UASB

Operating & maintenance manual

Paques B.V.
PO box 52
8560 AB Balk
The Netherlands
Tel. +31 (0)514 - 60 85 00
Fax +31 (0)514 - 60 33 42
Document: Operating & maintenance manual BIOPAQ® UASB
Type: UASB-Mk2 & UASB-Mk2 Up
Reference: -SMAN000238_ENA

PRODUCT INFORMATION

Product BIOPAQ® UASB

Type UASB-Mk2 & UASB-Mk2 Up

Client

Contact
Telephone
Fax

Supplier Paques BV
T. de Boerstraat 24
8561 EL BALK
PO Box 52
8560 AB BALK
The Netherlands
Contact [email protected]
Telephone +31 (0)514 60 85 00
Fax +31 (0)514 60 33 42

Document Operating & maintenance manual

Author MSI/MBR
Checked by JHB
Last modified by MBR
Date 18-07-2006
Reference -SMAN000238_ENA
Revision A

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Type: UASB-Mk2 & UASB-Mk2 Up
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GENERAL TERMS

This Operating and maintenance manual provides information on the safety, operation
and maintenance of the BIOPAQ® UASB. It is the responsibility of the owner of the
installation to compare and to complete this information with locally applicable regulations
and to convert it into a safety protocol for the operating personnel.

The installation design is based on specified operating conditions. These specifications

must be regarded as limit values and may not be exceeded.

For a stable operation the installation must be operated and maintained in accordance
with the procedures mentioned in the Operating & maintenance manual. Therefore this
manual must be available for the operating and maintenance personnel.

Improper use of these procedures can lead to dangerous situations.

Only qualified personnel, or personnel under supervision of authorised qualified persons,

is allowed to carry out operational, maintenance and constructional activities on the
installation.

Although utmost care has been taken to provide sufficient information to operate and
maintain the Paques installation, this manual can and will not cover every possible event.
In cases of differences in content between translations of the same document the English
version shall prevail.

Subject to alteration(s).

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TABLE OF CONTENTS

GENERAL TERMS 3
1. INTRODUCTION 6
1.1 Support 6
2. SAFETY INSTRUCTIONS 7
2.1 Safety at work 7
2.2 Dosing 8
2.3 Sludge and process liquids 8
2.4 Hazardous gases and vapours 9
2.4.1 Biogas 9
2.4.2 Hydrogen 10
2.4.3 Ventilation air and chemical vapours 10
2.4.4 Hazardous area classification 10
2.5 Working at a height 13
2.6 Working in confined spaces 13
2.7 Malfunctions 14
2.8 Emergencies 14
2.8.1 Shutting down the installation 14
3. OPERATIONAL DESCRIPTION 15
3.1 BIOPAQ® UASB reactor 15
3.2 Biogas treatment 16
3.2.1 Biogas flow metering 16
3.2.2 Condensate separation 16
3.2.3 Overpressure protection 16
3.2.4 Buffering 19
3.2.5 Gas flare 19
3.3 Ventilation 20
3.4 Influent 20
3.4.1 Nitrite & nitrate 20
3.4.2 Sulphite & sulphate 21
3.4.3 Fats, oils & greases (FOG) 21
3.5 Control parameters 21
3.5.1 Biomass (granular sludge) 21
3.5.2 Chemical Oxygen Demand (COD) 22
3.5.3 COD load and volatile fatty acid concentration 23
3.5.4 Pre-acidification degree 24
3.5.5 Specific biogas production 24
3.5.6 pH 24
3.5.7 Alkalinity (pH buffering) 25
3.5.8 Temperature 26
3.5.9 Nutrients 26
3.5.9.1 Nitrogen (N), phosphate (P) and sulphur (S) 27
3.5.9.2 Calcium (Ca), magnesium (Mg) and potassium (K) 27
3.5.10 Calcium (precipitation) 28
3.5.11 Hydrogen sulphide 29
3.5.12 Summary of control parameters 29
4. START UP PROCEDURE 30
4.1 Technical inspection 30

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4.1.1 Leakage test 30

4.1.2 Hydraulic test (water run) 31
4.1.3 Checking of functional specification 31
4.2 Technological start up 31
4.2.1 Start up conditions 31
4.2.1.1 Process conditions 32
4.2.1.2 Influent 32
4.2.2 Inerting biogas system 32
4.2.3 Sludge inoculation 33
4.3 Start up 34
4.4 Normal operation 36
4.5 Restart 36
4.5.1 With external recirculation or shorter than 5 days 36
4.5.2 Without external recirculation or longer than 5 days 36
5. OPERATING PROCEDURES 37
5.1 General process control 37
5.2 Routine work 37
5.2.1 Daily 37
5.2.1.1 Process 37
5.2.1.2 Mechanical 38
5.2.1.3 Metering & control equipment 38
5.2.2 Weekly 38
5.2.3 Monthly 38
5.2.4 Annual 39
5.3 Cleaning instructions 39
5.4 Temporary shut down 39
5.5 Major maintenance 40
5.6 Emptying the installation 40
5.7 Dismantling and disposal of the installation 40
5.8 Protection against frost 40
5.9 Spare parts 41
6. PROCESS MALFUNCTION AND TROUBLESHOOTING 42
6.1 Process malfunction 42
6.1.1 Acidification of the reactor 42
6.1.2 Inhibitors 43
6.1.3 Wash out of granular sludge 44
6.2 Troubleshooting 44
6.2.1 Process Troubleshooting 44
6.2.2 Mechanical troubleshooting 45
7. LIST OF (TECHNICAL) TERMS 46
8. APPENDICES 50
8.1 Appendix A: Specifications 50
8.2 Appendix B: Operating procedures 50
8.3 Appendix C: Troubleshooting 50

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1. INTRODUCTION

The BIOPAQ® Upflow Anaerobic Sludge Blanket (UASB) reactor is designed to convert
dissolved and degradable organic impurities from wastewater into biogas.

This operating manual describes the safety aspects, functioning and operation of
the BIOPAQ® UASB reactor.

In section 2 the safety aspects regarding the BIOPAQ® UASB reactor are described.
Then, in section 3 the process description of the installation is given. The start up
procedure of the BIOPAQ® UASB process is described in section 4. Section 5 gives a
summary with regard to recommended maintenance and monitoring procedures. For
process malfunction and troubleshooting please refer to section 6.

Specifications, operating instructions and troubleshooting manuals are given in

appendices A to C.

Note: All figures given are illustrative examples. These can differ with respect to
actual delivery.

1.1 Support
For components not made by Paques, please refer to the relevant supplier’s manual.

For operating or technical support please contact:

Paques Services
[email protected]
Tel: +31 514 608 759 (direct)
Fax +31 514 603 342

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2. SAFETY INSTRUCTIONS

For safe operation Paques recommends that the following regulations be taken into
account as a minimum.

2.1 Safety at work

Everyone, working or otherwise present on the site of the BIOPAQ® UASB reactor, must
work in accordance with the local applicable safety provisions. The following general
regulations must be taken into account as a minimum:
• Smoking and open fire are prohibited.
• Warning signs and other instructions must be taken into account.
• Eliminate any hazardous situation and report it.
• Maintain order and tidiness in the workplace.
• Keep all paths, platforms etc. free of obstacles.
• Use personal protection equipment if necessary.
• Be responsible for personal hygiene.
• Do not eat, drink and smoke in the vicinity of the installation.
• Be aware of all applicable Material Safety Data Sheets (MSDS or safety sheet).
• Always wear a portable H2S detector.
• While working on the installation wear a mobile gas detector for H2S, LEL (Lower
Explosion Limit) and OX (low oxygen alarm).
• Immediately leave the area, with the use of an escape gasmask with a proper filter,
when the H2S concentration exceeds 10 ppm.
• Evaluate possible hazardous situations before (a section of) the installation is shut
down.
• Inform all persons involved in advance of work on the installation and the possible
hazardous or unacceptable situations during this work.
• Be careful with moving parts. Keep hands and loose clothing and long hair away from
rotating parts.
• Only qualified personnel may carry out work on the electrical installation. Other
personnel may not open the control cabinet and other electrical components.

