oakton pH carriers. The varying operational conditions applied over
110 meter. Total polysaccharides (PS) and protein (PT) concen- time were the same for both reactors. From runs 14, the
trations of the biomass attached to the plastic carrier elements organic loading rate was gradually increased by increasing
were also determined. For PS and PT determination assays, the inuent COD. Subsequently (runs 46), both the COD
two representative carriers from each reactor were placed in concentration in the incoming wastewater and the HRT
a falcon tube, to which a solution of 1 N NaOH was added. were proportionally reduced to maintain the COD loading
The tubes were heated during 5 min at 90 C in order to pro- rate constant at 3.2 kgCOD/(m3 d) (or 12.8 gCOD/(m2 d)).
mote complete cell lysis. Subsequently, PS concentration was
measured according to Dubois et al. (1956) whereas PT con- removal remained stable, as indicated by the high COD
centration was determined by the Bradford assay (Bradford, removal obtained within this period.
1976). Nitrogen mass balance was conducted by considering Ammonium proles in the inuent and efuent of MBBR1
the inuent nitrogen (as ammonium) and the efuent nitrogen and MBBR2 are shown in Fig. 2. During the biolm formation
(as remaining ammonium and nitrite and nitrate formed by period within run 1, ammonium removal was slightly higher
nitrication). The total amount of inuent ammonium which in the reactor lled with Kaldnes K1 media (MBBR1 ) in com-
was found back as nitrate/nitrite in the bulk liquid was desig- parison with that containing Mutag Biochip carriers (MBBR2 ).
nated as soluble nitrogen conservation whereas the difference Nevertheless, after 40 days of operation, nearly complete
between those two was referred to as total nitrogen removal. ammonium removal was obtained in both reactors, regard-
Nitrogen was considered to account for about 10% of the cell less of the carrier material used. Despite the gradual increase
dry weight (Gerardi, 2003). Given that biolm development in the organic loading rate from 0.8 kgCOD/(m3 d) (run 1) to
is a dynamic process governed by attachment and detach- 3.2 kgCOD/(m3 d) (run 4), nitrication performance remained
ment of biomass to solid surfaces, the biolm surface specic very stable, as demonstrated by the high ammonium removal
detachment rate (kd ) was calculated. Calculations procedures (>90%) achieved within this period. On the other hand, the
are shown in Supplementary material. reduction of HRT from 12 to 6 h and consequent increase in

3. Results

3.1. General description of the reactors operation: COD


removal and nitrogen conversions at different organic
loading rates

After inoculation of the reactors with activated sludge from a


municipal wastewater treatment plant, around 20 and 30 days
were necessary to achieve constant attached biomass con-
centration in MBBR1 and MBBR2 , respectively. This period is
referred to as start-up phase, during which the plastic carriers
were being colonized by the microorganisms at the initially
applied organic loading rate (0.8 kgCOD/(m3 d)) (Table 1). With
the exception of this transient period, COD removal was Fig. 2 Inuent () ammonium (equal for both reactors)
observed to be higher than 90% in both reactor systems and efuent ammonium concentrations proles over the
(Fig. 1). Despite the gradual increase in the organic loading course of the operation of MBBR1 () and MBBR2 (). The
rate from 0.8 kgCOD/(m3 d) (run 1) to 3.2 kgCOD/(m3 d) (run 4), grey shaded area within run 1 refers to the start-up phase,
COD removal was observed to be above 95% in both MBBRs. during which the biolm was establishing in the carrier
From runs 46, period during which the organic loading rate elements. The inuent ammonium concentration in run 6
was kept constant at 3.2 kgCOD/(m3 d) (12.8 gCOD/(m2 d)) by was half of that applied in the previous runs. However, the
proportionally decreasing the inuent COD and the HRT, the nitrogen loading rate was kept constant by reducing the
performance of both systems in terms of organic matter HRT from 6 to 3 h.
Process Safety and Environmental Protection 1 0 0 ( 2 0 1 6 ) 131141 135

