The development of continuous flow reactors (CFRs) employing aerobic granular sludge (AGS) for the retrofit of existing wastewater treatment plants (WWTPs) using a continuous-flow activated sludge (CFAS) system has garnered increasing interest. This follows the worldwide adoption of AGS technology in sequencing batch reactors (SBRs). The better settleability of AGS compared to AS allows for process intensification of existing wastewater treatment plants without the difficult conversion of often relatively shallow CFRs to deeper AGS-SBRs. To retrofit existing CFAS systems with AGS, achieving both increased hydraulic capacity and enhanced biological nutrient removal necessitates the formation of granular sludge based on the same selective pressures applied in AGS-SBRs. Previous efforts have focussed mainly on the selective wasting of flocculent sludge and retaining granular sludge to drive aerobic granulation. In this study a pilot-scale CFR was developed to best mimic the implementation of the granulation mechanisms of full-scale AGS-SBRs. The pilot-scale reactor was fed with pre-settled municipal wastewater. We established metrics to assess the degree to which the proposed mechanisms were implemented in the pilot-scale CFR and compared them to data from full-scale AGS-SBRs, specifically with respect to the anaerobic distribution of granule forming substrates (GFS). The selective pressures for granular sludge formation were implemented through inclusion of anaerobic upflow selectors with a water depth of 2.5 meters, which yielded a sludge with properties similar to AGS from full-scale SBRs. In comparison to the CFAS system at Harnaschpolder WWTP treating the same pre-settled wastewater, a more than twofold increase in volumetric removal capacity for both phosphorus and nitrogen was achieved. The use of a completely mixed anaerobic selector, as opposed to an anaerobic upflow selector, caused a shift in EBPR activity from the largest towards the smallest size class, while nitrification was majorly unaffected. Anaerobic selective feeding via bottom-feeding is, therefore, favorable for the long-term stability of AGS, especially for less acidified wastewater. The research underlines the potential of AGS for enhancing the hydraulic and biological treatment capacity of existing CFAS systems.

There is a growing interest to implement aerobic granular sludge (AGS) in existing conventional activated sludge (CAS) systems with a continuous flow-through configuration. The mode of anaerobic contact of raw sewage with the sludge is an important aspect in the adaptation of CAS systems to accommodate AGS. It remains unclear how the distribution of substrate over the sludge by a conventional anaerobic selector compares to the distribution via bottom-feeding applied in sequencing batch reactors (SBRs). This study investigated the effect of the anaerobic contact mode on the substrate (and storage) distribution by operating two lab-scale SBRs; one with the traditional bottom-feeding through a settled sludge bed similar to full-scale AGS systems, and one where the synthetic wastewater was fed as a pulse at the start of the anaerobic phase while the reactor was mixed through sparging of nitrogen gas (mimicking a plug-flow anaerobic selector in continuous flow-through systems). The distribution of the substrate over the sludge particle population was quantified via PHA analysis, combined with the obtained granule size distribution. Bottom-feeding was found to primarily direct substrate towards the large granular size classes (i.e. large volume and close to the bottom), while completely mixed pulse-feeding gives a more equal distribution of substrate over all granule sizes (i.e. surface area dependant). The anaerobic contact mode directly controls the substrate distribution over the different granule sizes, irrespective of the solids retention time of a granule as an entity. Preferential feeding of the larger granules will enhance and stabilise the granulation compared to pulse-feeding, certainly under less advantageous conditions imposed by real sewage.

In this study a mathematical framework was developed to describe aerobic granulation based on 6 main mechanisms: microbial selection, selective wasting, maximizing transport of substrate into the biofilm, selective feeding, substrate type and breakage. A numerical model was developed using four main components; a 1D convection/dispersion model to describe the flow dynamics in a reactor, a reaction/diffusion model describing the essential conversions for granule growth, a setting model to track granules during settling and feeding, and a population model containing up to 100,000 clusters of granules to model the stochastic behaviour of the granulation process. With this approach the model can explain the dynamics of the granulation process observed in practice. This includes the presence of a lag phase and a granulation phase. Selective feeding was identified as an important mechanism that was not yet reported in literature. When aerobic granules are grown from activated sludge flocs, a lag phase occurs, in which not many granules are formed, followed by a granulation phase in which granules rapidly appear. The ratio of granule forming to non-granule forming substrate together with the feast/famine ratio determine if the transition from the lag phase to the granulation phase is successful. The efficiency of selective wasting and selective feeding both determine the rate of this transition. Brake-up of large granules into smaller well settling particles was shown to be an important source for new granules. The granulation process was found to be the combined result from all 6 mechanisms and if conditions for either one are not optimal, other mechanisms can, to some extent, compensate. This model provides a theoretical framework to analyse the different relevant mechanisms for aerobic granular sludge formation and can form the basis for a comprehensive model that includes detailed nutrient removal aspects.

