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)

MBBR (Moving Bed

Bioreactor)

Includes Return Activated

Sludge (RAS)

Fixed film & Suspended
growth

No RAS - Once through

process

Fixed film Only

Return Activated Sludge

Waste Activated Sludge

Slide - 3

IFAS and MBBR Webcast

Waste Sludge

March 18, 2010

The IFAS Advantage

(Comparative Nitrification Upgrade Example)
Conventional

Existing
Aeration

IFAS

Expanded
Aeration

Suspended Growth Only

Slide - 4

IFAS and MBBR Webcast

Modified
Existing
Aeration

Suspended and
Attached Growth

March 18, 2010

Equipment Components
Media

Aeration equipment

Anoxic
Zone
Mixers

Media retention
sieves

Slide - 5

IFAS and MBBR Webcast

March 18, 2010

Free-Floating Media Manufacturers

Headworks (Hydroxyl)

Kruger / AnoxKaldnes

Siemens / AGAR

Lotepro Linpor
Slide - 6

IFAS and MBBR Webcast

March 18, 2010

Life Cycle Cost Analysis

Millions

(Activated sludge Nit/Denit Upgrade)

$80
$70

NPV Cost

$60
$50

O&M
Construction

$40

Equipment
$30
$20
$10
$0
Conventional

IFAS

Step-Feed

MBR

BAF

Process Option

Slide - 7

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

IFAS

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

MBBR

HRC/DAF

Return Activated Sludge

Slide - 8

Waste Activated Sludge

IFAS and MBBR Webcast

Waste Sludge
March 18, 2010

Slide - 9

IFAS and MBBR Webcast

March 18, 2010

Slide - 10

IFAS and MBBR Webcast

March 18, 2010

BUILDING A WORLD OF DIFFERENCE

Process Design
Considerations

Slide - 11

IFAS and MBBR Webcast

March 18, 2010

IFAS Process Configurations

OX
Media

OX
Media

2 or 3 OX cells in series

Higher kinetic rates

Optimum DO control

Avoid media migration

OX
Media
RAS

Nitrification
MLR
AX

OX
Media

OX
Media

OX
Media
RAS

Two-Stage Nitrogen Removal

IFAS is Compatible
with Bio-P

Carbon
Supplementation

MLR
AN

AX

OX
Media

OX
OX
OX
Media Media
Media

2nd AX
OX
Media

RAS

Four-Stage Nitrogen Removal

Slide - 12

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

AX

Ox1
BOD Rem.
DO=2.0mg/L

Ox2
Media Nitr.
DO=4.0mg/L

Ox3
Polish
DO=
1.0mg/L

RAS
Slide - 13

IFAS and MBBR Webcast

March 18, 2010

MBBR Process Configurations

AB

Industrial Pretreatment
OX
Media

Reduce COD load

Remove toxic compounds that

could inhibit nitrification

RAS

Industrial Pretreatment MBBR

Industrial
Load

Nitrification

Activated sludge upgrade

Post nitrification and/or

denitrification

OX
Media

OX
Media

Nitrification MBBR
HRC

AB
RAS

OX
Media

DAF
Actiflo/
Densadeg
Cloth filter

Post Nitrification MBBR

High Rate AS
Slide - 14

IFAS and MBBR Webcast

March 18, 2010

MBBR Process Configurations (Cont.)

Denitrification

Two-stage

Four-stage

Internal Recycle
AX
Media

Not compatible with Bio-p

OX
Media

AX
Media

OX
Media

IFAS and MBBR Webcast

Waste
Sludge

Carbon
Supplementation
2nd AX
OX
Media

Four-Stage MBBR

Slide - 15

OX
Media

Two-Stage MBBR

Internal Recycle
AN

OX
Media

Waste
Sludge

March 18, 2010

Nutrient Removal Check List

BOD Removal

Nitrification

Denitrification

Biomass

Biomass

Biomass

Air

Air

No Air

Time

More Time

Time

Alkalinity

Soluble BOD

Slide - 16

Biological Phosphorus Removal

Biomass (Phosphorus Accumulating Biomass)

Time

Soluble BOD (as VFA)

Cycles of Air, No Air IFAS ONLY (currently)

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

Slide - 17

IFAS and MBBR Webcast

March 18, 2010

Biomass Quantification
(gTSS/m2 media surface area)
2nd Anoxic

1st

Oxic

2nd Oxic

1st Anoxic

6 g/m2

28

g/m2

13 g/m2

9 g/m2

South Adams
County MBBR
Slide - 18

IFAS and MBBR Webcast

March 18, 2010

Broomfield Seasonal Attached Biomass

MLSS (mgTSS/L)

5,000

30

Attached Biomass,
Second Zone in Series (Oxic)

Attached Biomass,
First Zone in Series
(Oxic)

