2 05MasteringMBBRprocessdesignforcarbonandnitrogenabatement

Mastering MBBR process design
for carbon and nitrogen abatement

« Moving Bed Biofilm Reactor »
by Robert Lafond*, D.Lamarre*,
A. Gadbois*, C. Johnson †
* John Meunier Inc.
†Anox Kaldnes
Presented at the BC WWA Annual

Conference and Exposition,
April 27th-30th 2008, Whistler (BC)
Outline of presentation
 MBBR AnoxKaldnes / VEOLIA historical

Expertise
 MBBR technology
MBBR technology and description
Dimensioning
 BOD removal & nitrification pilot

Municipal BOD removal and Nitrification
Quebec pilot nitrification in cold water ( 5oC)
 Conclusion
MBBR technology historical
 MBBR technology is the combination of conventional

activated sludge and biofilter technology
MBBR:
Conventionnal Biofilter:
activated sludge:
Moving Static fixed
Free biomass fixed biomass
biomass
 1986 Anox founded at Lund University (Sweden),

R&D
 1989 Kaldnes founded to commercialize the MBBR

technology
Technical University of Trondeim ( Norway )
 2003 Anox acquire Kaldnes to create….

AnoxKaldnes Group
This new group will commercialize and
promote the MBBR technology
MBBR Historical
 Technical center:
Focus on biological
treatment using MBBR
technology manufacturing
by AKI
Sweden, Norway
 More than 80 employees

8 PhD , 20 Masters ,
MBBR historical
AnoxKaldnes group is acquired

at 100% in 2007
by
 MBBR was developed to give a solution for retrofit

application of WWTP
 MBBR was designed to increase the capacity and lower

the effluent requirement of an existing WWTP
 MBBR application are:

1. BOD removal
2. Ammonia removal
3. Pre- and/or Post Denitrification
4. IFAS process (HYBAS™)
Some Anox Kaldnes projects around the world
Type: 63 Plants for BOD Removal

10 Plants for BOD Removal & Nitrification
9 Plants for Post-Denitrification
18 Plants for Total Nitrogen Removal
10 Plant for Nitrification (HYBASTM)
Size: 10 Plants - 20 - 80 MGD (75,700 m3/d - 151,400 m3/d)

12 Plants - 4 - 10 MGD (15,140 m3/d - 37,850 m3/d)
27 Plants - 1 - 4 MGD (3,785 m3/d - 15,140 m3/d)
61 Plants - < 1 MGD (< 3,785 m3/d)
MORE THAN 500 INSTALLATIONS AROUND THE WORLD

MBBR technology
MBBR
Equipment
MBBR technology: Equipment
 Media
 Aeration grid
 Sieve (media screen)
 Blowers
MBBR ™ Technology Moving Bed™ Biofilm Reactor
• The process is based on the biofilm principle.

The core of the process is the biofilm carrier
elements made from polyethylene .
• Media material is made of virgin polyethylene
with a density similar of water ( 0,94 à 0,96).
 The biofilm carrier elements are being kept
suspended and in continuous movement in the
water by aeration.
• The carriers are designed to provide a large
protected surface for the micro-organisms and
a good mass transfer.
MBBR media : Media functions
 Good support of biomass

 Facilitate the wastewater flow through the
media
 Protect biomass, mainly nitrifiers, to increase
the process removal efficiency
 Fill percentage of 67% max.
MBBR media: Media functions
Biomass support
Flow trough media
Protect biomass
MBBR technology: media
 K 1 TM : 500 m²/m³
10 mm Ø x 7 mm
 K 3TM : 500 m²/m³

25 mm Ø x 9 mm
 BioChip PTM : 900 m²/m³

48 mm Ø x 2 mm
 NatrixTM : 200 m²/m³

44 mm Ø x 36 mm
MBBR technology: aeration grid
- Zero maintenance
- Anchored and supported in the basin
- Mixing of media at 67% fill (maximum conditions)
- In-Field Oxygen transfer comparable to fine bubble aeration
- Stainless steel for durability
MBBR technology: sieve
Fixed-in place stainless steel

sieve assemblies. Designed for
2 inch’s head loss per reactor at
peak hydraulic flows.
MBBR technology
BOD removal & Nitrification

