14th European Biosolids and Organic Resources Conference

SUSTAINABLE TREATMENT OF REJECT WATER AND INDUSTRIAL EFFLUENT BY

PRODUCING VALUABLE BY-PRODUCTS
Driessen, W.1, Abma, W.1, Van Zessen, E.1, Reitsma1 G. and Haarhuis, R.2
1

Paques BV, The Netherlands, 2Waterstromen, The Netherlands

Corresponding Author Tel: +31 514 60 8500 Email: w.driessen@paques.nl

Abstract
Nutrient removal, carbon footprint and energy consumption of sewage treatment are key issues
to be addressed in the very near future. This paper describes the experiences at the sewage
treatment works (STW) Olburgen in The Netherlands with specific technologies which play a key
role in minimizing energy consumption, carbon footprint and maximizing biogas utilization and
nutrient recovery.
The paper describes several upgrading activities at STW Olburgen since 2002. Implementation
of dedicated treatment of anaerobic digester reject water (dewatering liquor) combined with
industrial effluent, proved to be the most cost-effective and energy efficient as compared to
combined treatment in e.g. an activated sludge plant. Special attention is given to the
production of valuable by-product like green energy (power), struvite fertilizer and biomass
seed material.
Wastewater from a nearby located food factory is pre-treated in an anaerobic UASB reactor and
subsequently combined with reject water from the digesters. The mixture is treated for nutrient
removal in a Phospaq struvite reactor to remove phosphorous followed by a One-Step
Anammox reactor for removal of nitrogen. The final effluent of the Anammox reactor is
returned into the existing activated sludge plant of STW Olburgen.
The anammox process is up to 60 % more energy efficient than conventional activated sludge
plants. The anammox process allows valorization of the complete effluent by anaerobic
treatment maximizing biogas production. No by-pass for supplying a carbon source for
denitrification as in traditional biological nutrient removal plants is needed. The biogas from the
UASB reactor (up to 3 Mln m3/a) is purified in a biological Thiopaq scrubber to allow utilization
by a CHP unit (630 kWe). Excess heat generated in the CHP units is used to heat the digesters
and to a lesser extend the UASB reactor. The struvite (up to 60 t/a) produced in the Phospaq
reactor is used as a fertilizer additive. The granular biomass generated in the UASB reactor (ca
750 m3/a) and the One-Step Anammox reactor (ca 100 m3/a) is used as seed material to
(re)start other biological reactors.
Key words
Biosolids, Anaerobic digestion, Biogas, Reject Water, Nutrient recovery, Struvite, Fertilizer,
Anammox

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Introduction
The sewage treatment works (STW) Olburgen has a capacity of 90,000 population equivalent
(p.e.). The STW Olburgen treats a combination of municipal sewage and industrial effluent. At
STW Olburgen the excess sewage sludge is anaerobically digested and subsequently dewatered.
The digester reject water from the dewatering was originally reintroduced into the existing
activated sludge plant. The industrial effluent, which originates from a nearby potato processing
plant, is pre-treated in an anaerobic UASB reactor.
Over the last years STW Olburgen underwent various upgrades. In order to allow the biogas
produced to be utilized in a CHP (combined heat power) unit. for power generation the biogas a
biological scrubber was installed to remove hydrogen sulphide (H2S). The sewage treatment
works of Olburgen has been further upgraded in order reach compliance with the European
Frame Work Directive for which the discharge of N and P had to be reduced to 10 mg N/l and 1
mg P/l. To improve the effluent quality a separate and dedicated treatment for the reject water
from dewatering of anaerobically digested sewage sludge (biosolids) in combination with
industrial (potato) wastewater was installed.
As compared to treatment in an activated sludge plant with nitrification/denitrification and
chemical P removal, the separate treatment of the combined flows of sewage sludge reject
water and of industrial wastewater proved to be more cost-effective and energy efficient (Abma
et al, 2009). Among others benefits include: savings on investment cost, savings on electrical
power balance of 1.5 GWh per annum, savings on reactor volume (and footprint) of
approximately 21,300 m3 and savings of sludge production of around 600 t/a. The plant has
been financed and operated by the DBFO company Waterstromen which owns and operated
parts of STW Olburgen.

