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Carbon and nitrogen removal using a novel
horizontal flow biofilm system
Michael Rodgers *, Aoife Lambe, Liwen Xiao
Department of Civil Engineering, National University of Ireland, Galway, Ireland
Received 15 July 2005; received in revised form 29 April 2006; accepted 19 May 2006
Abstract
This 365-day laboratory study examined the performance of a novel horizontal flow biofilm reactor (HFBR) system in the treatment of a
synthetic domestic-strength wastewater. The HFBR system comprised two biofilm reactors positioned one above the other: Reactor 1 contained a
stack of 8 horizontal plastic sheets with 25 mm high spacing frustums and Reactor 2, under Reactor 1, contained a stack of 18 horizontal sheets with
11 mm high frustums. The sheets were arranged so that when the wastewater was pumped onto the top sheet of Reactor 1, for 10 min every hour, it
flowed along that sheet, and onto and back along the sheet underneath, and so on down through the system, resulting in biofilm development on the
sheets. The hydraulic and filtered chemical oxygen demand (CODf) loading rates were 155 l/(m2 d) and 47 g/(m2 d), respectively, based on the
system plan area. The effluent CODf concentration was 33 mg/l. Nearly full nitrification occurred with 56% total nitrogen (TN) reduction at the
loading rate of about 4.7 g TN/(m2 d). During the study period, the solids yield was only 0.1 g SS/g CODf removed. The system was easy to
construct and operate, did not clog and could be used for complete biodegradable COD removal, nitrification and partial nitrogen removal.
# 2006 Elsevier Ltd. All rights reserved.
Keywords: Biofilm; Horizontal flow reactor; Carbon and nitrogen removal; Nitrification
www.elsevier.com/locate/procbio
Process Biochemistry 41 (2006) 2270–2275
1. Introduction
There is a need for simple low-maintenance biological
technologies for treating domestic wastewater from small
isolated communities. This treatment should include the
oxidation of biodegradable carbon and nitrification, since
organic carbon and ammonia nitrogen (NH3 + NH4+) cause
oxygen depletion in receiving water bodies [1] and furthermore,
NH3 is toxic to fish and other aquatic organisms. Also, a guide
concentration for non-ionized ammonium (NH4) of 0.05 mg/l
in drinking water is recommended by the EEC [2]. In the past,
Imhoff tanks and septic tank systems were often used to treat
the wastewaters from small communities. The Imhoff tank only
provides primitive treatment and an effective septic tank system
requires a large percolation area of suitable unsaturated soil. In
temperate climates, a septic tank acts mainly as a settlement
tank with little biological treatment [3] and produces an effluent
high in organic carbon and nitrogen [4,5]. If a suitable soil
percolation area is not available, then an on-site technology
* Corresponding author. Tel.: +353 91 750462; fax: +353 91 750507.
E-mail address: [email protected] (M. Rodgers).
1359-5113/$ – see front matter # 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.procbio.2006.05.019
such as a filter system, a mechanical aeration system or a
wetland [6–8] is required to treat the septic tank effluent; these
technologies could also be used to treat Imhoff tank effluent.
However, on-site filters can clog, mechanical failures can occur
in aerobic package systems [9] and large areas are required for
constructed wetlands.
Biofilm wastewater treatment reactors are now commonly
used to treat wastewaters from small communities because of
the availability of high specific surface-area plastic media and
the robustness of the biofilm process. In biofilm systems, the
microorganisms are attached in a biofilm to the surface of an
inert packing material or substratum. A biofilm develops on the
substratum as a result of: (i) transport of cells and nutrients to
the substratum by diffusion and advection; (ii) adsorption of
cells to the substratum and the consequent formation of the
biofilm; (iii) growth and other metabolic processes within the
biofilm; (iv) detachment of portions of the biofilm [10].
Biofilms can be used under aerobic, anoxic and anaerobic
conditions to biologically remove organic carbon, nitrogen and
phosphorus from wastewater. Biofilm technologies that are
normally used for nutrient removal include rotating biological
contactors, fluidised bed reactors, trickling filters, moving bed
reactors and soil percolation areas. In biofilm systems, organic
M. Rodgers et al. / Process Biochemistry 41 (2006) 2270–2275 2271
material and nutrients in the wastewater are utilised by the
biofilm as wastewater flows past and through the biofilm.
