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A paper mill producing 500,000 ton of graphic paper annually has an on-site wastewater treatment plant that treats 7,240,000 m³ of wastewater per year, mechanically first, then biologically and at last by ozonation. Increased paper production capacity led to higher COD load in the mill effluent while production of higher proportions of brighter products gave worse biodegradability. Therefore the biological capacity of the WWTP needed to be increased and extra measures were necessary to enhance the efficiency of COD reduction. The full scale implementation of one MBBR with a volume of 1,230 m³ was accomplished in 2000 followed by another MBBR of 2,475 m³ in 2002. An ozonation step with a capacity of 75 kg O₃/h was added in 2004 to meet higher COD reduction demands during the production of brighter products and thus keeping the given outflow limits. Adding a moving bed biofilm reactor prior to the existing activated sludge step gives: (i) cost advantages when increasing biological capacity as higher COD volume loads of MBBRs allow smaller reactors than usual for activated sludge plants; (ii) a relief of strain from the activated sludge step by biological degradation in the MBBR; (iii) equalizing of peaks in the COD load and toxic effects before affecting the activated sludge step; (iv) a stable volume sludge index below 100 ml/g in combination with an optimization of the activated sludge step allows good sludge separation--an important condition for further treatment with ozone. Ozonation and subsequent bio-filtration pre-treated waste water provide: (i) reduction of hard COD unobtainable by conventional treatment; (ii) controllable COD reduction in a very wide range and therefore elimination of COD-peaks; (iii) reduction of treatment costs by combination of ozonation and subsequent bio-filtration; (iv) decrease of the color in the ozonated wastewater. The MBBR step proved very simple to operate as part of the biological treatment. Excellent control of the COD-removal rate in the ozone step allowed for economical usage and therefore acceptable operation costs in relation to the paper production.

To provide the first step towards a microbial ecology-based understanding of irreversible membrane biofouling, four laboratory-scale membrane bioreactors (MBRs) were operated to investigate the identity of bacterial populations highly correlated with irreversible membrane biofouling. The conventional MBR was divided into two separate experimental units. Unit one consisted of four suspended-growth, activated sludge, sequencing batch bioreactors treating a synthetic paper mill wastewater. Unit two consisted of a microfiltration membrane cell. Amplified ribosomal deoxyribonucleic acid restriction analysis (ARDRA) was used to compare the predominant bacterial populations in samples of mixed liquor and irreversibly bound to the membrane surface. The results of ARDRA showed a significant difference between the planktonic and sessile bacterial communities suggesting that irreversible biofouling of microfiltration membranes may be more highly correlated to specific bacterial populations rather than the total, bulk concentration of biomass. A custom-built mini-flow cell and light microscopy were used to visualise the early formation of biofilms by two pure cultures (Escherichia coli and Acinetobacter calcoaceticus) on membrane surfaces. The results confirmed that A. calcoaceticus was able to enhance the initiation of biofilm formation on microfiltration membranes.

This study reports on a multivariate analysis of the moving bed biofilm reactor (MBBR) wastewater treatment system at a Canadian pulp mill. The modelling approach involved a data overview by principal component analysis (PCA) followed by partial least squares (PLS) modelling with the objective of explaining and predicting changes in the BOD output of the reactor. Over two years of data with 87 process measurements were used to build the models. Variables were collected from the MBBR control scheme as well as upstream in the bleach plant and in digestion. To account for process dynamics, a variable lagging approach was used for variables with significant temporal correlations. It was found that wood type pulped at the mill was a significant variable governing reactor performance. Other important variables included flow parameters, faults in the temperature or pH control of the reactor, and some potential indirect indicators of biomass activity (residual nitrogen and pH out). The most predictive model was found to have an RMSEP value of 606 kgBOD/d, representing a 14.5% average error. This was a good fit, given the measurement error of the BOD test. Overall, the statistical approach was effective in describing and predicting MBBR treatment performance.