Fig. 3 Average fraction of ammonium, nitrite and nitrate found in the efuent relative to the total inuent nitrogen
(entirely as ammonium) over the 6 experimental runs. The amount of soluble nitrogen which was not found back in the
efuent (i.e., not conserved within the system) was either used for biomass growth or lost to the atmosphere in the form of
nitrogen gas resulting from denitrication.

the nitrogen loading rate from 0.2 to 0.4 kgNH4 + N/(m3 d) in conditions, the amount of nitrogen used for biomass syn-
the transition from run 4 to 5 was accompanied by ammonium thesis became more relevant. Consequently, less ammonium
concentration peaks in the efuent of both reactors, which was available for nitrication and the amount of oxidized
reected a drop in the ammonium removal (Fig. 2). The impact nitrogen (nitrate/nitrite) generated has therefore diminished,
of the lower HRT on nitrication was felt most in MBBR2 , where contributing to decrease the nitrogen conservation in the bulk.
it took 60 days to re-establish full ammonium conversion. On Furthermore, by considering the amount of soluble nitrogen
the other hand, only 20 days were necessary to reach efuent present in the efuent (as ammonium, nitrite and nitrate)
ammonium concentrations of about 1 mgN/L in MBBR1 after and that expected for fully aerated nitrifying reactors with no
the hydraulic shock loading. Ammonium removal was also anoxic zones intentionally implemented (calculated by sub-
observed to be negatively inuenced with a second decrease tracting the nitrogen used for biomass growth from the total
in the HRT occurred in run 6, even though both the organic nitrogen fed), 20 to 40% of nitrogen was still missing. Possi-
and nitrogen loading rate were the kept the same as in the bly, this amount of nitrogen was lost to the atmosphere in
previous experimental condition (run 5). the form of nitrogen gas resulting from denitrication, as will
The nitrogen conversions taking place in the MBBRs can be discussed further on. Taking into account the inuent and
be better visualized in Fig. 3, where the percentage each efuent measurements, total nitrogen removal was observed
nitrogen compound in the efuent (as remaining ammonium to vary from 50 to 86% in MBBR1 and from 35 to 73% in MBBR2 .
or nitrate/nitrate resulting from nitrication) relative to the
inuent nitrogen (entirely as ammonium) is displayed. Fur- 3.2. Attached and suspended biomass fractions
ther information on the inuent and efuent total nitrogen
concentrations in each experimental stage can be found in The dynamics of the volatile suspended and attached biomass
Fig. S2. over the six experimental stages is displayed in Fig. 4. For
In both reactors, nitrate accounted for the majority of comparison with the amount of biomass present in suspen-
the nitrogen in the output stream whereas nitrite was only sion, the sludge adhered to the carriers was also expressed in
detected in minor amounts (less than 2%). Furthermore, the g/L. In MBBR1 , the attached biomass concentration gradually
total amount of soluble nitrogen found in the efuent was increased from 3 gVAS/L (run 1) to 5.5 gVAS/L (run 4) as the
observed to decrease from runs 1 to 4. However, within the organic loading rate was raised. Within the period in which
period during which the organic loading rate was kept con- the organic load was kept constant (runs 46), it remained rel-
stant (runs 46), only a slight variation in the efuent nitrogen atively constant at around 6 gVAS/L (Fig. 4a). Even though the
was observed in the two reactors. In fact, as the organic load- media lling fraction was chosen to have the same theoreti-
ing rate was gradually increased in the rst four experimental cal surface area for biolm growth in both reactors, average

Fig. 4 Average attached (VAS) and suspended (VSS) biomass concentrations in MBBR1 (a) and MBBR2 (b) obtained in each
operational condition. The number above the bars indicates the volumetric organic loading rate applied in each
experimental stage. The same y-axis scale was used in (a) and (b) for better comparison between the results of each system.
136 Process Safety and Environmental Protection 1 0 0 ( 2 0 1 6 ) 131141

Fig. 5 Contribution of the attached and suspended biomass to the overall ammonium removal, as estimated from the
batch tests. (a) MBBR1 (Kaldnes K1) and (b) MBBR2 (Mutag Biochip).

