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Anaerobic treatment of maize processing waste water

(Nejayote) in a packed bed reactor cascade
a b c d e
E. Civit , C.Duran de Bazúa , G. Engelmann , S. González. & L. Hartmann
a
Instituto Nacional de Tecnología Industrial, Alvear 1168., Mar del Plata, 7600, República
Argentina.
b
Departamento de Alimentos, Facultad de Química, Universidad Nacional Autónoma de
México (UNAM), Ciudad Universitaria., México, 04510, D. F. México.
c
United Nations, ESCAP., Bangkok 2., Thailand
d
Instituto de Ingenieria, UNAM. Ciudad Universitaria, México, 04510, D. F. México.
e
Institut für Ingenieurbiologie und Biotechnologie, Abwassers Universität Karlsruhe,
Karlsruhe 1., 7500, Federal Republic of Germany.
Published online: 17 Dec 2008.

To cite this article: E. Civit , C.Duran de Baza , G. Engelmann , S. Gonzlez. & L. Hartmann (1984) Anaerobic treatment of
maize processing waste water (Nejayote) in a packed bed reactor cascade, Environmental Technology Letters, 5:1-11, 89-96

To link to this article: http://dx.doi.org/10.1080/09593338409384257

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 ANAEROBIC TREATMENT OF MAIZE PROCESSING
WASTE WATER (Nejayote) IN A PACKED BED
REACTOR CASCADE

E. Civit., Instituto Nacional de Tecnología Industrial. Alvear 1168. 7600 Mar del Plata. República Argentina.
C. Duran de Bazúa*., Departamento de Alimentos, Facultad de Química. Universidad Nacional Autónoma de
México (UNAM). Ciudad Universitaria. 04510 México D. F. México.
G. Engelmann., United Nations, ESCAP. Bangkok 2. Thailand.
S. González., Instituto de Ingenieria. UNAM. Ciudad Universitaria. 04510 México D. F. México.
L. Hartmann., Institut für Ingenieurbiologie und Biotechnologie des Abwassers. Universität Karlsruhe.
7500 Karlsruhe 1. Federal Republic of Germany.
(Received 5 October 1983; in final form 18 January 1984)
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ABSTRACT

Maize i s t h e s t a p l e food i n Mexico. When processed f o r human consump-

t i o n , an a l k a l i n e l e a c h i n g technique i s used b e f o r e g r i n d i n g . The
e f f l u e n t s , known as nejayote, contain high c o n c e n t r a t i o n s of s o l u b l e and
i n s o l u b l e organic m a t t e r , and have a pH ranging between 9 and 12.
Anaerobic b i o l o g i c a l treatment was c a r r i e d out with the c l a r i f i e d
e f f l u e n t s i n a f i v e - r e a c t o r cascade. R e a c t o r s were packed with 35mm P a l l
r i n g s , had a t o t a l working volume of 117.5 l, and a working temperature
of 34°C. Organic l o a d , measured as COD (chemical oxygen demand) and DOC
( d i s s o l v e d organic c a r b o n ) , ranged between 0.5 t o 1.7 kg COD/m3d, and
0.3 t o 0.8 kg D0C/m3d. Nejayote r e t e n t i o n times i n t h e cascade ranged
between 1 and 23 d. Reduction of o r g a n i c load occurred mainly i n f i r s t
r e a c t o r , with e x c e p t i o n of l-d r e t e n t i o n time experiments. Gas p r o d u c t i o n
r a t e s were a l s o c o n s i d e r a b l y higher i n f i r s t r e a c t o r , between 20.5 t o
60 l (22°C, 1 b a r ) / d . Quality of gases was a l s o c o n s i s t e n t l y b e t t e r i n
f i r s t r e a c t o r , with compositions from 65.2 t o 91% methane i n volume.

