MARKET LEADER FOR

FUNCTIONAL SURFACES
EFFICIENT SOLUTIONS FOR WATER
AND AIR TREATMENT
Biofilm Processes
DECADES OF EXPERIENCE
WITH BIOFILM PROCESSES
For more than four decades we have been working
with biofilm processes in water treatment.
We have equipped hundreds of trickling filters
with fills and we provide support in design and
engineering, also for IFAS (Integrated Fixed Film
Activated Sludge).
 3

ENERGY.
ENGINEERING.
EXCELLENCE.
Since the takeover of the Heat Exchangers segment of applications and exhaust air cleaning – always inspired
the GEA Group AG by Triton Partners, the activities in by our profound sense of responsibility for the overall
the cooling tower business, water treatment, exhaust air management of resources and a clean environment. We
cleaning and agricultural engineering were combined under deliver excellence and achieve customer satisfaction
the name of ENEXIO. everywhere in the world. Our global network of employees
works with an unceasing commitment to high quality,
ENEXIO stands for Energy. Engineering. Excellence. ecology and cost-effective products and services.

With our experience and pioneering spirit in engineeering, Our brands BIOdek®, TUBEdek®, PLASdek®, MASSdek®,
manufacturing and service, we deliver state of the SANIPACKING® and HUMIPACKING® stand for our know-how
art solutions for power plants, water and wastewater in different applications.

ENEXIO Water Technologies

Areas of Activity

Biological water treatment Sedimentation processes Mass transfer (air treatment) Cooling tower installations
TRICKLING FILTERS – OLD HAT?
NOT WITH THE
RIGHT TECHNOLOGY!

You achieve

> 90 % nitrification

10 x higher hydraulic capacity

4x higher biological capacity

An example:

BEFORE
Trickling filter with stone filling – clogged
and overflooded

SOLUTION
An upgrade with structured fills on a
concrete substructure or on our PIERdek.
Replace random fills, stone or lava with
structured plastic fills.

AFTER
You will be amazed at the increased
performance of the modified trickling filter
with over 90% nitrification!
 5
BIOdek ®

Trickling Filter
ENEXIO BIOdek® Trickling Filter 10
3

1 Influent 2
2 Circulating arms
1 Influe
3 Hydraulic or motorized drive 7 2 Circul
BIOdek®
4 Various types of media to suit approach VERTICAL FLOW FILLS
Roughing
3 Hydra
4 Variou
5 Vent windows 4 to sui
5 Vent w
6 PIERdek support system
8 6 PIERd
7 Filter shell BIOdek®
7 Filter
Fine Cleaning 8 Bacte
8 Bacteria growing to treat water CROSS-FLUTED FILLS
9 Efflue

9 Effluent 10 Cover

10 Cover (optional)

5 6 9

© ENEXIO Water Technologies GmbH

TRICKLING FILTERS SOLUTIONS

FOR THE TWENTY-FIRST CENTURY
Trickling filters have provided valuable service in treating Know-How
waste water for many years. They have proven to be simple Although many equations and design rules for the trickling
to run, reliable, energy efficient and have met the treatment filter process have been published – it needs a lot of know-how
levels currently required with sufficient upward potential. and experience to find the most suitable design for each
Design algorithms, developed in recent years, make trickling project. This know-how has been acquired by our specialists
filters the ideal technology even for warm and cold climate during 25 years of filter design and operational experience.
zones.
We make it available for you and ensure your project provides:
Today trickling filters are a modern and highly attractive • reliable compliance with effluent standards
process due to the development of various kinds • maximum economic benefit for customers
of structured plastic media, specialized for different • optimum operation reliability
applications: • accurate hydraulic parameters for rotary distributors
• Full carbonaceous treatment and nozzles
• Nitrification to very low concentrations
• Denitrification
• High rate applications

