Effluents of pulp and paper mills are relatively simple to treat by activated sludge process - in theory. Some severe problems have arisen in practice, however.
Temperatures of incoming waste waters have risen during last years. The most obvious reason for this phenomenon is the increased recirculation of process waters inside the mills. Poor sedimentation of flogs, caused by the heavy growth of filamentous bacteria, has also become to be more and more hard problem for purification plants. There may be some kind of correlation between temperature and bulking of sludge?
Another problem, potentially very hazardous, is the growth and recirculation of Legionella pneumophila inside activated sludge process. The role of Protozoa has now been established: they act as carrirs of bacteria backwards in returned sludge.
Dosing of nutrients into biological treatment steps isn't any hard task anymore because the need of phosphorus and nitrogen has been studied very deeply, and simpe AT LINE testing for the optimization of them is easy to perform in the mill labs.
Two problems, mentioned before, still exist and need R&D activities to be solved: bulking of the sludge (by filamentous organisms) and L.pneumophila.
Thursday, February 26, 2009
Monday, February 16, 2009
Transfer of microbiological control from institutes to mill labs
Rapid development of analytical microbiology has been obvious during last 20 years.
After the beginning of IM's career in paper industry (est. 1982) a significant increase of novel methods has taken place. Slow and labourous colony count analyses have been replaced with novel, advanced methods in certain laboratories on 1990's.
Biomass, surface hygiene, condition of activated sludge, biofilm formation - among even more subjects - can be assayed by luminometric methods today.
Light and UV microscopy is another basic tool of paper industry microbiology today. Very valuable results have been achieved with TEM on 1980's and articles about sporeforming bacteria and biofilms, based on electron microscopy, have published by researcher all over the world. TEM is, however, such an advanced research instrument which is practically impossible to apply into everyday microbiological control of pulp and paper mills. Confocal microscopy has given brand new ideas about the structure of biofilms but it is also a too complicated method for mill labs. In opposite, light and epifluorescence microscopy aren't too expensive; they definitely need a lot of training for the personnel which is no big problem, however: in Finland (and IM is sure, in other countries, too) are training companies who will have annual microbiology courses for paper industry under titles like "Paper Industry Microscopy" and "Methods for Process and Product Hygiene in Paper Industry".
Tools of molecular biology have replaced the previous generation's major tool, FAME (Fatty Acid Methylated Esters - an application of gas chromatography to perform identifications of bacteria). But the limits of PCR and similar methods are obvious: they cannot show what is really happening inside the machines! They only give - valuable, of course - information about microbial species but do not explain and forecast those metabolic reactions, succession of population, risk of biofilm formation etc. which are more important for the drive of machines, good housekeeping of raw materials and product hygiene.
Basic methods of modern microbiology like DEFT, ATP Assay, PCR and other should therefore be combined with simple simulators, driven in mill labs. This is already possible: the first system for this target, PMEU (Portable Microbiological Enrichment Unit) has been tested and used by IM since the beginning of 2000's and it has been proven to be a most valuable tool for rapid raw material, process and biofilm studies today.
An ecological point of view shall be applied to everyday mb control of the pulp and paper mills. This question is discussed in the article "Paperikone - ekosysteemi ja bioreactori" ("Paper Machine - An Ecosystem and A Bioreactor") by JM in the annual of Finnish Microbiology Society (INOCULA 2007 / 1 - unfortunately only in Finnish). Understanding of these two natures of a paper machine gives new chances for the mills: it gives the ability to forecast microbiological events inside the processes and it also give extra time to prevent problems.
After the beginning of IM's career in paper industry (est. 1982) a significant increase of novel methods has taken place. Slow and labourous colony count analyses have been replaced with novel, advanced methods in certain laboratories on 1990's.
Biomass, surface hygiene, condition of activated sludge, biofilm formation - among even more subjects - can be assayed by luminometric methods today.
