GB Membranbuch 300106mebran

Municipal Water and Waste Management
Membrane Technology
for Waste Water Treatment
Institut fr
Siedlungswasserwirtschaft
der RWTH Aachen
Membrane Technology
Edited by:
Univ.-Prof. Dr.-Ing. Johannes Pinnekamp
Dr. rer. nat. Harald Friedrich
Institute of Environmental Engineering
Head of Department
of the RWTH Aachen University
Waste Management, Soil Conservation,

Water Management
Ministry for Environment and Nature Conservation, Agriculture and Consumer Protection
of the federal state North Rhine-Westphalia

Volume 2
Membrane Technology
Edited by:
Univ.-Prof. Dr.-Ing. Johannes Pinnekamp
Institute of Environmental Engineering
Head of Department
of the RWTH Aachen University
Waste Management, Soil Conservation,

Water Management
Ministry for Environment and Nature Conservation, Agriculture and Consumer Protection
Institut fr
Siedlungswasserwirtschaft
der RWTH Aachen
Preface
Preface
Membrane technology for the treatment of water and
In municipal waste water treatment, certain types of
waste water shows impressively how innovative, future-
membrane installations the biomembrane filtration
orientated, and economically meaningful environmental
plants (membrane bioreactor process) havent been
protection technology can be. In the past 100 years of
used often so far, both for historical and economical
modern water and waste water treatment for households
reasons. But the application of membrane processes in
and enterprises, no other new technology has been intro-
municipal waste water treatment may be proven to be
duced offering so many positive effects like the membrane
cost-effective, in particular if the following conditions
technology.
occur:
Numerous different problems in water treatment can be
the space for the new construction or the expansion
solved, simultaneously resulting in significantly better
for waste water treatment plants is limited,
cleaning of the waste water.

the possibilities for subsequent recycling of the treated
Membrane technology allows the internal recovery and
waste water are to be used,
reprocessing of solid and dissolved substances.

advanced or additional standards for the effluent
Due to the wide range of available membranes and
quality of the waste water are required,
modules, technically suitable systems for nearly every

type of problem in water treatment can be found.
toxic substances have to be removed,
A large number of scientific institutions, industrial enter-
hygienically excellent waste water quality is demanded.
prises, water suppliers and waste water boards have participated in the development and application of membrane
In Germany, the biomembrane filtration process has
technology. The Federal Government as well as the
become competitive already today in the field of domestic
governments of the federal states support this technical
and small waste water treatment plants as well as in ship
development.
waste water treatment plants, and increasingly in municipal waste water treatment.
In Germany, membrane technology today represents a

proven alternative to classical processes of municipal and
Membrane technology can be applied in diverse fields of
industrial waste water treatment. This pays off in terms
industry, which is proven by a large number of references.
of ecology and economy because the usage of membrane
In industrial waste water treatment, membrane technology
technology denotes fewer costs for water supply and
is used for production-integrated pollution control.
waste water disposal as well as industrial production, and

also results in significantly less environmental stress.
Preface
With the help of membrane technology, water the sol-
This publication presents the membrane technology and
vent most frequently used in industry can be cleaned
its application in municipal and industrial waste water
to such an extent that it may be reused. The substances
treatment in Germany according to the state of the art
filtered from the water may also be reused again for
and science. Examples of installations realized in an in-
industrial processes. Although its impossible to realize a
dustrial scale in municipalities and industrial enterprises
completely closed water circuit by membrane technology,
demonstrate the range of application and the efficiency
the waste water quantity may be significantly reduced by
of membrane installations including planning, con-
multiplied usage of the water. Thus the enterprises save
struction and operation as well as the related costs. Thus
costs.
planners, municipalities responsible for waste water

disposal and licensing authorities are provided with a
fundamental basis for the decision whether membrane
technology might be a solution for their specific problem.
Eckhard Uhlenberg
Sigmar Gabriel
Prof. Dr. Andreas Troge
Minister for Environment and
Federal Minister for the Environment,
President of the Federal
Nature Conservation, Agriculture
Nature Conservation and Nuclear
Environmental Agency
and Consumer Protection of the
Safety
federal state North Rhine-Westphalia
imprint
This scientific elaboration was supported by

the Ministry for Environment and Nature Conservation,
Agriculture and Consumer Protection
of the federal state North Rhine-Westphalia.
Responsible
FiW Verlag
Mies-van-der-Rohe-Strae 17
Head of Department
D-52074 Aachen
Waste Management, Soil Conservation, Water Management

Phone: +49 (0) 241- 80 2 68 25
Dr.-Ing. Viktor Mertsch
Fax:
Waste Water Disposal and Waste Water Technology
E-Mail: verlag@fiw.rwth-aachen.de
+49 (0) 241- 87 09 24
Ministry for Environment and Nature Conservation,

Agriculture and Consumer Protection
ISBN
3-939377-01-5
ISBN
978-3-939377-01-6
Revising the contents of this 2 nd updated edition
Layout
FiW at the RWTH Aachen University
ID-Kommunikation
M. Lange, Dr.- Ing. F.-W. Bolle, Dr.-Ing. S. Schilling,
S 1, 1
S. Baumgarten (ISA, RWTH Aachen)
D-68161 Mannheim
Revising the contents of the 1st edition 2003:
Phone: +49 (0) 6 21 - 10 29 24
FiW and ISA, RWTH Aachen
Fax:
M. Lange (chairperson), S. Baumgarten, F.-W. Bolle,
E-Mail: info @idkommunikation.de
+49 (0) 6 21 - 10 29 91
Dr.-Ing. T. Buer, J. Schunicht, Dr.-Ing. K. Voenkaul

Team accompanying the 1st edition 2003:
Cover photo
Dr. V. Mertsch, I. Dierschke, K. Drensla, A. Kaste,
Erftverband
RBD A. Schmidt, Prof. Dr. W. Schmidt, S. Tenkamp,

Dr.-Ing. J. R. Tschesche, C. Wiedenhft, T. Wozniak,
Dr. K. Zimmermann
Print
Greiserdruck GmbH & Co. KG
Assessment of the 1st edition 2003:
Karlsruher Strae 22
Prof. Dr.-Ing. P. Cornel, Dr.-Ing. W. Firk,
D-76437 Rastatt
Dr.-Ing. J. Oles, Dr.-Ing. T. A. Peters, U. Voss

Phone: +49 (0) 72 22 - 105 -129
Translation:
Fax:
F. Pohl
www.greiserdruck.de
German edition
A German edition titled
Siedlungswasser- und Siedlungsabfallwirtschaft
Nordrhein-Westfalen: Membrantechnik
fr die Abwasserreinigung
is available with the following ISBN:
ISBN 3-939377-00-7
ISBN 978-3-939377-00-9
The translation was supported by:

Umweltbundesamt
Postfach 330022
D-14191 Berlin
+49 (0) 72 22 - 105 -137
List of contents
Basics of Membrane Technology
27
1.1
Basics of Material Separation by means of Membrane Technology
28
1.2
Membrane Processes in Waste Water Purification
29
1.2.1
Micro- and Ultrafiltration
32
1.2.2
NF
Nanofiltration
33
1.2.3
RO
Reverse Osmosis
34
Membrane Materials, Structure and Classification
35
1.3
1.3.1
Origin and Materials
35
1.3.2
Morphology, Structure and Manufacturing
36
1.4
Membrane Forms and Modules
38
1.5
Arrangement of Modules
46
1.6
Operating Modes
48
1.7
Formation of Covering Layers
50
1.8
Measures for Maintenance of the Filtration Capacity
52
1.9
Other Aspects Concerning the Use of Membrane Technology in Waste Water Treatment 55
Membrane Technology in Municipal Waste Water Treatment
61
2.1
The Membrane Bioreactor Process
66
2.1.1
Description of the Process and Fields of Application
66
2.1.2
Membrane Modules
70
2.1.3
Planning and Operation of Membrane Bioreactors
82
2.1.3.1
Design
82
2.1.3.2
Mechanical Design and Planning
87
2.1.3.3
2.1.4
89
92
2.1.4.1
Investments
92
2.1.4.2
Operating and Maintenance Costs
94
2.2
Concrete Examples of Membrane Bioreactors
95
MF
Waste Water Treatment Plants with Microfiltration Membrane Installations in Germany
98
2.2.1.1
MF
Seelscheid Waste Water Treatment Plant and Training Centre
2.2.1.2
MF
Bchel Pilot Plant
101
2.2.1.3
MF
Richtheim Waste Water Treatment Plant
103
2.2.1.4
MF
Eitorf Waste Water Treatment Plant (Commissioning)
104
2.2.1.5
MF
Xanten-Vynen Waste Water Treatment Plant (Commissioning)
106
2.2.1.6
MF
Piene Waste Water Treatment Plant (in Planning Stage)
107
2.2.1.7
MF
Rurberg-Woffelsbach and Konzen Waste Water Treatment Plants (Commissioned)
108
2.2.1.8
MF
Kohlfurth Waste Water Treatment Plant, Process Water Treatment
109
2.2.1.9
MF
Dormagen Waste Water Treatment Plant, Process Water Treatment (Commissioned)
110
MF
Installations Outside of Germany with Microfiltration Membranes
111
2.2.2.1
MF
Glasgow Waste Water Treatment Plant, Scotland
112
2.2.2.2
MF
Ebisu Prime Square Building Waste Water Treatment Plant, Japan
114
2.2.2.3
MF
St. Peter ob Judenburg Waste Water Treatment Plant, Austria
115
UF
Waste Water Treatment Plants in Germany with Ultrafiltration Membranes
116
2.2.3.1
UF
Nordkanal Waste Water Treatment Plant
116
2.2.3.2
UF
Monheim Waste Water Treatment Plant
118
2.2.3.3
UF
Markranstdt Waste Water Treatment Plant
121
2.2.1
2.2.2
2.2.3
MF
Operation
Investments and Operating Costs
microfiltration
UF
ultrafiltration
NF
nanofiltration
RO
98
reverse osmosis
List of contents
2.2.3.4
UF
Rdingen Waste Water Treatment Plant
2.2.3.5
UF
Schramberg-Waldmssingen Waste Water Treatment Plant
125
2.2.3.6
UF
Knautnaundorf Waste Water Treatment Plant
127
2.2.3.7
UF
Simmerath Pilot Plant
128
2.2.3.8
UF
St. Wendel Golf Course
130
2.2.3.9
UF
Glessen Waste Water Treatment Plant (Planning Stage)
132
UF
Installations Outside of Germany with Ultrafiltration Membranes
133
2.2.4.1
UF
Pilot Plants at the Beverwijk Waste Water Treatment Plant, The Netherlands
134
2.2.4.2
UF
Varsseveld Waste Water Treatment Plant, The Netherlands
136
2.2.4.3
UF
Brescia Waste Water Treatment Plant, Italy
137
2.2.4.4
UF
Sntis Waste Water Treatment Plant, Switzerland
139
2.2.4
2.3
123
Small Waste Water Treatment Plants, Mobile Installations and

Ships Waste Water Treatment with Membrane Technology
2.3.1
Busse-MF Installation from the Company Busse
140
2.3.2
MF
UltraSept Installation from the Company Mall
142
2.3.3
MF
Small Waste Water Treatment Plant for 4 PE in North-Rhine Westphalia
143
2.3.4
UF
Kreditanstalt fr Wiederaufbau (KfW), Service Water Treatment
143
2.3.5
UF
and Huber
HoneyComb
144
2.3.6
MF
Mobile Installations for the Use in Military Camps
146
2.3.7
MF
Ships Waste Water Treatment Plants with Membrane Technology
147
2.3.8
UF
Cruise Liner Queen Mary 2
148
Grey and Black Water Treatment on Ships
150
2.4
Downstream Membrane Stage for Waste Water Disinfection
152
2.4.1
Process Description and Fields of Application
152
2.4.2
Membrane Modules Used
152
2.4.3
Operating Experience
153
UF
Large-Scale Applications in Germany for Waste Water Disinfection by Ultrafiltration
153
2.4.4.1
UF
Geiselbullach Waste Water Treatment Plant
154
2.4.4.2
UF
Merklingen Waste Water Treatment Plant
155
2.4.4.3
UF
Bondorf-Hailfingen Waste Water Treatment Plant
157
UF
Large-Scale Applications Outside of Germany for Waste Water Disinfection by Ultrafiltration 159
2.4.5.1
UF
Torreele, Belgium
159
2.4.5.2
UF
Katowice Treatment Plant, Poland
161
2.4.5.3
UF
Bedok Waste Water Treatment Plant, Singapore
162
2.4.4
2.4.5
2.5
Small Waste Water Treatment Plant
MembraneClearBox
from the Company Huber AG
2.3.9
MF
140
MF
Example for the Design of a Membrane Bioreactor
163
2.5.1
Design Basis
163
2.5.2
Interpretation of the ARA-BER Calculation According to the Design Recommendations for

Membrane Bioreactors
164
2.5.3
Design of the Membrane Filtration Stage
165
2.5.4
Printout of the Design Results with ARA-BER
166
microfiltration
UF
ultrafiltration
NF
nanofiltration
RO
reverse osmosis
List of contents
Membrane Technology in Industrial Waste Water Treatment
3.1
Brief Overview
168
3.2
Objectives and Applications in Different Industrial Branches
170
3.3
Decision Criteria
172
3.4
Economic Efficiency of Membrane Installations in Industrial
3.5
3.5.1
3.5.1.1
3.5.1.1.1
RO
3.5.1.2
Waste Water Treatment
174
Sample Applications of Plants in Germany
177
Food Industry
179
Potato Starch Production
180
Food Industry, Emsland Strke GmbH
181
Malt Houses
182
3.5.1.2.1
RO
Malthouse Durst Malz H. Durst Malzfabriken GmbH & Co. KG
183
3.5.1.3
UF
Food Industry, BEECK Feinkost GmbH & Co. KG
184
UF
Printing Industry, Peter Leis
185
Paper Mills
186
3.5.2
3.5.3
3.5.3.1
NF
3.5.4
Paper Mill Palm, Works Eltmann
187
Textile Industry
188
3.5.4.1
UF
Textile Industry, Drews Meerane
189
3.5.4.2
MF
Silk Weaving Mill PONGS
191
Textile Finishing Works Gerhard van Clewe GmbH & Co. KG
193
3.5.5
RO
Fibre Industry, Vulcanized Fibre
195
3.5.6
UF
Plastics Industry, Troplast
197
Laundries
198
3.5.4.3
3.5.7
3.5.7.1
Laundry Alsco
198
3.5.7.2
Textile Service Mewa GmbH
201
3.5.8
Metal Processing Industry
203
3.5.8.1
UF
Metal Processing Industry, Rasselstein Hoesch GmbH
204
3.5.8.2
UF
Metal Processing Industry, Faurecia Bertrand Faure Sitztechnik GmbH & Co. KG
205
Metal Processing Industry, Electroplating Enterprise Rudolf Jatzke
206
3.5.8.3
3.5.8.4
3.5.9
Metal Processing Industry, Wieland Werke AG
208
Treatment of Waste Water from Car Painting
210
210
3.5.9.1
UF
Treatment of Waste Water from Car Painting, DaimlerChrysler AG
3.5.9.2
NF
Treatment of Paint Waste Water from the Production of Spare Parts in the Ford Works,
Cologne
211
Pharmaceutical Industry, Schering
213
Miscellaneous
215
Landfill Leachate
215
3.5.11.1.1
RO
Alsdorf-Warden Landfill
218
3.5.11.2
MF
Fish Hatchery
220
3.5.11.3
UF
Power Stations, Dresden Gas and Steam Turbine Heating Power Station (GuD)
221
3.5.11.4
UF
De-oiling of Bilge Water
223
3.5.11.5
Swimming Pools
225
3.5.11.5.1
Swimming Pool, Aquana Freizeitbad GmbH & Co. KG
225
3.5.10
UF
3.5.11
3.5.11.1
3.5.11.5.2
3.6
3.6.1
MF
167
microfiltration
UF
UF
Swimming Pool, Freizeitbad Copa Ca Backum
227
Sample Applications of Plants Outside of Germany
229
Food Industry
230
ultrafiltration
NF
nanofiltration
RO
reverse osmosis
List of contents
3.6.1.1
UF
Muesli Production at the Kellogg Company, Great Britain
3.6.1.2
UF
Primary Starch Production at Raisio Chemicals, Belgium
232
3.6.1.3
UF
Dairygold Food Products, Ireland
233
3.6.1.4
UF
Dairy Crest Limited, Great Britain
235
3.6.1.5
UF
Malthouse Sobelgra n. v., Belgium
236
3.6.2
3.6.3
RO
Laundry Massop, The Netherlands
239
MF
Pharmaceutical Industry, Penicillin Production at the Company Sandoz /Biochemistry, Spain
240
Miscellaneous
242
Animal Carcass Disposal Plant of SARIA Bio-Industries, France
242
3.6.4
3.6.4.1
UF
3.6.4.2
3.6.4.2.1
230
UF
Mechanical-Biological Waste Treatment Plant
244
Waste Disposal at the Company TIRME, Spain
244
Instructions and Standards in Membrane Technology
247
Summary and Outlook
251
References
253
Annex
263
A.1
Addresses (mentioned in the concrete examples)
264
A.1.1
Locations of the membrane systems in Germany
264
A.1.2
Planners and manufacturers of installations, membrane manufacturers, Consulting Engineers
268
A.1.3
Scientific assistance for the realization of this publication
272
A.1.4
Other institutions and persons having contributed to the contents
274
A.1.5
Other information sources in the field of membrane technology
275
A.2
Possibilities for promotion
276
A.2.1
Development programs and advisory service of the Federal Government
276
A.2.2
Development programs of the federal states
277
A.2.3
Development programs of the EU in the field of pollution control and water management 282
A.3
Short check lists for Figure 2-1
284
A.4
286
A.5
Work report of the ATV-DVWK working group

IG-5.5 Membrane Technology: Treatment of industrial waste water and
Part I
MF
10
process water by membrane processes and membrane bioreactor processes
288
Membrane processes
288
A.5.1
Introduction
288
A.5.2
Choice of a membrane process
291
A.5.2.1
Determination of the necessary molecular separation size
291
A.5.2.2
Determination of the membrane material
291
A.5.2.3
Determination of the membrane module
293
A.5.2.4
Determination of the operating mode of membrane installations
295
A.5.3
Examples for the use of membrane processes
296
A.5.4
Planning of membrane installations
296
A.5.4.1
Acquisition of basic data
296
A.5.4.2
Planning and design
296
A.5.4.2.1
Preliminary laboratory tests
296
microfiltration
UF
ultrafiltration
NF
nanofiltration
RO
reverse osmosis
List of contents
A.5.4.2.2
On-site pilot tests
A.5.4.2.3
Planning of the installation
297
Assessment criteria for the choice of a membrane installation
298
A.5.5.1
Technical assessment of a membrane process concerning employment and completeness
298
A.5.5.1.1
Definition of the terms of reference
298
A.5.5.1.2
Material and mass fluxes during operation of a membrane installation
298
A.5.5.1.3
Utilization or discharge of the resulting products
299
A.5.5.1.4
Pretreatment
299
A.5.5.1.5
Technical realization
299
A.5.5.1.6
Redundancies
299
A.5.5.1.7
References/similar applications
299
A.5.5.2
Operating costs
299
A.5.5.2.1
Equipment
299
A.5.5.2.2
Auxiliaries
299
A.5.5.2.4
Service life and replacement of membranes
299
A.5.5.3
Change of the conditions during operation of the installation
300
A.5.5.4
Other items
300
A.5.5.4.1
Failures
300
A.5.5.4.2
Preliminary tests
300
Questionnaire for the acquisition of process data
300
A.5.6.1
Description of the separation problem to be solved with the help of a membrane process
300
A.5.5
A.5.6
A.5.6.2
297
Concerning the assessment or the integration of a membrane process into an

overall treatment concept
301
A.5.6.3
Sizing of the installation
301
A.5.6.4
Requirements for the construction of the membrane installation
301
Part II
Aerobic membrane bioreactor processes
301
A.5.7
General information
301
Construction
302
Arrangement
302
A.5.8
A.5.8.1
A.5.8.1.1
Immersed membrane modules
302
A.5.8.1.2
Dry-arranged membrane modules
302
A.5.8.2
Control of the covering layer
303
A.5.8.2.1
Control of the covering layer in immersed systems
303
A.5.8.2.2
Covering layer control in dry-arranged systems
303
A.5.8.2.3
General facts
304
A.5.8.3
Cleaning strategies
304
Requirements for the influent
306
A.5.9
A.5.9.1
General information
306
A.5.9.2
Mechanical pretreatment
306
A.5.9.3
Mixing and equalizing tank
307
A.5.9.4
Calcium concentration
307
A.5.9.5
Iron and aluminium content
307
Instructions for the design of membrane bioreactors
307
A.5.10
A.5.10.1
General information
307
A.5.10.2
Space requirements
308
A.5.10.3
Elimination rates
308
11
List of contents
A.5.10.4
Aeration
309
A.5.10.5
Hydraulics
309
A.5.10.5.1
Flexibility
309
A.5.10.5.2
Recirculation
309
A.5.10.6
Influence of the temperature
310
Specific features of membrane bioreactors
310
A.5.11.1
Sludge features
310
A.5.11.1.1
Characterization of the sludge
310
A.5.11.1.2
Rheological properties
310
A.5.11.1.3
Excess sludge production
311
A.5.11.1.4
Sludge treatment
311
A.5.11.1.5
Foam development
311
Economic efficiency
312
A.5.11
A.5.12
A.5.12.1
Definition of economic efficiency
312
A.5.12.2
Investment/capital costs
312
A.5.12.3
Operating costs
313
A.5.12.4
Comparison of cost-relevant factors
314
A.5.13
Examples in the field of industrial waste water (Europe)
315
A.5.14
Literature
315
2 nd Work report of the DWA Committee of Experts KA-7
A.6
Membrane bioreactor process from 19th January 2005

A.6.1
Introduction
317
A.6.2
Description of the membrane bioreactor process
318
A.6.3
Instructions for planning and design
322
A.6.4
Sludge treatment
326
A.6.5
Chemical cleaning of the membrane modules
328
A.6.6
Energy demand
329
A.6.7
Upgrading of existing municipal waste water treatment plants
331
A.6.8
Instructions for start-up
332
A.6.9
Costs
333
A.6.10
Annual costs
336
A.6.10.1
Loan servicing and membrane replacement
336
A.6.10.2
Operating costs
336
A.6.11
Final remark
336
A.6.12
Advantages and risks of the membrane bioreactor process
337
General facts
337
Glossary
337
Literature
341
A.6.12.1
A.6.13
A.6.14
12
317
A.7
Large-scale membrane installations for drinking water treatment in Germany 343
A.8
Glossary
344
A.9
List of abbrevations
346
List of figures
27
Figure 1-1
Operating principle of micro- and ultrafiltration membranes
28
Figure 1-2
The different fields of application of membrane processes
29
Figure 1-3
Size of typical waste water constituents and the pore size of membranes applied
30
Figure 1-4
Idealized representation of a pore membrane and a solution-diffusion membrane

[according to MELIN 1999]
31
Figure 1-5
Classification of membranes [according to RAUTENBACH 1997]
35
Figure 1-6
Scanning electron micrographs of cross-sections of different membranes
37
Figure 1-7
Top view of the active layer of a polyethylene membrane (MF/UF) [AGGERVERBAND 2002]
37
Figure 1-8
Top view of the broken edge of a polyethylene membrane (MF/UF), the active layer is visible
[AGGERVERBAND 2002]
37
Figure 1-9
Membrane and module forms
38
Figure 1-10
Tube modules [photo: WEHRLE WERK AG]
40
Figure 1-11
Capillary or hollow-fibre modules [photo: KOCH MEMBRANE SYSTEMS]
41
Figure 1-12
Spiral-wound modules [schematic drawing: N. N. 2001], [photo: NADIR FILTRATION GMBH]
42
Figure 1-13
Cushion module [schematic drawing and photo: ROCHEM UF SYSTEME GMBH]
43
Figure 1-14
Disc-tube module (DT module) [PALL 2001]
44
Figure 1-15
New Multibore capillaries from the company inge AG [photo: INGE AG]
45
Figure 1-16
From the membrane element to the membrane stage
46
Figure 1-17
Series connection of modules [according to BAUMGARTEN 1998]
46
Figure 1-18
Parallel connection of modules [according to BAUMGARTEN 1998]
47
Figure 1-19
Arrangement of several modules according to the fir tree structure

[according to RAUTENBACH 1997]
Figure 1-20
47
Schematic representation of a membrane in cross-flow- and dead-end filtration

[according to MELIN 1999]
49
Figure 1-21
Filtration intervals in dead-end operation [according to RAUTENBACH 1997]
49
Figure 1-22
Schematic overview of the filtration resistances on the membrane surface and inside the membrane
[KRAMER, KOPPERS 2000]
51
Figure 1-23
Effect of membrane cleaning on the flow at constant pressure
53
Figure 1-24
Molar masses of selected natural organic constituents in domestic waste water
58
Figure 1-25
Molar masses of selected organic trace substances
59
61
Figure 2-1
Background planning operation of a municipal membrane bioreactor, contents of the chapter

Membrane technology in municipal waste water treatment
Figure 2-2
Conventional waste water treatment according to the activated sludge process and possibilities for
the arrangement of a membrane stage at municipal waste water treatment plants [OHLE 2001]
Figure 2-3
65
Comparison of the germ load in the effluent of waste water treatment plants [BAUMGARTEN,
BRANDS 2002]
Figure 2-5
64
Flow sheet of a waste water treatment plant with membrane bioreactor process and downstream
membrane stage
Figure 2-4
63
68
Schematic representation of the space requirements of a conventional activated sludge plant

(edged in blue) and of a membrane bioreactor (edged in red), example: Nordkanal waste water
treatment plant [ERFTVERBAND 2002]
69
13
List of figures
Figure 2-6
ZeeWeed -module from the company ZENON
70
Figure 2-7
Arrangement of several ZeeWeed -modules ZW 1000 in a cassette [photo: ZENON 2004]
71
Figure 2-8
Plate module from the company Kubota
71
Figure 2-9
Basic schematic of the plate module double-decker from the company Kubota
[AGGERWASSER GMBH 2004]
72
PURON module and module component [photo: PURON AG]
73
Figure 2-11
Membrane module from Martin Systems AG
74
Figure 2-12
Huber VRM process [photos: HANS HUBER AG, MARTIN SYSTEMS AG]
75
Figure 2-10
VUM
Figure 2-13
Huber
Figure 2-14
Membrane element and membrane module from the company Mitsubishi [photo: ENVICARE ]
process [HANS HUBER AG]
76
Figure 2-15
Plate module from the company A3 GmbH [photo: A3 GMBH]
77
Figure 2-16
Membrane module from US Filter Corporation [photo: US FILTER CORPORATION 2004]
78
Figure 2-17
Membrane module from the Keppel Seghers Belgium [photo: KEPPEL SEGHERS BELGIUM NV]
78
Figure 2-18
Membrane system from Weise Water Systems GmbH & Co. KG

[WEISE WATER SYSTEMS GMBH & CO. KG]
79
Figure 2-19
Ceramic plate membranes from the company ItN Nanovation [photo: ItN NANOVATION]
80
Figure 2-20
Membrane module and configuration of the modules in the rack with underlying aeration device
[photos: ItN NANOVATION]
80
Figure 2-21
Basic layout sketch of the rotation disc filter
81
Figure 2-22
Modules of the rotation disc filter in laboratory scale [photo: FRAUNHOFER IGB]
81
Figure 2-23
Specific excess sludge production in membrane bioreactors [ATV-DVWK 2000a]
83
Figure 2-24
Oxygen transfer coefficient (-values) of the Rdingen and Markranstdt waste water treatment
plants with fine-bubble diffuser aeration [CORNEL ET AL. 2001]
Figure 2-25
View and principle of a screening facility for membrane bioreactors (Markranstdt waste water
Figure 2-26
Energy demand of a membrane bioreactor (8,000 PE) with simultaneous aerobic sludge
treatment plant) [HUBER 2002, STEIN 2002a]
86
87
stabilization [STEIN ET AL. 2001]
91
Development of membrane replacement costs [ISA 2002; CHURCHHOUSE, WILDGOOSE 2000]
94
Figure 2-28
Flow sheet of the Seelscheid waste water treatment plant [according to AGGERVERBAND 2004]
99
Figure 2-29
Membrane installation at the Seelscheid waste water treatment plant
Figure 2-27
[photos: AGGERVERBAND 2004]

Figure 2-30
99
Existing sand filter tanks, to be used for the training installations [photo: AGGERVERBAND 2004]
100
Figure 2-31
Flow sheet of the training installations [according to AGGERVERBAND 2004]
100
Figure 2-32
View of the Bchel pilot plant [photo: ISA RWTH AACHEN]
101
Figure 2-33
Flow sheet of the Bchel pilot plant [BAUMGARTEN 2001b]
101
Figure 2-34
Flow sheet of the membrane bioreactor [according to BAYERISCHES LANDESAMT FR
Figure 2-35
Figure 2-36
WASSERWIRTSCHAFT 2004]
103
Flow sheet of the Eitorf waste water treatment plant [according to GEMEINDEWERKE EITORF 2004]
104
Eitorf waste water treatment plant with covered membrane tanks between the buildings in the
foreground
Figure 2-37
Figure 2-38
105
Membrane installation in container construction for the Xanten-Vynen waste water treatment plant
[photo: A3 GMBH]
14
76
106
Flow sheet of the Xanten-Vynen waste water treatment plant, including the planned membrane
bioreactors [according to LINEG 2004]
106
Figure 2-39
Flow sheet of the membrane bioreactor [according to CITY OF GUMMERSBACH 2004]
107
Figure 2-40
Flow sheet of the Kohlfurth waste water treatment plant [according to WUPPERVERBAND 2004]
109
List of figures
Figure 2-41
Flow sheet of the Dormagen waste water treatment plant [according to CITY OF DORMAGEN 2004]
110
Figure 2-42
Aerial photograph of the Swanage waste water treatment plant [photo: AQUATOR GROUP]
111
Figure 2-43
Flow sheet of the Glasgow sludge treatment plant [according to AGGERWASSER GMBH 2004]
112
Figure 2-44
Top view of the sludge treatment plant and of a tank of the membrane installation
[photo: AGGERWASSER GMBH 2001]
113
Figure 2-45
Ebisu Prime Square Building [photo: AGGERWASSER GMBH 2004]
114
Figure 2-46
Waste water treatment plant in the basement of the Ebisu Prime Square Building
Figure 2-47
Figure 2-48
114
Flow sheet of the waste water treatment plant [according to AGGERWASSER GMBH 2004]
114
Flow sheet of the St. Peter ob Judenburg waste water treatment plant
[according to ENVICARE 2002]
115
Figure 2-49
St. Peter ob Judenburg waste water treatment plant [photos: ENVICARE]
116
Figure 2-50
Rotary screen of the fine screen installation
117
Figure 2-51
Flow sheet of the Nordkanal waste water treatment plant [according to ERFTVERBAND 2004]
117
Figure 2-52
Membrane installation at the WWTP Nordkanal
118
Figure 2-53
Monheim waste water treatment plant [photo: BAYERISCHES LANDESAMT FR

WASSERWIRTSCHAFT (Bavarian Office for Water Management) 2004]
Figure 2-54
119
Flow sheet of the Monheim waste water treatment plant [according to BAYERISCHES
LANDESAMT FR WASSERWIRTSCHAFT 2004]
119
Figure 2-55
Module cassettes during in-air cleaning [photo: CITY OF MONHEIM 2004]
120
Figure 2-56
Process stages at the Markranstdt waste water treatment plant [STEIN 2002a].
121
Figure 2-57
Process stages at the Markranstdt waste water treatment plant [STEIN 2002a]
122
Figure 2-58
Flow sheet of the Rdingen waste water treatment plant
124
ZeeWeed
Figure 2-59
View into the two filtration lines during fitting of the
Figure 2-60
Schramberg-Waldmssingen waste water treatment plant [photo: STADTWERKE SCHRAMBERG
cassettes [photo: ERFTVERBAND]
(municipal utilities) 2004]

Figure 2-61
125
Flow sheet of the Schramberg-Waldmssingen waste water treatment plant [according to

STADTWERKE SCHRAMBERG 2004]
Figure 2-62
124
126
Membrane installation at the Schramberg-Waldmssingen waste water treatment plant

[photos: STADTWERKE SCHRAMBERG 2004]
126
Figure 2-63
Flow sheet of the Simmerath demonstration plant [according to WVER 2004]
128
Figure 2-64
Membrane installation at the Simmerath waste water treatment plant [photos: PURON AG 2003] 129
Figure 2-65
Flow sheet of the golf course St. Wendel waste water treatment plant [according to ST. WENDEL] 130
Figure 2-66
Module rack at the golf course St. Wendel waste water treatment plant [photos: ItN NANOVATION]
131
Figure 2-67
Flow sheet of the Glessen waste water treatment plant [according to ERFTVERBAND 2004]
132
Figure 2-68
Aerial photograph and flow sheet of the Lowestoft waste water treatment plant [ZENON 2002]
133
Figure 2-69
Photos of the pilot installations and membrane modules at the test field of the Beverwijk waste
water treatment plant [DHV 2004]
135
Figure 2-70
Flow sheet of the Varsseveld waste water treatment plant [according to DHV 2004]
136
Figure 2-71
Flow sheet of the Brescia waste water treatment plant [according to ZENON GMBH 2004]
137
Figure 2-72
Aerial photograph of the Brescia waste water treatment plant [photo: ZENON GMBH 2004]
138
Figure 2-73
View and flow sheet of the membrane bioreactor according to the ZenoGem process on the Sntis
[ZENON 2002]
Figure 2-74
View of the Busse MF small waste water treatment plant (formerly
Figure 2-75
Flow sheet of a Busse-MF installation [BUSSE 2002]
139
BioMIR )
[BUSSE 2002]
140
141
15
List of figures
Figure 2-76
Schematic representation of the UltraSept installation from the company Mall [MALL 2002]
142
Figure 2-77
Grey water treatment plant at KfW
143
Figure 2-78
Membrane installation for the treatment of service water in the cellar of KfW
[WEISE WATER SYSTEMS GMBH]
Figure 2-79
144
Plot plan of a small waste water treatment plant with membrane technology installed in a
multicompartment septic tank [HUBER AG 2004]
Figure 2-80
Figure 2-81
145
Small waste water treatment plant MembraneClearBox from Huber AG [photos: HUBER AG 2004] 145
Transportation of the container plant by an emergency vehicle and schematic representation of
the plant [A3 GMBH 2004]
Figure 2-82
146
View of a MEMROD ships waste water treatment plant according to the membrane bioreactor
process for 250 persons [VA TECH WABAG 2002]
Figure 2-83
148
Ultrafiltration module Pleiade for waste water treatment on Queen Mary 2

[photo: ORELIS SA 2004]
148
Figure 2-84
Photo of the Queen Mary 2
149
Figure 2-85
Flow sheet of the waste water treatment plan of Queen Mary 2 [according to ORELIS SA 2004]
149
Figure 2-86
Flow sheet of waste water treatment according to the two-stream solution

[according to ROCHEM UF 2004]
150
3
Figure 2-87
Membrane bioreactor BioFilt with three lines at 4.5 m of permeate per day each [ROCHEM UF 2004] 151
Figure 2-88
Low-pressure reverse osmosis for grey water treatment for 600 m3 of permeate per day
[photo: ROCHEM UF 2004]
Figure 2-89
Figure 2-90
Treatment installation at the Geiselbullach waste water treatment plant

[photos: AMPERVERBAND 2002]
155
Figure 2-91
Flow sheet of the Merklingen waste water treatment plant [according to RP TBINGEN 2004]
155
Figure 2-92
Pressure tubes of the ultrafiltration plant at the Merklingen waste water treatment plant
[RP TBINGEN 2004]
Figure 2-93
Figure 2-95
Figure 2-96
156
Flow sheet of the Bondorf-Hailfingen waste water treatment plant [according to BONDORFHAILFINGEN WASTE WATER UNION 2004]
Figure 2-94
158
Membrane installation at the Bondorf-Hailfingen waste water treatment plant under construction
[photos: BONDORF-HAILFINGEN WASTE WATER UNION 2004]
158
Flow sheet of the Torreele treatment plant [according to ZENON GMBH 2004]
160
Flow sheet of the ultrafiltration installation for process water treatment in Katowice
[according to ZENON GMBH 2004]
161
Figure 2-97
Flow sheet of the treatment plant [according to ZENON GMBH 2004]
162
Figure 2-98
General view of the treatment plant [photo: ZENON GMBH 2004]
163
Figure 2-99
Ultrafiltration membrane installation [photo: ZENON GMBH 2004]
163
167
Figure 3-1
Motive planning operation of a membrane installation, overview of the contents of the chapter
Membrane technology in industrial waste water treatment
Figure 3-2
16
151
Flow sheet of the Geiselbullach waste water treatment plant [according to AMPERVERBAND 2004] 154
169
Objectives and economic interests for the use of a membrane installation in industrial waste water
treatment
170
Figure 3-3
How to proceed in the planning of an installation for industrial waste water treatment
173
Figure 3-4
Factors influencing the economic efficiency of membrane installations
175
Figure 3-5
Flow chart of potato starch production
180
List of figures
Figure 3-6
Flow chart of the treatment of process- and potato pulp water at Emsland Strke GmbH
[according to LOTZ 2000]
Figure 3-7
Figure 3-8
181
Reverse osmosis installation at Durst Malzfabriken GmbH & Co. KG, Gernsheim [LINDEMANN 2001] 183
Flow chart of the waste water treatment at BEECK Feinkost GmbH [according to
KOCH-GLITSCH GMBH 2001]
184
Figure 3-9
Ultrafiltration installation at the Grafische Handelsvertretung Peter Leis [LEIS IN EFA 2000]
186
Figure 3-10
Nanofiltration installation at the paper mill Palm, works Eltmann (left) [SCHIRM 2001] and detail of
the tube module arrangement as feed-and-bleed structure (right) [according to SCHIRM 2001]
188
Figure 3-11
Flow sheet of the waste water treatment and processing plant [according to ZENON GMBH 2004] 190
Figure 3-12
Conversion of the waste water treatment plant at PONGS Textil GmbH
191
Figure 3-13
Flow sheet of the membrane bioreactor of the company PONGS [according to A3 GMBH 2004]
192
Figure 3-14
Ultrafiltration installation at the textile finishing plant van Clewe [BTTGER 2001]
194
Figure 3-15
Flow sheet of the process water treatment at the vulcanized fibre works GmbH & Co. KG
[AMAFILTER 2001]
Figure 3-16
Figure 3-17
Figure 3-18
195
Reverse osomosis installation at the vulcanized fibre works Ernst Krger GmbH & Co. KG
[photo: AMAFILTER]
196
Ultrafiltration installation at the company HT Troplast AG [photo: HT TROPLAST]
197
Flow sheet of the waste water treatment process in the laundry ALSCO [according to
WEHRLE UMWELT GMBH 2004]
199
Figure 3-19
Membrane installation in the laundry Alsco [photos: WEHRLE UMWELT GMBH 2004]
200
Figure 3-20
Flow sheet of the treatment plant of Textile Service Mewa GmbH [according to ENVIRO CHEMIE 2004] 201
Figure 3-21
Ultrafiltration plant at Textile Service Mewa [photo: ENVIRO CHEMIE 2004]
202
Figure 3-22
Nanofiltration plant at Textile Service Mewa [photo: ENVIRO CHEMIE 2004]
202
Figure 3-23
Ultrafiltration installation at the company Rasselstein Hoesch [photo: MFT GMBH]
204
Figure 3-24
Ultrafiltration installation at the company Faurecia, Bertrand Faure Sitztechnik GmbH & Co. KG
[KASTEN 2001]
205
Figure 3-25
Mode of operation of the electrolysis membrane [SCHMIDT 2002]
207
Figure 3-26
Ultrafiltration installation at the works Werk Langenberg of Wieland Werke AG [MUNLV 2001]
209
Figure 3-27
Ultrafiltration installation in the DaimlerChrysler works at Dsseldorf [HARMEL 2001]
210
Figure 3-28
Flow sheet of paint-spraying [IMB + FRINGS WATERSYSTEMS GMBH 2004]
211
Figure 3-29
Nanofiltration plant at the Ford works Cologne [photo: IMB + FRINGS WATERSYSTEMS GMBH 2004] 212
Figure 3-30
Aerial photograph of the waste water treatment plant at Schering AG [photos: SCHERING AG 2004] 213
Figure 3-31
Flow sheet of the waste water treatment plant [according to SCHERING AG 2004]
214
Figure 3-32
Optical inspection of a membrane module [photo: SCHERING AG 2004]
215
Figure 3-33
Process combination according to the state of the art for the treatment of landfill leachate without
using membrane processes [ROSENWINKEL, BAUMGARTEN 1998]
Figure 3-34
216
Process combination according to the state of the art for the treatment of landfill leachate using
membrane processes with and without biological pretreatment [completed according to
ROSENWINKEL, BAUMGARTEN 1998]
216
Figure 3-35
Reverse osmosis installation at the landfill Alsdorf-Warden [MAURER 2001]
218
Figure 3-36
Structure of the composite membrane [MAURER 2001]
219
Figure 3-37
Flow sheet of a circuit installation for the treatment of waste water from fish hatchery
[UMWELTBUNDESAMT 2004]
221
Figure 3-38
Flow sheet of the RKU process [according to DPC 1997]
222
Figure 3-39
Ultrafiltration unit for the RKU process [photo: THERM-SERVICE]
223
Figure 3-40
Flow sheet of bilge de-oiling [according to DEUTSCH 2001]
224
17
List of figures
Figure 3-41
Water recirculation and treatment at the Aquana Freizeitbad [according to DEGEBRAN ]
226
Figure 3-42
Water treatment at the Freizeitbad Copa Ca Backum [according to L. V. H. T. 2001]
228
Figure 3-43
Flow sheet of the waste water treatment plant at the Kellogg Company in Manchester
[according to WEHRLE UMWELT GMBH 2004]
Figure 3-44
Cross-flow ultrafiltration at the Kellog Company in Manchester [photo: WEHRLE UMWELT

GMBH 2004]
231
Figure 3-45
Flow sheet of the membrane bioreactor at Raisio Chemicals [according to HUBER AG 2004]
232
Figure 3-46
Huber VRM process (rotating modules) [photos: HUBER AG 2004]
232
Figure 3-47
Flow sheet of the waste water treatment plant at Dairygold Food Products, Ireland
Figure 3-48
Figure 3-49
234
Complete plant at Dairygold Food Products with the membrane installation in the foreground
[WEHRLE UMWELT GMBH 2004]
234
Flow sheet of the waste water treatment at Dairy Crest, Great Britain [according to
236
Figure 3-50
Aerial photograph of the malthouse Sobelgra in the Antwerpen harbour [photo: PURON AG]
237
Figure 3-51
Flow sheet of the company-owned waste water treatment plant of the company Sobelgra
[according to PURON AG]
Figure 3-52
238
Schematic representation of the membrane bioreactor (left) and membrane modules (right)
[photo: PURON AG]
238
Reverse osmosis installation at the laundry Massop, Kerkrade [ROTH 2001]
239
Figure 3-54
Flow sheet of the membrane bioreactor in Barcelona [according to AGGERWASSER GMBH 2004]
241
Figure 3-55
Membrane bioreactor and membrane modules under construction at the company Sandoz in Spain
Figure 3-53
[photos: AGGERWASSER GMBH 2004]

Figure 3-56
Figure 3-58
Figure 3-59
241
Flow sheet of the membrane bioreactor at SARIA Bio-Industries in Bayet [according to

ZENON GMBH 2004]
Figure 3-57
243
General view of the membrane bioreactor of the animal carcass disposal plant in Bayet
[photo: ZENON GMBH 2004]
243
Container with fitted modules at SARIA Bio-Industries in Bayet [photo: ZENON GMBH 2004]
243
Flow sheet of the waste water treatment plant at the company TIRME, Spain [according to
245
Figure 3-60
Waste water treatment plant at the company TIRME [photos: WEHRLE UMWELT GMBH 2004]
245
Annex
263
Figure A-1
Schematic representation of the basic principle of a membrane process
289
Figure A-2
Classification of membrane and filtration processes
289
Figure A-3
Cross-section of a phase-inversion membrane, example: UF hollow-fibre membrane
292
Figure A-4
Composite membrane
292
Figure A-5
Front view of a tube module with 5.5 mm tubular membranes [photo: X-FLOW]
294
Figure A-6
View of a cushion module [type ROCHEM FM]
294
Figure A-7
Principle of a spiral-wound module
295
Figure A-8
298
Figure A-9
Schematic comparison of the conventional activated sludge process with the membrane
bioreactor process
Figure A-10
Figure A-11
18
231
302
Arrangement of the immersed membrane modules in the aerobic section of the

activated sludge tank
303
Arrangement of the immersed membrane modules in an external filtration tank
303
List of figures
Figure A-12
Membrane modules in dry arrangement
Figure A-13
Qualitative relationship between necessary membrane surface area, energy demand and flow
304
Figure A-14
Membrane filtration in dry arrangement
318
Figure A-15
Ways of configuring an immersed membrane filtration
319
Figure A-16
Schematic representation of different module constructions
320
Figure A-17
Typical operating modes of the membrane modules
321
Figure A-18
Influence of the solids concentrations on the -value for fine-bubble pressure aeration installations
325
Figure A-19
Specific energy consumption of the Markranstdt WWTP [STEIN, KERKLIES 2003]
330
Figure A-20
Specific energy consumption of the KA Monheim WWTP [WEDI 2003]
331
Figure A-21
Example for the distribution of construction costs of a membrane bioreactor for approximately
300 m3/h [WEDI 2003]
Figure A-22
303
334
Orienting net cost guide values for the ready-for-use membrane filtration installation without
structural part [WEDI 2003]
335
19
List of tables
Table 1-1
Pressure-driven membrane processes in waste water purification
31
Table 1-2
Characteristic features of micro- and ultrafiltration
32
Table 1-3
Characteristic features of nanofiltration
33
Table 1-4
Characteristic features of reverse osmosis
34
Table 1-5
Characteristic values, advantages and disadvantages of module types with tubular membranes
39
Table 1-6
Characteristic values, advantages and disadvantages of module types with flat membranes
39
Table 1-7
Formation of covering layers in membrane filtration [according to BAUMGARTEN 1998]
51
Table 1-8
Methods for reduction and removal of covering layers
52
Table 1-9
Examples of cleaning chemicals and their applications
54
Table 1-10
Molecular separation size and transmembrane pressure of pressure-driven membrane processes
55
Table 1-11
Data on the size of viruses and bacteria
56
Table 1-12

