Impact of thermal hydrolysis on VFA-based carbon source production from fermentation of sludge and digestate for denitrification: experimentation and upscaling implications

Stricter nutrient discharge limits at wastewater treatment plants (WWTPs) are increasing the demand for external carbon sources for denitrification, especially at cold temperatures. Production of carbon sources at WWTP by fermentation of sewage sludge often results in low yields of soluble carbon and volatile fatty acids (VFA) and high biogas losses, limiting its feasibility for full-scale application. This study investigated the overall impact of thermal hydrolysis pre-treatment (THP) on the production of VFA for denitrification through the fermentation of municipal sludge and digestate. Fermentation products and yields, denitrification efficiency and potential impacts on methane yield in the downstream process after carbon source separation were evaluated. Fermentation of THP substrates resulted in 37-70 % higher soluble chemical oxygen demand (sCOD) concentrations than fermentation of untreated substrates but did not significantly affect VFA yield after fermentation. Nevertheless, THP had a positive impact on the denitrification rates and on the methane yields of the residual solid fraction in all experiments. Among the different carbon sources tested, the one produced from the fermentation of THP-digestate showed an overall better potential as a carbon source than other substrates (e.g. sludge). It obtained a relatively high carbon solubilisation degree (39 %) and higher concentrations of sCOD (19 g sCOD/L) and VFA (9.8 g VFA_COD/L), which resulted in a higher denitrification rate (8.77 mg NOx-N/g VSS∙h). After the separation of the carbon source, the solid phase from this sample produced a methane yield of 101 mL CH₄/g VS. Furthermore, fermentation of a 50:50 mixture of THP-substrate and raw sludge produced also resulted in a high VFA yield (283 g VFA_COD/kg VS_in) and denitrification rate of 8.74 mg NOx-N/g VSS∙h, indicating a potential for reduced treatment volumes. Calculations based on a full-scale WWTP (Käppala, Stockholm) demonstrated that the carbon sources produced could replace fossil-based methanol and meet the nitrogen effluent limit (6 mg/L) despite their ammonium content. Fermentation of 50-63 % of the available sludge at Käppala WWTP in 2028 could produce enough carbon source to replace methanol, with only an 8-20 % reduction in methane production, depending on the production process. Additionally, digestate production would be sufficient to generate 81 % of the required carbon source while also increasing methane production by 5 % if a portion of the solid residues were recirculated to the digester.