Biofilm2009_EvaDalentoft

Practical implementation of a biofilm system

When? Why?

Where? How?

Eva Dalentoft

a biofilm is a group of micro-organisms and their extra cellular products, attached to a solid surface

Biofilm

Imbedded particulate matter

Stagnantliquidlayer

indiffusion

absorption

outdiffusion

Reaction

Hydrolysis

erosion

Bulk liquid phase

Biofilm Carrier media

The biofilm process

AnoxKaldnes MBBR process

The process was invented in Norway, and further developed for different applications in Norway and Sweden

The process is patented, and is only delivered by us and our licensees

Moving Bed Biofilm Reactor

The principle

Aerobic reactor

Anoxic reactor

1) Aeration in aerobic reactorsand slowly moving propellers in anoxic reactors assuremixing

2) Sieves/grids are used to retain the carriers in the reactor

3) No sludge recirculation4) Several reactors in series

may be used to developspecialized bacteria in everystage

The process is based on the biofilm principle and the heart of the process is the carriers made of polyethylene or polypropylene with a density close to that of water

The carriers are designed to give a large protected surface for the bacteria to grow on

The reactors are filled with up to 67 % of carriers

The carriers are kept in suspension in the water by aeration or mixing

The MBBR biofilm process

Bio media Sieves/Mixers Aeration

+ Design

AnoxKaldnesTM biofilm process99% Know How 1% Plastic

Key equipment

Carrier description

HDPE or HDPP with or without lime900BiofilmChip P

HDPE or HDPP with or without lime200F3

HDPE or HDPP with or without lime1200BiofilmChip M

HDPE500Kaldnes K3

HDPE, with lime500Kaldnes K1 Heavy

HDPE500Kaldnes K1

MaterialProtectedSurface areaMedia

The MBBR reactor

And inside the reactor...And inside the reactor...

When ?

Hey Perikles, can you tell

me, when canI use an

AnoxKaldnesTM MBBR

solution?

Everytime!

Where industrial applications

AnoxKaldnesTMMBBR

Solutions

BreweriesPulp Mills

Chemical industries

Dairies

Oil and Gas

Pharmaceuticalindustries

Paper Mills

Slaughteries

After existingprocesses

Where municipal applications

AnoxKaldnesTMMBBR

Solutions

In existing processes

In combination with other technologies

In cold and warmwater applications

In package plants

In almost any tank or basin

As stand-alonesolutions

Before existingprocesses

Why?

Versatile

Compact

Scalable

Why?

Robust

Simple

Tolerant to solids

Why?

Great to combine with other technologies

Perfect for upgrades

Delivered with biological expertize

MBBR as sole biotreatmentKaldnesTM, NatrixTM

MBBR as pre-treatment (roughing, BASTM)

MBBR as post-treatment(polishing, LagoonGuardTM)

MBBR in activated sludge (HYBASTM/IFAS)

How - examples?

At a fruit juice factory for removal of > 95 % COD

Simple Robust Compact Tolerant to solids Prepared for future upgrade

Activated sludgetreatment

Sludge from MBBR

Pharmaceutical industry with a toxic wastewater and a high degree of variation in the composition

AstraZeneca

AstraZeneca in Sdertlje, SwedenTreatment of pharmaceutical process wastewater

TOC degradation 75 % TOC degradation 93 % TOC degradation 98 %

AstraZeneca ABFull scale started 1997

Reactors with Fungi at AstraZeneca AB

Fungi

AstraZeneca AB 1992-1996Development work (bench scale)

Alternative MBBR configurations fornutrient removal plants

Pre-denitrification MBBRBOD/Nitrif.DN

Flocc.

NO3 recycle Secondary sep.(Primary sed.)Chem.

Post-denitrification MBBRBOD/Nitrif. DN

Flocc.

Secondary sep.Primary sed. (Chem.)Chem.

Flocc.

Carbon

Combined denitrification MBBRBOD/Nitrif. DN

Flocc.

Secondary sep.Primary sed. Chem.

