USE OF IMMOBILIZED FILM REACTOR

Abstract: Biofilters (3) for treating contaminated air (5) use immobilized biofilms on filter support media to biodegrade sorbed volatile organic compounds (VOCs) and biotransform inorganic oxides to sulfur (SOx) and nitrogen (NOx) to residuals such as carbon dioxide, water and various acids (HCL, H2SO4, HNO3). The buffers in the trickling liquid (9) neutralize the acid. Some preferred support materials include pelletized solids, pelletized peat, pelletized compost, pelletized activated carbon, hydrogel beads, ceramics, and straight passage media such as extruded ceramics and extruded carbon. Pelletized supports and straight passage supports permit removal of excess biomass by hydraulic or chemical cleaning and minimize pressure loss. The biofilters are characterized by low pressure drop across the bed, good contact of influent gas with the biomass, and satisfactory biomass adherence to the support. The biofilters are easily cleaned of excess biomass or are self-cleaning.

Description: USE OF IMMOBILIZED FILM REACTOR Field of the Invention; This invention involves biodegradation and/or biotransfor- mation of volatile contaminants in the gas phase under control- lable aerobic and/or anaerobic conditions. The invention has broad application for removing volatile, harmful contaminants in the gas phase. Background of the Invention; Recently there has been increased interest in the removal of organic and inorganic contaminants present in low concentra¬ tions from gas streams. Conventional technologies that have been used industrially for organics include (1) adsorption onto porous substances such as activated carbon; (2) absorption into liquid medium followed by stripping of the liquid; (3) combustion or incineration; and (4) pervaporation using selective membranes to selectively remove the harmful vola- tiles. Lime treatment is used in scrubbers to remove sulfur oxides from stack gases. Chemical addition and reaction is based on control of nitrogen oxides. These technologies present several problems, including disposal of generated wastes (for example, calcium sulfate, unused lime and spent activated carbon) , cost of equipment, materials and energy required for operation. While biological treatment of aqueous waste streams has been an established practice, the use of biofilters for treatment of air or gaseous streams has not been extensively investigated in the United States. Pomeroy and Carlson have reported an approach for removal of sewage-related odors (Pomeroy, R.D., "Controlling Sewage Plant Odors". Consulting Engineers Vol 20; (1963) p. 101; Carlson, et al, "Soil Beds for the Control of Sewage Odors", J. Water Pollution Control Federation, Vol. 38 No. 5 (1966) 829-840. The primary mechanism for removal of the odorous compounds such as hydrogen sulfide, mercaptans, terpenes, amines, etc, may have been adsorbed on support material. There was no disclosure of - . - biodegradation. It is, furthermore, known that soil beds are effective in removing sulfur-containing gasses and can serve as a sink for hydrocarbons. In more recent years, methods for use of biofilters have been disclosed in Europe. It has been found that an important operating parameter is the moisture content of the filter bed, which plays an important part in determining removal efficien¬ cy. It has also been determined that the most active microbes in a biofilter are the heterotrophic and chemoorganotrophic groups. Actinomycete spp. are particularly useful since they can act on a wide variety of organic compounds and are capable of killing pathogens under some conditions. Conventional biofilter technology using soils and peat or compost have been widely used in Europe with more than 500 field applications for control of volatile organic compounds (VOCs) and odors. These applications usually involve low VOC concentrations (<300 ppm) . In this technology, the void space in the filter media controls the air flow rates through the biofilter. Soil biofilters with low void space have low air flows and generally use up to 15 minutes of air retention time. Peat or compost biofilters, called biotower, with higher bed void space usually require less than two minutes, of air retention time. Typical pressure losses across the filters range from less than 2 to 12 inches of water. Solid nutrients and buffers such as limestone are incorporated in the media material The contaminated air is prehumidified to supply needed moisture. Additional water maybe sprayed intermittently on the top of the bed. For VOC control, the start-up acclima¬ tion typically requires about one month to reach full removal of VOCs. Filters operating at low VOC concentrations are reported to remove VOCs for several (1 to 5) years before the filter media is replaced and the filter operation reacclimated. It is known that the distribution of the microbes in a biofilter may vary at different parts of the filter. Popula- tion density is usually highest at the gas entrance of the biofilter, where the microbes preferentially metabolize the more readily degradable influent compounds. In prior art systems, the slowly degradable compounds biodegraded in all portions of the biofilter. However, the upper portion of the biofilter became under-loaded as to amount of biomass since the microbes at the lower levels consume more of the biodegradable * 5 