This study investigated the anaerobic digestion of an algal–bacterial biofilm grown in artificial wastewater in an Algal Turf Scrubber (ATS). The ATS system was located in a greenhouse (50°54′19ʺN, 6°24′55ʺE, Germany) and was exposed to seasonal conditions during the experiment period. The methane (CH₄) potential of untreated algal–bacterial biofilm (UAB) and thermally pretreated biofilm (PAB) using different microbial inocula was determined by anaerobic batch fermentation. Methane productivity of UAB differed significantly between microbial inocula of digested wastepaper, a mixture of manure and maize silage, anaerobic sewage sludge, and percolated green waste. UAB using sewage sludge as inoculum showed the highest methane productivity. The share of methane in biogas was dependent on inoculum. Using PAB, a strong positive impact on methane productivity was identified for the digested wastepaper (116.4%) and a mixture of manure and maize silage (107.4%) inocula. By contrast, the methane yield was significantly reduced for the digested anaerobic sewage sludge (50.6%) and percolated green waste (43.5%) inocula. To further evaluate the potential of algal–bacterial biofilm for biogas production in wastewater treatment and biogas plants in a circular bioeconomy, scale-up calculations were conducted. It was found that a 0.116 km² ATS would be required in an average municipal wastewater treatment plant which can be viewed as problematic in terms of space consumption. However, a substantial amount of energy surplus (4.7–12.5 MWh a⁻¹) can be gained through the addition of algal–bacterial biomass to the anaerobic digester of a municipal wastewater treatment plant. Wastewater treatment and subsequent energy production through algae show dominancy over conventional technologies. Graphical abstract

The increasing share of renewable electricity in the grid drives the need for sufficient storage capacity. Especially for seasonal storage, power-to-gas can be a promising approach. Biologically produced methane from hydrogen produced from surplus electricity can be used to substitute natural gas in the existing infrastructure. Current reactor types are not or are poorly optimized for flexible methanation. Therefore, this work proposes a new reactor type with a plug flow reactor (PFR) design. Simulations in COMSOL Multiphysics ^® showed promising properties for operation in laminar flow. An experiment was conducted to support the simulation results and to determine the gas fraction of the novel reactor, which was measured to be 29%. Based on these simulations and experimental results, the reactor was constructed as a 14 m long, 50 mm diameter tube with a meandering orientation. Data processing was established, and a step experiment was performed. In addition, a k_La of 1 h⁻¹ was determined. The results revealed that the experimental outcomes of the type of flow and gas fractions are in line with the theoretical simulation. The new design shows promising properties for flexible methanation and will be tested.

Industrial digestates from short-fibre residues, generated in paper recycling mills, are driving interest in resource recovery. This study aims to explore their potential for water recovery. Understanding particle dynamics aids in optimizing dewatering for digestate management. The particle size distribution in this study revealed significant fractions: 20 μm (11–16%). Pre-treatment with Na4P2O7 and H2O2 enhances settling and lowers total dissolved solids (TDSs) but results in variation of size distribution. Additionally, this study investigates further water reuse in paper mills, focusing on the quality of ultrafiltration (UF) permeate obtained from the digestate of short fibres. UF permeate analysis reveals deviations from freshwater standards in paper mills. Despite effective TS removal, UF permeate falls short of paper mill water standards due to high TDSs, electrical conductivity, and nutrient concentrations, necessitating further downstream treatment with nanofiltration or reverse osmosis. A substantial reduction of permeate flux from 31 to 5 L/(m2·h) over the time indicated fouling and inefficient membrane wash. The silt density index of the UF membrane at 30 min registered 2.1, suggesting potential fouling. Further investigations on optimizing UF operations to enhance permeate flux and exploring alternative UF membranes are required.

The present work aimed to study the mainstream feasibility of the deammonifying sludge of side stream of municipal wastewater treatment plant (MWWTP) in Kaster, Germany. For this purpose, the deammonifying sludge available at the side stream was investigated for nitrogen (N) removal with respect to the operational factors temperature (15–30°C), pH value (6.0–8.0) and chemical oxygen demand (COD)/N ratio (≤1.5–6.0). The highest and lowest N‐removal rates of 0.13 and 0.045 kg/(m³ d) are achieved at 30 and 15°C, respectively. Different conditions of pH and COD/N ratios in the SBRs of Partial nitritation/anammox (PN/A) significantly influenced both the metabolic processes and associated N‐removal rates. The scientific insights gained from the current work signifies the possibility of mainstream PN/A at WWTPs. The current study forms a solid basis of operational window for the upcoming semi‐technical trails to be conducted prior to the full‐scale mainstream PN/A at WWTP Kaster and WWTPs globally.