attached biomass content in the Mutag Biochip carriers of The biolm surface specic detachment rate (kd ) was cal-
MBBR2 only amounted to around 1.5 gVAS/L (Fig. 3b). Further- culated for each operational run and the results are shown in
more, unlike that observed in MBBR1 , adhered solids in the Fig. S5. Overall, as the COD loading rate was increased from
supports of MBBR2 only slightly increased as the organic load- runs 14, a pronounced increase was observed in kd , reecting
ing rate was increased. The comparison between the quantity an increase in the amount of suspended solids which were
of attached biomass per m2 of support for the two different sheared from the carriers. kd value was kept within 0.3 and
media is illustrated in Fig. S3. The average surface biomass 2.4 gVSS/(m2 d) in MBBR1 and 0.2 to 2.4 gVSS/(m2 d) in MBBR2 .
content in MBBR1 (around 18 g/m2 ) was found to be approxi-
mately 2.5 times higher than in MBBR2 (around 7 g/m2 ). Inert 3.3. Polysaccharides and protein concentrations in the
material (xed solids) in the biolm of MBBR1 and MBBR2 only biolm
accounted for about 15% and 10% of the total attached solids,
respectively. Given the importance of polysaccharides (PS) and proteins
It is also important to note that, particularly in the Kaldnes (PT) as structuring agents of the biolm, the concentrations of
K1 carriers, great part of the biomass was not effectively these polymeric substances in the attached biomass were reg-
attached to the support, but entrapped with the biomass ularly determined over the operation of the reactors. Following
xed to it (Fig. S4). From the SEM analysis, the thickness of the trend observed for the adhered solids, higher PS and PT
the biolm effectively adhered to this particular media was contents were found in the biolm of MBBR1 in comparison
observed to be around 1.2 mm (Fig. S4a). On the other hand, with MBBR2 (Fig. S6). However, PT/VAS and PS/VAS ratios for
the porous structure of the Mutag Biochip carrier made this both MBBRs were observed to be very similar throughout the
determination more difcult to be accomplished for this sup- experimental runs. Furthermore, PS/PT ratio remained prac-
port. In fact, only a very thin layer of biomass was observed tically constant at around 0.4 from runs 14. As the HRT was
in the surface of this media, whereas a considerable amount gradually reduced in runs 5 and 6, the increase of PS content
of solids were found inside the pores located along the depth was more pronounced than that of PT. Hence, PS/PT ratio grad-
of the carrier (Fig. S4b). Interestingly, at this specic location, ually increased, reaching up to 0.55 (MBBR1 ) and 0.6 (MBBR2 )
the biomass appeared in the form of dense agglomerates, not in the last experimental stage. During this period, the biolm
covering the whole pore space. Given the possible inaccuracy of both reactors experienced an overproduction of gelatinous
of the biolm thickness measurements for this porous carrier, polymeric substances (see Fig. S7 for more details).
no absolute value is reported. Nevertheless, by considering the
maximum nominal length of the carrier (Table S1) and the fact 3.4. Nitrifying activity tests
that biomass was distributed mainly inside the pores, a biolm
layer lower than 0.81.2 mm can be expected. The batch tests were initially conducted to observe the
As regards to the volatile suspended solids (VSS), it rep- inuence of the increasing organic loads on the maximum
resented only a fraction of 10% of the total volatile solids biomass specic nitrifying activity. With the enhanced het-
(VAS + VSS) at the lowest organic load (run 1) in both reac- erotrophic growth resulting from the gradual increase of
tors (Fig. 4). However, further increase in the COD loading rate the inuent organic load (runs 14), the specic ammo-
from runs 14 was accompanied by a considerable increase nium removal rate gradually decreased (Fig. S8). Subse-
in amount of bulk phase biomass in both systems. In run 4, quently, at constant COD loads (runs 46), it varied within
in which the organic loading rate reached the highest value the range of 1.22.3 mgNH4 N/(gVTS h) (in MBBR1 ) and
(3.2 kgCOD/(m3 d)), VSS accounted for 28% of the total amount 3.05.6 mgNH4 N/(gVTS h) (in MBBR2 ).
of biomass in MBBR1 , whereas this fraction reached up to 48% Taking into consideration the considerable amount of sus-
in MBBR2 , practically equalling the amount of solids attached pended solids observed especially from run 2 onwards (Fig. 4),
to the media (Fig. 4b). At this particular condition, the plas- batch experiments were conducted with and without the
tic carriers of both reactors exhibited the thickest biolm and carriers to separately estimate the amount of ammonium oxi-
were completely saturated with biomass (see Fig. S4). With dized either by the attached or by the suspended biomass
the decrease of HRT from runs 46, the amount of VSS was (details of the calculation procedures can be found in Section
observed to decline as a result of biomass washout, although 2). The volumetric ammonium removal rates obtained with
the organic loading rate was kept constant within this period. each type of biomass is presented in Table S2. Interestingly,
The percentage of inert biomass within the TSS was around on basis of the activity batch tests results, it could be inferred
25% and 21% in MBBR1 and MBBR2 , respectively. that the contribution of the suspended biomass to the total
Process Safety and Environmental Protection 1 0 0 ( 2 0 1 6 ) 131141 137