compounds. In the conventional fine particle filter this situation of uneven distribution of biomass can gave rise to * channelling with inefficiency and possible break-through of the less degradable compounds. In addition, it is not possible to remove the gradually increasing biomass and replenish the 10 decreasing nutrients. Eventually the media of these biofilters must be replaced. A biofilter system, termed the BIKOVENT system, consisting of prefabricated concrete parts which form an aeration plate to give uniform air distribution combined with drainage ducts 15 was developed by Drs. Hans Gethke and Detlef Eitner of Aachen, West Germany. The BIKOVENT system has been used extensively in West Germany and Austria for odor control and for control¬ ling volatile organic compounds (VOCs) in waste air streams. The technology has recently been introduced into the United 20 States by Biofiltration, Inc., Gainsville, Florida. A second conventional biofilter, the BIOTON filter using peat or compost support in a biotower configuration has also been developed in Europe. The BIOTON technology offered by Clair Tech, b.v. of The Netherlands has also been introduced 25 into the United States by Ambient Engineering, Inc. , Matawan, New Jersey. These conventional biofilters present a major disadvantage in that biomass build-up occurring in the biofilter with time cannot be removed. Such buildup leads to filter plugging and ultimately requires replacement of the 30 media, forcing process shutdown. U.S. patent 2,200,580 discloses use of a method of treating fluid to control odors. No method of biotransforma- „ tion or biodegradation of gases is taught therein. Schulhoff (U.S. Patent 2,188,162) teaches an aerobic biofilter having ,35 tubes for the.treatment of liquids. Bayer teaches a method of cleaning exhaust air of acidic environment. The instant invention requires higher pH both for degradation and bio- transformation. Summary of the Invention: The biofilters of the invention consist of three basic components: (1) a solid media incorporated in a bed supports microorganisms capable of degrading organics and biotrans- forming inorganics; (2) a liquid trickling film which keeps the organisms moist while supplying them with nutrients and buffers; and (3) a gaseous stream containing volatile organic or inorganic contaminants which is contacted with the support material. A variety of material can be used as the support material. The support material may take a variety of forms, such as cylindrical pellets, spheres, rashig rings, irregular shapes, or hollow tubes or fibers. All supports are made of wettable material and surfaces of preferred supports are porous. The supports must be such that microorganisms can adhere thereto. The supports may be made of hydrophilic plastics. The principle advantage of this invention is that it allows removal of excess biomass build-up and excessive pressure drop in the filter. Thus the media does not need to be replaced and uninterrupted operation of the filter is permitted. Biofilters of the invention also may use a combination of anaerobic and aerobic organisms by creating differing environments (nitches) in appropriate sequences within the biofilter. Brief Description of the Figures: Fig. 1 is a drawing of the biofilter with heat jacket wherein the support is pelleted activated carbon. Fig. 2(a) is a drawing of a cross section of a straight passage support media. Fig. 2(b) is a drawing of a cross section of a filter of extruded ceramics Fig. 3 depicts a biofilm reactor. Figs. 3(a) depict biofilm with entering gas flow on the side of the biomass. Fig. 3(b) depicts biofilm with entering gas flow on the side of the film opposite the biomass. Fig. 4 depicts a bioreactor for use in transforming SO and NO χ in stack gas Fig. 5 shows a biofilter support in a corrugated arrange¬ ment. Detailed Description of the Invention; Biofilters for treating contaminated air use immobilized biofilms on filter support media to biodegrade sorbed VOCs and biotransform inorganic oxides to sulfur (SO χ ) and nitrogen (NO χ ) to residuals such as carbon dioxide, water and various acids (HC1, H 2 S0 4 , HN0 3 ) . The buffers in the trickling liquid neutralize the acid. Some preferred support materials include pelletized soils, pelletized peat, pelletized compost, pelletized activated carbon, hydrogel beads, ceramics, and straight passage media such as extruded ceramics and extruded carbon. Pelletized supports and straight passage supports permit removal of excess biomass by hydraulic or chemical cleaning and minimize pressure loss. The biofilters are characterized by low pressure drop across the bed, good contact of influent gas with the biomass, and satisfactory biomass adherence to the support. The biofilters are easily cleaned of excess biomass or are self-cleaning. A particularly useful material for use in accord with the teachings of the invention are thin-walled extruded ceramic materials such as those used in catalytic converters in cars. These extruded ceramic provides high void fractions with thin walls which provide very large surface area to hold large amounts of biomass per unit volume of reactor. Such materials minimize the size of the biofilter. Such a filter is seen at Fig. 2(b) wherein 15 is the side of the column and 16 indicates a wall of the extruded ceramic. The biofilters of the