Smith & Loveless Inc.

Design Considerations for Packaged

Membrane Bioreactor (MBR) Wastewater
Treatment Systems

Applying Membrane Bioreactors (MBR) in lieu of conventional
activated sludge systems delivers higher effluent quality while
eliminating secondary clarification processes. These systems
incorporate flat-sheet or hollow-fiber membranes with pore
sizes measured in micrometers or nanometers, which allow
for complete retention of solids inside the treatment system.
Effluent total suspended solids concentrations (TSS) below
conventional detection limits are often achieved, depending on
influent values and system design parameters.
This high filtration level allows MBR systems to push the
limits of conventional activated sludge treatment and provide
multiple design benefits for project applications, including
higher organic loading rates, typically smaller footprints,
decreased sludge production, and overall better bio-treatment.
With the growing demand for smaller more efficient package
wastewater treatment systems, MBRs are becoming an
increasingly applied in the larger water industry footprint.

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MBRs are not necessarily a solution for all applications, and diffusion, which means it requires less total volume of air while
they can have higher capital cost than conventional treatment in operation; however, the drawback is that fine bubble diffusers
processes. However, with expert engineering, an MBR system are generally more expensive. When selecting an aeration
can be designed to perform at optimum efficiency in terms of system during the project design, the SOTE, along with other
both biological treatment and energy consumption. Following is parameters, should be evaluated to find the most efficient and
a discussion about some design considerations, which can be economical application for the treatment system as a whole.
overlooked during the design and implementation of an MBR
system for a particular project. These areas include diffusion These methods to estimate aeration requirements have been
and managing the relationship between treatment facility widely accepted for the design of conventional activated sludge
footprint, loading rates and energy efficiency. systems. When they are applied to MBR systems, however,
another value called Alpha can become just as important.
Fine Bubble vs Coarse Bubble Diffusion Alpha is defined as the ratio of the oxygen transfer rate in
One of the primary design considerations for suspended growth mixed liquor to that in clean water. This value is considered as
activated sludge treatment is the aeration system. The aeration a correction factor and varies with the type of aeration device,
system must (1) provide adequate mixing to keep all solids in aeration intensity, wastewater characteristics, mixed liquor
suspension, (2) supply enough oxygen to meet both the organic concentrations, along with other parameters.
and inorganic oxygen demand of the influent wastewater,
(3) satisfy the oxygen demand for endogenous respiration of MBR systems with mixed liquor concentrations three to four
the biomass, and (4) maintain an aerobic environment with times higher than other activated sludge systems can operate
a minimum dissolved oxygen concentration throughout the with Alpha values much lower than conventional systems,
aeration tank. In many situations the design comes to one and the degree at which the Alpha value is decreased can
important question, fine bubble diffusers or coarse bubble sometimes be overlooked. The general understanding that
diffusers? fine bubble diffusers are more efficient at transferring oxygen
in water may not hold true in a system with high suspended
The difference between the two can be explained by looking at solids concentrations. To illustrate this relationship,
one value, standard oxygen transfer efficiency. Standard oxygen Figure 1 demonstrates the effect of the MLSS on Alpha and
transfer efficiency (SOTE) is the value that expresses a diffuser’s Figure 2 shows the relationship of aeration requirements for
ability to transfer the oxygen from air into the water. Fine bubble both fine bubble and coarse bubble with increasing mixed
diffusion generally maintains a higher SOTE than coarse bubble liquor concentrations.

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Figure 1 – MBR Alpha Values with Increasing MLSS
coarse
Figure 2 – Corresponding MBR Air Requirements with
Increasing MLSS
coarse
As one can see in Figure 2, the airflow requirement for
coarse bubble is lower than fine bubble with increased MLSS
concentrations. This gives coarse bubble diffusers the advantage
in both oxygen transfer and energy efficiency for MBR systems.
Although there are many other factors that need to be considered,
with a little experience and proper engineering consideration,
an MBR can be designed for optimum efficiency, making it an
even more attractive alternative in the packaged wastewater
treatment market.
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Footprint vs Loading Rate vs Energy efficiency –
Finding a Balance
Packaged MBR systems maintain multiple advantages over
packaged conventional activated systems. Membrane filtration
allows a system to build up MLSS concentrations more effectively,
than with secondary clarification, and in many applications
operate at MLSS concentrations three to four times higher
or above 10,000 mg/L. Higher MLSS concentrations allow for
smaller tanks, longer solids retention times, and in most cases
more stable and treated water. Although a higher concentration
seems to provide only benefits, at what point does it not?
As any engineer will tell you, designing is the art of considering
the pros and cons of every aspect of a system and finding the
best possible solution. When considering the application of a
MBR system there are a few key parameters that need to be
considered to find that solution. These parameters include
footprint, organic loading rate, and energy efficiency.
Footprint refers to the physical size of the system tank and
ancillary equipment. Because MBR aeration tanks nominally
operate at higher organic loading rates, namely MLSS
concentrations three to four times higher than conventional
activated sludge aeration tanks, the MBR tank is generally
be three to four times smaller. But why stop there… can an
MBR be designed to handle loading rates six to eight times
more? The short is answer is no. Aside from the mechanical
constraints, some physiochemical changes occur at high MLSS
concentrations that can be undesirable. As explained earlier,
higher MLSS concentrations will decrease the Alpha factor for
the aeration system requiring more total airflow to obtain the
same oxygen supply. Secondly, higher MLSS concentrations
increase water viscosity. High viscosity water is difficult to filter
through membranes and will require more total membrane
surface area to filter the same amount of water.
Forcing an MBR to treat the maximum possible organic load for
the sake of maximum efficiency and lowering the system footprint
ultimately defeats the purpose. The organic loading rates to a
system are typically measured as pounds of BOD per day per
volume. So respectively with increased MLSS concentrations
and smaller tank volumes, a system will have higher organic
loading rates. MBR systems that try to operate with higher
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MLSS concentrations using high organic loading rates, of zone, causing small biological particle sizes that can decrease
80 lbs/d-kft3 and above, will be forced to operate at shorter waters filterability through membranes. So it is generally safe
than desired solids retention times. When an MBR is operating to say that systems that operate at lower MLSS concentrations
with low solids retention it can are more energy efficient.
easily be upset by fluctuating
flows, temperatures, or organic So how do we make a system as
loads and may have issues with effective as possible? The answer
nitrogen removal. to this will vary, and each system
will have its own definition of
What makes a system energy effective. Some systems will
efficient? There are many pieces try to fit within the smallest
of equipment within a MBR possible footprint by operating
that require energy, but the at MLSS concentrations 16,000
largest energy consumer is the mg/L and above, sacrificing
blower. The higher the oxygen energy efficiency. Some would
requirement, the higher energy rather operate at high organic
requirement, and as discussed loading rates, above 80 lbs/d-
previously, as MLSS increases so kft3, with the same high MLSS
does the amount of air required concentrations, sacrificing
to provide the same amount of reliability. Smith & Loveless
oxygen. design prefers to find the balance
between the MBR footprint and
This concept can have a double organic loading rates to find the
negative when also decreasing most energy efficient system. We
the footprint of a system. The find that an MBR operating with
increased aeration required, and a MLSS concentration ranging
decrease tank volume in which to inject the air, creates a large from 10,000 to 15,000 mg/L provides a good balance of
SCFM per unit volume or energy density. High energy densities energy efficiency and biological stability, while generating
will create highly turbulent environments inside an aeration reliable high quality effluent.

©2018, Smith & Loveless Inc., Brochure No. 9554-2

Online: smithandloveless.com • Phone: 913.888.5201 • FA X: 913.888.2173