SYSTEMS, METHODS, AND APPARATUS FOR INCREASING BIOREACTOR CAPACITY USING SILICA POLYMERS

1 . A method for increasing microbial population, the method comprising:

supplying nutrients and silica polymers containing microorganisms to a bioreactor to form a first suspension; and

controlling temperature, pressure, and nutrient conditions in the bioreactor to produce a second suspension with increased carrying capacity as compared to a control bioreactor containing microorganisms without the silica polymers.

2 . The method of claim 1 , wherein the increased carrying capacity of the bioreactor is at least 1.5 times carrying capacity of the control bioreactor containing microorganisms without the silica polymers.

3 . The method of claim 1 , wherein the microorganisms are aerobic.

4 . The method of claim 1 , wherein the microorganisms are anaerobic.

5 . The method of claim 1 , wherein the microorganisms produce a biofuel.

6 . The method of claim 5 , wherein the biofuel is selected from the group consisting of methanol, ethanol, and butanol.

7 . The method of claim 1 , the silica polymers are precipitated silica granules having a porous structure and loaded with microorganisms throughout the pores of the precipitated silica granules.

8 . A method for increasing the carrying capacity of a wastewater treatment facility, the method comprising:

introducing silica polymers containing microorganisms to a bioreactor containing wastewater to form a first suspension;

maintaining the bioreactor under conditions to produce a second suspension, wherein the second suspension has at least two times more total suspended solids than a control bioreactor without application of silica polymers;

separating, by a mechanical process, the second suspension to produce a fraction containing suspended solids and a treated water stream, wherein a portion of the fraction containing suspended solids is recycled to the bioreactor.

9 . The method of claim 8 , wherein the silica polymers containing microorganisms are introduced to a wastewater stream under aerating conditions to form the first suspension.

10 . The method of claim 8 , wherein the silica polymers are precipitated silica granules having a porous structure and loaded with microorganisms throughout the pores of the precipitated silica granules.

11 . The method of claim 8 , further comprising:

adding a flocculating agent to the second suspension.

12 . The method of claim 8 , wherein a portion of the fraction containing suspended solids is supplied to an additional bioreactor under anaerobic or anoxic conditions to produce digested products.

13 . The method of claim 12 , further comprising:

separating the digested products to remove water from the digested products and produce a filter cake.

14 . A system for increasing the carrying capacity of a wastewater treatment plant, the system comprising:

an aeration basin configured to mix wastewater and silica polymers containing microorganisms to produce a first suspension;

a bioreactor configured to receive the first suspension and produce a second suspension with at least two times more total suspended solids than the wastewater stream;

a first solid-liquid separator configured to receive the second suspension from the bioreactor and produce a first fraction containing suspended solids and a treated water stream; and

a second solid-liquid separator configured to receive the first fraction containing suspended solids and produce a second fraction containing suspended solids and a waste product stream containing suspended solids, wherein the second fraction is recycled to the bioreactor.

15 . The system of claim 14 , wherein the silica polymers are precipitated silica granules having a porous structure and loaded with microorganisms throughout the pores of the precipitated silica granules.

16 . The system of claim 14 , further comprising:

a third solid-liquid separator configured to receive the waste product stream and produce a water stream and a filter cake.

17 . A system for increasing the carrying capacity of a wastewater treatment plant, the system comprising:

a bioreactor configured to receive silica polymers containing microorganisms and wastewater and produce a suspension with at least two times more total suspended solids than the wastewater;

a first solid-liquid separator configured to receive the suspension from the bioreactor and produce a first fraction containing suspended solids and a treated water stream; and

a second solid-liquid separator configured to receive the first fraction containing suspended solids and produce a second fraction containing suspended solids and a waste product stream containing suspended solids, wherein the second fraction containing suspended solids is recycled back to the bioreactor.

18 . The system of claim 17 , further comprising:

a third solid-liquid separator configured to receive the waste product and produce a water stream and a filter cake.

19 . The system of claim 17 , wherein the silica polymers are precipitated silica granules having a porous structure and loaded with microorganisms throughout the pores of the precipitated silica granules.

20 . A method for increasing microbial population, the method comprising:

supplying silica polymers and nutrients to a bioreactor containing microbes to form a first suspension, wherein the silica polymers provide a substrate for microbial growth; and

controlling reaction conditions in the bioreactor to produce a second suspension with increased carrying capacity as compared to a control bioreactor containing microorganisms without the silica polymers.