Advantages of biofilm systems over suspended growth systems
include: (i) reduced sludge production; (ii) high sludge age
benefiting slow growing bacteria, such as nitrifiers; (iii)
denitrification in anoxic zones at depth in the biofilms [11];
(iv) greater process stability [12]. The disadvantages of biofilm
systems include: (i) speed limitation in rotating biological
contactors (RBC); (ii) risk of clogging in sand and peat filters;
(iii) back washing required in biological aerated filters (BAF);
(iv) carrier separation in moving bed biofilm reactors (MBBR)
[13].
In the context of the above, the objective of this project was
to develop a biofilm wastewater treatment system – a horizontal
flow biofilm reactor (HFBR) – that could be suitable for on-site
carbonaceous oxidation and nitrification and would be simple,
robust and easily maintained. In designing the system, the
authors aimed to maximise the advantages of biofilm systems
whilst minimising their disadvantages.
2. Materials and methods
2.1. Construction of the horizontal flow biofilm reactor (HFBR)
The laboratory system consisted of a synthetic wastewater feed tank, an
electronic timer, a peristaltic feed pump and a horizontal flow biofilm reactor
system. The unit was operated in a temperature-controlled room at an average
temperature of 11 8C. The horizontal flow biofilm system consisted of two
reactors with Terram geosynthetic sheets, stacked one on top of the other with
frustums upwards (Fig. 1). The internal dimensions of each reactor tank,
constructed from plastic storage bins were 320 mm by 400 mm in plan and
240 mm deep. The top reactor, Reactor 1, comprised 8 sheets with 25 mm high
frustums, and the bottom reactor, Reactor 2, comprised 18 sheets with 11 mm
high frustums. It was estimated, on the basis of loading rates on other biofilm
systems, that COD removal with its associated thick heterotrophic growth
would occur mainly in Reactor 1, but would cause no clogging due to the 25 mm
high frustums. Also, it was considered that nitrification and its associated thin
biofilm could develop without clogging in Reactor 2 with its 11 mm high
Fig. 1. Vertical section of the horizontal flow biofilm reactor system showing
the arrangement of the sheet (310 mm � 350 mm in plan) and wastewater flow
paths. The frustum heights were 25 and 11 mm high in Reactors 1 and 2,
respectively.
frustums. The horizontal sheets, 310 mm � 350 mm in plan, were assembled
one above the other, so that wastewater flowed along one sheet, discharged to
the sheet underneath, and then flowed back along that underneath sheet, and so
on down through the two reactors. The influent end of each sheet was offset
40 mm from the discharge end of the sheet above to capture the flow. The sheets
were sealed – to prevent leakage – at the inflow end and along the two sides with
a 20 mm strip of L shaped PVC to ensure horizontal flow along the sheets. The
horizontal top surface area of each sheet was 0.1085 m2. The reactor system was
raised above the floor on a timber platform to facilitate sampling of the effluent.
Daily maintenance of the system included preparation of the synthetic
wastewater, cleaning feed tanks, feed-lines, sampling, testing and measuring
flow rates. At commissioning of the system, activated sludge from a municipal
wastewater treatment plant was mixed with synthetic feed and applied to the
system. Recycling of effluent was carried out for the first 2 days of the
experiment to generate a high biomass concentration on the sheets.
2.2. Sampling and analysis for water quality parameters
Samples were tested for water quality parameters in accordance with the
Standard Methods for the Examination of Water and Wastewater, APHA
AWWA WEF 19th Edition 1995 [14]. Total and filtered chemical oxygen
demands (CODT, CODf) were measured by the titrimetric dichromate method.
Filtered samples were obtained by filtering wastewater samples through What-
man glass fibre filters (pore size 1.2 mm). Ammonia-nitrogen was tested by
method 4500-NH3 D with a NH 500/2 WTW ion selective electrode and WTW
pH 320 m. Nitrate–nitrogen was tested by method 4500-NO3� D with a nitrate
WTW82362 ion selective electrode and WTW pH 91 m. Total nitrogen (TN)
was tested using a DR/2010 spectrophotometer (HACH company). Dissolved
oxygen (DO) was measured with an electrochemical membrane type electrode
(WTW cellOx 325) and a WTW oxi 330 m. The pH was measured using a
WTW SenTix 50 pH electrode and a WTW pH 91 digital meter. Oxidation
reduction potential (ORP) was measured by a Dolmen 23 redox combination
electrode and recorded on a WTW 330 digital meter. DO, ORP and pH
measurements were taken immediately after sample collection. All electrodes
were calibrated before and after measurement as specified by the manufac-
turers’ instructions.
