BV Webinar Slides

BUILDING A WORLD OF DIFFERENCE
Process and Practical Design Considerations for the IFAS and MBBR Technologies
Mark Steichen, P.E. Heather M. Phillips, P.E.
IFAS and MBBR Webcast March 18, 2010
Agenda Overview of IFAS/MBBR Process Design Considerations Practical Design Considerations Applications in North America Questions & Answers
Slide - 2
IFAS and MBBR Webcast
March 18, 2010
IFAS and MBBR - Whats the difference? IFAS (Integrated Fixed Film Activated Sludge)
Includes Return Activated Sludge (RAS) Fixed film & Suspended growth
MBBR (Moving Bed Bioreactor)

No RAS - Once through process Fixed film Only
Return Activated Sludge Waste Activated Sludge Waste Sludge
Slide - 3
March 18, 2010
The IFAS Advantage

(Comparative Nitrification Upgrade Example) Conventional IFAS
Existing Aeration
Expanded Aeration
Modified Existing Aeration
Suspended Growth Only
Suspended and Attached Growth
Slide - 4
March 18, 2010
Equipment Components
Media Aeration equipment
Media retention sieves
Anoxic Zone Mixers
Slide - 5
March 18, 2010
Free-Floating Media Manufacturers
Headworks (Hydroxyl)
Kruger / AnoxKaldnes
Lotepro Linpor
Slide - 6
Siemens / AGAR
Life Cycle Cost Analysis

(Activated sludge Nit/Denit Upgrade)
Millions
$80 $70 $60
NPV Cost
$50
O&M
$40 $30 $20 $10 $0 Conventional IFAS Step-Feed MBR BAF
Construction Equipment
Process Option
Slide - 7
March 18, 2010
Drivers for use of IFAS and MBBR MBBR IFAS

Site constraints or restriction Upgrade of existing activated sludge for N&P removal FC are designed for high SLR Volume limitations require both suspended and fixed film inventory Must meet stringent NH3-N limit Can integrate with Bio-P Resiliency to peak wet weather flows due to lower MLSS and SLR Severe site constraints or restrictions requiring footprint advantage of the MBBR/HRC process configuration Post nitrification and denitrification MBBR applications Client preference some clients have a preference for fixed film and are concerned with operational complexity of activated sludge, or IFAS Upgrade of trickling filter or RBC plants that have poor final clarifiers Resiliency to peak wet weather flows - very low MLSS of 200 to 300 mg/L
IFAS
MBBR
Return Activated Sludge Waste Activated Sludge IFAS and MBBR Webcast
HRC/DAF
Slide - 8
Waste Sludge March 18, 2010
Slide - 9
March 18, 2010
Slide - 10
March 18, 2010
Process Design Considerations
Slide - 11
March 18, 2010
IFAS Process Configurations

OX Media OX Media OX Media RAS
2 or 3 OX cells in series Higher kinetic rates Optimum DO control Avoid media migration
MLR AX OX Media OX Media OX Media RAS
Nitrification
IFAS is Compatible with Bio-P

MLR AN AX
OX Media
Two-Stage Nitrogen Removal

Carbon Supplementation 2nd AX OX Media
OX OX OX Media Media Media RAS
Four-Stage Nitrogen Removal

Slide - 12
March 18, 2010
Optimized IFAS MLE Configuration

Three oxic cells in series to increase efficiency Ox1 - suspended growth zone for BOD removal DO of 2.0 mg/L Ox2 media zone for nitrification DO of 4.0 mg/L to increase biofilm nitrification rate best bang-for-media $ Ox3 suspended growth polishing zone DO of 1.0 mg/L Deplete oxygen for internal recycle
MLR
Ox1 BOD Rem. DO=2.0mg/L Ox2 Media Nitr. DO=4.0mg/L Ox3 Polish DO= 1.0mg/L
AX
RAS
Slide - 13
March 18, 2010
MBBR Process Configurations

Industrial Pretreatment Reduce COD load Remove toxic compounds that could inhibit nitrification
Industrial Load OX Media
AB
RAS
Industrial Pretreatment MBBR
Nitrification Activated sludge upgrade Post nitrification and/or denitrification HRC AB

RAS OX Media DAF Actiflo/ Densadeg Cloth filter
OX Media
OX Media
Nitrification MBBR
Post Nitrification MBBR

High Rate AS
Slide - 14
MBBR Process Configurations (Cont.)