Light and UV microscopy is another basic tool of paper industry microbiology today. Very valuable results have been achieved with TEM on 1980's and articles about sporeforming bacteria and biofilms, based on electron microscopy, have published by researcher all over the world. TEM is, however, such an advanced research instrument which is practically impossible to apply into everyday microbiological control of pulp and paper mills. Confocal microscopy has given brand new ideas about the structure of biofilms but it is also a too complicated method for mill labs. In opposite, light and epifluorescence microscopy aren't too expensive; they definitely need a lot of training for the personnel which is no big problem, however: in Finland (and IM is sure, in other countries, too) are training companies who will have annual microbiology courses for paper industry under titles like "Paper Industry Microscopy" and "Methods for Process and Product Hygiene in Paper Industry".
Tools of molecular biology have replaced the previous generation's major tool, FAME (Fatty Acid Methylated Esters - an application of gas chromatography to perform identifications of bacteria). But the limits of PCR and similar methods are obvious: they cannot show what is really happening inside the machines! They only give - valuable, of course - information about microbial species but do not explain and forecast those metabolic reactions, succession of population, risk of biofilm formation etc. which are more important for the drive of machines, good housekeeping of raw materials and product hygiene.
Basic methods of modern microbiology like DEFT, ATP Assay, PCR and other should therefore be combined with simple simulators, driven in mill labs. This is already possible: the first system for this target, PMEU (Portable Microbiological Enrichment Unit) has been tested and used by IM since the beginning of 2000's and it has been proven to be a most valuable tool for rapid raw material, process and biofilm studies today.
An ecological point of view shall be applied to everyday mb control of the pulp and paper mills. This question is discussed in the article "Paperikone - ekosysteemi ja bioreactori" ("Paper Machine - An Ecosystem and A Bioreactor") by JM in the annual of Finnish Microbiology Society (INOCULA 2007 / 1 - unfortunately only in Finnish). Understanding of these two natures of a paper machine gives new chances for the mills: it gives the ability to forecast microbiological events inside the processes and it also give extra time to prevent problems.
Monday, February 9, 2009
Challenges of Biotech
IM will refer the excellent book "The Biotech Investor" by Tom Abate (Owl Books, 2003, New York) again. IM also tries to reserve his time to read it through, no matter it is a dense collection of biotech and marketing facts.
In the preface of this book Tom Abate says:
"Biotechnology is an experimental field. Only a handful of of biotech companies currently have products on the market. The vast majority of biotech firms run at a loss during long developmental cycles aimed at proving their founding thesis. Experiments take time, and they often fail. Even when experiments have been done, and their results analyzed and presented at scientific meetings, biotech medicines undergo an excruciating process of regulatory review the can lead to approval, rejection or demands for more testing...In biotech time, development horizons strech for years, even decades."
This is familiar for every modern biotech researchers. Dr. Abate refers medicine research but relatively similar problems may arise when a novel microbiological analyse method is the subject of the research. Approval is then depending not on the health of the customers but the potential markets (IM's opinion). IM still thinks that such a development task can be fulfilled in only years, but marketing may be a challenging task, indeed.
Contacts between paper industry personnel and biotech researchers shall be developed. There are other alternatives than the traditional fairs and exhibitions: discussions in Internet blogs, nings etc. would help significantly to present all modern microbiological tools and evaluate their use in paper industry microbiology. Unfortunately the main problem, time, still stays, even gets worser: people tend to be in a hurry in their working life today. To reserve a period, even short, to investigate new methods will still be worth to do!
In the preface of this book Tom Abate says:
"Biotechnology is an experimental field. Only a handful of of biotech companies currently have products on the market. The vast majority of biotech firms run at a loss during long developmental cycles aimed at proving their founding thesis. Experiments take time, and they often fail. Even when experiments have been done, and their results analyzed and presented at scientific meetings, biotech medicines undergo an excruciating process of regulatory review the can lead to approval, rejection or demands for more testing...In biotech time, development horizons strech for years, even decades."