Sampling of the system for water quality analysis involved collection of an
influent sample, an effluent sample from Reactor 1 and an effluent sample from
Reactor 2, on a thrice-weekly basis. Samples to monitor the performance down
through the sheets of the treatment process were collected approximately every
2 weeks from each sheet. These samples for profiles were pipetted from three
locations on each sheet and combined to form a composite sample.
2.3. Hydraulic retention time
A pulse tracer experiment using NaBr was carried out to assess the hydraulic
characteristics of a clean reactor system. The experiment was commenced by
pumping tap water onto the top sheet of Reactor 1 for 10 min every hour at the
rate of 155 l/(m2 d)—based on the top plan area of the system. For the tracer
test, a known concentration of bromide was pumped onto the top sheet for one
10-min pumping period. Tap water was applied again during subsequent 10-min
pumping periods. The pumping regime was the same as that used in the
wastewater treatment study. Samples were collected at the base of the unit
and analysed using a bromide WTW ion selective electrode and WTW pH
320 m. Sample times and volumes were recorded. The tap water was pumped
onto the unit over a period of 15 h after the bromide was applied to ensure near
full recovery of the tracer material.
Fig. 2 shows the normalised bromide concentration plot for the HFBR. The
hydraulic retention time of the clean reactor system, HRT, was calculated [15]
from the pulsed tracer experiments using the following equation and the HRT
was determined experimentally as 8.3 h:
t ¼P
itiCiViDtiPiCiViDti
where t is the mean time of passage (HRT) (h), ti the time at the ith measurement
(h), Ci the tracer concentration at the ith measurement (mg/l), Dti the time
increment about Ci and Vi is the volume at the ith measurement (l).
M. Rodgers et al. / Process Biochemistry 41 (2006) 2270–22752272
Fig. 2. Normalised plot for the bromide tracer concentration (C) exiting from a
clean horizontal flow biofilm reactor as a fraction of the inflow concentration (C0).
Table 1
Composition of synthetic wastewater used as influent to the horizontal flow
reactor system
Constituent Concentration (mg/l)
Glucose 200
Yeast 30
Dried milk 120
Urea 30
NH4Cl 60
Na2PO4�12H2O 100
KHCO3 50
NaHCO3 130
MgSO4�7H2O 50
FeSO4�7H2O 2
MnSO4�H20 2
CaCl2�6H2O 3
Fig. 3. Filtered COD concentrations in the influent, effluent from the top reactor
and from the bottom reactor against time in days.
2.4. Hydraulic and organic loading rates
The HFBR was tested over 365 days at an organic loading rate of 47 g COD/
(m2 d) and a hydraulic loading rate of 155 l/(m2 d) based on the top plan area of
the system; the hydraulic loading based on the total top surface area of the sheets
was 6 l/(m2 d). Daily, 16.8 l of synthetic wastewater was applied intermittently
to the top sheet of Reactor 1 at a rate of 70 ml/min for 10 min every hour—the
Table 2
Analytical results from the influent, and effluent from Reactor 1 (Sheets 1–8) and R
operation (Days 60–365)
CODT
(mg/l)
CODf
(mg/l)
SS
(mg/l)
TN
(m
Influent
Average 385.3 325.3 50.6 3
Std. dev. 55.6 52.1 12.8
No. samples 127 127 127 12
Effluent Reactor 1
Average 71.6 55.7 14.5 2
Std. dev. 14.3 9.1 7.2
No. samples 127 127 127 12
Effluent Reactor 2
Average 46.2 33.0 11.2 1
Std. dev. 9.7 5.8 5.6
No. samples 127 127 127 12
same as in the tracer test. The 2 areal hydraulic loading rates used in the present
system allow a comparison of its performance to be made with other systems,
e.g. 4 l/(m2 d) for a soil filter system, 40–100 l/(m2 d) for an intermittent sand
filter and 100 l/(m2 d) for a peat filter [8]. The feed wastewater was similar to
that used by Odegaard and Rusten [16] and the composition of the synthetic
wastewater is given in Table 1.
3. Results and discussion
The average influent and effluent concentrations are shown
in Table 2 for Days 60–365, when a near steady state was
reached. The strength of the feed wastewater was similar to
low-strength domestic wastewaters [17]. Overall, the HFBR
system removed 90% of the CODf and 56% of the total nitrogen
applied, and achieved almost full nitrification.