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Use your common sense regarding safety measures!

2.2 Dosing
Advice and instructions on safe handling of chemicals can be found in the MSDS of the
relevant supplier(s). An MSDS can be obtained from the supplier and must be affixed by the
dosing installation.

An MSDS provides among other things information on:

• Preventive measures and personal protection equipment that must always be used
when working with the chemicals in question.
• Treatment procedures in case of exposure to or ingestion via the skin, eyes, mouth or
respiratory tract.
• Procedures for removing spilled chemicals.

2.3 Sludge and process liquids

Hydrogen sulphide (H2S) gas may be given off by sludge (biomass) and process water,
particularly if it is stored in a (sealed) container. Dried sludge is flammable. The following
minimum precautions are recommended:
• Always wear a H2S detector.
• Spilled sludge must be removed immediately in accordance with the specified
procedures of the MSDS.
• The personal protection equipment specified in the MSDS must always be present and
used.
• Avoid direct contact with sludge and process water. If the eyes or skin of a person have
been in contact with sludge or process water, they must be cleaned immediately with
drinking water.

All process liquids in the reactors and tanks may contain chemicals and micro-organisms.
For this reason it is recommended that these process liquids be treated with extreme
caution. Take the right personal protection measures such as the use of waterproof
shoes, gloves and safety goggles.

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2.4 Hazardous gases and vapours

Biogas, hydrogen gas, ventilation air and chemical vapours may be released by the
installation during sampling, maintenance work and/or disasters. All these gases involve
potential risks because they may be explosive, flammable, suffocating and/or toxic.

2.4.1 Biogas
Biogas has approximately the following composition:
• Methane (CH4) 50 - 90 vol. %
• Carbon dioxide (CO2) 10 - 45 vol. %
• Hydrogen sulphide (H2S) 0.2 – 3.5 vol. %
• Water (H2O) 0 - 5 vol. %

The exact biogas composition depends on the wastewater characteristics and the pre-
treatment. Biogas is potentially flammable, suffocating, toxic and/or explosive because it
contains methane and hydrogen sulphide.

Methane (CH4)
• Lower explosion limit (LEL) 4.4 vol. % in air.
• Upper explosion limit (UEL) 16.0 vol. % in air.

Hydrogen sulphide (H2S)

• Minimum odour limit 0.1 ppm
• Maximum odour limit 70 ppm
• MAC value 10 ppm
• Lower explosion limit (LEL) 4.3 vol. % in air.
• Upper explosion limit (UEL) 46.0 vol. % in air.

Hydrogen sulphide is a toxic gas and in low concentrations can be identified by its
penetrating odour of rotting eggs, in high concentrations it can no longer be smelled.
Hydrogen sulphide irritates the eyes and the respiratory tract. In high concentrations
hydrogen sulphide is lethal.

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Anyone in an area where hydrogen sulphide can be released must carry a portable H2S
detector and be equipped with a fully certified (and regularly checked) gas mask with a
suitable filter.

2.4.2 Hydrogen
Hydrogen may be produced during the acidification of wastewater. If the relevant tanks
are continuously ventilated the hydrogen concentration remains sufficiently low. However,
if the ventilation fails or is manually shut down, within a few hours the hydrogen
concentration may rise to a critical level.

• Lower explosion limit (LEL) 4.0 vol. % in air.

• Upper explosion limit (UEL) 76.0 vol. % in air.

2.4.3 Ventilation air and chemical vapours

Certain rooms and/or tanks are ventilated. This ventilation air may contain different gases
and vapours, such as hydrogen sulphide (toxic), hydrogen gas, methane (explosive) and
carbon dioxide (may displace oxygen).

The vapours of chemicals used may have the same harmful effect as the liquid or solid
form. For this consult the MSDS of the supplier.

2.4.4 Hazardous area classification

Around the BIOPAQ® UASB reactor a hazard zone applies that relates to the possible
exposure to biogas. Biogas is flammable, suffocating, toxic and/or explosive because it
contains (among other things) methane and hydrogen sulphide.

This hazard zone is schematically drawn in figure 2.1. Please check the applicable
‘Hazardous area classification’ for reactor specific details.

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Figure 2.1: Explosion and fire hazard zone BIOPAQ® UASB reactor

Everyone, present in the hazard zone of the reactor, must work in accordance with the
local applicable safety provisions. The following general regulations must be taken into
account as a minimum:
• The entrance to the top of the reactor must be restricted.
• Only instructed and authorize personal may enter the top of the reactor.
• Workers must carry a mobile gas detector for H2S, LEL (Lower Explosion Limit) and OX
(low oxygen alarm) and an escape gasmask with a proper filter. Workers must know
how to use these personal safety guards.
• Workers must withdraw immediately, with the use of an escape gasmask with a proper
filter, when the H2S alarm sounds.
• The BIOPAQ® UASB reactor is equipped with a high biogas pressure- and a low water
level- alarm [see figure 3.3 and 3.4]. Both alarms warn for the possibility of biogas
escaping at the top of the reactor. An alarm situation should be indicated by an optical
and/or acoustic alarm and workers should withdraw before the explosion conditions are
reached.

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During maintenance activities, the critical explosion conditions must be

carefully watched using a LEL and H2S detection. In the BIOPAQ® UASB
process methane (CH4) and hydrogen sulphide (H2S) gas are produced
simultaneously in reasonable fixed ratio. Therefore Paques uses H2S as an
additional indication for critical explosion conditions, due to this specific
biogas composition. The H2S alarm will sound long before the critical
explosion conditions are reached.

Maintenance with a LOW chance of unwanted biogas release

Sometimes it is inevitable to perform maintenance within the hazard zone, with a LOW
chance of unwanted biogas release, due to normal operation. This maintenance is only
permitted if the worker at least follows the regulations as mentioned earlier in this
paragraph. Maintenance with a LOW chance of unwanted biogas release involves the
following activities:
• Filling the reactor with granular sludge during start up.
• Checking if the covers show signs of wear.
• Checking if the rubber cover seals are damaged.
• Recoating the (closed!) covers.

Maintenance with a HIGH chance of unwanted biogas release

It is also inevitable to perform maintenance within the hazard zone, with a HIGH chance of
unwanted biogas release, due to normal operation. This maintenance is only permitted if the
worker at least follows the regulations as mentioned earlier in this paragraph and is wearing
a full-face gasmask with a proper filter. Maintenance with a HIGH chance of unwanted
biogas release involves the following activities:
• Taking a biogas sample.
• Opening the covers on top of the reactor in order to inspect and/or adjust (the overflow
of) the separation module.
• Filling the reactor with granular sludge during normal operation.
• Replacing damaged rubber cover seals.

For all other maintenance the reactor has to be taken out of operation, inertisized and
emptied according to operating procedures Shutting down the reactor, Shutting down and
inerting the biogas system and Emptying the reactor (Appendix B).

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Special risks, concerning the BIOPAQ® UASB reactor, are:

• Shutting down the mechanical ventilation at the top of the reactor (if available),
considerably increases the risk of exposure to process air and/or biogas while present
on top of the reactor.
• When the covers the top of the reactor are removed process air and/or biogas may be
released.

2.5 Working at a height

The installation is not fitted as standard with fencing, cage ladders and platforms. Make
sure prior to working at a height that the right fall protection equipment is present. Check
the fixing of cage ladders, platforms and fencing (if present) each month.

2.6 Working in confined spaces

Work in confined spaces must be carried out following the local applicable standard. The
following minimum safety regulations are advised:
• Close all inflow gas, water and chemical pipes with blind or plug flanges.
• Ventilate the tank well. Maintain ventilation during work.
• Put an extra ventilator at a tank opening for extra fresh air.
• Before beginning work remove all process liquids and sludge from the tank. Rinse/flush
with clean water.