Process description
An overall schematic of the various implemented process steps at STW Olburgen is shown I
figure 1.
Anaerobic Digestion

The sewage sludge from STW Olburgen is digested in two digesters with a volume of 1500 m3
each. The digesters are operated under mesophilic conditions. The digesters are loaded with
approximately 160 m3/d of a mixture of primary and secondary sludge with an estimated dry
matter content of 4-6 %. The digestate is dewatered by decanter centrifuges and subsequently
biologically dried (by composting) followed by incineration (the latter is compulsory according
to Dutch Law).
The wastewater from the food factory is treated in two existing UASB reactors with a volume of
1200 m3 each. A third spare reactor tank is currently used as settling tank collecting solids. In the
UASB reactor the wastewater flows in an upward mode through a dens layer of anaerobic
granular biomass. The biomass converts the COD into biogas. The biogas produced provided
mixing in the reactor. A separator in top of the reactor ensures biomass retention. The reactors
are operated under mesophilic conditions at 37 0C.

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Biogas
(clean)

CHP
Sulphur (S)

Biogas
(H2S)

THIOPAQ Scrubber

Influent
potato
processing
plant

Biogas

UASB
Magnesium oxide
(MgO)

C lean
effluent

Dewatering

Air

Air

Sewage
Sludge

Solids

DIGESTER

ANAMMOX

PHOSPAQ
Struvite
(MgNH4PO4.6H2O)

Figure 1

An overall schematic process layout of the reject and industrial effluent treatment
THIOPAQ Biogas Purification

The biogas from the UASB reactor is treated in the biological Thiopaq scrubber, comprising a
gas scrubber and a bioreactor. In the scrubber section the biogas is brought in contact with the
alkaline liquid of the bioreactor allowing the H2S in the biogas to be absorbed in the liquid phase
(equation 1). In the bioreactor the absorbed H2S is converted to elemental sulphur and caustic is
produced (equation 2).
H2S

OH-

HS-

H2O

(1)

HS-

O2

So

OH-

(2)

In a Thiopaq-desulfurization unit, hydroxide (OH-) is consumed in the scrubber, while in the

bioreactor hydroxide is produced as a by-product. As a result caustic (NaOH) consumption in the
Thiopaq process is less than 5% as compared to the usage in conventional chemical caustic
scrubbers. Figure 2 presents a schematic flow diagram of the biological Thiopaq biogas
scrubber.

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BIOGAS
with H2S

BIOGAS
Clean

SCRUBBER

AIR
Vent air
out
BIOREACTOR
AIR

Figure 2

SEPARATOR

So

General flow schematic of Thiopaq desulfurization plant

The installed Thiopaq was designed for a maximum gas flow of 500 m3/h and 100 kg sulphur
per day. The removal of H2S allows the biogas to be utilized in a CHP unit. In this way availability
of the CHP is maximized and maintenance cost (e.g. due to oil exchange) are significantly
reduced.
Nutrient Removal PHOSPAQ Reactor

Reject water from the sludge dewatering (decanter centrifuges) of the anaerobically digested
sewage sludge and anaerobically treated industrial effluent are both characterized by relatively
high concentrations of phosphorous and nitrogen (especially ammonia).
In order to remove phosphorous the combined effluents are treated in two so-called Phospaq
struvite reactor in which by addition of magnesium-oxide (MgO) struvite (magnesiumammonium-phosphate) is produced. The Phospaq reactors have a volume of 300 m3 each. The
following overall reaction formula describes the overall formation of struvite (magnesiumammonium-phosphate (3):
Mg2+ + NH4+ + PO43- MgNH4PO4 . 6H2O

(3)

Air is introduced to the reactor to (1) provide sufficient mixing to obtain a good quality of
struvite crystals, (2) strip CO2 and enhance struvite formation and (3) provide some oxygen to
oxidize COD. A sophisticated patented separator system at the top of the reactor is applied to
retain the struvite and biomass into the system. The aeration system and separator are
designed to avoid scaling due to struvite precipitation. Struvite is harvested from the bottom of
the reactors and subsequently dewatered by a screw press and put into a container. Figure 3
shows photograps of the struvite produced.