et al., 2010). In this context, once the specic surface area


is known for a given carrier, its size and shape are usually
not important for design purposes (degaard et al., 2000). In
this study, the media lling ratio was chosen in order to have
the same theoretical specic area for biolm growth in both
reactors. Due to this fact and taking into account that the
two MBBRs were always subjected to the same feeding pat-
tern over time, similar attached biomass concentrations were
expected in both systems. However, it was observed that the
Kaldnes K1 carriers (media used in MBBR1 ) allowed obtaining
higher attached biomass concentrations compared to those
reached in MBBR2 , where the Mutag Biochip was employed as
Fig. 6 Specic ammonium oxidation rates obtained with support media (Fig. 4 and Fig. S3). These ndings suggest that
the attached (biolm) and suspended biomass in MBBR1 the amount of attached biomass which can be achieved in a
and MBBR2 from runs 26. The data representing run 1 is MBBR system does not only depend on the theoretical biolm
not shown since the activity batch test was not conducted surface area shown by the support material, but also on the
for this particular experimental condition. carrier conguration. The Mutag Biochip carriers present in
MBBR2 have a parabolic shape which is frequently subjected
to shear forces and attrition due to intensive contact with the
nitrifying activity was very pronounced (Fig. 5). Furthermore, surrounding liquid and with other media. These conditions
the amount of ammonium estimated to be nitried by the bulk favour the detachment of biolm and the amount of attached
phase biomass becomes even more signicant as the organic solids tends to decrease. On the other hand, the Kaldnes K1
loading rate increased at constant HRT (runs 24). In run 4, media consist of cylindrical-shaped carriers which have a pro-
when the highest concentration of suspended biomass was tected surface area in its inner part which is not subjected
observed in both reactors (Fig. 4), the amount of ammonium to direct collision with other particles, favouring the accumu-
removed by the suspended biomass was estimated to account lation of biolm. Furthermore, this media conguration also
for around 85% of the total ammonium removed in both reac- facilitates the entrapment of biomass in the biolm matrix,
tors (Fig. 5). In order to evaluate how the relative importance as observed in this study (Fig. S4), while the Mutag Biochip
of the suspended biomass to the overall ammonium removal does not. Consequently, the amount of attached solids which
is affected by the HRT, this parameter was gradually reduced can be achieved in the former support is enhanced. However,
from 12 h (run 4) to 6 h (run 5) and subsequently from 6 h (run it should be pointed out that the entrapped biomass portion
5) to 3 h (run 6), while the organic loading rate was kept con- found in the protected zone of the Kaldnes K1 carriers was
stant by decreasing the inuent COD accordingly. As it can be only loosely bound to the biolm and therefore much more
seen, the fraction of the inuent ammonium estimated to be susceptible to detachment than the solids effectively attached
removed by the suspended solids gradually decreased reach- to the plastic media. This may explain the huge increase in
ing a minimum value of 35% (MBBR1 ) and 42% (MBBR2 ) in run 6. the biolm loss rate observed in MBBR1 as the applied organic
Besides the important role played by the bulk phase solids loading rate was increased (Fig. S5).
in the nitrication process, the specic nitrifying activity of Another point which should be considered is that the sur-
the suspended biomass (VSS) was observed to be considerably face area of the carrier provided by manufacturers may change
higher than that of attached biomass (VAS) in both reactors over time due to the overgrowth of biolm and consequent
(Fig. 6). The VSS-specic nitrication rate reached up to 20 media clogging (Forrest, 2014). Contrary to the Kaldnes K1
and 11 times higher than the VAS-specic nitrication rate in media, the Mutag Biochip carrier is a ne porous chip-type
MBBR1 and MBBR2 , respectively. Nevertheless, a great increase media in which microorganisms form colonies in the pro-
in the specic nitrifying activity of the biolm was noticed tected pores. Although the theoretical volume-specic surface
as the HRT was decreased to 3 h in run 6. This result coin- area of this carrier is reported to be 3000 m2 /m3 , it might be
cides with the higher fraction of ammonium oxidized by the possible that the effective area for biolm growth decreases
attached biomass under this particular experimental condi- as biomass attaches to the media. This may also explain
tion (Fig. 5). In general, both the attached and suspended the lower attached biomass content found in MBBR2 . Overall,
biomass-specic nitrifying activities were observed to be these outcomes suggest not only the specic area for biolm
higher in MBBR2 than in MBBR1 , and tended to decrease as the attachment of the support media but also its characteristics
COD load was increased at constant HRT (runs 24). Further- (shape, size and surface) should be taken into account for the
more, the performance of the reactor lled with Mutag Biochip design and operation of MBBR systems.
media was very comparable to that of MBBR1 , despite the lower MBBRs usually present relatively low amount suspended
attached biomass concentrations observed in this reactor. solids in the efuent, commonly within the range of
150250 gSS/m3 (degaard et al., 2010). Consequently, easier
4. Discussion biomass-efuent separation can be achieved in such biolm
systems in comparison to conventional suspended growth
4.1. Effect of carrier type on attached biomass reactors. However, the efuent of high organic loaded MBBRs
accumulation and biolm sloughing at increasing COD may contain signicant amounts of biomass in the bulk phase,
loading rates as observed previously (Melin et al., 2004). In the current
study, it was observed that at the highest surface organic load
From literature it is known that the key factor for the design applied (around 13 gCOD/(m2 d)), the carriers of both systems
of moving-bed biolm reactors is the effective surface area were completely saturated with biomass and got clogged.
available for biomass growth (degaard et al., 2000; Ferrai As a result, the specic surface detachment rates increased,
138 Process Safety and Environmental Protection 1 0 0 ( 2 0 1 6 ) 131141

