Waste Management 21 (2001) 717–724 www.elsevier.com/locate/wasman Sequential (anaerobic/aerobic) biological treatment of Dalaman SEKA Pulp and Paper Industry effluent Ulas Tezel a, Engin Guven b,*, Tuba H. Erguder a, Goksel N. Demirer a a Middle East Technical University, Department of Environmental Engineering, Inönü Bulvari, 06531 Ankara, Turkey b Civil and Environmental Engineering, Marquette University, PO Box 1881, Milwaukee, WI 53201-1881, USA Received 13 June 2000; received in revised form 24 January 2001; accepted 29 January 2001 Abstract In the pulp and paper industry, lignin and other color compounds are removed by chemical agents in bleaching process. Use of chlorine-based agents results in production of degradation products which include various chloro-organic derivatives. Since these new compounds are highly chlorinated, they cause a problem in the treatment of pulp and paper industry wastewaters. Chemical precipitation, lagooning, activated sludge, and anaerobic treatment are the processes used for treating pulp and paper effluents. Furthermore, a combination of these processes is also applicable. In this study, the effluent of Dalaman SEKA Pulp and Paper Industry was examined for its toxic effects on anaerobic microorganisms by anaerobic toxicity assay. Additionally, this wastewater was applied to a sequential biotreatment process consisting of an upflow anaerobic sludge blanket as the anaerobic stage and a once-through completely mixed stirred tank as the aerobic stage. Results indicated that: (1) Dalaman SEKA Pulp and Paper Industry wastewater exerted no inhibitory effects on the anaerobic cultures under the studied conditions, and (2) application of a sequential biological (anaerobic/aerobic) system to treat the Dalaman SEKA Pulp and Paper Industry wastewater resulted in approximately 91% COD and 58% AOX removals at a HRT of 5 and 6.54 h for anaerobic and aerobic, respectively. # 2001 Elsevier Science Ltd. All rights reserved. Keywords: Pulp and paper industry; Upflow anaerobic sludge blanket (UASB); Completely mixed stirred tank (CMSTR); Anaerobic; Aerobic 1. Background The main processes that are involved in the manufacture of paper are debarking, pulping, separation of pulp from cooking liquor, bleaching, stock preparation and making the final paper product. In the bleaching process, lignin and other color compounds are removed by chemical agents. The oxidation agents used for bleaching, central to the industry, are chlorine-based such as Cl2, ClO2, hypochlorite, NaOCl, etc. There are also oxygen-based oxidation agents (such as H2O2, Na2O2, O3, etc.) under consideration, but they are far from wide-scale applications. Use of chlorine-based agents results in the production of degradation products which include various chloro-organic derivatives. The technology of the bleaching process and in-mill control * Corresponding author. Tel.: +1-414-288-1607; fax: +1-414-2887521. E-mail address: engin.guven@marquette.edu (E. Guven). is under continuing improvement. But yet, treatment of bleaching process wastewater externally is necessary [1]. Thus, treatment of pulp and paper industry effluents containing chlorinated compounds is still of vital importance. The general characteristics of the pulp and paper industry effluent can be listed as: (1) high lignin content, (2) high absorbable organic halide (AOX) concentration (due to the bleaching process), (3) color, (4) low biodegradability which is indicated by their high chemical oxygen demand to biochemical oxygen demand ratios (COD/BOD), often in the range of 4–6, and (5) potential toxicity problems. The typical treatment processes for pulp and paper effluents are chemical precipitation, lagooning, activated sludge, and anaerobic treatment. When the economic concerns and the rate of treatment are considered, anaerobic treatment can offer a viable treatment option for these wastewaters. Many researchers studied removal of organic compounds from pulping effluents. In terms of chemical 0956-053X/01/$ - see front matter # 2001 Elsevier Science Ltd. All rights reserved. PII: S0956-053X(01)00013-7 718 U. Tezel et al. / Waste Management 21 (2001) 717–724 precipitation, depending on the coagulant and studied wastewater (unbleached kraft effluent, bleached kraft effluent, neutral sulphite semi-chemical, etc.), various removal efficiencies (20–85% for AOX, 20–91% for COD and 36–100% for color) were achieved [2–12]. A three-stage chemical treatment using FeCl3, H2SO4, and alum in successive stages resulted in a total BOD reduction of 50%, with a turbidity reduction greater than 82%, and a practically colorless effluent. All other single coagulants or combinations of chemical coagulants resulted in lower BOD reductions [13]. It was also reported that the percent AOX reduction by combined chemical and biological treatment ranged from 53 to 59% depending on the operating conditions of the biological treatment process [14]. In an aerated lagoon, 37% of the totally bound chlorine and 24% of the non-purgeable organic carbon (NPOC) were removed [15]. In another study, 32% AOX removal was achieved in treatment of conventional mill wastewater by an aerated lagoon system [16]. The performance data for aerobic, facultative, and anaerobic ponds are summarized for pulp and paper wastewaters in Table 1 [17]. In an activated sludge plant treating kraft mill wastewater, 40–50% AOX and COD removals were achieved. In another mill, which had a BOD loading of about seven times higher than the former, a COD reduction of 34% and an AOX removal of 20–30% were achieved [18]. A 70% COD removal in a UASB reactor was reported [19]. Biological AOX removal was studied for 2 years and 30–35% removal for aerobic, 40–45% for anaerobic and 50–55% removal for anaerobic–aerobic sequential treatment were observed [20]. When two reactor systems as two-stage bioreactors in series followed by a settler with solids recycle were studied, one system was operated in an anaerobic-aerobic mode (NA) and the second in an aerobic mode (AA). However, no obvious difference between NA and AA systems (57 and 59% removal of AOX, respectively) was obtained [1]. Zitomer and Speece [21] stated that the ability of an aerobically activated sludge process to reduce toxicity is highly variable even when efficient suspended solids and BOD removal is achieved. Anaerobic reactor followed by aerobic reactor is more successful at reducing toxicity. Reductive dechlorination may occur in anaerobic stage and produces less chlorinated organics. These organics may be further biotransformed in conventional aerobic stage [21]. In this study, a pulp and paper industry effluent from Dalaman SEKA Pulp and Paper Industry was examined for its toxic effects on anaerobic microorganisms by anaerobic toxicity assay. Additionally, this wastewater was applied to a sequential biotreatment process consisting of an UASB as the anaerobic stage and a once-through CMSTR as the aerobic stage. 2. Materials and methods 2.1. Inocula 2.1.1. Municipal anaerobic digester sludge (MADS) Municipal anaerobic digester sludge (MADS), which was used in batch experiments, was obtained from anaerobic digesters of the Ankara Municipal Wastewater Treatment Plant, Turkey. The digesters are cylindrical in shape and made of concrete with a retention time of 14 days. The average flow of sludge from primary thickeners to each digester is 805 m3/day. The pH in the digesters ranges between 7.00 and 7.70. Before using, the sludge was thoroughly mixed and filtered through a screen with a pore size of 1 mm. Where a more concentrated sludge was needed, it was settled in an Imhoff cone for 24 h and the sludge remaining under the supernatant was used. 2.1.2. Anaerobic granules Anaerobic granules, which were used in the UASB reactors, were obtained from the wastewater treatment plant of Tekel Pasabahce Factory, Istanbul, Turkey. The organic loading rate of the treatment plant is 30 kg COD/m3 day with a flow of 60 m3/day. The pH of the reactor ranges between 6.0–9.0. 