Before and during the inspection or work it must be established whether the empty tank is
safe for the operating personnel to do the work or inspection. To do this, the following
measurements need to be carried out:

1) LEL measurement: the concentration of explosive gases must be lower than 1 % LEL
(H2 < 0.04 vol. % and/or in combination CH4 < 0.04 vol. %).
2) OX measurement: the oxygen concentration must be between 20 and 21 vol. %.
3) H2S measurement: the hydrogen sulphide concentration must be less than 10 ppm.

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These measurements can be carried out with a portable gas detector. If, despite all the
precautionary measures, the gas alarm does go off, everyone in the area should stop
work immediately and leave.

Work in confined spaces should always be carried out by at least two people. One person
keeps watch outside the confined space and keeps in contact with the person in the
confined space. This ‘tank watcher’ raises the alarm if there is an accident. The tank
watcher must, under all circumstances, remain outside the confined space and should
never enter it to help other employees.

2.7 Malfunctions
A malfunction results in an unusual situation. Take extra care during a malfunction,
because this can create hazardous situations. For example:
• Accumulation of hazardous gasses, causing higher pressures.
• Extreme pH value of a process liquid.
• Release of biogas into unusual and unexpected places.

2.8 Emergencies
During emergencies always follow the locally applicable safety provisions. Shut the
installation down and, during an evacuation, leave the site calmly; do not run! Always walk
at right angles to the wind direction from the source.

2.8.1 Shutting down the installation

During accidents the influent and all other dosing must be stopped. Take into account that
the biogas production may fall slowly (may take several days) and will not stop immediately
after the influent has been stopped.

The shut down of the installation is further described in the operating procedures Shutting
down the reactor and Shutting down and inerting the biogas system (Appendix B).

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3. OPERATIONAL DESCRIPTION

In the BIOPAQ® UASB reactor anaerobic biomass (granular sludge) converts organic
components (expressed in Chemical Oxygen Demand, COD; explained in chapter 7: List
of Technical Terms and section 3.5.2: Chemical Oxygen Demand, (COD)) from
wastewater into biogas. Biogas consists mainly of methane (CH4), carbon dioxide (CO2)
and a small fraction of hydrogen sulphide (H2S).

3.1 BIOPAQ® UASB reactor

The influent is pumped into the BIOPAQ® UASB reactor through the influent distributing
system. The influent then flows to an expanded bed of granular sludge (the biomass).
Here the biodegradable COD is converted into biogas. This biogas makes sure that the
sludge bed is properly mixed. Because of
the biogas production part of the sludge is
floated upwards. The reactor is provided
with separation modules on top, to separate
the treated wastewater, granular sludge and
biogas. The separation modules consist of
gas hoods, where the gas is separated from
the water. The biogas is subsequently
collected in the gas collection dome and
then led through the gas outlet to the biogas
treatment.
®
Figure 3.1: BIOPAQ UASB reactor

The effluent flows through a settling zone between the gas hoods of the separation
modules, where the sludge has time to settle. The effluent leaves the reactor through the
overflow chutes on top of the separation modules.

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The three phase (water, granular sludge and

biogas) separators are made of plastic to prevent
corrosion. Figure 3.2 shows a BIOPAQ® UASB
separation module.

®
Figure 3.2: BIOPAQ UASB separation module

3.2 Biogas treatment

For safe operational management, Paques strongly recommends that the biogas system
has at least been equipped with flow metering, condensate separation, overpressure
protection, buffer and flare. The overpressure protection can be present either
mechanically (valve) or as a water seal.

3.2.1 Biogas flow metering

Paques recommends the use of continuous biogas flow metering for optimum process
control of the BIOPAQ® UASB reactor. The link between biodegradable COD load and
biogas production allows optimal adjustment of the loading to the reactor capacity while
preventing COD overloading.

3.2.2 Condensate separation

Biogas is saturated with water. The temperature of the biogas in piping outside of the
bioreactor will fall resulting in condensation. The condensate must be removed from the
biogas via a condensate drainage point with water seal [figure 3.6 and 3.7, water seal A].
This water seal must continuously be checked and adjusted automatically.

3.2.3 Overpressure protection

The biogas system must be equipped with uncontrolled biogas release detection and
overpressure protection. Uncontrolled biogas release is monitored with an effluent level
alarm (L) on the BIOPAQ® UASB reactor and an overpressure alarm (P) on the biogas
pipeline. Once unwanted biogas release is detected (L- and/or P-alarm), a
beacon/sounder combination unit on top of the reactor as well as at the bottom of the
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reactor alarms the reactors’ surroundings. The influent pump is now only operated to
control the effluent level of the reactor.

The overpressure protection can be effected both mechanically [figure 3.3, B] and by
means of a water seal [figure 3.4, B]. The mechanical overpressure protection device
must be located at the highest point in the gas line, as close as possible to the BIOPAQ®
UASB reactor. This principle is shown schematically in figure 3.3. Contact the owner of
the installation when neither of these safety measures is in place, because safe operation
of the installation is impaired.

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Biogas
P
B overpressure

L F

Effluent

SCRUBBER

OPTIONAL
User

Influent
Condensate
L LL L

Water
A – Condensate separation
A B - Mechanical overpressure protection device

Figure 3.3: BIOPAQ® UASB reactor with mechanical overpressure protection device [B, 35 cm water column
(mbar)], reactor effluent level alarm (L) and overpressure alarm (P), scrubber (optional), gas buffer, gas flare
and condensate separation via water seal [A, 50 cm water column (mbar)].

An example of overpressure protection using a water seal is shown schematically in figure

3.4. The blow off of the overpressure protection device must be located near the highest
point in the gas line, as close as possible to the BIOPAQ® UASB reactor.

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P
Biogas
overpressure

!
Maximum pressure drop: 10 cm WC (mbar)
(between reactor and overpressure protection device)
F
L

Effluent

SCRUBBER

OPTIONAL
User

Influent
Condensate
L LL L

Water
B A – Condensate separation
A B – Overpressure protection via water seal

Figure 3.4: BIOPAQ® UASB reactor with overpressure protection via water seal [B, 35 cm water column
(mbar)], reactor effluent level alarm (L) and overpressure alarm (P), scrubber (optional), gas buffer, gas flare
and condensate separation via water seal [A, 50 cm water column (mbar)].

3.2.4 Buffering
The biogas produced leaves the BIOPAQ® UASB reactor with an irregular, pulsating flow.
Paques recommends that these fluctuations are being buffered using a pressure-resistant
buffer (operating pressure of 31 cm water column) with variable volume.

3.2.5 Gas flare

Depending on the situation the biogas produced can be used as a fuel, e.g. for a boiler.
Irrespective of the situation Paques has recommended that the BIOPAQ® UASB reactor
be equipped with a downstream gas flare (operating pressure 28 cm water column). In this
way the biogas can always leave the reactor under controlled and safe conditions.

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3.3 Ventilation
According to Paques’ standards, the top of the reactor should always be actively
ventilated with the help of the ventilation system. This prevents odour emission and
possible accumulation of biogas. The ventilation flow is set during start up.

3.4 Influent
The influent properties determine the success of the anaerobic degradation. The influent
normally comes from a pre-acidification tank or buffer tank. In this tank fluctuations in
chemical composition and flow rate are balanced and the wastewater is partly pre-
acidified. In addition, this (these) tank(s) can be used for nutrient dosing and pH
correction.

During shut down the reactor contents (process water and granular sludge) may NOT flow
out of the reactor via the influent pump and influent line. This would result in biomass loss.
If the liquid level in the reactor falls too low, biogas may escape from the reactor via the
separation modules. Backflow of the reactor contents must be prevented at all times by a
well-functioning non-return (check) valve and an actively controlled valve that closes when
the pressure or level drops.

