Abstract:
An integrated treatment process and apparatus is provided for removing selected contaminants from both liquid and gaseous waste streams. A multistage separation and bio-oxidation substrate is provided in a column through which the contaminants are passed. The substrate components provide absorption, adsorption, ion exchange, solubility, and bio-degradation qualities to the column to effectively separate and destroy a wide range of contaminants in industrial waste streams.

Description:
FIELD OF THE INVENTION 
     This invention is directed towards a biological treatment system which is suitable for removing and/or degrading a wide variety of contaminants. The treatment system is able to effectively handle volatile organic compounds (VOCs), volatile organic hazardous air pollutants (VOHAPs), light to middle weight petroleum distillates, and a variety of other organic pollutants. The treatment system is able to effectively treat these pollutants from both gas and liquid waste streams. 
     BACKGROUND OF THE INVENTION 
     The Clear Air Act Amendment (CAAA) of 1990 requires industrial and commercial facilities to control emissions of a wide range of Volatile Organic Hazardous Air Pollutants (VOHAP), Volatile Organic Compounds (VOCs), particulates, and gases causing acid rain and precursors for depletion of stratospheric ozone layers. The CAAA contains 10 titles, each addressing specific guidelines and compliance rules for each area of concern. 
     Title III of the CAAA requires all industrial and commercial facilities located within “non-attainment” areas to reduce their VOC emissions below the threshold value. The term “non-attainment” means areas or metropolis which have not met the National Ambient Air Quality Standards (NAAQS) in terms of ozone, NO x  and particulate matter. 
     Title III of the CAAA requires 174 source categories/industry groups requiring control of emissions of 188 Hazardous Air Pollutants (HAPs). Each source category is a specific type of industrial or commercial operations which emits pollutants to the ambient air. A facility becomes a major source when it emits over 10 tons per year of a single HAP, or over 25 tons per year of all HAPs combined into the air. 
     Further, industry and regions in all parts of the country are undertaking aggressive efforts to limit the release of all types of hazardous materials. Public reporting criteria have increased the scrutiny and public pressure on all industries which generate or release toxic or hazardous materials. As a result, many industries are undertaking renewed efforts to control the production or release of hazardous materials. 
     Title III of the CAAA exposes numerous industrial emission sources which were not regulated or controlled before. These sources require installation of emission control technologies. At present, many industrial and commercial facilities have turned to aqueous scrubbing techniques or thermal oxidation processes such as incineration to curb their emissions. Incineration, while achieving a high destruction efficiency, is expensive in terms of capital and operating costs. Further, off-site incinerators which may serve many industries, face ever more opposition from citizens who have health concerns over incinerations efficacy and safety. Incineration of halogenated VOCs and HAPs are also extremely corrosive to the contact parts and may produce highly toxic substances such as dioxin. 
     Aqueous scrubbing technologies for VOC control do not have the corrosion or toxic byproduct formation problems like the incineration technologies. However, the scrubbers can only be effective for hydrophilic VOCs and HAPs and also require effective means for disposal of scrub water. For hydrophobic contaminants, such as the majority of the regulated VOCs and HAPs, aqueous scrubbing is generally not effective for emission control. 
     Both the incinerator and the scrubber technologies are not well suited or compatible for accepting and treating facility wastewater. In other words, both the technologies are applicable for treatment of only air streams. For hydrophilic contaminants, scrubbers could potentially use facility wastewater. However, since scrubbers merely transfer the contaminants from the gaseous to the liquid phase, and do not destroy, degrade or decompose, other forms of treatment operation(s) are necessary to dispose or discharge the scrub water. 
     SUMMARY OF THE INVENTION 
     It is an object of this invention to provide a material and process which effectively treats a diverse group of pollutants. 
     It is a further object of this invention to provide a material and a process which can effectively remove pollutants from gaseous as well as liquid waste streams. 
     It is a further and more particular object of this invention to provide an apparatus and process which uses selected sorbents along with bio-solids to first remove (separate/concentrate) and to then degrade contaminants from a waste stream. 
     These and other aspects of the invention are made possible by features of applicants&#39; AGB (Ashalata, Gostha Bihari) Process which involves the use of a novel bio-reactor utilizing microorganisms embedded in selective sorbents to sorb and bio-oxidize VOCs and HAPs from facility exhausts. As used herein, the term “sorb” includes both adsorptive and absorptive capabilities. In a single operative step, a multistage unit provides for the initial removal and subsequent degradation/detoxification of organic contaminants by utilizing bio-solids, selective sorbents, moisture and micro-nutrients. 