Denitrification Two-stage Four-stage Not compatible with Bio-p
Two-Stage MBBR
Waste Sludge AX Media OX Media Internal Recycle OX Media OX Media
Internal Recycle AN AX Media OX Media
Carbon Supplementation 2nd AX OX Media Waste Sludge
Four-Stage MBBR
Slide - 15
March 18, 2010
Nutrient Removal Check List

BOD Removal Biomass Air Time Nitrification Biomass Air More Time Alkalinity
Biological Phosphorus Removal Biomass (Phosphorus Accumulating Biomass) Time Soluble BOD (as VFA) Cycles of Air, No Air IFAS ONLY (currently)
Slide - 16
Denitrification Biomass No Air Time Soluble BOD
March 18, 2010
Broomfield WWRF (Colorado)

Mixed Liquor Recycle Primary Effluent
Oxic with Media Anaerobic Anoxic

To Secondary Clarifiers
FEQ Return
Mixed Liquor Recycle

RAS from Clarifiers
Phase 1 (8 mgd) - online in 2003, exceeded design expectations Phase 2 (12 mgd) under construction Reduced media fill fraction from 48% to 30% Reduced number of blowers from 3 to 2
Slide - 17
March 18, 2010
Biomass Quantification (gTSS/m2 media surface area)

2nd Anoxic 1st Anoxic 28 g/m2 13 g/m2 1st Oxic 2nd Oxic
6 g/m2 9 g/m2
South Adams County MBBR

Slide - 18
March 18, 2010
Broomfield Seasonal Attached Biomass

6,000 5,000 MLSS (mgTSS/L) 4,000 3,000 2,000 1,000
Effluent Ammonia MLSS
25 20 15 10 5 0
Temperature
0 1/1/04 4/1/04 7/1/04 9/30/04 3/31/05 6/30/05 9/29/05 3/30/06 6/29/06 12/30/04 12/29/05 9/28/06 12/28/06
Slide - 19
March 18, 2010
Effluent Ammonia (mgN/L) Temperature (C) Attached Biomass (gTSS/m2)
Attached Biomass, First Zone in Series (Oxic)
Attached Biomass, Second Zone in Series (Oxic)
30
Basic Design Parameters

Activated Sludge Hydraulic Retention Time Solids Retention Time Integrated Fixed Film Activated Sludge Combination of both Biofilms Hydraulic Retention Time Surface Area Loading Rate BOD Nitrogen
Slide - 20
March 18, 2010
Moving Bed Biofilm Reactors

Just like trickling filters, ammonia removal is a function of the BOD loading rate. Ammonia concentrations at South Adams County:
Anoxic 1: ~12 mg/L Anoxic 2: ~11 mg/L Oxic 1: ~11 mg/L Oxic 2: < 5 mg/L Oxic Oxic Anoxic Anoxic Anoxic Primary Effluent ~30 mg/L
Slide - 21
To Clarifiers
Nitrate Recycle Oxic Oxic
Anoxic
Media in the Basins

Surface Area Loading Rate vs. Removal Rate

1.50 Specific Ammonia Removal Rate (gN/m /day) 100%
1.25
80%
1.00
0.75
0.50
0.25
0.00 0.00
0.25
0.50
0.75
1.00
2
1.25
1.50
Specific Ammonia Loading Rate (gN/m /day)

Slide - 22
March 18, 2010
The Effect of BOD Loading on Effluent Ammonia
Slide - 23
Plant Effluent Ammonia (mg-N/L) MBBR Temperature (C) 10 15 20 25 30 35 40 0 12/19/03 03/18/04 06/16/04 09/14/04 12/13/04 03/13/05 06/11/05 09/09/05 12/08/05 03/08/06 06/06/06 09/04/06 12/03/06 03/03/07 06/01/07 08/30/07 11/28/07 02/26/08 05/26/08 08/24/08 11/22/08 02/20/09 05/21/09 08/19/09 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Biotower in Series with MBBR Biotower Parallel to MBBR Biotower Offline (All Flow to MBBR) 5
Temperature Approx Specific BOD Loading Rate Specific Ammonia Loading Rate Effluent Ammonia (7-d avg)
2 2
Seasonal ammonia limits: 10 24 mg/L, or Report
Specific Ammonia Loading Rate (gN/m /d) Approx. Specific BOD Loading Rate (gO /m2/d)
The Effect of Dissolved Oxygen Concentration