Parallel laboratory investigations were conducted to examine aspects of two distinct but related bioprocess strategies for low sludge production in the treatment of the same TCF kraft pulp mill effluent. The purpose of this article has been to compare the performance results from these two bench-scale trials with respect to nutrient demands, nutrient discharge, COD removal, and waste sludge characteristics. The LSP (Low Sludge Production) process can be used to significantly reduce sludge yield with excellent sludge characteristics. These sludge characteristics seemed to be related to elevated protozoan grazing pressures. The BAS (Biofilm-Activated Sludge) process achieves similar reduced sludge yields and sludge characteristics while at the same time significantly reducing the nutrient demands and discharge levels. For both LSP and BAS process optimization, the selector nutrient loading is critical to the overall process performance. Selector nutrient requirements are distinct from the overall process nutrient requirements.

Thermophilic aerobic treatment of settled pulp and paper mill effluent was studied under mill premises with two comparative pilot processes; suspended carrier biofilm process (SCBP) and activated sludge process (ASP). Full-scale mesophilic activated sludge process was a reference treatment. During the runs (61 days) hydraulic retention times (HRTs) were kept 13+/-5 h and 16+/-6 h for SCBP and ASP, respectively. Corresponding volumetric loadings rates (VLR) were 2.7+/-0.9 and 2.2+/-1.0 kg CODfilt m(-3)d(-1). Temperatures varied between 46 to 60 degrees C in both processes. Mesophilic ASP was operated with HRT of 36 h, corresponding VLR of 0.7 kg CODfilt m(-3)d(-1). Both SCBP and ASP achieved CODfilt (GF/A filtered) removals up to 85%, while the mesophilic ASP removal was 89+/-2%. NTU values were markedly higher (100-300) in thermophilic effluents than in mesophilic effluent (30). Effluent turbidity was highly dependent on temperature; in batch experiment mesophilic effluent sample had NTU values of 30 and 60 at 35 degrees C and 55 degrees C, respectively. As a conclusion, both thermophilic treatments gave high CODfilt removals, which were close to mesophilic process removal and were achieved with less than half of HRT.

A process of advanced oxidation treatment discussed here has been developed in the last seven years. A technical plant for treatment of paper mill wastewater started operation in 1999. Advanced oxidation treatment is defined here as a combination of chemical and biochemical oxidation applied to a completely biodegraded effluent. The process is a combination of ozonation with following biodegradation in a biofilm reactor. The combination makes use of the effect of partial oxidation in which with reduced use of expensive chemical oxidants persistent COD becomes biodegradable. A far-reaching elimination of AOX, colour and other disturbing substances like complexing agents is achieved simultaneously. The partially oxidized compounds, now biodegradable, are eliminated in a following biofilm reactor. Using single-stage systems, COD elimination rates of up to 60% are achieved with 0.4 to 1.0 g ozone per g COD eliminated in the combined process. With a two-stage system COD elimination of 85% with 0.65 g/g has been achieved in pilot tests. The quality of the treated effluent suits fresh water requirements for most types of paper production, so that either a total closure of the water circuits or - due to increasing concentrations of electrolytes, which are not eliminated by this process - a substantial closure to about 20% of the original amount of fresh water can be achieved.

A combination of the suspended carrier biofilm process and the activated sludge process (biofilm-activated sludge--BAS) has been shown to be very successful for the treatment of different types of pulp and paper mill effluents. The robust biofilm pre-treatment in combination with activated sludge results in a stable, compact and highly efficient process. Recent findings have shown that nutrient limited operation of the biofilm process greatly improves the sludge characteristics in the following activated sludge stage, while minimising sludge production and effluent discharge of nutrients. The nutrient limited BAS process was implemented at full scale at the Södra Cell Värö kraft mill and taken into operation in July 2002. After start-up and optimisation over about 5 months, the process meets all effluent discharge limits. The removal of COD is close to 70% and the removal of EDTA greater than 90%. Typical effluent concentrations of suspended solids and nutrients during stable operations have been 20-30 mg/L TSS, 0.3-0.5 mg/L phosphorus and 3-5 mg/L nitrogen. The sludge production was 0.09 kgSS/kg COD removed and the sludge volume index was 50-100 mL/g.