25

Temperature

4,000

20

3,000

15
MLSS

2,000

10

1,000

5
Effluent Ammonia

Slide - 19

IFAS and MBBR Webcast

12/28/06

9/28/06

6/29/06

3/30/06

12/29/05

9/29/05

6/30/05

3/31/05

12/30/04

9/30/04

7/1/04

4/1/04

0
1/1/04

Effluent Ammonia (mgN/L)

Temperature (C)
Attached Biomass (gTSS/m2)

6,000

March 18, 2010

Basic Design Parameters

Activated Sludge

Hydraulic Retention Time

Solids Retention Time

Biofilms

Hydraulic Retention Time

Surface Area Loading Rate

Integrated Fixed Film Activated

Sludge

Slide - 20

BOD

Nitrogen

Combination of both

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

To
Clarifiers

Oxic 2:
< 5 mg/L

Nitrate Recycle
Oxic
Oxic
Anoxic
Anoxic

Oxic
Oxic

Anoxic

Anoxic
Primary
Effluent
~30 mg/L
Slide - 21

Media in the Basins

IFAS and MBBR Webcast

March 18, 2010

Surface Area Loading Rate vs. Removal Rate

Specific Ammonia Removal Rate (gN/m /day)

1.50

100%

1.25

80%

1.00

0.75

0.50

0.25

0.00
0.00

0.25

0.50

0.75

1.00

1.25

1.50

Specific Ammonia Loading Rate (gN/m /day)

Slide - 22

IFAS and MBBR Webcast

March 18, 2010

Slide - 23

Temperature
Approx Specific BOD Loading Rate

IFAS and MBBR Webcast

08/19/09

05/21/09

02/20/09

11/22/08

08/24/08

05/26/08

02/26/08

11/28/07

08/30/07

06/01/07

03/03/07

12/03/06

09/04/06

06/06/06

03/08/06

12/08/05

09/09/05

06/11/05

03/13/05

25
Biotower Parallel
to MBBR

Biotower
in Series
with
MBBR

12/13/04

09/14/04

30

06/16/04

35

03/18/04

12/19/03

Plant Effluent Ammonia (mg-N/L)

MBBR Temperature (C)

Biotower Offline
(All Flow to MBBR)
7.0

6.0

5.0

20
4.0

15
3.0

10
2.0

5
1.0

0
0.0

Approx. Specific BOD Loading Rate (gO /m2/d)

8.0

40

Specific Ammonia Loading Rate (gN/m /d)

The Effect of BOD Loading on Effluent Ammonia

Seasonal ammonia limits: 10 24 mg/L, or Report

Specific Ammonia Loading Rate

Effluent Ammonia (7-d avg)

March 18, 2010

The Effect of Dissolved Oxygen Concentration

Boundary Layer
2,5

Media Surface

Bulk
Liquid

Streamer

Gas
Layer

Ammonia removal rate (g NH4/m2/d)

Biofilm
Layers

2,0

1,5

1,0
O

oa
cl
i
an
rg

0
0,

D
BO

2
/m

1
2
3
4
5

0,5

6
7

0,0
0

10

Oxygen concentration (mg 02/l)

Source: 2007 IWA/WEF Nutrient Removal Specialty Conference,

Worskhop B (AnoxKaldnes)
Slide - 24

IFAS and MBBR Webcast

March 18, 2010

Residual DO vs. biofilm nitrification

Fort Myers, FL MBBR
Process Model Simulation

DO Sensitivity

12.0
y = 60.222x-2.4082
R2 = 0.9715

Effluent Ammonia, mg/L

11.0
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
0

10

11

12

DO, mg/L
Slide - 25

IFAS and MBBR Webcast

March 18, 2010

Modeling a Biofilm System

Biofilm
Layers

Media Surface

Maximum biofilm
thickness

Biomass per unit surface

area

Inert content of biofilm

Nitrification and
denitrification rates

Attachment and
detachment rates

How do these vary in

each zone?

Boundary Layer
Gas bubbles

Slide - 26

Solids attaching
and detaching
Bulk Liquid
Streamer

IFAS and MBBR Webcast

March 18, 2010

GPS-X (Hydromantis)

Commercial
Simulators

BioWin

GPS-X

West

Aquifas

Others

But models must be

calibrated to site-specific
conditions.

Slide - 27

BioWin (Envirosim)

IFAS and MBBR Webcast

March 18, 2010

Demonstration, Pilot and Bench Studies

Demonstration

Pilot

Configure one or more

treatment trains and monitor
full-scale performance.

Design a small-scale system

to mimic full-scale
performance, using plant
wastewater.

Bench

Slide - 28

Smaller, lab-scale
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.