invention are adaptable for use in controlling sulfur and nitrogen oxides in contaminated gases. The packed filters of the invention can effectively be used to reduce acid rain. The invention, when adapted to S0 χ and N0 χ control, also provides for biological transformation of sulfur and nitrogen oxides (SO χ ,NO χ ) to sulfur and nitrogen gas with recovery of the sulfur and release of the nitrogen gas into the atmosphere as described subsequently. A particularly important aspect of the invention is the preparation of the filter with organisms particularly effective for the degradation of the target contaminant. For example, a specifically adapted biomass may be prepared by bubbling stack gasses containing sulfur and nitrogen oxides through a liquid phase reactor to provide organisms particularly adapted to oxidize sulfur and nitrogen oxides in the stack gas. The bioprocess, using microbial degradation, requires nutrients, water, sufficient buffer for pH control, and, for a few VOCs, selected co-metabolites to destroy VOCs. It is essential that the surfaces supporting the biomass be wettable. The support material should be porous so that the liquid nutrients can be evenly distributed by capillary action and the pores provide areas protected from hydrodynamic shear forces so that the microorganisms can attach initially. For optimal attachment the following characteristics are preferred: (1) Size of straight passages can vary from 25 straight passages per square inch (superficial surface area per unit volume = 20 inch/1 3 inch) to 400 straight passages per inch. (80 2 inches/l 3 inch) ; (2) bed void fraction >0.3 but typically >0.6; (3) open pores to allow free distribution of water in support material; (4) electrically neutral surface; (5) Hydrophilic surface; (6) shear stress due to liquid flow less than 5.0 N/m 2 ; (7) high porosity of support media; and (8) media surface roughness with peaks/valleys exceeding 0.05 microns. Preferred materials for pellet material has the following characteristics: (1) bed void fraction exceeding 0.3; (2) adequate rigidity of the pellets for structural integrity and hydraulic cleaning; (3) pellet chemical compatibility and contaminants and cleaning agents; (4) electrically neutral surface; (5) hydrophilic surface; (6) high porosity) and (7) rough media surface with peaks/valleys exceeding 0.05 microns. Gas entering the biofilter may be humidified or water may be sprayed intermittently in the biofilter in order to prevent drying of the column. Variations in the contaminant concentra- tions are accommodated by control of contaminant transport from the air to the biofilm, sorptive capacity of the biofilm, and adsorption of filter media. In most instances, the contami¬ nants are transported as gases under low pressure to the biofilter which is kept constantly moistened with a liquid film which keeps the microorganisms moist and provides necessary nutrients and buffers to the system. In practice of the invention, buffer and nutrients may also be incorporated as solids in the filter media or added to the filters in liquid streams entering at appropriate levels of the filter. Moisture may also be added by prehumidification of the contaminated air or alternatively as aqueous spray into the biofilter. Needed co-metabolites may be added to the recirculating liquid stream. The process of the invention requires modest amounts of energy to move air though the biofilter. The transport of the organics to the reactive sites may occur in several different ways. Transport of the organic from the gas phase to the solid support and subsequent adsorption/ absorption of the organic material to the support with subse- quent exposure to the biofilm is frequent when porous materials are used. Such porous support materials as activated charcoal may be particularly useful when at least one VOC is readily adsorbed. The organic may be held on and in the support. Organisms of the biofilm may then act on the organic compound which has been removed from the air stream as the organic compound becomes available on passage from the support materi¬ al. In some instances, the organics may be selectively absorbed from the air flow into the support to a biofilm on the opposite side of the support. This may occur, for example, when the support is a straight path porous tube with biofilm on one side of the support wherein moisture flows down the biofilm but does not contact the incoming air stream containing the contaminant. The biodegradation in the biofilm on the opposite side of the support may be anoxic or anaerobic. Fig. 3 depicts a biofilm reactor wherein the gas enters the chamber with the immobilized film bed (22) at the gas inlet (21) . The media with nutrients enters the filter from above (25) and passes through the filter to the a pump (23) which pumps the nutrient-containing fluid for recycling. Fresh nutrients may be added in the line (24) to replenish the supply. Fig. 3(a) shows the support media (26) with biomass (27) wherein the gas flow (28) flows on the side of the biomass. Fig. 3(b) shows the same filter with the gas flow (28) on the side of the porous media support and on the side opposite the biofilm. In other instances, the biofilter may be arranged so that the organic or inorganic contaminant in the gas phase is transported to the liquid film with subsequent dissolution of the