leading to a higher amount of suspended solids. For instance the thickness of the biolm adhered to the supports in MBBR1
when HRT and the organic loading rate were set at 12 h and was observed to be very signicant (about 1.2 mm). Under such
3.2 kgCOD/(m3 d) (run 4), respectively, the VSS concentration conditions, the free passage of nutrients and oxygen through
reached up to 2.3 g/L in MBBR1 . This value is actually within the attached biomass layer is restricted, subjecting the inner
the normal range observed in conventional activated sludge parts of the biolm to substrate- and oxygen-limited condi-
reactors (Metcalf and Eddy, 2003). Excessive biolm thickness tions. As reported in previous studies, the biolm zones near
has been already reported to potentially lead to sloughing the substratum are potentially colonized by inert biomass
events and elevated efuent suspended solids concentrations (Zhang and Bishop, 1994). This is especially the case of thick
(Downing et al., 2013). Given the considerable amount of solids microbial lms as those observed in the Kaldnes K1 media,
in suspension resulting from biolm detachment in the high in which the amount of viable biomass may decrease con-
loaded MBBRs and taking into account that the characteris- siderably from the outer surface to the bottom of the biolm
tics (e.g., particle size, composition, texture and morphology) (Zhang and Bishop, 1994). On the other hand, the biomass
of the biomass sloughed-off from MBBR carriers are different attached to the at disk-type Mutag Biochip carriers in MBBR2
from occulent activated sludge (Nof et al., 2013), the clarify- was mainly distributed as a substantially thin layer over the
ing unit should be specically designed to meet the efuent surface of both sides the carriers or in the form of agglom-
quality requirements. erates growing inside their pores (Fig. S4). As the nutrients
The excessive production of gelatinous exopolysaccharides and oxygen could reach the biolm from the two sides of the
by the microorganisms (Fig. S7) and consequent increase of media, the transport of these elements through the attached
biolm PS/PT ratio (Fig. S6) observed in run 6 was an unex- bacteria was facilitated. Indeed, the fraction of inert material
pected observation, as no similar event had been observed in in the biolm of MBBR2 was observed to be lower than that of
the two previous stages subjected to the same organic loading MBBR1 . Moreover, the specic biolm activity (assessed from
rate (runs 4 and 5). Therefore, it is speculated that this nding ammonium oxidation experiments) in MBBR2 was higher than
can be interpreted as a response of the biomass in an attempt in MBBR1 (see Fig. 6), compensating for the lower amount of
to not be washed out from system at the lowest HRT applied. solids attached to the media. Hence, from a conversion point
Nevertheless, regardless of its main causes, the results suggest of view, the results suggest that it is more important to max-
that under constant organic loads, the hydraulic conditions imize the active biolm surface area within the reactor than
may induce changes in bacterial behaviour. It is relevant to the total attached biomass content.
mention that the particular episode of exopolymers overpro- However, apart from the inuence of the media type
duction noticed in this study may affect some of the sludge on attached biomass distribution in the carrier and the
properties, such as its settleability. In those circumstances, consequent role played by the support on the biolm con-
the use of chemical coagulants can be an option to improve versions, the results also suggested that there were other
efuent clarication (degaard, 2006; degaard et al., 2010). factors affecting the overall performance of the MBBRs which