The average CODf in the influent, 325.3 mg/l, was reduced
to 55.7 mg/l in Reactor 1 and was then further reduced to
33 mg/l in Reactor 2 (Fig. 3). The average non-biodegradable
COD in the effluent was 30 mg COD/l, and this was determined
by aerating a batch sample of effluent until no change in CODf
concentration occurred [19]. Fig. 4 shows the CODf profile
down through the sheets during steady-state operation. In
Reactor 1, 61.5% of the CODf was removed in the top 5 sheets,
giving the removal rate of about 6.2 g CODf/(m2 d) based on the
eactor 2 (Sheets 9–26) in the horizontal flow biofilm system during steady-state
g/l)
NH4–N
(mg/l)
NO3–N
(mg/l)
pH DO
(mg/l)
1.6 21.6 0.5 7.8 6.5
3.7 3.4 0.2 0.2 0.6
7 127 127 127 127
2.7 21.7 0.9 8.0 5.5
2.8 2.7 0.6 0.6 0.5
7 127 127 127 127
3.9 2.2 11.8 7.7 6.8
3.2 4.7 3.6 0.5 0.6
7 127 127 127 127
M. Rodgers et al. / Process Biochemistry 41 (2006) 2270–2275 2273
Fig. 4. Profile of CODf concentrations down through the sheets of the hor-
izontal flow biofilm reactor system during steady-state operation (Days 60–
365).
Fig. 6. Profile of nitrate–nitrogen (NO3–N) concentrations down through the
sheets of the horizontal flow biofilm reactor system during steady-state opera-
tion (Days 60–365).
total surface area of the top five sheets; a further 21% was
removed in Sheets 6–8; and in Reactor 2, 6.9% was removed in
Sheets 9 and 10.
During this test series, the average organic areal removal
rates of 45.3 g CODf/(m2 d) and 1.8 g CODf/(m
2 d) were
achieved, based on the top plan area and total sheet surface area,
respectively. A removal rate of 3.1 g COD/(m2 d) was reported
for a constructed wetland system [18] for a similar wastewater.
Ammonium-nitrogen removal was also at steady state from
approximately Day 60 to 365, during which time the average
influent ammonium–nitrogen concentration was 21.6 mg/l and
the average effluent from Reactor 2, was 2.2 mg/l. There was an
increase in ammonium–nitrogen concentrations (Fig. 5) in the
top six sheets that can be attributed to ammonification of
organic nitrogen present in the influent. From Sheet 7 onwards
there was a reduction in the ammonium–nitrogen concentration
due to cell synthesis and nitrification resulting in 90% removal.
The average removal rate in Sheets 8–15 was about 0.35 g NH4-
N/(m2 d) based on the total sheet surface area, which was
comparable with the removal rates of 0.234 g NH4-N/(m2 d)
[20] and 0.756 g NH4-N/(m2 d) [21] reported in constructed
wetlands. A profile of nitrate–nitrogen concentrations is shown
in Fig. 6. The average nitrate–nitrogen concentration increased
up to 13.95 mg/l in Sheet 19, after which it reduced to 11.8 mg/l
in the final effluent.
Fig. 5. Profile of ammonium–nitrogen (NH4-N) concentrations down through
the sheets of the horizontal flow biofilm reactor system during steady-state
operation (Days 60–365).
The average TN concentration was 31.6 mg/l in the influent,
22.7 mg/l in the Reactor 1 effluent, and 13.9 mg/l in the Reactor
2 effluent, which gives a 28.2% and a 27.8% reduction in
Reactors 1 and 2, respectively. This total 56% reduction in TN
corresponded to areal removal rates of 2.7 g N/(m2 d) and about
0.1 g N/(m2 d), respectively, based on the top plan surface area
and the total sheet surface area of the system. The TN removal
rates were of a similar order to the removal rate of 0.268 g TN/
(m2 d) achieved in a constructed wetland system [18], but the
footprint area required was much smaller for the HFBR. The
removal of nitrogen in this study, which was greater than
expected, could be attributed to uptake in cell synthesis and
denitrification in anoxic zones in the biofilm.
Average dissolved oxygen concentrations increased in
Reactor 1 from 1.1 mg/l on Sheet 1 to 5.5 mg/l on Sheet 8
and in Reactor 2 from 5.8 to 6.8 mg/l. The high dissolved oxygen
concentration in the effluent indicates that there was an adequate
oxygen supply for biochemical reactions. The pH of the influent
was 7.8, suitable for carbonaceous oxidation and nitrification.
Oxidation–reduction potential (ORP) profiles (Fig. 7) show
that on Day 4, when 74% COD was removed and no nitrification
occurred, ORP values were 21.3 EH mVon Sheet 1, 192.8 EH mV
on Sheet 4 and 207.7 EH mV on Sheet 26. The increase in ORP
with sheet number is due to reducing substrate and an increase in
the dissolved oxygen concentration. This ORP range is indicative
Fig. 7. Oxidation–reduction potential (ORP) profiles down through the sheets
of the horizontal flow biofilm reactor system on Days 4, 18, 32 and Days 60–
365.