[KOPPE, STOZEK 1999]
57
Table 1-13
Molar masses of selected organic trace substances [MUNLV 2004]
59
61
Table 2-1
Advantages of the membrane bioreactor process compared to the conventional activated sludge process 66
Table 2-2
Performance data of membrane bioreactor plants compared to conventional activated sludge plants
Table 2-3
Table 2-4
[DOHMANN ET AL. 2002]
67
Cleaning methods
90
Savings potentials and additional costs concerning the investments of membrane bioreactors
compared to conventional activated sludge plants
Table 2-5
93
Data of the large-scale membrane bioreactors treating municipal waste water in Germany,
as of December 2004
96
Table 2-6
Membrane bioreactors under construction or in planning stage in Germany, as of December 2005
97
Table 2-7
Minimum requirements, discharge consent and operating values of the Seelscheid waste water
Table 2-8
Input values for the design of the Eitorf membrane bioreactor [according to
treatment plant [according to AGGERVERBAND 2004]

GEMEINDEWERKE EITORF (municipal utilities) 2004]
Table 2-9
98
104
Demands on the effluent quality of the Rurberg-Woffelsbach and Konzen waste water treatment
plants [according to WVER 2004]
108
Raw waste water and permeate quality [according to AGGERWASSER GMBH 2004]
114
Table 2-11
Influent and effluent concentrations of the waste water treatment plant
115
Table 2-12
Minimum requirements and discharge consent of the Nordkanal waste water treatment plant
Table 2-13
Minimum requirements, discharge consent and operating values of the Monheim waste water
Table 2-14
Minimum requirements, discharge consent and operating values of the Markranstdt waste water
Table 2-10
[ERFTVERBAND 2004]
treatment plant [BAYERISCHES LANDESAMT FR WASSERWIRTSCHAFT 2004]
treatment plant [STEIN 2002a]
Table 2-15
116
120
121
Minimum requirements and discharge consent of the Rdingen waste water treatment plant
[according to ENGELHARDT ET AL. 2001]
123
Discharge consent of the Simmerath waste water treatment plant [WVER 2004]
128
Table 2-17
Operating values of the membrane bioreactor in Simmerath [WVER 2004]
129
Table 2-18
Minimum requirements, discharge consent and operating values of the golf course St. Wendel
Table 2-16
waste water treatment plant [CITY OF ST. WENDEL 2005]
20
27
130
List of tables
Table 2-19
Table 2-20
Table 2-21
Demands on the effluent quality of the Glessen waste water treatment plant
[according to ERFTVERBAND 2004]
132
Key features of the individual pilot installations [DHV 2004]
134
Raw waste water concentration, operating values and requirements of the Brescia waste water
treatment plant [ZENON GMBH 2004]
Table 2-22
Requirements for the effluent quality of small waste water treatment plants and measured effluent
values of the Busse-MF installation
Table 2-23
138
141
Characteristic values of different membrane modules for the filtration of effluents from the test
installations of Berliner Wasserbetriebe and the test installations at the Geiselbullach, Halfingen
Table 2-24
Table 2-25
and Merklingen waste water treatment plants
152
Membrane installations for waste water disinfection in Germany
153
Demands on the effluent quality and operating values of the Bondorf-Hailfingen waste water
treatment plant [BONDORF-HAILFINGEN WASTE WATER UNION 2004]
157
Table 2-26
Quality of the effluent of the Wulpen waste water treatment plant [ZENON GMBH 2004]
159
Table 2-27
Waste water quality at the inlet and outlet of the ultrafiltration installation for treatment of the
effluent of the Katowice WWTP after secondary clarification up to process water quality
[ZENON GMBH 2004]
Table 2-28
Design results according to the approach of the University Group (HSG) for a conventional waste
water treatment plant with TSBB = 12 g/l
Table 2-29
161
164
Determination of the necessary volumes, taking into account different requirements for the
design of membrane installations
164
167
Table 3-1
Objectives for the utilization of membrane technology in industrial waste water treatment
171
Table 3-2
Sequence of planning for a membrane installation [according to THEILEN 2000; PETERS 2001]
174
Table 3-3
Sample applications for the use of membrane technology in industrial waste water treatment
in Germany
178
Table 3-4
Quality of the recycling water 2 [ENVIRO CHEMIE 2004]
203
Table 3-5
Inflow values, effluent requirements and operating values of the plant [SCHERING AG 2004]
214
Table 3-6
A
Table A-1
Sample applications for the use of membrane technology in industrial waste water treatment
outside of Germany
229
Annex
263
Contacts for development programs of the federal states and selected development programs
concerning waste water avoidance, closed process water circuits
278
Table A-2
Membrane processes and their fields of application
291
Table A-3
Overview of the most current membrane materials for the different membrane processes
293
Table A-4
Features and fields of application of different module types
294
Table A-5
Membrane installations in West European industry
314
Table A-6
Characteristic data of designed membrane bioreactors [WEDI 2002a]
324
Table A-7
Studies on the dewaterability of excess sludge on a large-scale centrifuge
327
Table A-8
Membrane-specific annual cost shares
336
21
22
Introduction
What is membrane technology?
Membrane processes in waste water treatment
Membrane technology is a physical process for the sepa-
Due to high efficiency and the possibility of saving costs,
ration of material mixtures in which the membranes
membrane processes currently represent a proven alter-
function like a filter. The separated substances are neither
native to classical procedures for many applications in
thermally nor chemically nor biologically modified. In
the waste water treatment.
waste water treatment membrane technology is also used

in combination with other purification methods, e. g.
The high purification efficiency of membrane processes,
biological procedures.
in particular the combination of an activated sludge stage

with downstream micro- or ultrafiltration, makes it pos-
Fields of application
sible to meet the requirements of tertiary waste water

treatment that are legislated for the protection of surface-
World-wide the field of application of membrane techno-
and groundwater. Without membrane technology, these
logy is becoming more and more broad. While its begin-
requirements can often only be met by a combination of
nings lay in the field of water purification in the desali-
different process stages (e. g. activated sludge stage, con-
nation of sea and brackish water in arid zones, it is used
ventional filtration, disinfection). By using membrane
for decades also for the separation of valuable materials
technology, it is possible in certain cases to reduce the
from small water volumes, e. g. in biotechnology, in the
costs of water supply and waste water treatment as well
pharmaceutical and chemical industry, the metal-work-
as production costs.
ing industry and in the food and beverage industry.

In addition, membrane technology got accepted as effi-
Objectives in waste water treatment
cient and economic procedure for the treatment of highstrength industrial waste water. Membrane technology
In municipal and industrial waste water treatment, mem-
has been tested and applied for the last ten years for the
brane processes are applied to satisfy the following objec-
treatment of comparably low-loaded and big water volu-
tives:
mes in drinking water treatment as well as in municipal

waste water treatment (membrane bioreactor process).
retention
(e. g. of solid matter including biomass, of hazardous
Membrane processes are used in drinking water treatment

to improve the retention of particles and to remove micro-
material, of dissolved matter by reverse osmosis)

purification
organisms. Ultrafiltration is predominantly used in this
(e. g. for industrial water treatment, for disinfection by
field because not only germs but also viruses are safely
retention of bacteria)
retained. Membrane processes for drinking water preparation are not treated in detail in this publication. Existing
plants with membrane technology are listed in Annex A7.
concentration
(e. g. for the recycling of valuable substances)
fractionation
(e. g. for separation into two or more components)
The membrane processes microfiltration, ultrafiltration,

nanofiltration and reverse osmosis are classified according to the size or molar mass of the separated substances.
Their different molecular separation sizes allow for the
choice of the suited process for the particular task. For
more complex tasks, the combination with other processes, e. g. biological or chemical processes, is a possibility.
In the same way, two membrane processes may be combined.
23
Introduction
Advantages of membrane technology in waste
With view to possibly increasing requirements for the
water treatment
waste water treatment technology, the attractiveness of

the membrane bioreactor process (micro- or ultrafiltra-
The membrane bioreactor process with immersed mem-
tion) combined with a downstream nanofiltration or
branes can be used for industrial as well as municipal
reverse osmosis installation will grow. Due to the high
waste water treatment. Compared to conventional waste
attainable sludge age and the downstream membrane
water treatment processes (activated sludge stage, secon-
stage, the membrane bioreactor process is also suited for
dary treatment, filtration, disinfection), it has many
the removal of some organic trace substances.
advantages which also have economic effects:

Structure and contents of this publication
saving of the process stages secondary stage, sand filtration, UV disinfection,
the very compact design; compared to the activation
This publication gives an overview of the present use of

membrane processes in municipal and industrial waste
process, the necessary activation volume is only
water treatment, in Germany in particular. Membrane
approx. 30 %,
technology is still being developed and the number of
the higher purification efficiency by complete reten-
application possibilities continues to increase.
tion of particles and bacteria, and, depending on the

membrane process, also viruses,
better removal of organic trace substances by a higher
This publication is intended for both specialists and laymen. It is less a comprehensive textbook or manual for
sludge age and the establishing of special micro-orga-
the solution of all problems concerning design, building
nisms
and operation of a membrane installation than rather an
the possibility to arrange downstream an additional
instrument, which sensitizes the reader to these ques-
membrane stage (nanofiltration or reverse osmosis) to
tions and offers solutions. The reference to practice and
retain organic trace substances and possibly also dis-
the relevance of membrane technology to waste water
solved substances.
treatment becomes clear by the description of installation examples from the municipal and industrial field in
Prospects
Germany and outside of Germany. The locations of the

installations described are shown in the following figure.
Further development and application of membrane technology in the field of water and waste water treatment
will continue in the next years. The growth forecasts
concerning world-wide application of membrane processes are approx. 10 15 % per year for waste water treatment and about 20 % per year for drinking water treatment (including sea water desalination). (Plants for drinking water treatment existing in Germany are compiled in
Annex 7). Due to continuous development of membrane
materials and module constructions as well as process
design and process engineering, a still broader range of
applications is opened up.
Moreover, the cost-effectiveness of membrane processes
continuously improves compared to other waste water
treatment processes, since the water and waste water costs
generally rise and the specific membrane prices go down.
24
Introduction
Sites of the waste water treatment plants with membrane technology in Germany described in this publication
! municipal plants with microfiltration
industrial plants with reverse osmosis
! municipal plants with ultrafiltration
or the combination UF/RO
industrial plants with microfiltration
industrial plants with the combination
industrial plants with ultrafiltration
UF/NF
industrial plants with nanofiltration
industrial plants with the combination

MF/UF/NF/RO
25
Introduction
The contents of this publication is subdivided into several

partial chapters, each of them representing a complete
unit. Therefore they can be read independently from each
other and allow the reader to orient himself according to
the focus of his interests. The following overview summarizes the contents of the individual chapters and shows
the reader the way through the publication.
Structure and contents of this publication
Guideline
Chapter 1: Basics
Membrane technology in waste water treatment
Chapter 2:
Municipal waste water treatment
Chapter 3:
Industrial waste water treatment
Chapter 4: Instructions and standards

Annex: Contacts, possibilities for promotion
26
1.1
Basics of Material Separation by means of
Membrane Technology
Material separation by means of membrane technology is
The driving force for the separation process is the pres-
a physical separation process. Compared with other sepa-
sure difference between the feed and permeate side, the
ration technologies, this technology has the advantage
so-called transmembrane pressure difference or
that the separated materials are neither thermally nor
transmembrane pressure. It is applied by overpressure on
chemically or biologically modified. The fields of applica-
the side of the feed or low pressure on the side of the
tion of membrane processes stretch from simple filtration
permeate. Dependent on the membrane employed, the
of solids, e. g. separation of activated sludge in municipal
transmembrane pressure is between 0.1 bar and 70 bar,
waste water treatment, up to the separation of materials
in special cases it is up to 120 bar.
within the molecular range, e. g. retention of dissolved

salts in seawater desalination.
The characteristics selectivity and capacity are of decisive importance for the economic efficiency of a mem-
The operating principle of a membrane can be described
brane process. The selectivity describes the ability of a
in the wider sense like that of a filter. As shown in Figure
membrane to differentiate between the components of a
1-1, a substance mixture, called feed or raw solution (e. g.
mixture and thus to separate one phase from the other.
raw waste water) is separated by the membrane. The part
By capacity of a membrane, we understand the flow
which passes through the membrane almost unhindered is
under specific operational conditions. The flow is defined
called permeate or filtrate. To waste water purification
as the volumetric flow rate per unit surface area (unit:
the permeate represents the treated phase. The portion
L/(m2 h)).
retained by the membrane is the brine or concentrate.

Figure 1-1
Operating principle of micro- and ultrafiltration membranes
large particles
small particles
raw solution,
waste water, feed
membrane
28
brine,
concentrate
permeate,
filtrate
Another important feature of a membrane is described by
In an industrial company, the employment of a mem-
the parameter permeability. It is defined as the quotient
brane process for waste water purification may be fea-
from flow and the accompanying transmembrane pres-
sible, particularly if a useful integration into the produc-
sure (unit: L/(m h bar)). The permeability of a mem-
tion process is possible. Besides the treatment of the
brane is influenced by the membrane condition and the
waste water, it is also frequently aimed at reusing the per-
filtration characteristics of the waste water (see chapter
meate and possibly the concentrate, so that these can be
1.7). The latter depend on the material composition and
recycled into the production process.
the characteristics of the waste water mixture, e. g. temIn municipal waste water purification, the membrane
perature, particle-size distribution and viscosity.
processes microfiltration (MF) and ultrafiltration (UF) are

1.2
used. For industrial waste water purification, nanofiltra-
Membrane Processes in Waste Water Purification
tion (NF) and reverse osmosis (RO) are also of importance. These four processes are therefore described in the
There are various membrane processes which differ in
following.
their molecular separation size and the driving force

which has to be expended. Which process is employed
Figure 1-2 indicates the molecular weight and the size of
depends on the waste water composition and the separa-
the materials which can be separated by microfiltration
tion goal.
(MF), ultrafiltration (UF), nanofiltration (NF) and reverse

osmosis (RO).
The separation goal in municipal waste water purification

is above all the separation of the cleaned waste water
The size of some waste water constituents and the pore
from the biomass in order to meet the effluent standards.
size of the membranes applied are presented in Figure 1-3.
Figure 1-2
The different fields of application of membrane processes
filtration
microfiltration
ultrafiltration
nanofiltration
1.000.000
500.000 200.000 100.000
20.000
10.000
reverse osmosis
200
molecular weight
[g/mol] or [Dalton]
no scale
organic acids
simazine
mercury
nonylphenol
bisphenol A
benzo-a-pyren
EDTA
diclofenac
saccharrose
amoxicilline
poliomyelitis virus
influenza virus
mumps virus
herpes virus
acetic acid
salt (NaCl)
glycine
phenol
bacillus subtillis
escherichia coli
viruses
bacteria
activated sludge flocs
100
aproximate size
logarithmic scale
10
0,1
0,01
0,001
29
Figure 1-3
Size of typical waste water constituents and the pore size of membranes applied
microfiltration
ultrafiltration
pore size: 0,1 5 m
pore size: 0,005 0,1 m
typical
pore size:
0,04 m
activated sludge flocs
influenza virus
escherichia coli
macro-molecular weight
organic substances
membrane
typical
pore size:
0,4 m
membrane
low-molecular weight
organic substances
monovalent ion
polyvalent ion
Table 1-1 provides an overview of the membrane proces-
The concentration process of a component to be separa-
ses presented, with driving force and application possibil-
ted by a membrane is represented in an idealized manner
ities. Further details about the individual processes are
for a pore membrane and a solution-diffusion membrane
given in the following sections 1.2.1 to 1.2.3.
in Figure 1-4. With the pore membrane, the component

to be separated is retained by the membrane due only to
Two mechanisms are essentially responsible for the mass
its size. In the course of concentration, a sharp separa-
transfer in membrane processes: transfer by pores and
tion on the membrane surface can be recognized. When
transfer due to diffusion. In real membranes both trans-
entering into the membrane, the concentration of the
fer modes can occur in parallel; however, the idealized
component in the feed drops down to the concentration
classification of membranes is as follows:
in the permeate.
pure pore membranes (porous membranes) and
However, with a solution-diffusion membrane a
pure solution-diffusion membranes (dense mem-
reduction of the concentration also takes place within
branes)
Separation by pore membranes (MF, UF) is based on a
sieving effect, while differences in solubility and diffusivity are responsible for the selectivity of solution-diffusion membranes (NF, RO) [RAUTENBACH 1997].
30
the membrane due to the transportation mechanisms.
nanofiltration
reverse osmosis
pore size: 0,001 0,01 m
pore size: 0,0001 0,001 m
typical
pore size:
0,0004 m
membrane
membrane
typical
pore size:
0,004 m
Table 1-1
Pressure-driven membrane processes in waste water purification
Membrane process
Phase separation
Driving force
Application
Microfiltration
liquid/solid
pressure difference 0,1 3 bar
separation of solid matter from suspensions
Ultrafiltration
liquid/liquid
pressure difference 0,5 10 bar
separation of macromolecular or colloids, disinfection
Nanofiltration
liquid/liquid
pressure difference 2 40 bar
separation of dissolved organic molecules and polyvalent inorganic ions
Reverse osmosis
liquid/liquid
pressure difference 5 70 bar
separation of organic molecules and of all ions
in special cases up to 120 bar
Figure 1-4
Idealized representation of a pore membrane and a solution-diffusion membrane [according to MELIN 1999]
pore membrane
solution-diffusion-membrane
wiF
feed
side
wiF
permeate
side
feed
side
permeate
side
wiF
wiP
wiP
wiP
concentration of the waste water

constituents in the feed
concentration of the waste water
constituents in the permeate
31
1.2.1
MF
UF
Micro- and Ultrafiltration

Microfiltration (MF) and ultrafiltration (UF) belong to the
pressure-driven membrane processes. Concerning operat-
separation of activated sludge and water
ing pressure and molecular separation size, they are cate-
disinfection
gorized between nanofiltration and filtration (e. g. sand
pretreatment prior to a reverse osmosis plant
filtration). The separation mechanisms of the Mf and UF
phosphate removal after precipitation
membranes are similar and the fields of application may

strongly overlap (Figure 1-2), so that both are described
in this chapter.
Waste water recycling and reuse as process water
According to the principle of a porous filter, by MF
Treatment of landfill leachate combined with a
for different purposes

and UF all those particles that are larger than the membrane pores are retained completely. The particles held
back can develop a covering layer on the membrane surface. This layer then holds back smaller particles which,
without a covering layer, would pass through the mem-
biological stage
Recovery of water-based paint from spray booth
effluents by concentration
e. g. in the metal-working industry:
Prolongation of the service life of electro-dipcoat
brane (process controlled by the covering layer).
bathes
Concentration of water-oil emulsions
Characteristic features of micro- and ultrafiltration are
Recycling of degreasing baths
summarized in Table 1-2.

In waste water purification, micro- and ultrafiltration are
used for the separation and retention of particulate and
emulsified waste water constituents. Typical applications
include:
Table 1-2
Characteristic features of micro- and ultrafiltration
Mikrofiltration (MF)
Ultrafiltration (UF)
Operation mode (see Chapter 1.6)
cross-flow- and dead-end-operation
cross-flow- and dead-end-operation
Operating pressure
0,1 3 bar (transmembrane)
0,5 10 bar (transmembrane)
Separating mechanism
screening controlled by covering layer, if necessary
screening controlled by covering layer, if necessary
Molecular separation size
solids > 0,1 m (see figure 1-2)
colloids: 20.000 200.000 Dalton*,

solids > 0,005 m (see figure 1-2)
Membrane types
Module types
predominantly symmetric polymer or ceramic membranes
asymmetric polymer composit or ceramic membranes
(see chapter 1.3)
(see chapter 1.3)
spiral-wound, hollow-fibre and tube modules,
spiral-wound, hollow-fibre and tube modules,
plate or cushion modules
plate and cushion modules
* [Dalton], numerically equivalent to the molecular weight (MW) in [g/mol]
32
1.2.2
NF
Nanofiltration
Nanofiltration (NF) is a pressure-driven membrane pro-
Up to now nanofiltration has not been used in municipal
cess which is preferentially used for the recycling of
waste water treatment.
aqueous solutions. Concerning operational pressure and

separation size, nanofiltration is categorized between
reverse osmosis and ultrafiltration. By means of NF mem-
Relief of ion exchangers or downstream reverse osmosis
branes, the retention rate for particles with a molecular

mass greater than 200 g/mol is high; this corresponds to
a molecule diameter of approx. 1 nm.
units
Removal of colour in the waste water of the textile and
the pulp and paper industry
Demineralization of waste water containing surfactants
Typical of NF membranes is their ion selectivity. The

retention of a dissolved salt is determined by the valency
In general:
of the anion. Therefore most salts with monovalent
Retention of multivalent ions (e. g. SO42-, Cd2+, Cr2+),
anions (e. g. Cl-) can pass through the membrane, where2-
but permeation of monovalent ions (e. g. Cl-, Na+)
as multivalent anions (e. g. SO4 ) are retained [RAUTEN-
Retention of organic compounds
BACH 1997]. Characteristic features of nanofiltration are
Separation of components with lower and higher mole-
represented in Table 1-3.
cular weight in aqueous solutions
Table 1-3
Characteristic features of nanofiltration
Nanofiltration
Operating mode (see chapter 1.6)
cross-flow-operation
Operating pressure
2 40 bar (transmembrane)
Separation mechanism
solubility/diffusion/charge (ion selectivity)
dissolved matter: 200 20.000 Dalton* solids > 0.001 m (see Figure 1-2)
Membrane types
asymmetric polymer or composite membrane (see chapter 1.3)
Module types
spiral-wound, tube, and cushion modules
33
1.2.3
RO
Reverse Osmosis
Reverse osmosis (RO) serves to separate components of a
Reverse osmosis has no importance in municipal waste
solution. It is based on a pressure-driven process, the
water treatment. Fields of application are [RAUTENBACH
driving force resulting from the difference of the electro-
1997]:
chemical potential on both sides of the membrane. The

non-porous RO membranes can retain dissolved material
with a molecular weight of less than 200 g/mol com-
Concentration of drainage water from mines contain-
pletely, so that reverse osmosis achieves a higher separation efficiency than nanofiltration. Since dissolved salts
are retained to a very high extent, RO has a history
as a proven membrane procedure, which is already state
of the art for example in the desalination of sea- and
ing CaSO4
Dewatering of flushing water from photo laboratories
for silver recovery
Treatment of waste water from textile dyeing (cotton
and polyester dyeing)
brackish water. Characteristic features of reverse osmosis
Concentration of cellulose washing water
are compiled in Table 1-4.
Recovery of phosphoric acid

Treatment of waste water from bleacheries
Treatment of landfill leachate
Table 1-4
Characteristic features of reverse osmosis
Reverse Osmosis (RO)
Operating mode (see chapter 1.6)
cross-flow-operation
Operating pressure
5 - 70 bar (transmembrane), in special cases up to 120 bar
Separation mechanism
solubility/diffusion
dissolved matter: < 200 Dalton* (see Figure 1-2)
Membrane types
asymmetric polymer- or composite membrane (see chapter 1.3)
Modul types
spiral-wound, tube, plate, cushion or disc-tube modules
34
1.3
Membrane Materials, Structure and Classification
Membranes are classified according to different features
(Figure 1-5), which are briefly explained in the following:
Origin
Material
Morphology and structure
Manufacturing process
Figure 1-5
Classification of membranes [according to RAUTENBACH 1997]
membrane
synthetic
origin
biological
liquid
inorganic
organic
material
morphology
solid
non-porous
porous
porous
1.3.1
Origin and Materials
Membranes can be of biological and synthetic origin and
Depending on waste water composition and characteris-
differ according to structure, functionality and material
tics as well as operational requirements, different ma-
transfer. While biological membranes, e. g. cell mem-
terials are used for membranes. Membrane materials are
branes, are indispensable for human and animal exist-
organic (e. g. cellulose, polymer membranes) or inorganic
ence, in waste water purification only synthetic, solid
(e. g. ceramic membranes).
membranes are used.
35
Organic membranes
1.3.2
Morphology, Structure and Manufacturing
At present synthetic polymer membranes are used predominantly because it is possible to select a polymer suita-
Concerning the morphology of membranes, we distin-
ble for the specific separation problem from the existing
guish between pore mem-branes and solution-diffusion
huge number of synthetic polymers. Moreover, compared
membranes (see Figure 1-5 and chapter 1.2). Inorganic
to other materials, polymer membranes are often chea-
membranes are always pore membranes.
per.
The structure of a membrane may be symmetric or
For the separation of a constituent, the structural charac-
asymmetric. While symmetric membranes have a nearly
teristics of the polymers used, like thermal, chemical and
homogeneous structure all over the thickness of the
mechanical stability, and the permeability are decisive.
membrane, asymmetric membranes are made up of two
Examples of organic polymer membranes are for example
layers.
polysulfone (PS), polyacrylonitrile (PAN), polyethersulfone (PES), polypropylene (PP), polyvinylidene fluoride
The layer on the side of the feed (active layer) determines
(PVDF), acetylcellulose, and polyamide (PA) membranes.
the separation behaviour of the membrane, while the

porous layer below serves as support. The supporting lay-
Inorganic membranes
er ensures the mechanical stability of the membrane and

hinders the permeate flow only little. The aim of asym-
In the recent past inorganic membranes have gained
metric membrane design is to keep the active layer as
more and more importance. They are used especially if
thin as possible and, with this, minimize the filtration
the employment of polymer membranes is excluded
resistance of the membrane. With solution-diffusion
because of the characteristics of the raw waste water or
membranes it is therefore possible to obtain flows which
if the organic membrane surfaces have to be cleaned
are 50 to 100 times higher than with comparable symme-
frequently and intensively due to the waste water com-
tric membranes [MELIN 1999].
position.
Today asymmetric organic membranes are usually manuInorganic membrane materials are ceramics, aluminum,
factured as phase inversion or composite membranes.
high-grade steel, glass and fiber-reinforced carbon, of
The active layer and supporting layer of the phase inver-
which ceramic membranes at present have the greatest
sion membranes are made from the same material.
importance in waste water purification. Compared to
However, in the case of composite membranes, the active
organic membranes, the advantages of ceramic mem-
layer and supporting layer consist of different materials,
branes are high resistance against heat and chemicals,
so that both layers can be optimized with a view to cus-
with correspondingly a high regeneration capacity, as
tomizing the characteristics required in each case.
well as reduced aging and long service lives. Disadvantages are above all the higher investments due to the
Figure 1-6 shows scanning electron micrographs of phase
membrane material and more expensive module con-
inversion membranes (a), (b) as well as of a composite
structions.
membrane (c). Figure 1-7 and Figure 1-8 represent the

active layer of a polyethylene membrane at different
resolutions.
36
Figure 1-6
Figure 1-7
Scanning electron micrographs of cross-sections of
Top view of the active layer of a polyethylene
different membranes
membrane (MF/UF) [AGGERVERBAND 2002]
denitrification
symmetric
membranelayer
200 m
symmetric polymer membrane (MF) [N.N. 2002a]
active
layer
Figure 1-8
supporting
layer
Top view of the broken edge of a polyethylene

membrane (MF/UF), the active layer is visible
[AGGERVERBAND 2002]
7 m
asymmetric composite membrane
(RO) [FRIMMEL, GORENFLO 2000]
active
layer
supporting
layer
7 m
asymmetric polymer phase inversion membrane
(UF) [N.N. 2001a]
37
1.4
Membrane Forms and Modules
Depending on the manufacturing process, we distinguish
capillary and hollow-fibre module. For flat membranes
two basic membrane forms:
we distinguish plate, spiral-wound, cushion and disc-tube

modules.
tubular membranes and

flat membranes
The different module forms can be characterized regarding the arrangement of the separation layer, the compo-
These membranes are arranged in an engineered unit,
nent density and, with the tubular diaphragms, regarding
the module. Besides the membrane itself, the module is
the diameter (free flow cross-section) (Table 1-5, Table 1-6).
of decisive importance for the efficiency of a membrane
Due to the different characteristics related to performan-
stage. There are a huge number of different module con-
ce and operation (e. g. operating mode, susceptibility to
structions because the modules are adapted in their con-
blockage, simple backwashing etc.) and the surface-speci-
struction to meet the requirements of the end use.
fic module costs, certain module types are preferentially

used depending on the waste water to be treated. A prere-
The basic membrane forms, which depend on the condi-
quisite for module selection is in each case the selection
tions of production, are assigned to the module forms
of the membrane process and/or the membrane which is
represented in Figure 1-9. In some special cases this strict
suitable for the separation problem. Table 1-2 (MF and
allocation is not permissible, e. g. if some membranes
UF), Table 1-3 (for NF) and Table 1-4 (for RO) can be used
used in tube modules were manufactured by the tubular
to identify which module types are used in the different
processing of flat membranes. Concerning tubular mem-
membrane processes.
branes, we distinguish as module constructions the tube,
Figure 1-9
Membrane and module forms
membrane form
module form
tubular
flat
tube modul
spiral-wound module
capillary module
cushion module
hollow-fibre module
plate module
disc-tube module
38
Table 1-5
Characteristic values, advantages and disadvantages of module types with tubular membranes
Tubular membranes
Arrangement of the
Tube module
Capillary module
Hollow-fibre module
inside
outside/inside
outside/inside
separation layer
Inside diameter
5,5 ... 25 mm
0,25 ... 5,5 mm
0,04 ... 0,25 mm
Component density
< 80 m2/m3
< 1.000 m2/m3
< 10.000 m2/m3
Operating mode
cross-flow
dead-end/cross-flow
dead-end
Advantages
hardly susceptible to blockage
high component density
extremely high component density
low pressure loss operation controlled
cheap production backwashing possible
favourable specific membrane costs
by covering layer is possible
on the permeate side
high pressure resistance
low component density
low pressure resistance
susceptible to blockage pressure loss
Disadvantages
Table 1-6
Characteristic values, advantages and disadvantages of module types with flat membranes
Flat membranes
Plate module
Spiral-wound module
Cushion module
outside
outside
outside
Component density
40 ... 100 m2/m3
< 1.000 m2/m3
ca. 400 m2/m3
Operating mode
cross-flow
dead-end/cross-flow
dead-end/cross-flow
Advantages
membranes can be changed separately
cheap production few seals
little pressure losses on the permeate side
hardly susceptible to blockage
high component density
hardly susceptible to fouling
many seals
long flow path on the permeate side
mechanical cleaning not possible
many seals
Arrangement of the
separation layer
Disadvantages
risk of blockages
The following figures present module forms which are

used particularly in industrial waste water treatment.
They are described with the help of pictures and/or flow
sheets. Further examples and explanations concerning
e. g. the plate and capillary modules used in municipal
waste water treatment are given in chapter 2.1.2.
39
Tube modules
Inside a jacket or a pressure tube, several supporting
tubes of smaller diameter which are perforated or permeable to the permeate, are combined. The tubular membrane layer is applied on the inside of the tubes. The feed
is pumped through these tubes and is collected in the
outside space between the pressure tube and supporting
tubes and is then withdrawn at a connecting piece on
the pressure tube.
Figure 1-10
Tube modules [photo: WEHRLE WERK AG]
permeate
feed
permeate
feed
permeate collector
brine
connection
thread
sealing rings
membrane-supporting tube
membrane
40
Capillary or hollow-fibre modules

In a pressure tube, a large number of capillary and/or
case, filtration takes place from outside to inside and the
hollow-fibre membranes are combined into a module.
permeate is withdrawn on the inside of the capillaries/
Comparable to multichannel tube modules, the capilla-
fibres.
ries and/or fibres can be fed with the feed stream so that
filtration takes place from inside to outside.
More capillary module forms are described in chapter 2.1.2.
In addition there is a construction for which membrane

capillaries/fibres with an outer coating are used. In this
Figure 1-11
Capillary or hollow-fibre modules [photo: KOCH MEMBRANE SYSTEMS]
feed: inside
feed: outside
permeate
feed
feed
permeate
permeate
hollow fibre
feed
pressure tube
bonding (resin)
41
Spiral-wound modules
This module consists of one or more membrane bags
the permeate to flow between the membranes. The cylin-
which are wound helically with one spacer each (feed
dric module resulting from the whirl is supplied to the
spacer) around the permeate collecting pipe. The mem-
front with the feed, which flows through the module in
brane bags are closed at three sides and at the open side
an axial direction. While the feed flows through the
the bags are attached to the perforated permeate collec-
space outside of the membrane bags resulting from the
tion pipe. The inside of the membrane bags is filled with
feed spacer, the withdrawn permeate flows inside the
a porous plastic textile (permeate spacer), which allows
membrane bags helically to the permeate collection pipe.
Figure 1-12
Spiral-wound modules [schematic drawing: N.N. 2001], [photo: NADIR FILTRATION GMBH]
feedspacer
central tube
membrane
d
fee
w
flo
permeateflow in the
central tube
permeate spacer
42
permeate in the
permeate chanal
Cushion modules
Cushion modules are constructed by analogy to spiral-
As can be seen in the figure, several cushions can be inter-
wound modules from membrane bags with intermediate
connected via the permeate openings. The cushion packa-
woven fabric fleece. In this case all sides of the bags are
ges are then inserted into a pressure tube with modular
closed and the permeate is withdrawn through one or
character. In its wall is the permeate collection pipe with
more openings, provided with round seals, in the cushion
connections and seals for the corresponding permeate open-
provided.
ings of the cushion packages as well as for the following

components of the pressure tube.
Figure 1-13
Cushion module [schematic drawing and photo: ROCHEM UF SYSTEME GMBH]
permeate channel (permeate discharge)

permeate-drainage pin
membrane
cushion stack
pressure tube
spherical shell
spacer
raw water
membrane
drainage fleece on
permeate side
spacer
1 3 mm
(variable channel height)
support plate
drainage fleece on
permeate side
membrane
permeate drainage permeate
channel
pin
43
Disc-tube module (DT module)

The disc-tube module (Figure 1-14) is made of supporting
The preassembled disc-membrane stack is fitted into a
discs and membrane cushions which are alternately
pressure tube. The raw water is fed between the inside
stacked on a tie rod, so that open flow channels result
wall of the pressure tube and the sealing rings at the edge
between the discs and the membrane cushions on the
of the discs to the annular gap in the first disc of the
side of the raw water. The supporting discs of the DT
disc-membrane stack and filtered from outside to inside
module are provided at their outer edge with a sealing
through the membrane cushions.
ring which juts out evenly at both sides. An annular gap,

formed by ribs, through which the raw water flows
The permeate is withdrawn via the round lead-through
during operation, a slot for sealing between membrane
in the center of the membrane cushions, the discharge
cushion and supporting discs, and a lead-through for the
slots in the supporting discs and a drill-hole in the end
tie rod with permeate discharge slots are arranged centri-
piece of the membrane stack. The open annular gaps and
cally. The membrane cushions are made of flat mem-
the flow paths between the membrane cushions and the
branes with internal woven fabric fleece and are welded
discs also allow for the treatment of liquids with higher
at the outside.
colloids or solids loads.
Figure 1-14
Disc-tube module (DT module) [PALL 2001]
44
The membrane system from the company inge AG

Another development is the module from the company
water, comparable to the single capillary modules with
inge AG with new, so-called, Multibore capillaries. As
inside flow. In the case of capillary membranes with in-
Figure 1-15 shows, these capillaries have seven drillings
side flow and small feed channel dimensions, higher
each, which have approximately the inside diameter of
solid contents frequently cause blockages. Therefore, the
conventional single capillaries. Thus, the mechanical
preferred field of application of the Multibore capillaries
integrity of the membrane capillaries is increased and
is drinking water processing.
capillary breaks occur more rarely than with single capillaries.

The Multibore capillaries are operated according to the
inside-outside principle, i. e. supplied from their inside
with the raw water to be filtered. Thus they are applicable only in the case of small solid contents in the raw
Figure 1-15
New Multibore capillaries from the company inge AG [photo: INGE AG]
45
1.5
in series, so that according to Figure 1-17, the concentrate
Arrangement of Modules
flow of a module serves as feed for the next module and

the permeate of the single modules is brought together.
A membrane stage is a unit functioning in itself, which

consists of modules, pumps, valves etc. Besides the selec-
With parallel connection (Figure 1-18), the feed is dis-
tion of a membrane or a membrane module suitable for
tributed to the individual modules connected in parallel.
the waste water mixture to be separated, the arrangement
The number of modules in parallel connection depends
and/or connection of the modules is critical to the per-
on required the capacity of the membrane stage. The
formance of a membrane stage (Figure 1-16). In waste
modules in parallel connection are called a block. The
water treatment, the volumetric flow to be separated and
waste water-specific permeate yield or the concentration
the permeate quality or permeate yield to be obtained are
within a block corresponds to the yield or concentration
important.
that is attained with one module.
We distinguish two basic connections of modules:
While in municipal waste water treatment pure parallel
series connection and
connection dominates, combinations of both basic con-
parallel connection
nection types are used in industrial waste water treatment in order to achieve the desired purification goal or
Series connection is used if the permeate yield from one
the maximum concentration:
module is not sufficient. Several modules are connected
Figure 1-16
From the membrane element to the membrane stage
membrane element
module
modul connection
membrane stage
desired
effluent
quality
feed
concentrate
Figure 1-17
Series connection of modules [according to BAUMGARTEN 1998]
feed
concentrate
permeate
46
fir tree structure (Figure 1-19)
block is reduced so that, e. g. with tube modules, the
feed-and-bleed structure
overflow conditions are adapted to the requirements also

in the downstream membrane elements.
Figure 1-19 shows an example of the fir tree structure

which is frequently used (e. g. in the seawater desalina-
If the fir tree structure cannot be used because the feed
tion). The modules within blocks one and two are con-
flow rate is smaller than is necessary for the module ap-
nected in parallel and all three blocks among themselves
plied, the feed-and-bleed structure or the recircula-
in series. With this structure, the concentrate flow is con-
tion cycle is used within each block. With this structure
tinuously concentrated or minimized from block to block
the feed flow rate is increased by mixing the concentrate
and the permeate yield is correspondingly increased. Since
with a part of the feed by internal recirculation. Thus a
the permeate is withdrawn from each block, the volume-
higher concentration or higher permeate yield can be
tric flow to be treated reduces from block to block. There-
achieved with one module. This is used for example in
fore, the number of modules required in the following
landfill leachate treatment.
Figure 1-18
Parallel connection of modules [according to BAUMGARTEN 1998]
feed
concentrate
permeate
Figure 1-19
Arrangement of several modules according to the fir tree structure
[according to RAUTENBACH 1997]
permeate
1st block
2nd block
feed
3rd block
concentrate
47
1.6
Operating Modes
In principle, we distinguish two filtration operating
In cross-flow operation the formation of a covering layer is
modes:
diminished because there is a continuous flow over and

parallel to the membrane. Thus, a state of equilibrium at
dead-end or static filtration and
the membrane surface between development and remo-
cross-flow or dynamic filtration
val of the covering layer is achieved by the shear forces.

The overflow is typically generated by pumps. However,
Cross-flow operation is used in nanofiltration and reverse
other systems may also be used, such as generating the
osmosis. In ultra- and microfiltration both operating
overflow by introducing gas below the modules, i. e. by
modes are possible.
the ascending gas-feed mixture, or the movement of the

membranes themselves (see chapter 2.1.2). A disadvan-
In the cross-flow mode (cross-current filtration) the feed
tage of cross-flow operation compared to dead-end opera-
is pumped parallel to the membrane surface and the per-
tion is the higher energy demand as a result of the over-
meate is withdrawn diagonally to it. In dead-end ope-
flow energy which has to be continuously applied.
ration the membrane is fed orthogonally, comparable to

a coffee filter. Figure 1-20 illustrates the differences bet-
The term semi-cross-flow or semi-dead-end pro-
ween the two operating modes.
cess is also increasingly used. In this case, process elements of the two operating modes cross-flow and dead-
Due to the retention of suspended material, a covering
end are combined in order to reduce the energy con-
layer develops on the feed side, which diminishes the fil-
sumption in contrast to the pure cross-flow process. An
tration capacity. As a result, the permeate flow decreases
example of a semi-cross-flow operation is intermittent
with progressive process duration. As preventive measure,
overflow of the membrane according to the cross-flow
the entire module is submitted in intervals to backwashing.
principle combined with backwashing intervals so that

the developing covering layer can be removed.
Figure 1-21 shows the decrease of the permeate flow, VP,

at a constant feed pressure, pF, as set target (left) and the
increase of the feed pressure at a constant permeate flow
as set target (right) over the filtration interval. By removal of the covering layer during the backwashing interval, ideally the original filtration capacity will be reached
again.
48
Figure 1-20
Schematic representation of a membrane in cross-flow- and dead-end filtration [according to MELIN 1999]
cross-flow operation
dead-end operation
feed
feed
permeate
permeate
Figure 1-21
Filtration intervals in dead-end operation [according to RAUTENBACH 1997]
backwashing
interval
backwashing
interval
feed pressure pF
permeate flow Vp
filtration
interval
feed pressure pF
permeate flow Vp
filtration
interval
time t
time t
set target :
constant feed presure pF
set target :
constant permeate flow Vp
49
1.7
Formation of Covering Layers
The formation of covering layers can have different cauMunicipal and industrial waste waters contain organic
ses, which also determine the composition of the layer.
and inorganic matter. During purification of these waste
We distinguish [BAUMGARTEN 1998]:
water by means of a membrane, the constituents of the

feed concentrate and a separation of particles at the
biological fouling (briefly: biofouling)
membrane surface occurs due to the selective effect of
colloidal1) fouling
the membrane. With increasing operating time, this
scaling
results in the development of a covering layer. Covering

layers can be used to a certain extent in a beneficial way
Biofouling
for filtration (e. g. in order to increase the purification

degree), but often they are undesirable because they
Biofilm formation on the membrane surface is caused by
diminish the permeate flow and thus the performance of
adhesion and the growth of micro-organisms [FLEM-
the membrane.
MING 1995]. Biofouling means that the biofilm causes a

reduction of the performance of the membrane system
The reducing performance of the membrane is based on
by decreasing the specific membrane flow [FLEMMING
an increase in the filtration resistance, which increases
2000]. Plant shut-downs should be treated with caution,
the output membrane resistance (Rm) (Figure 1-22).
since under these conditions the number of bacteria on

the membrane surface may increase dramatically [BAKER
Concerning the micro- and ultrafiltration membranes,
ET AL. 1998].
the increased covering layer resistance results from adsorption (RA), pore blockage (Rp) and the covering layer
Colloidal fouling
formation itself (Rc). However, the increase of the filtration resistance of the tight nanofiltration and reverse
From the accumulation of colloids results a kind of film
osmosis membranes is due to a concentration polarisa-
or mucus on the membrane surface, which leads to a
tion (RCP) of dissolved matter, the concentration of which
reduction of the filtration capacity.
rises with increasing filtration duration.