INTRODUCTION

Due t o t h e ever i n c r e a s i n g c o s t s and more s t r i n g e n t requirements f o r

the removal of o r g a n i c s from w a s t e w a t e r s , development of i n n o v a t i v e , c o s t
e f f e c t i v e wastewater treatment system a l t e r n a t i v e s a r e r e q u i r e d . E x i s t i n g
a e r o b i c t r e a t m e n t systems a r e c o n s t r a i n e d by p h y s i c a l l i m i t a t i o n s as t o
the amount of oxygen t h a t can be t r a n s f e r r e d i n t o the r e a c t o r . A l t e r n a t e l y ,
a n a e r o b i c t r e a t m e n t systems have proved e f f e c t i v e for s u b s t a n c i a l reduc-
t i o n of t h e organic content of wastewaters, and a l s o t o produce energy
in t h e form of byproduct methane gas. Development of t h e anaerobic f i x e d -
f i l m columns or f i l t e r s , and f l u i d i z e d bed r e a c t o r s a r e r e c e n t approaches
for reducing tankage volume requirements and o p e r a t i o n c a r e . Attached
microorganisms growth and r e t e n t i o n time i n those r e a c t o r s combine t h e
advantages of high, biomass r e t e n t i o n i n the r e a c t o r with s h o r t e r h y d r a u l i c
detention times.
The primary purpose of t h i s study was t o a s c e r t a i n the c o n d i t i o n s
whereby a n a e r o b i c non-methanogenic and methanogenic microorganisms could
s u c c e s s f u l l y be grown on nzjayotz, t h e wastewater of t h e t r a d i t i o n a l
l e a c h i n g technique used i n t h e p r e p a r a t i o n of corn (Zea may¿) f o r food
purposes i n Mexico and C e n t r a l America. Secondary purposes included t h e
assessment of the removal of s o l u b l e o r g a n i c s u b s t r a t e s as f u n c t i o n of
s t r e n g t h and feed flow r a t e .

89
 EXPERIMENTAL PROCEDURE

An a n a e r o b i c c a s c a d e , c o n s i s t i n g of f i v e i d e n t i c a l r e a c t o r s , was
c o n s t r u c t e d from p l e x i g l a s s , a s shown i n F i g u r e s l a and l b ( 1 ) . P i p i n g
and v a l v e s were made of PVC. The system was housed i n a c o n t r o l l e d
t e m p e r a t u r e room (22°C). As o p t i m a l t e m p e r a t u r e f o r mesophile b a c t e r i a
(2) ranges between 30 and 35°C, s t a i n l e s s s t e e l h e a t i n g c o i l s were
i n s t a l l e d inside each r e a c t o r , maintaining liquid temperature a t 33 +
0.5°C. Reactors volume was 28.5 t each, and working volume was 23.5 L.
The reactors were packed with p l a s t i c P a l l r i n g s , 35 mm diameter, 430
rings in each reactor, randomly arranged (78 kg/m3, 19,000 pieces/m 3 ,
160 m2surface/m3, 90% f r e e volume). To avoid channeling, four plexiglass
ring "doughnuts" were d i s t r i b u t e d along the reactor walls. Liquid level
in reactors was controlled by a dynamic head tube resembling a vented
inverted siphon on the f i n a l effluent l i n e . Valved liquid sampling ports
(P) permitted grab sampling from each stage as well as from influent and
e f f l u e n t . Upper end of reactors was sealed and screwed in order to avoid
gas leakage. Gas collected in each stage was vented through a common
manifold to a container (50 Z capacity) or individually measured a f t e r
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each reactor. See Figure l a . To measure volumetric gas production r a t e ,

volume displacement of a liquid solution of NaCl was measured in a
graduated beaker per unit time. Gases were then q u a l i t a t i v e l y analyzed
in an Orsat apparatus.

Treated effluent

Ooltoms
0 Valves P Sampling valve

Figure 1a. Schematic diagram of the anaerobic cascade f i l t e r .

90
 Influent Effluent

1 Bottomplate with
biomass discharge valve
2 Packing support
perforated plate
3 Heating stainless
steel coil
4 Baffle rings :o
avoid channeling
5 tipper sealing and
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screwed lid to avoid

gas leakage
6 Rubber stopper
to prevent ?as leakage
in piptng.
V = 28.35 1
v
working = 23.5 I

[L]=[rnm]