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Figure 3

Photograph of struvite in container and microscopic view of struvite crystals

Nutrient Removal One Step ANAMMOX Reactor

In order to meet the stringent discharge limits decrease energy consumption for nitrogen
removal, the effluent from the struvite reactor is subsequently treated in a one-step Anammox
reactor to remove nitrogen. In the one-step Anammox reactor (Strous et al. 1997) ammonium
is converted into nitrogen by a combination of nitritation and anammox bacteria. The anammox
bacteria convert ammonium (NH4) and nitrite (NO2-) into nitrogen gas (N2) without requiring an
external carbon source and using a minimum of oxygen (figure 4). The simplified conversion in
this reactor is:
2 NH4+ + 0.85 O2

0.9 N2 + 0.2 NO3- + biomass

(4)

The applied reactor is filled with granular biomass and equipped with a patented biomass
separator on top of the reactor. The Anammox reactor is aerated continuously and controlled
by online measurement of ammonium and nitrite.
In contrast to conventional nitrification-denitrification the conversion of ammonium via the
anammox (anaerobic-ammonia-oxidation) process does not require organic carbon and uses a
minimum amount of energy (Jetten et al, 1997, see figure 4). As a result a bypass of raw
effluent, providing COD as is required for conventional denitrification, is not needed. In case of
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Olburgen a bypass of industrial wastewater is made obsolete as the use of the anammox process
allows valorization of the complete effluent generating maximum possible amounts of biogas.
In addition the anammox conversion consumes less oxygen, saving almost 60 % in power
consumption (for aeration) as compared conventional nitrification-dentrification.

Figure 4

Biological nitrogen cycle including the Anammox route

Results
Anaerobic Treatment

The anaerobic digesters produce approximately 750,000 m3 biogas per annum. About 88 % of
the biogas generated by the digester is utilized in a CHP unit with a capacity of 190 kWe. About
10 % is used in for direct heating of the digester, while 2 % is flared-off. While the CHP has been
operated for many years in the nearby future the biogas from the digesters is anticipated to be
compressed and directed to the nearby food factory.
The UASB reactors are loaded with a COD load up to 20,000 kg COD per day generating
approximately 2.5 to 3.0 Mln m3 biogas per annum. The removal efficiency on soluble COD is
amount approximately 85-90 %. The UASB reactors produce approximately 750 m3 of granular
anaerobic sludge annum is produced. The sludge has a natural dry matter of approximately of 810 % and does not require further dewatering. The sludge is used for inoculation of other
anaerobic sludge bed reactors and has a positive commercial value.
THIOPAQ Biogas Purification

The Thiopaq scrubber treats a flow of 300-450 m3/h. Figure 5 shows a photograph of the
Thiopaq unit.

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Figure 5

Photograph of Thiopaq unit including scrubber column (r), bioreactor (m) and CHP
unit (l)

The H2S levels in the biogas are generally varying between 5000 ppm and 6000 ppm (by volume).
H2S levels in the biogas are reduced from an average of 5200 ppm to less than 100 ppm. Detailed
results are presented in figure 6.

8000

7000

H2S CONCENTRATION (ppmv)

H2S in
H2S out

6000

5000

4000

3000

2000

1000

0
0

50

100

150

200

TIME (days)

Figure 6

H2S concentrations in inlet and outlet of Thiopaq scrubber

About 300 m3/h of the clean biogas is utilized in a CHP unit producing an average of 630 kWhe
of electrical power. The heat of the CHP is used to heat up the effluent into the UASB reactor. In
future any excess biogas from the Thiopaq scrubber is anticipated to be mixed with the
digester biogas and directed to the nearby located food factory.

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Nutrient removal - PHOSPAQ reactor

In 2008 the Phospaq reactor was loaded with an average of approximately 200 kg PO4-P per
day. An average amount of 150 kg P per day was recovered through struvite formation. The
average inlet and outlet concentrations of PO4-P were 80 m/l and 17 mg/l respectively.
The produced struvite has been tested as fertilizer in crop tests and found suitable as substitute
for commercial fertilizers (DLV Plant, 2008). The approximate size of the harvested struvite
crystals was kept at around 0.7 mm. The produced struvite is in compliance to EU regulations
for use as a fertilizer (Staatsblad, 2007). The struvite is harvested at a dry matter of around 75 %
and currently used as a valuable co-product as a slow-release fertilizer.
Nutrient Removal - One-Step ANAMMOX reactor

The OneStep Anammox reactor has been loaded up to 1200 kg per day without compromising
its removal efficiencies. Higher volumetric capacities are feasible as biomass concentrations in
the reactor can be increased with a factor of 3 if needed. Inlet and outlet ammonium
concentrations of the one-step Anammox reactor were 300 mg NH4-N/l and 30 mg NH4-N/l
respectively. In 2008 the average removal of ammonium was 91 %, whereas higher removal
efficiencies of 95 % have been recorded for prolonged times. Approximately 100 m3 of highly
active granular anammox biomass is estimated to be extracted per year. The granular biomass is
used as seed material to enhance start-up of new one-step anammox reactors. The
performance (expressed in 30 day moving average) of the one-step Anammox reactor during
2008 is shown in figure 7.

