Jaeger Group of Companies

Energy efficiency and capacity increase for aerobic treatment

Delivering customer value

based on
 40 years experience in
fine bubble aeration
 20 years innovation in
IFAS textile fixed bed
technology
40 Years of Innovation: Rubber. Jäger. Diffuser.

 At the beginning of the 1970’s aeration

systems did not longer meet the
requirements of waste water treatment
entirely.
 So Arnold Jäger developed cooperating with
the leading German wastewater treatment
plants the first rubber membrane diffuser.
 Since 1975, Gummi-Jäger produced more
than 40 Millions membranes and diffusers
 Arnold Jäger and his sons took out more
than 30 patents on aeration technology in
Europe and the USA.
 The R&D team of the Jaeger Group
perpetually works to improve the aeration
technology. „

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 2
We grew up with rubber

 Since 1942 application-oriented advisory

service, material-oriented construction and
system related development are the key for
the Jäger Group’s success.
 Our competence and efficiency continuously
raised according to the customers’ demands.
 Our success is based on continuous product
innovation, advice independent from the
material as well as a friendly, competent
service and zero-defect philosophy
competent service.
 The family business in its 3rd generation
operates worldwide and is a qualified partner
in the field of automotive, environmental and
agricultural industry as well as in machine
and plant engineering and crude oil
exploration.
© Jäger Umwelttechnik GmbH
25.02.2015 / Slide 3
Global presence in niche markets

Mechanical Engineering Automotive Waste Water Treatment Agricultural Technology

Renewable Energy Exploration Technology

© Jäger- Unternehmensgruppe
25.02.2015 / Page 4
 Facts & Figures of the “Waste Water” group 2012

Jäger Umwelt-Technik GmbH & Co. KG

Sales 5 Mio. Euro

Staff 7 Environmental Engineers

2 Sales & Marketing
10 Manufacturing staff
Locations Hannover (HQ) Germany
Vienna Austria
Bangkok Thailand
22 partners worldwide

Jäger Rubber & Plastics /(Shenzhen) Ltd.

Sales 3 Mio. Euro

Staff 3 Environmental Engineers

10 Sales & Marketing
25 Manufacturing Staff
Locations Shenzhen (PRC)

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 5
Characterization of wastewater

„normal“
inflow and  „normal
Load“ (e.g.
„normal“ Dryweather)
Concentration

Low inflow
 Low Load
and low (e.g. Nights)
Concentration

High inflow
 High Load
and high (e.g. Surg)
Concentration

high inflow  „normale

and low Load“ (e.g.
Concentration Rain Weather)

© Cleartec Water Management GmbH

25.02.2015 / Seite 6
Energy efficiency and capacity increase

IFAS (integrated fixed film activated sludge) textile fixed bed

combined with

Ultra fine bubble aeration

© Cleartec Water Management GmbH

25.02.2015 / Slide 7
WWTP – Flow Chart

25.02.2015 / Slide 8
WWTP - Biological Stage

C N
N

C
N

C N

C
C
N N
N

Conventional Activated Sludge Tank with suspended Biomass

Suspended heterotrophe Suspended autotroph

(for C-Elimination) (for Nitrification)
© Cleartec Water Management GmbH
25.02.2015 / Seite 9
IFAS – Explanation

IFAS process (Integrated Fixed Film Activated Sluge) Activated

Sludge tank with Cleartec System
suspended combined with sessile biomass
© Cleartec Water Management GmbH
25.02.2015 / Seite 10
IFAS textile fixed bed combined with ultra fine bubble aeration

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 11
Cleartec – a closer look

1 Growth stripes

2 Biofilm, sessile biomass

3 Flexibility

4 removal of old biomass

5 bacterial metabolism processes

6 aeration

7 vertical flow

8 suspended biomass

© Cleartec Water Management GmbH

25.02.2015 / Slide 12
Textile fixed bed: 2 basic materials

 3-dimensional BioCurlz
 6 laces per unit
 Specific surface:
32m²/m²

 2-dimensional BioTextile
 flat woven fabric
 Specific surface:
23m²/m²

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 13
2-dimensional Cleartec - fabric

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Slide 14
3-dimensional BioCurlz

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Slide 15
 IFAS Cleartec Biotextile (1)

 Significant expansion (up to 100%) with little

or no additional aerobic volume
 Increased Biological Nutrient Removal
(BNR)
 Improved solids settling (typical SVI’s less
than 80)
 Greater resistance to hydraulic solids washout
 Increased resilience to shock loading
 Reduced solids flow to clarifiers, increasing
clarifier capacity
 Up to 50% less energy than other
MBBR/Moving Bed IFAS systems
 MBBR: OC 4-6 mg/l
 Cleartec: OC <2 mg/l