Nitrification Filters, Gothenburg, Sweden Municipal WWTP Ernesettle, Great Britain Trickling filter in industry with 16 m media depth
Region Basel, Switzerland
 TRICKLING FILTERS - FOR NEW PLANTS
AND UPGRADES
FOR INDUSTRIAL AND MUNICIPAL
APPLICATIONS
Modern trickling filters can be adopted at each stage of
wastewater treatment. With the correct design application
trickling filters can be used to replace or complement existing
equipment at whatever stage.
Wastewater treatment

Primary treatment

BIOdek®
TUBEdek®

Aerobic Anaerobic
Anoxic Primary
trickling filter –
fixed-bed reduction of BOD sedimentation
Preliminary cleaning
Primary Treatment

Intermediate treatment

Aerobic trickling filter Aerobic trickling filter / IFAS

BOD and Ammonia reduction BOD reduction / Nitrification
Biological Treatment Stage
(Secondary Treatment)

Intermediate treatment

Aerobic trickling filter

– Nitrification
Tertiary Treatment

Final sedimentation

Phosphorus removal

Receiving waters
 7

Trickling Filter
in Dubai

INDIVIDUAL SOLUTIONS
FOR MANY APPLICATIONS
Municipal supervision. The fixed biofilm process has a high protection
Trickling filters with our media can be designed to meet against inhibiting compounds and other varying influences,
stringent standards of new treatment plants. Therefore, they which gives a better treatment stability compared to other
are the ideal process for full secondary treatment. They treatment methods, such as Activated Sludge. Temperature
are also utilized as a cost-effective add-on stage either to reduction of the waste water through the filter is often
decrease the load as pre-treatment where the capacity of an welcome as an additional effect. ENEXIO BIOdek® filters
existing plant has to be increased or as a special treatment are particularly efficient in applications requiring partial
stage to meet new standards dictated by legislation. treatment to meet consents for discharge into municipal
The versatility of our media range enables existing assets and sewers.
treatment systems to be upgraded to meet future needs with
minimum costs and disruptions to the treatment capacity. Upgrading Existing Filters
One cost-effective solution to increase the treatment
Industrial capacity of an existing trickling filter plant is to replace an
Industrial waste water is characterized by special features existing rock or random media with our modern, structured
like increased salinity or temperature or unbalanced organic polypropylene media. Due to the more open structure and
loads and differing pH levels. ENEXIO BIOdek® filters are able higher effective surface area, around 3 times the organic
to treat such waste with little sludge production and high load and up to 10 times the hydraulic flow can be applied to
energy efficiency, utilizing small plant footprint and little our media compared to rock media.

Trickling Filter in the USA Trickling Filter in Great Britain Trickling Filter in Great Britain
TRICKLING FILTERS
A PROCESS FOR
MANY APPLICATIONS
In one-step biological processes for elimination of BOD5 and
ammonium, in tertiary nitrification, denitrification and in high-
load filters – trickling filters are demonstrating their advantages
everywhere.
 9

BIOdek® cross-fluted fill with BIOdek® vertical flow fill with

high specific surface area low risk of clogging

PROCESS ENGINEERING
DIFFERENT REQUIREMENTS
Secondary Treatment Filters High Rate Filters
This treatment process reduces BOD and ammonia Extremely high treatment rates can be achieved by using
within the waste water to levels that can be discharged high rate filters, thus minimizing the site footprint. High rate
into watercourses without compromising the condition filters are loaded at rates of 1.0 to 5.0 kg BOD/m³/d. They
of the receiving waters. The loading rates applied to are normally designed to reduce the BOD loads by between
BIOdek® secondary filters are typically between 0.2 and 50% and 70%. The energy input is less than 0.2 Kwh per kg
1.0 kg BOD/m³/d depending on the required effluent reduction in BOD. Particularly when dealing with an easily
quality and chosen process configuration. With appropriate treatable wastewater, a strong biomass growth will be
topographic layout BIOdek® filters can operate in gravity created. BIOdek® vertical flow media structure has the
feed mode without the supply of additional energy. No other optimal design to steadily expel the excess sludge.
aerobic water treatment process offers this advantage.
Denitrification
Tertiary Nitrification Filters Research through the past decade has proven that anoxic
This type of filter is typically installed to upgrade an existing trickling filters are a reliable process for denitrification.
treatment process to enable the plant to meet tighter Based on our research, we have patented a process solution,
ammonia discharge consents. The nature and type of which enables even shallow filters to efficiently denitrify.
biomass that establishes itself within tertiary nitrification By a simple method the filter media is sealed against
filters produces negligible amounts of solids. Provided the atmospheric oxygen, forcing the biomass to use nitrate
plant is within its suspended solids consent, no additional within the effluent stream for the supply of oxygen.
capital expenditure is required for post filter settlement.
BIOdek® is particularly effective for this application due
to its long retention times, crossflow structure and high
specific surface area which all combine to produce a very
high specific nitrification rate producing very low ammonia
concentrations in the effluent.