contaminant into the aqueous phase. The contaminants may then be acted on directly by the biofilm or may be transported to a solid support with subsequent adsorption/absorption, then back diffused from the support material onto the biofilm with subsequent degradation. In most instances, the organics or inorganics diffuse through the biofilm with concurrent oxida- tive degradation or biotransformation. The liquid stream may run countercurrent, co-current, or at cross flow to the gaseous stream. Countercurrent flow provides the most efficient use of the biofilter. Organic and inorganic chemicals contaminating air that may be profitably exposed to the process include petroleum chemicals, solvents (chlorinated and un chlorinated aliphatic and aromatic compounds) , industrial chemicals (alcohols, ketones, etc.), organo-sulfur compounds, SO χ and NO χ . The process of the invention can be used when concentrations of the VOCs or organic chemical in air or gas phase range from a trace to thousands of ppm. The use of the biofilter to remove sulfur oxides (SO χ ) and/or nitrogen oxides (NO χ ) from stack gases has never been taught. Biofilters of the instant invention differ from conven¬ tional technologies in several ways. The biofilters in accord with this disclosure provide wide flexibility to maximize efficacy and to lower cost of operation in removal of volatile organic compounds (VOCs) . In addition, these biofilters can be adapted to remove sulfur and nitrogen oxides (SO χ and NO ) from stack gases. In accord with the teachings disclosed herein, various organisms, including both aerobic and anaerobic organisms, can be used. Mixed cultures that have been accli¬ mated to specific organics can be used in accord with the ' 5 teachings herein. Pure cultures which are particularly useful for degrading specific organics may also be used. By the methods taught herein aerobic and anaerobic organisms may be used sequentially to degrade a mixture of organics containing components that are recalcitrant under some conditions. In 10 some instances, the vertical stratification of the microorgan¬ isms with different predominant organisms existing at various levels of the biofilter may occur through the process of natural selection. In other instances, microorganisms of a certain type may flourish at a specific locational niches which 15 maximizes their growth due to the existence of controlled optimum conditions, such as type or concentration of co- metabolites and nutrients, pH, temperature, and oxidation/ reduction potential. The continuous, controlled degradation which can be 20 attained in accord with the teachings of this disclosure prevent break-through of the contaminants. While initial concentration of the contaminants in the support material and biofilm will increase initially, when a steady-state is established the rate of transport of the contaminants from the 25 gas phase to the support material becomes balanced by the rate of biodegradation or biotransformation of the contaminants and by cell production. A high rate of bioactivity is possible because of the existence of the immobilized biofilm, which can contain a significantly higher concentration of the icroorgan- 30 isms than that found in liquid phase conventional activated sludge. Since the rate of biodegradation is dependant on the concentration of the microorganisms, a significantly high . concentration in the biofilm will result in an increased rate of biodegradation and biotransformation. * 35 By the methods of the invention, unlike in aqueous waste biotreatment, it is possible to avoid contamination of the support material by nonbiodegradable organics or high molecular weight contaminants which cause problems in completely mixed continuous systems, such as in activated sludge plants or fluidized bed reactors which handle aqueous waste streams. Since the organic contaminants are introduced into the biofil- ter through the gas phase, high molecular weight materials or entrained particles can be removed by pretreatment such as water spraying, and are not passed into the biofilter. A variety of materials could be used as the support material, including peat, compost material, soil, activated carbon, synthetic polymers, synthetic hydrogels and porous rocks. If the support material is fine, such as activated charcoal or soil, the material must be pelletized to facilitate air flow and biomass removal. If the support material is in pellet form, the biofilter is arranged in a packed bed with constraints on the gas/liquid ratio to prevent flooding in the column. In many preferred embodiments the support material may be in straight passage arrangement in the form of a hollow tube or a fiber. When the support material is in a straight passage arrangement allowable parameters for the liquid and gas flows are more flexible, since there is less likelihood of flooding. The shape chosen for any biofilter will depend on the space available and nature of the gas stream. For example, filters having square, rectangular, triangular or circular cross-sections may be used. The functional differences will primarily exist between those that have a cross-sectional area that remains constant throughout the height of the column and those wherein the cross-sectional area increases with height. For example, the biofilter bed may be cylindrical or conical, while a bed