Figure 1b.
Packed bed reactor

Maturation experiments were carried out for building up of the active

biological film. These experiments were carried out in a t o t a l time of
73 d, changing loading conditions, as shown in Table I. Gas production
r a t e s of each reactor as well as t o t a l gas volume per unit time was
monitored along the maturation period. Liquid effluent dissolved organic
carbon (DOC), and pH were monitored every day. DOC was measured with an
organic carbon analyzer, Maihak AG, by t r i p l i c a t e , on supernatant of
samples that had been centrifuged at 2000 rpm for 2 minutes. When DOC
concentrations, and gas production r a t e s varied less than +10% for 3
successive days, chemical oxygen demand (COD) of liquid was then measured,
following the dichromate method (3). At this point, loading conditions
were changed. Operation for a minimum of 5 days following a step change
in loading was required to achieve quasi-steady-state operating conditions
After 45 days, i t was observed that the l a s t two reactors produced very
low gas r a t e s . Therefore, only f i r s t three reactors were monitored the
remaining maturation time. Feeding stock for maturation period was a
synthetic wastewater (molasses-based solution with urea, and sodium phos-
phate to obtain a C:N:P r a t i o of 11:1:0.28). Composition for 18-£ médium
was: tap water, 324 g molasses, 19 g urea, 14 g Na2HP0if. 2H2O.

91
 Experimental Residence Influent organic load Organic load removal Gas production
step time. Kg COO/m"'fl Kq IX)C/m r" in firnr reactor, in f i r s t reactor
d con DOC .C(?.7.°C,1 bar)/'.!

I (1 - 31) 15 0.68 0 30 92.6-94. 8 9.1 5-94 1 -16.3

II (32- 80) 23 0.50 0 21 93.5-96. 1 91 1-94 5 20.5
III. (81-123) 1 1.73 0 83 87.8-94. 0 75 6-Ü7 1 GO.]
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TABLE I Loading c o n d i t i o n s and resultG obtained a f t e r neiayote treatment in n

f i v e - r e a c t o r anaerobic cascade (T w = 33*C, V = 117.5 f )

Gas i n Total noc

Perioc Retention time Rate Load reactor I gas removal
d d t/d kgD0C/m3d ¡JA f./d %

1 - 12 10 11 .75 0.03 2.4R n.U 00.5

13 - 19 7 16.79 0.07 3.86 8.12 8?.6

20 - 34 4 26.44 0.12 7.74 20.34 90.7

35 - 44 3 39.17 0.24 16.20 41.38 89.3

45 - 73 * 1.8 39.17 0.41 30.00 42.R0 92.6

TABLE I I Loading c o n d i t i o n s and r e s u l t s o b t a i n e d during maturation

eexperiments in
xperiments i a five-reactor
na five-re anaerobic cascade (T =33CT.,
V = 1 1 7 . 5 I, * V = 7 0 . 5 I )
w Vf

92
 = 15 d 9 = 23 d G = 1 d
100%

90% 1-

DOC
removal
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80%

50 100 t (d)
Figure 2. Percent organic Load, measured as doc, in nejayote a f t e r
anaerobic treatment in a packed reactor cascade.

0 = 15 d 8 = 23 d 8 = 1 d
pH PH

Reactor 1
2
3
4
5

50 100 t (d)

Figure 3. Variation in pH during anaerobic experiments with nejayote.

93
 1

I
gas_. Q = 15 d 0 = 23 d e = 1 d
d
•

. 60 «

- 30

t
i •
&

O
«Reactor 1 a
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o 3
4
5 50 100
i i