BIOdek® cross-fluted fills BIOdek® vertical flow fills

INCREASED CAPACITY OF ACTIVATED
SLUDGE PLANTS
UP TO 40% WITH ENEXIO BIOdek® IFAS
Installation of a BIOdek® IFAS system in an activated sludge
plant can generate 40% higher capacity without having to
build new aeration tanks.
Additional biomass grows on the fills contained in the
BIOdek® IFAS providing an increase in sludge age and thus
achieving a higher capacity of your plant.
 11

ENEXIO BIOdek® IFAS systems

BIOdek® IFAS
• Complete modules
and units for IFAS
• Aeration and BIOdek® FBR
agitators are • Complete
optional modules and
• Multiple units for fixed
combinations of beds
length and width • Plug-&-Play
• Height variations tank unit
regardless of length
and width BIOdek® SAF
• IFAS and fixed bed for larger projects
• Components for a complete installation

BIOdek® IFAS (integrated fixed film activated sludge)

EASY RETROFIT IN
RUNNING OPERATION
Activated sludge plants are characterized by flexibility in straight channels of the fills minimize the risk of clogging
the process and high capacities. On the other hand, biofilm and promote water circulation. If necessary aerators are
processes are stable and effectively withstand organic and installed that are matched to the specific requirements for
hydraulic overloads. BIOdek® IFAS combines the advantages carbon or nitrogen removal. Equipped with an agitator,
of both processes. under anoxic conditions BIOdek® IFAS can be used for
denitrification.
BIOdek® IFAS can be delivered as a plug-and-play module
ready for installation and thus enables simple upgrades and In addition to the complete modules and units depicted
retrofits, which if needed can be executed step-by-step above, BIOdek® IFAS, BIOdek® FBR, and BIOdek® SAF, we
during running operation. Thus, you do not have any also deliver our BIOdek® MOFIX as a complete customer-
downtimes and associated costs. specific system. As an expert in the field of biofilm processes
with more than 40 years of experience, we would be
The ENEXIO IFAS system consists of robust, aging-resistant pleased to advise you in the configuration of your IFAS.
plastic fills with a high surface in an installation frame. The

BIOdek® IFAS in the factory Delivery of BIOdek® IFAS BIOdek® IFAS installed
 PROCESS COMPARISON
BIOFILM VS ACTIVATED SLUDGE
In addition to activated sludge, biofilm processes are an effective and cost-
efficient process for biological cleaning of wastewater. Use of biofilm processes
is possible in separate plants as trickling filters or through extension and
integration in activated sludge plants as IFAS.

Process comparison

Biofilm Activated sludge IFAS

Energy

Maintenance costs

Robustness

Operation

Operating
personnel

Slugde
characteristics
(SVI)

Load on secondary
clarification

Effluent quality

Suitability for
industrial
wastewater

Suitability for
municipal
wastewater

Space
requirements
 13

Trickling filters for

biological treatment
with nitrification
Great Britain

BIOFILM PROCESSES –
THE ALTERNATIVE TO
ACTIVATED SLUDGE PROCESSES
Trickling filters offer a proven alternative to activated sludge processes. The simple design and installation, the material resistance
of the BIOdek® packs, the energy efficiency and uncomplicated operation also enable use in regions with minimal infrastructure.
The biofilm process is robust against fluctuations in the inflow load and delivers good results even without complex process
control, which means that highly-qualified personnel are not required.

