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Performance parameters were studied in an alternative full-scale dairy effluent treatment system comprising two anaerobic sludge-blanket reactors in parallel arrangement with upward flow, internal fat-separation by flotation, external lamella settler and floated material digester. Reactors were initially inoculated with flocculent sludge and granulated in a high-load stage. Using loading rates up to a maximum 5.5 kg COD/m(3) x d-hydraulic residence time of 17 hours- reactor efficiency was found to remain stable around 90% of COD. Average sludge digester efficiency using a loading rate of 3.5 kgVS/m(3) x d with a lipid content of 47% of COD amounted to 78% of VS (87% of lipid removal). LCFA inhibition as assayed using palmitate was found to depend not only on the palmitate concentration but also on the palmitate-to-biomass concentration ratio.

An Imhoff tank was reconstructed into a 250 m3 UASB reactor in order to treat a malting plant wastewater. The UASB was inoculated with sludge from an anaerobic lagoon used for slaughterhouse wastewater treatment. After two months of operation the reactor achieved full load with an HRT of 17 h, a COD removal higher than 80% and a biogas production of 300 m3/day (77% average methane content), with an organic loading rate of 3.6 kgCOD/m3.d (0.24 kgCOD/kgVSS.d). A yield coefficient of 0.09 gVSS/gCODrem was found from a mass balance. The fat present in the inoculated sludge (48 mg/gSSV) did not affect the start up performance. Sludge from the inoculum with high content of fat (270 mg/gSSV), was separated by flotation in the first week of operation. The COD removal efficiency was scarcely influenced by the reactor operation temperature (17-25 degrees C).

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BACKGROUND Vinasse is a wastewater from bioethanol production with a very high concentration of organic matter, usually from 40 to 80 gCOD L‐1. These features make this wastewater attractive for treatment in an anaerobic system. Anaerobic processes allow the valorisation of this highly polluting wastewater as an energy resource in an environmentally friendly way. RESULTS A multiscale approach was followed, using batch tests, continuous bench scale reactors, and a full‐scale upflow anaerobic sludge bed (UASB) reactor. Potential inhibition due to high potassium concentrations was evaluated. Using batch tests, the IC50 potassium concentration was determined to be around 6 g L‐1, but continuous reactors could adapt the biomass to this concentration level without removal efficiency decay. A load of 20 gCOD L‐1 d with chemical oxygen demand (COD) removal efficiencies between 60% and 80% were reached in bench scale UASB and expanded granular sludge bed (EGSB) reactors. Finally, a 100 m3 UASB reactor located in a distillery was tested under industrial conditions. A load of 0.6 kgCOD kg‐1VSS d‐1 was achieved with a COD removal efficiency of 78%. CONCLUSION Although potassium was inhibitory for the inoculum, the sludge from a continuously operated reactor can be adapted to high potassium concentrations without affecting its performance. The real possibility of working with undiluted vinasse was also verified. For distilleries like the Uruguayan case, which produces 18 000 m3 of bioethanol per year, 5x10 m3 of biogas per year, with 68% methane, could be expected, representing an energy potential of about one‐third of the main fuel produced. © 2017 Society of Chemical Industry

A full scale UASB reactor treating the effluent of a malting plant was operated during nearly two years. During 37 weeks of operation the reactor worked with a COD removal efficiency of 80% and a biogas production of nearly 300 m(3)/d with a methane content of 77%. After the start up and during these months of operation the volumetric organic load was 4 kgCOD/m(3).d and the specific organic load was between 0.2-0.4 kgCOD/kgVSS.d. The sludge SMA in this period was around 0.25 kgCOD/kg VSS.d. On week 37 as a result of a problem at the industrial process the pH in the reactor dropped to a value of 4.8. After pH recovering, the reactor worked with fluctuating COD values in the exit and showed a downward trend in the COD removal efficiency. On week 81 the presence of filaments in the granules was detected. High proportion of Chloroflexi filaments were detected by FISH in the sludge. Changes in the microbial population caused by the low pH probably destabilize the reactor performance. The presence of filamentous granules in the sludge and its further growing could be encouraged by the pH drop and the low specific organic load applied to the reactor. The low specific organic load was a consequence of the high VSS content in the UASB reactor, due to the lack of purges. The length of the filaments attached to the granules grew throughout time. In order to eliminate the sludge with poor settlement properties a recycle was applied to the reactor. As a consequence, low amount of granular sludge stayed in the reactor. At the end, COD concentration in the influent reached higher values than in normal operation; at the same time a complete sludge wash out occurred. On the other hand, using the same sludge (after the recycle implementation) in a bench scale reactor the good properties of the sludge were completely recovered.

At the present time, organic solid wastes from industries and agricultural activities are considered to be promising substrates for biogas production via anaerobic digestion. Moreover solids stabilisation is required before reutilization or disposal. Slaughterhouses are among the most important industries in Uruguay and produce 150,000 tons of ruminal content (RC) and 30,000 tons of blood per year. In order to determine the influence of the solids and blood contents, the ammonia inhibition and the inoculum adaptation co-digestion batch tests were performed. A set of experiences with TS concentration of 2.5%, 5% and 7.5% and different ratios of RC/blood were carried out using an inoculum from an UASB reactor. In all experiences fast blood hydrolisation was observed. A higher methane production was detected in the experiences with higher TS content. However, the fraction of solids degradation was lower in these experiences. A plateau in the biogas production was found. The free ammonia level, which was above the reported inhibitory levels, could explain this behaviour. After the inhibition period the biogas production restarted probably due to the biomass acclimatisation to the ammonia. In order to determine the inoculum adaptation a new experiment was performed. The inoculum used was the sludge coming from the first set of experiences. Based upon batch tests a 3.5 m3 pilot reactor was designed and started up. Ammonia inhibition was avoided by the start-up strategy and in two weeks the biogas production was 3.5 m3/d. The VS stabilisation with a solid retention time of 20 days was of 43%. The pilot reactor working at steady state had a TS concentration of 3-4% with a ratio of RC/blood of 10:1 at the entrance.