     Wastewater may be used to provide the moisture and part of the organic (carbon) food sources for the bio-reactor. The wastewater may be sprayed directly over the bio-solids and the sorbents. Depending on its characteristics, the wastewater may be pretreated or conditioned so as to be conducive to the bio-solids and the sorbents. A facilities&#39; gaseous emissions are then passed through a multistage sorption unit of the bio-reactor. Each stage of the sorption unit is stacked with a blended mixture of selective sorbents and bio-solids. Depending on the characteristics of the contaminants, the mixture may additionally contain pH buffering ingredients, surface active agents and boosters to enhance selective metabolic activities. The sorbents and the bio-solids are kept moist by adding preconditioned wastewater in the form of fine mists or globules. 
     As the contaminated emissions passes through the stages of the bio-reactor, the selective sorbents capture the contaminants. Once captured, the contaminants provide a metabolic source for the microorganisms. Oxygen and micronutrients such as nitrogen (N), phosphorous (P) and potassium (K) are supplied via the wastewater and aids in the process of bioxidation or metabolization which converts the contaminants to CO 2 , H 2 O and trace quantity of mineral salts. The mineral salts are only formed for contaminants containing atoms other than carbon (C), oxygen (O) and hydrogen (H). The treated exhaust exiting the last stages essential contains air, CO 2 , H 2 O vapor, and ultra trace quantities of non-reacted contaminants. 
     The integrated AGB Process collects the facility wastewater and performs pretreatment or conditioning. The conditioning entails reducing the concentrations of the wastewater contaminants to a level which enhances the subsequent injection into the sorption unit of the bio-reactor. The primary unit operation for conditioning is a stripper cum bio-reactor vessel where the wastewater is pulsated in the presence of sorbents and bio-solids similar to those used in the sorption unit. The pulsation treatment allows the microbes sufficient time to bio-oxidize and reduce the wastewater contaminant concentration. The pulsation also strips (dislodges) the volatile contaminants such that it can be combined with the facility exhaust for passage through a BIO-SORPTION unit. Moreover, the pulsation also suspends and grows the microbes in an aerobic state and stimulates the growth of microbes most conducive for bioremediation of the contaminants. 
     One part of the wastewater, after pulsation, is generally filtered before injection into the bio-treatment unit. Following filtration, the filtered wastewater is introduced to the bio-treatment unit along with the gaseous emissions. The other part of the pretreated wastewater can either be discharged or reused within the facility. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES 
     FIG. 1 is a schematic view of the AGB Process. 
     FIG. 2 is a chart entitled “Table-2” showing the performance data for removal of VOC mixtures. 
     FIG. 3 is a chart entitled “Table-3” showing the performance data for removal of hazardous air pollutants. 
     FIG. 4 is a chart entitled “Table-4” showing the performance data for removal of light hydrocarbon mixtures. 
     FIG. 5 is a chart entitled “Table-5” showing the reduction in the VOC concentration. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     For a better understanding of the invention, reference may be made to the embodiments exemplary of the invention shown in accompanying FIG. 1, which is a schematic of the AGB Process. 
     Referring to FIG. 1, the exhausts from a production or manufacturing facility containing VOCs and HAPs are drawn by a high pressure centrifugal blower ( 2 ). The exhausts can be combined with the stripping air emanating from the stripping/bio-oxidation tank ( 1 ). Tank ( 1 ) receives facility or plant wastewater containing VOCs and HAPs. Depending on the type of contaminants, bio-solids are periodically added to tank ( 1 ) for bio-oxidation. Tank ( 1 ) is equipped with devices for injection of compressed air and/or low pressure steam to facilitate dislodging, stripping and transport of the contaminants to the suction side of blower ( 2 ). Tank ( 1 ) is also equipped with a device for temperate indication and control to facilitate effective stripping and concurrent bio-oxidation. Tank ( 1 ) is operated within a temperature range of 80° F.-150° F. The diffuser ring provides a mechanism for adding stripping fluids uniformly. 
     Blower ( 2 ) is powered with an electric motor to impart sufficient kinetic and pressure energies to overcome line losses and pressure drops. Blower ( 2 ) discharges the combined exhausts and the stripped air to a bio-treatment column known as the BIO-SORPTION unit ( 3 ). The BIO-SORPTION unit ( 3 ) is packed with three or more stages of mixtures of selective sorbents inert packing material and bio-solids. Each stage is maintained with a packing height of 2 ft. to 4 ft. The top of each stage is sprayed as needed with pretreated wastewater to maintain preferred moisture levels within the packed mixtures. Spraying is accomplished with several mist nozzles fed by the high pressure water pump ( 6 ). To protect the nozzles from clogging, the pretreated wastewater, before injection, is filtered using a backwash filter ( 7 ). From time-to-time, the backwater filter ( 7 ) is backwashed to remove solids which are returned to the tank ( 1 ). 
     The combined exhausts and the sprayed water mists flow concurrently through the packed mixtures in the BIO-SORPTION unit ( 3 ). During this flow passage, the contaminants present in the fluid streams are transferred to the mixtures by a combined mechanism of absorption, adsorption and solubilization. This combined mechanism provides the foundation for the bio-degradation/bio-oxidation of the organic contaminants. For inorganic contaminants (if present), this mechanism provides a means for binding and stabilization such that the contaminants are retained within the BIO-SORPTION unit ( 3 ). 
     The following Table-1 illustrates the various sorbents, inert materials, and bio-solids present in a typical packed mixture and their functionality in the above treatment process. 
     
