To understand the long-term stability of nitrifying granules in a membrane bioreactor (GMBR), a membrane module was submerged in an airlift reactor to eliminate the hydraulic selection pressure that was believed to be the driving force of aerobic granulation. The long-term monitoring results showed that the structure of nitrifying granules could remain stable for 305 days in the GMBR without hydraulic selection pressure; however, the majority of the granule structure was actually inactive due to mass diffusion limitation. As a consequence, active biomass free of mass diffusion limitation only inhabited the top 60–80 µm layer of the nitrifying granules. There was a dynamic equilibrium between bioflocs and membrane, i.e., 25% of bioflocs attached on the membrane surface within the last nine days of the backwash cycle in synchronization with the emergence of a peak of soluble extracellular polymeric substances (sEPS), with a concentration of around 47 mg L⁻¹. Backwash can eventually detach and return these bioflocs to the bulk solution. However, the rate of membrane fouling did not change with and without the biofloc attachment. In a certain sense, the GMBR investigated in this study functioned in a similar fashion as an integrated fixed-film activated sludge membrane bioreactor and thus defeated the original purpose of GMBR development. The mass diffusion problem and sEPS production should be key areas of focus in future GMBR research.

The impact of adding a modified Ludzack–Ettinger (MLE) configuration with Nitrate Recycle (NRCY) on continuous-flow aerobic granulation has yet to be explored. The potential negative effects of MLE on sludge densification include that: (1) bioflocs brought by NRCY could compete with granules in feast zones; and (2) carbon addition to anoxic zones could increase the system organic loading rates and lead to higher feast-to-famine ratios. Two pilot-scale plug flow reactor (PFR) systems fed with real domestic wastewater were set up onsite to test these hypotheses. The results showed that MLE configuration with NRCY could hinder the sludge granulation, but the hindrance could be alleviated by the NRCY location change which to some extent also compensates for the negative effect of higher feast-to-famine ratios due to carbon addition in MLE. This NRCY location change can be advantageous to drive sludge densification without a radical washout of the sludge inventory, and had no effects on the chemical oxygen demand (COD) and nitrogen removal efficiencies. The PFR pilot design for the MLE process with a modified NRCY location tested in this study could be developed as an alternative to hydrocyclones for full-scale, greenfield, continuous sludge densification applications.