Ten-Thousand-Ton Scale Engineering Practice of Retrofitting a UASB Reactor into an Aerobic Granular Sludge Process
This study presents a full-scale engineering practice of retrofitting an idle upflow anaerobic sludge blanket (UASB) reactor into an aerobic granular sludge (AGS) system for treating low-strength municipal wastewater. The design capacity was 20,000 m3/d (maximum 24,000 m3/d), achieving separate treatment of industrial and domestic wastewater to reduce operational costs. Systematic analysis covered hydraulic capacity enhancement, effluent quality, pollutant removal efficiencies, sludge granulation progress, and operational costs. Results showed rapid start-up: the system reached 75% of design capacity by day 10 and 90% by day 26. During a 4-month operation, average removal efficiencies for COD, NH4+-N, TN, and SS were 83.2%, 97.0%, 75.9%, and 94.4%, respectively, even under low influent BOD5/TN ratios (typically below 4). Granulation progressed quickly: by day 44, average particle size was 2.6 times that of the inoculum and over 4 times that of flocs, with granules (>200 μm) accounting for 17.3%; by day 110, these values increased to 3.2 times and 5 times, with granule proportion reaching 33.4%. Compared to the previous year (June–August), the AGS process reduced electricity consumption, chemical consumption, and sludge production by 77.3%, 25.4%, and 30.4%, respectively, while saving 65.6% of footprint. This ten-thousand-ton case provides a practical basis for AGS technology application in China.