2.1.3. Aerobic cultures Aerobic cultures were obtained from the aeration tanks of the activated sludge units of the Ankara Municipal Wastewater Treatment Plant, Turkey, with a sludge age and organic loading of 2.8 days and 165,000 kg BOD5/day, respectively. Table 1 Performance of lagoon systems in treatment of pulp and paper wastewaters Lagoon configuration Area (acres) Depth (ft) Detention (day) Loading (lb/acre day) BOD5 removal (%) Aerobic — facultative Anaerobic ponds Aerobic — anaerobic 84 71 2520 5.0 6.0 5.5 10 18.4 136 157 347 28 87 50 94 U. Tezel et al. / Waste Management 21 (2001) 717–724 2.2. Pulp and paper effluent Pulp and paper effluent (PPE) was obtained from Dalaman SEKA Paper Industry, Turkey. During the entire research, PPE was taken twice from the industry (PPE-1, PPE-2). PPE-1 had a COD of 450–500 mg/l and volatile suspended solids (VSS) concentration of 51 4.2 mg/l, whereas PPE-2 had a COD of 5500–6000 mg/l and VSS of 820 28.3 mg/l. Before using in the continuous reactor experiments, the PPE was thoroughly mixed, strained through a 175-mm sieve and stored in a 10-liter glass container. 2.3. Preparation of basal media To supply necessary micro and macro nutrients and alkalinity, basal media (BM) was used in the batch experiment. The composition of the BM is as follows (concentrations of the constituents are given in paranthesis as mg/l): NH4Cl (1200), MgSO4.7H2O (400), KCl (400), Na2S.9H2O (300), CaCl2.2H2O (50), (NH4)2HPO4 (80), FeCl2.4H2O (40), CoCl2.6H2O (10), KI (10), MnCl2.4H2O (0.5), CuCl2.2H2O (0.5), ZnCl2 (0.5), AlCl3.6H2O (0.5), NaMoO4.2H2O (0.5), H3BO3 (0.5), NiCl2.6H2O (0.5), NaWO4.2H2O (0.5), Cysteine (10), NaHCO3 (6000) [22]. 719 2.4.5. Volatile fatty acids (VFA) and bicarbonate alkalinity Volatile fatty acids and bicarbonate alkalinity were measured according to the titration procedure described by Anderson and Yang [25]. 2.4.6. Color Color of the samples were measured by using a Hach DR/2000 spectrophotometer operated at a wavelength of 455 nm [24]. 2.4.7. AOX The AOX concentration of the samples was measured by an analytical instrument containing boat control, control, furnace, coulometer cell and micro coulometer (Euroglas) units and a printer (Kipp & Zonen). After filtering the samples through 0.45 mm filter paper the procedure explained in ‘‘Manual for Determination of AOX, POX and EOX’’ (1988) was followed. 2.5. Experimental set-up 2.4.3. Gas production Gas production in serum bottles was measured using a gas replacement device consisting of a 50-ml burette with a water reservoir. A needle connected via latex rubber tubing to the burette was inserted through the serum bottle stopper, and the volume of the water displaced from the cylinder by gas was recorded. The collected gas was vented after the measurement. 2.5.1. Batch experiment In order to investigate the toxicity of the PPE-1 on MADS, an anaerobic toxicity assay (ATA) experiment was conducted as described by Demirer and Speece [22] and Owens et al. [26]. The ATA experiment was performed in 125-ml serum bottles capped with natural rubber sleeve stoppers. MADS (10 ml )with a VSS of 14,925 35 mg/l and 10 ml of five times concentrated BM were inoculated into the bottles. After 3–4 min purging with a mixture of 25% CO2 and 75% N2 gases for proper pH and anaerobic conditions, serum bottles were incubated in a room that was maintained at 35 2 C. Acetic acid was supplied as the primary substrate into the bottles. The acetic acid concentration in the serum bottles was stochiometrically restored to 1050 mg/l daily depending on the gas produced the previous day. After observing steady state gas production (that is when the daily variation in gas production is less than 10%) 5, 10, 20, 30 mL of PPE were injected into the bottles. The total liquid volume in the bottles was completed to 50 ml by injecting tap water (Ankara, Turkey) where necessary. All the control and test serum bottles were run as duplicates. After spiking, the serum bottles were monitored for 14 days. 2.4.4. COD COD concentrations were determined according to an EPA approved reactor digestion method [24]. A Hach COD reactor and a Hach DR/2000 spectrophotometer operated at a wavelength of 620 nm were used. COD detection limit was 18 mg/l. Therefore, effluent COD values of 0–18 mg/l corresponded to 100% COD removal in calculations. 