Figure 7

Ammonium nitrogen loadings of the One-Step Anammox reactor

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The combined treatment of reject water and industrial UASB effluent has been in operation for 3
years with good performance. Figure 8 presents the overall nutrient removal treatment plant
including the Phospaq and one-step Anammox reactors.

Figure 8

Schematic and photograph of Phospaq and one-step Anammox reactors

The treatment by the Phospaq and one-step Anammox reactor of the digester reject water
and UASB effluent has demonstrated to be an effective method for reducing N and P
concentrations of in the final effluent of the STW Olburgen. Nitrogen concentration in the final
STW effluent was effectively reduced from an annual average concentrations of 15 mg N/l to
levels less than 8 mg N/l. Phosphorous was reduced from an annual average concentration of 8
mg P/l to less than 4 mg P/l.
A simplified overall schematic of the treatment plant for digester reject water and industrial
effluent at the STW Olburgen including the generation of valuable by-products is presented in
figure 10.
As the Anammox process does not require any bypass of raw wastewater for nitrogen removal,
all effluents can be anaerobicallly treated resulting in a total power generation of 820 kWe.
Furthermore approximately 55 ton P per annum is recovered as usable fertilizer and the
granular biomass from the anaerobic UASB (approx. 750 m3/a)and Anammox reactors (approx.
100 m3/a) is used for seeding other similar reactors. In future the digester biogas and any excess
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of biogas from the UASB reactors (not utilized by the 690 kWe CHP unit) will be diverted to the
nearby food factory replacing natural gas.

Figure 9

Schematic of reject water and industrial wastewater treatment including by-products

produced

Recovery of phosphate, sulfur and biogas and saving of energy is relevant for a wide range of
applications including treatment of reject water from biosolids digesters and other organic
solids waste digesters.

Conclusions
1. The combination of the Phospaq struvite reactor and one-step Anammox reactor has
proven to be a reliable and cost effective method for purification of highly nutrient (N, P)
loaded effluents like digestor reject water and potato factory wastewater.
2. The struvite produced in the Phospaq reactor is a valuable resource for fertilizers.
3. The Anammox process allows maximum valorization of effluents highly loaded with
nitrogen. Energy savings (for aeration) up to 60% may be obtained and (external) carbon
sources are not required.
4. The biological Thiopaq biogas desulphurization process maximizes gas utilization in CHP
units at reduced operational costs due to biological caustic regeneration.

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11

References
Abma, W.R., Driessen, W.J.B.M., Haarhuis, R. and Van Loosdrecht, M.C.M. (2009) Upgrading of
sewage treatment plant by sustainable & cost-effective separate treatment of industrial
wastewater, Proceedings of the 2nd IWA Specialized Conference on Nutrient Management in
Wastewater Treatment Processes, 185-194.
Abma, W., Schultz, C.E., Mulder, J.W., Van Loosdrecht, M.C.M., van der Star, W.R.L., Strous, M.
and Tokutomi, T. (2007) The advance of Anammox. Water 21, 36, 36-37.
DLV Plant (2008) Orientatie toepassingsmogelijkheden Mg-struviet als meststof in de Land- en
Tuinbouw. (in Dutch)
Jetten, M.S.M., Horn, S.J. and Van Loosdrecht, M.C.M. (1997) Towards a more sustainable
municipal wastewater treatment system. Water Science & Technology, 35(9), 171-180.
Strous, M., van Gerven, E., Kuenen, J.G. and Jetten, M.S.M. (1997) effects of aerobic and
microaerobic conditions on anaerobic ammonium-oxidizing (Anammox) sludge.
Appl.Environ.Microbiol. 63, 2446-2448
Staatsblad (2007) Besluit van 4 juli 2007, houdende wijziging van het Uitvoeringsbesluit
Meststoffenwet, het Besluit gebruik meststoffen en het Lozingenbesluit open teelt en
veehouderij (overheveling Meststoffenwet 1947 en Besluit kwaliteit en gebruik overige
organische meststoffen). Staatsblad 251 (in Dutch)

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