having a triangular cross-section may have the same cross-section dimensions throughout its length or may be shaped like an inverted pyramid. Designs such as conical or inverse pyramidal design will result in increased residence time of the gas stream in the upper portion of the bed due to lower superficial gas velocity, thereby allowing the slower degrading organics to be removed from the gas stream. Both supports in packed beds and in straight passages may have segments that act as niches ("shelters") for microorgan¬ isms. The organisms growing on the support material can be varied from location to location. When the organisms are less robust, some of the organisms may be more able to survive and effect transformation of contaminants when they are sheltered in the niches The microorganisms may be immobilized in polymeric matrices that allow diffusion of the target organic contami¬ nant, but effectively block other organics present in the gas stream from inhibiting the biodegradation process and/or from poisoning the reaction. In some instances, the support materials may be gels that immobilize microorganisms. (See Example 4.) The design of the biofilter is based on two important considerations: (1) pressure drop in the biofilter for the gaseous stream and (2) percentage removal of the contaminant due to biodegradation or biotransformation. The pressure drop will increase as the air velocity is increased in a bed of a given void fraction. In beds of pelletized media, the pressure drop also depends on the pelletized media size with pressure drop decreasing as media size is increased due to increased void space. For removal of volatile organics tested in the examples, void fraction should be > .1 where void fraction is: total volume of void spaces total volume of the bed Increased air velocity requires increased volume of the bed to maintain a fixed residence time and achieve a desired percent¬ age of removal of the specific organics. The air velocity is also increased to respond to increased pressure drop. Since the primary energy cost in the operating system is related to cost of pumping the gas with the pollutant through the biofil¬ ter, increasing energy use in the filter results in increased operation cost. Therefore, to maximize total cost effective¬ ness the operating cost incurred and the depreciation cost of equipment must be taken into consideration in the design of a particular system. The biofilter may be used in conjunction with a stripper to transfer the organics from the liquid waste stream to a gas stream. In that case, the stream used to strip the organics may be the air flow or may be a treated gas stream recycled from the biofilter. Nitrogen may be used as stripper and/or carrier when the system contains anaerobic bacteria. In a biofilter, several different environments to support specific types of microbials at different locations in the filter may be created. As indicated, support structure and delivery of nutrients can be adapted so that different niches provide environments suitable for organisms that require special environments. Furthermore, species desired at a particular location can supported by injecting nutrients particularly needed by the target species. The addition of reagents into the environment in order to introduce specific levels of oxygenation of the environment at a given level makes it possible to have columns that have anaerobic growing conditions that induce anaerobic microbial growth in one location and aerobic growing conditions inducing growth of aerobic organisms at another location. Biofilters of the invention may combine anaerobic and aerobic organisms by creating differing environment nitches in appropriate sequences within the biofilter. For example, when nitrogen is used for stripping and/or propelling the VOCs, the initial flow of air into the filter will support anaerobic organisms. Aerobic conditions may be created selectively at any level in the filter. One method involves injecting through the side of the biofilter a very dilute solution of hydrogen peroxide (3% w/v) . Catalase, a terminal respiratory enzyme present in most aerobic living cells , breaks the hydrogen peroxide down into water and oxygen to create aerobic condi- tions at the site of the injection of the peroxide solution. High concentration of VOCs (>300 ppm) in air produce substantial amounts of microbial growth in the biofilter. Technology of the invention using pelletized or straight passage supports permit removal of excess solids. Increasing biogrowth gradually causes filter plugging accompanied by excessive pressure losses. The pelletized media can be cleaned periodically. The cleaning may be achieved hydraulically or by use of chemical biocides followed by hydraulic washing. The straight passage configurations continuously release solids in the liquid stream leaving the biofilter. Hence, the straight passage filters may be self-cleaning. Example 1: Activated carbon pellets, packed bed. A schematic of the..biofilter system as shown in Fig. l. It consists of a packed column 3 wherein carrier line 4 and substrate line containing the contaminant 5 feeds into the biofilter through gas inlet 8. A flow meter on the carrier line 6 and a flow meter on the substrate line 7 allows the operator to control the amount and rate of VOC delivery to the bottom of the biofilter. Liquid