Application Areas
Application Areas
1. Carbon removal
2. Ammonia removal
3. Pre- and/or Post Denitrification
4. IFAS process (HYBAS™)
Application Areas: Carbon Removal
 BOD/COD Removal
• Greenfield project, requiring complete treatment, where space
limitations are a factor.
Complete Treatment
Application Areas: Carbon Removal
BASTM Process
1) MBBR operated as Flow-Through Process (No RAS)

2) MBBR will be used like a Roughing Reactor to reduce significantly
the BOD concentration (70% to 80%)
Application Areas: Nitrification
 Ammonia Removal
• Greenfield or cold temperature projects where nitrification is
needed and space is a factor,
Application Areas : Lagoon Guard™
 After a lagoon which performs BOD removal and

limits upgrade.
MBBR reactors will be installed after lagoon #1 to :
- optimize ammonia removal
- and increase BOD removal
Aerated Aerated
Lagoon #1 Lagoon #2
Application Areas: Pre- and/or Post
Denitrification
Pre-Denitrification of re-circulated nitrate

rich wastewater using influent soluble BOD
for carbon source.
Post-Denitrification with addition of carbon

source (methanol, ethanol, glycol) for Dilute
Wastewater.
Application Areas
Denitrification IFAS
COD
HYBASTM (IFAS) System HYBASTM (IFAS) System

with Pre DN (Anoxic Zone) with Post DN (Anoxic Zone)
COD
HYBASTM (IFAS) System with Pre & Post-DN (Anoxic Zone)

Outline of presentation
 MBBR AnoxKaldnes / VEOLIA historical

Expertise
 MBBR technology
MBBR technology and description
Dimensioning
 BOD removal & nitrification pilot
Municipal BOD removal and Nitrification
Quebec pilot nitrification in cold water ( 5oC)
 Conclusion
MBBR design…
How are the MBBR reactors designed ?
 Determine the removal rate per specific media

surface for BOD and ammonia.
SALR: Surface Area Loading Rate

MBBR design
SALR value is determined with pilot test results using

the same media in similar conditions.
Main parameters to be modified during the tests will be:
 Flow and concentration

 Media volume in reactor (total media surface)
 Water temperature
Anox Kaldnes performed more than 75 pilots in Europe

and North America.
MBBR design
With pilot test results , we will determine the removal rate

per reactor
Removal rate for MBBR #1
Removal rate =
(C in – Cout) x Flow
Spec. Surface of media
50 % SALR =
(C in ) x Flow
Spec. surface of média
Importance of field data when designing !

Ammonia and BOD removal
Application
Broomfield (Colorado)
 Municipal : 30,000 m3/day

 Ammonia effluent requirement < 1 mg/l
 Ammonia influent = 37 mg/l

 COD = 310 mg/l
 BOD (t) = 146 mg/l
 TSS = 98 mg/l
 Media: K1
 Two reactors in series: Nit - Nit
Reactor Volume (L) Fill %
#1 Nitrification 660 40%

Aerated

Aerated
 Nitrification ; Reactor #1 and #2
• Hydraulic Retention Time (HRT); 1,2 to 2,9 hours

• Water temperature between 12o to 18o C
• Completely mix reactor
Complete nitrification after pilot equilibrium
01/12/2000
5/04/2001
88%= 1.15 / 1.30