Scaling
Increased resistances due to adsorption (Ra) and pore
blockage (Rp) normally cannot be reduced by measures
Scaling can be described as coatings on the membrane
such as backwashing or the like, so that during severe
formed by inorganic precipitations (crystallization). Usu-
pore blockage another membrane material should be
ally they only occur with NF and RO membranes if, for
used. On the other hand covering layer formation can be
example, the solubility limit of dissolved salts is exceeded
decreased or undone by increasing the overflow velocity
by excessive concentration on the membrane surface.
or backwashing the membrane with permeate in intervals [PANGLISCH ET AL. 1996].
Table 1-7 summarizes the substances which can cause the

three types of covering layer presented.
Measures against covering layer formation and thus for

maintenance of the filtration capacity are treated in the
following chapter.
1)
colloidal = finely spread out, finely dispersed
50
Figure 1-22
Schematic overview of the filtration resistances on the membrane surface and inside the membrane
[KRAMER, KOPPERS 2000]
permeate side
feed side
Rp
Ra
Rm
Rc
Rcp
Table 1-7
Formation of covering layers in membrane filtration [according to BAUMGARTEN 1998]
Covering layer formation
Fouling
Scaling (crystallization)
Biofouling
Colloidal fouling
germs
colloidal silicic acid and silicates
CaSO4
bacteria growth due to nutrient supply in the feed
colloidal hydroxides (e. g. Fe and Mn)
CaF2
formation of mucus by micro-organisms
organic colloids (e. g. humic substances, proteins)
BaSO4
SiO2
Mg(OH)2
51
1.8
Measures for Maintenance of the Filtration Capacity
The utilization of membranes in waste water treatment is
are considered during construction and operation of the
practically feasible only if the covering layer formation
membrane plant (Table 1-8):
(chapter 1.7) is controlled so that safe and economic operation can be ensured.
pretreatment measures
process configuration
The development of covering layers due to fouling or
membrane and module characteristics
scaling can be avoided or reduced if the following aspects
cleaning
Table 1-8
Methods for reduction and removal of covering layers
reduction, prevention, removal of covering layers
pretreatment
optimisation of the
constructional design
cleaning
process configuration
sieve
process design
membrane material
cleaning agent
prefiltration
overflow
structure
cleaning interval
cooling
flushing method
module design
concentration
neutralisation
module conception
preprecipitation
Pretreatment measures
Optimization of the process configuration
In municipal waste water treatment, the pretreatment for
The formation of covering layers is determined essential-
the membrane bioreactor (chapter 2.1.3.2) takes place in
ly by the operating mode dead-end or cross-flow opera-
the mechanical stage (e. g. rake, grit chamber, primary
tion and the process control. By operational measures,
settlement tank). In this stage material which would
such as increasing the backwashing volume or the back-
disturb the filtration process, such as coarse particles, fats
washing time in dead-end operation, or increasing the
and fibres, are removed.
overflow velocity in cross-flow operation, covering layer

formation can be reduced.
Material contents and composition of industrial waste

water vary considerably. The pretreatment measures for a
However, due to increased energy demand for higher
membrane plant have to be chosen according to the re-
overflow velocity and because of the permeate loss due
quirements of the waste water composition. Mechanical,
to more frequent backwashing, these measures are not
physical, biological and chemical procedures can be used.
very economical and can only be optimized during the
Examples are mentioned in Table 1-8.
operation of a plant.
52
Structural design
Membrane material and membrane structure have the
modification of their characteristics [LINDAU ET AL.
largest influence on the formation of covering layers
1998; PIERACCI ET AL. 1998; LINDAU, JNSSON 1999;
since the membranes interact directly with the covering
AMANDA ET AL. 2000].
layer forming materials at the inlet. Depending on material properties and the charge of a membrane, contami-
For example, the module configuration determines how
nation at the membrane is adsorbed less or more strongly.
large a pressure increase can be applied to overcome the

filtration resistance caused by the covering layer. This
The most important structural characteristics regarding
pressure increase is allowed only within the scope of the
the covering layer formation are the roughness of the
module-specific maximum operating pressure. It must
membrane surface, the pore diameter, porosity (share of
also be considered in light of the economic operation of
the hollow space2)), and the pore size distribution. The
the membrane stage.
smoother the surface and the smaller the pore diameter,

the smaller the susceptibility to blockage. Also, the ten-
Cleaning
dency for membrane contamination is, in general, smaller with a homogeneous pore distribution [KRAMER,
If the desired permeate flow is no longer realizable eco-
KOPPERS 2000]. In recent years numerous efforts have
nomically, a cleaning plan established by the membrane
been made to increase the efficiency of membranes by
manufacturer is applied. Restoration or increase of the
2) Porosity
in [%] is defined as the volume of the hollow space in a membrane layer compared to the total volume of the membrane layer
Figure 1-23
Effect of membrane cleaning on the flow at constant pressure
irreversible
fouling
flow
cleaning interval
cleaning
with
cleaning
without
cleaning
constant pressure
time
53
permeate flow is brought about by cleaning with a mem-
The effectiveness of cleaning does not only depend on
brane-compatible cleaning agent. The course of the flow
the cleaning agents applied and their chemical activity,
over time at a constant transmembrane pressure with and
but is also determined by factors such as temperature, pH
without chemical cleaning is represented in Figure 1-23.
value, contact or reaction time, concentration of the ac-
Despite the significant improvement of the flow capacity
tive substance, and mechanical forces. The cleaning result
by the chemical cleanings, the flow decreases with in-
improves with higher temperatures or longer cleaning
creasing filtration time. This phenomenon is explained
times. At higher temperatures the cleaning time can be
by irreversible fouling, which cannot be eliminated by
reduced, or the temperature can be lower with a longer
cleaning.
cleaning time. In order to adjust the pH value, it is necessary to consider not only the compatibility with the
For membrane cleaning, chemical cleaning agents are
membrane- or the module material, but also the specific
used in combination with backwashing (permeate side)
effectiveness of the cleaning agent in dependence on the
or flushing (feed side). In principle, we distinguish three
pH.
types of cleaning:
For handling the cleaning chemicals, the references on
1. backwashing/flushing of the membrane
possible hazards of the respective safety data sheets must
2. interim cleaning using chemicals in lower concentra-
be considered. This is of special importance in cases where

the personnel are not familiar (or only to a limited extent)
tion, e. g. weekly
3. intensive cleaning using chemicals in higher concen-
with the use of hazardous materials, e. g. at waste water

treatment plants.
tration, e. g. biannually
The cleaning agents used for intensive cleaning have a
Moreover it has to be considered that some cleaning che-
higher concentration than those used for interim clean-
micals, after having been used for cleaning, may have
ing. The cleaning agent is chosen depending on the sub-
undesirable effects on the permeate quality. After clea-
stances in the covering layer (Table 1-9).
ning these cleaning solutions have to be collected, if

necessary, and disposed of separately.
Table 1-9
Examples of cleaning chemicals and their applications
Covering layer substance
Cleaning agents applied
Calcium-, magnesium scaling
Acids, e. g. citric acid, acetic acid
Metal hydroxide, inorganic colloids
Acids, e. g. citric acid
Organic substances
Anionic surfactants, oxidants, e. g. hypochlorite, hydrogen peroxide,

alkaline cleaning agents, e. g. caustic soda solution
Bacteria, germs
54
Disinfectants, e. g. hypochlorite; biocides
1.9
waste water treatment, pressure-driven immersed mem-
Other Aspects Concerning the Use of Membrane
brane systems with micro- or ultrafiltration membranes
Technology in Waste Water Treatment
are predominantly used. The pore size of these membranes ensures the retention of solids and of macromole-
Molecular separation size and transmembrane
cular or colloidal substances up to the size mentioned in
pressure
Table 1-10. The separation of smaller particles or substances with lower molecular weight requires nanofiltration
The choice of a membrane process depends on the waste
or reverse osmosis membranes.
water composition and the separation task. In municipal
Table 1-10
Molecular separation size and transmembrane pressure of pressure-driven membrane processes
Membrane process
Size of the particles, colloids or molecules to be separated
Transmembrane pressure
Microfiltration
solids > 0,1 m
Ultrafiltration
200.000 20.000 D *
0,1 3 bar
Nanofiltration
20.000 200 D *
2 40 bar
Reverse osmosis
< 200 D *
5 70 bar
0,5 10 bar
* Dalton, numerically equivalent to the molecular weight in [g/mol]
The driving force or the transmembrane pressure, which
ring effect is normally improved, so that in some cases it
is necessary for the filtration process, has to overcome
is possible to attain with a micro-filtration membrane the
the resistance to filtration. It consists of the resistance of
separation result of an ultrafiltration process.
the membrane, the resistance by adsorption and clogging

of the pores in the membrane, the covering layer at the
In many cases, the structure and thickness of the cover-
feed side and concentration polarization [KRAMER 2000].
ing layer is of higher importance for material separation
The transmembrane pressure of immersed membrane
than the membrane itself. In particular with microfiltra-
systems in municipal applications is between 0.05 and
tion processes, the formation of a reversible covering lay-
0.2 bar in normal operation. The pressure is generated by
er formation is even wanted, as long as the flow is not
pumps installed at the permeate side. If the tanks with
too strongly reduced, because inside membrane clogging
the membranes are arranged above the permeate collec-
by smaller particles is avoided. It is of importance that a
ting tank, it is possible to use the difference of the water
steady operation results in which covering-layer-forming
levels, i. e. the hydrostatic pressure, as transmembrane
and covering-layer removing effects are compensated.
pressure.
Even with microfiltration membranes, the covering layer
Influences on the filtration process and maintenance
is able to retain, for example, a high percentage of viruses,
of the performance of the filtration operation
which are much smaller compared to bacteria, although

a retention by the membrane pores is not expected
In the filtration process, a covering layer is formed by
[MELIN, RAUTENBACH 2004]. Since the size of bacteria
particles which are retained by the membrane and accu-
is approx. 0.2 m up to 10 m and of viruses approx.
mulate on its surface. Thus the resistance to filtration
0.02 m up to 0.250 m, viruses are retained completely
increases and the permeate flow is reduced, but the filte-
only by ultrafiltration membranes.
55
Table 1-11
Data on the size of viruses and bacteria
Name
Length [m]
Width [m]
Diameter [m]
Bacteria [STARR ET AL. 1981]

Bacteriodes pneumosintes
0,2
< 0,1
0,25
0,1
Bacillus subtilis
2,5
0,75
Escherichia coli
0,6
Mycoplasma spp.
Achromatium oxaliferum
Cristipira pectinis
100
36 72
1,5
Viruses [SCHLEGEL 1976]
Smallpox virus
0,3
0,2
Influenza
0,1
Poliomyelitis
0,02
Table 1-11 gives an overview of the size of bacteria and
hypochlorite or hydrogen dioxide, has proven successful.
viruses.
To realize chemical cleaning, it is necessary to install a

dosing station for chemicals which is correspondingly
To attain stable operation of a membrane installation,
equipped. Cleaning (in situ or on air) can be automated
not only coverin-layer-forming and covering-layer-remov-
to a great extent.
ing effects have to be compensated, but the development

of fouling must also be limited.
Preparation and realization of chemical cleaning require

increased staff employment. For cleaning of the modules
Fouling results from bacteria producing extracellular
in a separate cleaning chamber, even more staff is needed.
polymeric substances (EPS) which mainly consist of poly-
The membrane modules under cleaning are not available
saccharides with incorporated proteins and accumulate
for the filtration process. This has to be considered in the
around the cells as mucous capsules. The manifold rea-
design of the installation (larger membrane surface area).
sons for the development of these mucous capsules are
According to current knowledge, a precautionary opera-
not yet completely clarified. Bacteria species producing
ting and cleaning strategy, which is adapted to the hy-
mucous EPS are necessary for the development of the
draulic load, is technically and economically useful. This
activated sludge floc. By forming a mucous matrix on the
includes planning of a sufficient membrane surface area
membrane, EPS have a negative effect on the filtration
and operation of the membranes at moderate transmem-
process. Therefore the process control has to be designed
brane pressure differences.
in such a way that the development of EPS is minimized

as far as possible.
Within the scope of an optimized operating concept,

buffering of hydraulic peak loads in an upstream balanc-
In practice, chemicals are used to counteract the fouling
ing tank may be useful to reduce the membrane surface
process. The utilization of an acid, e. g. citric acid, and a
area.
cleaning chemical with oxidative effect, e. g. sodium
56
Performance of micro- and ultrafiltration membranes
Activated sludge flocs consist of colonies of different bacteria species. The species pseudomonas, archobacter, ba-
The model for material transport in micro- and ultrafil-
cillus, micrococcus, aerobacter and in particular zoogloea
tration membranes is based on the idealized pore model,
are found most frequently. Indications on the size of acti-
i. e. bigger particles, activated sludge flocs and bacteria,
vated sludge vary, e. g. with diameters of 50 to 200 m
substances with a molar mass of more than 20,000 g/mol
[HARTMANN 1983] or 5 to 30 m [KRIEBITZSCH 1999],
are not able to pass through the membrane capillaries
i. e. sized which are also retained by microfiltration mem-
because of their size. Dissolved substances such as acetic
branes.
acid or urea cannot be retained, unless they are adsorbed

at substances which are retained. By ultrafiltration mem-
Performance of nanofiltration and reverse osmosis
branes, substances with a molar mass of at least 20,000
membranes
g/mol can be retained.

To separate organic components from aqueous solutions,
In municipal waste water treatment, the membrane bio-
a nanofiltration or reverse osmosis membrane has to be
reactor process (a combination of activated sludge pro-
used. Nanofiltration membranes achieve considerable
cess and membrane process) is used in order to remove
retention performances for substances with a molar mass
also dissolved, biodegradable constituents. Degradation
of 200 g/mol and more, while reverse osmosis membranes
of organic matter with development of biomass and con-
also retain dissolved organic components with a molar
version processes such as nitrification and denitrification
mass of 100 150 g/mol nearly completely. Table 1-12
take place in the same way as in the conventional acti-
and Figure 1-24 show the molar masses of some selected
vated sludge process. The substances adsorbed at the acti-
waste water constituents.
vated sludge flocs are retained safely by micro- or ultrafiltration membranes.
Table 1-12
Molar masses of selected natural organic constituents in domestic waste water [KOPPE, STOZEK 1999]
Name
Chemical formula
Molar mass [g/mol]
Natural organic constituents

Makropollutants
Acetic acid
C2H4O2
60
Citric acid
C6H8O7
112
Sucrose
C12H22O11
342
Glycine
C2H5O2N
75
Urea
CH4ON2
60
Estradiol
C18H24O2
272
Toluol
C7H8
Mikropollutants
92
Synthetic organic constituents

Trichloroethene
C2HCL3
132
Dichloro benzene
C6H8CL10
435
Sorbic acid
C6H8O4
144
57
Figure 1-24
nanofiltration
reverse osmosis
100
200
300
400
500
molecular
weight
[g/mol]
acetic acid
urea
glycine
toluol
citric acid
trichloroethene
sorbic acid
estradiol
saccharose
dichloro benzene
A special feature of nanofiltration membranes is their ion

selectivity. Negatively charged ion groups on or in the
membrane retain dissolved salts with polyvalent anions,
Group 1: Substances present in low concentrations

in the waste water (e. g. Atrazin)
Group 2: Substances which are detected in the
while monovalent anions are able to pass through the
inflow and partly in the effluent above the detection
membrane nearly unhindered. In industrial applications
limit and whose concentrations are considerably re-
this feature is used to recover valuable material from the
duced between inflow and effluent (e. g. naphtalin,
process waste water (e. g. treatment of waste water from

car painting, recovery of dyes in paper mills or in the
textile industry).
nonylphenols, bisphenol A)
Group 3: Substances which are detected in the
inflow and partly in the effluent above the detection
limit and whose concentrations are not or only slightly
For municipal waste water treatment, nanofiltration
reduced (e. g. diclofenac)
membranes open a special perspective for the retention

of organic trace substances.
In Table 1-13 and, some organic trace substances are

selected whose retention can be expected on account of
As resulted from investigations, it is useful to classify the
their molar mass. The real, quantifiable retention perfor-
organic trace substances into three groups with view to
mance has to be determined by practical tests. At present
their concentrations in the waste water and their degra-
intensive studies are realized concerning this subject.
dation behaviour [MUNLV 2004].
58
Table 1-13
Molar masses of selected organic trace substances [MUNLV 2004]
Name
Chemical formula
Molar mass [g/mol]
Bisphenol A
C15H20O2
228
EDTA
C10H16N2O2
292
Trifluralin
C13H16F3N3O4
335
Polycyclic aromatic hydrocarbons
C22H12
276
Nonylphenol
C15H24O
220
TCEP
C6H12O4P1Cl3
285
TCPP
C9H18Cl3O4P
327
ClC6H4OC(CH3)2CO2H
214
Organic trace substances of group 3

Organophosphates
Pharmaceuticals
Clofibric acid
Carbamazepine
C15H12N2O
236
Naproxen
C14H14O3
230
Diclofenac
C14H11Cl2NO2
296
Figure 1-25
Molar masses of selected organic trace substances
nanofiltration
reverse osmosis
200
300
clofibric acid
nonylphenol
bisphenol A
naproxen
carbamazepin
400
molecular weight
[g/mol]
polycyclic aromatic hydrocarbons

TCEP
EDTA
diclofenac
TCPP
trifluralin
59
For operation with high sludge ages, membrane biorec-
Demands on the operating personnel
tors need considerably smalller activation volumes, compared to conventional plants. It can be assumed that
A membrane bioreactor differs from a conventional acti-
under these conditions an adaptation of the biomass
vated sludge plant with view to operation and process
takes place which allows increased removal of hardly
engineering. At present there is still need for training of
removable waste water constituents (cf. e. g. substances of
the operating personnel of membrane installations. Con-
groups 2 and 3). Complete removal of substances which
cerning the membrane bioreactor process, the Erftver-
possibly are not removed in the membrane biorector
band offers a training series at the waste water treatment
(e. g. substances of group 3) can be attained by direct
plant Nordkanal. In cooperation with MUNLV NRW, the
downstream arrangement of a nanofiltration stage or a
Aggerverband currently installs a training facility on the
reverse osmosis. Interconnection of another treatment
membrane bioreactor process at the site of the waste
stage, as required in conventional activated sludge
water treatment plant Seelscheid.
plants, is not necessary.
60
Membrane Technology in Municipal

Waste Water Treatment
Membrane technology has been used for decades in
In the beginning of the chapter the relevant process
industrial waste water treatment. In municipal waste
engineering is explained in more detail. There exist two
water treatment, however, it has been applied only
ways of arranging the membrane stage in a municipal
for several years.
waste water treatment plant (Figure 2-2):
The main drivers for the recent increased application
integration of the membrane stage into the
of membrane technology in the municipal waste water
activated sludge plant, and
treatment market are the new engineering approach con-
downstream arrangement of the membrane
cerning membrane modules which are directly immersed
stage into the effluent of a conventional biological
into the activated sludge tank, and further development
waste water treatment plant.
of membranes (micro- and ultrafiltration membranes). It

is because of these developments that this technology is
In Germany, the integration of the membrane stage
now able to compete with well-established treatment
as combination of activated sludge process and membrane
processes (e. g. the conventional activated sludge process)
filtration the socalled membrane bioreactor pro-
and that the purification efficiency has clearly improved.
cess (chapter 2.1) is of greatest importance. This pro-
During the last decades considerable efforts have been
cess is used
made in the field of waste water treatment, which has

resulted in a significant positive effect on the quality of
in waste water treatment plants (chapter 2.2), as well as
water bodies. However, further improvement in water
in small sewage treatment plants and ships sewage
pollution control has to be realized in the future, specifi-
treatment plants (chapter 2.3).
cally, measures for the removal of germs, bacteria and

viruses from waste water as well as for retention or degra-
The membrane bioreactor process can be explained as
dation of micro-pollutants (e. g. substances affecting the
follows: The membrane stage is used inplace of a secon-
endocrine system or residues from medicaments) must be
dary clarifier tank to separate the biologically treated
addressed.
water from the biomass. Depending on the module

system applied, one can distinguish between internal
The following pages provide an overview of the potential
membrane modules (i. e. fitted into the activated sludge
of membrane technology in the municipal waste water
tank, Figure 2-2, 2a) and external membrane modules
market. The drivers for existing plants to apply membrane
(i. e. installed outside tanks, Figure 2-2, 2b).
technology will be discussed. The following chapters deal

with these examples as well as with technical and econo-
Membrane stages arranged downstream of bio-
mic conditions and aspects of planning and operation.
logical treatment stages (Figure 2-2, 3) are used to obtain
Figure 2-1 serves as guide to the chapter so that the
complete retention of solids and farreaching disinfection
reader may choose directly the subjects in which he is
of the effluent (see chapter 2.4).
interested most.
62
Figure 2-1
Background planning operation of a municipal membrane bioreactor, contents of the chapter
Membrane technology in municipal waste water treatment
Procedure
Example
p. 286
Motive
Information
New construction, upgrading,

extension of activated sludge
stages
Concrete examples
p. 95 ff.
Associations
Further measures
Target
p. 66 ff.
p. 286
p. 266 ff.
p. 69
Purification requirements
Consulting engineers
Local situation
Analysis of the
actual situation
...
p. 64
p. 286
p. 270 ff.
Integration of existing tanks
Membrane modules
New construction of tanks
Economic efficiency
p. 70 ff
Study of variations
Membrane modules
...
p. 286 f.
Design of the membrane

bioreactor
p. 92 ff.
p. 70 ff.
p. 163
Concrete examples
p. 95 ff.
Consulting engineers
Planning,
design,
configuration
Plant configuration
Plant manufacturers
p. 82
p. 287
Operation
...
p. 87
p. 270 ff.
Cleaning
Concrete examples
Energy consumption
Plant operators
p. 95 ff.
Staff
p. 89 f.
p. 89 f.
p. 266 ff.
63
Figure 2-2
Conventional waste water treatment according to the activated sludge process and possibilities for the
arrangement of a membrane stage at municipal waste water treatment plants [OHLE 2001]
conventional process engineering in municipal waste water treatment

effluent
raw waste water

RE/SFF
VK
BB
BB
NK
if nec. more farreaching measures
e.g.: NN, SF, UV
1
integration of the membrane stage in municipal waste water treatment
raw waste water
2a
effluent
RE/SFF
VK
If nec. FS
optional
RE/SFF
VK
If nec. FS
optional
BB
effluent
raw waste water
2b
BB
BB
downstream arrangement of the membrane stage in municipal waste water

raw waste water
effluent
RE/SFF
VK
BB
BB
NK
RESFF screen, grit and grease trap

VK
primary settlement tank
FS
fine screen
64
BB
NK
SF

2nd settlement tank
sand filter
M
UV
NN
membrane stage
UV treatment
post-nitrification stage
With view to water pollution control, membrane techno-
membrane stage (nanofiltration or reverse osmosis), the
logy represents a future-oriented solution. Thanks to the
elimination of organic trace substances can also be
high attainable sludge age and another downstream
expected. Figure 2-3 shows such a process combination.
Figure 2-3
Flow sheet of a waste water treatment plant with membrane bioreactor process and downstream
membrane stage
membrane Stage I
(MF/UF)
denitrification
stage
rake
fine screen
(optional)
nitrification
stage
grit and
grease
trap
membrane stage II
(NF/UO)
outflow
raw water inflow
recirculation
optional
process
supplement
excess sludge
65
2.1
stage can be operated at much higher biomass concentra-
The Membrane Bioreactor Process
tion than in conventional plants. With the latter, biomass concentrations of MLSS < 5 g/l are typical, while the
2.1.1
membrane bioreactors working at present are operated at
Description of the Process and Fields of Application
MLSS concentrations of 9 16 g/l. Thus it is possible to

reduce the aeration tank volumes at equal sludge loading
The membrane bioreactor process is a combination of
by up to 75 % compared to conventional plants.
biological waste water treatment according to the activa-
Table 2-1 summarizes the main advantages of the use of
ted sludge process and the separation of the sludge-water
the membrane bioreactor process in municipal waste
mixture by membrane filtration. Waste water treatment
water treatment.
in the true sense takes place by metabolic and conversion

processes in the biological stage (activated sludge process). Simplifying we can say that the carbon and nitro-
Table 2-1
gen compounds present in dissolved form in the waste
Advantages of the membrane bioreactor process
water are converted to CO2 and N2 and integrated into
compared to the conventional activated sludge
the biomass. This task is done by micro-organisms which
process
are found as suspended sludge flocs in the activated sludge

tank.
Advantages
complete retention of solid matter:
To separate the treated waste water from the suspended
- improved effluent quality concerning the parameters COD and BOD5
biomass, membrane stages with pressure-driven micro-
- far-reaching disinfection of the effluent, i. e. secondary settling, filtration and disinfection plant are replaced
or ultrafiltration membranes are used. The membranes
- no influence on the effluent quality by floating or bulking sludge nor
ensure a complete retention of solids and biomass, so
scum formation (possibly lower demand for auxiliary agents)
that a secondary settling tank for phase separation downstream of the activated sludge tank is not necessary. The
smaller aeration tank volumes due to higher biomass concentration
result is a treated waste water which is free of solids and,
existing plant components can be used for plant expansions
to a far-reaching extent, disinfected. Therefore the em-
less space required for the waste water treatment plant
ployment of a membrane stage in municipal waste water
expansion of plants by addition of modules
treatment is particularly interesting if higher demands on

the quality of the treated waste water are made.
Considering the aspects mentioned in Table 2-1, today
For the membrane bioreactor process, one distinguishes
the membrane bioreactor process proves to be, from the
between internal and external arrangement of the mem-
economic point of view, an advantageous option com-
brane modules. Internal arrangement means that the
pared to other process techniques, under the following
membrane modules (Figure 2-2, 2a) are immersed within
general conditions:
the bioreactors into the mixed liquor (immersed system).

With external arrangement the mixed liquor is withdrawn from the bioreactors and the membrane modules,
usually tubular modules, are fed in cross-flow operation
(Figure 2-2, 2b). For financial reasons only immersed
membrane systems are used in municipal waste water treatment (chapter 2.1.2).
Since the efficiency of phase separation by the membrane
bioreactor process is to a great extent independent of the
settling characteristics of the mixed liquor, the aeration
66
Demands on the effluent quality

If higher demands are made on the discharge parameters
reactors represent an economically interesting solution.
(standard monitoring or hygienic parameters) (e. g. for
As shown by Table 2-2, the effluent quality is clearly better
the discharge into weak receiving waters, drinking
than that of conventional waste water treatment plants.
water protection areas or bathing water), membrane bio-
Table 2-2
Performance data of membrane bioreactor plants compared to conventional activated sludge plants
[DOHMANN ET AL. 2002]
Parameter
Conventional
Membrane bioreactor
activated sludge plant

Solids (filterable solids)
mg/L
10 15
COD
mg/L
40 50
< 30
Ntot
mg/L
< 13
< 13
Ptot (with simultaneous precipitation)
mg/L
0.8 1.0
< 0.3
hygienically alarming
bathing water quality
<5
< 20
0.2 0.4
0.7 1.5
Microbiological quality
Dry matter content in the
g/L

Specific energy consumption
kWh/m3
Studies on the hygienic quality of the effluent have shown
plant [BAUMGARTEN, BRANDS 2002] is compared in
that by using membrane bioreactors it is possible to com-
Figure 2-4 to that of the Bchel pilot plant (in each case
ply with the standards of the EU Directive on Bathing
mean values from multiple sampling). Concerning the
Waters without further treatment measures. To illustrate
hygienic effluent parameters, it is evident that the mem-
the high effluent quality of membrane bioreactors,
brane plant is superior to conventional plants.
the germ load of a conventional waste water treatment
67
Figure 2-4
Comparison of the germ load in the effluent of waste water treatment plants
[BAUMGARTEN, BRANDS 2002]
conventional WWTP
membrane bioreactor
EU guide value
EU limit value
1.000.000
100.000
10.000
1.000
100
10
1
E. coli
[MPN/100 ml]
total coliforms
[MPN/100 ml]
faecal streptococci
[MPN/100 ml]
salmonellae
[MPN/100 ml]
coliphagae
[PFU/l]
total number of germs

[colony-forming unit]
Sewer system
Local situation
If the catchment area is mainly drained by a separate
Due to higher biomass concentrations in membrane bio-
sewer system, the membrane surface area to be installed
reactors, it is possible to reduce the aeration tank vol-
into the aeration stage of the waste water treatment plant
umes by 50 to 75 % compared to conventional plants. If
is much smaller than in plants where waste water from
the surface area available requires compact construction,
combined systems is treated. Thanks to lower hydraulic
a membrane bioreactor may represent suitable technical
fluctuations, the membrane stage is optimally used and
solution. This is shown in Figure 2-5 by way of example
thus is competitive with alternative technical methods for
for the comparison of variations for the new construc-
waste water treatment, even if no higher demands on the
tion of the Kaarst waste water treatment plant.
effluent quality are made.

However, an increase in sewer infiltration water requires
more membrane surface area. Therefore, membrane processes should be used preferentially in applications with
low amounts of sewer infiltration water compared to the
waste water volume.
68
Figure 2-5
Schematic representation of the space requirements of a conventional activated sludge plant (edged in
blue) and of a membrane bioreactor (edged in red), example: Nordkanal waste water treatment plant
[ERFTVERBAND 2002]
Rebuilding or expansion of installations

Existing installations which have to be rebuilt or expanded
technology in their efficiency calculations for new pro-
(e. g. because of higher demands on the effluent quality or
jects or even to give it priority in planning, clearly indica-
increased waste water volumes) can be readily converted
tes its competitiveness compared to conventional techno-
to membrane bioreactors. The membrane stage can be
logy. According to KWL, even a change towards mem-
integrated at low cost into existing components of the
brane technology is expected which will not come out on
plant, so that demolition or new construction of aeration
top because of enhanced purification requirements, but
tanks is not necessary. This is especially advantageous if
only because of economic aspects taking into account
an expansion of the surface of the plant to be upgraded is
further reductions of the membrane costs as well as pro-
not possible due to the local situation.
cess optimizations [WALTHER 2001].
Since in future the costs for installed membrane surfaces

will decrease (chapter 2.1.4), it can be expected that the
economic efficiency of the membrane process will further
increase. The decision of the water boards (Aggerverband,
Erftverband, Kommunale Wasserwerke Leipzig (KWL)),
which have already gained experience with large-scale
application of membrane technology, to include membrane
69
2.1.2
Capillary module from the company ZENON, Canada
Membrane Modules
The hollow fibre module presented in Figure 2-6 (product
For a long time it has been known that membranes are
name: ZeeWeed ) consists of hundreds of tubular mem-
able to separate activated sludge from water. However,
branes with a diameter of 3 mm oriented vertically be-
during only the last ten years, module systems have been
tween two plastic blocks (top and bottom header). The
developed which are a relevant process variation, com-
capillary tubes (pore size ~ 0.04 m) are charged from
pared to sedimentation, in municipal waste water treat-
the outside with the mixed liquor; the permeate flows
ment because of low capital and operating costs.
into the interior of the capillary tubes and is discharged

by a collecting channel integrated into the top header.
Until now the so-called low pressure processes using
To minimize the formation of a covering layer, coarse to
immersed modules have been the most widespread. Micro-
medium bubble air is introduced at the bottom header
or ultrafiltration modules are immersed directly into the
which generates an up-flow movement of the mixed
mixed liquor and withdraw the biologically treated water
liquor and causes the capillary tubes to move between
as filtrate at transmembrane pressures of < 0,5 bar in low-
the headers. Additional covering layer removal is possible
pressure or submergence operation (gravity flow). At
by cyclic backwash of the modules at the filtrate side in
present, capillary modules from the company ZENON
the so-called backpulse mode. Filtration of six minutes
and plate modules from the company Kubota have a high
and a backwash time of 30 seconds is a common operat-
share in the modules being used worldwide on an indus-
ing mode.
trial scale. These modules as well as the latest national

and international developments are presented in the following sections.
Figure 2-6
ZeeWeed-module from the company ZENON ,
left: schematic presentation from the operating principle of a module [OHLE 2001],
right: photo of the technical realization as module cassette [photo: ZENON]
air intake
permeate
discharge
backwash
top header with integrated
permeate collecting channel
membrane
bundle
permeate channel
supporting layer
membrane
rising mixed liquor
support frame with integrated

air tube
bottom header
blower
support frame
70
During the last years, the module configuration from the
Figure 2-7
company ZENON has been continuously optimized. A
Arrangement of several ZeeWeed -modules
rather compact configuration has been obtained with the
ZW 1000 in a cassette [photo: ZENON 2004]
current capillary module, ZW 500 d (Figure 2-6). The

module cassette presented in Figure 2-7, ZW 1000 (pore
size of the membranes: 0.02 m), had been designed originally for drinking water treatment, but is also used e. g.
for tertiary treatment or for the treatment of the effluent
of a final clarifier or a sand filtration unit.
Plate module from the company Kubota, Japan
The plate modules (Figure 2-8) consist of a support plate
on which the membrane sheet (pore size: ~ 0.4 m) is
welded at both sides. A drainage and backing fleece is
fixed between the plate and the membrane. The support
plate is provided with drainage channels which come
together in a suction branch for permeate withdrawal.
The individual plates are combined vertically with a
distance of 6 mm parallel to each other to create a plate
package that is fitted into a support frame (Figure 2-8).
The sides of the support frame are closed. The support
frame is installed in an up-flow channel, at the bottom
Figure 2-8
Plate module from the company Kubota,
left: schematic presentation of the operating principle [according to KRAFT, MENDE 1997],
right: photo of the technical arrangement of the plate modules as plate package [photo: KUBOTA]
filtrate collecting
channel
filtrate
suction branch
membranepackage
collecting channels
drainage fleece
membrane
support
membrane
up-flowchannel
pressure
aerator
air
suspension
71
Figure 2-9
Basic schematic of the plate module double-decker from the company Kubota [AGGERWASSER GMBH 2004]
membrane package at the top

membrane package at the bottom
aeration device
of which is arranged a device for exhaustive pressure
mixture, can be used twice. Therefore the energy demand
aeration. Due to the injected air, the mixture of sludge,
for module aeration is considerably reduced
water and air rises and flows over the membrane, ensuring removal of the covering layer. The filtrate is dis-
Module system from the company PURON AG
charged by low pressure at the filtrate side or by the

hydrostatic pressure of the active water head (gravity
A new immersed module system consisting of capillary
flow") via the filtrate collecting channel which is connec-
membranes with a pore size of 0.1 m was developed
ted with the suction branches of each plate. The covering
about five years ago at the RWTH Aachen University and
layer on the plate is not removed by backwashing on the
is now available for application in water and waste water
permeate side. Filtration is instead interrupted in inter-
treatment. Production and marketing of the new mem-
vals while the modules are continuously aerated [KRAFT,
brane filters are realized by the company PURON which
MENDE 1997]. The break interval for expansion of the
belongs to the KOCH-GLITSCH group.
membranes and removal of the covering layer varies according to the waste water composition. In some munici-
The patented basic idea of the PURON module is confi-
pal installations, filtration of nine minutes followed by a
guring membrane fibres as bundles which are only fixed
break of one minute has proven to be efficient.
at the bottom, while their closed top ends move freely in

the mixed liquor to be filtered (Figure 2-10).
As a further development of the combination of up-flow

channel and plate package design, the so-called double-
In the centre of each fibre bundle of a module, a nozzle
decker is now offered for large-scale applications (Figure
is arranged to introduce air for movement and cleaning
2-9). Two plate packages are arranged on top of each
of the membranes. The air flows up through the mem-
other, so that the air introduced, i. e. the activated sludge
brane fibre bundle from the inside to the outside. Mem-
72
Figure 2-10
PURON module and module component [photo: PURON AG]
PURON-module
module component
filtrate
filtrate
air bubbles membrane fibre
air
membrane fibres
fibre holder
filtrate
module row
air conduit
central air intake

single-sided fixation of membranes
assembly from single membrane bundles
brane coatings or fouling material are discharged from
Kompetenznetzwerk Wasser NRW (competence net-
the module. Hair and fibrous compounds are also slipped
work water North-Rhine Westphalia). This pilot study
off to the top, which helps to prevent the problem of
allows individual components of the membrane module
their accumulation and sticking to the membrane even
to be operated under real conditions, i. e. with changing
with relatively coarse prescreening. Due to defined air
loads. The experiences from this first pilot study were the
intake, the aeration time of the modules is reduced to
basis for the construction of a technical installation at
5 10 % of the filtration time, and thus the energy de-
the Simmerath waste water treatment plant for 750 PE in
mand for overflow is reduced.
NRW. This technical installation has been operating since

the end of 2002 within the scope of a research and devel-
In the technical module of PURON a multitude of these
opment project.
module components are arranged in parallel. The total

membrane surface area of the PURON module is 504 m2.
The fittings and connections of the module are designed
to be compatible with existing module systems.
Pilot tests have been run since August 2001 at the AachenEilendorf waste water treatment plant within the scope
of a field study on membrane bioreactors promoted by
73
Module system from Martin Systems AG

The Martin Systems AG markets a new module system
side and on top of each other. For example, one siClaro
called siClaro. According to information from the manu-
membrane module of the type FM 643 ready for connec-
facturer, the innovations of this system are the structure
tion (see Figure 2-11, right) consists of 12 module blocks
of the filter and the operating mode of the system.
with a total membrane surface area of 72 m2.
For the modules, flat membranes with a pore width of
By using fine-bubble membrane tube aerators below the
35 nm are used. Each membrane is welded on a support-
module package, higher oxygen input is attained. Thus
ing scaffold with an open grate structure. A drainage
the air input which is additionally necessary to supply
fleece is not necessary. The supporting scaffolds with the
the micro-organisms is reduced. Backwashing with filtrate
spacers necessary for effective cleaning of the membrane
is not necessary because the membranes are fixed trans-
surface are welded to module blocks. Filtrate collectors
versally to the cleaning water-air mixture.
are welded on top and bottom of each module block

transversally to the supporting scaffold. Thanks to this
Figure 2-11 shows a scheme of the module (left) and a
self-supporting construction, the material thickness of
module package (right).
the supporting scaffold is rather small. This allows for a

large number of variations in combining the module
blocks to a connectable module package. For technical
application, several module blocks are connected side by
Figure 2-11
Membrane module from Martin Systems AG, left: schematic representation of a module block,
right: connectable module package [photo: MARTIN SYSTEMS AG]
74
VRM process with rotation plate modules and VUM

process from Huber AG, Germany
The VacuumRotationMembrane system (Huber VRM
area of few square metres are used. The individual filter
process) has been used since 2001 already on an industri-
plates in the module are covered with ultrafiltration
al scale at the Knautnaundorf, Saxony, waste water treat-
membranes and arranged in parallel. The VUM mod-
ment plant. The modules (pore size ~ 0.04 m) consist of
ules are submerged into the liquid to be filtered, and the
plate segments (plate packages) arranged in parallel, each
filtrate is drawn off directly across the flat membranes
of which is provided with a connection to draw off the
with a pore size of 0.04 m. The mixed liquor is generated
permeate (Figure 2-12). The structure of the plate seg-
in a flush box below the module. It flows diagonally to
ments is similar to that of the Kubota plates. The plate
the filtration flow direction in order to remove the cover-
packages are arranged around a rotating hollow shaft and
ing layers from the filtering surfaces. The modules can be
are connected by permeate collecting pipes by which the
stacked and combined as a module package so that com-
permeate is withdrawn continuously at low pressure.
pact filtration units can be easily adapted to each indivi-
In the centre of the plate package, air is continuously
dual case.
introduced radially and rises between the plates. Due to

the rotation of the plate package, the complete membrane surface is overflown by the rising activated sludge
mixture, so that the covering layer is removed.
Huber AG markets the vacuum upstream membrane
process (VUM process) (Figure 2-13) primarily for small
and decentralized waste water treatment plants. In this
process, small plate modules with a membrane surface
Figure 2-12
Huber VRM process [photos: HANS HUBER AG, MARTIN SYSTEMS AG], left: view of a filtration unit,
right: filtration unit installed at the Knautnaundorf waste water treatment plant
75
Figure 2-13
Huber VUM process [HANS HUBER AG], left: view of a module package in two-storey arrangement,
right: view of a module
Figure 2-14
Membrane element and membrane module from the company Mitsubishi [photo: ENVICARE ]
76
Module system from Mitsubishi AG

Mitsubishi, known among other things for its car produc-
fibres are arranged perpendicular to the up-flow sense of
tion, also produces membranes for the filtration of water
the activated sludge mixture. In practical operation the
and waste water and distributes them packaged in a
membrane surface is kept free of fouling matter as far as
module under the designation Sterapore-SUN (see Figure
possible by an air flow which is constantly introduced. In
2-14). The hollow-fibre membranes are made from poly-
addition, periodic backwashing of the membranes with
ethylene with a pore size of 0.4 m. They are fixed hori-
permeate is provided. Up to three membrane modules can
zontally between the permeate-collecting channels and
be arranged on top of each other, the relative air require-
immersed into the activated sludge. Thus, the hollow
ments being lower for three modules than for two.
Membrane system from the company A3 AbfallAbwasser-Anlagentechnik GmbH

Another membrane development from NRW is from the
backwashed on the permeate side. Experience with the
company A3 Abfall-Abwasser-Anlagentechnik GmbH/
use of the membrane material has been acquired for
Hese Umwelt GmbH. The system is based on the principle
several years in the following fields:
of plate membranes (pore size ~ 0,4 m) which can be
filtration of compost leachate
produced at rather low costs by choosing special material
filtration of liquid manure
and employing sophisticated construction principle.
filtration of fermentation residues from biogas installations
Figure 2-15 shows the view of a prototype and a con-
filtration of activated sludge from textile waste water
struction example. Due to a new configuration of the

membrane plate, the membranes developed by the company A3, unlike the Kubota plate membranes, can be
treatment plants
filtration of activated sludge from municipal waste
water treatment plants
Figure 2-15
Plate module from the company A3 GmbH [photo: A3 GMBH],
left: photo of the one-storey construction, right: top view of a plate module
77
Module system from US Filter Corporation
Figure 2-16
Membrane module from US Filter Corporation
The company US Filter produces and distributes an
[photo: US FILTER CORPORATION 2004]
immersed membrane system with the product name

MemJetTM that is comparable to the systems from the
companies ZENON and PURON. The membrane modules
permeate
consist of bundled capillary membranes (pore size ~

0.2 m) which are fixed at both ends (Figure 2-16). A
mixture of air and activated sludge is introduced by a
two-phase nozzle at the bottom of the module. According to information from the manufacturer, this arrangement is especially designed to efficiently control the
reversible covering layer and to ensure good intermixing
in the membrane reactor so that deposits and fouling on
mixed
liquor
air
the membranes are counteracted. The permeate is withdrawn at the top header of the module. Figure 2-16
shows a schematic presentation and a photo of the membrane module.
Membrane system from Keppel Seghers Belgium
Figure 2-17
Membrane module from the Keppel Seghers
The membrane system produced and distributed by

Seghers Keppel under the product name Unibrane is
comparable in form to that of the company Kubota.
The membrane module consists of plate membranes
with a nominal pore size of 0,1 m manufactured by
the company Toray.
The modules can be installed as one- or two-storey construction, adapted to the conditions of the respective
application. Figure 2-17 shows a top view of the modules
submerged in clear water.
78
Belgium [photo: KEPPEL SEGHERS BELGIUM NV]
Membrane system of Weise Water Systems

GmbH & Co. KG
The MicroClear filter module consists of immersed ultra-
the covering layer, filtration is interrupted in intervals
filtration modules in which membranes with a pore
while the modules are continued to be aerated. The raw
size of 0.05 m are fitted. According to the concrete
water is filtered from outside to inside via the membranes
application, the module consists of 26 40 single filter
and the permeate is discharged using a vacuum at the
plates (see Figure 2-18) arranged in parallel. The filter
front side of the module by a collecting tube. Depending
plates are available with varying space, depending on the
on the necessary capacity, between 1 and 100 MicroClear
raw water quality. Coarse to medium bubble air is intro-
filters can be stacked in a frame on top of each other or
duced periodically into the modules according to the
side by side (Figure 2-18).
needs, so that the activated sludge mixture flows up.

