Aerobic Granular Sludge: The Future of Wastewater Treatment: Y. V. Nancharaiah, M. Sarvajith and T. V. Krishna Mohan
Aerobic Granular Sludge: The Future of Wastewater Treatment: Y. V. Nancharaiah, M. Sarvajith and T. V. Krishna Mohan
Aerobic Granular Sludge: The Future of Wastewater Treatment: Y. V. Nancharaiah, M. Sarvajith and T. V. Krishna Mohan
Figure 1. State-wise distribution of sewage generation and treatment capacity in India (data sourced
from ref. 17).
Figure 3. Morphology of (a) activated sludge and (b) aerobic granlar sludge. Scale bar: 1 mm.
Parameter Goal
attracted research attention (Figure 6) for its promising treating mixed wastewater with 30% sewage and 70%
technological applications in domestic and industrial industrial wastewater from printing and dyeing, chemical,
wastewater treatment9. textile and beverage industries14. Studies on full-scale GS
Research has shown that GS performs better than AS plants reported long start-up periods of up to 10 months
(Table 3) in removing contaminants from the waste- for achieving reasonable granulation (80% of biomass in
water33. GS has been demonstrated to degrade a variety the form of granules). It is to be noted that these full-
of toxic and recalcitrant organic compounds such as azo scale plants were used for treating wastewater consisting
dyes, phenols, metal chelating agents, organophosphorus of significant proportion (30–70%) of industrial effluents.
compounds, nitroaromatic compounds, anilines and It appears that long start-up periods are required for GS
pharmaceuticals in laboratory-scale bioreactors34–38. formation, and for establishing nitrogen and phosphorus
Formation of GS and wastewater treatment were also removal when this technology is considered for sewage
demonstrated in aerobic pilot-scale bioreactors39–41. A treatment.
full-scale GS plant has been set-up in The Netherlands Several strategies have been proposed for the devel-
for treating mixed wastewater comprising 65% sewage opment of GS as well as to minimize start-up period
and 35% industrial (slaughter house) wastewater13. under real sewage conditions. Mixing of industrial
Another full-scale plant has been set-up in China for wastewater with sewage40,42, or addition of acetate to
Figure 6. Year-wise distribution of publications on aerobic granular sludge for wastewater treatment
(Scopus-indexed publications with keywords ‘aerobic granules’, ‘aerobic granular sludge’, ‘aerobic gra-
nular biomass’, ‘aerobic granular microbes’, or ‘aerobic microbial granules’ as on March 2019 are in-
cluded).
sewage43,44 was reported. Addition of particles of granu- imposed for forming GS from bioflocs8,32,50. These
lar activated carbon has been reported for the rapid operating conditions allow selection of slow-growing
development of GS45–47. Addition of zeolite and magne- microbes such as nitrifiers, polyphosphate accumulating-
tite (Fe3O4) powder was shown to promote granule organisms and glycogen-accumulating organisms in the
formation from AS48,49. However, all these studies have form of compact and dense granules32,47. Settling veloci-
been carried out using synthetic effluent with either glu- ties of granules are much higher than that of bioflocs, and
cose or acetate as the carbon source. Therefore, neither are responsible for enhanced biomass retention in the bio-
these substrates nor their concentrations are representa- reactor. Both granular structure and increased biomass
tive of real sewage. Though these studies are useful for levels are responsible for achieving higher biological
getting an insight into the granulation process, the results nutrient (N and P) removals in GS plants. Due to large
cannot be directly extrapolated to granulation under particle size (about 0.2 mm and higher) and compact
treatment of real sewage. Thus, it is desirable to develop microstructure, it is possible to maintain aerobic, anoxic
newer strategies for cultivating functional GS under real and anaerobic microenvironments within an individual
sewage conditions. granule even during aeration phase51,52. Maintenance of
different redox conditions in granules facilitates occur-
rence of oxidation and reduction reactions simultaneously
Comparison of treatment efficiency, land and contributes to simultaneous C, N, and P removal
footprint and costs from wastewater26–43. Biomass concentration of 10 g/l
and higher is feasible in GS plants due to effective bio-
Bioreactor operating condition, such as anaerobic feeding mass retention13,30,42,43. Therefore, biomass concentrations
coupled to short settling period prior to decanting are are much higher in GS plants compared to conventional
400 CURRENT SCIENCE, VOL. 117, NO. 3, 10 AUGUST 2019
REVIEW ARTICLES
AS plants. Higher biomass concentrations can achieve appears to be different. Pronk et al.13 reported a lower
effective and rapid removal of contaminants and improve energy consumption of up to 48% in full-scale GS
volumetric conversion capacities. process than AS process. Energy savings were partly due
GS is capable of performing all biological reactions for to lower electricity demand for aeration because of
effective removal of organic carbon, nitrogen and phos- deeper water treatment tanks in the GS process leading to
phorus from wastewater in a single bioreactor tank. In more efficient oxygen transfer. But, the energy for aera-
addition, separation of GS and treated wastewater is car- tion becomes comparable between the GS and AS
ried out in the same bioreactor tank. The characteristics processes if treatment tanks of similar depth are used3.