Equipping the systems with differently structured packings (BIOdek®) permits an individual adaptation of the filters to the specific
cleaning task at hand. The application areas C-removal, nitrification, and denitrification can be achieved simultaneously or with
separate filters.

• Minimal energy consumption • Easy operation

In trickling filters the oxygen requirement in general The robust biofilm process allows uncomplicated
is covered through natural convection and thus saves regulation through the water supply, which can be
investment costs, as well as operating costs. Likewise, adapted to the actual load situation. With trickling filters,
with adequate ambient conditions, there is the possibility surface load and flushing intensity can be adjusted
of implementing water feeding by gravity without through the rotary distributors. Biofilm processes can
additional pumps. Thus, in municipal wastewater also be operated without highly-qualified operating
treatment plants, as compared to activated sludge, personnel.
savings of up to 70% occur.
• Minimal sludge accumulation
• Robust process Fixation of the organisms in the biofilm prevents a
Through its structure the biofilm is far more robust to flushing out of the biomass and increases the age of the
fluctuation in the influent load and influent quality, and to sludge. Downstream of the trickling filter only the excess
variable hydraulic loads. The process is far more resistant sludge must be separated, thickened and dewatered.
to sudden overload and supply of toxic substances than Sludge recirculation is not necessary.
is the case with activated sludge processes, and shows
only a minimal change in the effluent quality. Retention • Improved sludge characteristics
time in the trickling filter can be adjusted as needed with Sludge from biofilm processes shows better settling
a recirculation. characteristics. Together with the fundamentally lower
sludge accumulation, a more compact dimensioning
of the secondary clarification and of the recirculation is
possible.
THE RIGHT BASIS IS REQUIRED
PIERdek SUPPORT STRUCTURE
Our to BIOdek® fills specially matched support structures
offer fast and easy installation.
 15

ENEXIO PIERdek Support Structure

ENEXIO PIERdek
Prefabricated
fastening kit

PIERdek SUPPORT SYSTEM

SAFE, STABLE AND EASY TO INSTALL
PIERdek is a prefabricated carrier system for trickling filter fill media and can be used in tanks of any size and with
any pack height.

PIERdek installs quickly and easily since only half of the In addition, ENEXIO PIERdek contains a prefabricated
supports (posts) must be anchored in the ground. fastening kit that ensures a permanent connection of
the grating to the beams and to the supports. The two-
PIERdek consists of rigid PVC pipe supports with a lower dimensional alignment of the grating and the beam stabilizes
base plate and head plate on top. The base plate sits on a the overall structure and distributes the lateral forces over
disk that helps compensate for ground inclination (up to 5%). the entire area of the support structure.
The head plate supports a pair of rigid FRP beams arranged
in parallel. Pultruded FRP grating with 60% open surface is
placed on the head plate in parallel but at right angles to the
FRP beams. Optionally, the grating elements can be replaced
by rectangular FRP pipes (for tank diameters < 6 m).

Installation of PIERdek in a trickling filter

 WASTEWATER TREATMENT
WORLDWIDE
INDIVIDUAL AND PRACTICE-ORIENTED
SOLUTIONS
Trickling filters are a proven process even under difficult
local conditions. The prerequisites are precise planning
and dimensioning.

Climate zones of the earth

For the EXPOVAL project, data from wastewater treatment locations
in different climate zones was collected and evaluated centrally.
The map shows the average wastewater temperatures of several of
these locations.

