Water has become a critical resource due to increased manufacturing activities. However, there is a lack of detailed information on water management and consumption by industries. In the recent bibliography, lean-green was established as a good approach for achieving sustainability in manufacturing industries, but few studies have aimed to achieve both operational and environmental improvements in water consumption. In this paper, we present a multi-case study in the agri-food industry in which water consumption in company activities is monitored, allowing them to improve their industrial processes based on lean-green practices, leading to a zero-waste strategy for this critical resource. The aim of this paper is to demonstrate the importance of having detailed knowledge regarding water consumption in order to discover, in a lean-green context, new improvement opportunities which could remain hidden by the current way of analysing consumption.

In a circular economy (CE) environment, it is important to make good and efficient use of resources and consider that the waste generated in production processes can be a valuable resource. However, the tools and methodologies conventionally used to analyze and evaluate production systems are based on techniques focused on linear production management models, where the primary purpose is to reduce the treatment and management of waste as much as possible and where productive and environmental efficiency are not evaluated simultaneously. Changing the paradigm from a linear to a circular economy requires that a new strategy for production systems be defined, one that makes production processes simultaneously circular and efficient (in terms of quality and productivity). In this context, a holistic vision is needed when implementing CE strategies. Therefore, the main aim of this paper is to provide evidence, through two real case studies in the use of water, that the management of this resource without considering systemic thinking may not be the most circular solution. Main results showed that improvements based on the traditional approach of reducing resource use cannot provide the best results if they are supported only by current process consumption without considering the circularity of resources.

Phosphorus has been considered as a pollutant to be removed from the wastewater. In the last years, however, it has been considered a valuable asset that needs to be recovered due to its shortage in nature. The study of optimum phosphorus management in wastewater treatment plants is not straightforward, due to the complexity of technologies and configurations that may be applied for phosphorus removal and recovery. In this context, plant-wide mathematical modelling and simulation tools are very useful for carrying out these studies. This paper introduces a study carried out at the Sur WWTP (Madrid) to assess optimum phosphorus management strategies based on the PWM. The mathematical model made it possible to describe the phosphorus flux and its characterization throughout the plant. Finally, an exploration by simulation with WEST (TM) was carried out to analyse different plant configurations and different operational strategies to optimize phosphorus management strategies in the Sur WWTP.

This paper introduces a new mathematical model built under the PC-PWM methodology to describe the aeration process in a full-scale WWTP. This methodology enables a systematic and rigorous incorporation of chemical and physico-chemical transformations into biochemical process models, particularly for the description of liquid-gas transfer to describe the aeration process. The mathematical model constructed is able to reproduce biological COD and nitrogen removal, liquid-gas transfer and chemical reactions. The capability of the model to describe the liquid-gas mass transfer has been tested by comparing simulated and experimental results in a full-scale WWTP. Finally, an exploration by simulation has been undertaken to show the potential of the mathematical model. (C) 2017 Elsevier Ltd. All rights reserved.

Given the shift in perception of wastewater treatment plants as water resource recovery facilities, conventional mathematical models need to be updated. The resource recovery perspective should be applied to new processes, technologies and plant layouts. The number and level of models proposed to date give an overview of the complexity of the new plant configurations and provides a wide range of possibilities and process combinations in order to construct plant layouts. This diversity makes the development of standard, modular and flexible tools and model libraries that allow the incorporation of new processes and components in a straightforward way a necessity. In this regard, the plant-wide modelling (PWM) library is a complete model library that includes conventional and advanced technologies and that allows economic and energetic analyses to be carried out in a holistic way. This paper shows the fundamentals of this PWM library that is built upon the above-mentioned premises and the application of the PWM library in three different full-scale case studies.