of GS make sure that no secondary clarifiers, and sepa- MBR-based WWTPs are proven to be energy intensive
rate anoxic and aerobic compartments are required. Thus, mainly because of two reasons: (i) they require high rate
land footprint of the GS process is significantly reduced of sludge return pumping, and (ii) high aeration rate at
compared to the conventional AS process. A reduction of the membranes to minimizing fouling. The energy
up to 75% in the land footprint has been estimated13,53. demand for an MBR is roughly 50–70% higher than that
Recently, Bengtsson et al.3 also reported that the GS of the GS process3.
process requires 40% to 50% smaller footprint compared
to the conventional AS process. Due to enhanced settling
properties of GS, bioreactors can be operated at 10 g/l GS technology in India
and higher biomass concentration. This can significantly
increase the treatment capacity of the plant. Therefore, The GS technology is being successfully implemented at
the GS process requires smaller footprint (20–30%) as full scale and currently promoted as Nereda®53 wastewater
against conventional SBR based on AS. The footprint of treatment technology. A full-scale GS plant has been set-
the GS system is comparable to that of MBR, the other up in The Netherlands for treating mixed sewage stream
compact treatment option. Due to effective retention, containing significant fraction (35%) of slaughter-house
MBRs can also achieve high biomass concentration and wastewater13. Though it is increasingly considered for
offer efficient treatment. Though MBRs are compact and treating sewage, the full-scale GS systems have been
give better effluent quality, they require costly membrane mainly applied for treating mixed sewage. Even while
and face membrane-fouling problems54. treating sewage mixed with significant proportion of
Due to single reactor tank design, the number of tanks industrial wastewater, long-term operation of plants has
and mechanical equipment required for the GS process is been reported for achieving granulation and establishing
much less compared to the AS process. Secondary clarifier nutrient (N and P) removal. In spite of issues with respect
tanks, biomass and effluent recirculation systems of the to granulation and stability, the GS process is a promising
AS process are not required for the GS process. Moving method due to advantages like lower land footprint, lower
decanters normally used for withdrawing the treated costs, effective nutrient removal and lower sludge pro-
wastewater in conventional SBRs are not essential for duction compared to AS-based systems (Table 4). As of
the GS systems. Nereda®53 uses simultaneous filling– now, there are no full-scale GS plants treating either
drawing for decanting the treated wastewater from full- sewage or industrial wastewater in India.
scale GS bioreactors13. Due to plug-flow pattern, decanting GS research has gained popularity among the scientific
of treated wastewater with minimum suspended solids community across the world (Figure 6) for developing
has been reported. High biomass concentration of the GS sustainable technologies for aerobic treatment of industrial
system may contribute to substantial reduction in bio- and domestic wastewater9. Formation of GS was studied
reactor volume. All these aspects are directly factored in in laboratory-scale bioreactors for biological removal of
lowering the capital expenditure (CapEx) of the GS various organic and inorganic pollutants of interest to
process-based WWTPs. Operation and maintenance nuclear fuel cycle operations18,35,36. Research showed that
expenditure (OpEx) of these WWTPs are expected to be stable GS can be developed for biological removal of
lower due to (i) reduction in equipment, (ii) lower energy various organic (i.e. tributyl phosphate, n-butanol, dibutyl
for aeration, and (iii) no movement of biomass and efflu- hydrogen phosphate, 2,4-dinitrotoluene, nitrilotriacetic
ent between the treatment tanks. Lower sludge production acid, p-nitrophenol, textile dye and acetonitrile) and inor-
and sludge management practices are the additional ganic (i.e. ammonia, nitrate and phosphorus) contami-
aspects contributing to lower energy requirement of the nants18,34–36,55,56. Research shows that GS is a better
GS plants. Recent estimates suggest up to 30% lower choice for removing recalcitrant or toxic pollutants from
energy consumption for the GS process compared to wastewater arising from industrial processes, including
other AS technologies, when similar depth tanks are used nuclear fuel cycle operations. GS is becoming a future
for the bioreactors3. Lower energy costs of the GS standard for developing effective bioremediation and
process are because of no return sludge pumping and wastewater treatment solutions.