40%= 1.42/3.55
Reactor #1
Reactor #2

Broomfield WWTP – Influent Data
Month, Year Influent Total Alkalinity
Flow TSS BOD5 NH3-N NO3-N NO2-N Total P PO4-P (as CaCO3) Temp
(MGD) mg/L mg/L mg/L mg/L mg/L mg/L mg/L mg/L ( C)
July-03 4.73 349.70 185.30 30.71 2.57 2.17 7.02 1.39 246.00 20.63
August-03 4.85 321.81 195.86 32.15 2.74 2.42 6.62 1.66 238.00 21.61
September-03 4.76 337.59 202.32 33.61 2.81 2.17 7.38 1.39 245.20 21.11
October-03 4.48 464.50 221.38 35.16 3.44 2.75 8.38 1.78 244.25 19.98
November-03 4.35 337.33 218.90 33.85 3.81 2.80 7.32 1.27 230.75 17.80
December-03 4.09 322.13 216.83 33.76 3.80 Ammonia conc. between
2.77 7.12 1.79 229.40 15.93
January-04 4.28 308.10 206.86 34.88 4.18 2.88 7.36 2.64 204.25 14.62
February-04 4.34 286.71 202.38 35.88 4.36 28,4 to 44,3 mg/l
3.18 7.35 1.57 214.50 14.21
March-04 4.25 376.22 217.35 37.00 4.09 3.03 7.72 2.27 225.40 15.32
April-04 4.52 406.29 223.05 34.83 3.44 2.71 8.56 1.81 234.00 16.18
May-04 4.59 422.77 221.23 36.39 2.99 2.31 8.39 0.93 241.00 17.91
June-04 4.58 421.05 187.73 32.92 2.23 2.10 7.70 1.10 245.00 19.50
July-04 4.90 420.32 188.24 28.41 1.96 2.19 7.12 0.82 242.00 20.77
August-04 5.06 370.22 192.05 29.66 1.72 1.81 6.91 0.92 244.25 21.51
September-04 4.93 368.82 224.00 32.27 1.72 2.04 6.95 1.18 243.33 21.02
October-04 4.93 299.29 226.62 34.48 2.21 1.84 7.66 1.37 249.00 19.80
November-04 4.56 309.82 200.45 36.48 2.57 3.01 7.67 1.86 242.20 17.11
December-04 4.49 315.23 217.14 36.52 2.97 3.45 7.29 1.98 254.50 15.25
January-05 4.37 374.32 201.27 40.43 3.17 3.45 8.24 3.87 297.00 14.27
February-05 4.38 368.21 214.53 40.59 3.25 2.63 9.66 5.05 283.00 14.13
March-05 4.41 380.12 199.60 39.07 3.25 2.88 8.61 3.67 284.00 14.87
April-05 4.75 323.20 169.05 44.30 2.00 1.72 7.90 4.29 274.50 15.85
May-05 4.89 375.57 189.57 34.29 1.87 2.38 9.97 4.67 301.00 17.03
June-05 5.18 372.09 203.32 39.46 0.06 0.12 9.86 4.75 303.40 18.59
July-05 4.83 379.29 197.57 31.08 0.11 0.15 9.50 3.79 254.50 20.81
August-05 5.25 428.22 204.57 29.46 0.06 0.08 8.74 3.10 246.60 21.58
September-05 5.07 419.41 210.82 30.10 7.58 3.08 251.25 21.26
October-05 5.53 344.74 185.65 31.12 7.00 2.89 262.50 19.75
November-05 5.10 292.09 213.36 34.89 9.04 4.93 296.80 18.06
December-05 4.93 285.26 220.43 37.88 10.56 6.77 273.50 15.68
January-06 4.75 375.76 232.29 38.27 12.38 7.22 255.75 15.16
February-06 4.49 373.37 218.10 35.50 8.69 3.51 250.75 14.09
March-06 4.31 313.82 221.91 41.88 9.06 4.25 256.60 14.35
April-06 4.47 375.76 229.17 39.02 9.98 5.11 258.50 15.83
Broomfield WWTP – Effluent Data
Month, Year Total
TSS BOD5 NH3-N NOX-N Total P PO4-P Temp
mg/L mg/L mg/L mg/L mg/L mg/L ( C)
July-03 2.37 2.58 0.25 7.16 0.15 0.01 20.63
August-03 2.74 1.60 0.17 6.80 0.74 0.48 21.61
September-03 2.55 2.23 0.18 5.78 1.69 0.99 21.11
October-03 2.96 2.66 0.25 6.33 1.53 0.90 19.98
November-03
December-03
2.63
4.11
1.62
1.88
0.22
0.25
7.70
8.62
Ammonia conc. between
1.12
1.42
0.56
1.01
17.80
15.93
January-04
February-04
5.73
4.96
2.75
2.33
0.77
0.95
10.48
9.28
0.11 to 0.25 mg/l
1.37
1.17
1.15
0.55
14.62
14.21
March-04 3.25 2.24 1.02 9.33 2.15 1.45 15.32
April-04 5.58 2.36 0.32 6.78 1.25 0.80 16.18
May-04 4.00 1.85 0.23 7.20 0.18 0.01 17.91
June-04 3.64 1.72 0.16 7.20 0.29 0.08 19.50
July-04 3.70 1.78 0.26 6.15 0.24 0.03 20.77
August-04 2.85 1.91 0.16 5.79 0.23 0.05 21.51
September-04 3.12 1.62 0.17 5.77 0.16 0.03 21.02
October-04 2.22 1.68 0.14 5.93 0.58 0.38 19.80
November-04 3.33 1.67 0.16 7.55 0.48 0.29 17.11
December-04 4.48 2.13 0.17 7.65 0.78 0.46 15.25
January-05 4.93 2.19 0.17 8.21 1.04 0.71 14.27
February-05 5.91 2.66 0.25 8.26 2.63 2.03 14.13
March-05 4.85 2.21 0.25 7.20 1.18 0.87 14.87
April-05 4.92 2.34 0.41 8.03 0.79 0.46 15.85
May-05 4.08 2.51 0.26 8.37 1.48 1.19 17.03
June-05 2.57 2.43 0.14 11.56 1.33 1.11 18.59
July-05 2.54 2.10 0.18 10.89 1.54 1.50 20.81
August-05 3.32 2.10 0.16 11.70 1.17 0.92 21.58
September-05 3.09 1.88 0.11 10.78 0.44 0.38 21.26
October-05 3.76 1.93 0.10 11.42 1.31 1.34 19.75
November-05 4.87 3.33 0.19 12.85 2.43 2.06 18.06
December-05 6.20 3.57 0.21 10.80 1.81 1.18 15.68
January-06 5.87 3.94 1.21 1.83 1.31 15.16
February-06 5.36 3.58 0.04 11.20 1.79 1.42 14.09
March-06 8.17 4.33 0.52 11.78 3.12 2.38 14.35
April-06 7.30 3.00 0.18 12.28 2.05 1.68 15.83
Nitrification in cold water
Ste-Julie WWTP
(Québec)
Ste-Julie (Québec)
 Large increase of city population