2.5.2. Continuously operated reactors An Upflow Anaerobic Sludge Blanket (UASB) reactor was set up using a plexiglass column with an inner diameter of 5.2 cm and length of 1 m with an effective volume of 2.1 l. Anaerobic granules with a TVS of 280 g/l were placed into the reactor to a height of 27 cm. Additionally, 1.35 m of 2 m wire given a spiral shape was submerged into the sludge in order to facilitate the 2.4. Analytical Methods 2.4.1. Suspended solids (SS), volatile suspended solids (VSS), total solids (TS) and total volatile solids (TVS) SS, VSS, TS, and TVS were measured according to Standard Methods 2540 [23]. 2.4.2. pH pH in samples was measured by a bench-top pH meter (Jenway Ltd., Essex, UK) and a general purpose pH electrode (Cole Parmer, Niles, IL,USA). 720 U. Tezel et al. / Waste Management 21 (2001) 717–724 Fig. 1. Schematic illustration of the reactor system. release of gas produced and avoid sludge floating. Thus, the effective volume of the reactor was 0.57 liters. Both ends of the column were closed with cork covered by Teflon tape. Teflon tubing was used at the inlet and outlet of the reactor. All connectors used in the setup were made of Teflon. The substrate was pumped continuously upwards into the reactor from the bottom. There was no recycle. Longitudinal mixing was mainly caused by rising gas bubbles and dispersion. The reactor was placed in the temperature controlled room at 35 2 C (Fig. 1). PPE was introduced to the reactor as the feed. However, in order to maintain sufficient alkalinity in the influent, 2 g/l of NaHCO3 was added to the feed. COD, volatile acids, bicarbonate alkalinity, liquid flow, pH, and AOX were measured during the experiment. A once through Completely Mixed Stirred Tank Reactor (CMSTR) was included as the aerobic system at the effluent of the UASB after 51 days in the test in order to explore the effect on AOX and COD removal efficiency. The aerobic reactor consisted of a 1-liter plastic container with an effective volume of 0.75 liter. Since no sludge recycle was applied to the aerobic system, the SRT of the aerobic system was equal to the HRT. Aeration and mixing were maintained by a diffuser type aerator delivering 800 standard ml/min air (Fig. 1). The aerobic system was placed out of the temperature-controlled room where the temperature was 28 2 C. VSS in the reactor was measured as 290 28 mg/l. 3. Results and discussion 3.1. Batch experiment The purpose of the batch experiment was to obtain general information on the toxicity of PPE-1. Five sets of test bottles each containing two test bottles with the same amount of wastewater were monitored over 14 days by adding acetic acid according to the gas produced the previous day. The mean daily gas production in two bottles of each set tested was normalized by dividing by the mean of the daily gas production in the control set. The daily standard deviation of duplicate bottles was less than 10% of the mean gas production. Fig. 2. Normalized anaerobic toxicity assay results of pulp and paper effluent. U. Tezel et al. / Waste Management 21 (2001) 717–724 Such standard deviations indicate that the results obtained are statistically dependable. As shown in Fig. 2, no reduction in gas production was detected for PPE-1. Therefore, it was concluded that PPE-1 had no inhibitory effect on anaerobic microorganisms under studied conditions. The increase in gas production observed after the injection of 20 and 721 30 ml of PPE-1 may be caused by the additional organic load from the wastewater. 3.2. Continuously operated reactors Two different PPE samples were studied during the experiment. The results obtained during the experiment Fig. 3. Results obtained from continuous reactor experiments of PPE-1. 