This is familiar for every modern biotech researchers. Dr. Abate refers medicine research but relatively similar problems may arise when a novel microbiological analyse method is the subject of the research. Approval is then depending not on the health of the customers but the potential markets (IM's opinion). IM still thinks that such a development task can be fulfilled in only years, but marketing may be a challenging task, indeed.
Contacts between paper industry personnel and biotech researchers shall be developed. There are other alternatives than the traditional fairs and exhibitions: discussions in Internet blogs, nings etc. would help significantly to present all modern microbiological tools and evaluate their use in paper industry microbiology. Unfortunately the main problem, time, still stays, even gets worser: people tend to be in a hurry in their working life today. To reserve a period, even short, to investigate new methods will still be worth to do!
Wednesday, February 4, 2009
Good News' Day?
It is now published: TV news told tonight about the fusion of KCL (national pulp and paper R&D center) and VTT (national center of technical R&D) in Finland.
As an insider for several years, IM has seen the synergy of these two institutes and their university partners. Now, as an outsider observer, IM was slightly surprised but, after a moment of wondering, he understands the basic facts which have led to this solution.
This new, big R&D center will work towards R&D solutions more effectively and economically, IM hopes. It also comes time to invite small, scientific enterprises to have cooperation with this major R&D unit. They will give fresh views on several areas like process control, hygiene and energy savings. They have been the origin of new ideas in several cases during IM's career, indeed.
IM is therefore looking forward optimistically! "Small can be beautiful"!
As an insider for several years, IM has seen the synergy of these two institutes and their university partners. Now, as an outsider observer, IM was slightly surprised but, after a moment of wondering, he understands the basic facts which have led to this solution.
This new, big R&D center will work towards R&D solutions more effectively and economically, IM hopes. It also comes time to invite small, scientific enterprises to have cooperation with this major R&D unit. They will give fresh views on several areas like process control, hygiene and energy savings. They have been the origin of new ideas in several cases during IM's career, indeed.
IM is therefore looking forward optimistically! "Small can be beautiful"!
Wednesday, January 28, 2009
The need of paper machine biocides?
IM is wondering: are there any other sector of process industry, where microbes are allowed to grow like in paper industry?
Biotechnological processes, of course. But their populations are carefully selected and controlled. And they are employers of the company, not criminals trying to cause harm to the company.
Some significant changes in paper industry processes have taken place after the rise of active environmental care. Both the closure of water circulation and the cancelling of biocides having mercury as an active incredient are favorable for the environment, of course. But the microbial growth inside the paper machines has activated at the same time.
The beginning of neutral paper production led to an "ecocatastrophe" inside paper machines. The rise of pH value (as well as the rise of temperature, caused by the extended recirculation of water) was fatal for slow, acid-loving fungal growth. New mineral additives are an important source of certain types of bacteria, causing severe problems like production of slime, spoiling of the process compounds and hygiene faults of the products.
IM has published an article "Paper Machine: an Ecosystem and a Bioreactor" (INOCULA 1/2007. Helsinki, Finland). Many readers agree: paper machines offer ecological niches for bacteria, and the controlled environments of wet end circulations are very much similar with those of biotechnical processes, based on chemostatic fermentors.
A lot could be do to make paper machines more unfavorable growth environment for microbial contaminants. Very good results have been achieved in some projects where ecological aspects have been taken into account. These issues will be discussed later in this blog.
But the main question is: how much biocides we still need to control the microbial growth in all regions of a paper machine?
Incoming raw materials, sorry to say, may be very contaminated: the highest value of total count during IM's career has been over 100 000 000 cfu/g in a mineral slurry (which was fortunately replaced by a fresh lot by the supplier!). It is therefore obvious that a continuous control - both analytical and practical - is needed for starches, mineral pigments and other contaminated raw materials. This does not mean that all lots are spoiled: there are suppliers which know their response to deliver pure products to the mills but all kind of errors in biocidic pre-treatment, transport and storage of these products may happen.
