1. Introduction
The Membrane BioReactor (MBR) is an established technology for the treatment and reuse of domestic and industrial wastewater [
1]–[
3]. They are based on solid/liquid activated sludge separation through synthetic membranes made of different materials and operated by positive or negative (suction) force. The membrane filtration range for MBR includes micro- and ultra-filtration [
4]. In MBR, the role of membranes is to separate the supernatant from the suspended solids, and this may be obtained adopting mainly two possible configurations: i) membranes submerged in the bioreactor (submerged-MBR), ii) membranes immersed in the secondary clarifier or in another separate vessel (sidestream-MBR). The MBR technology offers different advantages with respect to the conventional activated sludge (CAS) systems, including a significantly reduced footprint. This is mostly due to the possibility of operating the system with higher concentrations of suspended solids of the mixed liquor (MLSS) and to the absence of a secondary clarifier. Submerged MBR allows the adsorption, biodegradation and membrane separation in the same biological tank [
5]. Moreover, wastewater treatment plants (WWTP) based on the MBR technology usually produce permeates of excellent quality with very low levels of total suspended solids (TSS), turbidity, chemical oxygen demand (COD), biological oxygen demand (BOD) and pathogens [
6]. In specific situations, MBR can be coupled or integrated to other technologies to ameliorate the wastewater treatment performance [
7], [
8].
Nevertheless, a limitation to the application of MBR is the occurrence of membrane fouling and pore clogging which deteriorate the system’s performance, require maintenance efforts, and may shorten service life. Both phenomena are detectable by monitoring the resistance to filtration opposed by the materials that tend to accumulate over the membrane surface or into the membrane structure, called transmembrane pressure (TMP) [
9]: when the TMP (in absolute values) rapidly increases, the membrane is fouling/clogging, leading to a decrease in permeate flux. The mechanisms of fouling are: i) adsorption of soluble microbial products (SMP) and extracellular polymeric substances (EPS), colloids and other particles into/on the membranes; ii) deposition of sludge flocs on the membrane surface with consequent formation of a “cake” layer on the membrane surface; iii) changes in membrane and/or mixed liquor composition during long-term operation (e.g., change of bacterial community and biopolymer components in the cake layer, degradation of membrane composition) [
10].
Periodic maintenance of MBR systems is often accomplished either by backwashing the membranes, i.e. reversing the permeate flow, or by relaxation from suction, which simply involves stopping permeate extraction for a defined time interval. These techniques do not influence the ordinary functionality of the bioreactor, they are conventionally incorporated into most MBR designs as standard operational strategies for fouling control, and normally do not require chemical reagents without any risk of membrane degradation/damage [
11], [
12].
When TMP thresholds determining significant and critical reductions of flux are passed despite the periodic maintenance, the membrane needs to be removed from the biological tank to be cleaned [
13]–[
15]. For MBR treating municipal wastewater, a water jet-rinsing is ordinarily enough to remove the pore clogging and excess sludge accumulation, and to recover the initial set flux. If the flux is not recovered due to a deep fouling of membrane pores, a chemical treatment is needed [
16]. On the contrary, when the TMP does not tend to increase and the quality of permeate decreases, the integrity of membranes should be tested, with a possible (partial or complete) replacement of them [
17]. This may imply a relevant burden in terms of investment cost.
In the last decade, the Self-Forming Dynamic Membrane BioReactors (SFD MBR) were developed as a cost-effective alternative to conventional UF-based MBR, and its applications in the wastewater treatment have been studied [
18], [
19]. The SFD MBR is a particular MBR where inert materials (meshes, nets) with a medium-large pore-size (in the range of 10-500 µm) are used as support for the formation of cake layers, these becoming the real biological membrane [
20]. Different studies revealed that the main chemical and physical characteristics of the SFD MBR permeate can have similar values of those of conventional MBR, apart from the microbiological quality indicators, so still needing a post-disinfection step, especially in the case of effluent reuse. The main advantage of SFD MBR with respect to the classical MBR is that chemical or other deep cleaning procedures are rarely used, because the medium-large pore-size support media are less exposed to critical clogging than the UF membranes used in MBR, and a physical cleaning is usually enough to remove the cake layer from the support surface. In conventional MBR, the gel layers that may develop over the long term can clog the membrane pores [
21]. To solve this, the modules are submitted to chemical treatment for the oxidation and removal of sticky and colloidal substances that pass inside the small pores. In SFD MBR, the control and limitation of the clogging gel layer is easier due to the larger pore-size, and often the physical methods, such as water jet-rinsing, surface air sparging, permeate backwash, flux relaxation, reveal efficient [
22]. Afterwards, the filtration system can soon be restored, so that the biological membrane can form again. The easy removing and then reforming of the biological membrane explain the reason why it is also called “dynamic membrane” (DM) [
23].