722 U. Tezel et al. / Waste Management 21 (2001) 717–724 are given in Figs. 3 and 4 for PPE-1 and PPE-2, respectively. PPE-1 was fed to the UASB reactor for 35 days with HRTs of 34, 17 and 8.6 h. When the HRT was 17 h. the maximum COD removal (60%) and the maximum color removal (46%) were achieved with 28% AOX removal. Maximum AOX removal (45%), however, was obtained with HRT of 34 h at which maximum COD and color removals were 44 and 42%, respectively. VFA was also monitored as an important indicator of the performance of the reactor. The VFA values measured throughout the experiments were very low indicating a proper operation of the reactor (Fig. 3). PPE-2 was introduced to the same UASB as PPE-1, but this time an aerobic reactor was installed downstream. The UASB was operated with HRTs of 8.6 and 5 h whereas HRTs of the aerobic system were 11 and 6.5 h, respectively (Fig. 4). A maximum of 93% COD Fig. 4. Results obtained from continuous reactor experiments of PPE-2. U. Tezel et al. / Waste Management 21 (2001) 717–724 removal was achieved with 8.6 h HRT in the UASB reactor. The addition of the aerobic reactor did not affect the overall performance in terms of COD at Day 2. At 8.6 h HRT, AOX and color removals achieved were 54 and 52%, respectively, in the anaerobic reactor. An additional 5% removal of AOX was achieved in the aerobic reactor (Day No. 2). A maximum of 85% COD, 50% AOX and 90% color removal were achieved at 5 h HRT in UASB (Day No. 8). The aerobic reactor fed with the effluent of UASB provided an additional 8% AOX and 6% COD removal with 6.5 h HRT (Day No. 11). Thus, total removal increased to 91 and 58% in terms of COD and AOX, respectively. However, that 5 h HRT adversely affected the system because of high loading. Through the end of the experiment, efficiencies in COD, color and AOX removal were decreased to 55, 30, 35%, respectively, in the UASB. No additional removal was achieved in the aerobic reactor in terms of COD and AOX, but 10% additional color removal was still observed in the aerobic stage (Day No. 13). Habets and Knelissen [19] reported 70% COD removal in a UASB reactor at an organic loading rate of 19 g COD/l day and HRT of 2.5 h. In this study, at an organic loading rate of 16 g COD/l day and 5 h HRT, COD removal efficiencies of 85 and 91% were obtained in UASB and at the end of aerobic stage, respectively (Fig. 4). Moreover, highest AOX removal efficiencies obtained were 52 and 58% in UASB and at the end of aerobic stage respectively (Fig. 4). These results are slightly higher but consistent with the results Ferguson [20] reported. 4. Conclusions and recommendation In this study, Dalaman SEKA Pulp and Paper Industry’s wastewater, which contains chlorinated organics, was examined for its toxicity under anaerobic conditions and its treatability by a sequential UASB and aerobic once-through CMSTR reactor configuration. The following conclusions can be drawn according to the experimental results obtained in this study: 1. Based on results of the anaerobic toxicity assay (ATA) test, Dalaman SEKA Pulp and Paper Industry wastewater exerted no inhibitory effects on the anaerobic cultures under the studied conditions. 2. Application of a sequential biological (anaerobic/ aerobic) system to treat the Dalaman SEKA Pulp and Paper Industry wastewater resulted in approximately 91% COD and 58% AOX removals at a HRT of 5.0 and 6.5 h for anaerobic and aerobic, respectively. AOX removal efficiency is promising when compared with the separate application of conventional aerobic and anaerobic treatment. COD removal, on the other hand, is 723 sufficiently high when compared with the values presented by the previous studies, which were stated before. 3. A color removal efficiency of 90% was achieved in the anaerobic reactor at an HRT of 5.0 h. Addition of an aerobic reactor to the system did not affect the color removal significantly. 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