should be considered to explain our ndings. As previously
4.2. Effect of increasing organic loading rates and described, both systems have shown stable nitrication and
carrier type on organic matter removal, nitrication and full ammonium removal even at most extreme condition of
specic nitrifying activity organic load, although they presented signicantly different
attached biomass contents. It is well known that nitrication
The long-term experiment in which the two MBBRs were is directly inuenced by the applied organic loading rate, with
compared side-by-side for 700 days has shown that both sys- high COD loads favouring the development of fast-growing
tems could accommodate increasing COD loading rates up to heterotrophs (Rittmann and Manem, 1992). As autotrophic
12.8 gCOD/(m2 d). Running a lab-scale MBBR system at similar nitriers compete poorly for oxygen and nutrients, espe-
surface organic loads, Aygun et al. (2008) also observed high cially in high loaded attached growth processes, they tend to
organic matter removal efciency (close to 95%). Javid et al. be overgrown by heterotrophic organisms (Figueroa and Sil-
(2013) operated a MBBR process subjected to surface organic verstein, 1992; Ohashi et al., 1995). Under such conditions,
loading rates varying from 2.4 to 11.6 gBOD5 /(m2 d), which is nitriers are potentially forced deeper into the biolm, where
within the range applied in this study. The performance of the a greater mass transport resistance is experienced (Rittmann
reactor was kept stable even at the highest load applied and a and Manem, 1992). Hence, nitrication in the biolm may
high efuent quality was achieved over the entire operation. be negatively impacted. As presented before, at the high-
Overall, the efcacy of MBBRs in tolerating increasing organic est organic load applied in this study (3.2 kgCOD/(m3 d)), the
loads is well reported in literature. However, little research plastic carriers were completely saturated with heterotrophic
has been undertaken on the effect of different media on their biomass and got clogged, making the diffusion of oxygen and
performance under high COD input. substrate through the biolm more difcult. Herewith, a harsh
In this study, the type of carrier used in each reactor environment was created to sustain nitrifying activity in the
did not impact the overall performance of the system. Even biolm and a sharp decrease in the nitrication performance
though the attached solids concentration in MBBR2 was lower was expected. Nevertheless, high ammonium removal lev-
than that observed in MBBR1 , organic matter and ammonium els were sustained in both MBBRs. As the suspended solids
removal were similar in both systems under the experimental became very relevant as the COD load was gradually increased,
conditions employed. First, one can consider that this result reaching similar amounts in both systems (Fig. 4), we sus-
is possibly related to the biomass distribution pattern over pected that the bulk phase biomass could have been directly
the two different media, which present distinct shape, size involved in the nitrogen conversions.
and surface characteristics. In MBBR1 , the largest fraction of Moving-bed biolm reactors are usually operated at low
biomass was located at the inside of Kaldnes K1 carriers (Fig. HRTs (degaard, 2006) which are theoretically not sufcient
S4), which were observed to be completely clogged at the high- to support the growth of slow growing nitrifying organisms in
est organic load. Furthermore, as evidenced by SEM analysis, suspension. Depending on site-specic conditions, nitriers
Process Safety and Environmental Protection 1 0 0 ( 2 0 1 6 ) 131141 139