Sweden
5 - 10°C

Germany
15°C

Nicaragua Georgia
30°C 22°C

United
Arab
Emirates
31°C

arctic
cold
cool-temperate
warm-temperate
warm
hot
very hot, often humid
 17

Problems involved in planning and dimensioning

trickling filter plants in other climate zones

If the local wastewater temperatures are not taken

into account this can
• result in over-dimensioning in warm climate
zones or
C-Elimination
• under-dimensioning in cold climate zones
C-Elimination
United C-Elimination
Arab Emirates Nitrification
31 °C
Nitrification
Germany Part Nitrification
Overdimensioned
15 °C

Sweden
8 °C
© ENEXIO Water Technologies GmbH

EXPOVAL PROJECT FOR TRICKLING FILTERS

EXTENSION AND VALIDATION OF
DIMENSIONING RULES
ENEXIO Water Technologies participated in the EXPOVAL Project of the German Federal Ministry for Education and Research
(BMBF), initiated in 2013, in the sub-project Trickling Filters. The objective of the project was an extension of the DWA dimensioning
rules used in Germany for wastewater treatment to the conditions of other countries. Particularly an adaptation to wastewater
temperatures that are lower and higher than they are in Germany, as well as the consideration of higher salt concentrations were the
objectives.

Since trickling filters are robust and stable in operation, they the United Arab Emirates, provided data from which planning,
are an effective, suitable solution for wastewater treatment dimensioning and operating information could be obtained.
particularly in regions with a difficult infrastructure. However,
in the past applying the dimensioning fundamentals used in The influence of temperature and the increased salt
Germany (DWA rules) did not produce satisfactory results. concentrations were taken into account and application limits
These rules were adjusted to the conditions of a temperate of the trickling filter process were defined. Relevant values, such
climate. In hot or cold climate zones, use of these rules resulted as volumes, construction height, flushing forces, etc. were put
in an over-dimensioning or under-dimensioning of trickling into a decision matrix, which also took into account cleaning
filters and hence uneconomic construction and operation. objectives, determination of the monitoring values, and criteria
for the selection of fill types.
Practicable dimensioning algorithm
Measuring campaigns on industrial-scale and semi-industrial We are using the newly determined dimensioning algorithm for
trickling filters in Nicaragua, Georgia, Namibia, Albania, and all of our trickling filter projects.

Batumi, Georgia Dubai, U.A.E. – Pilot plant Managua, Nicaragua

SAVE TRANSPORT COSTS
THROUGH ON-SITE INSTALLATION
Welding of the foils locally at the construction
site enables a cost-effective transportation.
Because the foils take up less volume than
complete fill modules, considerable costs can
be saved through delivery at the building site.
 19

Cost-saving installation
on-site

ENEXIO ENEXIO

ON-SITE ASSEMBLY
COST-EFFECTIVE AND ENVIRONMENTALLY-
FRIENDLY OIXENE OIXENE

For many applications, ENEXIO Water Technologies delivers can also provide additional training. The welding devices
not only finished packings, but also extruded foils. These required for manufacturing can be rented from ENEXIO as
can be welded together directly at the installation site. The well.
foils only take up approximately one tenth of the volume,
as compared to complete modules. This enables cost-
effective transport, even over long distances. Frequently Loading capacity
the lower wage costs in the destination country, which ENEXIO ENEXIO

enable additional savings are another advantage of on-site Truck

manufacturing. ~ 60 m³ fills or
~ 780 m³ foils
Welding on site is an environmentally-friendly procedure,
since it can be executed without adhesives or solvents.
Moreover installation through welding can easily be
executed without complications.
40" Container
Our illustrated manuals instruct your technical personnel ~ 50 m³ fills or
to assemble and weld the foils on site. This means that the ~ 700 m³ foils
installation is easy to handle. If desired an ENEXIO supervisor

Mobile welding container Welding and sawing on site

 www.enexio.com

© ENEXIO Water Technologies GmbH. Subject to modification. All rights reserved. EN-REV00-10-2019

ENEXIO Water Technologies GmbH

2H Components and Solutions
Dieselweg 5, 48493 Wettringen, Germany
Phone +49 2557 9390-0 | Fax +49 2557 9390-49
2h.germany@enexio.com
www.enexio.com