Certain sites of paper machines also need biocidic treatments all the time. Chosing proper solutions for biocide programs (type of biocide, active compound, dosing sites, timing etc.) of a paper machine is a challenging tasks. In best cases, both the paper mill and biocide personnel are sitting down and discussing of the individual problems of the paper process hygiene.
When specified laboratory services, having tools like PMEU and biofilm microscopy, are included, the final result can be optimal one. Paper industry microbiologists can also help significantly by declaring the effects of process parameters on the growth of planktonic and biofilm bacteria.
The more competence is included, the better solution will be find.
Biotechnological processes, of course. But their populations are carefully selected and controlled. And they are employers of the company, not criminals trying to cause harm to the company.
Some significant changes in paper industry processes have taken place after the rise of active environmental care. Both the closure of water circulation and the cancelling of biocides having mercury as an active incredient are favorable for the environment, of course. But the microbial growth inside the paper machines has activated at the same time.
The beginning of neutral paper production led to an "ecocatastrophe" inside paper machines. The rise of pH value (as well as the rise of temperature, caused by the extended recirculation of water) was fatal for slow, acid-loving fungal growth. New mineral additives are an important source of certain types of bacteria, causing severe problems like production of slime, spoiling of the process compounds and hygiene faults of the products.
IM has published an article "Paper Machine: an Ecosystem and a Bioreactor" (INOCULA 1/2007. Helsinki, Finland). Many readers agree: paper machines offer ecological niches for bacteria, and the controlled environments of wet end circulations are very much similar with those of biotechnical processes, based on chemostatic fermentors.
A lot could be do to make paper machines more unfavorable growth environment for microbial contaminants. Very good results have been achieved in some projects where ecological aspects have been taken into account. These issues will be discussed later in this blog.
But the main question is: how much biocides we still need to control the microbial growth in all regions of a paper machine?
Incoming raw materials, sorry to say, may be very contaminated: the highest value of total count during IM's career has been over 100 000 000 cfu/g in a mineral slurry (which was fortunately replaced by a fresh lot by the supplier!). It is therefore obvious that a continuous control - both analytical and practical - is needed for starches, mineral pigments and other contaminated raw materials. This does not mean that all lots are spoiled: there are suppliers which know their response to deliver pure products to the mills but all kind of errors in biocidic pre-treatment, transport and storage of these products may happen.
Certain sites of paper machines also need biocidic treatments all the time. Chosing proper solutions for biocide programs (type of biocide, active compound, dosing sites, timing etc.) of a paper machine is a challenging tasks. In best cases, both the paper mill and biocide personnel are sitting down and discussing of the individual problems of the paper process hygiene.
When specified laboratory services, having tools like PMEU and biofilm microscopy, are included, the final result can be optimal one. Paper industry microbiologists can also help significantly by declaring the effects of process parameters on the growth of planktonic and biofilm bacteria.
The more competence is included, the better solution will be find.
Monday, January 26, 2009
Checkpoints of a paper machine.
Imagine yourself as a bacterium.
You are coming to the paper mill - maybe waterborne, maybe as a bug or as a spore in a lot of starch or mineral pigment.
What will happen to you?
Do you find an ecological niche inside the machine?
I am sure, you will find.
You will find a wet surface, some of your genes will be activated for the living inside a biofilm.
You have fellow bugs there. You could even communicate chemically.
And, after a period of lush life inside the biofilm, you get older and will be released into the water current.
And you wish, that there are no detectives, controlling your movements inside the paper machine: wet end systems, pulp and broke systems, mineral slurry and starch size routes...
The detectives belong to HACCP. They know where you will hide...
- This is my dream. Tools for this kind of HACCP are already available.
You are coming to the paper mill - maybe waterborne, maybe as a bug or as a spore in a lot of starch or mineral pigment.
What will happen to you?
Do you find an ecological niche inside the machine?