Thus shear forces occur at the membrane surface which
help to control the reversible covering layer. To remove
Figure 2-18
Membrane system from Weise Water Systems GmbH & Co. KG [WEISE WATER SYSTEMS GMBH & CO. KG],
left: structure of a filter element, right: filter system in two-storey arrangement
filter plate
membrane
spacer
filtrate outlets
79
New membrane module developments in Germany
Figure 2-19
Ceramic plate membranes from the company ItN
Module system from ItN Nanovation
Nanovation [photo: ItN NANOVATION]
The membrane system from the company ItN Nanovation consists of immersed modules mounted from ceramic plate membranes (Figure 2-19). According to the
manufacturer, the membrane material is -Al2O3 for the
supporting layer and -Al2O3, TiO2 or ZrO2 for the active
separating layer. The membranes are available with different molecular separation sizes in the fields of microand ultrafiltration.
One module comprises 86 membrane plates with a spacing of 7 mm between the plates. The active membrane
surface area of a module is approx. 11 m2. Eight modules
can be combined maximally to a rack.
Figure 2-20
Membrane module and configuration of the modules in the rack with underlying aeration device
[photos: ItN NANOVATION]
The aeration device consists of tube aerators provided
the ceramic membranes, the manufacturer expects high
with slots.
thermal and chemical resistance as well as long service

life, thus a broader range of application.
To control the covering layer, the membrane modules are

aerated during the filtration of activated sludge from the
Module system from Fraunhofer IGB, Stuttgart
bottom with coarse-bubble air. As special advantages of
The rotation disc filter from Fraunhofer Institut fr Grenz-
80
flchen- und Bioverfahrenstechnik (IGB) (Fraunhofer
tional speed varies between 200 and 500 revolutions per
Institute for Interface and Bioprocess Technology) con-
minute, according to the type and the concentration of
sists of a cylindric case in which a membrane disc stack is
the waste water constituents. The rotation disc filter can
fitted on a rotating hollow shaft (Figure 2-21). The rota-
be arranged dry or operated as immersed system.
Figure 2-21
Basic layout sketch of the rotation disc filter
rotating hollow shaft

membrane filter discs
cylindric casing
solid outlet
filtrate
inflow
The membranes are made from a ceramic material
Figure 2-22
and can achieve relatively high permeate flows. At pres-
Modules of the rotation disc filter in laboratory
ent ceramic discs with an outside diameter of 152 or
scale [photo: FRAUNHOFER IGB]
312 mm and in six molecular weight separation sizes are

commercially available. Figure 2-22 shows a dry-arranged
lab-scale module with pressure casing.
In immersed arrangement, the rotation disc filter is used
without the pressure casing. The permeate passes the
separating layer on the membrane disc from outside to
inside and is withdrawn by the hollow shaft. The covering layer is controlled by centrifugal force that causes the
laminar boundary layer sticking to the filtering disc to
flow radially to the outside. The result is continuous
renewal of the covering layer.
81
The results from pilot plant operation have shown that
deviations from design, planning and operation of con-
the rotation disc filter is insensitive to clogging and accu-
ventional activated sludge stages are focused on in this
mulation and sticking of fibrous material which reduce
section. The following items are discursed:
the performance of membranes. Therefore, it is also suited for the filtration of digested waste water sludge digestion. At present a demonstration plant for filtration of
pretreatment of the raw waste water (mechanical waste

water treatment)
waste water sludge is operated at the Heidelberg waste

water treatment plant. In 2005, a large-scale installation
process design and calculation of the biological and
for sludge filtration will be built at the Tauberbischofs-
membrane filtration stages (reactor volume and mem-
heim waste water treatment plant. At both plants, cera-
brane surface area)
mic membranes with a pore size of 0.2 m are used.

design of the aeration equipment
Other module systems for the separation of
activated sludge and water
design of sludge treatment
Besides the module systems described in the previous sections, there are others that, like some of those mentioned
above, are not yet applied on a large scale in municipal
operation of the membrane stage including membrane

cleaning and
waste water treatment in Germany. However, some

manufacturers have references in Europe, America, and
Asia (e. g. the modules for immersed systems from the
variations in boundary conditions and safety in the

case of disturbances
companies Rhodia and Norit). For several years the number of manufacturers and new module developments has
2.1.3.1
been steadily increasing.
Design
2.1.3
The design of a membrane bioreactor can be realized
Planning and Operation of Membrane Bioreactors
according to the design principles for conventional activated sludge stages, i. e. to the standard ATV-DVWK-A 131
The new membrane filtration process has important
[ATV-DVWK 2000c] or to the approach of the University
design-specific, constructive and operational differences
Group [DOHMANN ET AL. 1993]. In addition, the Insti-
compared to conventional waste water treatment. The
tute for Environmental Engineering of the RWTH Aachen
most important aspects are summarized in this section.
University will author in the first half of the year 2005
They are based on the findings from the first years of
an upgrade of the design tool ARA-BER, whose devel-
operation of large-scale installations, a large number of
opment is financed by the Land North-Rhine Westphalia.
lab-scale and semi-technical studies, including findings

from The Netherlands (field test Beverwijk) [V.D. ROEST
In conventional design, an iterative process is used to
ET AL. 2002], and the publications of the ATV-DVWK
design the volumes of activated sludge tanks and secon-
committee of experts KA 7 Membrane Bioreactor Pro-
dary settlement tanks because of the interactions bet-
cesses [ATV-DVWK 2000a, DWA 2005].
ween both process steps. This is not necessary in the case

of membrane bioreactors. Under the boundary condi-
This committee with representatives of operators, manu-
tions listed in the following sections it is possible to
facturers and scientists, elaborates a standard for mem-
design the membrane stage and the activated sludge
brane bioreactors analogous to with the standard ATV-
tanks to a great extent independent from each other.
DVWK-A 131, so that a binding regulation can be expect-
Chapter 2.5 contains an example for the design of a
ed after some years. In anticipation of this standard, the
membrane bioreactor based on the following recommendations.
82
For sludge ages < 30 days, the activated sludge tanks
tors [ATV-DVWK 2000a], presented in Figure 2-23, have
are designed according to the proven design method of
to be considered since, due to the higher sludge age, the
ATV or the University Group approach mentioned above.
usual approach for determining the excess sludge produc-
For higher sludge ages, the recommendations of the ATV-
tion is not valid.
DVWK committee of experts KA 7 Membrane Bioreac-
Figure 2-23
Specific excess sludge production in membrane bioreactors [ATV-DVWK 2000a]
1.4
excess sludge [kg TS/kg BOD5]
1.2
1.0
1.2
1.0
0.8 0.8
0.6
0.6 0.4
TS0/BOD5
design range
0.4
minimal excess sludge production
nutrient removal tTS = 15d
0.2
0
0.001
0.01
0.1
sludge loading [kg BOD5 /(kg TS d)]
In Germany, up to now all existing and planned large-
However, in practice TSBB design values in the range of
scale membrane bioreactors for municipal waste water
10 15 g/l have proven to be well-suited to the opera-
treatment are designed for sludge loadings of BTS, BOD5
tion of membrane bioreactors, because in this range the
0,08 kg BOD5/kg ,TSd. This design value is chosen to
mixed liquor has good filterability characteristics, and
achieve nitrogen removal at simultaneous aerobic sludge
the oxygen input can be managed in an economic way.
stabilization (sludge age > = 25 d).
The sludge volume index, SVI, has no relevance for

membrane bioreactors.
In the design of activated sludge tanks, the total solids

content (TSBB) and the sludge volume index (SVI) in the
As a result of the higher TSBB content of 10 15 g/l in
activated sludge stage are considered in dimensioning
membrane bioreactors, according to module types and
the volumes of the activated sludge and secondary settle-
recommendations of the manufacturers, at equal sludge
ment tanks. For membrane bioreactors this is not the
loadings, the activated sludge tank volumes are three to
case. In principle, the TSBB can be independently chosen
four times smaller, compared to conventional activated
to determine the volume of the activated sludge tank.
sludge stages, at equal sludge loadings. The smaller volume
83
of the activated sludge tanks as well as the volume of the
The critical load case may occur during combined water
final clarifiers which does not exist in the case of mem-
flow as a result of flushing water hammers with NH4-N
brane installations are relevant to the buffering capacity
peak concentrations occurring in parallel in the inflow.
and the degradation efficiency because of shorter hydrau-
However, if there are no such peak concentrations at
lic retention periods.
combined water flow, but only peak concentrations at

dry weather flow depending on the time of the day, the
In order to comply with discharge standards for nitrogen,
critical load case has to be explained with the help of
it is therefore necessary to maintain for the critical design
concentration hydrographs recorded during a representa-
case a minimum retention period in the activated
tive period.
sludge tank. The recommendation of a necessary minimum

retention period of 6 h (or 8 h for more far-reaching
The recommendation of a minimum retention time of
demands) at a design temperature of 10 C for the critical
6 h for the decisive load case and at a design temperature
design case can be undercut, if the necessary volume of
of 10 C represents the current state of knowledge. With
the membrane installation would be larger than the
the help of the knowledge acquired with the operation
volume of the activated sludge tanks which results in
of membrane bioreactors, the current recommendations
conventional design with a volume allowance of up to
for the design of membrane bioreactors are further devel-
50 % (with a chosen TSBB = 10 15 g/l in the activated
oped.
sludge stage). It has to be considered absolutely that the

nitrification volume of the membrane installation (with
The smaller reactor volume of membrane bioreactors has
VDeni, MBR / VNitri, MBR = 1), due to the volume limitation
an effect not only on possible breaking through of peak
(VMBR, max = 1,5 VBB, conventional, 10-15 g TS/l ), will not be smaller
inflows, but also on the capacity of the denitrification
than the necessary nitrification volume with conventional
stage. In large-scale membrane bioreactors, typical facili-
design (at a chosen TSBB = 10 15 g/l in the activated
ties are constructed up to now with upstream denitrifica-
sludge stage). The necessary tank volumes can be provided
tion tanks. As a result of the smaller activated sludge
by designing larger activated sludge tanks or by designing
tank volume, undesired effects may occur, e. g. increased
supplemental balancing tanks. The recommendations
oxygen carry-over from the nitrification or filtration zone
concerning the necessary retention period, the relation
to the denitrification zone. This effect is reinforced by
between nitrification and denitrification volume of the
high recirculation rates from the filtration zone.
membrane installation as well as the volume limitation

to the 1.5-fold volume of the activated sludge tanks with
In order to reduce the effects of increased oxygen carry-
conventional design (at a chosen TSBB = 10 15 g/l in the
over, the volume of the denitrification zone has to be
activated sludge stage) are based on simulation studies
equated with that of the nitrification zone (VDN : VN = 1),
carried out at the Institute of Environmental Engineering
in contrast to the design of conventional activated sludge
of RWTH Aachen University. The effluent concentrations
stages. In order to take different operating states into
of a fictitious conventional waste water treatment plant
account, part of the denitrification zone should be design-
and a ficititious membrane bioreactor with a connection
ed as a variable zone. This zone with a size of approx.
size of 100,000 PE were modelled with varying membrane
30 50 % of the denitrification zone, must be arranged
bioreactor volume. Assuming that the standard parameter
in the activated sludge tank according to the require-
set (e. g. BORNEMANN ET AL. for the Activated Sludge
ments of operation. It is also possible to credit the filtra-
Model No. 1) is also valid for membrane bioreactors and
tion zone for the nitrification volume. In this case it is
considering a fluctuation factor of 1.7 and a given design
necessary to consider the operating mode of module
load, the resulting effluent concentrations of both simu-
aeration as well as the lower oxygen input value (refer to
lated waste water treatment plants were comparable, at a
section Demand for aeration of the membrane modules).
membrane bioreactor volume which leads to a hydraulic

retention period of 6 h for the critical load case.
84
To avoid oxygen carry-over into the denitrification zone
The membrane surface should be dimensioned in such a
and to optimize oxygen utilization in the nitrification
way that the surface-specific flows allow for a constant
zone, relaxation zones should be provided upstream of
operation of the membrane modules, even in the case of
the sludge recirculation flow.
peak flows. Short events, i. e. for a few hours, where the

maximum flow is exceeded, are possible but should be
If the filtration zone is separated from the other zones, it
avoided with a view to long-term maintenance of a
might be useful not to recycle the return sludge into the
high permeability. With new or cleaned membranes,
nitrification tanks rather than the denitrification tanks.
the permeability rates are usually in a range of more than
In this configuration it is possible to control both inter-
150 200 L/(m2 h bar). In-tensive cleaning is normally
nal cycles recirculation sludge from the nitrification
necessary at a permeability < 100 L/(m2 h bar).
stage into the denitrification stage and return sludge from

the membrane stage independently from each other.
If the design concept for the installation is that one or

more module cassettes or filtration lines are permanently
The measures mentioned may contribute to reduce the
in a cleaning cycle (e. g. in larger installations), the sur-
VDN/VN ratio.
faces being cleaned must be excluded when dimensioning

the membrane surface area.
In order to obtain phosphorus effluent values according

to the discharge standards, phosphate precipitation
When determining the necessary membrane surface area,
should be carried out according to the proven recom-
internal process water quantities, e. g. from screen clean-
mendations (e. g. ATV-DVWK-A 131, N. N. 2000b]). Nor-
ing, have also to be considered.
mally a precipitant is dosed into the activated sludge

stage, i. e. simultaneous precipitation takes place. The
Experience acquired with membrane bioreactors in ope-
increased specific excess sludge volume resulting from
ration has shown that it is possible, with the membrane
simultaneous phosphate elimination by precipitating
modules commercially available, to apply a net design
salts can be determined according to the ATV standard
flux of 25 L/(m2 h ) at temperatures of the mixed liquor
A 202 [OHLE 2001].
of 8 C, based on the effluent flow of the complete installation. With a design temperature of 10 C this range may
Design of the membrane filtration stage
be higher by 15 % [ATV-DVWK 2000a].
By analogy with the conventional activated sludge pro-
Design of the aeration equipment
cess, the phase separation, i. e. the membrane stage, has

to be dimensioned for membrane bioreactors. In con-
With the membrane bioreactor process, the higher TS
trast to conventional activated sludge stages, the typical
content in the activated sludge tank leads to higher
membrane bioreactor design total solids content TSBB of
viscosity of the mixed liquor compared to conventional
10 15 g/l has a non-quantifiable influence on the
activated sludge stages. This has an influence on the
dimensioning of the membrane surface to be installed.
material transfer and the oxygen transfer coefficient ,
The following factors have to be taken into account in
as shown by Figure 2-24.
dimensioning and calculation of the membrane

stage and the membrane surface area required:
maximum inflow to the membrane bioreactor and the
maximum effluent flow
the performance data of the membrane modules utilized
(surface-specific flow) depending on the features of the
medium to be filtered (temperature, viscosity, etc.)
85
Figure 2-24
Oxygen transfer coefficient (-values) of the Rdingen and Markranstdt waste water treatment
plants with fine-bubble diffuser aeration [CORNEL ET AL. 2001]
Markranstdt
Rdingen
1.0
0.8
alpha value[-]
0.6
0.4
0.2
0
5
10
15
20
TS content [g/l]
This factor has to be considered in the design of the
tions of the aeration demand of membrane stages can be
aeration equipment for oxygen transfer. Oxygen transfer
expected as a result of improved module concepts (see
measurement in the activated sludge stages of the Mark-
chapter 2.1.2).
ranstdt and Rdingen waste water treatment plants have

shown a decrease in the -value with rising solid matter
The oxygen transfer taking place together with the
content (Figure 2-24). -values of 0.75 have been measured
aeration of the membrane modules can be credited for
with a TS content of 7 g/l, they decreased to 0.4 with a
the biological degradation. The respective -value should
TS content of 17 g/l.
be assessed as 0.17 0.20 (TSBB = 16 10 g/l) [SEYFRIED

2002].
If TSBB = 12 g/l is selected as the basis for the calculation

of a membrane bioreactor, an -value of 0.6 should be
Sludge treatment
chosen for the oxygen transfer. This corresponds approximately to the -values of conventional installations with
First experiences acquired with the treatment of sludge
fine bubble aeration [CORNEL ET AL. 2001].
from membrane bioreactors have shown that the sludge

qualities do not differ very much from aero-bically stabi-
The necessary blower power for the overflow of the
lized sludge from conventional installations. Tests for
membrane modules can be estimated as 7.5 25 W
dewatering aerobically stabilized sludge at the Rdingen
per m2 of membrane surface installed, depending on the
waste water treatment plant and the Bchel pilot plant
module. Since the demand for aeration as well as the
have shown that dried solid matter contents of 25 30 %
aeration strategies (coarse or medium bubbles, perma-
can be obtained with the usual aggregates (chamber filter
nent, intermittent) strongly depends on the concepts of
press, centrifuge), under equal operating conditions and
the module manufacturers, the design of the aeration is
with a comparable demand for flocculants [ENGEL-
normally realized by the manufacturers. Further reduc-
HARDT ET AL. 2001; N. N. 2003c; DICHTL, KOPP 1999;
86
BRANDS ET AL. 2000; VAN DER ROEST 2001; DRENSLA
sand and grease trap is sufficient because they show less
ET AL. 2001].
tendency to accumulation and sticking of fibrous matter

[N. N. 2000c].
Concerning the digestibility of sludge from membrane

bioreactors, similar values as for sludge from conventio-
In order to meet the requirements for pretreatment for
nal plants have been determined for simultaneous
membrane bioreactors, the screen manufacturers have
aerobic sludge stabilization with the help of the specific
already developed new products. An example is the
digester gas production [BRANDS ET AL. 2000; VAN DER
membrane screen offered by the company Huber AG
ROEST 2001].
(Figure 2-25) for finest screening of the raw waste water

in the inlet to a membrane bioreactor stage.
2.1.3.2
Mechanical Design and Planning
Concerning mechanical design and planning, membrane
Figure 2-25
bioreactors do not differ considerably from conventional
View and principle of a screening facility for
activated sludge plants. This is also true for possible failure
membrane bioreactors (Markranstdt waste water
scenarios which have to be considered e. g. for approval
treatment plant) [HUBER 2002, STEIN 2002a]
planning. Therefore only those aspects that additionally

have to be taken into account compared to conventional
municipal waste water treatment plants are mentioned in
the following.
For the membrane bioreactor process, mechanical treatment of the inflowing waste water is especially important.
From experience with large-scale installations it is known
that the membrane modules used are susceptible to accumulation and sticking of fibrous material and therefore
to clogging [BAUMGARTEN 2001a]. This results in an
insufficient flow across the membrane surface which leads
to a reduction of the performance or may even cause
damage of the membranes [ENGELHARDT ET AL. 2001].
Therefore all undesired material such as grease, hair or
other coarse matter has to be removed from the raw
waste water. This has to be done much more carefully
than in conventional activated sludge plants. The quality
of pretreatment does not only depend on the features of
the influent, but also on the membrane module used. For
capillary membranes, mechanical pretreatment consisting of a fine screen in the inlet zone (3 5 mm), followed by a sand and grease trap as well as a fine sieve with
a slit width of < 1 mm is recommended [MEYER 2001;
DRENSLA 2001]. Experiences with plate membranes have
shown that pretreatment with a 3 mm screen as well as a
87
Design of the installation with view to failure
Design of the installation with view to the arrange-
scenarios
ment of membrane surfaces and reactors
Compared to conventional activated sludge plants, in the
In the case of new constructions, the membrane stage
case of membrane bioreactors failures have to be consi-
should be designed in principle in two lines which are
dered which affect the performance of the membrane
hydraulically uncoupled, i. e. separate tanks including the
stage. Total breakdown of the membrane stage is the worst
peripheral equipment, in order to allow for separate opera-
case scenario for these installations, similar to the failure
tion of each line for the complete inflow from the activated
of the secondary settlement tanks in conventional plants.
sludge tank. The system has to be dimensioned hydraulically for these inflow volumes. Allowances for the permeate
Therefore the pretreatment stages (screen, sand and grease
capacity of the membranes are necessary if the capacity
trap and, if necessary, separator for light density material)
reserves of the membranes have already been completely
of membrane bioreactors, being critical to the long-term
utilized in the design of the installation for Q max.
functioning of the membranes, have to be designed with

careful attention to breakdowns caused by common failure
The same is true for installations with three or four lines,
scenarios that can be excluded in the design of conven-
for which the operational breakdown of one line has to be
tional municipal plants. Accidents in the catchment area
considered in planning. Concerning multiple-line (> 4)
of the waste water treatment plant must also be considered.
installations, the membrane stages should be calculated

in such a way that the maximum water volumes can be
In the case of critical influents due to accidents in the
treated, under design conditions, by 80 % of the membrane
catchment area of waste water treatment plants, the inlet
surface area available.
of the membrane bioreactor stage has to be closed, if

necessary, to avoid intoxication of the biomass as well as
The mechanical design of the membrane stages should be
damage to the membranes. This can be realized by special
realized in such a way that in the case of necessary mem-
sensors (e. g. conductivity sensors) in the inlet zone of the
brane replacement, the above mentioned minimum mem-
waste water treatment plant so that sewers with storage
brane surface in waste water treatment plants < 10,000 PE
capacity and overflow, and stormwater overflow tanks
(corresponding to a combined water flow of Q m < approx.
(e. g. unused primary settlement tanks) can be activated
246 m3/h, i. e. a daily in-flow of Q d < approx. 2,250 m3/d)
in the case of accidents. The storage volume should be
can be quickly removed and installed, replaced or cleaned,
calculated in such a way that in the case of combined
if necessary. The membrane suppliers have to ensure that
waste water flow, the influent to the membrane bioreac-
the membrane surfaces required are available and ready for
tor can be stored for two hours. In this case the mixing
installation within two or three working days. Concerning
and equalizing tank volume mentioned in chapter 2.1.3.1
single-line installations, it must be possible to install the
can be taken into account with a view to maintaining
membrane surfaces during operation (filled tanks).
the minimum retention period. However, the impoundment or storage volume which is necessary to comply
For plants with more than 10,000 PE (corresponding to a
with the standards for combined water treatment (ATV
combined water flow of Q m > approx. 246 m3/h or a daily
standard A 128) must not be set off with the buffer vol-
inflow of Q d > approx. 2,250 m3/d)1), both requirements
ume to be installed.
mentioned in the last sections are of secondary importance

because even with indirect discharges caused by failures,
It is also possible to build scum-boards and discharge
damaging of the complete membrane stage is rather im-
devices so that in the case of critical and unauthorized
probable as a result of dilution effects. Moreover, larger
indirect discharges, e. g. oil, petrol etc., a direct charge of
installations can be designed with multiple lines if suffi-
the membranes can be prevented.
cient capacity reserves are available.
1)
Assumptions according planning standard ATV-DVWK-A 131 [ATV-DVWK 2000c]: x s = 14 h/d, x f = 24 h/d, specific infiltration water flow = 0.5Q S ,
Q m = 2Q S +Q f
88
Measurement, control and regulation technique
Since the cleaning agents to be used have caustic, oxidizing or corrosive effects, requirements concerning the
Besides the measurement, control and regulation techni-
choice of materials for tanks (e. g. plastic sealings) and
que applied today at municipal waste water treatment
aggregates (e. g. high-grade steel, PE) as well as for safety
plants, additional parameters to be measured have to be
at work (e. g. discharge devices for gases (chlorine), accord-
considered when using membrane technology. In parti-
ing to the recommendations of GUV or DVGW for MAC
cular, the permeability of the membranes has to be ob-
values) have to be considered in planning.
served and recorded separately for each line. This is necessary in order to ensure that cleanings are carried out in
Appropriate tanks or stockrooms have to be provided for
time so that a sufficient permeate capacity is maintained.
the storage of the chemicals necessary for the cleaning

solutions.
Within the scope of these measurements, suction pressure

and flow have to be recorded online, considering con-
2.1.3.3
struction measures and hydrostatic influences on the
Operation
pressure measuring. Inhibiting influences in flow measurement have to be excluded.
Measures for maintenance of the filtration capacity
For operation and cleaning of the modules, the require-
For safe operation of a membrane bioreactor, the mainte-
ments according to the recommendations of the manu-
nance of a sufficient filtration capacity is of similar im-
facturers (e. g. pause control, backwash periods and volume
portance as the maintenance of the settlement features
flows, alarm in the case of module aeration failure) have
of activated sludge in a secondary settlement tank. While
to be taken into account.
in conventional plants the settlement features of the activated sludge can be influenced only to a limited extent
Power supply
(e. g. floating sludge, bulking sludge or problems with

foaming), the filtration capacity of membrane bioreactors
For possible power failures, a stand-by power supply
can be maintained by regular operational measures, i. e.
should be provided similar to conventional plants, in
membrane cleanings.
case a two-side current input to the waste water treatment plant is not possible. Anyway the process control
Cleaning is necessary for all membranes available on the
technique as well as the permeation have to be supplied
market, since in spite of sufficient pretreatment and module
with power, and the power demand for minimum module
aeration, the permeability of the membrane modules and
aeration (about 25 30 % of the design value) has to be
thus the flow performance at constant transmembrane
ensured.
pressure, starting from a design flow rate of e. g. 25 L/(m2h),

decreases continuously during operation. This reduction
Buffer tanks or reserves in the freeboard height are also
of the performance is due to an increase in the resistance
possible which allow for impoundment operation during
to filtration by organic and inorganic covering layers on the
a short period.
membrane surface and clogging of the membrane pores,

which cannot be avoided by operational measures such
Membrane cleaning
as overflow and possible backwash of the membranes.
To maintain the filtration capacity, regular cleaning of
For maintenance or intensive cleanings, acid, alkaline
the membrane modules is necessary, which may take place
and oxidative cleaning agents are used which are suited
either in the activated sludge tank/filtration tank or in
to restore the original filtration capacity.
separate tanks. Depending on the concept of the membrane manufacturers, heating for the separate tank or the
In each case the instructions of the membrane or module
cleaning solution has to be provided.
manufacturer have to be observed, since the cleaning
89
methods may vary considerably according to the specific
installed modules, cleaning takes place in the activated
module.
sludge, in cleaning solution or on air. In this case the

filtration tanks are emptied so that the modules are
Maintenance cleanings are performed in situ in the
suspended freely.
activated sludge. They take place regularly once or twice

a week using low concentrations of cleaning agents (e. g.
External cleaning (ex situ) is realized at cleaning solution
150 mg/L of active chlorine). They are used for example
temperatures of 30 35 C. For better mixing, the mem-
TM
for ZeeWeed
and Puron modules. During an extended
brane can be aerated during the cleaning process, so that
backwashing phase, the cleaning agent is added to the
the chemicals are distributed more evenly. External clean-
permeate and pumped into the modules which are
ing provides the best result, but this method requires
immersed into the mixed liquor.
higher operating expense [DRENSLA, SCHAULE 2004].

Table 2-3 summarizes the cleaning methods for immersed
Intensive cleanings with higher concentrations of
membrane systems.
chemicals (e. g. 500 2,000 mg/L of active chlorine) have

to be performed every 3 to 6 months, depending on the
Due to the high concentrations of chemicals, intensive
degree of contamination. By analogy to maintenance
cleanings may damage organic membrane materials and
cleanings, the modules are cleaned while they are im-
thus have negative effects on the membrane service life.
mersed (in situ) or in separate tanks (ex situ). With
Table 2-3
Cleaning methods
Membrane modules installed (in situ)
in the activated sludge
in the cleaning solution
on air
Membrane modules removed (ex situ)
The chemicals are dosed from the permeate side.

The tanks are emptied and filled with the cleaning
Cleaning in a separate cleaning cell, the
solution, the cleaning solution is dosed from the
chemicals are dosed from the feed side at
feed side.
temperatures of 30 35 C.
The water level is lowered, the chemicals are

dosed from the permeate side.
At present the use of sodium hypochlorite as cleaning
methods are being developed which shall reduce the AOX
agent provides the best results. However, high concen-
concentration in the rinsing waters and avoid foaming in
trations of cleaning agents may have negative effects
the waste water treatment plant [DRENSLA, SCHAULE
such as damage of the biomass and foaming of the acti-
2004].
vated sludge stage, so that overdosing must be avoided.

Especially in the case of in-situ cleanings, negative effects
At present less critical cleaning agents such as hydrogen
on the effluent quality may occur due to e. g. increased
peroxide or citric acid are being tested in some mem-
AOX concentrations in the permeate. But this can be pre-
brane bioreactor installations, so that soon alternatives
vented by permeate recycling into the biological stage. In
for sodium hypochlorite will be available.
the course of studies on the pretreatment of rinsing

waters from extensive external cleaning, pretreatment
90
Energy demand
In existing membrane bioreactors, specific energy con-
Figure 2-26 presents by way of example the specific
sumption rates of 0.8 to 2.0 kWh/m of permeate were
energy consumption rate of the Markranstdt waste
determined. Approximately 50 80 % of this value is
water treatment plant as a function of the throughput.
used for module aeration, which, however, provides most
The energy consumption rate of the membrane stage
of the oxygen transfer necessary for biological treatment.
(suction pumps and module blowers), the recirculation
The throughput of the installation, the TS content (oxy-
pumps, the agitators, the fine-bubble blowers, and the
gen transfer coefficient) and the waste water temperature
inlet structure have been considered.
have been identified as the main factors influencing the

specific energy demand. At present, the specific energy
While the energy consumption of recirculation pumps,
demand of membrane bioreactors is still higher than that
agitators and inlet pump station are nearly independent
of conventional waste water treatment plants, but the
of the throughput, clear dependencies exist for the opera-
effluent quality concerning hygiene-relevant parameters
tion of the membrane stage and the fine-bubble aeration.
is better. For the Markranstdt and Monheim waste water
It has been shown that with larger waste water flows
treatment plants, the specific energy demand related to
to be treated, the specific energy consumption rate of the
the average inflow volume in the range of 0.8 kWh/m3
membrane stage is 22 % lower than for a smaller through-
0.9 kWh/m [DWA 2005]. The fluctuation ranges for dif-
put. The same tendency is observed for the specific ener-
ferent parts of the specific energy demand (e. g. cross-flow
gy demand of the fine-bubble aeration. In this case the
aeration, permeate/recirculation, additional demand for
energy demand can be reduced by 48 %. Energy is saved
aeration) are indicated in the DWA working report [DWA
by increasing the performance of the fine-bubble aera-
2005] (see Annex 6).
tion and switching off the coarse-bubble aeration during
Figure 2-26
Energy demand of a membrane bioreactor (8,000 PE) with simultaneous aerobic sludge stabilization
[STEIN ET AL. 2001]
1.6
membrane stage
(suction pumps)
and module aeration
specific energy demand [kWh/m3]
1.4
recirculation pumps
1.2
agitators
1.0
0.88
fine-bubble aerators
0.8
inflow pumping station

0.85
0.6
0.69
0.16
0.4
0.2
0.05
0.21
0.12
0
1,000 - 1,500
0.14
0.01
0,09
0.11
0.01
2,000 - 2,500
0,01
0.1
0.01
> 3,000
3
plant throughput [m /d]
91
filtration pauses, or by reducing the performance of the
2.1.4
fine-bubble aeration at continuous coarse-bubble aeration
Investments and Operating Costs
during filtration [STEIN ET AL. 2001].

2.1.4.1
Due to ongoing optimizations in plant operation as well
Investments
as module design and overflow, further reduction of the

energy consumption rate can be expected. Early develop-
The investments for the construction of a membrane bio-
ments such as the introduction of intermittent aeration,
reactor consist of the costs for the components of mecha-
two-storey arrangement of modules on top of the air
nical pretreatment, biological waste water treatment and
injection device, and operation of rotating membranes
biomass separation and, if necessary, for excess sludge
has already resulted in a reduction of overflow-specific
treatment. From the experience acquired to-date, the
energy costs by approx. 50 %. The Kommunale Wasser-
savings potentials and additional costs for the investments
werke Leipzig (municipal waterworks) expect that the
compared to conventional waste water treatment techno-
energy consumption for MBR treatment will ultimately
logy can be summarized as follows in Table 2-4.
be reduced to the range of conventional plants [STEIN

ET AL. 2001].
Starting from the typical costs for conventional waste

water treatment technology [BOHN 1993; GNTHERT,
Manpower requirements and qualification
REICHERTER 2001], the savings made in process engineering (smaller tank volumes, secondary settlement and pos-
Besides training and sensitization of personnel for addi-
sibly more tertiary treatment steps become unnecessary)
tional problems which result from the operation of a
with the membrane bioreactor process can be divided
membrane bioreactor (e. g. concerning membrane opera-
among the investments for additional expenditures as well
tion, cleaning, emergency operation in case the measure-
as for the membrane separation stage itself. According to
ment, control and regulation systems break down), there
RAUTENBACH ET AL. [2000], the savings potential for the
are no extra demands on staff qualification.
components of a membrane bioreactor which are not part

of the membrane stage were 20 30 % for a plant size of
Experiences from the Rdingen waste water treatment
100,000 PE (compared to a conventional activated sludge
plant (3,000 PE) have shown that the personal expendi-
plant with secondary settlement and sand filtration).
ture after start-up, repair of faults and a training period is
Assuming a typical specific cost at that time of 200 euro per
at present approximately 0.5 man-days per day. This
m2 of membrane surface installed (including peripheral
value is in the range of conventional plants of comparable
equipment such as pipes, suction pumps, measurement,
size run by the Erftverband [DRENSLA 2001].
control and regulation equipment), nearly the same total

investment for both variations were required.
During the start-up period of the Markranstdt waste

water treatment plant (8,000 PE), the necessary working
The results of the tender process for the construction of
time expenditure was assessed as unsatisfactorily high.
the Kaarst waste water treatment plant (80,000 PE) in 2001
This was due in particular to failures of the peripheral
have turned out favourably for membrane technology. The
equipment of the membrane stage. After improvement of
offers submitted for membrane technology (20.3 22.1
the operational stability, the working time expenditure is
million euro) were 1.7 3.4 million euro lower than those
now in the range of conventional activated sludge plants
for a comparable conventional plant without advanced
or only slightly greater with a maximum of one additional
treatment (23.7 million euro) [ENGELHARDT 2002].
working hour per day [STEIN 2002a].

Based on the costs of membrane bioreactors built to-date
and on the results of tenders for new projects, the following categories can be used to assess the investment:
92
Table 2-4
Savings potentials and additional costs concerning the investments of membrane bioreactors compared to
conventional activated sludge plants
Process stage
Savings potential
Additional costs
finer mechanical pretreatment

hollow-fibre membranes 1 mm
plate membranes 3 mm
necessary to protect the membrane modules
Biological treatment
activated sludge tank volumes 3 to 4 times smaller because

of operation at increased TS content of 12 to 16 g/L
Biomass separation/
secondary settlement tank not necessary downstream
costs for the membrane stage are higher than for con-
advanced treatment
processes for further treatment of the biologically treated
ventional secondary settlement tanks due on the one
waste water at higher demands on the effluent (sand
hand to the costs of the membrane modules themselves
filtration, disinfection) not necessary
and on the other hand to peripheral equipment (measurement, control and regulation equipment, piping, suction
pumps, compressors, cleaning facilities etc.)
Sludge treatment
usually no anaerobic sludge stabilization (digester) because
higher energy costs due to aerobic sludge stabilization,
the biomass is aerobically stabilized
no utilization of digester gas from primary and secondary sludge (with plants > 50.000 PE)
The inhabitant-specific costs have to be assessed be-
At present, specific module costs for the first invest-
tween 250 and 1,400 euro. This margin is mainly due to
ment (including peripheral equipment) of 75 150 euro
different drainage systems. With combined systems, the
per m2 of membrane surface can be assessed. These values
complete installation has to be dimensioned for the com-
vary according to membrane manufacturers and the surface
bined waste water flow (usually 2Q T). Conversely, the
used. Based on the developments made in the course of
membrane stage of plants with separate systems only need
the last years, an increase in the number of module system
half of the membrane surface area compared to a com-
suppliers can be expected. Rising sales as well as increased
bined system. Moreover, the surface-specific costs of the
competitive pressure will also have positive effects on the
membrane modules decrease with increasing installation
module costs. Figure 2-27 shows the development of the
size, and therefore have to be considered in direct depend-
membrane replacement costs over the last decade and
ence on the total investments.
a forecast for the year 2005 according to CHURCHHOUSE,

WILDGOOSE [2000]. In addition, the module-specific
The share of investments for the membrane stage
costs on the basis of the tender results of different German
(including peripheral equipment, machinery and piping)
waste water treatment plants are listed. According to this
in the total costs is in the range of 30 60 %. This wide
cost curve, more significant cost reductions can be expec-
range also depends on the drainage system. Additional
ted in future. For the Monheim waste water treatment
influencing factors are the underlying membrane and
plant, for example, membrane replacement costs of 58 or
module costs, which during the last years have shown a
50 euro/m2 after a membrane service life of 7.5 or 8 years,
downward trend. Moreover, in the course of further tech-
respectively, have been assessed [RESCH 2002; STEIN
nical development an increase in the performance of the
2002b].
modules can be expected, so that the membrane surface

area to be installed, and thus the specific costs for the
membrane stage, will decrease.
93
Figure 2-27
Development of membrane replacement costs [ISA 2002; CHURCHHOUSE, WILDGOOSE 2000]
according to Churchhouse (2000)
gathering ISA RWTH (2003)
450
400
membrane replacement costs o/m2
350
300
250
KA Rdingen1
3.000 PE
200
150
GKW Nordkanal1
80.000 PE
100
KA Markranstdt1
8.000 PE
50
KA Monheim
9.700 PE
0
1990
1995
KA Markkleeberg2
30.000 PE
2000
2005
year
1
Specific net costs for installed membrane surface area (without peripheral equipment, first installation), calculated back on the basis of the
results of the call for tenders; according to information from the manufacturers, low costs can be expected for membrane replacement.
Estimation of the operator [STEIN 2002b]
2.1.4.2
Operating and Maintenance Costs
The annual operating and maintenance costs related to
2. Membrane cleaning:
waste water volumes or the population connected consists
To maintain the filtration capacity, the membranes
of different cost types. Compared to the costs of conven-
have to be cleaned regularly. Therefore, the costs for
tional waste water treatment processes, the following dif-
chemicals (about 0.25 1.00 euro/(m3 a) and additio-
ferences result for the membrane bioreactor process:
nal labour costs have to be taken into account.

3. Maintenance:
1. Energy costs:
Operation of a membrane stage requires more energy
The typical cost for the maintenance of conventional
than that of conventional plants. From the operation
plants increases for membrane bioreactors due to the
of existing installations 3,000 PE, energy consump-
additional expenditure for maintenance of the mem-
tion rates of 0.8 1,4 kWh per m of waste water treat-
brane stage. The costs to be assessed result from the
ed have been determined. For the Nordkanal waste
real membrane service life (i. e. guaranteed by the
water treatment plant, an energy demand approx. 60 %
manufacturer; assumed up to now: 5 8 years, in
(0.8 kWh/m3) greater than for conventional plants
some cases 10 years [WOZNIAK 2002]) and from the
94
(0.46 kWh/m with anaerobic sludge stabilization and
anticipated membrane replacement costs. The main-
0.51 kWh/m3 with aerobic sludge stabilization) can
tenance costs decrease with longer service life and
be expected [ENGELHARDT 2002].
falling module costs.
4. Waste water charges:

As a result of the treatment efficiency of membrane
2.2
Concrete Examples of Membrane Bioreactors
stages, a reduction in the pollution load discharged

into water bodies can be expected.
In the following chapters, membrane bioreactors for the

treatment of municipal waste water are described which
The expenditure for the construction of a membrane
already have been realized or are under planning. The
stage can therefore be cleared with the waste water
concrete examples are arranged according to the loca-
charges paid to-date, provided that the requirements
tions (in or outside Germany) and the membrane process
according to 10 section 3 of the Waste Water Char-
applied (microfiltration or ultrafiltration). Large-scale
ges Act are met.
plants, pilot plants, small waste water treatment plants,

ships waste water treatment plants and mobile plants are
Since the higher energy and maintenance costs exceed
described.
the reduction in waste water charges, higher operating

costs of membrane bioreactors can be expected on the
In Germany, at present nine large-scale membrane biore-
whole. A comparison of operating costs has been realized
actors with capacities between 700 and 80,000 PE are
for the Nordkanal waste water treatment plant on the
operated. Five more installations will be put into opera-
basis of the offers [ENGELHARDT 2002]. According to
tion by the end of 2005. Ten plants will then exist in the
this study, the assessed waste-water-specific operating
state North-Rhine Westphalia (NRW). All installations
costs of the membrane bioreactor (0.24 0.25 euro/m3)
built in NRW have been promoted by funds from the state.
were higher by approx. 15 % than that of the conventio-
The state makes available additional funds for new appli-
nal solutions offered (0.20 0,22 euro/m3). Ranges for the
cations and more far-reaching scientific studies which
costs per year, related to energy demand and waste water
especially aim at optimizing the treatment capacity and
volume, for aeration and recirculation, the necessary
the operating cost.
chemicals etc. are indicated in the DWA working report

Membrane bioreactor process (see Annex A 6 [DWA
Table 2-5 gives an overview of the most important data
2005]).
for the plants in Germany, which will be described in

detail in the following sections.
In this case it has to be taken into account that plants

with differing effluent qualities are compared in cost
determination. In order to obtain the same effluent quality with conventional activated sludge plants as with
membrane bioreactors, an additional treatment stage
(e. g. disinfection stage) has to be arranged downstream
of the conventional plant. Under this condition the operating costs of membrane bioreactors should be the same
or lower.
Moreover, further technical developments of the membrane modules will lead in future to a reduction of the
energy costs and improvement of the performance, so
that the population-specific treatment costs will also
decrease.
95
Table 2-5
Data of the large-scale membrane bioreactors treating municipal waste water in Germany,
as of December 2004
Operator
Erftverband
Aggerverband
City of Monheim
Municipal Waterworks
Erftverband
Leipzig
North Rhine-
North Rhine-
Westphalia
Westphalia
Plant
WWTP Nordkanal
Capacity
80,000 PE
Federal State
Bavaria
Saxony
WWTP Seelscheid
Monheim WWTP
Markranstdt WWTP
Rdingen
10,500 PE
9,700 PE
at present 8,000 PE
3,000 PE
North RhineWestphalia
up to 12,000 PE
ZENON
Kubota
ZENON
ZENON
ZENON
Module type
capillary module
plate module
capillary module
capillary module
capillary module
Process
ultrafiltration
microfiltration
ultrafiltration
ultrafiltration
ultrafiltration
Membrane
84,480 m2
12,480 m2
12,320 m2
7,360 m2
4,846 m2
9,200 m3
2,310 m3
1,640 m3
approx. 1.800 m3
480 m3
Membrane
manufacturer
surface area
Bioreactorvolume
Maximum inflow
1,881 m /h
356 m /h
288 m /h
180 m /h
135 m3/h
Sewer system
combined system
combined system
combined system
combined system
combined system
Start-up
December 2003
August 2004
July 2003
January 2000
June 1999
Pretreatment
screen (5 mm)
step screen (3 mm)
fine screen (1 mm)
two-stage screen
screen (3 mm) grit and
grit and grease trap
grit chamber
grit channel
(up to 1 mm)
grease trap sieving of
the recirculation sludge
rotary screen (0.5 mm)
(0.5 mm) in partial flow

Special feature
expansion at the site of

the WWTP
Operator
Municipal Services
Aggerverband
Schramberg
Municipal Waterworks
Wasserverband
Leipzig
Eifel-Rur (WVER)
Federal State
Baden-Wrttemberg
North Rhine-Westphalia
Saxony
North Rhine-Westphalia
Plant
Schramberg WWTP
Bchel WWTP
Knautnaundorf WWTP
WWTP Simmerath
Capacity
2,600 PE
1,000 PE
at present 900 PE
700 PE
up to 1,800 PE
ZENON
Kubota
Martin Systems AG
PURON
Module type
capillary module
plate module
plate module
capillary module
Process
ultrafiltration
microfiltration
ultrafiltration
ultrafiltration
Membrane
4,400 m2
960 m2
756 m2
1,000 m2
730 m3
190 m3
68 m3
136 m3
Membrane
manufacturer
surface area
Bioreactorvolume
Maximum inflow
90 m3/h
40 m3/h
23 m3/h
being studied
Sewer system
combined system
combined system
separate system
combined system
Start-up
May 2004
August 1999
October 2001
2003
Pretreatment
screen (5 mm)
screen (3 mm) grit
two-stage screen
fine screen (3 mm)
fine screen (0.5 mm)
chamber, optional
(3 mm, 1mm)
primary treatment
Special feature
96
pilot plant
pilot plant
The positive experiences acquired to-date with membrane
Moreover, the application of the membrane bioreactor
technology and the membrane bioreactor are the reason
process is studied at a large number of other sites in
for water boards and municipalities to take the membrane
Germany. The waste water plants at the sites Xanten-
bioreactor process into consideration when planning new
Vynen (LINEG) and Richtheim (Municipality of Richt-
or up-grading existing plants as an alternative to conven-
heim in cooperation with Bayerisches Landesamt fr
tional waste water treatment processes. Especially those
Wasserwirtschaft (Bavarian Office for Water Manage-
operators (Wasserverband Eifel-Rur (WVER), Erftverband)
ment)) are mentioned here by way of example, which
who have acquired experience with membrane technology
will also be described in the following chapters.
are planning or building more membrane bioreactors

(Table 2-6).
Table 2-6
Membrane bioreactors under construction or in planning stage in Germany, as of December 2005
Operator
WVER
WVER
City of Eitorf
Linksniederrheinische
Erftverband
EntwsserungsGenossenschaft
North Rhine-
North Rhine-
North Rhine-
North Rhine-
North Rhine-
Westphalia
Westphalia
Westphalia
Westphalia
Westphalia
Plant
WWTP Rurberg
WWTP Konzen
WWTP Eitorf
WWTP Xanten-Vynen
WWTP Glessen
Design capacity
6,200 PE
9,700 PE
11,625 PE
2,000 PE (only
9,000 PE
Federal State
membrane installation)
Planned start-up
2005
2005
2005
2005
2005
State
commissioned
commissioned
commissioned
commissioned
planning stage
Membrane
Kubota
Kubota
Kubota
A 3 GmbH
not yet determined
Module type
plate module
plate module
plate module
plate module
not yet determined
Process
microfiltration
microfiltration
microfiltration
microfiltration
micro-/ultrafiltration
manufacturer
Membrane surface
approx. 13,440 m
23,040 m
10,240 m
2,000 m
12,320 m2 planned
area
Bioreactor volume
approx. 750 m3 planned
approx. 1,700 m3 planned