CarbonNO3 recycle

DN

Example of treatment plants with AnoxKaldnesTM MBBR process technology

Lillehammer WWTP 1994 Nordre Follo WWTP 1997

Gardermoen WWTP 1998 RA2 WWTP 2004

Design data

12491936842.7- - -

12491

420579058.51802152

696371066.22301502

600384065.06008601

Plant sizePrimary sed. area (m2)Tot. MBBR vol. (m3)Avg. biofilm carrier fill (%)Flocculation vol. (m3)Final sep. area (m2)

23007200

8050209801299016202097-14

9201300

2320548032907041014-14

7501125

230059004390460- - -

6-14

12001900

2500592529007551073-14

Design valuesAvg. flow (m3/h) Max. flow (m3/h)Design loads (kg/d)BOD5CODSSTot NTot PTemp. (oC)

2003199819971994Start-up

RA-2GardermoenNordre FolloLillehammerParameter

1Sedimentation 2DAF

Design data, cont.

In Out %

84 4.0 95395 27 9330 5.0 833.8 0.05 99

In Out %

172 3.2 98681 25 9652 7.0 878.1 0.18 98

In Out %

131 2.8 98 448 39 9136 9.7 73 5.5 0.20 96

In Out %

161 2.2 99491 35 9337 2.9 925.3 0.12 98

Efficiency, 2005 Average in-out conc.andtreatment efficiency

BOD5 (mg/L)COD (mg/L)Tot N (mg/L)Tot P (mg/L)

33.02.7

methanol- - -

25.92.1

glycol2.4

14.71.2

glycol2.2

18.31.9

ethanol3.3

Chemicals consumpt.Coagulantkg PAX/kg Premovedmol Al/mol PremovedCarbon sourceg CODadded/g TNremoved

RA-2GardermoenNordre FolloLillehammerParameter

1Sedimentation 2DAF

MBBR as sole biotreatmentKaldnesTM, NatrixTM

MBBR as pre-treatment (roughing, BASTM)

MBBR as post-treatment(polishing, LagoonGuardTM)

MBBR in activated sludge (HYBASTM/IFAS)

How more examples?

The BASTM biological process

Pre-treatment in one or two high loaded MBBR steps Further treatment in an AS Used mostly for industrial wastewater, but there are also limitedmunicipal reference projects

MBBR

Activated sludge

BASProcess advantages

Effective removal of the most easily degradable organic material without creating difficult sludge Lower sludge production Simpler operation than a CAS process COD reduction in the MBBR => lower load on the AS => less volumethan a low loaded CAS with the same far-reaching COD reduction The robust MBBR protects the more sensitive AS process

At Quesnel River Pulp, Canada

Production: BCTMP Flow: 20 000 m3/d, Organic load140 000 kg COD/d Effluent discharge limits: COD, TSS, NH4-N, toxicity Pre-treatment:

Flotation Gravity clarification

Biological process 2 step MBBR process, 2 x 3000 m3, 33 % filling HRT: 2 x 3.6 h, 7.2 h total Existing activated sludge plant 53 000 m3

Post-treatment: Flotation

At Quesnel River Pulp, Canada

Results COD removal: 80-85 % with 30-50 % removal of SCOD in MBBR process BOD removal: 99 % Sludge production: 0.12-0.17 kg TSS/kg COD removed SVI: 50-100 ml/g NH4-N: < 1 mg/l

Start up

Sludge Yield

0.000

0.200

0.400

0.600

0.800

1.000

18-Ja

n-2005

28-Ja

n-2005

7-F

eb-2005

17-F

eb-2005

27-F

eb-2005

9-M

ar-2005

19-M

ar-2005

29-M

ar-2005

8-Ap

r-2005

18-Ap

r-2005

SVI

0.000

100.000

200.000

300.000

400.000

18-Ja

n-2005

28-Ja

n-2005

7-F

eb-2005

17-F

eb-2005

27-F

eb-2005

9-M

ar-2005

19-M

ar-2005

29-M

ar-2005

8-Apr

-2005

18-Apr

-2005

At Zellstoff Stendal, Germany

Production: Bleached TCF and ECF kraft pulp Flow: 48 000 m3/d, Organic load 53 000 kg COD/d Effluent discharge limits: COD, BOD, TSS, total nitrogen, total phosphorus,

AOX, EDTA Biological process

2 step MBBR process + 2 step activated sludge process Post-treatment: Gravity clarification

70-75 % removal of COD, 35-40 % in MBBR 98 % removal of BOD 98 % removal of EDTA Sludge production:

0.12 kg TSS/kg COD removed

Results

BAS-in summary

Very good treatment results Excellent sludge characteristics Very low sludge production Compact Robust

QuickTime och en-dekomprimerare

krv s f r att kunna se bilden.