 No space available for additional lagoon
 Government effluent requirement more stringent
during winter season
Anox Kaldnes realized pilot study to

demonstrate BOD and nitrogen removal with
Lagoon Guard™ technology.
Ste-Julie Lagoon Guard ™ Pilot
 Lagoon Guard™ pilot installed at the outlet of

lagoon #1
 Lagoon #1 will reduce significantly BOD before

MBBR and will increase the nitrification efficiency.
o
 Temperature influent of MBBR reached 4 C
during test pilot
Lagoon Guard™
 Ammonia = 16 mg/l
 COD = 191 mg/l
 BOD = 63 mg/l
 Media: K1
 Two reactors in series : BOD - Nit
Reactor Volume (L) Fill %
#1 DBO 590 67%

Aerated

Aerated
Ste-Julie Pilot
October 2004 January 2005

BODt reduction
 Reactor #1 : BODt reduced by 25%

25%

Nitrification
 Reactor #2 : Nitrification at 60%
 Reactor #1 + Reactor #2: More than 78% of nitrification

60%

Ste-Julie Lagoon Guard ™ installation
 Following those successful results of pilot study, the city

of Ste-Julie installed one (1) Lagoon Guard™ reactor for
BOD removal only between lagoon #1 and #2.
 Lagoon Guard™ #2 for nitrification (Phase 2), will be

finalized later.
 Civil works of Lagoon Guard™ #2 are done at the same

time. In the future they will only have to add aeration
grids and media.
MBBR REACTORS
Nitrification in cold water
Where are we?
 MBBR pilot this winter to determine nitrification
rate in cold water (less than 5oC) on a long term
period (4 continuous weeks)
 Pilot test was realized at the effluent of lagoon
#1 at Terrebonne (Quebec).
 Typical conditions of aerated lagoons facility in
cold climate.
 Pilot test will be finished at the end of the month
of April
MBBR Pilot in cold water
Aerated
lagoons
Qavg = 30 000 m3/d
HRT = 15 days
• John Meunier Inc Pilot MBBR / Biostyr®

• Design for operation at -30°C and winds of 100 km/hr
• Qunit = 300 l/hr
Biostyr
Pilot
Influent pilot
MBBR
Reactor 2
Reactor 1
Volume = 300 L / reactor

Anox Kaldnes media K3
% Fill 50 %
• Preliminary results are very interesting.