M. Rodgers et al. / Process Biochemistry 41 (2006) 2270–22752274
of biological carbonaceous oxidation, since organic carbon
compounds are easily oxidised and can be removed at low EH
values. The ORP profiles from Days 18 and 32 show increases in
EH values in Reactor 2 due to the onset of nitrification. The range
at which nitrification occurred was 200–375 EH mV, which when
combined with the pH data (range 7.5–8) corresponds with the
Pourbaix biological nitrification window [22]. ORP measure-
ments in the effluent from an activated sludge system treating
medium and low-strength wastewaters indicate that values in the
range of 270–300 EH mV are optimal for COD biodegradation,
and 350–400 EH mV are suitable for nitrification [23]. An ORP
range of 200–400 EH mV was sufficient to achieve 92% and 84%
removal of COD and ammonium-nitrogen, respectively [24].
During steady-state conditions (Days 60–365) there was little
variation in the ORP values obtained, indicating that ORP was a
very useful stable monitoring parameter for this system. The final
effluent from the reactors had ORP values of 366� 26 EH mV
indicating a relatively high oxidising status, which is suitable for
nitrification.
In the HFBR system, the solids yield (Yobs) as a fraction of
the filtered COD removed was on average 0.173 g SS/g
CODrem, with a near constant ratio of approximately 0.1 g SS/g
CODrem for Days 270–365. This value is similar to that reported
by [25] for a membrane reactor and significantly lower than that
of 0.4 g VSS/g COD reported by Droste [26] for an activated
sludge plant. The rate of increase of sludge mass in the HFBR
decreased as the study progressed. Small amounts of solids
were discharged in the effluent, 14.5 � 7.2 mg/l and
11.2 � 5.6 mg/l from Reactors 1 and 2, respectively.
The tracer test on the clean reactor system gave a HRT of
8.3 h. This result is only indicative, as the actual HRT will
change as biofilm develops in the system. However, the HRT of
8.3 h is of a similar duration to that used in conventional
activated sludge processes for nitrification.
Based on the results achieved in this laboratory study, it
would appear that an on-site HFBR system with a foot print
plan area in the range of 1.5–4.0 m2/person-equivalent and a
stack of 26–30 plastic sheets with frustums could provide
adequate biofilm for biodegradable organic carbon removal and
nitrification of domestic wastewater. The design area values
would depend on the strength of the domestic wastewater and
climate. The reactor units could be placed in a tower
arrangement with a suitable pumped distribution system to
reduce the overall foot print area, as the depths of the two stacks
of sheets used in this study were less than 400 mm in total. It
would be prudent to install a clarifier after the system. The
design values would need to be proven in field tests.
4. Conclusions
In this study, a novel horizontal flow biofilm reactor (HFBR)
system – comprising 26 sheets arranged one above the other –
was developed and tested at 11 8C for 365 days using a
domestic-strength synthetic wastewater that was applied
intermittently for 10 min every hour at hydraulic and filtered
chemical oxygen demand (CODf) loading rates of 155 l/(m2 d)
and 47 g/(m2 d), respectively, based on the system plan area.
The main conclusions are as follows:
1. T
he HFBR had an average organic areal removal rate of45.3 g CODf/(m2 d), based on system plan area, giving a
final effluent concentration of only 33 mg CODf/l, most of
which was non-biodegradable.
2. A
lmost complete nitrification occurred.3. T
otal nitrogen removal was 56%.4. S
olids production during the study period was very lowtowards the end of the study period at 0.1 g SS/g COD
removed and the system retained almost all of its sludge for
over 365 days.
5. N
o clogging of the sheets occurred during the study.6. O
RP monitoring provided a useful simple indicator of steadystate development for the biofilm.
Overall, the system was simple to construct and operate with
minimal maintenance requirements, and achieved excellent
COD removal, nitrification and partial nitrogen removal with
low solids production. From this study, the system would
appear to have good potential as a suitable biological reactor for
treating domestic wastewater from small communities.
Acknowledgements
Funding from the Higher Education Authority of Ireland for
this project is gratefully acknowledged. Assistance from the
Environmental Change Institute at the National University of
Ireland is appreciated. Sincere thanks are due to R. Duffy, M.
O’Brien and G. Hynes for their help.
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