I am sure, you will find.
You will find a wet surface, some of your genes will be activated for the living inside a biofilm.
You have fellow bugs there. You could even communicate chemically.
And, after a period of lush life inside the biofilm, you get older and will be released into the water current.
And you wish, that there are no detectives, controlling your movements inside the paper machine: wet end systems, pulp and broke systems, mineral slurry and starch size routes...
The detectives belong to HACCP. They know where you will hide...
- This is my dream. Tools for this kind of HACCP are already available.
Some practical views into the future of biotechnology.
I will come back to the future of biotechnology.
The economical figures of traditional industries seem to be awful. We will see, what is the condition of such branches like paper, automobile and communication enterprises in 2010.
The optimistic view into biotechnology, presented by Osmo Kuusi in 1991, should be reviewed soon.
Another positive attitude has been presented by Tom Abate in "The Biotech Investor", published in 2003 and found by me under a layer of dust in the library of Jyväskylä University (Tom Abate 2003. The Biotech Investor: how to profit from the coming boom in biotechnology. Owl Books, New York).
Tom Abate tells about sectors of biotechnology like the previous authors, discovering this area. He calls them "The Genomics Wave", "The Proteomics Wave" , "The Biotech Toolmakers", "Green Genes", "The New Factories", "Brave New Worlds" and "The Biotech Clusters".
What these titles include, I'll try to explain whenever I have red this interesting book.
Before that, I have good news:
The leading newspaper in Central Finland, Keskisuomalainen, tells about the manufacturers of small-scale waste water treatment plants. Finnish legislations says that all small houses shall update their ww treatment systems before the end of 2013.
The count of these households is est. 300 000 in Finland!
Not to name the individual enterprises, there are a couple of small companies manufacturing/importing batch-type activated sludge systems in a small scale in our country. Two larger companies, having Finnish background, also exists.
Novel ideas to control the effluents of these mini-plants already exist, but the questions of evaluation, standardization etc. will have a sever effect on the application of these methods.
I think that it is now time for the Finnish government to accept these analytical methods to be applied by small-scale treatment plant producers.
Colony counts, developed in the beginning of 20th century, are valuable. But what we are needing today are the rapid methods for the control of both activated sludge itself and the effluents of these equipments.
The economical figures of traditional industries seem to be awful. We will see, what is the condition of such branches like paper, automobile and communication enterprises in 2010.
The optimistic view into biotechnology, presented by Osmo Kuusi in 1991, should be reviewed soon.
Another positive attitude has been presented by Tom Abate in "The Biotech Investor", published in 2003 and found by me under a layer of dust in the library of Jyväskylä University (Tom Abate 2003. The Biotech Investor: how to profit from the coming boom in biotechnology. Owl Books, New York).
Tom Abate tells about sectors of biotechnology like the previous authors, discovering this area. He calls them "The Genomics Wave", "The Proteomics Wave" , "The Biotech Toolmakers", "Green Genes", "The New Factories", "Brave New Worlds" and "The Biotech Clusters".
What these titles include, I'll try to explain whenever I have red this interesting book.
Before that, I have good news:
The leading newspaper in Central Finland, Keskisuomalainen, tells about the manufacturers of small-scale waste water treatment plants. Finnish legislations says that all small houses shall update their ww treatment systems before the end of 2013.
The count of these households is est. 300 000 in Finland!
Not to name the individual enterprises, there are a couple of small companies manufacturing/importing batch-type activated sludge systems in a small scale in our country. Two larger companies, having Finnish background, also exists.
Novel ideas to control the effluents of these mini-plants already exist, but the questions of evaluation, standardization etc. will have a sever effect on the application of these methods.
I think that it is now time for the Finnish government to accept these analytical methods to be applied by small-scale treatment plant producers.
Colony counts, developed in the beginning of 20th century, are valuable. But what we are needing today are the rapid methods for the control of both activated sludge itself and the effluents of these equipments.
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