Biofilm Layers Boundary Layer
2,5
Bulk Liquid
Gas Layer
Ammonia removal rate (g NH4/m2/d)
2,0
Media Surface
1,5
0 0, g
D BO 1
2 /m
1,0
O
Streamer
oa cl i an rg
2 3 4 5 6 7
0,5
0,0 0 2 4 6 8 10
Oxygen concentration (mg 02/l)
Source: 2007 IWA/WEF Nutrient Removal Specialty Conference, Worskhop B (AnoxKaldnes)

Slide - 24
March 18, 2010
Residual DO vs. biofilm nitrification

Fort Myers, FL MBBR Process Model Simulation
12.0 11.0 y = 60.222x-2.4082 R2 = 0.9715
DO Sensitivity
Effluent Ammonia, mg/L
10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 0 1 2 3 4 5 6 7 8 9 10 11 12
DO, mg/L
Slide - 25
March 18, 2010
Modeling a Biofilm System

Maximum biofilm thickness Biomass per unit surface area Inert content of biofilm
Solids attaching and detaching Bulk Liquid Streamer
Biofilm Layers
Boundary Layer Gas bubbles
Media Surface
Nitrification and denitrification rates Attachment and detachment rates How do these vary in each zone?
Slide - 26
March 18, 2010
Commercial Simulators
BioWin GPS-X West Aquifas Others
GPS-X (Hydromantis)
BioWin (Envirosim)
But models must be calibrated to site-specific conditions.

Slide - 27
March 18, 2010
Demonstration, Pilot and Bench Studies

Demonstration Configure one or more treatment trains and monitor full-scale performance. Pilot Design a small-scale system to mimic full-scale performance, using plant wastewater. Bench Smaller, lab-scale
Slide - 28
March 18, 2010
Designing a Pilot System

Allow adequate startup time biofilm systems can take several weeks to reach steady state. Mimic design conditions: Coldest temperature (nitrification, denitrification). Warmest temperature (if oxygen transfer is a concern). Flow and loading conditions. Dissolved oxygen concentrations. Chemical doses. Mixing intensities, hydraulics be aware of scale-down.
Slide - 29
March 18, 2010
Mamaroneck WWTP, Westchester County, NY

How do you expand this constrained site and meet ~ 4 mg/L TN?
Screening Grit Removal Primary Sedimentation
Stacked Final Settling Tanks Sodium Hypochlorite Disinfection
Activated Sludge
Slide - 30
March 18, 2010
6+ Month Pilots of IFAS and MBBR

Aeration System
Sodium Bicarbonate
Dissolved Air Flotation

M
Primary Effluent Feed From WWTP Intermediate Wet Well
FM
Feed Pump No. 1
R1
R2
R3
MBBR PROCESS (TRAIN NO. 1)

Aeration System
Sodium Bicarbonate
Feed Tank With Screen
Clarifier Unit
M M
Methanol
FM
To Drain
Feed Pump No. 2
R4
FM
R5
R6
Post Aeration
Waste Sludge
IFAS PROCESS (TRAIN NO. 2)

March 18, 2010
Slide - 31
MBBR with Post-Denitrification during the Last Month

Primary Effluent Feed From WWTP Intermediate Wet Well
Aeration System
Sodium Bicarbonate
Methanol
M
Feed Tank With Screen
To Drain
Feed Pump No. 1
R1
R2
R3
R6
Post Aeration
Clarifier Unit
Slide - 32
March 18, 2010
Major Findings
Both IFAS and MBBR pilots achieved < 4 mg/L TN. Temperature = 11C Hydraulic retention time = 3 hours First pilot study to test media in the anoxic zone of an IFAS system. Presence of media effectively doubled the denitrification rate using methanol. Phased implementation design complete. Phase 1: IFAS using existing clarifiers. Phase 2: MBBR using some of the existing clarifier volume as MBBR; dissolved air floatation
Slide - 33
March 18, 2010
Summary of Process Design Considerations