containing nutrients flows down onto the biofilter from line 9 under the control of a pump 10. The packed column contains pelletized activated carbon. An initial seed of biomass was supplied by recirculating the contents of a bioreactor through the biofilter, thereby allowing microorganisms to adsorb on the pellets. The aqueous bioreactor to develop the initial seed of biomass was initially operated and acclimated to the organics by continuous feeding of the organics into the bioreactor. A one-inch diameter, two foot tall bed was packed with activated carbon pellets of 4 mm diameter. The following are the values for the biofilter operating variables: Activated carbon support 3mm diameter and 4 mm height Bed dimensions 25 mm diameter, 600 mm height Bed volume 294 mL Influent gas compositions toluene 520 ppm trichloroethylene 25 ppm methylene chloride 180 ppm Influent COD loading 482-1447 g/day Ammonia-nitrogen cone. 1.6-4.8 gm/L/day Gas flow rate 50-150 mL/min Nutrient flow rate 500 mL/day total ammonia fed to col. 3.5 mg/day Suitable composition of the nutrient solution, consisting of a mixture of mineral salts, yeast extract, and trace ele- ents is given in table I. Pelletizing media for use in an immobilized film reactor (biofilter) . Use of pellets results in lower pressure drop in the bed, due to higher void fractions as compared to beds using small particle size media such as soil, compost, peat, etc. Furthermore, the higher void fractions make it possible to immobilize large amounts of biomass per unit volume of reactor. The beds of activated carbon pellets are also charac¬ terized by improved gas distribution in the bed. In beds containing fine particle media such as soil, compost, peat, etc, even distribution of the gas is difficult to maintain and the gas flow starts channelling in the bed, lowering the ef¬ ficiency of the system. It is possible to clean the pelletized media in these beds by flushing with water at high pressure, separating the media pellets and washing them with water, or using chemicals in hydraulic washing. It is, therefore, possible to recycle the pelletized media and biomass. In conventional biofilters with fine particle media, the particles become strongly attached to each other due to the biomass growth. Hence, it is difficult to force water through such beds, and it is not possible to remove the excess biomass. These fine particle media must, therefore, be discarded, unlike the pelletized media, and replaced when the biomass growth becomes excessive. Table I. COMPOSITION OF THE NUTRIENT MEDIA, TRICKLED THROUGH THE ACTIVATED CARBON BIOFILTER Salt Concentration (mg/L) KH 2 P0 4 85 . 0 j HPO^ 217 . 5 Na 2 HP0 4 266. 4 NH 4 C1 25. 0 MgS0 4 -7H 2 0 22 . 5 CaCl, 27 . 5 FeCl 2 -6H 2 00 0.25 Trace Elements MnS0 4 -H 2 0"4H 2 0 0. 0399 ZnSO 4 "7H 2 0 0. 0572 (NH 4 ) 6 Mθ 7 0 24 0. 0347 FeCl, E.. TA 0. 10 Yeast Extract 0.15 Activated carbon can adsorb many chemicals. This adsorp¬ tion capacity can be beneficial to the operation of the biofilter. Because of the adsorptive properties of the activated carbon, it is possible to selectively place co- metabolites useful during degradation on the biofilter to make the co-metabolite available for specific degradation processes. In this instance, toluene, which is a co-metabolite for trichloroethylene (TCE) degradation was selectively made available by adsorption onto the carbon with subsequent back diffusion into the biofilm. The gas flow rate into the biofilter was 50mL/min. The gas flow contained three contaminants: toluene, trichloro¬ ethylene and methylene chloride. All three contaminants were adsorbed onto the column initially, The column was able to remove 100% of the toluene initially. The data showed decreas¬ ing removal from the air stream during the adsorptive phase with drop to about 30% during the period of time when the adsorption onto the carbon had exceeded its capacity but the biomass had not reached optimum growth. With optimum growth of biomass, toluene removal increased to 100%. The trichloro¬ ethylene was adsorbed onto the activated carbon providing initial removals of 85%, The removals gradually decreased to 10%. As the biomass increased during the phase when the bed was being acclimated, TCE removal improved to 100% at full acclimation. The methylene chloride was also adsorbed onto the activated carbon to some extent, initially 30%, but was removed only slightly during the adsportive phase of operation. As acclimation and development of the biomass occurred, Methylene chloride removal efficiency increased to 100%. A control study on the activated carbon column was performed using a mixture of nutrient media and mercuric chloride that prevented any biomass growth in the biofilter. The biofilter carbon pellets were not seeded with biomass and in the presence of mercuric chloride, organisms entering the system were prevented from growing on the pellets. The break- through curves on the carbon column indicated gradual satura¬ tion of the activated carbon. After saturation, the exit concentration for all three chemicals became equal. On the biofilter (the carbon with biomass) this saturation effect did not occur, due to biodegradation. Example 2: Packed Bed Celite Biofilter A bed of two inches in diameter and two feet high was produced using as packing 5mm high cylindrical celite pellets (Manville