MIXING and MASS TRANSFER TECHNOLOGIES LLC

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Rocky Mountain Water Environment
Association Albuquerque, NM, USA Technical
Session number 17, Operations and
Management Wednesday, 930am, 14th, September,
2005 Enchantment CD PROCESS MODELING IFAS and
MBBR Systems using LinPor Al Warakomski, Mixing
and Mass Transfer Technologies Manfred Morper,
Linde
MIXING and MASS TRANSFER TECHNOLOGIES LLC LOTEPRO
ENVIRONMENTAL SYSTEMS and SERVICES
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FOAM MEDIA, Physical Characteristics
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FOAM MEDIA, Physical Characteristics
Blank Carrier Cube
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FOAM MEDIA, Physical Characteristics
MATERIAL POLYURETHANE POLYETHYLENE SHAPE CUB
OIDS 15x15x12 MM PORE STRUCTURE OPEN 30-40
Pores Per Inch POROSITY 97 open volume AREA
with 40 ppi media 853 FT2/FT3 _at_100
media TYPICAL MEDIA FILL 20 IFAS, 30 MBBR
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FOAM MEDIA, Physical Characteristics
ATTRITION OF MEDIA OCCURS THRU BUMPING AGAINST
OTHER SURFACES. THE EFFECT IS TO ROUND THE SHARP
EDGES OF THE MEDIA. THE RATE IS ABOUT 1 OF THE
MEDIA VOLUME PER YEAR FOR THE FIRST YEARS OF
OPERATION. A STABILIZATION OCCURS ONCE THE EDGES
ARE ROUNDED. IT HAS NOT BEEN NECESSARY TO MAKE
MAJOR REPLENTISHMENTS MEDIA AT ANY OF THE
OPERATING PLANTS
PRIMARY MEANS OF BIOMASS SOUGH OFF
Media jostling along media retention screens
and on impingement plate at end of air lift media
recycle lines
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SYSTEM CONFIGURATIONS WEF RF Nomenclature Integr
ated Fixed-Film Activated Sludge IFAS ( LinPor
-CN ) or Moving Bed Biofilm Reactor MBBR (
LinPor -N )
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SYSTEM CONFIGURATIONS
LinPor CN IFAS Media is installed in main
stream plug flow diffused air basin with screens
for retention and air lift return pumping. There
is bacteria both suspended and fixed on the
media.
LinPor N MBBR Media is installed in a reactor
after the secondary step. There is bacteria only
in insignificant amounts in suspension with the
majority fixed on the media.
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SYSTEM CONFIGURATIONS
IFAS The LINPOR-CNR Process There are 7 plants
operating treating over 42.9 million gallons of
wastewater per day with a cumulative operating
history of over 46
years using this process. The recent WEFRF
report "Investigation of Hybrid Systems for
Enhanced Nutrient Control" misclassifies many
of the LINPOR-NR systems as (IFAS) systems.
LINPOR-NR is a MBBR (Moving Bed Biofilm Reactor)
system. The correct list of LINPOR-CNR systems
which are IFASs is as follows MUNICIPAL
OPERATING PLANT LIST LOCATION
TYPE APPLICATION FLOW LENGTH
of OPERATION Gemeinde Illmensee/DEU
Carbonaceous/Nitrogenous 0.3MGD 14 Years Since
1987 Stadt Freising/DEU Carbonaceous/Nitrogenous 1
6.5MGD 9 Years Since 1992 Sidney/AUS Carbonaceo
us/Nitrogenous 2.9MGD 8 Years Since
1993 Hinterstoder/OST Carbonaceous/Nitrogenous
0.6MGD 7 Years Since 1994 Gemeinde
Unterfohring/DEU Carbonaceous/Nitrogenous
3.0MGD 3 Years Since 1998 AV Schotten-Nidda/DEU
Carbonaceous/Nitrogenous 4.5MGD 3 Years Since
1998 AV Stamberger See/DEU Carbonaceous/Nitrogeno
us 15.0MGD 2 Years Since 1999 Westerly, RI,
USA Carbonaceous/Nitrogenous 3.3MGD 2 years
Since 2003
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IFAS, LINPOR-CN Process Characteristics