3
1,200 m3
3
approx. 1,700 m3 planned
Maximum inflow
349 m /h
587 m /h
288 m /h
40 m /h
268 m3/h
Pretreatment
fine screen (3 mm)
fine screen (3 mm)
fine sieve
screen (3 mm)
screen (6 mm)
grit chamber
grit chamber
finest screen (0.5 mm)
finest screen (0.5 mm)
Special features
grit-/grease trap
fine sieve (0.5 mm)
discharge into
partly industrial waste
expansion of the WWTP
expansion of the WWTP
Rurtalsperre (Rur valley
water
at the site
at the site
reservoir)
97
2.2.1
MF
ent zones. The waste water flows centrally into an an-
Waste Water Treatment Plants with Microfiltration
aerobic zone (V = 500 m3) for increased biological phos-
Membrane Installations in Germany
phorus removal. The outside zone of the activated sludge

tank (V = 1.160 m3) is used for denitrification. Part of the
2.2.1.1
MF
tank (500 m3) can be aerated and used for nitrification,
Seelscheid Waste Water Treatment Plant and
depending on time and load.
Training Centre
The intermediate settling tank was decommissioned to
From 1974 to 1976, the Seelscheid waste water treatment
build the new three-line membrane stage on this surface,
plant had been designed for 3,000 PE. In a second stage,
which was commissioned in July 2004. The three mem-
from 1991 to 1992, it was expanded to a capacity of
brane tanks with a total volume of approx. 800 m3 serve
7,500 PE. The design at that time provided a final expan-
for nitrification. In each of the three tanks, 13 plate
sion up to 10,500 PE so that some structures, in particu-
membrane modules (type EK 400) from the company
lar the pipes, were designed for that size. Upgrading of
Kubota are installed. The total membrane surface area is
the waste water treatment plant to 10,500 PE according
12,480 m2. The recirculation flows and the aeration are
to the activated sludge process would have been very
controlled by fuzzy logic.
expensive due to limited space. In 2003, the membrane

bioreactor suggested itself as a more effective alternative
At present, the necessary transmembrane pressure differ-
with lower space demand.
ence is produced in gravity flow and can be supported

by permeate pumps. The filtrate is fed into a storage tank
For the expansion, two fine screens (3 mm spacing) were
(V = 100 m3). From there it is discharged by the existing
installed in the existing screen building in order to ensure
pipes into the Wenigerbach (a creek). Part of the treated
trouble-free operation of the waste water treatment plant,
waste water is used as process water at the waste water
especially of the membrane installation. Each of both
treatment plant. The concentrate is recycled into the
fine screens is able to treat the maximum waste water
denitrification zone or optionally into the aerobic zone.
flow of 99 L/s, resulting in a redundant system. The
The minimum requirements, the values of the discharge
aerated grit and grease trap, which existed before the last
consent and the operating values after four months of
upgrade, has a volume of V = 104 m . The calculated
operation are listed in Table 2-7.
hydraulic retention time in this structure is more than

17 min. in the case of stormwater flow and more than
The investment for upgrading of the Seelscheid waste
35 min. during dry weather flow. After having passed the
water treatment plant was approx. 4.6 million euro,
grit chamber, the waste water flows into the activated
supported by funds from MUNLV.
sludge tank which is built as a circular tank with differ-
Table 2-7
Minimum requirements, discharge consent and operating values of the Seelscheid waste water treatment
plant [according to AGGERVERBAND 2004]
Parameter
Unit
Minimum requirements
Discharge consent
Operating values
CSB
mg/L
90
40
< 20
BSB5
mg/L
20
10
no information
NH4-N
mg/L
10
< 0.1
Ntot
mg/L
18
18
<5
Ptot
mg/L
0.8
AOX
g/L
no information
50
98
Figure 2-28
Flow sheet of the Seelscheid waste water treatment plant [according to AGGERVERBAND 2004]
membrane stage/
nitrification
denitrificationtank
nitrificationtank
blower
installation
anaerobic
tank
sludge
feed
fine screen
3 mm
permeate
storage
receiving
water
grit
chamber
fine screen
3 mm
alternative
recirculation
process water
Figure 2-29
Membrane installation at the Seelscheid waste water treatment plant [photos: AGGERVERBAND 2004],
left: membrane tanks, right: machine cellar of the membrane installation
99
Training centre at the Seelscheid waste water

treatment plant
The training courses are intended for environmental
The Aggerverband (water board) will establish at the site
technicians, sanitation masters and future engineers from
of the Seelscheid waste water treatment plant a modern
universities. Completion of the training centre is scheduled
training centre for membrane technology. This will be
for the year 2005. The training centre is promoted by
done in cooperation with the Ministry for Environment
funds of the federal state North Rhine-Westphalia.
and Nature Conservation, Agriculture and Consumer Protection (MUNLV) of the state North-Rhine Westphalia,
Figure 2-30
the Bildungszentrum fr die Entsorgungs- und Wasser-
Existing sand filter tanks, to be used for the trai-
wirtschaft (BEW) (Training Centre for Water Management
ning installations [photo: AGGERVERBAND 2004]
and Waste Water Disposal), the Deutsche Vereinigung fr

Wasserwirtschaft, Abwasser und Abfall (DWA) (German
Association for Water Management, Waste water and
Waste), the Deutsche Gesellschaft fr Membrantechnik
(DGMT) (German Association for Membrane Technology)
and the RWTH Aachen University. The centre is supported
by funds from the state North-Rhine Westphalia. Besides
training rooms and eight laboratory working places, four
membrane bioreactors with upstream denitrification and
various membrane systems will be installed in the tanks
of the former sand filtration system in order to realize
practical training (see Figure 2-31 and Figure 2-30).
Figure 2-31
Flow sheet of the training installations [according to AGGERVERBAND 2004]
denitrification
nitrification/
membrane stage
recirculation
blower
installation
recirculation
blower
installation
recirculation
blower
installation
recirculation
blower
installation
raw waste
water
fine screen
3 mm
optional
inflow
raw waste
water
fine screen
0,75 mm
100
to treatment plant
2.2.1.2
MF
Bchel Pilot Plant

Within the scope of a research project Upgrading of the
Figure 2-32
Bchel waste water treatment plant using membrane
View of the Bchel pilot plant [photo: ISA RWTH
technology promoted by the Ministry for Environment
AACHEN]. Foreground: filtration container. Back-
and Nature Conservation, Agriculture and Consumer
ground, left: activated sludge tank of the pilot
Protection (MUNLV) of the state North-Rhine Westpha-
plant. Background, right: primary settling tank of
lia, the Aggerverband (water board) has operated from
the overall plant
1999 to 2001 a membrane bioreactor pilot plant. This

R&D project was realized on behalf of Aggerverband by
the Institute of Environmental Engineering of RWTH
Aachen University and ATEMIS (consulting engineers).
The reason for the project was the necessary expansion
of the Bchel waste water treatment plant from the
existing capacity of 12,000 PE to 25,000 PE. Besides the
limited space available, stringent demands on the effluent
quality made by the district government Cologne, due to
the situation of the plant in a nature reserve, had also to
be taken into consideration. Therefore, the Aggerverband
searched for an alternative to conventional waste water
Figure 2-33
Flow sheet of the Bchel pilot plant [BAUMGARTEN 2001b]
permeate
nitrification and membrane container V = 80 m3
RS
membrane stage 1
nitri-/denitrificationtank V = 100 m3
membrane stage 2
blower
station
membrane
reactor
blower station
nitrification
feed
101
treatment technology. After detailed cost comparisons,
After a start-up period during which faults of the mecha-
the membrane bioreactor process turned out to be the
nical installation were remedied, the plant was operated
most interesting alternative. The Aggerverband decided
nearly trouble-free. After a six-month operating phase
to run a pilot plant within the scope of expansion plan-
where each of the filtration stages was operated with net
ning in order to acquire experience with this technology.
specific flows of 27 L/(m3h), the transmembrane pressure

increased from approx. 80 mbar to average values of
The pilot plant was situated at the site of the Bchel
approx. 150 mbar due to fouling. Therefore, chemical
waste water treatment plant and is fed with a partial flow
in-situ cleaning had to be carried out in order to ensure
of the mechanically pretreated waste water from the exi-
the throughput of the plant. With this it was possible to
sting plant. Mechanical pretreatment consisted of a
restore the original membrane capacity nearly completely
step screen (3 mm), an aerated grit and grease trap and a
[WOZNIAK, BAUMGARTEN 2001, BAUMGARTEN
primary settling tank. To feed the pilot plant, the partial
2001b].
flow could be taken either upstream or downstream of

the primary settling tank.
After conclusion of the pilot tests, an expansion at the

site of the Bchel waste water treatment plant according
The waste water was pumped by a lifting pump into the
to the conventional activated sludge process was pre-
denitrification zone of the pilot plant. Nitrification took
ferred for economic reasons. However, as a result of the
place only in the zone of the downstream membrane
experience acquired with membrane technology, the
stage (Figure 2-33) because under normal conditions the
Aggerverband favoured under technical aspects the fur-
air injected for the overflow of the membranes is sufficient
ther use of membrane technology for municipal waste
for complete nitrification. If this was not ensured, single
water treatment. Thus the experience acquired was in-
zones in the upstream denitrification tank could be aerated
cluded in the meantime e. g. in the expansion of the large-
and used for nitrification.
scale Seelscheid waste water treatment plant of the

Aggerverband (see chapter 2.2.1.1). For future new con-
The membrane stage consisted of two filtration lines
structions or expansions of plants, too, this technology
which could be operated independently from each other.
will be included in the studies of technical processes.
Each line is equipped with four plate packages containing 150 plate modules from the company Kubota. The
treated waste water was withdrawn by suction from the
filtration modules.
102
MF
2.2.1.3
Richtheim Waste Water Treatment Plant

In Bavaria, many decentralized waste water treatment
An inflow shaft, installed for the separation of coarse and
plants are situated in regions with stricter requirements
floating matter, serves as primary settling tank for coarse
for water pollution control (e. g. karstland) or discharge
and floating matter. The pretreated waste water then
into sensitive receiving waters, so that advanced waste
flows by gravity into the membrane bioreactor. The plate
water treatment may be useful or necessary, e. g. by sand
modules from the company Kubota (2 module packages
filtration and UV disinfection, ozonation or membrane
with 80 m2 membrane surface area each), which include
technology.
aeration, are installed in a prefabricated shaft which serves

as the membrane bioreactor. The oxygen demand is
Within the scope of a research project promoted by the
covered completely by aeration of the membrane mod-
Landesamt fr Wasserwirtschaft (LfW) (State Office for
ules. Figure 2-34 shows the flow sheet of the installation.
Water Management) in Bavaria, different processes for

the treatment of municipal waste water in decentralized
waste water treatment plants are studied at three sites.
The study focuses on the attainable effluent quality,
operational liability and expenditure.
The Richtheim waste water treatment plant is used to
perform the studies on the membrane bioreactor process.
It has a treatment capacity of 100 PE.
Figure 2-34
Flow sheet of the membrane bioreactor [according to BAYERISCHES LANDESAMT FR WASSERWIRTSCHAFT
2004]
flow
membrane stage
receiving
water
primary treatment
feed
blower
installation
103
MF
2.2.1.4
Eitorf Waste Water Treatment Plant (Commissioned)

The Eitorf waste water treatment plant receives municipal
The installation was originally intended for the joint tre-
waste water from the municipality of Eitorf, parts of the
atment of a high-loaded waste water flow from textile
city of Hennef and the waste water from commercial and
finishing with strong coloration and high AOX concen-
industrial enterprises. For expansion of the capacity of
trations (see Table 2-8). In order to increase the treatment
the plant from 33,000 PE up to now to approx. 46,500 PE
efficiency concerning these parameters (effluent require-
(value prognosticated for the year 2010), process variants
ment for AOX: 50 g/L), simultaneous addition of pulver-
using membrane technology were developed within the
ized activated carbon was tested successfully in the run-
scope of a study [NOLTING, KAZNER 2005]. Based upon
up on an industrial scale for the conventional plant
the comparison of the costs per year, the construction of
[KAZNER 2003] and on pilot scale for a membrane bio-
a membrane bioreactor turned out to be the most favour-
reactor [BAUMGARTEN 2005].
able solution for the expansion of the capacity for the

treatment of a partial waste water flow.
Table 2-8
Input values for the design of the Eitorf membrane bioreactor [according to GEMEINDEWERKE EITORF
Parameter
Qd
Inflow to the membrane bioreactor
Qh
QM
COD
BSB 5
TKN
NH4 -N
Ptot
AOX
1,800
145
288
1,152
486
108
62
13
0,4
m3 /d
m3 /h
m3 /h
kg/d
kg/d
kg/d
kg/d
kg/d
kg/d
Figure 2-35
Flow sheet of the Eitorf waste water treatment plant [according to GEMEINDEWERKE EITORF 2004]
feed
fine screen
3 mm
grit
chamber
primary treatment
75 %
biological reactor
clarifier
receiving
water
25 %
sludge
fine sieve
1 mm
denitrification
variable
tank
4-line
membrane stage
with nitrification
recirculation
104
Figure 2-36
Eitorf waste water treatment plant with covered membrane tanks between the buildings in the foreground
Due to operations-related closure of the dye-works, this
decker modules) with a total membrane surface area of
waste water flow will cease in future. A high-loaded waste
10,240 m2 are installed.
water flow from the food industry will be introduced

The investments for the construction of the membrane
instead.
bioreactor, which was commissioned in September 2005,

The membrane bioreactor consists of a denitrification
were 3.9 million euro, subsidized in part by the Ministry
tank (V = 300 m3), a variable zone equipped with aerators
for Environment and Nature Conservation, Agriculture
(V = 300 m ) for denitrification or nitrification and four
and Consumer Protection of the federal state North
nitrification tanks (150 m3 each), in which immersed plate
Rhine-Westphalia (MUNLV NRW).
modules from the company Kubota (type EK 400, double-
105
MF
2.2.1.5
Figure 2-37
Xanten-Vynen Waste Water Treatment Plant
Membrane installation in container construction
(Commissioned)
for the Xanten-Vynen waste water treatment plant

[photo: A3 GMBH]
In 1972, the Xanten-Vynen waste water treatment plant

was designed, according to the design principles at that
time, for 6,000 PE and triple dry-weather flow. Today the
biological stage is approved for 3,300 PE. At present,
approx. 3,160 PE are connected. Thus, the degree of capacity utilization is more than 95 % and has to be expanded
to 4,989 PE, due to anticipated population growth. The
connected quarters Vynen and Marienbaum are drained
for the most part by a combined sewer system. Only one
modern estate is drained by a separate system. The inflow
to the waste water treatment plant is exclusively of municipal origin.
Within the scope of a three-year research project, a twoline membrane bioreactor at the Xanten-Vynen waste
water treatment plant will be equipped with the plate
membrane system from the company A3 and operated in
Figure 2-38
Flow sheet of the Xanten-Vynen waste water treatment plant, including the planned membrane
bioreactors [according to LINEG 2004]
screen
grit
chamber
biological reactor
clarifier
effluent polishing
pond
feed
sludge
screen system
3 mm
denitrifification
membrane stage
nitrification
receiving
water
recirculation
denitrifification
membrane stage
nitrification
recirculation
106
blower
installation
parallel (see Figure 2-38). The total capacity of the two-line

membrane bioreactor will be approx. 2,000 PE.
To determine an optimum operating and cleaning

management program
Both membrane bioreactors will be operated under real
Both membrane installations are manufactured identically
conditions in parallel to the existing activated sludge stage
and fitted in one container each (Figure 2-37). For mecha-
to compare the cleaning efficiency of both systems. The
nical pretreatment, a screen with an aperture size of 3 mm
three-year test period has the following objectives:
is planned. The activation volume is 100 m3 each. Each

membrane installation is designed for a dry weather flow
To prove evidence of the operational safety and capacity
of 12.5 m3/h and a stormwater flow of 40 m3/h and has a

membrane surface area of 2,000 m2. The membrane instal-
of the installation
To study the economic efficiency of the membrane
lation will be commissioned still in 2005.
system
MF
2.2.1.6
Piene Waste Water Treatment Plant

(in Planning Stage)
The construction of a waste water treatment plant with a
It is planned to pretreat the waste water by a rotary
treatment capacity of 170 PE according to the membrane
screen with a spacing of 3 mm. The following buffer tank
bioreactor process is being planned for the quarter Piene
wih a volume of 40 m3 serves to buffer peak flows in the
of the city of Gummersbach.
case of combined water flow and to store the excess sludge.

From the storage tank the waste water is fed into the
Until now, the waste water of Piene is treated by three-
activated sludge stage (V = 40 m3) in which the immersed
chamber septic tanks. The treated waste water is discharged
membrane modules are integrated. It is intended to use
into a weak receiving water, The discharge consent
plate membrane packages from the company Kubota
requires a COD effluent concentration of < 70 mg/L and
with a total membrane surface area of 320 m2.
a BOD5 concentration of < 10 mg/L. Due to the situation

described above, a decision was made in favour of the
membrane bioreactor process. Figure 2-39 shows the flow
sheet of the membrane bioreactor.
Figure 2-39
Flow sheet of the membrane bioreactor [according to CITY OF GUMMERSBACH 2004]
biological reactor
membrane stage
receiving
water
fine screen
3 mm
feed
buffer tank
sludge
107
2.2.1.7
MF
Rurberg-Woffelsbach and Konzen Waste Water

Treatment Plants (Commissioned)
The Rurberg-Woffelsbach and Konzen waste water treat-
At Konzen, an activated sludge tank both for denitrifica-
ment plants of Wasserverband Eifel-Rur (WVER) (water
tion and nitrification precedes the membrane chamber.
board) are being expanded to a treatment capacity of
Additional nitrification volume is available in the mem-
6,200 PE and 9,700 PE, respectively. At present, both
brane chamber. Both installations are equipped with plate
expansion measures are realized. The plants will be put
membrane modules from the company Kubota. At the
into operation at the end of 2005.
Rurberg-Woffelsbach waste water treatment plant, a

membrane surface area of 13,440 m3 will be installed,
The current demands on the effluents of the Rurberg-
and of 23,040 m3 at the Konzen plant. For these mem-
Woffelsbach and Konzen waste water treatment plants
brane surface areas, 42 and 72 membrane-modules,
are listed in Table 2-9. The Rurberg-Woffelsbach waste
respectively, of the type EK 400 are provided. In this
water treatment plant discharges into the Rur reservoir
region, the membranes have to cope with a waste water
which is used for recreation purposes, and the Konzen
temperature in winter of less than 6 C.
waste water treatment plant uses the Laufenbach (a

creek) as receiving water which is situated in the drin-
According to the submittal results, the investments for
king water catchment zone. These were the reasons for
the Rurberg-Woffelsbach plant are approx. 5.5 million
the use of a membrane bioreactor at both sites.
euro (without planned lake duct, pumping station and

engineering) and 7.5 million euro for the Konzen plant
In future, the Rurberg-Woffelsbach waste water treatment
(without combined water treatment and engineering).
plant will be designed for a dry weather flow of 175 m3/h
Taking into account a subsidy of 50 % by the federal
and a stormwater flow of 349 m /h. The Konzen waste
state North Rhine-Westphalia for the membrane-specific
water treatment plant will treat a dry weather flow of
costs, the expansion of both waste water treatment
245 m /h and a stormwater flow of 587 m /h.
plants by the membrane bioreactor process is less

expensive than conventional upgrading.
The process concept for both plants includes mechanical

pretreatment by a fine screen with a spacing of 3 mm,
followed by a grit and grease trap and a fine screen with
a spacing of 0.5 mm. The fine screen will be redundant.
At the Rurberg-Woffelsbach waste water treatment plant,
biological waste water treatment takes place in an upstream
denitrification tank and a combined nitrification/membrane tank.
Table 2-9
Demands on the effluent quality of the Rurberg-Woffelsbach and Konzen waste water treatment plants
[according to WVER 2004]
Parameter
Unit
CSB
mg/L
BSB5
NH4-N
Ptot
108
Demands on the effluent of the
Demands on the effluent of the
Rurberg-Woffelsbach WWTP
Konzen WWTP
80
50
mg/L
20
15
mg/L
10
mg/L
0.5
0.2
MF
2.2.1.8
Kohlfurth Waste Water Treatment Plant,

Process Water Treatment
The Kohlfurth waste water treatment plant has a design
The sludge liquor is stored temporarily in a buffer tank.
capacity of 156,000 PE. It treats mainly municipal waste
It flows for nitritation into the first aeration reactor with
water by the conventional activated sludge process with
a volume of 200 m3. Autotrophic deammonification will
following anaerobic sludge treatment (see Figure 2-40).
take place in the second aeration reactor (V = 180 m3).
Concerning nitrogen removal, the Kohlfurth waste water
Two thickeners which are no longer used, serve as reac-
treatment plant was designed for a monitoring value of
tors for the activated sludge stage.
18 mg Ninorg /L. In future, it has to comply with a monitoring value of 13 mg Ninorg /L. With full capacity utilization
The two-line membrane installation arranged downstream
of the plant, at present it cannot be assured that this
of the activated sludge stage is installed in a separate
requirement is met in the qualified random sample. This
reactor. Each line contains two module packages (from
was the reason in autumn 2003 to plan a new treatment
the company Kubota, type EK 400) with a total membrane
facility for the process water from sludge dewatering.
surface area of 720 m2. The permeate of the membrane

installation is fed into the return sludge pumping station
At the Kohlfurth waste water treatment plant, the daily
and, with this, into the activated sludge stage of the
sludge liquor quantity from sludge dewatering is 300 m3
Kohlfurth waste water treatment plant.
with a NH4-N concentration of 700 1,000 mg/L. As new

treatment concept, the membrane bioreactor process was
The plant is working since January 2005. After a test ope-
chosen. The potential for autotrophic deammonification
ration phase, the operating mode of autotrophic deam-
in the membrane bioreactor will be studied in particular.
monification as well as of conventional denitrification

will be studied.
Figure 2-40
Flow sheet of the Kohlfurth waste water treatment plant [according to WUPPERVERBAND 2004]
carbon source
feed
flow
screen
grit
chamber
denitrification
primary treatment
biological
reactor
clarifier
grit
filtration
receiving
water
sludge
coarse sludge
prethickening
digester
digester
membrane
stage
sludge liquor
postthickening
storage
chamber
filter press
sludge
liquor
nitrification
denitrification
filtrate
recirculation
109
MF
2.2.1.9
Dormagen Waste Water Treatment Plant,

Process Water Treatment (Commissioned)
The Dormagen waste water treatment plant has a design
The concept using the membrane bioreactor for the treat-
capacity of 80,000 PE and treats predominantly municipal
ment of the sludge water turned out to be favourable in
waste water. After mechanical pretreatment, the waste
terms of technology and economic efficiency. The mem-
water is treated according to the activated sludge process.
brane installation is planned with two lines and will con-
The sludge is anaerobically treated (see Figure 2-41).
tain eight module packages from the company Kubota

(type EK 150) with a total membrane surface area of 960 m2.
The process water from sludge treatment consists of the

sludge liquor from the digester and the post-thickener as
The existing grit chamber will be converted to a nitrifica-
well as the centrate water from the centrifuges. It is stored
tion and denitrification stage in which the process water
temporarily in a balancing tank. The NH4-N concentra-
from the storage tank is fed. The membrane installation
tion of this process water is approx. 800 mg/L, which
will be fitted in a container on the existing grit chamber.
corresponds to a waste water load of approx. 15,000 PE.
The permeate of the membrane installation will be fed into
Due to this load, the waste water treatment plant reached
the inflow of the activated sludge tank for treatment.
its capacity limits from time to time. This was the reason
in autumn 2003 to plan a new sludge water treatment
The plant is under construction and will be put into
plant.
operation in 2005.
Figure 2-41
Flow sheet of the Dormagen waste water treatment plant [according to CITY OF DORMAGEN 2004]
feed
flow
screen
grit
chamber
bio-P
primary treatment
nitrifi- denitrication fication
clarifier
receiving
water
recirculation
sludge
thickening
digester
digester
if nec.
sludge
liquor
sludge liquor
postthickening
storage
centrifuge
membrane
stage
sludge
liquor
nitrification
... water
recirculation
110
denitrification
blower
installation
MF
2.2.2
Installations Outside of Germany with

Microfiltration Membranes
Membrane technology has been used in municipal waste
England. In 2000, the Swanage waste water treatment
water treatment since the nineties. The first large-scale
plant (Figure 2-42) on the South coast of England follow-
plants were built mainly in North America and Japan.
ed, with a capacity of 13,000 m3/d and 23,000 inhabi-
About 90 % of these installations have a capacity of less
tants connected. Until the end of 2001 this was the largest
than 100 m3/d. A larger plant with a design capacity of
membrane bioreactor treating municipal waste water.
about 5,700 m /d is situated in Powell River, Canada. The
The installation, equipped with the Kubota system, is
installations in North America and Asia are used nearly
situated directly on the beach and is hardly visible as a
exclusively to treat waste water from separate systems, at
result of complete casing.
differing cleaning requirements in the individual countries. Therefore, the experience acquired at those plants is
In Great Britain, the membrane bioreactor process is well
transferable only to a limited extent to European condi-
established not only with a view to technical but also to
tions.
economic aspects, so that a possible use of this process is

examined in the case of each new construction or expan-
However, since 1998 the use of membranes in the field of
sion of a plant.
municipal waste water treatment has increased worldwide.

Beyond many small installations, the first large-scale
In other European countries, e. g. in Italy/Lake Garda, or
waste water treatment plant in Europe (with a capacity
in Belgium, the first membrane bioreactors are being
of 1,900 m /d) was put into operation in 1998 at Porlock,
planned or are under construction.
Figure 2-42
Aerial photograph of the Swanage waste water treatment plant [photo: AQUATOR GROUP]
111
MF
2.2.2.1
Glasgow Waste Water Treatment Plant, Scotland

The Glasgow central sludge treatment plant treats sludge
The sludge water is treated by a three-line fine screen
of industrial as well as municipal origin. Between 7,800
(bar distance: 3 mm). Biological treatment takes place in
and 12,800 m of sludge with an average TS content of
an upstream-arranged denitrification tank (V = 2,300 m3)
2 2.5 % are treated daily, consisting not only of sludge
and four nitrification tanks operated parallel (Vtotal =
quantities produced locally, but also of sludge from the
9,400 m3), in which the membrane modules are immersed.
cities Shieldhall, Dulmuir, Paisley, Dalmarknock, Glasgow

Catchment and Daldowie.
The four-line membrane installation consists of 128 plate

membrane modules of the type EK 400 from the company
Sludge dewatering takes place in 12 centrifuges operated
Kubota with a total membrane surface area of 20,480 m2.
in parallel, following a 5 mm screen and storage tank of
Effluent concentrations of 40 60 mg/L COD and
30,000 m . The sludge is thickened to a TS content of
0.1 0.4 mg/L NH4-N are reached. The NO3-N effluent
30 % TS and then dewatered in six dryers to 90 92 % TS.
concentration is 30 mg/L on average.
About 200 450 m3 of sludge water are produced per day,

80 % of this quantity resulting from the centrifuges and
The sludge treatment plant presented in Figure 2-44 has
20 % from the dryers. This sludge water has COD con-
been operated since the year 2002.
centrations of 3,000 4,000 mg/L and NH4-N concentrations of 200 300 mg/L, which corresponds to a load of
approx. 180,000 PE related to NH4-N.
Figure 2-43
Flow sheet of the Glasgow sludge treatment plant [according to AGGERWASSER GMBH 2004]
nitrification, membrane stage
blower
installation
fine screen
3 mm
sludge water
fine screen
3 mm
denitrification
receiving
water
fine screen
3 mm
recirculation
112
Figure 2-44
Top view of the sludge treatment plant and of a tank of the membrane installation
footprint membranes
aeration device
113
MF
2.2.2.2
Figure 2-45 (left): Ebisu Prime Square Building
Ebisu Prime Square Building Waste Water
Figure 2-46 (right): Waste water treatment plant
Treatment Plant, Japan
in the basement of the Ebisu Prime Square

Building [photos: AGGERWASSER GMBH 2004]
The Ebisu Prime Square Building is a tower block in Tokyo

where all office rooms, sales space and restaurants are
housed on a total surface of 70.000 m2 (Figure 2-45).
When the tower block was built, a membrane bioreactor
was installed in the basement. The waste water is treated
to a degree that the permeate can be used as process water
for a laundry and for toilet flushing.
Figure 2-47 shows the flow sheet of the waste water treatment plant. The composition of the raw waste water and
the permeate is listed in Table 2-10.
The installation was put into operation in April 1997 and
3
plate modules have been cleaned chemically once or twice
is dimensioned for a permeate volume flow of 189 m /d.
a year. The TS content is kept between 15 and 20 g/L.
Equipment, maintenance and operation of the installa-
The transmembrane operating pressure is between 0.05
tion are realized by the company Kubota. Until now, the
and 0.1 bar.
Figure 2-47
Flow sheet of the waste water treatment plant [according to AGGERWASSER GMBH 2004]
membrane stage
permeate for laundry

and toilet flushing
fine screen
feed
blower
concentrate
disposal
Table 2-10
Raw waste water and permeate quality [according to AGGERWASSER GMBH 2004]
Parameter
Unit
Raw waste water
Permeate
COD
[mg/L]
60
<3
BOD5
[mg/L]
40
<2
Ptot
[mg/L]
n. n.
Ntot
[mg/L]
<1
filterable solids
[mg/L]
140 180
n. n.
114
MF
2.2.2.3
By installation of a wooden partition, the lagoon was
St. Peter ob Judenburg Waste Water Treatment
divided into an activation zone and a secondary settle-
Plant, Austria
ment zone. Both zones are connected by two overflows

in the partition. In the secondary settlement zone, the
With the waste water treatment plant of the municipality
activated sludge settles and is discharged by the sludge
St. Peter ob Judenburg (1,500 PE), the first experiences
hopper at the bottom. Culvert siphons lead to a pump
with membrane technology in the treatment of muni-
shaft with a submerged pump which recycles the activa-
cipal waste water in Austria have been acquired. For cost
ted sludge into the activation zone or withdraws it from
reasons, the waste water treatment plant was initially
the system.
planned and approved by the authorities as water treatment lagoons. Although the lagoons had been dimen-
To obtain complete nitrification, a separate nitrification
sioned rather large, the plant did not meet the treatment
tank made of reinforced concrete is installed downstream
capacity required by the Austrian Emission Ordinance
of the lagoon. The existing components for the growth
(Emissionsverordnung (EmV) 210/1996) Limitation of
of biomass have been removed and replaced by immersed
waste water emissions from waste water treatment plants
membrane modules from the company Mitsubishi. A
in settlement areas.
total membrane surface area of 945 m2 is installed in

9 cassettes. Since the completion of the research project
Within the scope of a research project realized in 2001
in 2002, the St. Peter ob Judenburg waste water treat-
and 2002, it could be demonstrated and implemented in
ment plant has been operated successfully according to
the following that the existing plant can meet the legal
the process concept presented above (Figure 2-48). Figure
standards without important constructional alterations
2-49 shows the membrane modules and the lagoon.
by using new aeration and mixing concepts combined

with immersed membrane filtration in the nitrification
tank (Table 2-11).
Table 2-11
Influent and effluent concentrations of the waste water treatment plant
Parameter
Unit
Influent
Effluent lagoon
Permeate
COD
[mg/L]
300 700
100 300
< 30
NH4-N
[mg/L]
25 45
25 35
< 1.0
Figure 2-48
Flow sheet of the St. Peter ob Judenburg waste water treatment plant [according to ENVICARE 2002]
membrane stage
settling pond 1
grit chamber
fine screen
3 mm
BB
NK
receiving
water
feed
recirculation
blower
installation
115
Figure 2-49
St. Peter ob Judenburg waste water treatment plant [photos: ENVICARE ],
left: membrane module, right: lagoon
2.2.3
UF
process at the Rdingen waste water treatment plant. The
Waste Water Treatment Plants in Germany with
waste water treatment concept was developed in close
Ultrafiltration Membranes
coordination with the Ministry for Environment and

Nature Conservation, Agriculture and Consumer protec-
2.2.3.1
UF
tion (MUNLV) of the state North-Rhine Westphalia. Due
Nordkanal Waste Water Treatment Plant
to its size, this plant represents new planning dimensions

and has demonstration character throughout Europe.
When the expansion of the Nordkanal waste water treatment plant became necessary, the original site had to be
The plant is designed for a capacity of 80,000 PE and a
given up due to the spatial development of the City of
combined water flow of 1,881 m3/h. It was commissioned
Kaarst. A new plant had to be built at another site. The
in 2003. The demands on the effluent quality are com-
Erftverband decided on the membrane bioreactor process
piled in Table 2-12.
because positive experience had been acquired with this

Table 2-12
Minimum requirements and discharge consent of the Nordkanal waste water treatment plant
[ERFTVERBAND 2004]
Parameter
Unit
Discharge consent
COD
mg/L
90
90
BOD5
mg/L
20
20
NH4-N
mg/L
10
10
Ntot
mg/L
18
18
Ptot
mg/L
116
At the site of the old waste water treatment plant, the
Figure 2-50
waste water is pretreated by a coarse screen and pumped
Rotary screen of the fine screen installation
to the new Nordkanal plant, situated a distance of 2.5 km

away, where the waste water is mechanically pretreated
by two step screens (5 mm spacing) operated in parallel
and two aerated grit and grease traps also operated in
parallel. Then the waste water is treated by two rotary
screens operated in parallel with an aperture size of 0.5 mm
(Figure 2-50) to protect the membranes in the nitrification stage. The emergency circuit of the rotary screens is
made safe by a fine screen with an aperture size of 1 mm,
so that the membranes are protected from the input of
coarse material into the activated sludge tank. Figure 2-51
shows the flow sheet of the Nordkanal waste water treatment plant.
The activated sludge stage has four lines, each of which
consists of upstream denitrification tanks, a variable tank
zone for either denitrification or nitrification, and of the
nitrification tanks with immersed membrane modules,
Figure 2-51
Flow sheet of the Nordkanal waste water treatment plant [according to ERFTVERBAND 2004]
nitrification
membrane stage
step screen
5 mm
feed
grit
chamber
grit
chamber
variablezone
denitrification
variablezone
rotary
screen
0,5 mm
screen
step screen
5 mm
denitrification
blower
installation
rotary
screen
0,5 mm
emergency
bypass
screen 1 mm
denitrification
variablezone
flow
denitrification
variablezone
recirculation
117
designed as activated sludge tanks with circulating flow.
Figure 2-52
The nitrification tanks are cased. The total volume of the
Membrane installation at the WWTP Nordkanal
activated sludge tanks is 9,200 m3. The sludge is stabilized

aerobically. As a result of flow simulations, agitators and
baffles were integrated into the activated sludge tanks
with circulating flow.
The membrane installation has been realized with eight
lines and equipped with capillary membranes from the
company ZENON (ZW 500c). A total filter surface area of
approx. 85,000 m2 has been installed because the District
Government Dsseldorf demanded to provide a reserve
of 25 % for the membrane filtration. For external chemical cleaning, a separate cleaning chamber is available.
The investment for the new construction of the Nordkanal waste water treatment plant was 21.5 million euro.
Approx. 6.6 million euro of this amount had been taken
over by the federal state North-Rhine Westphalia.
2.2.3.2
UF
Monheim Waste Water Treatment Plant

The waste water treatment plant of the city of Monheim
The Monheim waste water treatment plant is designed for
is situated in the sensitive karstland of the district Donau-
a capacity of 9,700 PE, based on a peak flow of 288 m3/h
Ries. It treats not only the waste water from the city of
and an average daily waste water flow of 2,400 m3/d.
Monheim, but also from the municipalities of Rgling

and Tagmersheim. The treated effluent is discharged into
As shown in the flow sheet of the Monheim waste water
the Gailach which infiltrates into the karst 6 km down-
treatment plant (Figure 2-54), the mechanical pretreat-
stream of Monheim. In 1998 and 1999, first concepts for
ment stage has two lines. Each line consists of a fine sieve
the discharge of waste water into the karst subsoil were
with an aperture size of 1 mm and a grit chamber. 75 %
developed.
of the maximum inflow can be treated by each line. The

mechanically pretreated waste water flows into the acti-
Within the scope of the large-scale pilot project Waste
vated sludge stage with a total volume of 1,660 m3, which
water treatment Gailach valley, the Free State of Bavaria
is also built in two lines. Each line consists of an upstream
supported the financing of the construction of a mem-
denitrification and a nitrification tank as well as two
brane bioreactor at the site of the Monheim waste water
membrane chambers which have been provided with a
treatment plant. The investment for the membrane bio-
coating resistant to chemicals to protect the concrete.
reactor was approx. 7.6 million euro, of which 5.8 mil-
The tanks for denitrification and nitrification have a
lion euro were granted as subsidy by the state Bavaria.
volume of 340 m3 each, while each of the four membrane
Figure 2-53 shows the Monheim waste water treatment
chambers has a volume of 75 m3. The sludge is stabilized
plant.
aerobically.
118
The membrane stage was designed for a specific filtration

3
Figure 2-53
capacity of 22 24 L/(m h) of combined flow. This volume
Monheim waste water treatment plant [photo:
can be increased at short notice up to 31 L/(m3 h) when
BAYERISCHES LANDESAMT FR WASSERWIRTSCHAFT
one membrane chamber is shut down. According to this
(Bavarian Office for Water Management) 2004]
design, the membrane stage contains 28 module cassettes

from the company ZENON (type ZW 500c) with a total
membrane surface area of 12,320 m2 filter. Filtration takes
place at a TS content of 12 g/L. Since the filtration lines
are installed in four separate chambers, chemical cleaning of the modules can be realized by pumping off the
activated sludge without removing the modules (on air).
The specific energy demand of the waste water treatment
plant is about 1 kWh per m3 of waste water. The manpower requirement corresponds to that of a conventional
plant.
Figure 2-54
Flow sheet of the Monheim waste water treatment plant [according to BAYERISCHES LANDESAMT FR
WASSERWIRTSCHAFT 2004]
membrane stage
recirculation
denitrification
sieve 1 mm
grit
chamber
sieve 1 mm
grit
chamber
recirculation
nitrification
blower
installation
feed
flow
receiving
water
recirculation
recirculation
119
Using the membrane process at the Monheim waste water
Figure 2-55
treatment plant, the requirements for the effluent quality
Module cassettes during in-air cleaning
are safely met, as can be taken from Table 2-13.
[photo: CITY OF MONHEIM 2004]
At present, the operation of the Monheim membrane

bioreactor is accompanied by a research program. Main
items of this study include testing and optimization of
the membrane bioreactor process and investigating the
effects of waste water discharge on the Gailach and the
groundwater.
Table 2-13
Minimum requirements, discharge consent and operating values of the Monheim waste water treatment
plant [BAYERISCHES LANDESAMT FR WASSERWIRTSCHAFT 2004]
Parameter
Unit
Discharge consent
Operating values
COD
mg/L
90
75
15
BOD5
mg/L
20
15
1.2
NH4-N
mg/L
10
0,1
Ntot
mg/L
18
10
Ptot
mg/L
0.6
120
2.2.3.3
UF
Markranstdt Waste Water Treatment Plant

The Markranstdt waste water treatment plant is situated
The reason for a new construction of this plant was the
in the southwest of Leipzig. It is one of more than 30
planned closure of the obsolete waste water treatment
waste water treatment plants of Kommunale Wasserwerke
plant which no longer complied with the requirements.
Leipzig (Municipal Waterworks). It was designed for
The deciding factors for the construction of a membrane
12,000 PE; the actual degree of capacity utilization is
bioreactor were the limited surface area of the site and
approx. 8,000 PE.
increased demands on the effluent quality (Table 2-14)

due to a weak receiving water.
Table 2-14
Minimum requirements, discharge consent and operating values of the Markranstdt waste water
treatment plant [STEIN 2002a]
Parameter
Unit
Discharge consent
Operating values
COD
[mg/L]
90
50
35
BOD5
[mg/L]
20
10
NH4-N
[mg/L]
10
Ntot
[mg/L]
18
18
15
Ptot
[mg/L]
Filterable solids
[mg/L]
no information
no set target
no information
Figure 2-56
Process stages at the Markranstdt waste water treatment plant [STEIN 2002a],
left: inflow chamber to the membrane bioreactor with overflow edge to combined water treatment,
right: combined water treatment tank
121
The plant has a hydraulic capacity of 180 m3/h. From the
Besides the waste water treatment plant, a combined
intercepting sewer of the combined sewer system, the waste
water treatment plant was built in parallel at the same
water is fed by a lifting pump via the inflow chamber
site. The waste water quantities which exceed the capacity
(Figure 2-56, left) to the mechanical pretreatment stage.
of the membrane stage during combined water flow are

stored temporarily and pretreated in parallel in two tanks
The two-line mechanical pretreatment stage consists
which serve as settling and storage tanks. These waste
of a step screen (3 mm spacing) (Figure 2-57, left) and a
water quantities are fed to the membrane installation
grit and grease trap. By a distributor the waste water
during periods with smaller inflow volumes. Thanks to
flows into the two-line activated sludge stage. It is

3
the combined water treatment plant, the necessary mem-
operated as upstream denitrification (VDN = 2 435 m )
brane surface area could be considerably reduced because
with downstream nitrification (VN = 2 435 m3). All tanks
it had not to be designed for the maximum inflow quan-
are equipped with agitators. In addition, aggregates for
tity, but only for 1.1 Q T .
fine-bubble aeration are installed over the whole surface

area of the bottom of the nitrification tanks.
Since the plant was commissioned in 2000, much knowledge has been acquired concerning the optimization of
The membrane modules for biomass separation from the
process engineering and control [MEYER 2001]. Improve-
company ZENON are arranged at the inner longitudinal
ment of mechanical pretreatment was especially impor-
sides in the upper zone of the nitrification tanks with a
tant. The screen installed initially was replaced by a com-
depth of 7 m. The total filter surface area of 7,360 m2 is
bination of coarse screen (5 mm spacing) and fine sieve
distributed in four lines, two each in both nitrification
with an aperture size of < 1 mm.
zones. Between the longwise arranged nitrification tanks

a cleaning shaft for external module cleaning is installed.
The modules can be removed by a fixed crane.
Figure 2-57
Process stages at the Markranstdt waste water treatment plant [STEIN 2002a],
left: step screen, right: nitrification and denitrification tanks
122
2.2.3.4
UF
Rdingen Waste Water Treatment Plant

The waste water treatment plant is situated in the territory
the groundwater so that in dry periods the water level of
of the municipality of Titz in the district of Dren in the
the receiving water is very low. Therefore, an important
immediate vicinity of the opencast mining Hambach. Its
portion of the receiving water is supplied by the effluent
catchment area comprises a predominantly rural region
from the Rdingen waste water treatment plant. On
with smaller villages which do not discharge commercial
account of this fact, the district government sets high
or industrial waste water. Groundwater depletion due to
standards for the discharge of waste water into this re-
mining prevents the contact of the receiving water with
ceiving water (see monitoring values in Table 2-15).
Table 2-15
Minimum requirements and discharge consent of the Rdingen waste water treatment plant
[according to ENGELHARDT ET AL. 2001]
Parameter
Unit
Discharge consent
Operating values
COD
mg/L
110
35
< 25
BOD5
mg/L
25
<3
NH4-N (at 5 C)
mg/L
< 0,5
Ptot
mg/L
0.5
< 0.3 (simultaneous precipitation)
AOX
g/L
50
< 50
For this reason, a new construction of the Rdingen
The inflow to the plant is mechanically pretreated by a
waste water treatment plant, which up to now consisted
fine screen with a spacing of 3 mm, followed by an aerated
of an activated sludge stage with intermittent denitrifica-
grit chamber (Figure 2-58). The waste water is then fed to
tion and simultaneous precipitation for phosphorus
the two bioreactors which are operated with intermittent
removal, was indispensable. Upgrading by conventional
nitrification/denitrification.
technology would have required investments of approx.

6.1 million euro for the construction of large activated
When the mixed liquor has passed the biological stage,
sludge tanks and a downstream floc filtration.
it flows into the two-line filtration stage, from where

the treated water is withdrawn by immersed microfiltra-
The Erftverband, as the responsible water board, decided
tion modules. The concentrated mixed liquor remaining
on the construction of a membrane bioreactor because in
in the filtration zone, which has a TS content higher by
1996 first knowledge on the operating mode, the effluent
4 g/L than in the rest of the activated sludge tank is pum-
quality to be attained and operational liability was ac-
ped back into the bioreactors.
quired in the course of successful operation of a pilot plant

using this technology. One million euro of the total costs
Each of the two filtration lines (Figure 2-59) consists of
of 2.8 million euro for the first large-scale installation in
six cassettes each with 8 modules from the company
Germany, which was put into operation in the middle of
ZENON. The total membrane surface area is 4,846 m2. A
1999, were taken over by the state North-Rhine Westphalia.
combined specific water flow of approx. 28 L/(m3h) has

been calculated as design capacity for the membranes.
The installation is designed for a daily waste water flow
The background for this higher than typical design speci-
of 450 m3. With combined water flow, up to 135 m3 per
fic flow rate were measures waiting to be done in the
hour are treated.
sewer system in order to reduce the infiltration water
123
Figure 2-58
Flow sheet of the Rdingen waste water treatment plant
nitri-/denitrification tank 1
nitri-/denitrification tank 2
partial flow
treatment
fine sieve
0,5 mm
V = 200 m3
feed
screen
3 mm
V = 200 m3
recirculation
grit and oil

chamber
blower station
nitrification
blower
station
membrane
reactor
RS
membrane
filtration
membrane
filtration
permeate
nitrification and
membrane container
V = 80 m3
rate. Therefore, smaller inflow volumes are expected with

3
resulting flow rates < 28 L(m h).
Figure 2-59
View into the two filtration lines during fitting of
the ZeeWeed TM-cassettes [photo: ERFTVERBAND]
To maintain the filtration capacity, the modules are not

only submitted to normal backwashing (300 500 sec. filtration, 30 sec. backwashing) and weekly intermediate
cleaning, but also to intensive chemical cleaning twice a
year. For this purpose the modules are removed from the
filtration tank and cleaned chemically, from inside and
outside, in a separate heatable container. With this, the
permeability of the membranes, and possibly necessary
capacity reserves, are restored.
Within the scope of a research project promoted by the
state North-Rhine Westphalia, the operation of the first
German large-scale membrane bioreactor was accompanied by scientists. The aim was to acquire more farreaching knowledge for new constructions of membrane
bioreactors, in particular about the operating mode of
124
the membrane modules in order to reduce the energy
Moreover, it turned out that the waste water needs better
demand of module aeration. The following measures
mechanical pretreatment because accumulation and
have been realized successfully:
sticking of fibrous material occurred on the hollow-fibre

membranes. For this reason, a partial flow of the activa-
single filtration lines are switched on or off depending

on the water volume to be filtered
ted sludge is treated by sieving between the activated

sludge tank and the filtration tank (see Figure 2-58) to
discontinuous aeration of the membrane modules
remove fibres and coarse material which get into the acti-
intermittent operation of the activated sludge stage to
vated sludge stage despite mechanical pretreatment
get small recirculation flows

2.2.3.5
[ENGELHARDT ET AL. 2001].
UF
Schramberg-Waldmssingen Waste Water

Treatment Plant
The Schramberg-Waldmssingen waste water treatment
waste water treatment plants. However, in 2001 it was
plant had been operated from 1995 to 1998 at the limit
decided to expand the plant at the same site with the
of its capacity. The consent for operation was limited to
membrane bioreactor process, because this was the most
31st December 1998. Since the effluent is discharged into
ecologically and economically favourable solution.
the weak and sensitive receiving water Heimbach (a

creek), discussions with the supervising authority had
The waste water treatment plant (Figure 2-60) is designed
determined in 1996 that the operation of a conventional
for 2,600 PE and a waste water flow of up to 90 m3/h.
waste water treatment plant without a tertiary treatment

stage would no longer be approved at this site. Before
As presented in the flow sheet of the plant (Figure 2-61),
expanding the plant, several alternatives were studied,
mechanical pretreatment is carried out by a screen (5 mm
including connection to and upgrading of neighbouring
spacing) and a grit chamber. Two slot sieves (0.5 mm spacing) operated in parallel are arranged downstream of the
grit chamber to protect the membrane stage. The activa-
Figure 2-60
ted sludge stage comprises an upstream denitrification
Schramberg-Waldmssingen waste water treat-
tank (V = 250 m3), a nitrification tank (V = 480 m3) and
ment plant [photo: STADTWERKE SCHRAMBERG
the membrane bioreactor.