Corporation, CA) pellets. The system was operated in the same manner as the activated carbon pellet biofilter. Celite, which is composed primarily of diatomaceous silica, has lower adsorption capacity for chemicals. Because the biomass attachment to the celite surface is relatively loose, it is easier to clean than that attached to activated carbon. The operating condition of the packed bed biofilter was as follows: pellet dimensions 6 mm diameter, 5 mm height biofilterbeddimensions 50 mm diameter, 900 mm height bed volume 1.8 liter influent gas flow rate 200-600 mL/ in liquid flow rate 0.5 liters/day toxics loaded (mg/da.) toluene 0.591-1.774 methylene chloride 0.186-0.557 trichloroethylene 0.034-0.101 chlorobenzene 0.058-0.174 ethylbenzene 0.027-0.082 total influent COD load 1.247-3.741 mg/day.liter ammonia loading 25-50 mg/day All compounds except trichloroethylene were completely mineralized to carbon dioxide. The incomplete mineralization of trichloroethylene (TCE) occurred because mineralization of TCE requires presence of the co-metabolite such as toluene, for degradation. Toluene is present in the lower section of the column. However, its gas phase concentration in the upper section of the bed is zero, because it completely degrades in the lower section of the biofilter. Hence, TCE does not degrade in the upper section of the biofilter. To assure the degradation of slowly degrading TCE, it would be appropriate to inject a co-metabolite into the upper section of the biofilter. Example 3: Straight Passage Celite Biofilter A straight passage celite biofilter was constructed using corrugated celite plates. A schematic of the biofilter is shown in Fig. 2(a) . The celite plates were arranged to provide vertical channels through which flow of air and liquid took place. The design and operating conditions for the biofilter are as follows: square column 4 X 4 inches column height 90 cm straight passage size 6 mm X 6 mm number of passages 99 gas flow rate 600-1600 mL/min. volume of biofilter 8.77 liters liq. nutrient flow rate 1.5 liters/day influentgas composition toluene 1.774-4.731 mg/day methylene chloride 0.557-1.485 mg/day TCE 0.101-0.269 mg/day chlorobenzene 0.174-0.464 mg/day ethylbenzene 0.082-0.218 mg/day total influent COD load 0.768-2.048 gm/liter.day ammonia loading 75-150 mg/day The air flow rate was controlled by a thermal mass flow controller. The desired composition of the contaminants in air was obtained by injecting the liquid mixture of the compounds into the air stream using a syringe pump. The contaminated air stream flowed countercurrently to the trickling nutrient solution which was pumped to the top of the biofilter by a centrifugal pump. The composition of the nutrient solution is shown below: Salt KH 2 P0 4 K > HP0 4 Na 2 HP0 4 NH 4 C1 MgS0 4 . 7H 2 0 CaCl 2 FeCl 2 . 5H 2 0 Trace Elements : MnS0 .4H 2 0 ZnS0 4 .7.H 2 0 (NH 4 ) 6 Mo 7 0 24 FeCl . EDTA Yeast Extract The nutrient solution exiting the bottom of the biofilter was drained. As the startup procedure for the biofilter, biomass from a pilot scale activated sludge plant treating hazardous waste was suspended in an aerated aqueous phase bioreactor (column 100 mm diameter, 700 mm height) . The bioreactor was fed daily with the VOC substrates. Nutrients consisting of a mixture of mineral salts, yeast extract and trace elements as indicated above were also added periodically. The biomass from the bioreactor was transferred to the biofilters by circulating the bioreactor suspension through the biofilter. The suspension was kept in the biofilter successfully attached to the support medium. The transfer of biomass from bioreactor suspension to the biofilter was confirmed by the fact that the bioreactor suspension drained from the biofilter at the end had lost its turbidity. All of the effluent compounds except for TCE were com¬ pletely mineralized. Referring to Fig. 2, 12 refers to the biofilm, 13 refers to the flow channel through which the gas and fluid flow, and 14 refers to the support plate. Example 4: Preparation of hydrogel beads Mixed culture acclimated to specific organics in a conventional mixed batch reactor is centrifuged at 3000 rpm and 5°C to obtain concentrated pellets of microorganisms, contain- ing about 55 mg of dry biomass per gm of pellet. The concen¬ trated pellets are mixed with distilled water in a 2:5 ratio by weight along with sodium chloride (0.05% w/w) in a blender. Sodium alginate (1.5% w/w) is then added slowly over a period of 2-3 minutes with continuous stirring to obtain a homogeneous cell suspension. The homogeneous cell suspension is then extruded as discrete droplets using a syringe pump, in a slowly stirred 500 ml solution of 0.1 M calcium chloride. As the droplet contacts calcium chloride solution, it hardens to form beads about 3-3.5 mm in diameter. The beads are then cured in 1.0 M calcium chloride solution for 24 hours at 4°C before use. The beads were packed in a bed in accord with the teach¬ ings of Example 1. A small 6 inch height bed of packed hydrogel beads was used experimentally to degrade toluene and/or trichloroethylene (TCE) . Toluene (inlet concentration = 300 ppm) degraded completely to carbon dioxide in 2 minutes gas retention time. TCE with an inlet concentration of 25 ppm, degraded completely when both toluene and TCE were present. When only TCE was introduced at 25 ppm inlet