A good understanding of the influent is the basis for optimum process control, because it
enables identification of a process malfunctions at an early stage. To prevent a process
malfunction the influent may not contain any toxic or disrupting substances, such as poly-
aluminium chloride and quaternary ammonium compounds.

3.4.1 Nitrite & nitrate

The influent of the BIOPAQ® UASB reactor may not contain more than 1 mg/l nitrite (NO2--
N) and 10 mg/l nitrate (NO3--N). As a result of higher nitrite and/or nitrate concentrations
nitrogen gas (N2) producing bacteria may develop in the methane producing granular
sludge. The biological anaerobic conversion of nitrite/nitrate into nitrogen gas is called
denitrification. The intermediates of denitrification (nitrite and other nitrogen oxides) have
an inhibiting effect on methane producing bacteria.

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3.4.2 Sulphite & sulphate

A sulphite (SO32-) concentration of 150 - 250 mg/l is toxic, which results in a decrease in
biogas production of 50% due to the toxicity of sulphite. The toxic effect on the biomass
can be reduced by slowly accustoming the biomass to sulphite. Normally a continuous
sulphite load does not therefore jeopardise the reactor operation. Big variations are however
harmful.

Sulphate (SO42-) is a relatively inert compound. Biomass requires small quantities as a

nutrient (as a source of sulphur). Sulphate reducing biomass can convert sulphate into
hydrogen sulphide (H2S) under the consumption of biodegradable COD. Sulphate has no
COD but the COD contents of H2S is 2 g COD/g H2S.

3.4.3 Fats, oils & greases (FOG)

Fats, oils and greases are sometimes present in the influent of the BIOPAQ® UASB
reactor. As long as these are not toxic, fats, oils and greases are acceptable up to a total
concentration of 50 mg/l. Higher concentrations may have an inhibiting effect on the
biodegradable COD removal and cause blockages of the reactor and/or wash out of
granular sludge.

3.5 Control parameters

3.5.1 Biomass (granular sludge)
The sludge bed of the BIOPAQ® UASB reactor consists of biomass in the form of granules:
the granular sludge. Figure 3.5 shows a
number of these anaerobic sludge
granules, both intact and sliced by a
laboratory annalist. The granular sludge
contains various bacteria groups,
including acidifying bacteria that convert
complex organic compounds into readily
degradable volatile fatty acids (VFA) and
biogas producing bacteria.
®
Figure 3.5: (Sliced) BIOPAQ UASB granular sludge

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Due to biomass growth the quantity of granular sludge in the reactor increases in time. In
addition to biomass growth, wash out and natural death of bacteria also takes place, which
results in the loss of a certain fraction of the biomass. The net biomass increase depends
on the ratio between growth and biomass loss.

The actual quantity of granular sludge and the ratio between biomass (VSS) and inorganic
solids (ash residue of TSS) is determined in the light of a sludge profile (Determination of
sludge profile – Appendix B). In general it can be stated that the BIOPAQ® UASB reactor
contains too much or too heavy granular sludge if the 4th sampling point contains more than
50 ml/l sludge and/or the 1st sampling point more than 50 – 60% ash residue of TSS.

Heavy sludge needs to be (partial) removed from the reactor on a regular basis, because
excess amounts can:
• Oust the biomass (inert material replaces the biomass).
• Damage the reactor internals.

The (Heavy) sludge removal during operation procedure is described in appendix B.

The BIOPAQ® UASB reactor may be damaged internally if it is operated with

excess or too heavy anaerobic granular sludge.

A surplus of granular sludge can easily be tapped off and stored (Storage of anaerobic
granular sludge - Appendix B). Even after a storage period of more than two years this
sludge can be reactivated almost as fast as fresh biomass. Consequently, the reactor can
be quickly started up again after a process malfunction by inoculation with the stored
granular sludge. In addition stored granular sludge can also be used to start up new
reactors. You can contact Paques Services to organise this.

3.5.2 Chemical Oxygen Demand (COD)

The Chemical Oxygen Demand (COD) of a wastewater is that quantity of oxygen
necessary to chemically oxidise the oxidisable substances present in the water. Paques
makes a distinction between the following COD fractions as shown in figure 3.6.

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Wastewater usually contains a dissolved and solid COD fraction. This fraction distribution
can be obtained by means of filtration. The colloidal material is also found in the dissolved
fraction. Both the dissolved and the solid COD fraction contain an inert and a degradable
part.

Note: The final fraction distribution depends on the analysis method used (for example
centrifugation, filtration, pore size of the filter, etc.).

CODdissolved CODbiodegradable

CODtotal

Colloidal

Colloidal
CODinert

CODbiodegradable
CODsolid
CODinert

Figure 3.6: COD fraction distribution in wastewater

3.5.3 COD load and volatile fatty acid concentration

Complex organic compounds from the wastewater (measured as COD) are converted in a
number of stages to biogas. To summarise:
1. Acidifying bacteria convert biodegradable COD into volatile fatty acids (VFA),
including acetate and hydrogen (H2) in a number of stages. VFA belong to the
dissolved, degradable COD fraction.
2. Biogas producing bacteria then convert the acetate produced into biogas.

For stable operation of the BIOPAQ® UASB reactor it is important that the load is
proportionate to the activity of the granular sludge. The granular sludge and biodegradable
COD load are well adjusted to each other when the VFA concentration measured in the
effluent is less than 5 meq/l. In addition to remaining VFA, the residual COD concentration
in the effluent depends on the inert COD fraction (see figure 3.9) and the quantity of
sulphide produced. This varies per type of wastewater.

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The VFA concentration of the water phase is determined by means of titration; this method
is described in operating procedure Volatile fatty acid (VFA) concentration and alkalinity
(Appendix B).

3.5.4 Pre-acidification degree

VFA is formed both in the upstream (buffer tanks, pre-acidification or other pre-treatment)
and inside the BIOPAQ® UASB reactor. The ratio between the VFA fraction (expressed in
COD) and the dissolved COD fraction in the influent determines the degree of pre-
acidification of BIOPAQ® UASB influent. An optimum pre-acidification degree is necessary
for a good ratio between acidifying and biogas producing biomass in the sludge granule.
Paques recommends a pre-acidification degree of approximately 35% of the dissolved
COD. A pre-acidification degree that is too high (> 50%) or too low (< 30%) results in
unbalanced growth, deteriorating granular structure, reduction of the COD removal
efficiency and potential biomass loss.

The pre-acidification degree is determined using the calculation method in the operating
procedure Calculations (Appendix B).

3.5.5 Specific biogas production

The specific biogas production is that quantity of biogas that is produced per 1 kg of
biodegradable COD removed.

The specific biogas production is determined using the calculation method in the operating
procedure Calculations (Appendix B).

3.5.6 pH
Optimum
The optimum pH in the sludge bed is between 6.5 and 7.5. For stable operation of the
BIOPAQ® UASB reactor the pH must be kept within this range.

Checking
The pH in the sludge bed of the BIOPAQ® UASB reactor can be measured with an on-line
pH meter. If the reactor is not designed with an on-line measurement, Paques recommends
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that the pH be regularly checked manually. Use the second or third sampling valve for this
(Technical Data Sheets - Appendix A).

Note:
In the case of manual pH checking the pH measured is usually higher than the
actual pH in the sludge bed. This is caused by the escape of CO2. The
reliability of the manual pH measurement can be increased as far as possible
by preventing contact with outside air and the pH in the liquid measured during
sampling.

Acidification
VFA and sulphides (H2S) occur both dissociated (charged, like HS-) and undissociated
(uncharged, like H2S). The ratio between the dissociated and undissociated fraction
depends on the pH. If the pH of the process water is reduced the undissociated fraction
increases. This undissociated fraction is the problematic form, because it can penetrate
through the cell membrane, which poisons the cell. A decrease in the reactor pH below 6.5
must therefore be prevented at all times.

