Performance assessment of ultrasonic sludge disintegration in activated sludge wastewater treatment plants under nutrient-deficient conditions

• Ultrasonic excess sludge reduction benefits from a higher SRT. • By increasing the SRT the electrical energy needed was reduced by 80% • Sludge disintegration can eliminate the need for the external nutrient addition. • Sludge disintegration positively impacts sludge settleability and effluent quality. • A low specific energy can lead to a sludge reduction efficiency of 15% to 40% Although biological oxidation is a commonly applied technique for the removal of pollutants in industrial and municipal wastewater, one major drawback is its excess sludge production, having both an environmental and economic impact. The integration of ultrasonic sludge disintegration in a conventional biological wastewater treatment plant was explored experimentally via assessing the long-term effects on excess sludge reduction by conducting on-site pilot tests at a food processing company and a biodiesel production plant. Two sequencing batch reactors, each with a maximum active volume of 700 L, were operated in parallel for the treatment of industrial wastewater with nutrient deficient characteristics (COD/N/P ratio of 100/1.4/0.12) for over 6 months. One of the reactors was equipped with a side-stream recirculation system to enable the ultrasonic treatment of part of the settled sludge, whereas the other was operated in a conventional way as a reference. The experimental results show a reduction of the observed sludge production yield by 15% to 45% for the ultrasonically treated sequencing batch reactor compared to the conventional one, at a relatively low specific energy of less than 6,000 kJ/kg DS when 15 to 30% of the total sludge mass is treated per day. It was proven that the sludge reduction efficiency is directly proportional to the applied sludge retention time, suggesting that the ultrasonic treatment converts part of the hardly biodegradable particulate material in the activated sludge and improves its biodegradability. During the long-term pilot experiment at the biodiesel production plant, the electrical energy needed for decreasing the excess sludge production by 1 ton could be reduced by more than 80% when the sludge retention time was increased from 11 to 44 days. In addition, the sludge settling characteristics at the food processing company were considerably improved by the ultrasonic treatment, enabling to reduce or even avoid the need for external addition of expensive nutrients to prevent sludge bulking. Finally, an improved effluent quality was observed. Improvements of 7 to 17%, 9 to 20% and 17 to 30% for COD, nitrogen and phosphorus removal, respectively, were established.