usually present maximum specic growth rates ranging from nitrication) decreased. Furthermore, the signicant washout
0.25 to 0.77 d1 (Randall et al., 1992). Considering the reciprocal of bulk solids with relatively high nitrifying activity adversely
of the average of these two values (i.e., 0.51 d1 ), the HRT nec- affected nitrication performance in the high loaded MBBRs.
essary to allow nitriers to grow in the mixed liquor phase was This was clearly observed under the lowest HRT applied (run
calculated to be around 2 days (48 h). In our study, the HRT was 6), when complete nitrication was never achieved (Fig. 2),
initially set at 12 h, being subsequently reduced to 6 and 3 h. even though the organic and nitrogen loading rate were the
Presumably, under these conditions, the suspended growth of same as those applied in run 5. This particular result empha-
nitriers would be hindered and nitrifying activity is expected sizes the importance of the suspended biomass to the overall
to occur mainly in the biolm. However, a recent work con- ammonium removal obtained in both reactors.
ducted by Piculell et al. (2014) has shown that there was always It is also interesting to note that, as demonstrated by the
some suspended biomass in MBBRs as a result of biolm batch experiments, the specic nitrifying activity of the sus-
sloughing, even at washout conditions. Furthermore, follow- pended biomass was quite higher than the respective biolm
ing the same line of reasoning, Masic and Eberl (2014) have activity, while both tended to decrease with the increas-
shown by mathematical modelling that suspended biomass ing COD load. However, it should be remarked that the
always contributes to ammonium removal in biolm systems. attached biomass-specic nitrication rate increased at the
These authors pointed out that neglecting the contribution of lowest HRT (run 6), although the applied volumetric organic
non-attached biomass leads to quantitatively different results. loading rate was kept the same as in the two previous exper-
Earlier studies reported that in hybrid moving-bed biolm- imental runs (Fig. 6). This nding is probably due to the
activated sludge processes (usually referred to as integrated higher washout of suspended solids occurred in this par-
xed-lm activated sludgeIFAS), the fraction of ammonium ticular condition, enabling a greater amount of ammonium
which is oxidized by the suspended biomass may account to be nitried by the attached biomass (Fig. 5). In turn, the
for 1070% of the overall nitrication (Albizuri et al., 2014). VAS-specic activity has raised considerably. In terms of sur-
On the other hand, studies reporting the operation of pure face nitrication rates, the maximum values were found to
moving-bed reactors often neglect the activity of nitriers in be 0.87 and 0.80 gNH4 N/(m2 d) in MBBR1 and MBBR2 , respec-
the bulk phase, assuming that nitrication only takes place in tively. Besides reporting slightly higher surface nitrication
the biolm (Piculell et al., 2014). rates (0.91.2 gNH4 N/(m2 d)) in a hybrid activated sludge-
In our study, we observed that the dynamics of suspended biolm reactor treating municipal wastewater, Christensson
and attached biomass fractions was substantially inuenced and Welander (2004) observed that more than 80% of the
by the COD input. The experiment has started with two pure overall nitrication was performed by the biolm. However, it
MBBR systems in which the suspended solids accounted for should be considered that their experiments were conducted
only 45% of the total biomass content. However, as the in lower COD loading ranges. Operating a hybrid bioreactor
organic loading rate was increased, the amount of dispersed containing porous ceramic particles as support media, Wang