• FIXED AND FREE BIOMASS IN BIOLOGICAL REACTOR IN
  IFAS CONFIGURATION (LINPOR-C and LINPOR-CN)
• MEDIA FILL 15-30 OF THE REACTOR VOLUME
• AVERAGE OVERALL REACTOR BIOMASS CONCENTRATION AT
  9000-12,000 mg/l
• INCREASED SRT ALLOWS BIOLOGICAL REACTOR VOLUMES
  50 OR LESS THAN ACTIVATED SLUDGE SYSTEMS WITHOUT
  MEDIA
• PROVIDES SIMULTANEOUS DENITRIFICATION
• IN IFAS MODE FREE BIOMASS DOES NOT EXHIBIT
  BULKING TENDENCIES
• THE CONTAINMENT OF THE FIXED BIOMASS IN THE
  REACTOR ALLOWS HIGHER CLARIFIER THRUPUT

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IFAS, LINPOR-CN Process Characteristics cross
sectional view
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IFAS, LINPOR-CN Process Characteristics plan view
PRETREATMENT with 8 mm screens
SCREEN THRU PUT _at_ MAXIMUM FLOW 368 gal/ft2/hr
PRIMARY MEANS OF BIOMASS SOUGH OFF
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IFAS, LINPOR-CN Process Characteristics cross
sectional view
AIR REQUIREMENTS for SHEAR ZONE 5 scfm per lineal
foot screen maximum 2 scfm per lineal foot screen
operating
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IFAS, LINPOR-CN Process Characteristics Spiral
Roll
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IFAS, LINPOR-CN Process Characteristics implementa
tion
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IFAS, LINPOR-CN Process Characteristics implementa
tion
High G, shear volume
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IFAS, LINPOR-CN Process Characteristics Bacterial
Population Characteristics
Cubes have been sectioned and inspected to
determine the concentration of bacteria
within. Under the design conditions there is a
dense population of bacteria from the surface to
a depth of about 1-5 mm, after which there is
a considerable drop off in cell density. The
concentration of dissolved oxygen also falls from
the surface toward the center. This creates an
anoxic center where denitrafying bacteria
predominate.
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IFAS, LINPOR-CN Process Characteristics Bacterial
Population Characteristics
Biomass in Carrier Pores (X 125)
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IFAS, LINPOR-CN Process Characteristics Bacterial
Population Characteristics
Biomass in Carrier Pores (X 350)
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IFAS, LINPOR-CN Process Characteristics Bacterial
Population Characteristics
Biomass on Carrier Surface _at_ 3mm depth
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IFAS, LINPOR-CN Process Characteristics Bacterial
Population Characteristics
FISH technology has been used to determine the
relative amounts of both nitrafiers
and nitrifiers in the suspended and fixed
state. There is about the same amount of
nitrafiers (ammonia oxidizers) in both states,
9-10. However the nitrifiers (nitrite oxidizers)
consist of 3 suspended and 7 fixed.
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IFAS, LINPOR-CN Process Design Parameters

• PARAMETERS THAT INFLUENCE NITRIFICATION RATE
• Temperature, DO, G turbulence, CODinfluent,
  NH4-N influent/effluent
• VOLUME OF THE NITRIFICATION BASIN
• SIMULTANEOUS COD DEGRADATION
• SIMULTANEOUS DENITRIFICATION
• SLUDGE PRODUCTION and EFFLUENT SUSPENDED SOLIDS
• OXYGEN CONSUMPTION
• ALKALINITY BALANCE