Slide - 29

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

Slide - 30

IFAS and MBBR Webcast

March 18, 2010

6+ Month Pilots of IFAS and MBBR

Aeration System

Dissolved Air Flotation

Sodium
Bicarbonate

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

Methanol

FM

To Drain
Feed Pump
No. 2

R4

R5

R6

Post
Aeration

FM

Waste Sludge

Slide - 31

IFAS PROCESS (TRAIN NO. 2)

IFAS and MBBR Webcast

March 18, 2010

MBBR with Post-Denitrification during the

Last Month
Primary Effluent Feed
From WWTP Intermediate
Wet Well

Aeration System

Sodium
Bicarbonate

Methanol

M
M

Feed Tank
With Screen

To Drain

Feed Pump
No. 1

R1

Slide - 32

R2

IFAS and MBBR Webcast

R3

R6

Post
Aeration

Clarifier Unit

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

IFAS and MBBR Webcast

March 18, 2010

Summary of Process Design Considerations

Surface area is the key.

Specific loading rates:

BOD

NH3N

NO3N

Design criteria depends

on desired removal rate
(permit limits)

IFAS & MBBR Media

(152 ft2/ft3)

Plastic Trickling Filter Media

(30 ft2/ft3)
Rock Trickling Filter Media
(15 ft2/ft3)
Slide - 34

IFAS and MBBR Webcast

March 18, 2010

BUILDING A WORLD OF DIFFERENCE

Practical Design
Considerations

Slide - 35

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

Slide - 36

IFAS and MBBR Webcast

March 18, 2010

Screening Requirements

Purpose

Slide - 37

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
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

Slide - 38

IFAS and MBBR Webcast

March 18, 2010

Aeration System Optimization

Consider summer versus
winter operation
DO Sensitivity

Winter

12.0
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

Effluent Ammonia, mg/L

11.0
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0

Consider lower DOs (2 to 3 mg/L)

to reduce airflow and energy

requirements

Slide - 39

IFAS and MBBR Webcast

DO, mg/L

March 18, 2010

10

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

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

Slide - 41

IFAS and MBBR Webcast

Basin overflow sieve at Broomfield

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

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

Stack-Up

Suggested maximum design criteria

Slide - 43

30 to 35 m/hr typical maximum

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

Slide - 44

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

Slide - 45

Ox1
Ox1 BOD Rem.

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

Slide - 46

Chlorinated sprays are

controlling foam in
Broomfield and Cheyenne

IFAS and MBBR Webcast

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

Slide - 47

Media storage

Media transfer pumps

Biofilm integrity during

storage?

Odors during storage?

IFAS and MBBR Webcast

March 18, 2010

BUILDING A WORLD OF DIFFERENCE

Applications of
IFAS/MBBR in North
America

Slide - 48

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

Slide - 49

IFAS and MBBR Webcast

March
October
18,10-14,
2010
2009

Primary Clarifiers and Converted Trickling Filters

Converted
Rock TF to
Anoxic
Volume

Primary
Clarifiers

Slide - 50

IFAS and MBBR Webcast

March
October
18,10-14,
2010
2009

IFAS Basins and Secondary Clarifiers

IFAS
Basins

Slide - 51

New Secondary
Clarifiers

Post
Anoxic

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

4.7 mgd ave. design flow

Slide - 52

IFAS and MBBR Webcast

March 18, 2010

Nitrification
MBBR

Chlorination
Dechlorination
Anaerobic
Digesters
Final Clarifiers
Primary
Clarifiers

Slide - 53

HPOAS

IFAS and MBBR Webcast

March 18, 2010

Construction of Moorhead MBBR

Low cost
construction

Media retention
sieves
Slide - 54

IFAS and MBBR Webcast

March 18, 2010

Headworks (Hydroxyl)

Slide - 55

IFAS and MBBR Webcast

March 18, 2010

-31F
-35C

Slide - 56

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

Slide - 57

IFAS and MBBR Webcast

March 18, 2010

Slide - 58

IFAS and MBBR Webcast

March 18, 2010

MBBR/DAF Process Configuration

(Fort Myers East WRF)

IR Pumping

Influent

AX

AX

OX

Sludge
Dewatering

OX

OX

Dissolved
Air Flotation

Disk
Filter

MBBR Process

Slide - 59

IFAS and MBBR Webcast

March 18, 2010

Slide - 60

IFAS and MBBR Webcast

March 18, 2010

Bundamba Advanced WTP Flow Schematic

Sodium Bisulfite and
Antiscalant

Disinfection (NH4 +
NaOCl)
Ferric

Diurnal Flow
Pre-Treatment EQ/storage

MF

RO

Secondary
Effluent

Slide - 61

UV/H2O2

Treated Water
Storage

Polymer

Gravity
Thickener

Lime, Carbon
Dioxide, NaOCl

RO Brine

IFAS and MBBR Webcast

Power Plants
Wivenhoe Dam

March 18, 2010

Slide - 62

IFAS and MBBR Webcast

March 18, 2010

Slide - 63

IFAS and MBBR Webcast

March 18, 2010

BUILDING A WORLD OF DIFFERENCE

Questions and Discussion

Slide - 64

IFAS and MBBR Webcast

March 18, 2010