       
         
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                 Part- 
                   
               
               
                 Sorbents/Bio- 
                 icle 
               
               
                 solids/Inert 
                 Size 
                 Functionality 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 A. 
                 Natural zeolite, 
                 2-4 
                 Adsorbs light VOCs and light hydrocarbons. Binds (ion- 
               
               
                   
                 e.g., 
                 mesh 
                 exchanges) ammonia and heavy metals present in the fluid 
               
               
                   
                 clinoptilolite, 
                   
                 streams. Increases bed utilization, and aids in microbial 
               
               
                   
                 mordenite, 
                   
                 growth and bio-oxidation. Increases bed porosity and reduces 
               
               
                   
                 chabazite, etc. 
                   
                 pressure drop. 
               
               
                 B. 
                 Cracked walnut 
                 2-4 
                 Absorbs light hydrocarbons, oils and greases, and provides 
               
               
                   
                 shell 
                 mesh 
                 extended surface areas for microbial contact and growth. 
               
               
                   
                   
                   
                 Increases bed porosity and reduces pressure drop. 
               
               
                 C. 
                 Activated carbon 
                 4-10 
                 Adsorbs VOCs and HAPs and aids in bio-film oxidation. 
               
               
                   
                 of vegetable or 
                 mesh 
               
               
                   
                 animal origin 
               
               
                 D. 
                 Crushed oyster 
                 5-10 
                 Provides pH buffering for the packed mixtures by slowly 
               
               
                   
                 shell 
                 mesh 
                 releasing complex calcium bearing material. 
               
               
                 E. 
                 Calcined expanded 
                 2-4 
                 An inert material, provides extended surfaces for the microbes 
               
               
                   
                 clay 
                 mesh 
                 to thrive and propagate. It also increases bed porosity and 
               
               
                   
                   
                   
                 reduces pressure drop. 
               