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 16
IFAS impact on FST

Sludge from convantional AST Sludge form IFAS AST

SVI 120 - 150 SVI 70 – 100

Normal settlement of Sludge Faster settlement, more

sludge can be returned in less
time
© Cleartec Water Management GmbH
25.02.2015 / Seite 17
 Comparison MBBR vs. Cleartec IFAS technology
MBBR Cleartec® textile installed in SS
The nature of the Cleartec Moving bed reactor frames with integrated aeration

fixed-bed system results in Technical

Material
small moving polymer carriers,
cylindrical shaped, foamed
Polypropylen filaments woven to 3D
laces or2D fabric
effective treatment without the description
Installation movable, free floating
flexible, fixed cages with integrated
aerators
concerns associated with
moving bed systems. Type of aerators coarse - fine bubble fine - mirco fine bubble

Aeration system
High, high airflow required to prevent Low, low airflow to control thickness of

 No Media Migration in Energy consumption settlement of carriers

OC > 5 mg/l
biofilm
OC 1,2 - 1,8 mg/l
basins or Media Loss into Installation fixed, bottom mounted
retrievable, integrated in cages, can be
lifted easy
the discharge waters dewatering of tank and separation of
cages with textile & aerators can be
Maintenance lifted aside the tank, easy & safe access
media required
 No Additional Aeration to aerators

Energy required for Specific surface for biomass

settlement
up to 1.200 m²/m³ 600 - 1.000 m²/m³

Mixing Volume displacement of

fixed bed
high (70% ) very low (<10%)
Process description

 No requirement for fine Energy consumption high low

screening middle - high high

High resistance agains hydraulic shock

agglomeration of carriers at outlet
 No degradation to sludge Process stability (downstream)
load
resistant against clogging / 3D perfusion
fine screen required
settle ability additional clarifier capacity required
Improved slude settlement velocity/no
additional clarifier capacity required

Investment costs low middle

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 18
Upgrade of WWTP Geiselbullach, Munich Germany (1)

 TYPE OF WWTP Municipal

 MAXIMUM FLOW 80. 000 m³/d
 CAPACITY 250. 000 PE
 BIOLOGICAL STAGE 2 lanes
2 anox tanks
2 anaerobic tanks
2 aerobic tanks
 OPERATION upstream denitrification
Bio-P (additional P-precipation)
 TREATMENT Nitrification
Denitrification
Stömungs- BioWin-
Bio-P Simulation Simulation

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 19
Position of the Cages in the aeration tanks

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 20
Retrofitting of WWTP Geiselbullach, Munich Germany (2)

 1987: Start up
 1995: Higher legal requirements in N-elimination led the operator to experiment
with different fixed-bed systems.
 1996: Our initial development of a retiform textile media was installed.
 2012: The IFAS system still provided the required effluent quality. But the aluminum
metal cages were corroded and failed.
 2013: After more than 17 years of operation retrofit of the complete aeration system

1987 2013
(without Cleartec®) (with Cleartec®)
Biological Biological
Inflow Effluent Inflow Effluent
Parameter efficiency efficiency
[mg/l] [mg/l] [mg/l] [mg/l]
[%] [%]
COD 310 53 82,9 543 22 95,9
BOD5 172 11 93,5 207 1,9 99,1
NH4-N 36 3,04* 90,5
32 11,1 32
0,35** 98,9
*January-December
**Mai-October (consent value by legal requirement)

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Page 21
Upgrade of WWTP Geiselbullach, Munich Germany (3)

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 22
Geiselbullach: High diffuser density equally spaced

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 23
Geiselbullach:
Retrievable cages with IFAS textile and integrated diffusers

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 24
Geiselbullach: Pilot cage aeration tank

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Slide 25
Geiselbullach: Biofilm / sessile biomass
3 days after commissioning @ TS 6 g/l

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Slide 26
WWTP Geiselbullach – Results of the commisioning phase

Biofilm / sessile biomass

2 Month after contact with waste

water

 Thick biofilm
 Complete flow / no blocking
 No redworms
 No EPS
 Suspended solids / TS 6 g/l

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Slide 27
Comparison of Aeration Systems: Surface aerators (1)

Aeration rotors  700mm Aeration rotor  1.000mm

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 28
Comparison of Aeration Systems: Surface Aerator (2)

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 29
 Comparison of Aeration Systems: Fine bubble diffusers

Line design Area design

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 30
Comparison of Aeration Systems: Fine bubble diffuser & mixer