The two-line membrane stage is equipped with 10 module
cassettes (type 500 c) from the company ZENON (see
Figure 2-62). The membrane surface area of approx.
4,400 m3 in total treats an average permeate flow of
2,160 m3/d.
The investment for the waste water treatment plant
amounted to 2.8 million euro. The state Baden-Wrttemberg prioritized this project and provided a subsidy of
34 % within the scope of the general promotion of waste
water treatment projects, so that the plant could be commissioned in 2004. For one year the University of Stuttgart assists with and documents the operation of the
plant and determines its treatment capacity.
125
Figure 2-61
Flow sheet of the Schramberg-Waldmssingen waste water treatment plant [according to STADTWERKE
SCHRAMBERG 2004]
nitrification,
membrane stage
fine screen
0,5 mm
feed
screen
5 mm
denitrification
nitrification
receiving
water
grit
chamber
blower
installation
fine screen
0,5 mm
recirculation
Figure 2-62
Membrane installation at the Schramberg-Waldmssingen waste water treatment plant [photos: STADTWERKE SCHRAMBERG 2004], left: view of the membrane tanks, right: membrane module
126
2.2.3.6
UF
Knautnaundorf Waste Water Treatment Plant

The Knautnaundorf waste water treatment plant of Kom-
For the first time the immersed system from the com-
munale Wasserwerke Leipzig (Municipal Waterworks) is
pany Martin Systems was used in the membrane stage
the newest membrane bioreactor put into operation in
(see chapter 2.1.2, figure 2-11). With a membrane sur-
Germany. With a capacity of 900 PE (expandable up to
face area of 756 m2, the performance of a German-
1,800 PE) and a peak inflow of 23 m /h, it is the smallest

large-scale membrane installation for municipal waste
developed membrane can be proven on technical scale.

The mechanical pretreatment stage is equipped with a
water treatment. Although no increased demands on
two-stage screen. The finest screen with an aperture
waste water treatment were made at this site, the mem-
size of 1 mm in the second stage will retain all unde-
brane bioreactor process came out on top in the tender
sired matter from the filtration zone.
results against conventional solutions because of lower
The bottom of the nitrification tank is fully equipped
investment requirements. An important feature of this
with aerators for the plate membranes to ensure opti-
site is the fact that it is fed by a separate sewer system.
mal oxygen input.
As such, it was possible to reduce the investment for the

membrane stage compared to plants working with a com-
After successful start-up in October 2001 and start of
bined sewer system [WALTHER 2001].
regular operation for several weeks, the plant had to be

shut down due to a non-authorized discharge (diesel oil)
The process engineering is comparable to that of the
in order to settle claims for damages. At present, state-
installations described above. The following special fea-
ments on the operational behaviour of the installation
tures have to be mentioned:
cannot be made because the plant has only been returned to operation in April 2002.
127
UF
2.2.3.7
Simmerath Pilot Plant

The Wasserverband Eifel-Rur (WVER) (water board) opera-
Conservation, Agriculture and Consumer Protection
tes a waste water treatment plants in the low mountain
(MUNLV) of the state North Rhine-Westphalia.
region of Eifel. Since the plants are situated in drinking

water catchment areas, more stringent demands on their
Within the scope of the pilot project, a membrane biore-
effluent quality are made. Low waste water temperatures
actor was installed in a separate building on the site of
in winter and a large amount of sewer infiltration create
the Simmerath waste water treatment plant. It is equip-
additional challenges for waste water treatment. At the
ped with immersed capillary membranes from the com-
Simmerath site, the WVER operates a waste water treat-
pany PURON which are tested in technical scale under
ment plant for 15,000 PE. Table 2-16 shows the demands
real conditions (Figure 2-64). The membrane bioreactor is
on the effluent quality of the membrane bioreactor.
designed for a capacity of 750 PE. It treats a partial flow

of the effluent from mechanical pretreatment (rotary
Starting from these boundary conditions, a membrane
screen with an aperture size of 3 mm) of the Simmerath
bioreactor pilot project was started in 2003 at the Simme-
waste water treatment plant. Without further presieving
rath waste water treatment plant, which is operated by
this partial flow is fed into the membrane bioreactor,
WVER and designed for 15,000 PE. The project is pro-
which consists of an activated sludge tank with a volume
moted by the Ministry for Environment and Nature
of 136 m3, which is divided into an upstream denitrifica-
Table 2-16
Discharge consent of the Simmerath waste water treatment plant [WVER 2004]
Parameter
Discharge consent
COD
BOD5
NH4-N
Ntot
Ptot
AOX
40 mg/l
10 mg/l
3 mg/l
18 mg/l
0.8 mg/l
50 g/l
Figure 2-63
Flow sheet of the Simmerath demonstration plant [according to WVER 2004]
feed
fine screen
3 mm
grit and
oil chamber
biological reactor
clarifier
receiving
water
sludge
fine screen
1 mm
membrane stage
denitrifikation
nitrifikation
recirculation
128
blower
installation
Figure 2-64
Membrane installation at the Simmerath waste water treatment plant [photos: PURON AG 2003],
left: denitrification and nitrification tanks with the hall for the membrane installation,
right: membrane cassette
tion stage with subsequent nitrification and the down-
cation or the nitrification zone. The permeate of the mem-
stream membrane stage with a volume of 20 m3. The TS
brane stage is fed into the in-flow of the Simmerath plant.
content in the tanks is between 10 and 14 g/L.

Over the course of the test period, the membrane modulThe membrane stage consists of two module cassettes with
es and their operation were continuously optimized so
a filter surface area of 500 m2 each, which are immersed
that the operation of the membrane installation clearly
and operated in two separate chambers. The sludge from
improved. The operating values of the membrane bio-
the membrane stage is recycled either into the denitrifi-
reactor are listed in Table 2-17.
Table 2-17
Operating values of the membrane bioreactor in Simmerath [WVER 2004]
Parameter
Operating values
COD
BOD5
NH4-N
Ntot
Ptot
AOX
< 30 mg/L
no Information
< 1 mg/L
< 8 mg/L
< 2 mg/L
g/L
Knowledge on the clogging behaviour as well as on the
At present, a second research period is active to test, among
problems with fibrous matter in membrane installations
other things, further developed membranes and to opti-
was acquired. Different treatment concepts were tested
mize the integration of the membrane modules into the
concerning their efficiencies. The treatment results of the
process engineering of the waste water treatment plant.
plant were documented and evaluated. It was discovered

that the denitrification process was influenced by the
O2 load recycled from the membrane chamber. This problem was solved by changing the process configuration.
129
2.2.3.8
UF
St. Wendel Golf Course

For several months, the City of St. Wendel has operated
this plant is infiltrated at the golf course. It is also possi-
at the site of the local golf course a new waste water treat-
ble to use it for golf course irrigation.
ment plant according to the membrane bioreactor process, which is currently treating the sanitary waste water
The construction and operation of the membrane biore-
of the golf course and the restaurant. At present the waste
actor are supported financially within the scope of a re-
water flow is approx. 3 m3/d. Next year the hotel belong-
search project promoted by the Ministry of the Environ-
ing to the golf course will be finished so that the load
ment of the federal state Saarland. A special innovation
of the waste water treatment plant will reach the design
represent the ceramic plate membranes (molecular sepa-
capacity of approx. 150 PE. 15 m of waste water will
ration size ~ 0.1 m) from the company ItN Nanovation
then be treated per day. Currently approx. 3 m3 of waste
which are used for the first time in Germany for munici-
water per day are treated in the new waste water treat-
pal waste water treatment. Within the scope of the rese-
ment plant. This volume will increase to 15 m3/d, when
arch project, the performance and the service life of the
reaching the design capacity. The waste water treated in
ceramic membranes will be examined. Especially con-
Table 2-18
Minimum requirements, discharge consent and operating values of the golf course St. Wendel waste
water treatment plant [CITY OF ST. WENDEL 2005]
Parameter
Unit
COD
mg/L
150
18
BOD5
mg/L
40
<4
Total number of Bakteria coli
Operating values
cfu/100 mL
< 100
Figure 2-65
Flow sheet of the golf course St. Wendel waste water treatment plant [according to ST. WENDEL]
biological reactor
membrane stage
waste water
buffer
tank
130
fine screen
3 mm
3mm
permeate
storage
infiltration
cerning the service life, it is expected that the ceramic
so that a total membrane surface area of 33 m2 is install-
membranes have a clear advantage compared to polymeric
ed. For capacity expansion, the stage will be upgraded by
membranes.
more modules.
The waste water treatment plant consists of a buffer tank

3
The operating and cleaning concept of the membrane
with a volume of 7 m , a rotary screen with an aperture
stage using immersed ceramic membranes can be compa-
size of 3 mm, an activated sludge stage with a volume of
red with that of immersed membrane systems on poly-
approx. 20 m and a downstream permeate storage tank.
mer basis. But due to the more solid ceramic membranes,
The waste water flows from the buffer tank and the rotary
it is possible, among other things, to use higher trans-
screen into the activated sludge stage in which the im-
membrane pressure differences, higher pressure levels
mersed membranes are installed. The membranes are
during backwashing and higher concentrations of clea-
aerated from below by slotted tubes. Thus the air is not
ning chemicals.
only used to control the covering layer on the membranes, but also for aeration of the activated sludge stage.
The investment of the plant was approx. 400.000 euro,
Since the tanks are completely intermixed, sludge recy-
75 % of which were taken over by the federal state Saar-
cling can be spared. Due to the small waste water volume
land. Besides the costs for the membrane bioreactor it-
flow, the TS content in the activated sludge stage current-
self, this sum of 400.000 euro comprises, among other
ly is about 4 g/L. The design capacity has been calculated
things, the costs for connection, an appropriate building
with a TS content of 12 g/L.
for the site and a sludge mineralization plant.
The membrane stage consists of a rack with three modules. Each module has a membrane surface area of 11 m2,
Figure 2-66
Module rack at the golf course St. Wendel waste water treatment plant,
left: top view, [photo: ItN NANOVATION], right: side view [photo: ABWASSERWERK ST. WENDEL]
131
2.2.3.9
UF
than the minimum requirements for waste water treat-
Glessen Waste Water Treatment Plant
ment plants of this size category (see Table 2-19).
(Planning Stage)
In order to comply in future, too, with the demands on
The design capacity of the Glessen waste water treatment
the effluent quality, the waste water treatment plant is
plant (Erftverband) is currently 5,000 PE. The effluent is
expanded using existing plant components. In this con-
discharged into a receiving water which infiltrates into
nection a waste water treatment plant with a pressure
the groundwater of a drinking water catchment zone.
pipe in a distance of 4 km will be also connected, so that
Therefore, the demands on the effluent quality are higher
the design capacity of the plant at the Glessen site after
Table 2-19
Demands on the effluent quality of the Glessen waste water treatment plant
[according to ERFTVERBAND 2004]
Parameter
Unit
Minimum requirements for
Discharge consent
WWTP of size category 3

COD
mg/l
90
30
BOD5
mg/l
20
NH4-N
mg/l
10
1.5
Ptot
mg/l
0.6
Figure 2-67
Flow sheet of the Glessen waste water treatment plant [according to ERFTVERBAND 2004]
recirculation
membrane stage/
nitrification
blower
installation
fine screen
5-6 mm
grit
chamber
screening
system
0.5 mm
132
receiving
water
0.5 mm
feed
denitrification
tank
nitrification
tank
expansion will be 9,000 PE. With dry weather flow, the

3
circulating flow for nitrification and denitrification has a
daily waste water quantity is 2,394 m .
total volume of 1,680 m3.
The Glessen waste water treatment plant is in the plan-
Planning is based on membranes from the company
ning stage. The concept (Figure 2-67) provides mechanical
ZENON installed in four tanks with 7 modules each of the
pretreatment by a single-line screen with a spacing of
type 500 c and a total membrane surface area of 12,320 m3.
6 mm. The grit chamber, with a volume of 53 m3, is
The TS content will be 12 g/L. The membrane installation
planned with a single line, followed by the two-line fine
was designed for a specific filtration capacity of 22 L/(m2 h),
screen with a spacing of 0.5 mm. The membrane bioreactor
which will have to be increased to approx. 30 L/(m2 h)
will be operated with simultaneous denitrification and
in case a membrane line has to be shut down on short
aerobic sludge stabilization. The activated sludge tank with
notice. The former secondary settling tank with a volume

of 560 m3 will be used as an equalization tank.
2.2.4
UF
Installations Outside of Germany with

Ultrafiltration Membranes
The largest membrane bioreactor in the world up to the
capacity of 46,000 PE (only for the membrane bioreactor)
year 2004, and one of the most modern plants in Eng-
(Figure 2-68). For this plant as well as for the Campbeltwon
land, is the Lowestoft waste water treatment plant which
waste water treatment plant (Scotland, 6,000 9,000 PE),
was put into operation in the beginning of 2002 with a
the ZenoGemTM system is used.
Figure 2-68
Aerial photograph and flow sheet of the Lowestoft waste water treatment plant [ZENON 2002]
vacuum pumps
ZeeWeedTM
inflow
membrane bioreactor 1
to inlet
structure
distributor
inlet
distributor lamella
structure
separator
ZeeWeedTM
backflush pumps
membrane bioreactor 2
permeate
storage tank
133
2.2.4.1
UF
Pilot Plants at the Beverwijk Waste Water

Treatment Plant, The Netherlands
From 2000 to 2004, the consulting engineers DHV and
Toray and Huber) have been tested with a view to their
the Stichting Toegepast Onderzoek Waterbeheer (Stowa)
capacity and suitability in practice.
have realized at the Beverwijk waste water treatment plant

(capacity: 450,000 PE) the decisive research project con-
The tests have been carried out on a test field built espe-
cerning the membrane bioreactor process in The Nether-
cially for this purpose with separate membrane bioreac-
lands. Over the course of these four years, various module
tors. The overview in Table 2-20 shows the important key
systems (ZENON, Kubota, X-Flow, Mitsubishi, Memfis,
features of the individual test installations.
Table 2-20
Key features of the individual pilot installations [DHV 2004]
Manufacturer
Type
Pore size
Membrane surface
Permeate flow
[m3/h]
Test period
[m]
[m2]
Huber
plate
0.038
360
15
10/03 07/04
Kubota
plate
0.4
240
10
05/00 07/02
Memfis
plate
0.05
112
05/02 06/03
Mitsubishi
hollow fibre
0.4
314
05/00 03/02
Toray
plate
0.08
137
02/03 02/04
X-Flow
tubular
0.03
220
05/00 04/02
ZENON
hollow fibre
0.035
184
03/00 10/02
0.035
55
03/01 03/03
0.035
90
11/02 08/03
(module ZW 500a)
ZENON
hollow fibre
(module ZW 500c)
ZENON
hollow fibre
(module ZW 500d)
The research project at the Beverwijk waste water treatment plant has been successfully completed [VAN DER
ROEST ET AL. 2002]. The large-scale plant at Varssefeld
has been planned and built on the basis of the results
from Beverwijk.
134
Figure 2-69
Photos of the pilot installations and membrane modules at the test field of the Beverwijk waste water
treatment plant [DHV 2004]
From left to right: Kubota, Kubota, Mitsubishi, Mitsubishi
From left to right: X-Flow, X-Flow, Zenon, Zenon
From left to right: Memfis, Memfis, Toray, Toray
From left to right: Huber, Huber
135
UF
2.2.4.2
Varsseveld Waste Water Treatment Plant,

The Netherlands
The membrane bioreactor at the Varsseveld waste water
in The Netherlands are faced with a hydraulic load in the
treatment plant is the first large-scale implementation of
case of stormwater flow which is greater by a factor three
this process in The Netherlands. It will be put into opera-
compared to the average waste water load. This is also
tion in the beginning of 2005. Since April 2004, a pilot
true for the Varsseveld waste water treatment plant. An
plant has been operated within the scope of a research
average daily waste water volume of 5,000 m3/d was de-
project at the site of the Varsseveld waste water treatment
termined. The supervisory authorities demand effluent
plant with a permeate flow of 3.5 m3/h to study process
concentrations of < 5 mg/L for nitrogen and < 0.15 mg/L
optimizations for the large-scale plant. In parallel, the
for phosphorus.
large-scale plant has been built. The project is realized and

assisted by the water board Rijn en IJssel, the Stowa, DHV
The membrane installation was built with four trains
and other institutions. The research project is financed
(Figure 2-70). A total membrane surface area of 20,160 m2
by the Stowa and the EU LIFE program (see also possibili-
of the company ZENON (module type: ZW 500 d) has
ties for promotion by EU in the annex).
been installed. The calculated specific stormwater flow is

37.5 L/(m3 h) of permeate. The membrane installation
The connection size of the Varsseveld waste water treat-
can be increased with additional modules, if necessary.
ment plant is 23,150 PE with a maximum waste water
The investment for the Varsseveld waste water treatment
volume flow of 755 m3/h. Waste water treatment plants
plant amounts to 10 million euro.
Figure 2-70
Flow sheet of the Varsseveld waste water treatment plant [according to DHV 2004]
circulation tank with aerated zone

and upstream denitrification
membrane stage
feed
outlet
fine screen
6 mm
grit
chamber
fine screen
0,8 mm
recirculation
136
UF
2.2.4.3
Brescia Waste Water Treatment Plant, Italy

The Brescia waste water treatment plant is an example for
the construction of very large tank volumes for a denitri-
the advantage of the membrane bioreactor process in the
fication system which was not possible with the space
case of necessary plant expansion at limited space available.
available. With the membrane bioreactor process, a plant

expansion has been achieved with alteration of only one
Since 1980, the Brescia waste water treatment plant existed
treatment line (Figure 2-71).
as three-line activated sludge plant. Each of the three

lines consisted of primary clarification, activated sludge
The secondary clarification tank was replaced by a four-
tank, secondary clarification and dosing station for chlo-
line membrane stage. 160 membrane cassettes of the type
rine. Due to more stringent demands on the Ntot effluent
500C (capillary membranes) from the company ZENON
concentration (< 15 mg/L), the waste water treatment
with a total surface area of 70,400 m2 are installed. 50 %
plant had to be expanded in 2000. Upgrading the con-
of the waste water volume flow of the Brescia waste water
ventional activated sludge process would have required
treatment plant (about 40,000 m3/d) is treated by the
Figure 2-71
Flow sheet of the Brescia waste water treatment plant [according to ZENON GMBH 2004]
denitrification
fine screen
3 mm
grit
chamber
primary treatment
nitrification
clarifier
recirculation
sludge
denitrification
nitrification
clarifier
flow
recirculation
feed
sludge
membrane stage
fine screen
3 mm
grit
chamber
primary treatment
denitrification
receiving
water
nitrification
recirculation
recirculation
existing plant
expansion
137
Figure 2-72
Aerial photograph of the Brescia waste water treatment plant [photo: ZENON GMBH 2004]
membrane bioreactor line. The remaining 50 % are treat-
Thanks to the conversion finished in 2002, the effluent
ed by the two conventional lines. Today the Brescia
values of the plant improved considerably. The raw waste
waste water treatment plant has a treatment capacity of
water concentration for some parameters, the operating
approx. 150,000 PE. Figure 2-72 shows an aerial photo-
values of the plant and the demands on the effluent qua-
graph of the Brescia waste water treatment plant.
lity are listed in Table 2-21.
Table 2-21
Raw waste water concentration, operating values and requirements of the Brescia waste water treatment
plant [ZENON GMBH 2004]
Parameter
Unit
Raw waste water
Operating values
Requirements
concentration
COD
mg/L
505
20
< 125
BOD5
mg/L
255
10
< 25
TS
mg/L
290
not detectable
TKN
mg/L
50
< 15 (Ntot)
Turbidity
mg/L
>50
< 10
no data
138
UF
2.2.4.4
Sntis Waste Water Treatment Plant, Switzerland

On the peak of the Sntis, a top station with restaurant
Thanks to the compact structure of the membrane tech-
and telecommunication centre is situated. To purify waste
nology, the installation could be integrated into the exist-
water and to treat waste water for non-potable drinking
ing building with very restricted space. It distinguishes
water purposes, the existing small waste water treatment
itself by high cleaning efficiency (effluent values: COD
plant was replaced in 2000 by membrane technology
< 30 mg/L, NH4-N < 2 mg/L) at extreme temperatures and
according to the ZenoGemTM process. The installation is
a high inflow dynamics due to rapid load changes at up
operated by Swisscom and Sntis-Schwebebahn AG
to 8,000 visitors per day.
(Funicular AG).
Figure 2-73
View and flow sheet of the membrane bioreactor according to the ZenoGemTM process on the Sntis
[ZENON 2002], situation of the membrane bioreactor on the Sntis and view of the modules [ZENON 2002]
kitchen waste water
grease separator
other inflow
nitrification
with ZeeWeedTM
sieve screw
denitrification
rail
transportation
sludge storage
settlement
buffer tanks
effluent
permeate
tank
disinfection
139
MF
2.3
2.3.1
Small Waste Water Treatment Plants, Mobile
Busse-MF Installation from the Company Busse
Installations and Ships Waste Water Treatment

with Membrane Technology
The company Busse Innovative Systeme GmbH produces

and sells an installation with membrane technology
Small or domestic waste water treatment plants are used
which is the first small or domestic waste water treatment
in Germany as long-term solution depending on the regula-
plant with type approval (Z-55.3-60) by Deutsches Insti-
tions of the water legislation of the individual states. In
tut fr Bautechnik (DIBt) (German Institute for Construc-
North-Rhine Westphalia, 53 section 4 Landeswassergesetz
tion Engineering).
(law on water) is decisive. According to this article, private

property-related waste water treatment is permissible only
The production started in autumn 1999. In the meantime,
for properties outside of coherently built-up areas.
more than 250 installations (as of 2005) are operated

with this technology worldwide with connection capaci-
According to an assessment by OTTO [2002], until the
ties from 2 to 32 PE. They are used for the treatment of
year 2006 up to 4 million German citizens will remain
waste water from detached houses and multiple dwelling
unconnected to a central sewer system and therefore are
units, office buildings, restaurants and hotels in Germany
responsible themselves for waste water disposal. In North-
and 10 more countries [BUSSE 2005]. By using membra-
Rhine Westphalia, at present about 580,000 inhabitants
nes, the Busse-MF system is very compact, as can be seen
are not connected to central sewer systems or waste water
in Figure 2-74, which is typical for a Busse-MF installa-
treatment plants. They treat their waste water by approx.
tion fitted in the cellar of a residential building.
130,000 small waste water treatment plants and cesspits

without outlet [MUNLV 2005].
As shown by the flow sheet in Figure 2-75, the system

consists of two tanks. The first tank (primary settling) is
With further technical development, membrane filtration
connected directly to the downpipe for waste water trans-
is becoming more and more accepted in the field of small
portation. It serves to separate coarse matter and to store
waste water treatment plants.
waste water and sludge temporarily. From the central
With membrane technology, small waste water treatment

plants are able to attain higher cleaning efficiencies at
Figure 2-74
high operational safety (Table 2-22). Besides ultrafiltra-
View of the Busse MF small waste water treatment
tion of the treated waste water, the operator can also use
plant (formerly BioMIR TM) [BUSSE 2002]
the treated water as non-potable water for domestic purposes, e.g. for toilet flushing or garden irrigation. In addition to ecological advantages, cost savings by reducing
the drinking water demand for non-potable water applications may be decisive to use this process concept.
In the meantime, several manufacturers offer or are developing corresponding systems. At present, the inhabitantrelated investments are between 1,000 and 1,500 euro
per inhabitant, depending on the size of the installation.
In addition, costs of 60 110 euro per inhabitant per year
arise for operation and maintenance.
In the following sections, the most fully developed systems
are presented which include numerous references.
140
Figure 2-75
Flow sheet of a Busse-MF installation [BUSSE 2002]
waste water from

bathroom, kitchen,
toilet
ventilation by
existing shaft
condenser
permeate
mammouth pump
with coarse-matter
separator
intermediate storage of
waste water and sludge
activated sludge stage

with filtration unit
tank zone, the liquid phase is pumped by a mammoth
this case, only the downstream activated sludge stage has
pump, which is protected by a plastic network, into the
to be upgraded with membrane filtration.
second tank (activated sludge tank) where biological

waste water treatment and phase separation take place
The treatment capacity is sufficient to meet the de-
using immersed plate modules from the company Kubota.
mands according to the approval principles for small waste
The transmembrane pressure difference necessary for per-
water treatment plants of DIBt [N.N. 2002d], as was alrea-
meate discharge is generated by the hydrostatic pressure
dy proven by independent studies [ROSENWINKEL ET
of the water head between the permeate outlet and filling
AL. 2001; KRAUME ET AL. 2000]. Table 2-22 shows a
level of the activated sludge tank. Thus there is no need
comparison of the limit values according to DIBt [N.N.
for a suction pump to withdraw the permeate.
2002d] and the mean values of qualified random samples

and 24-h-composite samples taken each month over a
The plant is usually installed in the cellar or the garage.
one-year test period [ROSENWINKEL ET AL. 2001]. It can
It is also possible to use an existing pit as an upstream
be seen that the effluent values remain below the stand-
waste water storage tank and coarse matter separator. In
ard values.
Table 2-22
Requirements for the effluent quality of small waste water treatment plants and measured effluent values
of the Busse-MF installation
Parameter
Unit
Limit values according
Effluent values
to DIBt 2000 for installations
Busse-MF installation
with nitrification [N.N. 2002d]
[ROSENWINKEL ET AL. 2001]
90
39
COD
mg/L
150
BOD5
mg/L
40
20
2.4 *
NH4-N
mg/L
10 (at > 12 C)
4.5
Filterable solids
mg/L
50
0.65 *
* higher effluent values are due to algae growth in the filtrate collecting tank
141
MF
2.3.2
UltraSept Installation from the Company Mall

Another system is the UltraSept installation marketed by
The installation is usually lowered completely into a pit
the company Mall GmbH (Figure 2-76). More than 50 of
excavated for this purpose. In case a multicompartment
these plants with a size of 6 to 40 connected inhabitants
septic tank already exists, it is possible to upgrade the
are operated in Germany.
existing tank with membrane technology to improve the

effluent quality. This alternative is less expensive than a
The installation consists of three compartments arranged
new installation.
according to the principle of a three-compartment septic

tank. The first two compartments are used for the pretreatment of the waste water according to the principle of a
multicompartment septic tank. The third compartment is
the largest. It contains the activated sludge stage and the
filtration unit for the discharge of the treated waste water.
For a membrane module, a module from the company
Weise is used.
Figure 2-76
Schematic representation of the UltraSept installation from the company Mall [MALL 2002]
feed
connection for outlet, aeration, control lead

mechanical stage
rubber seal (elastomer gasket)
biological stage
emergency
float switch
overflow
suction duct
aeration lead
membrane module (physical stage)
Mall UltraSept
applied for national technical approval
142
2.3.3
MF
Small Waste Water Treatment Plant for 4 PE

in North-Rhine Westphalia
Within the scope of a pilot project for decentralized waste
A small tank with a volume of 0.6 m3 is used to cover the
water treatment and treatment of non-potable water for
demand for non-potable water in the house. The tank is
domestic purposes, a small waste water treatment plant
installed below ground to prevent the new formation of
according to the UltraSept process is operated in the nor-
germs in the water during storage. The connections to the
thern Eifel (low mountain region in North Rhine-West-
domestic piping are realized according to the technical
phalia). The plant is installed at the part-time cattle breed-
principles of rainwater utilization.
ing farm of a four-member family.

The non-potable water which is not needed directly in
The membrane bioreactor has a nominal capacity of
the house, is stored in a long-term storage tank which, in
900 L/d and is fed with an actual waste water volume of
the case of this pilot project, is constructed as a foil pond
900 L/d. In addition to the waste water treatment plant,
with a volume of 36 m3. The water stored there is used to
two storage tanks for further utilization of the treated
clean the cow-sheds and to irrigate the garden [KLEMENS
waste water have been installed which buffer the differ-
2002].
ences between the production of and the demand for

non-potable water for domestic purposes.
2.3.4
UF
Kreditanstalt fr Wiederaufbau (KfW),

Service Water Treatment
At the Kreditanstalt fr Wiederaufbau in Frankfurt (KfW),
At first, the kitchen waste water is pretreated by a grease
a combination of a fixed-bed activated sludge stage and a
trap, and hairs etc. are removed mechanically from the
membrane stage is used for the treatment of grey water
shower waste water (Figure 2-77). Both pretreated waste
in such a way that it can be reused as service water. The
water flows are fed into an activated sludge stage.
grey water is composed of the shower water from the

employees apartments and the waste water from the tea-
The biological stage is realized as fixed-bed activated
houses and the kitchen of the board of management.
sludge stage with special components for biomass growth
Figure 2-77
Grey water treatment plant at KfW
shower waste water
ultrafiltration
toilets
sieve
grease
separator
buffer
tank
fixed bed
activation
storage
process
water
storage
kitchen waste water
143
developed by the company ACO Passavant. After having
Figure 2-78
passed this stage, the waste water is fed into a storage
Membrane installation for the treatment of service
tank and then filtered by an ultrafiltration installation, a
water in the cellar of KfW [WEISE WATER SYSTEMS
MicroClear plant from the company Weise Water Systems
GMBH]
GmbH (Figure 2-78). The installation is equipped with

immersed plate modules with a total membrane surface
area of 44 m2. An average permeate volume of 500 L is
filtered per hour by the membrane stage. Compared to
other membrane bioreactors with suspended biomass, this
plant receives waste water with rather low TS content,
formed only by the sludge output from the components
for biomass growth. Therefore, the plate membrane modules have relatively small spacings between the plates of
2.5 mm.
The treated water is fed into a storage tank. As service
water it is used among other things for toilet flushing in
the administration building and in the apartments of the
employees.
UF
2.3.5
Small Waste Water Treatment Plant Membrane

ClearBox
TM
TM
and Huber HoneyComb
from the
Company Huber AG
ules, the so-called VUM modules (VacuumUpstream

Membrane), which are equipped with ultrafiltration membranes. The clear water withdrawn by a vacuum pump
can either be used as non-potable domestic water, dis-
The company Hans Huber AG markets the small waste

water treatment plant MembraneClearBox
TM
and the
charged or infiltrated. The related aggregate and control

unit (Figure 2-80) can be installed close to the septic tank
HoneyCombTM system, which are used in particular for
in a heated control cabinet or in the cellar of the neigh-
decentralized waste water treatment in rural areas. Both
bouring residential building. The MCB plants are equipped
systems can be installed as expansion kits in existing or
with a remote control, which in case of a breakdown sends
new multicompartment septic tanks (Figure 2-79). The
an information via SMS, e-mail or fax.
process consists of the three steps pre-treatment, activation and membrane filtration. The MembraneClearBoxTM
According to information from the manufacturer, the
(MCB) can be used for up to 8 PE and the HoneyCombTM
operation of existing small waste water treatment plants
system for 9 150 PE.
has shown that the COD can be reduced by more than

95 % and ammonia nitrogen by approx. 98 %. The energy
The first compartment serves for primary treatment and
consumption for a 4-PE plant is about 2 kWh/d. In some
the second serves for primary treatment or as buffer tank,
plants, the excess sludge production has clearly decreased,
before the waste water is fed in free over-flow into the
e.g. in one plant from initially approx. 0.09 kg TS/(m3 d)
third compartment, which is built as an activated sludge
to only 0.015 kg TS/(m3 d) after a longer operation period.
tank. The assembly kit and an aeration system are install-
Even after more than one year of operation, excess sludge
ed in this tank. Depending on the size of the plant, the
removal was not necessary.
assembly kit consists of a varying number of plate mod-
144
Figure 2-79
Plot plan of a small waste water treatment plant with membrane technology installed in a multicompartment septic tank [HUBER AG 2004]
1. settling tank with overflow

for coarse desludging
1. settling tank with overflow

for coarse desludging
2. settling tank
with overflow
inflow
2. settling tank
with overflow
emergency
overflow
aeration
3. activated sludge tank

permeate discharge
inflow
membrane filtration
aeration
3. activated sludge tank
membrane filtration
Figure 2-80
Small waste water treatment plant MembraneClearBoxTM from Huber AG [photos: HUBER AG 2004],
left: aggregate and control unit, right: MCB expansion kit, consisting of plate module and aerator
145
2.3.6
MF
Mobile Installations for the Use in Military Camps

Missions of the German Armed Forces take place at various
at any time and in any location worldwide and transport-
locations in Germany and abroad for limited periods of
ed by nearly any means of transportation (Figure 2-81).
time. As such, long-term planning is often impossible. In

most cases, local infrastructure cannot be used so that
The waste water to be treated is pumped via a grinding
water supply and waste water disposal structures have to
unit to the container. Feeding from outside takes place by
be mobile, easy to handle and usable all over the world.
automatically heated and isolated tubes to ensure opera-
Moreover, they have to comply with the legal prescrip-
tion of the plant in cold areas. The membrane bioreactor
tions and the requirements of the troops employed.
fitted into the container includes six immersed plate membrane modules from the company A3 GmbH with a total
On account of these requirements, the Bundesamt fr
membrane surface area of 120 m2. The filtrate is withdrawn
Wehrtechnik und Beschaffung (Federal Office for Defence
by a frequency-controlled suction pump and pumped to
Technology and Provision), Koblenz, has charged A3
the discharge point. A plant of this construction type has
Abfall-Abwasser-Anlagentechnik GmbH (process techno-
been running since the beginning of 2004.
logy for waste and waste water), Gelsenkirchen, to design

and build a mobile waste water treatment plant which is
fitted into a 20-inch container (see Figure 2-81). The plant
is able to treat the waste water of 300 soldiers at ambient
temperatures between -32 C and +49 C to such an extent that it can be discharged or infiltrated in place. Thanks
to the containerized construction, the plant can be used
Figure 2-81
Transportation of the container plant by an emergency vehicle and schematic representation of the plant
[A3 GMBH 2004]
146
2.3.7
MF
The waste water is usually fed to the conventional plants
Ships Waste Water Treatment Plants with
in surges, depending on the moment of waste water pro-
Membrane Technology
duction. The waste water flows into the first aerated activation chamber. After a reaction time which results from
Waste water discharge from ships used for civilian or mili-
the plantspecific hydraulics, it flows as mixed liquor into
tary purposes is regulated by national and international
the second activation chamber. It is aerated again to en-
law. The governing body responsible for international
sure further degradation of the organic waste water pollu-
legislation is the International Maritime Organization
tants. The waste water is then fed to the secondary sett-
(IMO). The discharge of ships waste water is regulated in
ling tank and finally to the disinfection cell.
Annex IV of the IMO rules and standards (MARPOL 73/78).

As defined in these standards, the direct discharge of
The process technology described above has some weak
waste water is not permitted, unless it has been treated
points in particular for the application on board of ships
and disinfected by an officially approved installation.
because it has been directly copied from conventional
Annex IV has been put into force in September 2003, after
municipal waste water treatment. The specific boundary
the necessary conditions had been fulfilled in 2002 (trans-
conditions on ships were often neglected. Special prob-
fer into national legislation by a sufficient large number
lems occur in secondary settlement because sedimenta-
of countries).
tion is considerably disturbed by the movement of the

ship and continuous low-frequency vibrations resulting
For inland navigation ships, the regulation concerning the
from the ships engines. The result is regular occurences
discharge of waste water will change with Article 9.01 of
of sludge being discharged from the secondary settling
the Agreement on Collection, Handing over and Accept-
tank into the sea. Also, the development of organic halo-
ance of Waste in Rhine and Inland Navigation of the
genated compounds during the disinfection of the efflu-
Zentralkommission fr die Rheinschifffahrt (Central Com-
ent by means of chlorine bleach liquor is another critical
mission for Rhine Navigation) [ZKR 2000]. According to
issue related to water pollution.
this article, the discharge of domestic waste water will

not be permitted from 1st January 2005 for cabin ships
Since enclosed space on board of ships is extremely expen-
with more than 50 sleeping places and from 1st January
sive, all systems to be installed including waste water
2010 for passenger ships which are licensed for the trans-
treatment plants must be as small as possible.
portation of more than 50 passengers. The contracting

countries therefore commit themselves to establish ade-
The use of installations with microfiltration membranes
quate receiving stations until the dates defined above.
for waste water treatment has been successfully tested by
The prohibition of waste water discharge is not valid for
some projects [BRSS, RICHTER 2001]. Figure 2-82 shows
passenger ships which are equipped with a licensed ships
an example of such a plant. Waste water treatment plants
waste water treatment plant. This agreement has not yet
with membrane technology have the advantage that the
come into force (as of August 2005) because it has not yet
activated sludge plant can be operated at a dry matter
been ratified by each single member state.
content TS BB of up to 20 g/L so that the aeration tank

volume can be reduced to a quarter compared to a con-
Up to now, grey water (waste water from showers, hand
ventional plant. Also, by using microfiltration in the bio-
basins, floor inlets) and kitchen waste water has histori-
logical reactor, it is no longer necessary to provide a secon-
cally been fed directly (without biological pretreatment)
dary settlement zone. Separation of the activated sludge
into the disinfection cell of the waste water treatment
is ensured by the membranes independent of the settling
plant. For biological treatment of black water (waste
characteristics of the mixed liquor. In addition, the efflu-
water from toilets) on ocean ships, at present activated
ent quality is clearly better, and chlorination of the waste
sludge plants, often arranged as cascades, are used for
water for disinfection becomes unnecessary because of
preliminary treatment prior to disinfection.
germ retention.
147
UF
Figure 2-82
2.3.8
View of a MEMROD1) ships waste water treatment
Cruise Liner Queen Mary 2
plant according to the membrane bioreactor process for 250 persons [VA TECH WABAG 2002]
With a length of 325 m, a capacity of 2,620 passengers

and a crew of 1,250 persons, the Queen Mary 2 is one of
the biggest passenger cruisers in the world. Figure 2-84
shows a photo of the passenger cruiser Queen Mary 2.
In the hold of Queen Mary 2, the grey and black waters
are treated by a membrane bioreactor according to the
current state of technology. Decisive factors for the choice
of this installation were its compact construction and
high treatment capacity with the possibility to reuse or
to discharge the treated waste water. Thus the ship is
allowed to navigate in protected waters.
The daily waste water flow to be treated is approx. 1,100 m3.
After mechanical pretreatment by a hydrocyclone and a
fine screen with an opening size of 1 mm, the waste water
is fed into the activated sludge stage, which consists of
two tanks for denitrification and nitrification with a volume of 150 m3 each. Solid-liquid separation takes place in
cross-flow operation mode in an ultrafiltration installation. The total membrane surface area, consisting of two
modules with plate membranes (PleiadeTM) from the company Rhodia (see Figure 2-83), is 700 m2. The permeate
Waste water treatment with membrane technology for
Figure 2-83
inland passenger ships, which must be adapted to the
Ultrafiltration module PleiadeTM for waste water
boundary conditions of shipbuilding and operation, is
treatment on Queen Mary 2 [photo: ORELIS SA 2004]
being studied at present within the scope of a projects

promoted by the Ministry for Environment and Nature
Conservation, Agriculture and Consumer Protection of
the federal state North Rhine-Westphalia (MUNLV NRW).
After successful tests with pilot plants (in the years 2002
2004), the operation of a large-scale membrane bioreactor
will be studied on board of the event ship RheinEnergie
of Kln-Dsseldorfer Deutsche Rheinschifffahrt AG.
1)
MEMbrane Reactor Operation Device
148
Figure 2-84
Photo of the Queen Mary 2
volume flow is approx. 50 m3/h. For further reduction of
ultrafiltration system. It is planned to reuse about 50 % of
organic matter and for disinfection, an activated carbon
the waste water treated by this process combination as
filter and a UV installation are installed downstream of the
non-potable water on the cruise liner.
Figure 2-85
Flow sheet of the waste water treatment plan of Queen Mary 2 [according to ORELIS SA 2004]
biological reactor
feed
membrane system
outlet
recirculation
hydrocyclone
sludge
fine filter
1 mm
150 m3
150 m3
activated
carbon
UVdisinfection
sludge
149
2.3.9
UF
RO
Grey and Black Water Treatment on Ships

The concept for waste water treatment used today on ships
stream solution was influenced by knowledge and ex-
is the one-stream solution which consists of mixing grey
periences from the treatment of industrial waste water
water (from showers, handbasins, laundry) and black water
by membrane processes and the do-not-mix rule. The
(from toilets) and combined treatment by membrane bio-
do-not-mix rule says that, in general, it is easier and
reactors. Immersed membrane modules, which are also
more efficient to treat waste water with different compo-
used in municipal waste water treatment, are applied.
sition and clear concentration differences by different
Ultrafiltration installations with externally arranged mo-
processes. Figure 2-86 shows the two-stream solution
dules with open channels at the raw-water side have also
which has been implemented on 25 ships.
been designed.
The membrane technology from the company Rochem
For large waste water volumes, e.g. on cruise liners with
UF, presented by way of example, is based on ultra-
more than 1,000 passengers, the two-stream solution can
filtration and ultrafiltration + low-pressure reverse
be more effective. The grey water is treated by low-pres-
osmosis. It is shown in Figure 2-87.
sure reverse osmosis membranes. The permeate is available for technical purposes. The black water, the concentrate from low-pressure reverse osmosis and the kitchen
waste water are treated by a membrane bioreactor. The
filtrate can be discharged or reused in applications with
lower quality demands. The development of the two-
Figure 2-86
Flow sheet of waste water treatment according to the two-stream solution [according to ROCHEM UF 2004]
reverse osmosis
ultrafiltration
process water
grey water
blower
installation
membrane bioreactor
discharge / sullage
black water
blower
installation
150
Figure 2-87
Membrane bioreactor BioFilt with three lines at 4.5 m3 of permeate per day each [ROCHEM UF 2004]
Figure 2-88
Low-pressure reverse osmosis for grey water treatment for 600 m3 of permeate per day
[photo: ROCHEM UF 2004]
151
2.4
membrane stage. Additional pretreatment is not neces-
Downstream Membrane Stage for Waste
sary. Removal of dissolved phosphate compounds after
Water Disinfection
disinfection can be achieved by arranging a dosing station for precipitants upstream of the separation stage
2.4.1
[DITTRICH ET AL. 1998] to retain the precipitation sludge
Process Description and Fields of Application
in the downstream membrane stage.
The use of a membrane stage at the outlet of a waste water
2.4.2
treatment plant is applied to achieve disinfection of the
Membrane Modules Used
effluent to comply with higher standards (e.g. EU Bathing Water Directive) or to reuse the treated waste water.
Test studies (test installations of Berliner Wasserbetriebe
Disinfection by a membrane stage has advantages com-
at the Berlin Ruhleben waste water treatment plant
pared to conventional processes such as UV treatment,
[DITTRICH ET AL. 1998], plant at the Geiselbullach waste
ozonation or chlorination. Namely, no undesired bypro-
water treatment plant [SCHILLING 2001] and tests at the
ducts develop and the formation of chemical resistance
Hailfingen and Merklingen waste water treatment plants
of bacteria and viruses is not supported [DORAU 1999].
[MAIER, VOGEL 2003]) have proven the suitability of different micro- and ultrafiltration modules for secondary
For the most part, the waste water from the outlet of the
effluent disinfection. Table 2-23 presents the characteris-
waste water treatment plant is pre-sieved with a molecu-
tic values of the modules used for large-scale operation.
lar separation size of 500 m before it is fed into the
Table 2-23
Characteristic values of different membrane modules for the filtration of effluents from the test installations of Berliner Wasserbetriebe and the test installations at the Geiselbullach, Halfingen and Merklingen
waste water treatment plants
WWTP
WWTP
WWTP Geiselbullach
WWTP
WWTP
Berlin-Ruhleben
Berlin-Ruhleben
[according to
Bondorf-Hailfingen
Merklingen
[according to
[according to
SCHILLING 2001]
DITTRICH ET AL. 1998]
DITTRICH ET AL. 1998]
Manufacturer
MemBrain
Memtec
ROCHEM
ZENON
X-flow
Membrane process
ultrafiltration
microfiltration
ultrafiltration
ultrafiltration
ultrafiltration
Material
ceramics
PP1)
PAN2)
PVDF
Module type
multichannel tube
capillary module
cushion module
capillary module
capillary module
0.05 m
0.1 m
50 / 200 kD
0.02 m
150 kD
Mode of operation
dead-end
dead-end
dead-end
dead-end
dead-end
Operating pressure
0.5 2.0 bar
0.5 1.5 bar
0.5 2.0 bar
0.05 0.3 bar
0.5 2.0 bar
Specific flow
approx. 63 L/(m2 h)
approx. 70 L/(m2 h)
approx. 45 L/(m2 h)
approx. 40 L/(m2 h)
approx. 60 L/(m2 h)
Backwashing
with filtrate
with compressed air
with filtrate (filtrate
(filtrate side)
(filtrate side)
side) and compressed
side) and compressed
side)
air (feed side)
air (feed side)
3)
PES4)
module
Nominal molecular
separation size
(transmembrane)
1)
Polypropylen
152
2)
Polyacrylnitril
3)
Polyvinyldiflourid
4)
Polyethersulfon
UF
2.4.3
2.4.4
Operating Experience
Large-Scale Applications in Germany for Waste