Influent pH
Because the pH in the reactor generally rises, the influent pH can be set a little lower than
the optimum pH. If the reactor is operated with a low influent pH, then it is important that:
• The reactor liquid has sufficient buffer capacity.
• The reactor contents are well mixed (sufficient biogas production → good recirculation
flow rate).

3.5.7 Alkalinity (pH buffering)

Alkalinity is the capacity of a solution to buffer pH fluctuations. For the BIOPAQ® UASB
reactor the most important buffer system is the carbonic acid (H2CO3) / bicarbonate (HCO3-)
system (pH between 6.5 and 7.5). The alkalinity of the water phase is determined by
titration, this method is described in operating procedure Volatile fatty acid (VFA)
concentration and alkalinity (Appendix B). To prevent acidification of the BIOPAQ® UASB
reactor the effluent alkalinity must be at least 15 meq/l.

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Alkalinity increasing processes are:

1. Stripping CO2 from the BIOPAQ® UASB reactor.
2. Conversion of fatty acids into biogas.
3. Sulphate reduction.

3.5.8 Temperature

Optimum
The temperature has a strong effect on the growth rate and the activity of the bacteria in the
granular sludge, in particular on the biogas producing bacteria. These bacteria have a
temperature optimum between 30 and 38°C. Above 40°C their activity decreases
considerably. It is therefore necessary to keep the reactor temperature below 38°C.

Continuously lower temperature

If the reactor is continuously operated at a lower temperature (< 25°C), the initial start up
and any recovery after a restart will take longer. But, ultimately good biological activity rates
and hence COD removal efficiencies can also be obtained at a lower process temperature.

Sudden temperature drop

VFA producing bacteria are less sensitive to sudden temperature drops than biogas
producing bacteria. In case of a sudden temperature drop the biogas production falls more
quickly, which means that the chance of acidification of the sludge bed increases. To protect
the sludge bed against acidification the reactor must have a reduced load during a
temperature drop. In addition Paques recommends that the pH of the sludge bed be
temporarily checked more often. Use the second or third sampling valve for this (Technical
Data Sheets - Appendix A).

Considerable temperature fluctuations within a short time must be avoided because they
almost always cause a reduction in the biodegradable COD removal efficiency.

3.5.9 Nutrients
Biomass needs macro- and micro-nutrients for growth. Normally the wastewater contains
sufficient nutrients and extra dosing is not necessary. In some industries, such as for
example in the pulp & paper industry, the wastewater contains insufficient nutrients. In these
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industries extra nutrient dosing is necessary because a long-term nutrient deficit has a
negative effect on the sludge quality and ultimately the removal efficiency.

Extra dosing is always carried out upstream (for example pre-acidification tank or buffer
tank) and is matched to the composition of the specific wastewater. After start up the
dosing of the macro-nutrients N and/or P is further adjusted based on the measured
effluent concentrations of the nutrients.

As for all mirco-nutrients, Paques B.V. supplies the BIOPAQ® Micromix. This is a
balanced solution of trace metals, specifically developed for the BIOPAQ® UASB process.

3.5.9.1 Nitrogen (N), phosphate (P) and sulphur (S)

Bacteria need nitrogen (N), phosphate (P) and sulphur (S) for growth. Nitrogen is usually
dosed as urea solution (chemical formula written as CO(NH2)2 or CON2H4) and phosphate
as phosphoric acid (H3PO4). Compared to N and P, the sulphur (S) requirement is much
lower. Normally, S is present in a sufficient quantity in wastewater. If this is not the case,
extra sulphur is normally dosed as sulphuric acid (H2SO4). Paques recommends that the
initial dosing be calculated in the light of the following guidelines:

1. Fully acidified influent: CODbiodegradable : N : P = 900 : 5 : 1 (kg/m3)

2. Fully unacidified influent: CODbiodegradable : N : P = 350 : 5 : 1 (kg/m3)

After start up, control can best be carried out on the ammonium and phosphate
concentration in the effluent of the BIOPAQ® UASB reactor, taking into account any
variations in the biodegradable COD load. The following guidelines apply for this: NH4+-N >
5 mg N/l and PO43--P > 1 mg P/l.

3.5.9.2 Calcium (Ca), magnesium (Mg) and potassium (K)

Bacteria need calcium (Ca), magnesium (Mg) and potassium (K) to function well. Whether
dosing is necessary depends on the type of wastewater.

Calcium improves the granule forming properties of the sludge. In wastewater with high
calcium concentrations there is a high risk of calcium carbonate precipitation formation,
because calcium carbonate is poorly soluble. To keep the dissolved calcium concentration

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high, the pH must be kept low. In wastewater with low calcium concentrations Paques
recommends dosing a soluble calcium salt until the dissolved calcium concentration in the
wastewater is 70 mg Ca2+/l.

There is usually sufficient magnesium present. In wastewater with a high sodium

concentration (> 5000 mg Na+/l) Paques recommends that the dissolved magnesium
concentration be increased to 10 – 20 mg Mg2+/l, by dosing a soluble magnesium salt.

Extra potassium dosing also depends on the sodium concentration (> 5000 mg Na+/l).
Sodium and potassium are optimal balanced when the Na : K ratio is around 20 : 1.

3.5.10 Calcium (precipitation)

Under normal circumstances calcium (Ca2+) has a limited solubility in water. But the
dissolved calcium can be much higher (well over 1 g/l) when fatty acids are (temporarily)
produced in the clients’ production process. Calcium and the fatty acid produced are as it
were coupled to one another, enabling the calcium to be dissolved. In the BIOPAQ® UASB
reactor the fatty acid is converted into biogas and disappears from the water phase.
Dissolved calcium is left behind.

Biogas consists mainly of methane (CH4) and carbon dioxide (CO2). Depending on the pH,
part of the carbon dioxide produced as bicarbonate (HCO3-) and/or carbonate (CO32-) is left
in the water phase, where it functions as a new anion for calcium. With a pH of 6.5 – 7.0 the
majority will be present in the water phase as bicarbonate, as a result of which calcium
remains in solution. If the ratio between bicarbonate and carbonate changes and the
carbonate fraction in the water phase increases, calcium will then precipitate with carbonate
as calcium carbonate (CaCO3). Calcium carbonate precipitation can cause blockage of the
pipe work and must therefore be prevented. In these cases Paques recommends that the
following guidelines be taken into account:

1. Keep the Ca2+ influent concentration below 600 mg/l.

2. Keep the pre-acidification degree sufficiently low.
3. Prevent the stripping of carbon dioxide (CO2) from the water phase (for example by
keeping the effluent line completely filled with water).
4. The COD/Ca2+ ratio should not exceed 10 : 1 (kg : kg).

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3.5.11 Hydrogen sulphide

In addition to methane producing bacteria anaerobic granular sludge also contains sulphate
reducing bacteria. Sulphate reducing bacteria function in a comparable environment as
methane producing bacteria. They convert sulphate and/or sulphite into (hydrogen) sulphide
under the consumption of biodegradable COD from the influent. Hydrogen sulphide
formation is undesirable for the following reasons:
• H2S gas may be released from the effluent, as a result of which odour problems and
toxic H2S concentrations may occur in the ventilation air.
• Sulphate has no COD, but sulphide has a COD of 2 mg/mg S2-. Because sulphide in
the effluent is measured as COD, this gives a reduction in the COD efficiency.
• Corrosion problems in the water/air separators.
• Part of the sulphide leaves the reactor as H2S in the biogas. The biogas becomes toxic
and corrosion problems may arise for example in combustion plants, when biogas is
used as a fuel without pre-treatment or the permitted SO2 discharge limit may be
exceeded.
• Hydrogen sulphide is toxic. At concentrations of 150 mg/l H2S in the water phase the
biogas production falls by 50%. Increasing the liquid pH by one to two tenths can reduce
the toxic effect on the biomass.
• Methane producing biomass competes for biodegradable COD with the sulphate
reducing biomass.