Area design + additionally mixers

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 31
Energy coasts saving in Geselbullach 2014

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 32
JetFlex® HD Disc Diffuser HD-Series

JetFlex HD™ Disc Diffusers

Type  HD 200
 HD 270
 HD 340

Effective Diameter  184mm / 7ʺ

 218mm / 9ʺ
 295mm / 12ʺ

Air Flow  1,5 – 4,0 m³/h / 7ʺ

(depends on type)  1,5 – 7,0 m³/h / 9ʺ
 2,0 – 10,0 m³/h / 12ʺ

Potential retrofit for  Sanitaire®

(None of these companies are not  Nopon®
affiliated with the Jäger Group and the
products we manufacture to retrofit  Aercor®
these brands are neither original OEM
equipment nor are they specifically  Envicon®
approved for use by these
manufacturers)  EDI®

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 33
Bubble size: Slit Pattern & Sizes
Gap
Slit

Slit Size Properties

• maximize oxygen transfer and mixing

0.5mm – 1.0mm • operation with low air flow per unit
(fine) • large number of diffusers needed
(C; E; F; H; P; Q; R, S, U;
V; W) • high pressure loss by an increase of air flow
• high fouling and clogging potential

• adequate oxygen transfer by typical air flow

rate
1.25mm-1.75mm • pressure lost is modest
(medium)
(D; G; J; K; L; T) • reduce fouling potential
• long term service by reducing maintenance
frequency
• operation with high air flow but low oxygen
transfer
2.0mm – 3.0mm
(coarse) • also low pressure lost
(B; M; X) • minimum fouling or clogging
• special application (e.g. aquiculture)

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 34
Membrane Material for JetFlex™ Diffusers

Membrane Properties HD, TD TD, SD

EPDM EPDM EPDM Silicone Poly-Urethane

Performance Premium Special (VMQ) (PU)
(low plast.) (low plast.)
Plasticiser [%] 35 21 16 0 0
Polymer [%] 33 38 45 100 100
Carbon Black [%] 20 22 32 0 0
Others [%] 12 19 7 0 0
Hardness [Shore A] 40 ± 5 47 ± 5 53 ± 5 60 ± 5 N/A

Density [g/cm³] 1.09 ± 0.03 1.17 ± 0.02 1.11 ± 0.03 1.16 ± 0.03 1.18 ± 0.03
Operating [°C] Air 5 to +60 5 to +60 5 to +60 +5 to +100 5 to +65
Temperature
Tensile Strength [MPa] >6 >7 > 10 >9 45
Elongation at [%] > 400 > 400 > 600 > 600 > 600
Break
Tear Strength [N/mm] >6 > 4,5 >7 > 35 70

Wall Thickness [mm] 1.9 ± 0.15 1.9 ± 0.15 1.9 ± 0.15 1.5 ± 0.15 0.70 ± 0.05

Application municipal municipal and industrial industrial municipal and

share industrial share

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 35
Material testing of disc membranes (unperforated)

HD 270 EPDM: TD 65-100 EPDM:

Burst pressure 550 mbar Burst pressure 250 mbar

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 36
JetFlex® TD Tube Diffusers

JetFlex TD™ Tube Diffusers

Standard Type  TD 63
 TD 65-2
 TD 90-2

Perforated Length  1000mm

 750mm
 500mm

Bubble Size  fine (0,5 - 1,0mm)

 medium
(1,25 - 1,75mm)
 coarse
(2,0 - 3,0mm)
Air Flow  2,0 – 12,0 m³/h
(according to tube length)

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 37
JetFlex® SD Strip Diffusers

JetFlex SD™ Strip Diffusers

Standard Type  SD180/1500
 SD180/2000
Active membrane aerea  SD180/1500:
0,24 m²
 SD180/2000:
0,32 m²
Bubble Size  ultra fine
(0,2 - 1,0mm)
Specific oxygen transfer  18 – 30 gO2/(Sm³·m)
rate
(per m membrane length): (depending on bottom
coverage and specific air
load)
Air Flow  SD180/1500:
2,0 – 29,0 m³/h
 SD180/2000:
2,0 – 38,0 m³/h

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 38
JetFlex® high efficiency PU strip diffuser

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 39
 Comparison of oxygen transfer rate and operation range

30

28

26

24

22
gO2/Sm³

20

18

16
Strip Diffuser SD180/2000
14
Tube Diffuser TD65-2-G1
12 Disc Diffuser HD340

10
3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

Sm³/h.diff

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 40
Retrievable aeration system (strip diffuser)

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 41
Retrievable aeration system (strip diffuser)

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 42
Functional Zones

Three functional zones can be differed

when viewing an installed Cleartec® cage:

1. The lower sideflow zone:

Place where the diffusers are located.
The distance from the diffusers to the
Biotextile/BioCurlz should be between 40 –
50 cm.

