Case Studies

Case Study I. A full-scale integrated natural system has been used to treat high-strength potato processing water for 2 years [34]. The integrated natural system consists of free water surface and vertical flow wetland, and a facultative storage lagoon. Wetland components were designed for sequential treatment of the wastewater. Wastewater is pumped from a primary clarifier to ten hectares of free water surface wetlands constructed for sedimentation and mineralization of wastewater (W1/W2). The process water from the W1/W2 wetlands is sprayed onto 4 hectares of vertical flow wetland (W3) for oxidation of carbon and nitrogen. These wetlands were filled with 0.9 m of a local sand (D50=2.6 mm) excavated on site. These vertical flow wetlands were operated as intermittent sand filters with duty cycles of 6-72 hours. They were not planted with Phragmites australis due to poor growth when sprayed with the wastewater [15]. Water flows by gravity from the W3 into 2 hectares of denitrifying free water surface wetlands (W4). Raw process water is supplemented to augment denitrification in the wetlands. Treated process water flows into a 0.48 million m3 lagoon (126 million gallon), which provides facultative treatment and storage prior to land application (Fig. 12).

The wetlands were constructed in stages throughout 1994 and 1995 in Connell, Washington. Connell is located centrally in the Colombia Basin, which is an arid agricultural area sustained by irrigation water from the Colombia River. All wetlands were lined with 1.0 mm (40 mil) HDPF liner impregnated with carbon black for UV resistance. All free water surface wetlands had 20-30 cm (8-12 in.) of native soil placed on the liners as soil for Typha sp. and 2 spaces of Scirpus sp.

The wetlands system is designed to treat an annual average flow of 1.4 mgd (approx. 5300 m3/day) of wastewater with an annual average concentration of 3150 mg/L COD, 575 mg/L TSS, 149 mg/L TKN, and 30 ml/L NH4-N. The winter design temperature was 1°C, with the consideration that the flow to the engineered natural system was lower in the winter season, due to operational difficulties in the water supply system.

Regarding the operational results of the integrated natural system, there were excellent reductions of TSS and COD, while organic nitrogen was effectively mineralized. TKN was reduced by about two-thirds, which is the requisite amount for balancing irrigation and nitrogen supply to the crop [15].

The net COD removal through the system was greater than 90% all year round. The W1/W2 wetlands removed about 85-90% of the COD, and 80-90% of the TSS. The average COD loading to the W1/W2 was 0.5 kg/m3-day (31 lb/1000 ft3-day) and 0.3 kg/m3-day (18 lb/1000 ft3-day) for the summer and winter, respectively. This loading rate is similar to the low rate covered anaerobic lagoons used for COD reduction in food processing. The effluent concentrations from the wetlands are lower in COD and TSS than from equivalently loaded covered anaerobic lagoons [35,36].

The effluent TSS from W1/W2 wetlands is consistently less than 75 mg/L. The W1/W2 wetland plants have proven to be very effective in solids removal. The TSS concentration increases in the lagoon due to algae growth.

In terms of nitrogen removal, the treatment objective of the system is a 53% reduction in total nitrogen (TN). The wastewater application permit requires an annual nitrogen load of 500 kg/ha-year on 213 hectares of land used to grow alfalfa and other fodder crops. The results related to TN removal indicate that the wetlands operate better than design expectation.

With regard to organic carbon, the potato water mineralizes very rapidly so that >60% of the organic carbon was mineralized to NH4-N prior to entering the wetlands. This mineralization continued in the W1/W2 wetlands so that< 15 mg/L organic nitrogen remained.

More than 60% of the TN entering the W1/W2 wetlands was in the form of NH4-N, and 10-20% of the NH4 was removed from the W1/W2. The pH in the W1/W2 was always>7.0 and may have contributed to volatilization of NH4-N. The NH4-N removal through the vertical flow wetlands averages 85% during the summer and 30-50% during the winter.

Removal of nitrate and nitrite is critical for compliance with TN removal goals in order to minimize the amount of oxidized N applied in land. Reduction of COD or BOD is often viewed as a prerequisite to establishment of nitrifying conditions [37]. Dissolved oxygen is slightly higher in the winter, but most of the system is anoxic except for the vertical flow component. Alkalinity is sufficient to support nitrification (ca. 1000 mg/L) [15]. The majority of the denitrification occurred in the W4 wetlands. Endogenous carbon in the W4 wetland was inadequate to support significant denitrification. Addition of raw potato water allows>90% denitrification, but also resulted in increased effluent NH4-N concentrations. Approximately 5-7 NO3-N were removed for each NH4-N added.

Regarding the problem of odor, which generates from the decomposition of potato products, the strongest odors arose from the death of a large population of purple sulfur bacteria in the W1/W2 wetlands and the resulting sulfides>40 mg/L.

The integrated natural system is effective in reducing sulfate concentrations, from about 40 mg/L to 10 mg/L, in wetland W1. Because W1 is devoid of oxygen, sulfate has been reduced to sulfides or sulfur, including the possibility of hydrogen sulfide formation. The effluent of the treatment system has no serious odors. The final product is high-quality water with available nutrients and no odor problem during land application.

In comparing this integrated natural system with other treatment wetlands for treating food processing wastewaters, such as meat processing waters, it may be concluded that potato processing water is comparable to meat processing effluents in treatability [15]. Furthermore, it has been demonstrated that the use of this full-scale engineered natural system is a cost-effective treatment alternative for high-strength industrial wastewater. Continued research and development in operations and design of the full-scale system have resulted in better performance than that of the original design.

Activated Sludge Processes. In these processes, the preclarified wastewater is discharged into aeration basins/tanks, where atmospheric oxygen is diffused by releasing compressed air into the wastewater or by mechanical surface aerators. Soluble and insoluble organics are then removed from the wastewater stream and converted into a flocculent microbial suspension, which is readily settleable in sedimentation basins, thus providing highly treated effluent.

There is a number of different variants of activated sludge processes such as plug-flow, complete mixing, step aeration, extended aeration, contact stabilization, and aerobic sequential reactors. However, all operate essentially in the same way. These variants are the result of unit arrangement and methods of introducing air and waste into the aeration basin and they have, to a large extent, been modified or developed according to particular circumstances.

For the treatment of food and vegetable industrial wastewater, the common activated sludge methods are shown in Fig. 13.

With regard to potato wastewater treatment, the first full-scale activated sludge system was applied in the United States toward the end of the 1970s, by the R.T.French Company for treating their potato division wastewaters in Shelley, Idaho. Thereafter, many other potato processors installed biological treatment systems, most of which were activated sludge processes (Table 7).

Hung and his collaborators have conducted extensive research in various treatment processes for potato wastewater [10,16,17,20,38-41]. These included activated sludge processes with and without addition of powdered activated carbon, a two-stage treatment system of an activated sludge process followed by biological activated carbon columns, a two-stage

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