In addition to the pH the COD/Sulphate (SO42-) ratio in the influent is also an indication that
there is a chance of toxic effects due to sulphide. With a COD/SO42- ratio of 10:1 the effects
are negligibly small.

3.5.12 Summary of control parameters

The general control parameters are summarised in the table (Project-specific) control
parameters in appendix A. Any project-specific changes can be entered by the process
specialist on the spot in the same table.

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4. START UP PROCEDURE

Paques recommends that Paques personnel be present at the initial start up, because the
experience of the Paques start-up engineers will result in a start-up that is as smooth and
fast as possible. However, the installation should be fully completed and tested. It is
recommended that a month’s stock of all the required nutrients, neutralising chemicals
and nitrogen gas (N2) be present on the site. Also all the required analysis materials and
chemicals must be present in the laboratory.

All the equipment must be started up in accordance with the suppliers’ specifications.

4.1 Technical inspection

Prior to the technological start up the installation is technically inspected to ensure safety
and efficient start-up. The technical inspection consists of the following components:
• Leakage test
• Hydraulic test
• Functional specification check

4.1.1 Leakage test

The leakage test is carried out at the start of the hydraulic test. During the leakage test it
is determined whether the reactor with relevant pipe work is gas and watertight.

The leakage test is preferably carried out with clean (industrial or river) water (for the
reactor) and compressed air (for the gas system). If this is not present, the leakage test
may if necessary be carried out with process water. Pay attention here to the quality of the
process water used. Think particularly about the biodegradable COD concentration, TSS
concentration, pH and temperature.

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4.1.2 Hydraulic test (water run)

During the hydraulic test the reactor hydraulics are tested. For example, whether the
pumps and lines can cope with the flow rate and whether there are blockages in the pipe
work or nozzles. In addition the different set points are set and determined.

Always carry out the hydraulic test with water with a low COD concentration!

Perform a flow test of the influent distribution lines as described in Operating procedure
Flow test influent distribution lines (Appendix B). These test results serve as a reference
measurement for future flow tests.

Set the ventilation flow.

4.1.3 Checking of functional specification

During this check it is determined whether the installation operates as described in the
functional specification. Carry out this check during the hydraulic test (where possible) and
note here:
• Whether the signals of the on-line metering & control equipment in the field come in on
the right scale and place on the SCADA system (report deviations to the programmer).
• Whether all controls (for example pump) and regulations (for example pH) function
well from the SCADA system in the field.
• Test alarm and stand-by situations.

4.2 Technological start up

4.2.1 Start up conditions

Before the anaerobic granular sludge can be added to the reactor, the conditions
indicated in this paragraph must be checked and if necessary adjusted.

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4.2.1.1 Process conditions

The water already present in the BIOPAQ® UASB reactor must meet the conditions given
in table 4.1.
Table 4.1: Process conditions during start up

Process condition Minimum Optimum Maximum

VFA (meq/l) 0 <5 10

Pre-acidification degree (%) 30 35 50

pHsludge bed (-) 6.5 7.0 – 7.5 8.0

Alkalinity (meq/l) 15 - -

Temperature (°C) 25 30 – 38 40

Nutrients: Nitrogen (N) (CODbiodegradable : N) Depending on pre-acidification degree

Nutrients: Phosphate (P) (CODbiodegradable : P) Depending on pre-acidification degree

4.2.1.2 Influent
The influent of the BIOPAQ® UASB reactor must comply with the output data described in
the contract.

4.2.2 Inerting biogas system

During the hydraulic test the system is filled with water and air. Biogas production can be
expected directly after the inoculation of anaerobic granular sludge. To prevent critical
oxygen-biogas mixtures (LEL, see section 2) the biogas system must, before the sludge
inoculation, be inerted with nitrogen gas.

Inert the biogas system with nitrogen gas in accordance with operating procedure Shutting
down and inerting biogas system in appendix B.

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4.2.3 Sludge inoculation

®
The gas system of the BIOPAQ UASB reactor must be tested and guaranteed
gas-tight before the reactor may be inoculated with anaerobic granular sludge.

In the ideal case the reactor is inoculated with anaerobic granular sludge, with a volume of
20 - 50% of the reactor contents. The ideal sludge volume for start up depends on the
reactor type and the anticipated biodegradable COD load. It takes more time to bring the
reactor to the design COD conversion capacity if the reactor is started up with less sludge
than recommended.

It is recommended to analyse the anaerobic granular sludge (or have it analysed)

beforehand for the dry matter content (TSS), the organic matter content (VSS) and the
biological activity. With these data the total biodegradable COD conversion capacity of the
sludge inoculation can be calculated. This conversion capacity determines the
biodegradable COD load during start up. An example calculation is given in table 4.2.

Table 4.2: Example calculation of total conversion capacity of sludge inoculation. For the total conversion
capacity the conversion capacities of one or more sludge types are added together. In this example a sludge
mixture is assumed that comes from supplier A and supplier B.

Example calculation of total conversion capacity of sludge inoculation

Sludge inoculation A Volume of sludge inoculation 300 m3

VSS concentration 63 kg * m-3
Sludge activity 0.6 kg COD * kg VSS-1 * day-1

Sludge inoculation B Volume of sludge inoculation 100 m3

VSS concentration 59 kg * m-3
Sludge activity 0.6 kg COD * kg VSS-1 * day-1

Conversion capacity sludge inoculation A: 300 * 63 * 0.6 = 11340 kg COD * day-1

Conversion capacity sludge inoculation B: 100 * 59 * 0.6 = 3540 kg COD * day-1

-1
Total conversion capacity sludge inoculation 14880 kg COD * day

During the initial start up the optimum reactor temperature is usually not yet reached and the
biomass still has to get accustomed to the new process conditions. This temporarily results

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in a lower sludge activity. To prevent overload the reactor is loaded during the initial start up
with a convertible COD load that is based on 50% of the total conversion capacity. During
the initial start up the reactor from the example can be loaded with a COD load of:

Convertible COD load = 0.5 * 14880 = 7440 kg CODbiodegradable*day-1.

Based on an anticipated efficiency of for example 75% the reactor can be loaded during the
initial start up with a total COD load of:

Total COD load = (100/75) * 7440 = 9920 kg CODtotal*day-1.

During the first two weeks of the biological start up 10% sludge loss is normal. This is the
result of natural selection and adaptation of the biomass to the new situation. Small
granules of biomass can usually be found in the effluent from the reactor. The effluent is
then usually coloured black.

Fill the reactor with anaerobic granular sludge in accordance with operating procedure
Filling the reactor with granular sludge in appendix B.

4.3 Start up
The BIOPAQ® UASB reactor is started up, charged with influent, as soon as the biogas
system has been inerted with nitrogen gas, the reactor filled with anaerobic granular
sludge and the start up conditions have been met.

Procedure
1. Determine the total conversion capacity of the sludge inoculation (see example
calculation table 4.2).
2. Start up the BIOPAQ® UASB reactor with a biodegradable COD load that is equal to
50% of the total conversion capacity of the sludge inoculation.
3. Monitor the reactor as described in the Analysis schedule (appendix B).
4. Daily fluidise the sludge bed accordance with operating procedure Flow test influent
distribution lines (appendix B) for one week.
5. Increase the load in stages, depending on the analysis results.

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Increase the COD load by 10% if:

• the effluent VFA concentration is lower than 5 meq/l and
• the effluent pH is 6.5 or higher and
• there is no exceptionally high sludge wash out (less than 1 to 2 ml/l)

Reduce the COD load by 10% if:

• effluent VFA concentration is higher than 5 meq/l or if
• effluent pH is lower than 6.5 or if
• a lot of sludge is washed out (> 10 ml/l).

Note:
If the effluent VFA concentration is between 5 and 10 meq/l, after a few hours a fatty acid
analysis must be repeated.

• If the VFA concentration is falling → Maintain the present COD load

• If the VFA concentration is increasing → Reduce the COD load.

An effluent VFA concentration < 5 meq/l indicates that the reactor is performing well.

