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

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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

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

March 18, 2010

Equipment Components
Media Aeration equipment

Media retention sieves

Anoxic Zone Mixers

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IFAS and MBBR Webcast

March 18, 2010

Free-Floating Media Manufacturers

Headworks (Hydroxyl)

Kruger / AnoxKaldnes

Lotepro Linpor
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Siemens / AGAR
IFAS and MBBR Webcast March 18, 2010

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

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IFAS and MBBR Webcast

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

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Waste Sludge March 18, 2010

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IFAS and MBBR Webcast

March 18, 2010

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IFAS and MBBR Webcast

March 18, 2010

BUILDING A WORLD OF DIFFERENCE

Process Design Considerations

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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

IFAS and MBBR Webcast

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

IFAS and MBBR Webcast March 18, 2010

High Rate AS
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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

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IFAS and MBBR Webcast

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)
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Denitrification Biomass No Air Time Soluble BOD

IFAS and MBBR Webcast

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
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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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
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To Clarifiers

Nitrate Recycle Oxic Oxic

Anoxic

Media in the Basins

IFAS and MBBR Webcast March 18, 2010

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)

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IFAS and MBBR Webcast

March 18, 2010

The Effect of BOD Loading on Effluent Ammonia

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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

IFAS and MBBR Webcast March 18, 2010

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)

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IFAS and MBBR Webcast

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
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IFAS and MBBR Webcast

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?

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IFAS and MBBR Webcast

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.

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IFAS and MBBR Webcast

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
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IFAS and MBBR Webcast

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.
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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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)
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Design criteria depends on desired removal rate (permit limits)

IFAS & MBBR Media (152 ft2/ft3)

IFAS and MBBR Webcast

March 18, 2010

BUILDING A WORLD OF DIFFERENCE

Practical Design Considerations

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IFAS and MBBR Webcast

March 18, 2010

Practical Design Considerations Screening requirements Aeration system design Media retention sieves Approach velocities Foam and scum removal Maintenance provisions

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IFAS and MBBR Webcast

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
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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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 )
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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

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
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IFAS and MBBR Webcast

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.

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IFAS and MBBR Webcast

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
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Chlorinated sprays are controlling foam in Broomfield and Cheyenne

Foam suppression spray system

IFAS and MBBR Webcast

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?

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IFAS and MBBR Webcast

March 18, 2010

BUILDING A WORLD OF DIFFERENCE

Applications of IFAS/MBBR in North America

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

March October 18, 10-14, 2010 2009

Primary Clarifiers and Converted Trickling Filters

Primary Clarifiers

Converted Rock TF to Anoxic Volume

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IFAS and MBBR Webcast

March October 18, 10-14, 2010 2009

IFAS Basins and Secondary Clarifiers

IFAS Basins New Secondary Clarifiers Post Anoxic

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IFAS and MBBR Webcast

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
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4.7 mgd ave. design flow

IFAS and MBBR Webcast

March 18, 2010

Nitrification MBBR

Chlorination Dechlorination Anaerobic Digesters Final Clarifiers Primary Clarifiers HPOAS

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IFAS and MBBR Webcast

March 18, 2010

Construction of Moorhead MBBR

Low cost construction

Media retention sieves

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IFAS and MBBR Webcast

March 18, 2010

Headworks (Hydroxyl)

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IFAS and MBBR Webcast

March 18, 2010

-31F -35C

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IFAS and MBBR Webcast

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
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IFAS and MBBR Webcast

March 18, 2010

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

March 18, 2010

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IFAS and MBBR Webcast

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

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IFAS and MBBR Webcast

March 18, 2010

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IFAS and MBBR Webcast

March 18, 2010

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IFAS and MBBR Webcast

March 18, 2010

BUILDING A WORLD OF DIFFERENCE

Questions and Discussion

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IFAS and MBBR Webcast

March 18, 2010