2. The media zone:

The media zone is the area between lower
and upper supporting bar.
Within the media zone the flow is assumed
to be mainly vertical-upstream.

3. The upper sideflow zone:

The upper sideflow zone lies between
upper supporting bar and water level of
the tank.
© Cleartec Water Management GmbH
25.02.2015 / Seite 43
Flow Simulation in the aereated Tanks

© Cleartec Water Management GmbH

25.02.2015 / Seite 44
 Cages positioning

The cages can be distributed in

all the tanks with free distances
between the cages.

© Cleartec Water Management GmbH

25.02.2015 / Seite 45
Flow cascade with Biotextil Cleartec

© Cleartec Water Management GmbH

25.02.2015 / Seite 46
Anordnung mehrerer Festbetten

Back

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 47
Increased efficiency by high diffuser density

Different bottom
coverage ratios for
25 kgO2/h

Distance between diffusers 0.5m 1,0m 2,0m

Bottom coverage 28% 14% 7%

[floor area vs. membrane area]
Correction to 100% bottom -11% -13% -23%
coverage
Air flow rate 224 Sm³/h 272 Sm³/h 341 Sm³/h

Energy consumption 6.4 kW 7.6 kW 10.1 kW

SAE efficiency 3.9 kgO2/kWh 3.3 kgO2/kWh 2.5kgO2/kWh

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 48
Low air flows also help to increase efficiency

Lower air flow rate:

꞊ higher oxygen transfer

rate SOTE
꞊ lower headloss
in mbar
꞊ less energy con-
sumption overall
꞊ lower OPEX

But:
higher CAPEX

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 49
Abstract of References

WWTP Weißenborn
Weißenborn, Germany

Operating since 1999

Municipal, 5.500 PE

New plant with complete nitrification

100 2008-2010
90
90
80
Biological efficiency [%]
70
60 CSB 93,7
Legal requirements
50
[mg/l]

50 Target value
BSB5 98,3
40 Discharge
30 23 NH4-N 93,1
20 18
20 15
10 10
10 3,5 3,7 5
1,3
0
CSB BSB5 Nges NH4-N

© Cleartec Water Management GmbH

25.02.2015 / Seite 50
Abstract of References

WWTP- Terrassa
Terrassa, Spain

Operating since 2010

Municipal, 450.000 PE

Upgrading, Increase of performance

(C + N + P)

© Cleartec Water Management GmbH

25.02.2015 / Seite 51
Abstract of References

WWTP Kelleramt
Unterlunkhofen, Switzerland
Operating since 2007
Municipal, 12.800 PE
2013 Upgrade to 21.300 EW

Increase of performance, nitrification

© Cleartec Water Management GmbH

25.02.2015 / Seite 52
Kelleramt Modell in BioWin

Jäger Umwelt-Technik GmbH & Co. KG

Sales 5 Mio. Euro

Staff 7 Environmental Engineers

2 Sales & Marketing
10 Manufacturing staff
Locations Hannover (HQ) Germany
Vienna Austria
Bangkok Thailand
22 partners worldwide

Jäger Rubber & Plastics /(Shenzhen) Ltd.

Sales 3 Mio. Euro

Staff 3 Environmental Engineers

10 Sales & Marketing
25 Manufacturing Staff
Locations Shenzhen (PRC)

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 53
Spezifikation der Media in dem Modell

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 54
Spezifikation der Nachklärung in dem Modell

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 55
Ausgangswerte N, P

© Jäger Umwelt-Technik GmbH & Co. KG

25.02.2015 / Seite 56
Thank you for your attention.

Presented by:

Dipl.-Eng. Samer Alkhaddour

Region Manager (MENA)

Jäger Umwelt-Technik GmbH & Co. KG

Ruscheplatenstraße 14
31137 Hildesheim

Tel. 05121 9138 900

Fax. 05121 9138 999

www.jaeger-envirotech.com
s.alkhaddour@jaeger-envirotech.com

A company of the Jäger Group

Disclaimer: This information is based on our present state of knowledge and is intended to provide general notes on our products and their uses.
It should not therefore be construed as guaranteeing specific properties of the products described or their suitability for a particular application.
Any existing industrial property rights must be observed. The quality of our products is guaranteed under our General Conditions of Sale.

© Cleartec Water Management GmbH

25.02.2015 / Seite 57