The COD efficiency during the start up is normally 10 to 20% lower than the design
efficiency. This is caused by:
1. A reduced sludge activity, which gives a higher effluent VFA concentration.
2. Wash out of sludge (both sludge and VFA are measured as COD).
3. Too little (adapted) sludge in the reactor.
4. Toxicity (an inhibitor in the influent).

NOTE: Check the pH of the sludge bed regularly in order to determine local overload.
During start up a lower biodegradable COD load is causing a lower gas
production than normal. Therefore, it is possible that the reactor is not properly
mixed. The pH in the sludge bed needs to be higher than the influent.

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4.4 Normal operation

The BIOPAQ® UASB reactor functions under normal operation, when all the measured
values lie within the specified range.

4.5 Restart
This paragraph describes how the BIOPAQ® UASB reactor is restarted after this has been
temporarily shut down. The method depends on the configuration (with or without external
recirculation) and the duration of the shut down (longer or shorter than 5 days).

4.5.1 With external recirculation or shorter than 5 days

1. Start up the BIOPAQ® UASB reactor at 100% of the COD design load.
2. Monitor the reactor as described in the start up procedure (paragraph 4.3).

4.5.2 Without external recirculation or longer than 5 days

1. Refluidise the sludge bed accordance with operating procedure Flow test influent
distribution lines (appendix B).
2. Start up the BIOPAQ® UASB reactor at 60% of the COD design load.
3. Monitor the reactor as described in the start up procedure (paragraph 4.3). Pay special
attention to reactor acidification. Reduce the biodegradable COD load as described in
the start up procedure (paragraph 4.3) and increase the reactor pH to 7.0 – 7.5.
4. Increase the load in stages, depending on the analysis results.
5. Daily fluidise the sludge bed accordance with operating procedure Flow test influent
distribution lines (appendix B) for one week.

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5. OPERATING PROCEDURES

5.1 General process control

For continuous, safe operation Paques recommends that one person or a small group of
people must be given the responsibility for the operation of the installation. It is advisable to
keep an up-to-date logbook or datasheet in which measurement data and chemical
consumption are noted. If required, Paques can advise on process control in the light of
this datasheet. This can be done for various service levels. For this you can contact
Paques Services (see paragraph 1.1). In addition it is advisable to regularly update a
checklist. This guarantees that there are always sufficient chemicals and spare parts
present and that all equipment is in the optimum state of maintenance.

A stably operating BIOPAQ® UASB reactor is characterised by:

• Constant average biogas production;
• Low volatile fatty acid concentration in the effluent;
• Constant effluent pH;
• pH in the sludge bed is higher than the influent pH;
• No loss of granular sludge;
• TSS wash out is roughly the same as the TSS washed in;
• High effluent alkalinity;
• A constant COD efficiency (for constant influent COD).

5.2 Routine work

In this paragraph a summary is given of the routine work (inspection and maintenance) on
the BIOPAQ® UASB reactor as recommended by Paques. To support this, the following
appendices have been enclosed with this operating manual.
• Appendix B - Operating procedures.
• Appendix C - Troubleshooting.

5.2.1 Daily

5.2.1.1 Process
• Check whether any alarm situations exist and if so, rectify them.
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• Carry out the analysis programme (Analysis schedule - Appendix B) and check that the
values found fall within the specified values ((Project-specific) control parameters -
Appendix A).
• Assess the quality of the influent and effluent; report and note deviations.
• Read the process variables of the last 24 hours and check the Troubleshooting
procedures (Appendix C) in case of abnormal process values.

5.2.1.2 Mechanical
• Check the operation of all pumps. Note leakage, flow rate and noise. Rectify the
malfunction in accordance with the supplier’s instructions.
• Check the installation for leaks and blockages.
• Check the levels of the chemical storage tanks and fill up if necessary.

5.2.1.3 Metering & control equipment

• Check the control parameters and check that these parameters are within the specified
value ((Project-specific) control parameters - Appendix A).
• Compare the pH readings of the field equipment with the daily calibrated laboratory pH
meter. If these two measurements differ from one another by more than 0.2 pH units,
the field electrode must be calibrated. It must be cleaned (refer to supplier’s manual) or
replaced when calibration fails.

5.2.2 Weekly
• Clean and check metering equipment in accordance with the supplier’s instructions.
• Check the usability of safety materials.

5.2.3 Monthly
• Check if the discharge openings of the influent distribution lines are open in
accordance with Operating procedure Flow test influent distribution lines and unblock if
necessary [Unblocking influent distribution lines – Appendix B].
• Determine the sludge profile in accordance with Operating procedure Determination of
sludge profile.

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• Check if the covers show signs of wear (top coating fades away, fibres become
visible/tangible and dirt is absorbed). Coat the covers with a polyurethane (PUR)
coating if these signs are present.
• Check if the rubber cover seals are damaged. Replace worn seals.
• Maintenance of equipment in accordance with the supplier manuals.

• Keep the covers closed while recoating them.

• There is a HIGH chance of unwanted biogas release, if the seals of the
covers are being replaced. Consult § 2.2.1 Hazardous area classification
before starting this replacement.

5.2.4 Annual
• Check condition of the concrete and steel parts.
• Check the ventilation system.

5.3 Cleaning instructions

The installation can generally be cleaned with water.

5.4 Temporary shut down

It may be necessary for the BIOPAQ® UASB reactor to be shut down for a particular period.
This may vary from a few hours to a few weeks. The BIOPAQ® UASB reactor is shut down
via a number of stages.
1. Shut down the supply of COD by stopping the influent flow.
2. (If possible: Maintain the recirculation flow rate.)
3. Reduction of the biological activity, the biogas production falls.
4. Shut down biogas production.

The procedure is described in operating procedure Shutting down the reactor in appendix B.
The restart procedure is described in paragraph 4.5.

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Biogas production
After the influent has been stopped, the biogas production from readily degradable COD
gradually falls and will finally stop completely. Due to the reduction in the biogas production
the mixing of the sludge bed in the reactor is also reduced. Depending on the type of
wastewater the sludge bed may contain a certain concentration of slowly degradable COD
(for example solid matter). When the mixing has been reduced and the biogas production
from this slowly degradable COD is still taking place, there is still change on sudden biogas
release. This sudden thrust is also called the ‘belching’ of the reactor. The same safety
measures as during operation should be followed after shut down.

5.5 Major maintenance

Paques recommends a major overhaul on the BIOPAQ® UASB reactor every 5 years.
Paques personnel or personnel trained by Paques could do this for you. Take into account
that the reactor must always be empty and clean before any major maintenance can take
place.

5.6 Emptying the installation

For any inspections and maintenance it may happen that the BIOPAQ® UASB reactor (or
components of it) must be temporarily empty.

The emptying of the BIOPAQ® UASB reactor is described in the operating procedure
Emptying of the reactor in appendix B.

5.7 Dismantling and disposal of the installation

Dismantling and disposal of the installation must be carried out in accordance with the
local environmental regulations. Electrodes, gas Venturi tubes and cuvettes for chemical
analyses are chemical waste and must be disposed of as such.

5.8 Protection against frost

If there is a risk of frost Paques recommends insulating the installation and in addition
wrapping the lines that cannot be emptied with thermal tape (this might have been
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supplied as an option). Particularly during shutdown there is a great danger of frost

damage.

5.9 Spare parts

Paques recommends that at least one spare pH electrode be kept in stock. If the life of the
pH electrode is considerably shorter than the life specified by the supplier, it is
recommended that the electrode be replaced by a double junction (two chamber) system
or the reference electrode be placed outside the system (diaphragm tube & KCl solution).
Paques Services can help you further.