               
                 F. 
                 Composted bio- 
                 100- 
                 Absorbs and bio-oxidizes the organic contaminants in presence 
               
               
                   
                 solids (manures) 
                 200 
                 of moisture and micronutrients. May also provide some pH 
               
               
                   
                 from ruminant or 
                 mesh 
                 buffering for the packed material. 
               
               
                   
                 poultry origin 
               
               
                   
               
             
          
         
       
     
     Depending on the type of contaminants, the packed mixture may be prepared by tumbling a varied ratio of the above materials. However, for a common application of treating 300 ppm of HAPs such as toluene, xylene, hexane and trichloroethylene, the composition of the packed mixture is expected to be as follows: 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 A. Natural zeolite 
                  20% 
               
               
                   
                 B. Walnut shell 
                  20% 
               
               
                   
                 C. Activated carbon 
                  15% 
               
               
                   
                 D. Oyster shell 
                  5% 
               
               
                   
                 E. Calcined clay 
                  20% 
               
               
                   
                 F. Ruminant bio-solids 
                  20% 
               
               
                   
                   
                 100% 
               
               
                   
                   
               
             
          
         
       
     
     Before loading into the BIO-SORPTION unit ( 3 ), the above materials are premixed with hydrotropic surface active ingredients or surfactants such as DOWFAX hydrotrope. The surfactants are particularly important for the treatment of hydrophobic contaminants [light hydrocarbons, chlorinated organics], where the contaminant water solubilities are increased. An increase in the contaminant solubility increases the efficiency of the sorption process, thus increasing the bio-oxidation/bio-degradation efficiency as well. 
     The treated exhaust stream exits the BIO-SORPTION unit ( 3 ) along with the treated wastewater converted to the form of water vapor or humidity. The exit humidity of the exhaust is monitored and controlled by a controller (HIC), which controls the pressure pump ( 6 ). Any condensate generated within the BIO-SORPTION unit ( 3 ) is collected by transfer pump ( 8 ) and returned to tank ( 1 ). 
     Should the BIO-SORPTION unit ( 3 ) loose microbes or require a specific culture for bio-oxidation, tank ( 4 ) and pump ( 5 ) provide a mechanism for adding microbes or cultures to the stages within the BIO-SORPTION unit ( 3 ). The mechanism can also be used for addition of micronutrients to the stages, if it is so desired. 
     The AGB Process is shown to be effective for treatment and degradation of a wide variety of organic pollutants such as; alcohols, esters, aldehydes, ketones, aromatics, substituted aromatic and chlorinated compounds. Many of the pollutants that the AGB Process treat fall within the category of HAPs and VOCs. The AGB Process can also treat and degrade the light and middle distillate petroleum hydrocarbons, many of which are also listed VOCs. Table-3 and Table-4 show typical performance data for the AGB Process. 
     Table-4 essentially indicated that one stage of the BIO-SORPTION treatment can reduce the VOC concentration by over 90%. Table-3 shows that multistage BIO-SORPTION can remove and convert the HAPS with over 99% efficiency. 
     The reduction in off gas emissions and corresponding reductions in wastewater contaminants, as shown in Table-5, reflects more than a mere transfer of contaminants to the sorption materials. The sorption materials provide an environment where microorganisms can colonize the substrate and use the contaminants as a carbon or other metabolic source as evidenced by the formation of CO 2  measured in the exit stream (Table-3). In effect, the present invention first sequesters contaminants from the waste streams and secondly biologically oxidizes the contaminants to nonhazardous constituents. 
     Applicants&#39; process and apparatus makes use of low-cost, readily obtainable sorption materials to achieve the contaminant removal and destruction. As many variations and modifications of applicants&#39; invention will be apparent upon a reading of the disclosure and preferred embodiment, such variations and modifications fall within the spirit and scope of the invention as measured by the following appended claims.