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IFAS, LINPOR-CN Process Design Parameter
Correlations VN with BOD5 / TKN
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IFAS, LINPOR-CN Process Design Parameter
Correlations Simultaneous Denitrification Power
Function with F/M, BOD5 , DO
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IFAS, LINPOR-CN Process Design Modeling and
Simulation with EnviroSim' s Biowin Software
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IFAS, LINPOR-CN Operating Plants Freising,
Germany
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IFAS, LINPOR-CN Operating Plants Freising,
Germany
Parameters DESIGN OPERATION May-June
1995 Flow, MGD 5.2 6.9 BOD,
mg/l 222 225 COD, mg/l 397 425 TKN, mg/l
45.6 28 NH4N, mg/l 35.9 22 NOXN,
mg/l 2.6 5 Total N, mg/l 49.2
24 Effluent Quality BOD, mg/l 2 COD,
mg/l 20 TKN, mg/l -- NH4N, mg/l lt
5 0.3 NOXN, mg/l 7.3 Total N, mg/l
18 7.4 IFAS Reactor MLSSsuspended, mg/l
3800
7600 MLSSfixed, mg/l
15,000 18,000 MLSSaverage,
mg/l 5,800
9,680 Media Used, 22 20 Scope De
sign Build Design, Equipment supply, Supervision
of Construction and Startup Startup 1992
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IFAS, LINPOR-CN Operating Plants Westerly, RI, USA
Media Return
pH Probe
Effluent Screen
Media Return
Air Header
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IFAS, LINPOR-CN Operating Plants Westerly, RI,
USA
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IFAS, LINPOR-CN Operating Plants Westerly, RI,
USA
WINTER PERFORMANCE NH3, mg/l Total N,
mg/l Discharge Limit (June Oct only)
5.5 15.0 Actual Performance
(Winter 2003/2004) Oct. 03 0.5
4.9 Nov. 03 0.45
3.7 Dec. 03 0.65
3.5 Jan. 04 0.55
4.5 Feb. 04 0.45 2.8
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SYSTEM CONFIGURATIONS
LinPor CN IFAS Media is installed in main
stream plug flow diffused air basin with screens
for retention and air lift return pumping. There
is bacteria both suspended and fixed on the
media.
LinPor N MBBR Media is installed in a reactor
after the secondary step. There is bacteria only
in insignificant amounts in suspension with the
majority fixed on the media.
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SYSTEM CONFIGURATIONS
MBBR The LINPOR-NR Process There are 9 plants
operating treating over 67 million gallons of
wastewater per day with a cumulative operating
history of over e 88 years using this
process. The WEFRF nomenclature for this
configuration is a moving bed biofilm reactor
(MBBR). The recent WEFRF report "Investigation of
Hybrid Systems for Enhanced Nutrient Control"
misclassifies many of the LINPOR-NR systems as
IFAS (Integrated Fixed Film Activated Sludge)
systems. The correct list of LINPOR-NR systems
which are MBBRs is as follows MUNICIPAL
OPERATING PLANT LIST LOCATION
TYPE of APPLICATION FLOW LENGTH of
OPERATION Stadt Wyk auf Fohr/DEU Final Step
Nitrification 2.2MGD 13 Years since 1988
Gemeinde Halblech/DEU Final Step Nitrification
0.5MGD 12 Years Since 1989
Hohenlockstedt/DEU Final Step
Nitrification 0.3MGD 12 Years Since 1989
Stadt Aachen/DEU Final Step Nitrification 33.0MG
D 9 Years Since 1992 Stadt Heinsberg/DEU Final
Step Nitrification 5.0MGD 9 Years Since
1992 Stadt Koln-Weiden/DEU Final Step
Nitrification 7.5MGD 9 Years Since
1992 Aachen-Eilendorf/DEU Final Step
Nitrification 13.0MGD 9 Years Since 1992 Stadt
Erkelenz/DEU Final Step Nitrification 4.5MGD 8
Years Since 1993 Walfeucht-Haaren/DEU Final Step
Nitrification 1.7MGD 7 Years Since 1994
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MBBR, LINPOR-N Process Characteristics

• FIXED BIOMASS IN BIOLOGICAL REACTOR IN MBBR
  CONFIGURATION (LINPOR-N)
• OVERALL BIOMASS CONCENTRATION AT 1000-2000 mg/l
• LOW EFFLUENT TSS

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MBBR, LINPOR-N Process Characteristics Bacterial
Population Characteristics
Biomass _at_ midpoint of growth (X 100)
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MBBR, LINPOR-N Process Characteristics Bacterial
Population Characteristics
Biomass _at_ midpoint of growth (X 1000)
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MBBR, LINPOR-N Process Design Parameters

• PARAMETERS THAT INFLUENCE NITRIFICATION RATE
• Temperature, DO, G turbulence, CODinfluent,
  NH4-N influent/effluent
• VOLUME OF THE NITRIFICATION BASIN
• SLUDGE PRODUCTION and EFFLUENT SUSPENDED SOLIDS
• OXYGEN CONSUMPTION
• ALKALINITY BALANCE

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MBBR, LINPOR-N Process Design Parameter
Correlation
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MBBR, LINPOR-N Operating Plants Aachen, Germany

• Client City of Aachen
• Plant location Aachen-Eilendorf, Germany
• ProcessMBBR LINPOR-N
• CapacityDesign capacity 87 000 P.E.Wastewater
  flow 7.0 MGDPeak
  12.0 MGD TKN-load 1693.4lbs/day
• Effluent quality designedBOD5 lt
  7.0 mg/lNH4-N
  lt 1.0 mg/lachieved in 1995BOD5
  lt 2.0
  mg/l NH4-N lt 0.2 mg/l
• Start-up 1993

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MBBR, LINPOR-N Operating Plants Aachen, Germany




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QUESTIONS