recirculation of wastewater for nitrogen removal. The Various types of industrial wastewater (i.e. textile,
energy demand for aeration in the GS and AS systems dairy, pharmaceutical, hospital and effluents of nuclear
CURRENT SCIENCE, VOL. 117, NO. 3, 10 AUGUST 2019 401
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Table 4. Capabilities and advantages of granular sludge technology
Functional capabilities
Simultaneous COD, N and P removal from wastewater
Simple operational strategy for N and P removal
Pollutant removal via both biological oxidation and reduction reactions
Phosphorus removal via enhanced biological phosphorus removal
High biomass retention for faster treatment
Tolerant to toxic contaminants, shock loadings and environmental perturbations
No sludge bulking issues
Advantages
Compact and fast-settling biomass allowing smaller bioreactor volume
No secondary clarifiers
Smaller land footprint for the plant and savings on capital costs
Lower sludge production and easy sludge dewatering
Lower energy costs due to minimal recirculation flows
fuel fabrication) were treated using GS in laboratory- this necessitates development of newer strategies for
scale bioreactors to demonstrate the utility of the tech- improving granulation under sewage conditions. Further
nology28,32,50. To demonstrate its utility in sewage treat- research is necessary for understanding granulation
ment, pilot-scale plants have been set-up for treating real mechanisms, developing GS cultivation strategies, and
sewage under tropical climate conditions (https://www. sustainable excess sludge management practices for fully
ndtv.com/india-news/nuclear-engineers-fighting-water-pollu- exploiting granular sludge technology.
tion-with-sewage-treatment-plant-1768223). Pilot-scale stu- Currently, SBR technology is considered for STPs in
dies demonstrated that the GS technology is suitable for urban India. However, these plants still rely on AS
aerobic biological treatment of sewage under tropical for wastewater treatment. With certain modifications in
climate conditions. Alternative new strategies are being layout and operation, these AS SBRs can be converted to
developed to reduce the start-up period for granulation GS systems. Since GS is superior to AS in removing con-
and establishing nutrient (N and P) removal while treat- taminants and tolerating fluctuations in influent and envi-
ing sewage and saline wastewater. The mechanisms by ronmental conditions, it is promising for both capacity
which microbes form aggregates and granules in water extensions and new STPs.
are not yet understood. It is our endeavour to underpin
the mechanisms behind granulation and to develop inno-
Conclusion
vative biotechnological processes for sustainable waste-
water treatment.
The conventional AS process is no more considered sus-
tainable for wastewater treatment due to large land foot-
Future directions print, higher costs and complex process designs for
achieving nutrient (nitrogen and phosphorous) removal
The GS technology has proven to be a suitable option for biologically. GS is emerging as a new standard for sus-
aerobic biological treatment of sewage and a variety of tainable biological wastewater treatment and for meeting
industrial effluents. Nevertheless, most of the GS research stringent effluent discharge limits. GS is distinct from
has been carried out in laboratory-scale sequencing batch that of AS in terms of large particle size, compact micro-
reactors using synthetic wastewater with defined sub- structure, retaining slow-growing functional microbes,
strates and well-controlled operating conditions, which biopolymer composition, high settling velocities and lower
are not true representatives of real sewage and prevailing sludge volume index values. The GS process is advanta-
environmental conditions. Accumulated evidence indi- geous over the AS process in effective removal of conta-
cates that the formation of GS is feasible in moderate to minants, tolerability to changes in influent/environmental
high-strength industrial wastewater. Challenges exist in perturbations and lower sludge production. Accumulating
cultivating GS from activated sludge, especially while evidence indicates that the GS process is suitable for
treating real sewage which is low strength in terms of treating sewage and several industrial effluent. Currently,
biodegradable organic carbon. Previous studies in pilot- the GS process is the most favourable biological treat-
and full-scale systems reported several issues while treat- ment option considering advanced wastewater treatment
ing real sewage: (i) very long start-up periods of 10 and coupled with lower land footprint and costs. The GS
13 months for achieving ≥85% granulation10,14, and (ii) technology could be the better choice for both new treat-
smaller sized granules (0.2–1.3 mm) which may limit ment plants and capacity extension of existing wastewater
simultaneous nitrification and denitrification. Therefore, treatment plants in the coming years, to decrease the gap
402 CURRENT SCIENCE, VOL. 117, NO. 3, 10 AUGUST 2019
REVIEW ARTICLES
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