concentration, complete TCE degradation occurred after 7 days, indicating that anaerobic biomass had developed inside the hydrogel bead, thereby biodegrading TCE anaerobically without co-metabolite toluene, with the products of anaerobic degradation biodegrad¬ ing aerobically in the outer portion of the bead wherein aerobic biomass was predominant. Hence, the hydrogel bead allowed simultaneous anaerobic and aerobic degradation to occur due to the fact that oxygen diffusing into the bead was consumed in the outer portion of the bead, thereby allowing anoxic/ anaerobic conditions to prevail inside the bead. Hydrogel beads may also be used to encapsulate specialized microorganisms which cannot otherwise survive competitively in the environment. Encapsulating the microorganisms inside the hydrogel bead provides a protective atmosphere for the specialized organisms to grow in without being contaminated by other organisms that ordinarily exist in the environment. Example 5: Biotransformation of (SO χ and NO χ ) A bioreactor for gas phase biotransformation shown at Fig. 4 oxidizes SO x and N0 χ to sulfate and nitrate ions. Air (32) passes into flue gas inlet to mix with flue gas (31) passing into the packed column immobilized reactor (33) . Treated gas (34) passes out the top of the reactor. Sulfates and nitrates pass to an anaerobic reactor (36) containing sludge which is added at (38) . Gases from the anaerobic reactor pass to an a reactor (39) supplied with S0 2 (40) , where it is converted to sulfur. Solid material from the anaerobic reactor (36) passes to a separator wherein residual biomass and sulfur are expelled while the nutrients are passed into a line (42) for recycling wherein supplemental nutrients, including buffers to retain alkalinity may be added (41) . Air may be used as the source of additional oxygen to insure full biooxidation. The soluble S0 4= and N0 3 . ions in the aqueous stream exiting the oxidation reactor are bioreduced in the second reactor (36) using a waste organic source such as sewage sludge to elemental sulfur, H 2 S, and N 2 . The alkalinity produced in the bioreduction is used to neutralize the acid produced in the biooxidation process by recycling the aqueous phase from the anaerobic/anoxic bioreactor to the first bioreactor. Any H 2 S produced in the bioreduction process is reduced to elemental sulfur. Carbon dioxide, acting as a co- substrate, is transformed in the bioreactor to biomass.

Claims: Claims : 1. A biofilter comprising: a bed having straight passage supports with biomass adherent thereto; an inlet for admission of gaseous stream into the biofil¬ ter; and an inlet for a liquid stream positioned in such a manner that the liquid stream may run countercurrent, co-current or at cross-flow to the gaseous stream. 2. A biofilter of claim 1 wherein the straight passage supports are tubules. 3. A biofilter of claim 1 wherein the straight passage supports are hollow or solid fibers. 4. A biofilter of claim 2 wherein the straight passages are rectangular. 5. A biofilter of claim 1 wherein the supports are made of synthetic polymers. 6. A biofilter of claim 1 wherein the supports are made of diato aceous silica. 7. A biofilter of claim 4 wherein the supports are made of diatomaceous silica. 8. A biofilter of claim 3 wherein the supports are made of extruded activated carbon. 9. A biofilter of claim 1 wherein the supports are made of made of ceramics. 10. A method of degrading and/or biotransforming volatile, undesirable compounds , said method comprising the steps of: (1) exposing a gas stream containing said volatile compounds to solid support arranged in straight passages with biomass which is incorporated in a bed or on a support having straight passages to form a biofilter which is characterized by a minimum void fraction of >.l wherein the void fraction is: total volume of void spaces total volume of the bed ; (2) maintaining the biofilter in a moist state; (3) admitting a gaseous stream containing said volatile compounds into said biofilter ; and (4) allowing said gas stream to be exposed to said biofilter for sufficient time for said volatile compounds to be at least partially degraded before passing from said biofilter. 11. A method claim 10 wherein the support is a ceramic support. 12. A method of claim 11 wherein the support is extruded ceramic. 13. A method of claim 10 wherein the support is a fiber support. 14. A method of claim 10 wherein at least one volatile compound subjected to biotransformation is a sulfur oxide. 15. A method of claim 10 wherein the support material is arranged in straight passages. 16. A method of claim 10 wherein at least one volatile compound being degraded is an organic compound. ' 17. A method of claim 10 wherein at least one volatile compound subjected to biotransformation is a nitrogen oxide. 18. A method of claim 1 wherein anaerobic treatment is used with, preceeded by, or followed by aerobic treatment of the gas stream. 19. A method of claim 1 wherein the packing is hydrogel beads with encapsulated biomass. 20. A method of claim 1 wherein carbon dioxide is transformed into biomass.

Inventors: BISHOP DOLLOFF F, GOVIND RAKESH, BISHOP, DOLLOFF, F., GOVIND, RAKESH
Applicants: BISHOP DOLLOFF F, GOVIND RAKESH, BISHOP, DOLLOFF, F., GOVIND, RAKESH
Application year: 1993
Main classification: C02F3
IPC codes: A61L9, B01D53, C02F3