Surface area is the key. Specific loading rates: BOD NH3N NO3N
Plastic Trickling Filter Media (30 ft2/ft3) Rock Trickling Filter Media (15 ft2/ft3)
Slide - 34
Design criteria depends on desired removal rate (permit limits)
IFAS & MBBR Media (152 ft2/ft3)
March 18, 2010
Practical Design Considerations
Slide - 35
March 18, 2010
Practical Design Considerations Screening requirements Aeration system design Media retention sieves Approach velocities Foam and scum removal Maintenance provisions
Slide - 36
March 18, 2010
Screening Requirements
Purpose Remove materials that could entangle media or plug media retention sieves Design guideline 6 mm with primary treatment 3 mm without primary treatment Media size and shape should be considered
Slide - 37
March 18, 2010
Aeration system design

Multiple Functions Process air Mixing Sieve cleaning Fine or coarse bubble can be used Low maintenance requirements High structural integrity Oxygen transfer efficiency (OTE) is affected by: Diffuser type and arrangement (diffuser density, lateral spacing, airflow/diffuser, etc.) Media fill fraction Design for higher DO residual
Slide - 38
March 18, 2010
Aeration System Optimization

Consider summer versus winter operation
DO Sensitivity
Winter
Effluent Ammonia, mg/L
12.0 11.0 y = 60. 2 R =
Biofilm nitrification rates are low Consider higher DOs (4 to 5 mg/L) to reduce media requirements Summer Biofilm nitrification rates are high Consider lower DOs (2 to 3 mg/L) to reduce airflow and energy requirements
10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 0 1 2 3 4 5 6 7 8 9 10
DO, mg/L
Slide - 39
March 18, 2010
Media Retention Sieves

Types Cylindrical Wall Cylindrical sieves preferred for oxic zone Self cleaning Cylindrical sieve design criteria 2 inch headloss at peak flow HLR = 24 gpm/sf 1.5 fps recommended max velocity through wall orifice to control headloss Typical diameters (12 & 16 inch) Typical lengths (5, 10, & 12 feet )
Slide - 40
March 18, 2010
Media retention sieves (Cont.)

Media retention sieves also required for Dewatering ports Basin overflows Control media creep
Media creep at SAC
Basin overflow sieve at Broomfield
Slide - 41
March 18, 2010
Anoxic media zones

Use wall sieves, not cylindrical cylindrical sieves can disrupt mixing pattern Air knife is required Operates only a few minute per day Mixers Slow speed submersible (Landia, EMU, ABS) Impeller designed to protect media Mixing energy 0.75 to 0.95 bhp/kcf Locate to create spiral roll Other possible mixer types Vertical bridge mounted Hyperclassic Invent Enersave mixer
Slide - 42
March 18, 2010
Sieve Approach Velocity

Approach velocity Flow (Q+RAS+MLR)/Basin Cross-Sectional Area Leads to Media stack-up around sieves Potential problems Increased sieve headloss Erratic OURs due to poor media distribution Suggested maximum design criteria 30 to 35 m/hr typical maximum
Stack-Up
Slide - 43
March 18, 2010
Strategies to Reduce Approach Velocity and Avoid Media Stack-Up

Reduce basin length to width ratio < 4:1 if possible Increase mixing energy under sieves Reduce MLR during peak flows Use longer sieves, in multiple rows Include media return airlift pump Spiral roll aeration design More cells in series
Slide - 44
March 18, 2010
Example of How to Minimize Approach Velocity to Avoid Media Stack-up in a Plug Flow Reactor (Oxford, UK)
Media Zone Inlet Channel Gate to pass scum AX Ox1 BOD Rem. Ox1 Ox2 - Media Ox3 - polishing Ox3 - polishing Ox2 - Media AX Ox1 Ox1 BOD Rem.
Slide - 45
March 18, 2010
Foam and Scum Control

Design/operate to reduce foaming potential Avoid excessively long SRTs and over aeration Eliminate low DO areas Balance sidestream loads Avoid low alkalinity and pH Provide 2 to 3 ft of basin freeboard Chlorinated surface sprays
Slide - 46
Chlorinated sprays are controlling foam in Broomfield and Cheyenne
Foam suppression spray system
March 18, 2010
Maintenance Provisions
Design hydraulics for one train out-of-service Media shuffle plan for taking basin off-line Media storage Media transfer pumps Biofilm integrity during storage? Odors during storage?
Slide - 47
March 18, 2010
Applications of IFAS/MBBR in North America
Slide - 48
March 18, 2010
Yucaipa, California
Background Original plant Primary clarifiers Trickling filter activated sludge (TF/AS) process IFAS upgrade Expansion from 4 mgd to 8 mgd TIN of 6 mg/L 4-stage nit/denit configuration
Slide - 49
March October 18, 10-14, 2010 2009
Primary Clarifiers and Converted Trickling Filters
Primary Clarifiers
Converted Rock TF to Anoxic Volume
Slide - 50
March October 18, 10-14, 2010 2009
IFAS Basins and Secondary Clarifiers