Deammonification for nitrogen removal in municipal wastewater in temperate and cold climate zones is currently limited to the side stream of municipal wastewater treatment plants (MWWTP). This study developed a conceptual model of a mainstream deammonification plant, designed for 30,000 P.E., considering possible solutions corresponding to the challenging mainstream conditions in Germany. In addition, the energy-saving potential, nitrogen elimination performance and construction-related costs of mainstream deammonification were compared to a conventional plant model, having a single-stage activated sludge process with upstream denitrification. The results revealed that an additional treatment step by combining chemical precipitation and ultra-fine screening is advantageous prior the mainstream deammonification. Hereby chemical oxygen demand (COD) can be reduced by 80% so that the COD:N ratio can be reduced from 12 to 2.5. Laboratory experiments testing mainstream conditions of temperature (8–20°C), pH (6–9) and COD:N ratio (1–6) showed an achievable volumetric nitrogen removal rate (VNRR) of at least 50 gN/(m³∙d) for various deammonifying sludges from side stream deammonification systems in the state of North Rhine-Westphalia, Germany, where m³ denotes reactor volume. Assuming a retained N_organic content of 0.0035 kgN_org./(P.E.∙d) from the daily loads of N at carbon removal stage and a VNRR of 50 gN/(m³∙d) under mainstream conditions, a resident-specific reactor volume of 0.115 m³/(P.E.) is required for mainstream deammonification. This is in the same order of magnitude as the conventional activated sludge process, i.e., 0.173 m³/(P.E.) for an MWWTP of size class of 4. The conventional plant model yielded a total specific electricity demand of 35 kWh/(P.E.∙a) for the operation of the whole MWWTP and an energy recovery potential of 15.8 kWh/(P.E.∙a) through anaerobic digestion. In contrast, the developed mainstream deammonification model plant would require only a 21.5 kWh/(P.E.∙a) energy demand and result in 24 kWh/(P.E.∙a) energy recovery potential, enabling the mainstream deammonification model plant to be self-sufficient. The retrofitting costs for the implementation of mainstream deammonification in existing conventional MWWTPs are nearly negligible as the existing units like activated sludge reactors, aerators and monitoring technology are reusable. However, the mainstream deammonification must meet the performance requirement of VNRR of about 50 gN/(m³∙d) in this case.

The paper sector is characterised by high freshwater consumption and a strong need for improved resource efficiency. In this context, industrial digestates derived from short-fibre residues in paper recycling mills represent a promising substrate for water recovery within a circular economy framework. This study investigated the dewatering of short-fibre digestates as a pre-treatment for downstream membrane processes, aiming to maximise the liquid fraction (LF) recovery while minimising dry matter (DM) content. Seven scenarios were studied: sedimentation (S0); pre-sedimentation with chemical addition using iron(III) chloride (FeCl₃) + polydiallyldimethylammonium chloride (polyDADMAC) (S1), FeCl₃ + starch (S2), Nanofloc^® (S3), and polyDADMAC (S4); and direct dewatering without pre-sedimentation using polyDADMAC with cloth filtration (S5) and centrifugation (S6). With reference to the sedimentation supernatant, S4 achieved the highest DM separation efficiency of 76%, followed by S1 (64%), whereas S2 and S3 were below 40%. However, LF recovery relative to the initial digestate was limited in scenarios S1–S4 to 17% (170 g/kg_digestate), with DM concentrations of 2.0–4.8 g/kg_LF. In contrast, direct dewatering increased LF recovery substantially, with centrifugation (S6) achieving up to 690 g_LF/kg_digestate and cloth filtration (S5) 420 g/kg_digestate, while maintaining a low DM (1.7 g/kg_LF). Chemical oxygen demand (COD) and phosphorus (Ptot) were largely separated from the liquid fractions in all the scenarios. Nitrogen (Ntot) and ammonium (NH₄-N) in the LF remained more variable, ranging from 22 to 153 and 5 to 22 mg/kg_digestate, respectively. These results indicate that centrifugation with polyDADMAC is the most effective approach, suggesting that mechanical force with a chemical additive can be used for the efficient dewatering of short-fibre digestates.