t (d)
Figure 4. Total production of gas in anaerobic cascade using nejayote
(Solid line denotes average values for f i r s t reactor)
After maturation period, c l a r i f i e d nzjayotz was pumped to f i l t e r .
Loading conditions are given in Table I I . He.jCt.yotz was obtained from
laboratory simulation of leaching semiindustrial conditions carried out
in Mexico City's corn mills. Procedure to produce nzjdyotz i s presented
elsewhere (.4) . Total experimental time was 123 days. All variables were
monitored like for maturation experiments. In Figure 2 are shown the
organic carbon removal curves, and in Figure 3, the pH changes during
the experiments. Gas production rate versus time i s presented in Figure
4.
DISCUSSION
As i t may be seen in Fig. 2, for long retention times,,the increase
in DOC removal after the f i r s t reactor comparing i t with the other four
units i s almost negligible (no more than 5% versus more than 90%). This
phenomenon changes drastically as the retention time i s considerably
reduced. As the system started to s t a b i l i z e , the differences between
the reactors DOC removal became discrete ( i . e . less than 80% for the
f i r s t reactor and almost 10% difference with the second u n i t ) . As the
biosystems in the f i r s t reactor have less opportunity to deplete the
organics present in nzj&yotg., thé biocommunities in the other units
receive a more concentrated solution, and thus, improve their removal
efficiency. Also, gas production is improved, as Fig. 4 shows i t , when
residence times are reduced,increasing methane-COî r a t i o in gas quality
evaluations. Gas production phenomena may be associated to pH in solution
(5), since methanogenic bacteria require organic acids of low molecular
weight to synthetize methane. In Fig. 3, for long residence times, only
the f i r s t reactor maintained a slightly acid pH. On the other side, for'
one-day retention time, pH was considerably reduced in a l l five units,
and as a r e s u l t , methane production was highly enhanced. I t i s pertinent
to mention that no accurate gas volunie data could be' gathered with the
method employed, and no availability of flowmetering devices was possible
Thus, the results have to be look upon with some reserves. However, i t s
r a t i o , since a l l data were taken at the same conditions, may be conserva-
tively taken.
94
 CONCLUSIONS
Corn, i n medium size Mexican corn m i l l s , i s cooked under low heat i n
a lime s o l u t i o n f o r about one hour, and then allowed t o soak overnight.
Next day, cooking and steeping liquor tne.ja.yote.) i s discarded, and cooked
corn (n<Lx.ta.ma.Z) i s rinsed and ground t o a s o f t dough, l a t e r used to.
prepare tQH.tÁ.LLa.1), t h e s t a p l e food i n Mexico (Figure 5 ) .
Methane, produced in an anaerobic cascade can be u t i l i z e d as t h e heat
source f o r corn cooking since no compression i s needed, reducing energy
consumption i n t h e o v e r a l l process.
Experiments could not be continued because the cascade system were t o
be t r a n s p o r t e d to a countryside German potato plant laboratory. So f a r ,
the p o s s i b i l i t i e s of using an anaerobic cascade r e a c t o r system to digest
Yie.jG.yotz and produce methane as an a l t e r n a t i v e source of energy f o r corn
cooking look very promising.
Thus, experiments w i l l be continued i n Mexico a f t e r a new cascade
system i s b u i l t , and t e c h n i c a l as well as economical evaluations w i l l be
c a r r i e d out. With t h e information gathered, a p i l o t p l a n t w i l l be t h e
next step to be considered.
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Hiiole corn
kernels
I

Hixtaaaiisation
water
(cots cooking) •Energy
ICa (OH) ;! 'C, 3=1 n)

Overnight Biogas
soaking to be burned
(6- 15h)

Coofcing and Anaerobic

Water Rinsing rins ing
effluents Traataent
(Nejayose)

Treated effluents
i Corn muling
to sewage or
further treatasnt
and recycling
Tortilla
Manufacturing

L
Figure 5. Corn alkaline leaching cooking process (Nixtamalizacion)
for human consumption.

95
 ACKNOWLEDGEMENTS

T h i s work was c a r r i e d o u t from December 1980 u n t i l A p r i l 1981 i n t h e

f a c i l i t i e s provided by t h e I n s t i t u t f ü r I n g e n i e u r b i o l o g i e und Biotechno-,
l o g i e der U n i v e r s i t ä t Karlsruhe (Federal Republic of Germany). I t s use
i s g r a t e f u l l y acknowledged as well as the use of a n a l y t i c a l equipment,
r e a g e n t s , and raw m a t e r i a l s . Author Duran de Bazúa had no d i r e c t
economical support a f t e r July 1980 b u t r e c e i v e d i n d i r e c t family
a s s i s t a n c e through an Alexander von Humboldt S t i f t u n g (Federal
Republic of Germany) given t o h e r spouse.

REFERENCES

1. J . Rautenberg Diplomarbeit. F a k u l t ä t f. Bauingenieur- u. Vermessungs-

wesen. U n i v e r s i t ä t K a r l s r u h e , FRG (1981).

2. K. Imhoff; W.J. Müller; D.K.B. T h i s t l e w a y t e . "Disposal of sewage

and o t h e r waterborne w a s t e s " . B u t t e r w o r t h s , London, GB (1971).
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3. Deutsche E i n h e i t s v e r f a h r e n zur Wasser-, Abwasser- und Schlammunter-

schung. Verlag Chemie, Weilheim, FRG (1960).

4. C. Duran de Bazúa; R. Guerra; H. S t e r n e r . J. Food S c i . 44:940

(1979).

5. J.W.M. La R i v i è r e . Microbial ecology of l i q u i d waste t r e a t m e n t .

In: Advances of Microbial Ecology, Vol. I (M. Alexander Ed.).
Plenum P r e s s , New York (1977).

96