Water Disinfection by Ultrafiltration
The effluent quality measured at the test installations at

the Berlin Ruhleben waste water treatment plant proves
In Germany, three membrane installations are operated
that the limit values of the EU Bathing Water Directive
currently which serve for further treatment of the effluent
can be readily met with membrane treatment [DITTRICH
from a conventional waste water treatment plant (Table
ET AL. 1998].
2-24). A technical installation has been operated since

July 2000 at the Geiselbullach waste water treatment plant
According to first experiences with the modules applied
(Bavaria) of the Amperverband (water board). It treats the
up to now, specific flows of 35 70 L/(m2 h) can be ap-
effluent from the conventional waste water treatment
plied as a basis [DITTRICH ET AL. 1998; SCHILLING 2001].
plant up to process water quality so that it can be used as
To maintain the filtration capacity, High personnel and
process water at the waste water treatment plant. Thus it
financial expenditure for chemical cleaning must be con-
is no longer necessary to use groundwater for this purpose.
sidered.
In 2004, two more membrane installations for downFirst information on the treatment costs was acquired
stream tertiary waste water treatment have been commis-
with the help of semi-technical tests at Berliner Wasser-
sioned after preliminary tests at the Hailfingen waste water
betriebe. According to this information, in 1998 the spe-
treatment plant of the waste water union Bondorf-Hail-
cific total net costs for two different plant configurations
fingen and at the Merklingen waste water treatment plant
were between 0.25 euro/m2 and 0.42 euro/m2 of filtrate
of the municipality of Merklingen. They are described in
[DITTRICH ET AL 1998]. In comparison, the costs of con-
the following sections.
ventional processes, e.g. consisting of sand filtration and

subsequent UV treatment, are between 0.15 euro/m2 and
0.31 euro/m2 [DOHMANN 1997].
Table 2-24
Membrane installations for waste water disinfection in Germany
Operator
Amperverband
Municipality of Merklingen
Waste Water Union of
Bavaria
Baden-Wrttemberg
Baden-Wrttemberg
Geiselbullach WWTP
Merklingen WWTP
Bondorf-Hailfingen WWTP
250,000 PE
2,300 PE
9,000 PE
Bondorf-Hailfingen
Federal state
Installation
Capacity
Membrane manufactur
Modul typs
Process
Membrane surface area
Rochem
X-Flow
ZENON
cushion module
capillary module
capillary module
ultrafiltration
ultrafiltration
ultrafiltration
480 m2
420 m2
7.560 m2
153
UF
2.4.4.1
Geiselbullach Waste Water Treatment Plant

Up to now, groundwater has been used as process water at
ed in the outlet shaft of the waste water treatment plant,
the Geiselbullach waste water treatment plant. The conser-
which pumps the raw water into the storage tank of the
vation of this resource and closure of the process water
membrane installation. For pre-treatment, a filter with a
cycle, combined with a reduction of the waste water quan-
molecular separation size of 500 m and a flocculant
tity, were the reasons for further treatment of the effluent
dosing unit for iron(III) chloride sulphate is arranged up-
of the waste water treatment plant and its reuse as process
stream. The pretreated water is fed into the ultrafiltra-
water. Moreover, it was necessary to find an alternative to
tion installation. It consists of cushion modules from the
the use of groundwater for cooling of the district-heating
company Rochem with 480 m2 of membrane surface area
power stations because of continuous problems with the
in total, installed as cushion membranes in 60 pressure
development of coatings on the heat exchangers due to the
tubes (Figure 2-90). The permeate volume flow is approx.
iron and manganese concentrations in the water. The safe
(V = 60 m3). The storage serves to ensure a sufficient pro-
and hygienic quality of process water treated by a mem-
cess water quantity in order to cover the peak loads with
brane process, compared to UV disinfection, was the reason
up to 120 m3/h for some minutes. The specific energy
to decide on this technology.
consumption of the installation is indicated with 0.5 kWh

per m3 of treated process water [SCHILLING 2001].
After mechanical pretreatment, the waste water is treated

in the activated sludge stage which consists of a denitrifica-
The investment for the process water treatment plant was
tion zone, increased biological phosphorus removal and
410,000 euro. The specific operating costs amount to
a nitrification zone. A sand filtration unit is arranged
approx. 0.65 euro per m3 of treated process water. The
downstream of the final clarification (Figure 2-89).
installation was commissioned in July 2000. Start-up and

optimization of the process technology engineering covered the period up to the year 2002.
The raw water for process water treatment is withdrawn

after sand filtration by means of a submerged pump install-
Figure 2-89
Flow sheet of the Geiselbullach waste water treatment plant [according to AMPERVERBAND 2004]
Ringlace
cords
variable
anaerobic aerobic
anoxic
feed
screen
grit
chamber
primary
treatment
receiving
water
clarifier
sand filtration
flocculant
recirculation
storage
tank
sludge
excess
sludge
filter
process water for

cooling the CHP
154
ultrafiltration
Figure 2-90
Treatment installation at the Geiselbullach waste water treatment plant [photos: AMPERVERBAND 2002],
left: pressure tubes of the membrane installation, right: process water storage tank
UF
2.4.4.2
Merklingen Waste Water Treatment Plant

The Merklingen waste water treatment plant, designed for
Due to the special geological conditions of the Swabian
2,300 PE, is situated in the mountain region of Swabian
Jura, the treated waste water is discharged directly by an
Jura. In the case of dry weather flow, about 300 m of waste
infiltration shaft into the subsoil. The discharge location
water per day are treated. During wet weather flow, this
is situated in the zone III of a water protection zone, so
quantity may increase to 2,000 m /d.
that further treatment of the effluent became necessary.
Figure 2-91
Flow sheet of the Merklingen waste water treatment plant [according to RP TBINGEN 2004]
sand filter
nitrification
simultaneous denitrification
feed
screen
sand filter
clarifier
grit
chamber
storage
sludge
concentrate
membrane system
activated
carbon
permeat
storage
155
Since July 2004, part of the treated waste water from the
Following secondary clarification, one part of the waste
effluent of the plant has been treated by two different
water is treated by a slow sand filter, the other one by
process technologies (ultrafiltration and slow sand filtra-
ultrafiltration (Figure 2-92). The membrane installation
tion). An accompanying scientific program serves to com-
contains pressure-driven capillary membranes from the
pare both technologies for advanced waste water treat-
company X-flow with a molecular separation size of
ment with specific consideration of their capacity to re-
150 kD. The total membrane surface area in 12 pressure
move filterable solids, bacteria etc.
tubes is approx. 420 m2. The membranes are operated in

a dead-end process with inside-outside filtration. The maxi-
As presented in Figure 2-91, the waste water is fed into
mum specific filtration capacity has been calculated as

3
the activated sludge tank with a total volume of 366 m
60 L/m2 h.
after having passed a rake screen with a spacing of 5 mm

and a grit channel. Denitrification takes place simultane-
The investment for the ultrafiltration system was about
ously with nitrification, the sludge is aerobically stabilized.
530,000 euro. The state Baden-Wrttemberg has supported the installation with a subsidy of 70 %.
Figure 2-92
Pressure tubes of the ultrafiltration plant at the Merklingen waste water treatment plant [RP TBINGEN 2004]
156
2.4.4.3
UF
Bondorf-Hailfingen Waste Water Treatment Plant

The Bondorf-Hailfingen Waste Water Union was estab-
The treated waste water is discharged into the Kochhart-
lished in 1971 for the treatment of the waste water from
graben (Kochhart ditch). In summer, the flow of the Koch-
the Associated Municipalities Bondorf and of the district
hartgraben is very low or it carries water only downstream
Hailfingen of the city of Rottenburg on Neckar. In 1974
of the waste water treatment plant, respectively. In the
the mechanical-biological Bondorf-Hailfingen waste water
further course of the Kochhartgraben, the water infiltra-
treatment plant was built. From 1995 to 1999 it was up-
tes into the subsoil. The plant is situated in a water pro-
graded to achieve nitrogen elimination. Today the waste
tection area of the zone II a.
water treatment plant with a design capacity of 9,000 PE

is operated according to the activated sludge process with
Due to this special situation, the geological conditions
upstream denitrification, nitrification, biological phos-
and the need for groundwater protection, the water
phorus removal and aerobic sludge stabilization.
management authorities made special demands on the

effluent quality concerning phosphate content, filterable
The dry weather flow to the waste water treatment plant
solids and disinfection (Table 2-25).
is 36 L/s on average, the storm weather flow is 67 L/s.
Table 2-25
Demands on the effluent quality and operating values of the Bondorf-Hailfingen waste water treatment
plant [BONDORF-HAILFINGEN WASTE WATER UNION 2004]
Parameter
Unit
Effluent final clarification
Effluent membrane
Operating values
installation
Requirements
COD
mg/L
30
< 25
60
BOD5
mg/L
<4
15
NH4-N
mg/L
Ntot
mg/L
13
Ptot
mg/L
1.1
0.3
0.3*
Filterable solids
mg/L
15 - 30
n. n.
<5
bathing water quality
disinfection
Hygienics
* 24 h composite sampler
The plant is equipped with a mixing and compensating
in two lines, each equipped with membrane cassettes of
tank (V = 1.690 m3), a screen (6 mm spacing), a grit and
the type ZW 1000. The pore size of the membranes is
grease trap, activated sludge tanks (V = 2.330 m ) and two
0.02 m on average. The total membrane surface area of
secondary settling tanks with a total volume of 1,190 m3
approx. 6,700 m2 generates a permeate volume flow of
(Figure 2-93).
approx. 3,100 m3/d.
The positive results of the tests with three different mem-
The investment for the complete plant including build-
brane installations in July and August 2003 were the rea-
ing and civil engineering was about 1.25 million euro.
son for the construction of a large-scale membrane instal-
The state Baden-Wrttemberg supported the installation
lation with modules from the company ZENON which was
with a subsidy of approx. 50 %.
commissioned in December 2004. The installation is built
157
Figure 2-93
Flow sheet of the Bondorf-Hailfingen waste water treatment plant [according to BONDORF-HAILFINGEN
WASTE WATER UNION 2004]
mixing and
compensating tank
feed
bio-P deni-/nitrifikation tank

screen
membrane system
clarifier
receiving
water
clarifier
blower
installation
grit
chamber
recirculation
sludge
excess sludge
storage
Figure 2-94
Membrane installation at the Bondorf-Hailfingen waste water treatment plant under construction
[photos: BONDORF-HAILFINGEN WASTE WATER UNION 2004], left: building with membrane installation,
right: tank for membrane modules
158
2.4.5
UF
conventional activated sludge process with upstream de-
Large-Scale Applications Outside of Germany for
nitrification. The effluent values are compiled in Table 2-26.
Waste Water Disinfection by Ultrafiltration

The waste water treated by the Wulpen plant is fed via a
At present, few experiences exist in Germany with large-
channel into the ultrafiltration processing plant which
scale membrane filtration of the effluent of secondary
consists of mechanical pre-filtration, a five-line ultrafil-
treatment. However, some large-scale installations have
tration installation and a three-line reverse osmosis
been built worldwide, e.g. in the U.S.A., Great Britain
system with downstream UV disinfection (Figure 2-95).
and Australia [N.N. 2001; N.N. 1996; N.N. 1992]. Some

examples are described in the following sections.
The plant from the company ZENON has an average treatment capacity of 250 400 m3 permeate volume flow per
2.4.5.1
UF
hour. The ultrafiltration plant has five lines. 25 cassettes

of the type ZW 500c are installed which treat up to
Torreele, Belgium
9,000 m3 of waste water per day. One part of the treated

To ensure that groundwater is used as basis for drinking
waste water from ultrafiltration (about 10 %) is infiltrated,
water at the Belgian North Sea shore, the groundwater
the other part is further treated by reverse osmosis. The
must remain uninfluenced by seawater. For this purpose,
reverse osmosis membranes have been provided by the
a concept was developed in 2000 which comprises the
company Dow. The concentrate from the membrane
processing of treated waste water and subsequent infiltra-
stage is discharged into the sea via a brackish water chan-
tion into the dunes. This water serves for ground water
nel, approx. 90 % of the permeate is infiltrated.
recharge under the dunes and thus prevents the infiltration of salt water. After approx. 40 days of underground
The total investment of the processing plant was about
passage, it is reused as raw water for drinking water pre-
4.5 million euro. The energy demand for operation is
paration.
currently about 0.9 kWh per m3 of permeate [VAN

HOUTTE ET AL. 2004].
The treated waste water from the Wulpen plant is used as

feed water for this process. At the waste water treatment
plant Wulpen, the waste water is treated according to the
Table 2-26
Quality of the effluent of the Wulpen waste water treatment plant [ZENON GMBH 2004]
Parameter
Unit
Mean
Maximum
COD
mg/L
54
162
Cl
mg/L
340
1,140
Suspended solids
mg/L
19
Turbidity
NTU
11
TS
mg/L
1,130
1,950
159
Figure 2-95
Flow sheet of the Torreele treatment plant [according to ZENON GMBH 2004]
membrane stage
blower
installation
fine screen
NaOCl
10 %
outlet
storage
clarification
of WWTP
Wulpen
storage
fine screen
90 %
infiltration
UV-disinfection
storage
storage
reverse osmosis
160
pond
2.4.5.2
UF
Katowice Treatment Plant, Poland

In Katowice, the effluent from the Katowice waste water
The ultrafiltration plant consists of 18 cassettes of the
treatment plant is treated up to process water quality and
type ZW500 and prepares approx. 5,600 m3 of process
then used as cooling water for the Katowice power plant
water in total per day is processed, which is used as
situated at a distance of 12 km. The treatment takes place
additional cooling water for the cooling tower of the
with the help of a three-line ultrafiltration installation
Katowice power plant.
from the company ZENON (Figure 2-96). Table 2-27 shows

the waste water quality at the inlet and outlet of the membrane installation.
Table 2-27
Waste water quality at the inlet and outlet of the ultrafiltration installation for treatment of the effluent
of the Katowice WWTP after secondary clarification up to process water quality [ZENON GMBH 2004]
Parameter
Unit
Inlet
Outlet
COD
mg/L
35 - 51
27 - 34
BOD5
mg/L
2 - 32
< 2.0
Suspended solids
mg/L
6 - 32
< 1.0
Turbidity
NTU
10 - 50
< 0.1
Figure 2-96
Flow sheet of the ultrafiltration installation for process water treatment in Katowice
membrane system
blower
installation
power
station
feed
clarifier
blower
installation
additional
water
blower
installation
161
2.4.5.3
UF
Bedok Waste Water Treatment Plant, Singapore

The Bedok NEWater is the first of four planned plants
a first upgrade. Two expansions are already in the plan-
which treat waste water to meet the local industrial water
ning stage, so that the total capacity after completion
demand. The plant purifies the treated final effluent from
will be 117,000 m3/d.
a municipal waste water treatment plant. To ensure the

water quality for reuse of the waste water in industrial pro-
The filtrate is discharged by a pump at a low pressure of
duction, a decision was made In December 2001 on an
0.05 0.4 bar and fed into a reverse osmosis installation
overall process concept consisting of ultrafiltration,
for demineralization. Finally it is submitted to UV disin-
reverse osmosis and UV disinfection (Figure 2-97).
fection as a security measure. The concentrate is recycled

into the waste water treatment plant.
Figure 2-98 shows the waste water treatment plant with

The water produced according to the multi-barrier system
the buildings for ultrafiltration and reverse osmosis.
is called NEWater. It is used as process water for the

The treated effluent from the waste water treatment plant
electronic industry, for semiconductor manufacture and
flows through a 0.5-mm sieve and is then fed into the
also as cooling water for service buildings. A small per-
five-line ultrafiltration installation. To prevent the devel-
centage of the NEWater is also used for drinking water
opment of germs in the membrane tanks, chlorine is added.
preparation.
The installation is equipped with 70 capillary modules of

the type ZW 500c and has a capacity of 42,500 m3/d after
Figure 2-97
Flow sheet of the treatment plant [according to ZENON GMBH 2004]
ultrafiltration system
blower
installation
blower
installation
chlorine
outlet
fine sieve
0,5 mm
treatment
plant
blower
installation
concentrate to
WWTP
blower
installation
blower
installation
162
reverse osmosis
UVdisinfection
to industry
Figure 2-98
Figure 2-99
General view of the treatment plant [photo: ZENON GMBH 2004]
Ultrafiltration membrane installation

2.5
Example for the Design of a Membrane Bioreactor
2.5.1
Design Basis
The basis for the following calculation is the approach of the University
Group (HSG).
Design basis: Type of plant: simultaneous aerobic sludge stabilization
without pretreatment
Population equivalent
= 100,000 PE
specific waste water volume ws
= 130 L/(Ed)
Daily inflow Q d
= 19,500 m3/d
Sewer infiltration water flow Q f
= 6,500 m3/d
Combined water flow Q m
= 2.128 m3/h
Peak flow factor waste water x s
= 14
Pretreatment
= none
Fluctuation factor
= 1.70
Dry matter content in the activated sludge tank TSBB
= 12 g/L
alpha value
= 0.6
Resolubility factor (part of TKN in excess sludge) rX
=0
Sludge age t TS
= 25 d
Temperature in the activated sludge tank T
= 10 C
Simultaneous phosphate precipitation with Fe(III)Cl

The design of secondary settling tanks is not necessary for membrane
bioreactors.
163
A waste water treatment plant of the size class 5
Table 2-28
(> 100,000 PE) has to comply with the following
Design results according to the approach of the
monitoring values:
University Group (HSG) for a conventional waste

water treatment plant with TS BB = 12 g/l
Ninorg.
13 mg/l
NH4-N
10 mg/l
Ptot.
1 mg/l
Norg.
2 mg/l
V BB, conv, 12 g TS/L =
14.290 m3
V Nitri, conv, 12 g TS/L =
8.770 m3
V Deni, conv, 12 g TS/L =
5.520 m3
V Deni, conv, 12 g TS/L / VBB, konv, 12 g TS/L =
0.386
A printout of the calculation results of the activated

respond approximately with the dimension of the nitrifi-
sludge stage with the design program ARA-BER is enclosed

as chapter 2.5.4. Moreover, interim results are given in
cation zone (VDeni, MBR / VNitri, MBR = 1). The bigger of these
order to explain the progression of design (see Table 2-29).
volumes of the conventional design (VDeni, conv,12 g TS/L or

VNitri,conv, 12 g TS/L) has to be equated with the corresponding
2.5.2
volume of the membrane bioreactor, since a smaller nitri-
Interpretation of the ARA-BER Calculation
fication or denitrification volume of the membrane instal-
According to the Design Recommendations
lation (VDeni, MBR or VNitri, MBR) has to be included, compared
for Membrane Bioreactors
to a conventional design. To take special operating state

into account, a variable zone (Vvario) in the dimension of
The basis for the design of membrane bioreactors are the
30 50 % of the denitrification volume should be designed,
tank volumes determined for a conventional waste water
which can be arranged in the activated sludge tank ac-
treatment plant either according to ATV-DVWK-A 131 or
cording to the needs of operation.
to the approach of the University Group (HSG), considering already a TS content which is typical for membrane
Moreover, a minimum retention time thydraulic 6 h (with
bioreactors. The data determined for the exemplary in-
increased demands: thydraulic 8 h) has to be observed in
stallation are listed in Table 2-28.
the case of certain boundary conditions. It is possible to

undercut the recommended retention time if the volume
Due to the smaller reactor volume of membrane bioreac-
required to maintain the recommended retention time is
tors, undesired effects may occur, e.g. increased oxygen
bigger than the volume of the activated sludge tank of
carry-over from the nitrification or filtration zone into
the membrane installation, which in conventional design
the denitrification zone. To reduce these effects, the di-
has been determined with TSBB = 12 g/L and enlarged in
mension of the denitrification zone (VDeni, MBR) should cor-
addition by 50 %.
Table 2-29
Determination of the necessary volumes, taking into account different requirements for the design of
membrane installations
Requirements for MBR
V Deni, MBR : V Nitri, MBR = 1
Interim result
3
8,770 m > 5,520 m

=> 2 8,770 m
= 17,540 m
V MBR, tot. 1,5 VBB, conv, 12 g TS/l

t hydraulic 6 h
164
MBR
V BB, MBR
= 17,540 m3
V Nitri, MBR
= 8,770 m3
V Deni, MBR
= 8,770 m3
V BB, MBR
= 21,435 m3
V BB, MBR
= 8,357 m3
Here assumption: x Qmax = x S

=> x Qmax
= 14 h/d
=> Q critical load case
= Q d /x Qmax
After determination of the necessary volumes consider-
2.5.3
ing the different design criteria for membrane installa-
Design of the Membrane Filtration Stage
tions, the interim results are compared to determine the

decisive volume.
The surface areas of membrane filtration stages are designed according to the permeate flow.
The Table shows that for this example the resulting volume is bigger than the volume necessary to maintain the
The membrane modules available on the market at pre-
minimum retention time, considering the maximum
sent have a design flow (net flow) of 25 L/(m3 h) at 8 C.
volume allowance of 50 % for the volume of the activated sludge tank in conventional design (VBB, conv, 12 g TS/L).
At a design temperature of 10 C, the design flow may be
For this reason, the criterion VMBR, tot < 1,5* VBB,conv,12 g TS/L
increased by 15 % (" design flow = 28.75 L/(m3 h).
is not decisive in this case. Now it has to be examined

whether the nitrification or denitrification volume is suf-
Necessary membrane surface area for the example in-
ficient. Due to the criterion of maximum retention time,
stallation:
the required volume in this example is much smaller

than would be necessary for the compliance with the cri-
Necessary information:
terion VDeni, MBR / VNitri, MBR. Therefore the criterion of mini-
Design maximum flow Q m = 2,128 m3/h (in contrast to
mum retention time neither can be decisive for the design
the design of the reactor volume, the combined water
of the membrane installation.The volumes decisive for
flow is always decisive in the determination of the neces-
the example are listed in the following Table.
sary membrane surface area of municipal membrane bioreactors!)
of which
contained in it:
or:
VBB,MBR
VNitri,MBR
8,770 m3
VDeni,MBR
8,770 m
Vvario,30%
2,631 m3
Vvario,50%
17,540 m
4,385 m
Design specific flow of 28.75 L/(m3 h)

In addition, 1 % of the membrane surface area installed
must be maintained as reserve for cleaning measures (on
approx. 200 working days per year, 1 % of the surface area
In this case it is not possible to arrange compensating
is cleaned, i. e. the total membrane surface area is cleaned
volume because the total volume is required for the bio-
twice a year).
chemical processes. The resulting total retention time

with critical design inflow of Q critical load case = Q d/xQmax
3
= 1,393 m /h is 12.6 h.
From this results a necessary membrane surface area of

74,758 m3.
165
2.5.4
Printout of the Design Results with ARA-BER:
Waste water treatment plant:
membrane installation 100,000 PE
Type of installation:
simultaneous aerobic sludge stabilization
Total volume:
17,530 [m3]
Nitrification volume:
8,765
[m3]
Denitrification volume:
8,765
[m3]
VDeni / Vtot :
0.500
[-]
Design temperature:
10.0
[C]
Mean TS concentration:
12.00
[kg/m3]
Aerobic sludge age:
15.35
[d]
Total sludge age:
25.00
[d]
NH4-N (peak) (design value)
10.0
[mg/L]
NH4-N (mean) (design value)
2.0
[mg/L]
NO3-N (average) (design value)
6.6
[mg/L]
Dry weather flow Q t
1,199
[m3/h]
Combined water flow Q m
2,128
[m3/h]
Daily flow Q d
19,500 [m3/d]
Effluent values:
Backcharges:
BOD5
0.0
[kg/d]
TKN
0.0
[kg/d]
Ptot.
0.0
[kg/d]
Part of TKN in excess sludge = rX
0.00
[-]
TKN backcharge from rX
0.0
[kg/d]
Precipitation with:
iron(III) salt
Precipitant dosage
17.42
[g/m3]
Attainable P effluent value
1.00
[mg/L]
No calculation of secondary settling tanks
166
Membrane Technology in
Industrial Waste Water Treatment
3.1
Brief Overview
The application of membrane processes in industry has
The following chapter deals with the use of membrane
its origin in the field of production, with most references
technology in industrial waste water treatment. Motives,
in the beverage industry and in the pharmaceutical in-
objectives and decision criteria for the use of membrane
dustry and for the production of ultra-pure water [BROCK-
technology are discussed, cost-benefit analyses are made,
MANN 1998]. Due to rising costs for process water and
and successful examples from practice are briefly described.
for waste water discharge as well as increasing environmental awareness in industry, membrane processes are
Figure 3-1 on the next page shows the contents of the
now used more frequently for the treatment of industrial
chapter. It presents the most important steps from the
waste water.
motives and planning stage to the operation of a membrane installation. With the help of references to page
In industrial production, waste water is often produced
numbers and short check lists the reader is able to focus
discontinuously and its composition may vary signifi-
on individual sections of the chapter according to his
cantly. Joint treatment of high-strength industrial waste
interest.
water in municipal waste water treatment plants gives

rise to problems, especially when the treatment efficiency
For successful operation of a membrane installation,
of the municipal plant is limited or its biological treat-
detailed planning and pilot-scale testing by specialists is
ment capacity is not sufficient. In these cases separate
necessary, taking into account the existing boundary
treatment or pretreatment of industrial waste water is
conditions. Therefore the annex contains a list of con-
required for which membrane processes, as process- and
tacts for concrete planning intentions.
production-integrated measures, can make an important

contribution.
168
Figure 3-1
Motive planning operation of a membrane installation,
overview of the contents of the chapter Membrane technology in industrial waste water treatment
Procedure
Examples
p. 288
Information
Reduction of costs
Motive
Compliance with the standards
Objective
p. 170 ff.
p. 288
Incoming material flows
Effizienz-Agentur NRW
Outgoing material flows
PIUS-Check
Analysis of the actual situation
p. 279 f.
Independent consultants
p. 172
p. 288
Selection of
processes
Economic analysis
Membrane technology
...
Comparison of processes
Cost-benefit relation
p. 280 ff.
p. 172
p. 289
Preliminary tests
Consultants
Industrials
Plant manufacturers
Cleaning agent producer
Membrane producer
Laboratory tests
Planning and
pilot-scale testing
Choice of membranes
p. 174
p. 289
p. 174 ff.
Separation processes
...
Operator model
p. 174
p. 177
p. 270 ff.
Concrete examples
p. 177 ff.
Owner-operated enterprise
Operation and control
Internet portal
www.pius-info.de
p. 280 ff.
169
3.2
Objectives and Applications in Different Industrial
Branches
Membrane processes in industrial waste water treatment
can be arranged downstream of or integrated into the
separation of reusable material, auxiliary agents, byproducts and solvents directly at the source of origin
production process. Besides compliance with legal

standards (for discharge into public sewer systems or
recirculation of partial flows
into water bodies), this technology is also used for economic reasons (Figure 3-2). Typical objectives for the appli-
avoidance of large high-strength waste water flows
cation of membrane technology in industry include:

reuse of the concentrates as raw material or as secondary
raw material, or low-cost discharge
Figure 3-2
Objectives and economic interests for the use of a membrane installation in industrial waste water treatment
Avoidance of waste water
Optimization of treatment
processes
Closure of circulation systems

Recycling of process water from
waste water
Utilization of processes for compliance with effluent standards

Improvement of effluent parameters
Reduction of space or volume

requirements for waste water
treatment
Protections of sites
Objectives
Economic interests
170
Recovery of reusable material
Minimization of discharge costs
Reutilization of biomass
For reutilization in the production

process
As secondary raw material for
processing
For marketing
By production of pure material (e.g.

non-polluted water or solvents)
By concentration of pollutants
By separation in the production in

biotechnical processes
In biological waste water treatment
by recycling into the aeration reactor
Table 3-1
Objectives for the utilization of membrane technology in industrial waste water treatment
Industrial branch
Examples of objectives
Food industry
Treatment of waste water for use as process water

Higher protein output (potato starch production)
Tanneries
Separation of precipitated heavy metals from waste water and reuse as recycling water
Paper mills
Compliance with effluent standards

Fibre industry (e. g. vulcanized fibre)
Recovery of reusable material (ZnCl2)

Process water treatment
Textile industry
Recovery of size baths and indigo dyes

Separation of colour pigments
Plastics industry
Separation of softeners and reuse of the treated waste water as process water
Laundries
Treatment of the waste water and reuse as process water
Metal industry, electroplating
Separation of oil and emulsions [DRIESEN ET AL. 1998] and recycling

Recovery of scouring baths
Treatment of rinsing water
Printers, paint shops
Recovery of coloured pigments

Separation and concentration of mixed pigments to reduce the discharge costs
Car production
Process water treatment

Recovery of coloured pigments
Petrochemical industry
Treatment of reaction- and washing water [THEILEN 2000]
Power stations
Treatment of boiler feed water [THEILEN 2000]
Mining industry
Treatment of mine water and radioactive surface water [THEILEN 2000]
Navigation
Separation of oil and emulsions
Various branches, e. g. tanneries, breweries,
Biological waste water treatment using ultrafiltration and microfiltration processes for biomass
paper and textile industry
separation (membrane bioreactor process)
These process objectives may lead directly to cost-saving,
The treatment of small specific volume flows may also
e. g. by
be profitable in cases where reusable material is saved or

recovered. Various objectives for the use of membrane
reduction of the waste water load and possible reduction

of waste water levies for indirect dischargers or the waste
technology in industrial waste water treatment are summarized in Table 3-1.
water charge for direct dischargers,

savings of water and reusable material, if e. g. process
water is recycled or recovered.
171
3.3
Decision Criteria
Due to continuously rising costs for drinking- and pro-
Each planning phase comprises other detailed decision
cess water as well as for waste water discharge together
criteria which should be examined individually and coor-
with increasing environmental awareness, industrial en-
dinated by the entrepreneur together with the membrane-
terprises more and more frequently implement internal
and plant manufacturer. As a rule, existing knowledge
measures to minimize the waste water load and quantity.
about the waste water to be treated should be used, and

tests on different scales are imperative.
Such internal measures can be realized by using various

processes and process combinations. The choice of a
Table 3-2 summarizes the working steps which can be
technically and economically suitable process requires
carried out on the different scales. Careful planning is

critical for successful operation of each membrane instal-
structured analysis of the existing conditions and

clear definition of the objective.
Figure 3-3 shows the methods and criteria of decisionmaking for the selection of a suitable process. Since
membrane technology in industrial waste water treatment is the focus of attention, the decision tree presents
two alternatives membrane technique or alternative
processes from which only membrane technology is
studied in more detail.
Prerequisite for the selection of a successfully and economical membrane process is a comprehensive analysis of
the production processes, the water used and the waste
water produced. If after first assessment of the boundary
conditions the use of membrane technology proves to be
technically feasible in an enterprise, an adequate installation can be planned. Planning has to be carried out
step by step, so that the final result will be adapted
most favourably to the separation problem. The planning
stages for the realization of a large-scale installation are
presented in the flow sheet (Figure 3-3).
172
lation.
Figure 3-3
How to proceed in the planning of an installation for industrial waste water treatment
identification of the flow(s) to be treated
realization of
measures
avoidance or reduction
possible?
yes
no
terms of reference/objective
separation of
separation of
reusable material substance mixture
production of
process water
separation of
biomass
raw water
quality (physical and chemical)
reusable and hazardous material
quantity produced
quality requirements
boundary conditions
possibilities for reuse
concept of treatment strategy
hydraulic efficiency
under certain
circumstances
membrane technique
possible ?
no
alternative
processes
yes
pretreatment/
combination with other processes
draft of the flow sheet
identification of
membrane material
assessment of membrane
performance
is the process
expected to be profitable?
no
yes
choice of membrane (membrane material, membrane geometry)
preliminary tests (laboratory)

no
energy costs
membrane replacement
cleaning agents
number of cleanings
staff/service
positive test results ?

yes
choice of module
no
economic optimization
operating costs
overall economic efficiency
pilot tests
technical optimization
module form
pretreatment
hydraulic conditions
technically
optimized ?
economically
optimized ?
yes
yes
no
costs
investments
operating costs
benefit
recovery of reusable material
saving of discharge costs
saving of water and waste
water costs
large-scale installation
filtrate performance
retention rates
development of covering layer
economic efficiency
control of operation
cleaning and backwashing

intervals
pressure conditions
173
Table 3-2
Sequence of planning for a membrane installation [according to THEILEN 2000; PETERS 2001]
Scale
Working steps
Laboratory
Complete analysis of the waste water to be treated

Choice of the membrane in a test cell installation
Approximate determination of the most important process-engineering parameters such as transmembrane pressure and flow velocity
First tests on membrane cleaning
Pilot scale
Operation of a pilot installation:

Choice and test of the modules, module connection
Process optimization
On-site under operating conditions:
Cleaning intervals and demand for chemicals
Energy demand
Product quality in continuous operation
Analysis of the test results

Design of the installation
Analysis of economic efficiency
Large-scale installation
Control and optimization

of the operating parameters
of the energy demand
Determination of the overall efficiency (cost-benefit relation)
3.4
examples contain information about investments and
Economic Efficiency of Membrane Installations
operating costs as well as the resulting amortization period,
in Industrial Waste Water Treatment
as far as these data are accessible to the general public.

These indications only apply to the individual case. In
An important decision criterion for the choice of a waste
general, transfer to other installations of the same type is
water treatment process is its economic efficiency. It can
not possible because the specific boundary conditions
be assessed, for example, with the help of a cost-benefit
(e. g. production process and techniques) influence the
analysis and requires knowledge or estimation of the
costs in a significant way.
costs and the resulting benefits.

Due to some important factors of influence on costs and
From the examples in chapters 3.5 and 3.6 it is clear that
economic efficiency (Figure 3-4) of a membrane installa-
membrane technology (membrane processes and mem-
tion, this chapter can give only qualitative information
brane bioreactors) is used in most different industrial
on the costs. These factors are explained below.
branches for the treatment of waste water. These concrete
174
End use, or tasks and objectives
differ, even for enterprises of the same branch. It is not

useful to give numerical values because this might lead
Membrane installations are designed for a specific task

or treatment objective. In many cases, treatment beyond
to inaccurate assessment of the economic efficiency of

a membrane installation.
this objective is possible, but often involves additional

The cost-benefit relation of a membrane installation
costs.
may be positive or negative, depending on a large number of boundary conditions. These are for example the
Boundary conditions
water and waste water charges, the design capacity, pos The waste water characteristic determines the required
sibilities and costs for waste disposal, etc. More exam-
investment and operating costs of a membrane installa-
ples for boundary conditions influencing the costs are
tion. The waste water treatment costs may significantly
presented in.
Figure 3-4
Factors influencing the economic efficiency of membrane installations
tasks/objectives
boundary conditions
location
quality
requirement
waste water
quantity
hydraulic
efficiency
energy costs
waste water
charges
freshwater
price
...
planning and pilot tests

membrane bioreactor
membrane process
investments
operating costs
membrane material
membrane surface
module form
peripherical
equipment
operating mode
annual operating
period
energy demand
cleaning
cleaning agent
cleaning interval
membrane replacement
discharge costs
personal maintenance
insurance
costs for the building
benefit
protection of the plant location
compliance with limit values
reduction of waste water charges
reduction of discharge costs
recirculation
175
Planning, pilot tests and choice of the membrane
field of membrane technology (membranes, modules,
process
energy demand, etc.) the costs for the different materials

and modules will also change. With view to the product
Since each industrial enterprise produces a specific

waste water, a detailed planning and pilot test phase is
and market development, it is expected that the prices

for membranes in general will decrease.
necessary to examine the possible use of a membrane

process and to assess the costs. The expense for pilot
To ensure profitability of a membrane installation, full
tests, which may vary considerably, also belongs to the
use of the membrane surface by an optimal operating
costs for a membrane installation. Detailed planning
mode is essential because the costs rise with increasing
and comprehensive pilot tests contribute to avoiding
membrane surface area. However, doubling of the mem-
uneconomical design of the installation, to recognize
brane surface area does not result in a doubling of the
possible operating problems and to counteract them in
costs, since the expense for peripheral equipment of the
advance by corresponding design and operative
installation, such as measurement and control technique,
management.
has larger impact on smaller installations [e. G. VOSSENKAUL, MELIN 2001].
The type of the membrane process has an effect on the

investments and the operating costs. The membrane
The operating costs comprise several components. An
bioreactor has been assessed since 1997 as an economic
important component is the energy cost which depends
treatment process for concentrated waste water, e. g.
on the annual operating period and the operating mode
some industrial waste waters [ROSENWINKEL ET AL.
(cross-flow or dead-end). The energy demand of installa-
1997], while up to now this is true only to a limited
tions working in dead-end mode is lower than that of
extent for municipal waste water applications.
installations operated in classical cross-flow mode.
For each plant, investments and operating costs have to
Depending on each single case, the costs for membrane
be distinguished. Both categories can be subdivided into
cleaning must not be neglected. Optimized cleaning
more individual factors.
methods (chemicals, cleaning intervals) contribute to

minimize these costs and possibly extend the service life
The amount of investments depends among others
of the membranes. The longer the service life of the mem-
on the membrane material, i. e. the module costs, and
branes, the lower the costs for membrane replacement.
the membrane surface area installed. This is especially
The service life of membranes may significantly vary de-
true for large installations. Membrane material, surface
pending on the membrane material, waste water compo-
and form are chosen for the individual case considering a
sition, pretreatment, operating period and operating mode
number of criteria. STROH ET AL. [1997] compared for
(chapters 3.5 and 3.6, Concrete examples). In some cases
two applications clarification of fruit juice and oil/water-
(e. g. treatment of landfill leachate), service lives of five
emulsion filtration the amount of investment and ope-
years and more are standard.
rating costs resulting from the use of polymer and ceramic membranes. It turned out that the investment and
Moreover, the operating costs also include the discharge
the power demand for ceramic membranes are higher,
costs, insurance, personnel and maintenance costs. Per-
but that the costs for replacement of the membranes at
sonnel and maintenance costs are assessed in most cases
the same time are lower because of their longer service
as flat rate in percent of the investment costs, but they
life. Related to a cubic meter of filtrate, the use of cera-
also depend on the size of the installation. For example,
mic membranes may be more favourable in one case,
a study of the economic efficiency of installations for
while the use of polymer membranes is more favourable
sludge water treatment has shown that this value as a rule
in another one. The authors therefore emphasize that
should be corrected: for small installations it is higher, for
without exact relation to a concrete case, only general
large installations it is lower [VOSSENKAUL ET AL. 2000].
assessment is possible. With further developments in the
176
The breakdown of investments and operating costs is not
All examples described in the following sections are com-
necessary for the user of an installation run according to
piled in Table 3-3. The addresses of the companies and
an operator model, e. g. BOO (Build-Own-Operate).
enterprises are listed in the annex.
With this accounting method, the user of the installation

reimburses the quantity of treated waste water according
Statements on the total economic efficiency of the pro-
to a volume-specific price which already includes all costs
cesses described are made for the following concrete ex-
of waste water treatment.
amples as far as information was available. For the total

economic efficiency of a membrane installation, besides
The expenditure for a membrane installation is always
the construction, the choice of the operating parameters
seen in relation to the benefit and the savings expected.
is decisive above all and which can be optimized in detail
The benefit may consist of the protection of the enter-
only when the installation is finished. Since some of the
prise location, compliance with limit values or the reduc-
examples described are rather new or in planning stage,
tion of waste water charges and discharge costs. Savings
only limited operating experience exists for some of the
can be made by recirculation (recycling of process water
installations, especially concerning the service life of the
or recovery of reusable material). In some cases these
membranes. Only after a longer practical operating peri-
savings are very high, so that the membrane installation
od, experience will show how successful and economic
is amortized after a rather short time. But the amount of
membrane processes are in each single case.
savings compared to the expenditure and the amortization time to be expected have to be examined for each
The installations described are examples for large-scale
single case.
realization of the membrane process. Normally they cannot be transferred as a standard solution to another enter-
3.5
prise of the same industrial branch. The employment of
Sample Applications of Plants in Germany
membrane technology has to be examined for each single case concerning technical feasibility as well as econo-
In the following subsections the employment of different
mic efficiency.
membrane processes in various industrial branches in

Germany is presented with the help of exemplary installations which have been built on industrial scale and are
operating successfully or a in planning stage. Some of
these installations have been realized with the financial
backing of the Ministry for Environment and Nature
Conservation, Agriculture and Consumer Protection of
the federal state North Rhine-Westphalia (MUNLV NRW).
Examples from international practice are described in the
subsections of chapter 3.6.
Diverging from the sorting of the installations for municipal applications (see chapter 2.2), the examples are
sorted according to their use in industrial branches,
because combinations of different membrane processes
are also used in industrial waste water treatment. A short
introduction into the respective industrial branch precedes the description of the example installations. As introductory overview for each concrete example, the membrane process applied, the objectives attained or the
benefit of the installation are indicated.
177
Table 3-3
Sample applications for the use of membrane technology in industrial waste water treatment in Germany
Branch of
Company
Location
Start-up
industry
Potato starch
Membrane
Modules
Membrane
Chapter
surface area m2
process
Emsland Strke
Emlichheim
1997
RO
Tube modules
5,000
3.5.1.1
Durst Malz -
Gernsheim
1997
RO
Spiral-wound
1,333
3.5.1.2.1
industry
Malthouses
H. Durst Malz-
modules
fabriken
Food industry
Beeck Feinkost
Hamburg
1994
UF
Tube modules
100
3.5.1.3
Printing industry
Peter Leis
Solms
1998
UF
Ceramic tube
2.4
3.5.2
Paper mill
Paper mill Palm
Eltmann
1999
NF
15,000
3.5.3.1
Textile industry
Drews Meerane
Meerane
2001
UF
2,200
3.5.4.1
Textile industry
Silk weaving
Mhltroff
2004
MF
Plate modules
320
3.5.4.2
Gerhard van
Hamminkeln-
UF/NF/RO: 1997
MF/UF/
MF: tube modules
MF: 225
3.5.4.3
Clewe
Dingden
MF: 2001
NF/RO
UF: ceramic
UF/NF/RO: no
tube modules
information
modules
Spiral-wound
module
Immersed capillary modules
mill Pongs
Textile industry
NF/RO: spiralwound modules

Fibre industry
Vulcanized fibre
Geldern
1997
RO
312
3.5.5
38
3.5.6
UF: tube module
UF: 44
3.5.7.1
NF: spiral-wound
NF: 180
Spiral-wound
modules
Plastics industry
Troplast
Troisdorf
1998
UF
Ceramic tube
modules
Laundry
Laundry Alsco
Kaiserslautern
2000
UF/NF
module
Laundry
Textil Service
Gro Kienitz
1998
UF/NF
Mewa
UF: ceramic
UF: 60
tube modules
NF: 135
3.5.7.2
NF: spiralwound modules

Metal proces-
Rasselstein
sing industry
Hoesch GmbH
Metal proces-
Faurecia, Bert-
sing industry
rand Faure Sitz-
Andernach
1999
UF
Ceramic tube
Stadthagen
2000
UF
Flat membranes
1993
Membrane
2 cells per dialy-
electrolysis
sator
UF
Capillary modu-
4.56
3.5.8.1
modules
3.5.8.2
technik
Metal proces-
Electroplating
Bielefeld-Senne-
sing industry
Enterprise
stadt
1.1
3.5.8.3
44
3.5.8.1
Rudolf Jatzke
Metal processing industry
178
Wieland Werke
Langenberg
1998
les
Table 3-3
Sample applications for the use of membrane technology in industrial waste water treatment in Germany
Branch of
Company
Location
Start-up
industry
Treatment of
Membrane
Modules
Membrane
Chapter
surface area m2
process
DaimlerChrysler
Dsseldorf
1998
UF
Plate modules
30
3.5.9.1
Ford Werk
Kln
2001
NF
no information
no information
3.5.9.2
Schering
Bergkamen
2003
UF
Capillary modu-
15,840
3.5.10
460
3.5.11.1.1
waste water
from car painting
Treatment of
waste water
from car painting
Pharmaceutical
industry
Landfill leachate
les
Alsdorf-Warden
Alsdorf
1999
RO
landfill
Fish hatchery
Pilot installation
Power plants
GuD Dresden
Disc-tube
modules
Dresden
2004
MF
Plate modules
21
3.5.11.2
1996
UF
Ceramic multich-
15.2
3.5.11.3
1989
UF
Tube modules
23.6
3.5.11.4
1998
UF/RO
UF: capillary
UF: 42
3.5.11.5.1
modules
RO: 140
annel elements
De-oiling of bilge
water
Swimming pool
Aquana Freizeit-
Wrselen
bad
RO: spiralwound modules

Swimming pool
Freizeitbad
Herten
1998
Copa Ca Backum
UF
Hollow-fibre
300
3.5.11.5.2
modules
3.5.1
Food Industry
The generic term food industry is comprised of a large
Besides waste water treatment, membrane technology is
number of branches, such as the milk or meat processing
also used in the food industry for other purposes, such as
industry, processing of vegetables, finished products, the
concentration (e. g. of juice, milk, whey, egg whites), fil-
beverage industry etc. Correspondingly, the waste waters
tration (e. g. of juice, wine, beer) and alcohol removal
of the individual branches vary in their composition.
from beer. The alcohol fraction resulting from alcohol
They have in common only high organic loads.
removal is a suitable substrate for denitrification in waste

water treatment (as a methanol substitute).
In the following the use of membrane technology for the

treatment of waste water from the food industry is described
for three branches potato starch production, delicatessen
production and malt production and presented with
the help of concrete examples.
179
3.5.1.1
Potato Starch Production
In the Federal Republic of Germany, starch is produced
Potato starch is only produced only during a certain sea-
from maize, potatoes, wheat and rice. Of these raw mate-
son. The Fertilizer Ordinance (1996) dictates the storage
rials the potato has the highest water content. For starch
of potato pulp and irrigation water between 15th Novem-
production, the potatoes are carefully prewashed and then
ber and 15th January (even longer in the case of frost)
ground, separated from the pulp water (0,76 m of pulp
and limits the application in autumn to a maximum of
water per ton of potatoes) and washed out. The starch is
80 kg Ntot/ha.
produced from the ground potatoes, and the pulp water

is generally used to produce potato protein (Figure 3-5).
The concentration of the pulp water and closing of the
The residual pulp water is used for irrigation of farmland
internal water cycle are suitable measures to manage the
or evaporated. Potato pulp, which contains fine-ground
production limitations defined above. This can be obtained
peelings, cell walls, starch residues and pulp water, is de-
with the help of different procedures (e. g. membrane
watered. In Germany and the Benelux Countries, potato
technology).
pulp has been used for many years as fodder for dairy
cattle and young stock, and also partly for fat stock.
The entire production process results in sweeping and
washing water, pulp water and starch washing water. The
amount of washing water is about 1.8 to 2.8 m3 per ton
of starch. Characteristic constituents are potato pulp
water ingredients, fibres and mineral components (earth,
sand etc.).
Figure 3-5
Flow chart of potato starch production
starch
potatoes
grater
fractionation (wet procedure)
fibres
potato pulp water
protein precipitation
potato protein
soluble matter
potato pulp
180
RO
3.5.1.1.1
Food Industry, Emsland Strke GmbH

Membrane process
Reverse osmosis
Start-up
1997
Objectives
Reduction of the waste water- and drinking water volume, higher protein yield
Membrane surface
5,000 m2
Modules
Tube modules
Permeate volume flow
62 m3/h
Pretreatment
Separation of fibres and pulp water
Benefit
Savings of energy, water, waste water, at the same time higher protein yield
The company Emsland Strke GmbH is the most impor-
In 1997, a reverse osmosis installation from the com-
tant producer of potato starch in Germany and is one of
pany Stork was commissioned in the Emlichheim plant
the worlds leading manufacturers of finished starch pro-
in order to reduce the quantity of waste water to be
ducts, potato protein, amino acids and sugar products
disposed of, to conserve drinking water and to recover
such as glucose syrup. The parent plant in Emlichheim,
more protein. The potato pulp water from starch produc-
established in 1928, has 405 employees. For the produc-
tion is separated in the cross-flow mode at an operating
tion of potato starch, starch derivates and potato protein,
pressure of 40 bar. Tube modules with a total membrane
water with drinking water quality is used and ultimately
surface area of 5,000 m2 filter a feed volume flow of
disposed of as waste water (sweeping and washing water,
140 m3/h. With daily backwashing and cleaning with
derivate waste water).
commercial enzymatic cleaning agents, the service life of

the membranes is about 6,000 hours. During the production campaign (about 120 days per year), the installation
works 24 hours per day, so that the membranes have to
be replaced after approx. two campaigns.
Figure 3-6
Flow chart of the treatment of process- and potato pulp water at Emsland Strke GmbH
[according to LOTZ 2000]
potatoes
fibres
water supply
fertilizer
feed
molasses
treatment
starch factory
potato pulp
water
process water
evaporation
reverse osmosis
potato pulp
permeate for
potato washing
brine
protein production
potato protein
fumes condensate
waste water
excess
treatment plant
for fumes condensate
receiving water
process waste water
181
The permeate (about 62 m3/h) from the reverse osmosis
3.5.1.2
system is used to wash the potatoes, while potato protein
Malt Houses
is produced from the brine. The remaining potato pulp

water is evaporated. The vapour condensates are fed to a
Malt is used as a raw material to produce alcohol from
dedicated waste water treatment plant and recycled after
starch-containing materials. Today a large number of brew-
further treatment at drinking water quality into the pro-
eries get malt from commercial malthouses which pre-
duction process (see also Figure 3-6).
dominantly use barley (about 2.5 million tons per year

[GUTSCH, HEIDENREICH 2001]) and partly wheat for
Thanks to the closed water cycle, more than 500,000 m3

3
malt production. The malt production process can be
of water are saved per year (250,000 m of washing water
broadly subdivided into the steps cleaning, soaking, ger-
by the permeate of the reverse osmosis installation and
minating and kiln-drying [KRAFT, MENDE 1997]. Due to
more than 250,000 m by closing the cycle with the vapour
high water consumption for washing and soaking, malt-
condensates). Other advantages of the membrane instal-
houses have to pay high costs for freshwater and waste
lation are a drastic reduction in the waste water volume
water disposal [GUTSCH, HEIDENREICH 2001].
and a higher protein yield.