The growing development of technologies and processes for resource treatment and recovery is offering endless possibilities for creating new plant-wide configurations or modifying existing ones. However, the configurations¿ complexity, the interrelation between technologies and the influent characteristics turn decision-making into a complex or unobvious process. In this frame, the Plant-Wide Modelling (PWM) library presented in this paper allows a thorough, comprehensive and refined analysis of different plant configurations that are basic aspects in decision-making from an energy and resource recovery perspective. In order to demonstrate the potential of the library and the need to run simulation analyses, this paper carries out a comparative analysis of WWTPs, from a techno-economic point of view. The selected layouts were (1) a conventional WWTP based on a modified version of the Benchmark Simulation Model No. 2, (2) an upgraded or retrofitted WWTP, and (3) a new Wastewater Resource Recovery Facilities (WRRF) concept denominated as C/N/P decoupling WWTP. The study was based on a preliminary analysis of the organic matter and nutrient energy use and recovery options, a comprehensive mass and energy flux distribution analysis in each configuration in order to compare and identify areas for improvement, and a cost analysis of each plant for different influent COD/TN/TP ratios. Analysing the plants from a standpoint of resources and energy utilization, a low utilization of the energy content of the components could be observed in all configurations. In the conventional plant, the COD used to produce biogas was around 29%, the upgraded plant was around 36%, and 34% in the C/N/P decoupling WWTP. With regard to the self-sufficiency of plants, achieving self-sufficiency was not possible in the conventional plant, in the upgraded plant it depended on the influent C/N ratio, and in the C/N/P decoupling WWTP layout self-sufficiency was feasible for almost all influents, especially at high COD concentrations. The plant layouts proposed in this paper are just a sample of the possibilities offered by current technologies. Even so, the library presented here is generic and can be used to construct any other plant layout, provided that a model is available.

This paper introduces a new general methodology for incorporating physico-chemical and chemical transformations into multi-phase wastewater treatment process models in a systematic and rigorous way under a Plant-Wide modelling (PWM) framework. The methodology presented in this paper requires the selection of the relevant biochemical, chemical and physico-chemical transformations taking place and the definition of the mass transport for the co-existing phases. As an example a mathematical model has been constructed to describe a system for biological COD, nitrogen and phosphorus removal, liquid gas transfer, precipitation processes, and chemical reactions. The capability of the model has been tested by comparing simulated and experimental results for a nutrient removal system with sludge digestion. Finally, a scenario analysis has been undertaken to show the potential of the obtained mathematical model to study phosphorus recovery. (C) 2015 Elsevier Ltd. All rights reserved.

This paper presents a new modelling methodology for dynamically predicting the heat produced or consumed in the transformations of any biological reactor using Hess's law. Starting from a complete description of model components stoichiometry and formation enthalpies, the proposed modelling methodology has integrated successfully the simultaneous calculation of both the conventional mass balances and the enthalpy change of reaction in an expandable multi-phase matrix structure, which facilitates a detailed prediction of the main heat fluxes in the biochemical reactors. The methodology has been implemented in a plant-wide modelling methodology in order to facilitate the dynamic description of mass and heat throughout the plant. After validation with literature data, as illustrative examples of the capability of the methodology, two case studies have been described. In the first one, a predenitrification-nitrification dynamic process has been analysed, with the aim of demonstrating the easy integration of the methodology in any system. In the second case study, the simulation of a thermal model for an ATAD has shown the potential of the proposed methodology for analysing the effect of ventilation and influent characterization. (C) 2014 Elsevier Ltd. All rights reserved.

Seven mixed sewage sludges from different wastewater treatment plants, which have an anaerobic digester in operation, were evaluated in order to clarify the literature uncertainty with regard to the sewage sludge characterisation and biodegradability. Moreover, a methodology is provided to determine the Anaerobic Digestion Model No. 1 parameters, coefficients and initial state variables as well as a discussion about the accuracy of the first order solubilisation constant, which was obtained through biomethane potential test. The results of the biomethane potential tests showed ultimate methane potentials from 188 to 214 mL CH4 g(-1) CODfed, COD removals between 58 and 65% and two homogeneous groups for the first order solubilisation constant: (i) the lowest rate group from 0.23 to 0.35 day(-1) and (ii) the highest rate group from 0.27 to 0.43 day(-1). However, no statistically significant relationship between the ultimate methane potential or the disintegration constant and the sewage sludge characterisation was found. Next, a methodology based on the sludge characterisation before and after the biomethane potential test was developed to calculate the biodegradable fraction, the composite concentration and stoichiometric coefficients and the soluble COD of the sewage sludge; required parameters for the implementation of the Anaerobic Digestion Model No. 1. The comparison of the experimental and the simulation results proved the consistency of the developed methodology. Nevertheless, an underestimation of the first order solubilisation constant was detected when the experimental results were simulated with the solubilisation constant obtained from the linear regression experimental data fitting. The latter phenomenon could be related to the accumulation of intermediary compounds during the biomethane potential assay. (C) 2013 Elsevier Ltd. All rights reserved.

his work presents a global model of sanitation system that integrates different simulation tools. The main objective of this work is to manage, in a controlled way, high salinity industrial discharges to ensure the stability of the sewer network and the municipally wastewater treatment plant.