Operational Considerations for Integration of AquaNereda Reactor Expansion with an Existing Activated Sludge Facility

Introduction The application of the AquaNereda® process, were aerobic granular sludge (AGS) is applied in a sequencing reactor, is often seen as a replacement for the conventional activated sludge process. AquaNereda(R) is a sequencing process that utilizes a single tank for react and settle phases, and therefore is often not compatible as a retrofit with existing activated sludge systems that utilize separate tanks for reaction (aeration basins) and settle (final clarifiers). While this can be seen as a limitation for the application of AquaNereda(R), there is an opportunity to construct an expansion of facilities with AquaNereda(R), and then integrate the AquaNereda(R) in parallel to a conventional activated sludge plant. Four Rivers Sanitation Authority (FRSA), located in Rockford, Illinois, is currently working towards this integrated overall facility. While maintaining 40 mgd of average day flow capacity in a more conventional biological nutrient removal (BNR) activated sludge facility, FRSA is adding an additional 10 mgd of average day flow capacity with a new AquaNereda(R) AGS facility. The AGS facility will be operational in 2025, with the BNR upgrades being completed in 2026. During design of the new facilities at FRSA, the largest question for integration of the processes became how to manage the waste activated granular sludge (WAGS). Given the characteristics of WAGS in terms of percent solids as well as the sequencing wasting schedule from AquaNereda(R), it was decided to send the WAGS into the activated sludge system and then to waste to solids handling (see Figure 1 for a process flow diagram). The waste activated sludge (WAS) would then contain flocs from the activated sludge process as well as WAGS. This simplified operation, but there were major questions related to the impact of WAGS on the activated sludge process. Potential oxygen demand impacts, nitrification rates, and settling rates were all of interest to FRSA to understand the impact of WAGS. While most facilities would rely solely on process modelling to assess these impacts, FRSA has access to WAGS for testing. The AquaNereda(R) demonstration facility is on site and operating with FRSA wastewater. This facility (treating 200,000 gpd) generates WAGS that can be utilized for testing. Approach and Methodology To help understand the impacts and strategies to manage WAGS from the AGS facility, a series of bench scale tests were completed using WAGS from the AquaNereda(R) demonstration facility and WAS from the existing FRSA aeration basins. Three sets of bench scale tests were completed:

*Settling rate testing to identify potential enhanced settling, as outlined by Daigger, Redmond, and Downing (2017)

*Specific oxygen uptake rate (SOUR) measurement, utilizing standard methods, to assess the oxygen demand of the WAGS. The WAGS have the potential to exert a significant oxygen demand, as past work has shown a biomethane production potential of WAGS that is similar to primary sludge (Guo et al., Digestibility of waste aerobic granular sludge from a full-scale municipal wastewater treatment system, 2020).

*Nitrification rate testing, as outlined by Melcer et al (2003), to identify any potential seeding effect from WAGS. Results and Outcomes To evaluate the effect of WAGS on the settling characteristics of the existing waste activated sludge (WAS), batch settling experiments were performed using WAS and a mixture of WAGS-WAS at various dilution ratios to generate settling curves. The WAGS-WAS mixture proportions were calculated based on the predicted WAGS flows from the new AGS facilities. Figure 2 provides the settling rate impacts. Addition of WAGS increased the settling rate of the activated sludge biomass. The effect on settling rate would increase the peak flow capacity of the activated sludge facilities from 110 mgd to 130 mgd. SOUR testing indicated that the WAGS would have a 25% higher oxygen uptake rate than WAS (Figure 3). This indicates that there will be an oxygen demand associated with either particulate COD bound in the WAGS or potentially stored carbon. This oxygen demand is considered during aeration operation in the activated sludge system. The nitrification rate of WAGS (4 mgN/gVSS-hr) was similar to the nitrification rate of WAS (3.9 mgN/gVSS-hr). This was an unexpected result, as the WAGS likely contains a high VSS content of particulate COD from the influent. The benefit is that the WAGS will be adding a significant load of nitrifiers into the activated sludge system, increasing system resilience. The outcomes from this testing highlight how construction of an AquaNereda(R) facility in parallel to an activated sludge facility can provide a net benefit to the activated sludge facility. Applicability AquaNereda(R) has been sold as the evolution of activated sludge, but the requirement for a sequencing reactor can been seen as a limitation. The work completed highlights how an AquaNereda(R) process can be constructed in parallel to an activated sludge system, with positive impacts on the activated sludge facility. Audience Appeal Anyone looking at process expansion, nutrient removal requirements, and aging infrastructure would benefit from this presentation.