A 45-liter microbial fuel cell (MFC) system was integrated into a full-scale wastewater treatment plant (WWTP). The system was operated under practical conditions with supernatant of a pre-thickener for 50 days in order to identify, whether higher power output and energy recovery is possible compared to the use of primary clarifier effluent, as used in a previous study. The higher COD (chemical oxygen demand) loading rates of supernatant neither increased power densities, nor energy recovery, but impact loads of total ammonia nitrogen (TAN) in concentrations > 800 mg/L (free ammonia nitrogen (FAN) > 40 mg/L) led to an instant collapse of power output and nutrient removal, which was reversed when ammonia concentrations decreased. Investigations in lab-scale under defined conditions verified that the inhibition of the exoelectrogenic biofilm is in fact caused by high levels of FAN. Here, COD removal, power output and energy recovery constantly decreased, when FAN-concentrations were increased above 64 mg/L.

A 45-L pilot MFC system, consisting of four single-chamber membraneless MFCs, was integrated into a full-scale wastewater treatment plant (WWTP) and operated under practical conditions with the effluent of the primary clarifier for nine months to identify an optimal operational strategy for stable power output and maximum substrate based energy recovery (Normalized Energy Recovery, NER). Best results with the MFC were obtained at a hydraulic retention time of 22h with COD, TSS and nitrogen removal of 24%, 40% and 28%, respectively. Mean NER of 0.36kWhel/kgCOD,deg and coulombic efficiency of 24.8% were reached. Experimental results were used to set up the first described energy balance for a whole WWTP with an integrated MFC system. Energetic calculations of the model WWTP showed that energy savings due to reduced excess sludge production and energy gain of the MFC are significantly higher than the loss of energy due to reduced biogas production.