Unique biofilm structure and mass transfer mechanisms in the foam aerated biofilm reactor (FABR)

The foam-aerated biofilm reactor (FABR) is a novel biofilm process that can simultaneously remove carbon and nitrogen from wastewater. A porous polyurethane foam sheet forms an interface between wastewater and aerated water, making it a counter-diffusional biofilm process similar to the membrane-aerated biofilm reactor (MABR). However, it is not clear how biofilm develops the foam interior, and how this impacts mass transfer and performance. This research explored biofilm development within the foam sheet and determined whether advective transport within the sheet played a significant role. Foam sheets with 2-, 4.5- and 9-mm thicknesses were explored. Oxygen, nitrate, nitrite and ammonia profiles in the sheet were measured using microsensors, and biofilm imaging studies were carried out using optical coherence tomography (OCT). On the foam’s aerated side, a dense nitrifying biofilm formed. Beyond the aerobic zone, much less biomass was observed, with a high porosity foam-biofilm layer. The higher effective diffusivity within the foam for the 4- and 9-mm sheets suggested advective transport within the foam channel structures. Using an effective diffusivity factor in conventional 1-D biofilm models reproduced the measured substrate concentration profiles within the foam. Four different practical conditions were modelled. The maximum TN removal efficiency was about 70% and a nitrogen removal flux of 1.25 gN.m−2.d−1. We conclude that mass transfer resistance occurred primarily in the dense, nitrifying layer near the aerated side. The rest of the foam sheet was porous, allowing the advective mass transfer.