biomass resulting from biolm sloughing became very sig- and Wu (2004), reported that both bulk and attached biomass
nicant, reaching up to 26% and 43% of the total biomass exhibited fairly similar nitrication activity. Their experiment
content in MBBR1 and MBBR2 , respectively. Under such con- was, however, conducted on autotrophic conditions, with
ditions, the bulk solids content became closer to those found no carbon source present in the synthetic inuent medium.
in hybrid bioreactors relying on both suspended and attached On the other hand, in our study, massive growth of het-
biomass growth (Bellucci et al., 2013). Given this scenario, erotrophic organisms in both attached and suspended phases
nitrifying activity batch tests were conducted to evaluate the was observed as a result of the high COD loading rates. Thus,
role of the suspended bacteria on the nitrication process. the relative importance of the nitrifying population within
Indeed, the results have revealed that the fraction of ammo- the overall bacterial community became signicantly smaller,
nium estimated to be nitried by the bulk phase solids was while the specic nitrication rates tended to decrease.
very signicant, and increased proportionally to the applied
organic loading rate at invariable hydraulic conditions (i.e., 4.3. The role of the media type on total nitrogen
constant HRT). Under high organic load conditions, biolm removal
detachment rates became more relevant, contributing to seed
the suspension with nitriers. Since the mixed liquor phase is Although the MBBR systems under study were continu-
not affected by mass transfer limitations to the same extent as ously kept under aeration and therefore only designed to
the biolm, the suspended biomass-specic nitrifying activ- accomplish COD removal and nitrication, high total nitrogen
ity was found to be much higher than that of the attached removal was observed (up to 86 and 73% in MBBR1 and MBBR2 ,
biomass (Fig. 6). Thus, as the COD loading rate was raised, the respectively). Partially, this was due to the increasing fraction
increasing percentage of ammonium oxidized in suspension of the incoming nitrogen assimilated by heterotrophic bacte-
may have compensated for the decreasing nitrifying activity ria for cell synthesis as COD loading rate was raised. Therefore,
of the biolm. This, in turn, allowed both MBBRs to achieve the amount of nitrogen available to be nitried has decreased
stable nitrication even when subjected to increasing organic and a higher soluble nitrogen loss was noted (Fig. 3). Fur-
loads. thermore, part of the inuent nitrogen which was not found
The results also indicated that at constant organic load- back as oxidized nitrogen (nitrite and nitrate) or residual non-
ing rates (e.g., runs 46), the HRT directly affected the amount nitried ammonium was possibly removed via denitrication.
of ammonium oxidized either by the suspended or attached Even though only aerobic conditions prevailed in the bulk liq-
biomass. Similarly to earlier investigations concerning the uid (DO ranging from 4 to 5 mg/L), the thick biomass layer
operation of MBBR systems (Piculell et al., 2014), the amount established in the carrier media of MBBR1 and MBBR2 possi-
of solids in suspension was observed to decrease as the HRT bly resulted in oxygen mass transport limitation and enabled
was reduced. Consequently, the relative importance of sus- the establishment of anoxic conditions in the inner zones of
pended biomass to the biological conversion processes (e.g., the biolm, where denitrication could take place. This also
140 Process Safety and Environmental Protection 1 0 0 ( 2 0 1 6 ) 131141

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