In a green economy context, the SFD MBR candidates as a lower pollutant and energy saving technology, because no chemicals are used for cleaning, and lower pressure is required for filtration (also achievable by gravity) with respect to conventional UF-based MBR.
In a previous paper, Salerno and co-authors showed the effectiveness of SFD MBR for the treatment of municipal wastewater and with limited maintenance needs, in tests with low sludge retention time (SRT) [
22]. The purpose of the present paper is to evaluate the performance of a bench scale SFD MBR treating real municipal sewage with a medium-high SRT of 30 days and having supporting media with two different pore-sizes, and with a maintenance strategy based on periodic air mass load (AML, large bubbles causing turbulence at the filtration surface) [
22]. In the first experiment, called test A, a 50 µm nylon mesh was used as support material for the development of SFDM with a periodic cleaning of the mesh with high air mass flowrate in short time. The second test, named test B, was identical to the first but using a 20 µm nylon mesh. The results of tests A and B were compared to those of a benchmark test, called test C, having the same conditions and mesh of test B, but a different maintenance strategy based on periodic relaxation from permeate suction. Finally, the best performance, both in terms of permeate quality and support cleaning requirements, was shown by test B (20 µm SFD MBR coupled to an AML of five minutes every four hours).
2. Materials and Methods
All SFD MBR bench scale plants, whose features are summarized in
Table 1, were operated at room temperature, continuously aerated, and under the same operating conditions, except for the pore-size of the support mesh and the strategy of the periodic maintenance.
In the bench scale SFD MBR, two filtration modules were positioned vertically and face-to-face, distant about 3 cm from one another, and every single module had a 6 x 6 cm filtration surface, for a total surface of 72 cm
2. Aeration was provided in the reactors by four external air pumps (M2K3, Schego, Germany), respectively connected to four fine-bubbles diffusers placed on the reactor bottom. The pumped air also ensured the necessary mixing of sludge to achieve a correct homogeneity of the suspended biomass. For every test, permeate suction was ensured by a peristaltic pump connected to the filtration modules with a set flowrate of 12.6 L d
-1. The TMP was measured by an analogic manometer placed between the dynamic membrane and the suction pump and recorded at least every hour between 09 am and 5 pm from Monday to Friday. In the test A, a support nylon mesh with a pore size of 50 µm was used, while a 20 µm nylon mesh was employed in tests B and C. When the TMP overcame the threshold of -200 mbar the modules were temporarily removed from the bioreactor, washed by tap water jet-rinsing, and finally reassembled to restart. As summarized in
Table 1, all systems had a periodic four hours cycle consisting in 229 min of suction and 11 min of no-suction. In tests A and B, the no-suction time was organized as follows: 3 min of simple suction break, 5 min of AML with an air flowrate of 42.0 L
air min
-1 tangentially to the filtering surfaces (still without any permeate suction), and other 3 min of suction break, as described by Salerno and colleagues [
22]. In Test C, the whole 11 min period was in simple no-suction mode, called relaxation. The bioreactor’s operating volume was maintained constant through a level control switch connected to the feed pump. The latter was turned on as the level control detected a decrease of reactor’s operating volume, and it was turned off when the volume had been restored. The general scheme for all plants is illustrated in
Figure 1.
The real pre-settled municipal wastewater was collected twice per week from a local treatment plant, characterized, diluted to the target value of 460 mgCOD L
-1, and finally given as feed to the SFDMBR.
Table 2 shows the average characteristics of the feed.
Both the feeding wastewater and the produced permeates were characterized twice per week in terms of suspended solids (SS), chemical oxygen demand (COD), total nitrogen (TN), ammonium, nitrite, and nitrate according to Standard Methods [
24]. Electrical conductivity and pH were measured with an InnoLab® Multi 9420 IDS (WTW, Weilheim, Germany), while permeate turbidity was determined by a 2100P turbidimeter (HACH, Loveland, CO, USA). The activated sludge was characterized in the same days of feed and permeate: The mixed liquor suspended solids (MLSS) and the sludge volume index at 30 minutes (SVI
30) of the SFD MBR activated sludge were measured according to Standard Methods [
24]. Conventionally, the SVI
30 is an evaluation test of sludge settling capacity [
25]. A phase contrast microscope BX50 (Olympus, Japan) was used to evaluate the morphological characteristics of the activated sludge.
Author Contributions
Conceptualization, C.S.; methodology, C.S., F.C. and A.P.; software, M.T.; validation, A.D., B.H. and A.B.; formal analysis, G.B., F.C.; investigation, S.B., G.B; resources, A.P.; data curation G.B., F.C., M.T.; writing—original draft preparation, S.B. and C.S.; writing—review and editing, S.B., C.S. and A.P.; visualization, A.D., B.H., A.B.; supervision, A.P.; project administration, A.P.; funding acquisition, A.P. All authors have read and agreed to the published version of the manuscript.