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6. PROCESS MALFUNCTION AND TROUBLESHOOTING

6.1 Process malfunction

6.1.1 Acidification of the reactor

‘Acidification of the reactor’ means: The accumulation of VFA in the reactor liquid with a pH
of less than 6.5. Possible causes of reactor acidification may be:
• Too low influent pH.
• A sudden temperature decrease.
• Presence of toxic components.
• Insufficient mixing of the sludge bed.
• Too high or too low reactor temperature.
• Too high COD load.
• Nutrients deficit.
• Too low pre-acidification degree.
• Too high solids concentration in the influent.
• Accumulation of solids in the reactor.

Under normal process conditions biogas is formed by the biogas producing bacteria in the
granular sludge from VFA. The optimum pH for this is between 6.5 and 7.5. If the normal
process is disrupted, for example by one of the above causes, the pH in the sludge bed falls
below 6.5 and the biogas production is inhibited and/or the biogas producing bacteria may
die.

The acidifying bacteria are less sensitive to low pH values. They remain active down to a pH
of 4. So for pH values of 4.0 and 6.5 the creation of VFA continues, while the breakdown
ceases. As a result of this the VFA will accumulate easily in the reactor liquid.

During acidification there is a chance that the BIOPAQ® UASB reactor gets into a vicious
cycle (figure 6.1).

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Methane producing Poor buffer capacity

capacity exceeded of process water

Poisoning of methane
producing bacteria
VFA concentration increases
increases

Fraction of undissociated
VFA increases

pH falls

Figure 6.1: The vicious cycle of reactor acidification

Immediately after a malfunction or overload, the VFA concentration in the effluent increases.
As a result the biogas production falls and depending on the alkalinity in the reactor, the pH
falls and the carbon dioxide content in the biogas increases. These effects reinforce one
another as a result of which ultimately, if no measures are taken to eliminate the cause, the
whole reactor activity comes to a standstill.

To break the vicious cycle the following measures must be taken:

• Reduce the COD load.
• Increase the influent pH.

As long as the pH of the sludge bed is above 7.0 (preferably around 7.5), a VFA
concentration of 10 to 15 meq/l has a slightly negative effect on the biogas producing
bacteria.

6.1.2 Inhibitors
If, at a constant load, a slow but sure increase of effluent VFAs is observed, there may be
an inhibitor in the influent. This inhibitor affects the activity of the sludge with the result of
a slowly deteriorating situation. An inhibitor may also be present for a very short period, for
example due to an unforeseen discharge.

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6.1.3 Wash out of granular sludge

The more granular sludge is washed out, the higher the sludge loading rate for the
remaining granular sludge will be. Possible causes for sludge wash out are:
• Too much grease or oil. These substances may form a thin layer round the sludge
granule, as a result of which the substrate cannot enter the granule and the biogas
cannot get out of it.
• The hydraulic load is too high (too high up flow velocity).
• The biodegradable COD load is too high. The sludge granules cannot let go of the
biogas produced quickly enough and as a result they float.
• Fibres or other solid particles in the influent. These solid particles can attach
themselves to the granule, which results in a reduced settlement velocity.
• The pre-acidification degree in the influent is too high, as a result of which the content
of acidifying bacteria in the sludge granule may be too low. As a result the granules
are not so strong and they disintegrate as time passes.
• Nutrient deficit.
• An increasing VFA concentration in the effluent.

6.2 Troubleshooting

6.2.1 Process Troubleshooting

The troubleshooting instructions have been prepared in accordance with current
knowledge. New insights can result in changes to these procedures.

Process malfunctions that may affect the process parameters, mentioned in section 3, can
result in a reduction in activity of the biomass. In extreme situations the biomass can even
be killed.

The reason for the reduction in the biological activity must be identified and resolved. The
information that is given in section 3, 4 and 5 is important for this.

The troubleshooting procedures in appendix C describe different events and measures

that can be taken. It is obvious that these procedures cannot be complete. Only the most
probably events are shown. You can contact Paques Services for advice when you
encounter an event not mentioned.

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6.2.2 Mechanical troubleshooting

For the mechanical troubleshooting of the various process components please refer to the
relevant operating instructions of the supplier.

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7. LIST OF (TECHNICAL) TERMS

AEROBIC
There is dissolved oxygen present in the water phase.

ANAEROBIC
There is no dissolved oxygen present in the water phase.

BIOGAS PRODUCTION - [m3/day]

Quantity of biogas that is produced per day.

BOD (Biological Oxygen Demand) - [mg O2/l]

The quantity of oxygen that bacteria need for the biological oxidisation of the
oxidisable substances present in the water. Several standardised procedures exist.

BOD/COD ratio
This ratio is a measure of the biological degradability of a wastewater; readily
degradable wastewater has a BOD/COD ratio of between 0.5 and 0.9.

COD (Chemical Oxygen Demand) - [mg O2/l]

The quantity of oxygen that is necessary for the chemical oxidisation of the
oxidisable substances present in the water.

COD Balance
The anaerobic system must be in balance, i.e. as much COD must enter the reactor
(influent) as leaves it (effluent, biogas and sludge).

CODinfluent = CODeffluent + CODbiogas + CODsludge

COD removal efficiency - [%]

The percentage COD in the influent COD that is removed.

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COD load - [kg COD * day -1]

The COD load of an anaerobic reactor is the quantity of COD that enters the reactor
per day.

FLOW RATE - [m3/hour or m3/day]

The quantity of wastewater that flows to a particular process component.

EFFLUENT - [m3/hour or m3/day]

The outgoing, treated wastewater.

HYDRAULIC RESIDENCE TIME (HRT) - [hour]

The residence time of the wastewater in the reactor.

IMHOFF SETTLEMENT VOLUME - [ml/l]

The quantity of settlable solids in the wastewater after half an hour of settlement time.

INFLUENT - [m3/hour]
The incoming wastewater.

KJELDAHL NITROGEN (Kj-N) - [mg Kj-N/l]

The total quantity of ammonium and organically bound nitrogen.

MSDS
Material Safety Data Sheet

REACTOR VOLUME - [m3]

The maximum quantity of water that the reactor can hold.

RECIRCULATION - [m3/hour]
The quantity of effluent that is recirculated to the reactor.

SEPARATION MODULE (THREE PHASE SEPARATOR)

In the separation module the wastewater, biogas and granular sludge are separated
from one another.

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SLUDGE ACTIVITY - [kg COD * (kg VSS)-1 * day-1]

The quantity of COD that can be converted per day by a quantity of biomass (VSS).
The quantity of biogas produced and the production time are a measure of the sludge
activity.

SLUDGE BED VOLUME - [m3]

The volume of sludge that is present in the reactor.

SLUDGE LOADING RATE (SLR, Sludge Loading Rate) - [kg COD * (kg VSS)-1 * day-1]
The quantity of COD per quantity of biomass (VSS) that enters the reactor per day.

SPECIFIC BIOGAS PRODUCTION (SGP) - [m3/kg CODremoved]

The quantity of biogas produced per kg of COD removed.

TSS (Total Suspended Solids) - [mg/l or %]

The quantity of suspended solids in water (so EXCLUDING dissolved substances).

UASB
Upflow Anaerobic Sludge Blanket

VLR (Volumetric Loading Rate) - [kg COD * m-3reactor * day-1]

The COD load per reactor volume per day.

VFA (Volatile Fatty Acids) - [meq/l]

Acetic acid : CH3 COOH
Propionic acid : C2H5 COOH
Butyric acid : C3H7 COOH
Lactic acid : C2H5OCOOH

An indication that the anaerobic polishing is not functioning well is when butyric acid
contributes significantly to the total VFA (i.e. >5%). Butyric acid can be noticed by its
characteristic odour (sweaty feet).

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VSS (Volatile Suspended Solids) – [mg/l or % of TSS (VSS = TSS – ash residue)]
The organic fraction of the TSS. This fraction can be determined by reducing to
ashes the sample from which TSS is determined. The higher the organic content, the
higher the activity of the sludge (more organic material means more bacteria).

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8. APPENDICES

8.1 Appendix A: Specifications

8.2 Appendix B: Operating procedures

8.3 Appendix C: Troubleshooting

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