• MBBR nitrification efficiency is good (< 5 oC)
• Ammonia effluent less than 5 mg/l all the time during equilibrium
of the MBBR
• Data are still being analyzed, full report will be available soon.
Conclusion
 MBBR is a recent and novel technology for municipal and industrial

wastewater treatment plant
 MBBR technology is very efficient for BOD and ammonia removal

for municipal and industrial application.
 Importance of field data to predict with Anox KaIdnes media the

overall efficiency for BOD removal and nitrification.
 Anox Kaldnes has more than 500 installations worldwide
 Pilot tests of nitrification in municipal cold water (< 5oC) with

promising results (ammonia effluent less than 5 mg/l)
QUESTIONS ?
Robert Lafond, P.Eng.

John Meunier Inc.
4105 Sartelon, Ville St-Laurent (QC), CANADA, H4S 2B3
RLafond@johnmeunier.com

2 05MasteringMBBRprocessdesignforcarbonandnitrogenabatement

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2 05MasteringMBBRprocessdesignforcarbonandnitrogenabatement

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Mastering MBBR process design

for carbon and nitrogen abatement

Presented at the BC WWA Annual

 MBBR AnoxKaldnes / VEOLIA historical

 BOD removal & nitrification pilot

 MBBR technology is the combination of conventional

 1986 Anox founded at Lund University (Sweden),

 1989 Kaldnes founded to commercialize the MBBR

 2003 Anox acquire Kaldnes to create….

 More than 80 employees

AnoxKaldnes group is acquired

 MBBR was developed to give a solution for retrofit

 MBBR was designed to increase the capacity and lower

 MBBR application are:

Type: 63 Plants for BOD Removal

Size: 10 Plants - 20 - 80 MGD (75,700 m3/d - 151,400 m3/d)

MORE THAN 500 INSTALLATIONS AROUND THE WORLD

 Sieve (media screen)

• The process is based on the biofilm principle.

 Good support of biomass

Flow trough media

 K 3TM : 500 m²/m³

 BioChip PTM : 900 m²/m³

 NatrixTM : 200 m²/m³

Fixed-in place stainless steel

BOD removal & Nitrification

1) MBBR operated as Flow-Through Process (No RAS)

 After a lagoon which performs BOD removal and

Pre-Denitrification of re-circulated nitrate

Post-Denitrification with addition of carbon

HYBASTM (IFAS) System HYBASTM (IFAS) System

HYBASTM (IFAS) System with Pre & Post-DN (Anoxic Zone)

 MBBR AnoxKaldnes / VEOLIA historical

How are the MBBR reactors designed ?

 Determine the removal rate per specific media

SALR: Surface Area Loading Rate

SALR value is determined with pilot test results using

 Flow and concentration

Anox Kaldnes performed more than 75 pilots in Europe

With pilot test results , we will determine the removal rate

Importance of field data when designing !

 Municipal : 30,000 m3/day

 Ammonia influent = 37 mg/l

 Two reactors in series: Nit - Nit

Reactor Volume (L) Fill %

#1 Nitrification 660 40%

#2 Nitrification 660 56%

 Nitrification ; Reactor #1 and #2

• Hydraulic Retention Time (HRT); 1,2 to 2,9 hours

Complete nitrification after pilot equilibrium

88%= 1.15 / 1.30

Importance of field data when designing !

 Large increase of city population

Anox Kaldnes realized pilot study to

 Lagoon Guard™ pilot installed at the outlet of

 Lagoon #1 will reduce significantly BOD before

 Two reactors in series : BOD - Nit

Reactor Volume (L) Fill %

#1 DBO 590 67%

#2 Nitrification 590 58%

October 2004 January 2005

 Reactor #1 : BODt reduced by 25%