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In this paper a new type of anaerobic reactor is presented. The system has been developed by Biothane Systems and is marketed under the name Biobed® EGSB reactor (Expanded Granular Sludge Bed). In this reactor it is possible to grow and maintain a granular sludge under high liquid (10 m/h) and gas velocities (7 m/h). The most striking feature is the growth of biomass in a granular form, similar to the UASB granules: no carrier material is used. The process is specially suitable to treat waste water that contains compounds that are toxic in high concentrations and that only can be degraded in low concentrations (chemical industry). An example is given for a waste water originating from a chemical factory (Caldic Europoort) in the Netherlands. In this factory formaldehyde is produced from methanol. The waste water is characterised by high concentrations of these compounds (formaldehyde to 10 g/l and methanol to 20 g/l). Due to the special configuration of the anaerobic reactor it is possible to realise a removal efficiency for both compounds of more than 98%. It is also possible to operate the reactor as an ultra high loaded anaerobic reactor (to 30 kg COD/m3.day) for applications in other sectors of industry (e.g. brewery, yeast, sugar, corn ethanol production etc).

Methanogenesis from formaldehyde mainly occurred via intermediates as confirmed by the increased concentrations of methanol and H2 in the liquid and gas phases respectively during formaldehyde conversion. While formaldehyde was readily transformed, the methane production rate was immediately and strongly inhibited. Formaldehyde toxicity was in part reversible since the methane production rate recovered after formaldehyde depletion. This recovery can not be explained by biomass growth. The toxicity of formaldehyde was also in part irreversible, since the degree of recovery was not complete. This loss in the methane production rate likely can be attributed to biomass decay as suggested by its linear relation with the amount of formaldehyde dosed, as well as by scanning electron microscopy observations. The addition of the same amount of formaldehyde either in a slug or in a continuous mode caused the same loss in the methane production rate. Thus for the treatment of formaldehyde-containing streams, a balance between loss in the rate (formaldehyde-related decay) and bacterial growth should be attained. By combining good biomass retention and internal dilution of the wastewater, industrial streams containing formaldehyde can still be treated anaerobically.

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