Operational disturbances in aerobic granular sludge (AGS) systems can result in aerobic availability of readily biodegradable COD (rbCOD). Different from activated sludge, morphological consequences on the short and long term are not well described in literature. This study investigated the effect of incomplete anaerobic uptake of acetate on the morphological and process stability of AGS using a lab-scale reactor. A fraction of the total acetate load was dosed aerobically, which was increased stepwise while monitoring granular morphology. A good granular morphology and an SVI of 40 ml/g were obtained during initial enrichment and maintained for ≤20% aerobic acetate load dosed at 4 mg COD/g VSS/h. Biological phosphorus removal efficiency was initially unaffected, but the aerobic acetate dosage rate did decrease the aerobic phosphate uptake rate. This led to loss of phosphorus removal for >20% aerobic acetate load dosed at 8 mg COD/g VSS/h over the course of 12 days. Subsequently, significant outgrowth formed on the granular surfaces and developed over time into finger-like structures. Under these high aerobic acetate loads the SVI increased to 80 ml/g and resulted in significant biomass washout due to deteriorating settling properties of the sludge. The sludge settleability and biological phosphorus removal recovered 10 days after aerobic feeding of acetate was stopped. Aerobic presence of rbCOD can be tolerated if mostly anaerobic acetate uptake is maintained, thereby ensuring stable granular morphology and good settleability. The high enrichment of phosphate accumulating organisms in the granular sludge through bottom-feeding and selective wasting of flocs makes aerobic granular sludge resilient to morphological deterioration in aerobic presence of rbCOD.

Spiral-wound membrane modules used in water treatment for water reuse and desalination make use of spacer meshes for keeping the membrane leaves apart and for enhancing the mass transfer. Computational fluid dynamics (CFD) has gained importance in the design of new spacers with optimized hydrodynamic characteristics, but this requires a precise description of the spacer geometry. This study developed a method to obtain accurate three-dimensional (3-D) geometry representations for any given spacer design from X-ray computed tomography (CT) scans. The method revealed that the filaments of industrial spacers have a highly variable cross-section size and shape, which impact the flow characteristics in the feed channel. The pressure drop and friction factors were calculated from numerical simulations on five commercially available feed spacers used in practice. Model solutions compared well to experimental data measured using a flow cell for average velocities up to 0.2 m/s, as used in industrial reverse osmosis and nanofiltration membrane operations. A newly-proposed spacer geometry with alternating strand thickness was tested, which was found to yield a lower pressure drop while being highly efficient in converting the pumping power into membrane shear. Numerical model solutions using CFD with geometries from CT scans were closer to measurements than those obtained using the traditional circular cross-section strand simplification, indicating that CT scans are very well suitable to approximate real feed spacer geometries. By providing detailed insight on the spacer filament shape, CT scans allow better quantification of local distribution of velocity and shear, possibly leading to more accurate estimations of fouling and concentration polarization.

The porosity of spacer-filled feed channels influences the hydrodynamics of spiral-wound membrane systems and impacts the overall performance of the system. Therefore, an exact measurement and a detailed understanding of the impact of the feed channel porosity is required to understand and improve the hydrodynamics of spiral-wound membrane systems applied for desalination and wastewater reuse. The objectives of this study were to assess the accuracy of porosity measurement techniques for feed spacers differing in geometry and thickness and the consequences of using an inaccurate method on hydrodynamic predictions, which may affect permeate production. Six techniques were applied to measure the porosity namely, three volumetric techniques based on spacer strand count together with a cuboidal (SC), cylindrical (VCC) and ellipsoidal volume calculation (VCE) and three independent techniques based on volume displacement (VD), weight and density (WD) and computed tomography (CT) scanning. The CT method was introduced as an alternative for the other five already existing and applied methods in practice. Six feed spacers used for the porosity measurement differed in filament thickness, angle between the filaments and mesh-size. The results of the studies showed differences between the porosities, measured by the six methods. The results of the microscopic techniques SC, VCC and VCE deviated significantly from measurements by VD, WD and CT, which showed similar porosity values for all spacer types. Depending on the maximum deviation of the porosity measurement techniques from −6% to +6%, (i) the linear velocity deviations were −5.6% and +6.4% respectively and (ii) the pressure drop deviations were −31% and +43% respectively, illustrating the importance of an accurate porosity measurement. Because of the accuracy and standard deviation, the VD and WD method should be applied for the porosity determination of spacer-filled channels, while the CT method is recommended for numerical modelling purposes. The porosity has a linear relationship with the flow velocity and a superlinear effect on the pressure drop. Accurate porosity data are essential to evaluate feed spacer performance in spiral-wound membrane systems. Porosity of spacer-filled feed channels has a strong impact on membrane performance and biofouling impact.