MBBR as sole biotreatmentKaldnesTM, NatrixTM

MBBR as pre-treatment (roughing, BASTM)

MBBR as post-treatment(polishing, LagoonGuardTM)

MBBR in activated sludge (HYBASTM/IFAS)

How more examples?

MBBR as post-treatment

The preceeding biological system removes organic content(and nitrifies).

The tertiary MBBR system nitrifies and/or denitrifies with highly enriched and specialized bacteria.

Example: Post-nitrification Post-denitrification with external carbon source

MBBR for post-nitrificationBergamo, Italy

Bergamo wastewater treatment plant: Old plant in Italy Needed post-nitrification to further enhance the

existing biological removal Limitation in terms of footprint for the new plant

Design load: Flow: 3,200 m3/h on average BOD5: 15,700 kg/d TN: 2,600 kg/d PO4-P: 440 kg/d

MBBR for post-nitrificationBergamo, Italy

Kaldnes MBBR biofilm process chosen: Easy to install High volumetric

removal rate Due to space limitation,

reuse of two old tanks

Post-nitrification in two steps: One reactor of 1,300 m3 installed in 1999 Second reactor, also of 1,300 m3, installed in 2002 to

increase the capacity further

MBBR for post-nitrificationBergamo, Italy

No final settling tank provided after the MBBR step since biomass growth is very low in the tertiary nitrification reactors

Filling degree in MBBR reactors: 56% with Kaldnes K1

Yearly average data:

20.922.2Temp (C)7371.8% removal

3.543.64Effluent NH4-N (mg/l)13.1312.92Influent NH4-N (mg/L)20012000

MBBR for post-denitrificationMalm, Sjlunda, Sweden

Designed for 550,000 PE Existing treatment steps in Sjlunda:

Primary treatment with pre-precipitation AS plant for BOD removal Trickling filters for nitrification Post-denitrification with MBBR process Flotation as tertiary treatment

MBBR for post-denitrificationMalm, Sjlunda, Sweden

Design load: Max. Hydraulic load: 5,940

m3/h Daily denitrification capacity

of 2,000 kg NO3-N at 10C Operation of the MBBR

processes Effluent of the trickling filters

distributed to 6 parallel MBBR lines, each with 2 compartments

HRT: 80 min at average load

MBBR for post-denitrificationMalm, Sjlunda, Sweden

Plant in full operation during 2000

SS produced in the MBBR treated in a DAF

Average data:

Total N in effluent from Sjlunda

50%61

~ 0.2

Carrier filling degreeCOD added (g/m3)Sludge production (g SS/g COD)

126,0000.216.8

Flow (m3/d)Tot P effluent (mg/L)Tot N effluent (mg/L)

ValueParameter

MBBR as sole biotreatmentKaldnesTM, NatrixTM

MBBR as pre-treatment (roughing, BASTM)

MBBR as post-treatment(polishing, LagoonGuardTM)

MBBR in activated sludge (HYBASTM/IFAS)

How more examples?

Hybas: the hybrid process

HybasTM = Combination of the best from two well-known technologies: Activated sludge process MBBR biofilm process

Used to upgrade existing activated sludge when looking for: Cost effective solution New standard to achieve (Nitrogen Removal, ...) Increase capacity (Flow or loads)

Comparative Nitrification Upgrade Example

ExistingAeration

Conventional HybasTMExpanded Aeration

ModifiedExistingAeration

Hybas: Advantages

Compact technology Nitrifiers or other longer sludge age bacteria grow on carriers Less activated sludge volume

Limited amount of carriers needed Specialized biomass Easily extendable Nitrification properties remain in case of activated sludge wash-out Nitrifiers protected from incoming toxic spills Lower temperature dependence Can be used in combination with Biological Phosphorous

Removal!

The City of Broomfield needed to find a cost efficient solution to meet new effluent qualifications and increased flows

Broomfield

In competition with four other alternatives Broomfield chose to upgrade the existing process to a Hybas biofilm process.

Solution

Removal efficiency of ammonia

0%20%40%60%80%

100%

12 14 16 18 20 22 24Te m pera ture (C)

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Activated sludge only

HybasTM

0%

20%

40%

60%

80%

100%

12 14 16 18 20 22 24

Temperature (C)

P

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R

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Every plant is unique and the local conditionsmust always be taken into consideration

Incoming load? Variations? Existing plant? Effluent limits? Future?

Leading the edge in biological treatment

[email protected]