IFAS Basins New Secondary Clarifiers Post Anoxic
Slide - 51
March October 18, 10-14, 2010 2009
Moorhead, Minnesota
Background First MBBR facility in North America using buoyant plastic media MBBR for tertiary nitrification following HPOAS
Slide - 52
4.7 mgd ave. design flow
March 18, 2010
Nitrification MBBR
Chlorination Dechlorination Anaerobic Digesters Final Clarifiers Primary Clarifiers HPOAS
Slide - 53
March 18, 2010
Construction of Moorhead MBBR
Low cost construction
Media retention sieves

Slide - 54
March 18, 2010
Headworks (Hydroxyl)
Slide - 55
March 18, 2010
-31F -35C
Slide - 56
March 18, 2010
Fort Myers, Florida
Background Green field water reclamation facility 12 mgd design average flow Irrigation and deep well injection Nit/Denite MBBR TN < 10 mg/L BOD < 10 mg/L TSS < 5 mg/L
Slide - 57
March 18, 2010
Slide - 58
March 18, 2010
MBBR/DAF Process Configuration

(Fort Myers East WRF)
IR Pumping
Sludge Dewatering
Dissolved Air Flotation
Influent
AX
AX
OX
OX
OX
Disk Filter
MBBR Process
Slide - 59
March 18, 2010
Slide - 60
March 18, 2010
Bundamba Advanced WTP Flow Schematic

Disinfection (NH4 + NaOCl) Ferric
Diurnal Flow Pre-Treatment EQ/storage
Sodium Bisulfite and Antiscalant
Lime, Carbon Dioxide, NaOCl
MF
RO
UV/H2O2
Secondary Effluent
Polymer
Treated Water Storage
Gravity Thickener
RO Brine
Power Plants Wivenhoe Dam
Slide - 61
March 18, 2010
Slide - 62
March 18, 2010
Slide - 63
March 18, 2010
Questions and Discussion
Slide - 64
March 18, 2010

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BUILDING A WORLD OF DIFFERENCE

IFAS and MBBR Webcast

March 18, 2010

MBBR (Moving Bed Bioreactor)

Return Activated Sludge Waste Activated Sludge Waste Sludge

IFAS and MBBR Webcast

March 18, 2010

The IFAS Advantage

Modified Existing Aeration

Suspended Growth Only

Suspended and Attached Growth

IFAS and MBBR Webcast

March 18, 2010

Media retention sieves

Anoxic Zone Mixers

IFAS and MBBR Webcast

March 18, 2010

Free-Floating Media Manufacturers

Life Cycle Cost Analysis

IFAS and MBBR Webcast

March 18, 2010

Drivers for use of IFAS and MBBR MBBR IFAS

Waste Sludge March 18, 2010

IFAS and MBBR Webcast

March 18, 2010

IFAS and MBBR Webcast

March 18, 2010

BUILDING A WORLD OF DIFFERENCE

Process Design Considerations

IFAS and MBBR Webcast

March 18, 2010

IFAS Process Configurations

IFAS is Compatible with Bio-P

Two-Stage Nitrogen Removal

OX OX OX Media Media Media RAS

Four-Stage Nitrogen Removal

IFAS and MBBR Webcast

March 18, 2010

Optimized IFAS MLE Configuration

IFAS and MBBR Webcast

March 18, 2010

MBBR Process Configurations

Industrial Pretreatment MBBR

Nitrification Activated sludge upgrade Post nitrification and/or denitrification HRC AB

Post Nitrification MBBR

MBBR Process Configurations (Cont.)

Internal Recycle AN AX Media OX Media

Carbon Supplementation 2nd AX OX Media Waste Sludge

IFAS and MBBR Webcast

March 18, 2010

Nutrient Removal Check List

Denitrification Biomass No Air Time Soluble BOD

IFAS and MBBR Webcast

March 18, 2010

Broomfield WWRF (Colorado)

Oxic with Media Anaerobic Anoxic

Mixed Liquor Recycle

IFAS and MBBR Webcast

March 18, 2010

Biomass Quantification (gTSS/m2 media surface area)