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.

Hydrothermal liquefaction (HTL) of lignocellulosic biomass produces multiple product fractions, including solid residue (SR), heavy bio-oil (HBO), aqueous phase (AP), and light bio-oil (LBO). This study mainly applied principal component analysis (PCA) and regression modeling to predict AP solution weight, LBO weight and fuel characteristics, and HTL wastewater biodegradability, as well as to improve prediction accuracy for SR and HBO under various operating conditions (temperature: 250–350 °C, residence time: 5–60 min, and the combined solid loading of three batches: 15–45 g). A complementary relationship between SR and AP weights found in PCA enabled the estimation of AP weight based on predicted SR values in a regression analysis. A modified partition coefficient was introduced to link LBO weight with the carbon content of AP and was predicted, enabling accurate LBO yield estimation. Although LBO fuel characteristics could not be modeled reliably, those of SR and HBO were predicted with improved accuracy over prior kinetic models. The concentration of catechol in HTL wastewater (HTL-WW) was also modeled from operating conditions and linked to half-maximal inhibitory concentration (IC₅₀) of R. jostii and A. niger as a biodegradability index. This work demonstrates the feasibility of predicting underrepresented HTL outputs using statistical approaches.