For waste water whose pollution load comes mainly from
the production of malt from cereals and which is discharged directly into a receiving water, the limit values
according to Appendix 21 of the Waste Water Ordinance
[ABWV 2002] are valid. Depending on the production
process applied, the waste water quantities and concentrations may vary significantly from one malthouse to
the other. Waste water constituents include suspended
substances (dust, earthy constituents, residues from cereals and husks), sugar, nitrogen-containing substances
(soluble proteins, vegetable fibrin), inorganic matter, and
possibly rubber and polyphenols.
For the treatment of malthouse waste water, membrane
technology can be used in various combinations which
have to be adapted to the specific case. Besides the example described below, treatment by microfiltration in lowpressure operation combined with a biological stage and
a closed process water cycle is also possible [KRAFT,
MENDE 1997].
182
3.5.1.2.1
RO
Malthouse Durst Malz

H. Durst Malzfabriken GmbH & Co. KG
Membrane process
Reverse osmosis
Start-up
1997
Objectives
Reduction of waste water quantities and costs
1,333 m2
Modules
about 470 m3/d
Pretreatment
Biological treatment (SBR), precipitation
Benefit
Savings of freshwater and cost reduction in waste water treatment and disposal
The Heidelsheim company H. Durst Malzfabriken GmbH
all undesirable malting residues from the water at an
& Co. KG is specialized in malt production for Pilsner
operating pressure of approx. 10 bar. The permeate com-
beer, but also furnishes special malt for other types of
plies with the requirements of the Drinking Water Ordi-
brewing. 25 people are employed in the works in Gerns-
nance and is recycled into the barley soaking process.
heim, one of the four plants which combined produce
The remaining brine (about 25 30 % of the total inflow
about 230,000 tons of malt per year.
to the membrane installation) is treated in the municipal

waste water treatment plant. In order to ensure the opera-
Large waste water quantities and disposal costs were the
tion of the spiral-wound modules, an antiscaling agent is
motives for Durst Malz to cooperate with Schwander GmbH
used and the modules are backwashed daily with citric
at Bad Vilbel, which together with Frings Recycling-Anla-
acid.
gen GmbH (today: imb+frings watersystems gmbh) developed the patented FriSch-Verfahren (FriSch process)
The employment of the membrane installation led to a
for the treatment of process water in the malt and bever-
reduction in the water demand and to considerable cost
age industry.
savings concerning the waste water surcharge. Another

advantage is the modular construction of the installation,
Promoted by Hessische Landes- und Treuhandgesellschaft
as it can be adapted without causing problems to varying
(HLT) Wiesbaden, today Investbank Hessen (IBH), an in-
production parameters.
stallation for the treatment of the malthouse waste water

was commissioned in 1997 at Gernsheim (Figure 3-7).
3
Figure 3-7
Since that time a daily amount of 700 m of water, con-
Reverse osmosis installation at Durst Malzfabriken
sisting of the barley soaking water and the washing water
GmbH & Co. KG, Gernsheim [LINDEMANN 2001]
of the production plants, is treated.

The malthouse waste water has a high COD content of
approx. 2,500 to 3,000 mg/l. By biological (SBR process1))
and physical-chemical (ferric chloride precipitation)
treatment, followed by fine filtration, this concentration is
reduced to 30 mg/l in the influent to the reverse osmosis
installation. Subsequently, spiral-wound modules in the
reverse osmosis installation (imb+frings watersystems
gmbh) with a total filter surface area of 1,333 m2 remove
1)
SBR process: Sequencing-Batch-Reactor process. All phases of the treatment process run in succession in one reactor.
183
UF
3.5.1.3
Food Industry
BEECK Feinkost GmbH & Co. KG
Membrane process
Ultrafiltration
Start-up
1994
Objectives
Comply with the COD limit values and reduce the waste water fees (surcharge for heavy polluters)
100 m2
Modules
Tube modules
Depending on the production, 3.5 6 m3/h
Pretreatment
Prefiltration
Benefit
Saving of waste water fees
The company BEECK Feinkost GmbH & Co. KG produces
ficient to comply with the COD discharge limit, and a sur-
delicatessen and salad dressings. More than 200 people
charge for excess COD concentrations was paid by the
are employed at the site in Hamburg.
plant.
Tanks and equipment used in the preparation of delicates-
In order to reduce the waste water fees, an ultrafiltration
sen and salad dressings, tanks and equipment are regular-
installation from the company KOCH-GLITSCH GmbH
ly cleaned using water and cleaning agents. During this
was commissioned in 1994. First of all, the solids are se-
process solids as well as emulsified fats and oils get into
parated by prefiltration from the waste water (Figure 3-8).
the waste water and give rise to high COD concentrations.
The prefiltered water is fed to a tank from which the ultra-
Treatment of the waste water by a grease trap was not suf-
filtration installation is charged. The installation is equipped
Figure 3-8
Flow chart of the waste water treatment at BEECK Feinkost GmbH [according to KOCH-GLITSCH GMBH 2001]
waste water
recirculation
after disconnection
of the inflow
100 %
pump shaft
tank
80 m3
concentrate
ultrafiltration
prefiltration
concentrate
particles
collecting tank
disposal
1%
sewer system
99 %
measuring/
monitoring
184
filtrate
neutralisation
with tube modules made of PVDF 2) membranes with a
The membranes are cleaned chemically once a week.
molecular separation size of 250,000 Dalton (KOCH-
With this operating mode, the service life amounts to
GLITSCH GmbH), which are operated in cross-flow mode.
4 5 years.
About 3.5 to 6 m of waste water per hour (depending on

the production) are filtered by 100 m2 of membrane sur-
The installation has not only ecological advantages, but
face area at an operating pressure of max. 6.2 bar.
is also profitable: By saving the surcharge for heavy polluters, the investment for the installation is amortized
Depending on the production, the inflow to the tank is
after three years.
closed so that the waste water is further concentrated by

recycling it to the ultrafiltration installation. The concentrate (1 % of the inflow) is disposed of, while the filtrate
(99 % of the inflow) is neutralized and discharged into
the sewer system.
2)
polyvinylidene fluoride
3.5.2
UF
Printing Industry, Peter Leis
Membrane process
Ultrafiltration
Start-up
Autumn 1998
Objectives
To manufacture a reusable product from polluted adsorption oils
2.4 m2
Modules
Ceramic tube modules
30 L/h
Pretreatment
Micro-settlement filtration to remove coarse matter, oil separator
Benefit
Saving of waste water disposal costs and new adsorption oils
The Grafische Handelsvertretung Peter Leis (graphical com-
ticles and paper dust. The system consists of a micro-sett-
mercial agency) at Solms, with five employees, supplies
ling filtration step to remove coarse matter, an oil separator
printers with print drums and chemicals, e. g. cleaning
and an ultrafiltration process to purify the oil phase.
oils for printing machines.
Ceramic tube modules (from the company Tami) with a

total membrane surface area of 2.4 m2 produce about 30 L
One of the services of the company consists of voluntary
permeate per hour at an operating pressure of approx. 3 bar.
return of used adsorption oils from its clients. Therefore
On average, the ultrafiltration installation (Figure 3-9)
a procedure has been developed which serves to convert
works 6 to 8 hours per day. Cleaning of the membranes
the polluted adsorption oils into a valuable reusable pro-
by removal and burning out becomes necessary after a
duct. This was done in cooperation with the companies
throughput of approx. 5,000 L. The service life of the
CARO Umwelttechnik GmbH (contact via NERAtec AG)
membranes ends on average after 20,000 L. The filtrate is
and Altenburger Elektronic GmbH.
reused as recycled high-quality adsorption oil, the concentrate is recycled into the settling filtration stage.
Since autumn 1998, a membrane installation has been

operating to separate the components oil, water, dye par-
185
Besides positive effects on the environment by closing
3.5.3
the product cycle, there are also economic advantages
Paper Mills
from the use of this process combination. The yearly costs

for waste water disposal were halved, and the use of new
Paper mills belong to the group of major industrial water
adsorption oils was reduced to only 25 % from which the
users. Water is needed for the production of printing pa-
customers profit. Under the present operational condi-
per for the press to process the fibrous raw material as
tions, the amortization of the investment of 51,000 Euro
well as for the production process in the paper machine
will be two years. These operational conditions were at-
itself. The water is taken for the most part from rivers
tained about 1.5 years after start-up of the installation.
and lakes and discharged after biological treatment. In

Germany the production of paper and cardboard is about
20 million tons per year, resulting in an average waste
water quantity of 10 m3 per ton of final product [VDP 2004].
Figure 3-9
For the discharge of waste water from paper and cardboard
Ultrafiltration installation at the Grafische Handelsvertretung
production into receiving waters, Appendix 28 of the
Peter Leis [LEIS IN EFA 2000]
Waste Water Ordinance [ABWV 2002] is valid.

For the production of new printing paper form waste paper, the applied printing ink has to be removed. Besides
water and air, auxiliary agents such as soap, sodium hydroxide, water glass, hydrogen peroxide and complexing agents
are needed. For the production of magazine paper it is
necessary to bleach the fibrous material.
In general, the waste waters from paper mills are highly
loaded organically. Their composition and other constituents, however, strongly depend on the raw material
used and the type of paper produced, therefore they may
differ considerably. Today membrane processes are still of
secondary importance in the treatment of waste water
from paper mills. In particular, the waste waters from
waste paper processing are nearly calcium-saturated which
leads to scaling. Moreover, they show high lignin contents
and a high percentage of fibrous material. Therefore the
use of membrane technology and of necessary pretreatment measures have to be carefully examined and planned.
186
3.5.3.1
UF
Paper Mill Palm, Works Eltmann
Membrane process
Nanofiltration
Start-up
December 1999
Objectives
Compliance with the standards for direct dischargers
15,000 m2
Modules
about 175 m3/h
Pretreatment
Biological treatment, sand filtration
Benefit
Compliance with the discharge standards; saving of process water after closure of the water cycle
The paper mill Palm with its headquarters at Aalen-Neu-
At present, the modules are backwashed daily. Once a week
kochen, Baden-Wrttemberg, belongs to the leading Euro-
(depending on the operating pressure) they are chemical-
pean manufacturers of newspaper printing paper and raw
ly cleaned, so that the service life of the membranes is
paper for the production of corrugated cardboard. In the
estimated to be 2 3 years. These operating parameters of
works Eltmann in Bavaria, 250 employees produce news-
membrane backwashing are still being optimized.
paper printing paper from 100 % waste paper.

The membrane installation at the works Eltmann ensures
From material processing and paper production results
compliance with the discharge standards and thus serves
waste water with COD and AOX loads, containing also
above all environmental protection. The planned closure
salts and dyes. In order to comply with the demands
of the water cycle and utilization of the permeate as pro-
for direct dischargers, the waste water is treated since
cess water will help to save freshwater, thus economic ad-
December 1999 by biological processes, followed by sand
vantages are expected.
filtration, and is then submitted to nanofiltration in

cross-flow mode by an installation from Wehrle Werk AG.
The installation has been promoted by the Deutsche Ausgleichsbank on behalf of the Federal Ministry for the Environment, Nature Conservation and Nuclear Safety (BMU).
The polyamide-based spiral-wound modules (KOCHGLITSCH GmbH) used in nanofiltration are arranged in a
feed-and-bleed configuration (see chapter 1.5 and Figure
3-10). At an operating pressure of 3 to 7 bar, a total membrane surface of 15,000 m2 treats a feed volume flow of
max. 195 m3 per hour. The output is 90 %, i. e. 175 m3 of
permeate per hour, which at present is still discharged
into the receiving water. Recycling of the permeate and
its use as process water are being planned. The concentrate is treated by lime milk and coagulants, an optimization of this treatment is being planned, too.
187
Figure 3-10
Nanofiltration installation at the paper mill Palm, works Eltmann (left) [SCHIRM 2001] and detail of the
tube module arrangement as feed-and-bleed structure (right) [according to SCHIRM 2001]
feed
1st circulation
permeate
concentrate
2nd circulation
permeate
concentrate
3rd circulation
permeate
concentrate
4th circulation
permeate
concentrate
concentrate
permeate
3.5.4
Textile Industry
In Germany there are about 1,100 textile factories, approx.
Since many medium-sized textile finishing enterprises are
150 of which are finishing works, which are, for the most
indirect dischargers, problems arise in municipal waste
part, small to medium-sized businesses [GESAMTTEXTIL
water treatment due to the parameters COD and colour
2000]. From the different fields of production result pro-
[GUTSCH, HEIDENREICH 2001]. Direct dischargers have
cess waters whose composition reflects the diversity of
to comply with the limit values according to Appendix 38
plant structures and production programs which vary
of the Waste Water Ordinance [ABWV 2002]. Besides pre-
with the seasons of the year. The discharge of these pro-
cipitation, flocculation and chemical oxidation, membrane
cess waters gives rise to increasing costs.
technology can also be used to obtain further removal of

colour from textile waste water.
The variety of processes in textile finishing hardly allows

general statements on the water consumption. However,
However, the great variety of waste waters from textile
approx. 60 80 L of waste water, partly strongly coloured,
finishing does not allow one to consider membrane pro-
results from the finishing of 1 kg of textiles [MARZIN-
cesses an economical and technically sound solution for
KOWSKI 1999]. Waste water from the cleaning of dye
all applications in this field. Possible employment and
preparation tanks is highly concentrated. On the other
performance of membrane technology requires individ-
hand, waste water from dyeing is loaded with dyes in
ual adaptation to each single case and location and should
lower concentrations. With only a few exceptions, these
be confirmed by detailed pilot tests. The treatment and
dyes are not biologically degradable or only partially de-
disposal of the brine are important considerations in the
gradable under aerobic conditions [BRAUN ET AL. 1997].
overall economic efficiency of the process [MACHENBACH 1998].
188
Various process combinations for the treatment of textile
treat the concentrates in a biological fixed-bed reactor.
waste water are being tested or have been applied in
In Germany, this process combination has not yet been
practice:
realized on an industrial scale [SCHFER ET AL. 1997;

GUTSCH, HEIDENREICH 2001].
To realize a closed water cycle in textile finishing, combination of a biological stage (immersed biodisks),
In a large-scale plant, waste water from dyeing is treated
cross-flow microfiltration and adsorption on activated
by a combination of a biological stage, adsorption, down-
carbon (complete decolourization) have been tested
stream reverse osmosis and activated-carbon filtration,
[WAIZENEGGER ET AL. 2000].
so that it can be directly discharged. The largest part of

the treated water is recycled into the production pro-
Tests have proven the suitability of nanofiltration for
cess as all-purpose process water [BRAUN ET AL. 1997].
the treatment of waste waters from the textile industry.

Moreover, it was possible to close the water cycle by a
combination of ultra- and nanofiltration as well as to
3.5.4.1
UF
Textile Industry, Drews Meerane
Membrane process
Ultrafiltration
Start-up
2001
Objectives
Reuse of the treated waste water
2,200 m2
Modules
Immersed capillary membranes
~ 34 m3/h
Pretreatment
Bent-sieve screen
Benefit
Reduction of fresh water consumption and of the waste water quantity, cost savings
The company Drews Meerane GmbH runs a textile finish-
The lower loaded waste water is treated by anaerobic and
ing plant from which high-strength waste water results.
aerobic processes, followed by sludge separation in a la-
The COD concentrations are between 1,000 and 1,500 mg/L.
mella separator (Figure 3-11). Finally the treated waste
Moreover, the waste water is strongly coloured due to the
water is discharged to the municipal waste water treat-
presence of by well water-soluble azo dyes.
ment plant.
The new concept for water and waste water management

intends separate treatment of partial flows with higher
and lower loads. A total of approx. 1,500 m3 of waste water per day is treated by the waste water treatment and processing plant. The share of the higher loaded waste water
is about 60 %. The COD concentrations in the higher
loaded flows are around 1,400 mg/L, in the lower loaded
flows approx. 1,100 mg/L.
189
Figure 3-11
Flow sheet of the waste water treatment and processing plant [according to ZENON GMBH 2004]
waste water treatment plant

lamella separator
anaerobic
reactor
aerobic
reactor
well water
excess sludge

recirculation
production
membrane stage
flow to municipal
treatment plant
lamella separator
anaerobic
reactor
aerobic
reactor
excess sludge
treated waste water
ozonisation
blower
installation
At first the higher loaded waste water is treated in an
installation is used as recycled water with an average
anaerobic reactor to break down the azo dyes and other
COD concentration of 160 mg/L mainly in textile print-
dyes. The resultant products are much smaller and are
ing processes for rinsing and cleaning purposes.
yellow up to colourless.
Thanks to this waste water treatment system, the COD
The waste water is then treated by an anaerobic process.
load to the nearby municipal waste water treatment plant
By means of the downstream lamellar clarifier, thickened
was reduced by approx. 500 kg/d. The economic efficien-
sludge is separated and recycled into the anaerobic reactor.
cy of the processing plant, compared to the conventional

waste water treatment plant operated in parallel, is achieved
Complete separation of the solid and the liquid phase
at a recycling quote of approx. 26 %. The recycling quote
takes place in the down-stream ultrafiltration system
really achieved is much higher.
with immersed capillary membranes from the company

ZENON. The membrane installation consists of six cas-
The project was promoted by Deutsche Bundesstiftung
settes of the type 500c with a total membrane surface
Umwelt (German Federal Foundation for the Environ-
area of 2,200 m . Treatment of the higher loaded waste
ment) and received in 2002 the Technology Promotion
water by this process combination achieves a reduction
Award of the Braunschweig Chamber of Industry and
of the COD concentration of 90 %. After final decoloura-
Commerce.
tion with ozone, part of the filtrate from the membrane
190
3.5.4.2
MF
Silk Weaving Mill PONGS
Membrane process
Microfiltration
Start-up
2004
Objectives
Reuse of the waste water/closure of water, circuits
320 m2
Modules
Double-decker modules/plate membranes
~ 2.5 m3/h
Pretreatment
Vibrating screen
Benefit
Expansion of the waste water treatment capacity Savings of costs for fresh water and waste water
discharge
Since 1993, the PONGS Textil GmbH in Mhltroff pro-
Due to increasing production and waste water quantities
duces and finishes large-dimensioned special clothes with
and the resulting discharge costs, the textile company
a width of up to 6,20 m, among other things. For this pur-
was faced in 1999 with the decision either to relocate the
pose, sized warps and weft threads are used.
production to another site or to implement a process

concept that ensures waste water treatment in spite of
Before further processing, the raw material is washed to
significant load variations and applies the reuse of a large
remove sticking size baths as well as waxes and oils which,
part of the treated waste water in the production process.
in general, are hardly biodegradable. The washing temperature is between 60 C and 95 C, depending on the
With the aim to lower the costs for the upgrading of the
substances sticking to the raw material.
existing waste water treatment plant, a concept was devel-
Figure 3-12
Conversion of the waste water treatment plant at PONGS Textil GmbH, left: conversion of the existing
trickling filter to a membrane bioreactor [photo: A3 GMBH 2004], right: new membrane bioreactor
[photo: A3 GMBH 2004]
membran bioreactor
191
oped in 1999 2000 that included converting the existing
The daily waste water flow to this installation is approx.
trickling filter to a membrane bioreactor. Figure 3-12 shows
60 m3 with COD concentrations from 8,000 mg/L to
the conversion of the old trickling filter to a membrane
15,000 mg/L. The waste water from the company PONGS
bioreactor (left) and the new membrane bioreactor (right).
is buffered in a mixing and compensating tank and flows

via a vibrating screen with a molecular separation size of
This membrane bioreactor, realized as cascade, was run
100 m to the membrane bioreactor stage. The activation
until another capacity enlargement in 2004. It consisted
volume is 240 m3. The membrane installation consists of
of two tanks arranged in series which were intensively
four double-decker modules (plate membranes) from the
aerated. The second tank was equipped with immersed
company A3. The pore size of the membranes is approx.
membrane modules from the company A3. The filtration
0.4 m, the total membrane surface area is 320 m2.
capacity of the installation could be maintained for six

months without chemical cleaning of the membrane
A large part of the treated waste water is reused in the
modules. Depending on process needs, the treated waste
production process. The company PONGS has set a treat-
water was used as process water in the textile company
ment target of COD concentrations < 200 mg/L for the
or discharged into the sewer system of the municipality.
reuse of the treated waste water. This target is attained

with COD effluent concentrations of less than 100 mg/L.
The successful operation of the plant showed that the

treatment of waste water from desizing by membrane
bioreactor processes is technically feasible and also costeffective. Enlargement of the capacity, necessary due to
increasing production capacity, was realized in 2004 with
the membrane bioreactor process, too.
Figure 3-13
Flow sheet of the membrane bioreactor of the company PONGS [according to A3 GMBH 2004]
production
membrane stage
process
waste water
mixing and
compensating
tank
sewer
system
vibrating screen
100 m
blower
installation
192
3.5.4.3
MF
UF
UF
RO
Textile Finishing Works Gerhard van Clewe GmbH & Co. KG
Membrane process
Microfiltration
Start-up
2001
Objectives
Reduction of the costs for waste water discharge and compliance with the requirements for indirect dischargers
225 m2
Modules
Tube modules
2.5 m3/h
Pretreatment
Dosing of liquid polymer and clay minerals to increase the particle size (improvement of the separation capacity)
Membrane process
Ultrafiltration, nanofiltration, reverse osmosis
Start-up
1997
no information
Modules
Ceramic tube modules (UF), spiral-wound modules (NF and RO)
12 m3/h in total
Pretreatment
Screen filtration (discotrainer) upstream of the ultrafiltration to separate fluff and other coarse particles,
bag filter upstream of nanofiltration
Benefit
Saving of process water and reduction of waste water costs
In 1954 the company Gerhard van Clewe has been estab-
installation. At operational pressures between 5.5 and 27
lished at Hamminkeln-Dingden. In 1973 the enterprise
bar, the permeate output is max. 12 m3 per hour. The per-
was expanded by a dye-works. Today, 190 employees in
meate is recycled to the pretreatment stage and the dye-
total are occupied with the finishing of textiles of all types.
house.
In textile finishing plants, different process waste waters
The three-stage membrane installation which works in
result from the production areas of pretreatment, dyeing,
the cross-flow mode serves to treat the partial flow con-
dye preparation, washing machines, and finishing. Their
taining the waste water from cotton dyeing and mesh
discharge gives rise to increasing costs. In order to reduce
finishing. It comprises the stages ultrafiltration (con-
these costs, the company van Clewe tried at first to reduce
struction and calculation by RIK, Dlmen), nanofiltra-
as far as possible the water consumption in the finishing
tion and reverse osmosis. To separate fluff and other
process. As a result, the concentrations in the waste water
coarse matter, a screen (discotrainer) has been arranged
increased, and it was no longer possible to comply with
up-stream. In the ultrafiltration stage (Figure 3-14), cera-
the limit values for AOX and heavy metals for the dis-
mic tube modules from the company atech innovations
charge into the municipal waste water treatment plant.
gmbh separate fine-particulate and dissolved polymeric

substances from the waste water. The filtrate passes a
Based on the results of a large number of tests with a pilot
downstream bag filter (protecting function) before it is fed
plant, a large-scale membrane installation from the com-
to the nanofiltration stage. In this stage, decolourization
pany CSM Filtrationssysteme GmbH & Co. KG, Bretten,
and partial demineralization are obtained using spiral-
was commissioned in 1996. Following expansion of the
wound modules made from synthetic polymer from the
installation in 1997, which was promoted by Deutsche
company Osmonics. The largest part of the salt and most
Bundesstiftung Umwelt, Osnabrck, and scientifically as-
of the COD load are removed by reverse osmosis using
sisted by the University of Wuppertal, both partial flows
spiral-wound modules made from polymer membranes
from the dye-house are fed separately to the membrane
(company Osmonics).
193
The second partial flow has a smaller volume and is less
permeate volume flow of 2.5 m3 per hour. The tube mod-
polluted. It consists of waste water containing pigment
ules are backwashed periodically, and fully-automated
dyes from dye preparation and dye coating, waste water
chemical cleaning takes place once a week.
from the tenter driers as well as from the purification of

waste air from the tenter driers. Since the beginning of
After reverse osmosis, the permeate is colour-free and
2001, this partial flow is fed to a microfiltration stage
contains only 3 % of the original COD load. This quality
after dosing of clay minerals and coagulants to increase
is sufficient to reuse the permeate from the membrane
the particle size and to improve the separation capacity.
stage (single-stage and three-stage) as process water. Thus
The microfiltration has been designed by MDS Prozess-
a recycling rate of up to 50 % of the total waste water
technik GmbH and calculated by the company BKT Burg-
amount is obtained. The concentrate from all stages is
grf GmbH. The installation is equipped with tube mod-
evaporated, dried by film driers and discharged into an
ules (Microdyn Modulbau GmbH) made from polymer
incineration plant for household waste.
mebranes and works in the cross-flow mode. The membrane surface with an area of 50 m2 in total processes a
Only the membranes of the ultrafiltration stage have to

be backwashed every three minutes. With this operating
mode, the ultrafiltration membranes have been in service
Figure 3-14
for seven years without showing loss of capacity (as of
Ultrafiltration installation at the textile finishing
August 2005). The service lives of the nanofiltration and
plant van Clewe [BTTGER 2001]
reverse osmosis membranes are 1.5 years. They have to

be cleaned only on the weekend with special membrane
cleaning agents.
Besides compliance with the standards for indirect dischargers, the membrane installation helps to save about
50 % of the waste water costs by a closed process water
cycle.
194
RO
3.5.5
Fibre Industry, Vulcanized Fibre
Membrane process
Reverse osmosis
Start-up
1997
Objectives
Cheap alternative for reduction of the rinsing water quantity and treatment of the zinc-dichloride waste water
312 m2
Modules
4 m3/h
Pretreatment
Prefiltration
Benefit
Saving of precipitation agents and flocculants, freshwater, waste water and zinc dichloride
Vulcanized fibre is a versatile material produced from re-
Approx. 30,000 m3 of rinse waste water are generated per
newable raw material. It is manufactured from non-glued
year in the production process. The waste water was typi-
cotton linters and pulp under the action of a zinc dichlo-
cally treated by conventional precipitation and floccula-
ride solution. The material is antistatic, elastic and of low
tion processes. The plant was interested in finding alter-
weight.
native treatment processes to reduce cost. In a preliminary study the Research Institute for Water and Waste Ma-
The 50 employees of the Ernst Krger GmbH & Co. KG
nagement (FiW) compared different processes and estab-
at Geldern produce, among other products, seals, guides
lished the contact with Amafilter Deutschland GmbH.
for weaving machines and stamped parts from vulcanized

fibre for the car industry, electrical industry and textile
Since 1997 not only ultrapure water for rinsing purposes
industry. An important production step is the washing
but also a high-quality zinc dichloride solution for the
off of zinc dichloride by several baths connected in series,
process bath have been recovered. This is made possible
from which results waste water containing a residual zinc
by prefiltration and downstream reverse osmosis
dichloride concentration.
(Amafilter Deutschland GmbH), which works continuously
Figure 3-15
Flow sheet of the process water treatment at the vulcanized fibre works GmbH & Co. KG
[AMAFILTER 2001]
water bath
lye bath
parchmentizing bath 70% ZnCl2
equalization of
losses
5m3/h
evaporator
zinc dichloride
permeate
4 m3/h
reverse osmosis
concentrate
1m3/h
195
in the effluent of the water bath (Figure 3-15 and Figure
Thanks to the financial backing of 50 % by a promotion
3-16). The spiral-wound modules with a total filter sur-
program3) of the federal state North-Rhine Westphalia, the
face area of 312 m2 treat a permeate volume flow of 4 m3
installation has been amortized after approx. four years.
per hour, at an operating pressure of 25 bar. Practical

operation has shown that the service life of the mem-
The employment of the reverse osmosis installation in
branes is greater than three years (up to six years). When
continuous vulcanized fibre production as well as the
the membranes had to replaced for the first time, another
integration of other waste water flows and the cooling
type of membrane was chosen which resulted in an
water to reverse osmosis have economic and ecological
increase of the capacity.
advantages. By closure of the water cycle the waste water

quantity was reduced by 80 % in total, and the freshwa-
The permeate of the reverse osmosis installation has the
ter demand by 90 % (about 18,000 m3 per year). Due to
quality of fully demineralized water so that it can be re-
this reduced demand, the costs for freshwater conditio-
cycled to the water bath. The brine contains the zinc di-
ning (softening of well water) decreased.
chloride which is reused in the lye bath of the production

process.
Moreover, precipitation and flocculation agents are saved,

and through targeted recovery the zinc dichloride remains
in the production cycle, which minimizes the additional
demand for this chemical.
3)
Promotion program (1997 1999) Initiative kologische und nachhaltige Wasserwirtschaft NRW (Action group Ecological and Sustainable Water
Management) [MURL 1996]
Figure 3-16
Reverse osomosis installation at the vulcanized fibre works Ernst Krger GmbH & Co. KG [photo: AMAFILTER]
196
3.5.6
UF
Plastics Industry, Troplast
Membrane process
Ultrafiltration
Start-up
1998
Objectives
Recirculation of the cooling water which has come into contact with the product
38 m2
Modules
approx. 9.5 m3/h
Pretreatment
Coarse filter, screen filter, cartridge filter
Benefit
Saving of freshwater and reduction of waste water costs
Since the beginning of the 20th century, special plastic
Besides ecological advantages, the installation is also pro-
material has been produced by the company HT Troplast
fitable. By reduction of the volume and the closed water
AG in Troisdorf. Today the company has 1,500 employees
cycle, waste water costs and groundwater resources are con-
at this location, about 180 of them working in the Trosi-
served, as the water consumption is reduced by 75 80 %.
fol branch, which produces safety-glass films for the car
Moreover, safe and low-maintenance process design has
industry and the building industry. In the course of the
contributed to the fact that the installation has been
production process, Trosifol, a flexible film on the basis
amortized after 2.5 3 years, in spite of the rather high
of polyvinyl butyral resin, is cooled. During this process,
investment of 348,000 Euro, which is due to full automa-
undissolved plasticizers (oily) get into the cooling water.
tion and corresponding control technology.
To separate the plasticizers from the process water, the

company decided in 1998, after study of various proces-
Figure 3-17
ses and discussions with the company Amafilter Deutsch-
Ultrafiltration installation at the company
land GmbH, to commission an ultrafiltration installa-
HT Troplast AG [photo: HT TROPLAST]
tion with an upstream filter for the separation of coarse

matter (coarse filter, screen filter, cartridge filter). The
ultrafiltration installation is equipped with ceramic tube
modules fro the company atech innovations gmbh and
is completed with a heat exchanger for water cooling
(Figure 3-17).
The membrane surface area with a size of 38 m2 works in
cross-flow mode at an operating pressure of 4 bar and processes a feed flow of 10 m3 per hour. 95 % of the inflow
are yielded as filtrate and fed back into the water cycle.
The concentrate is discharged by the waste water system.
The service life of the membranes is expected to be more
than 10 years.
197
3.5.7
Laundries
Waste water from laundries can be loaded with danger-
in laundries comprise either a combination of microfil-
ous pollutants. At present, laundry waste water is typical-
tration and nanofiltration or a reverse osmosis system
ly discharged with or without previous treatment into
[MENGE 2001].
municipal waste water treatment plants. There are still a

few laundries which discharge the waste water without
Appendix 55 of the Waste Water Ordinance [ABWV 2002]
treatment into receiving waters [GUTSCH, HEIDENREICH
is valid for waste water which is discharged directly into
2001]. For the treatment of low-loaded waste water from
a water body and whose pollution load mainly results
laundries (e. g. washing of hospital and hotel textiles),
from washing of dirty textiles, carpets, mats and fleeces
which is then recycled, membrane filtration processes are
in commercial enterprises and public institutions. For
often used in addition to biological treatment systems
waste water from dry cleaning of textiles, carpets and
and their combinations with chemical precipitation
products made from fur and leather, Appendix 52 of the
[MENGE 2001]. Installations for closing the water cycle
Waste Water Ordinance [ABWV 2002] is valid.
3.5.7.1
UF
NF
Laundry Alsco
Membrane process
Ultrafiltration
Start-up
2000
Objectives
Waste water treatment
44 m2
Modules
Tube modules
6.5 m3/h
Pretreatment
Vibrating screen
Benefit
Pretreatment prior to nanofiltration
Membrane process
Nanofiltration
Start-up
2000
Objectives
Waste water treatment
180 m2
Modules
Spiral-wound module
~ 6 m3/h
Pretreatment
Ultrafiltration
Benefit
Savings of costs for freshwater and waste water discharge
198
Since May 2000, the company ALSCO has operated a
The waste water of the partial flow mat cleaning/blue
commercial laundry in Kaiserslautern. To separate the
laundry is collected in an underground tank with a vol-
partial flow, the laundry volume is allocated to special
ume of approx. 5 m3. From there it is fed to a vibrating
engine groups which are connected by a pipeline system,
sieve to separate fluff and other coarse particles. After
so that the waste water of the partial flows can be col-
having passed the vibrating screen, the waste water is
lected and treated separately (Figure 3-18).
cooled down to a temperature of 38 C by a condensation

cooling tower and pumped into an aerated volume com-
The waste water from the partial flow mat cleaning/blue
pensating tank which holds approx. 65 m3. From there it
laundry consists of 30 m3/d of waste water from blue
is fed into the activation reactor which also holds 65 m3.
laundry and 45 m /d from mat cleaning. With a working

period of five days per week, the annual waste water quan3
tity from mat cleaning/blue laundry is 18,750 m /a.
After treatment in the activated sludge stage, the

waste water and the activated sludge are thickened in the
cross-flow ultrafiltration system to a solid matter content
The partial flow white laundry, which comes from the
of approx. 4 %. About 10 m3 of wet sludge per month are
washing of work clothes, towels and flatwork, is about
discharged to a waste water treatment plant at a local
95 m /d. This waste water is collected and fed to a cooling
chemical industry.
tower for temperature reduction, followed by neutralisation by means of CO2. The treated waste water of the
The ultrafiltration plant (Figure 3-19) contains four
white laundry is discharged by the sewer system into a
pressure pipes with 11 m2 of membrane surface area each
municipal waste water treatment plant.
and two empty pipes for future expansion. The membrane modules are equipped with organic tube modules
from the company Berghof with a free duct of 10.2 mm.
The permeate volume flow is approx. 6.5 m3/h.
Figure 3-18
Flow sheet of the waste water treatment process in the laundry ALSCO
washing
water
white
laundry
cooling
tower
tank
neutralisation
sewer system
recirculation
process water recycling
blue laundry
and mats
tank
vibrating
sieve
cooling
tower
volume
compensating
tank
biological
reactor
ultrafiltration
nanofiltration
blower
installation
wet sludge
concentrate
concentrate to
the sewer system
199
Figure 3-19
Membrane installation in the laundry ALSCO [photos: WEHRLE UMWELT GMBH 2004],
left: ultrafiltration installation, right: complete installation
The COD concentration in the waste water from mat
The costs of membrane cleaning have been determined
cleaning/blue laundry is 2,800 mg/L on an average and
as approx. 1 2 Cent/m3 of waste water.
maximally 5,000 mg/L. The COD concentration in the

permeate from the ultrafiltration system is between 80
The service life of the membranes has been calculated as
and 150 mg/L. AOX compounds do not occur because
4 6 years. With a service life of four years, membrane re-
chlorine bleach liquor is not used in the washing process.
placement costs of about 0.15 Euro per m3 of waste water
The permeate from the ultrafiltration meets the require-
will become necessary.
ments according to Annex 55 of the Waste Water Decree

and can be discharged into the local sewer system. The
According to the supplier of the plant (Wehrle Umwelt
specific energy consumption of the ultrafiltration is
GmbH), the specific operating costs of the ultrafiltration
approx. 4.0 kWh per m3 of permeate.
system as sum of energy-, membrane replacement- and

cleaning costs are approx. 0.40 Euro per m3 of waste
To reduce the fresh water and waste water costs at the

laundry, the waste water treated by ultrafiltration is further
treated by nanofiltration and reused as washing water.
The single-stage nanofiltration plant is equipped with
spiral-wound modules from the company Desal. The permeate is used again as washing water. The concentrate
flow (10 15 m3/d), which meets the requirements for indirect dischargers and those made by the local waste water
statutes, is discharged together with the waste water from
the white laundry into the municipal waste water treatment plant.
200
water.
UF
3.5.7.2
NF
Textile Service Mewa GmbH
Membrane process
Ultrafiltration
Start-up
1998
Objectives
Closed washing water circuits
60 m2
Modules
~ 4 m3/h
Pretreatment
Prefiltration / fluff sieve
Benefit
Reduction of the fresh-water demand and savings of detergents
Membrane process
Ultrafiltration
Start-up
1998
Objectives
Closed washing water circuits
135 m2
Modules
~1,5 m3/h
Pretreatment
Ultrafiltration
Benefit
Reduction of the fresh-water demand
At the site Gro-Kienitz, the textile service Mewa cleans
repair shops, etc. On account of legal constraints, the
very dirty work clothes from the industrial branches
waste water treatment process had to be upgraded in
metal industry, mechanical engineering firms, motorcar
1997. According to Annex 55 of the Waste Water Ordi-
Figure 3-20
Flow sheet of the treatment plant of Textile Service Mewa GmbH [according to ENVIRO CHEMIE 2004]
ultrafiltration 2
concentrate
storage
concentrate to
external discharge
feed
prefiltration
buffer and
precipitation
ultrafiltration 1
nanofiltration
sewer system
1,5 m3/h
recycling water 1
for preliminary and
general washing
1,5 m3/h
recycling water 2
for process water
201
nance, heavy metals and hydrocarbons have to be re-
Due to the residual organic load it can be used only to a
moved before the waste water can be discharged into the
limited extent in the preliminary and main washing pro-
public sewer system.
cesses. However, about 20 % of washing agents can be

saved thanks to the high detergent content in the recyc-
A treatment plant has been run since 1998 at the site of
ling water.
the laundry. The treatment plant treats 100 m of laundry

waste water per day to such an extent that it can be re-
The remaining permeate of the first ultrafiltration stage
used in the washing process. Figure 3-20 shows the flow
further treated by a downstream nanofiltration stage con-
sheet of the treatment plant.
sisting of spiral-wound modules with a total membrane

surface area of 135 m2 (Figure 3-22)
After having passed a prefiltration and precipitation stage,

the waste water flows into the first ultrafiltration stage
About 1.5 m3 of permeate are produced per hour (recyc-
which consists of six modules with 47 ceramic bars each
ling water 2). The recycling water 2 is treated to such an
(Figure 3-21)
extent (see Table 3-4) that it can be used for rinsing purposes in the main washing process. Thus the freshwater
By filtration over the total membrane surface area of
demand is lowered.
approx. 60 m2, a permeate volume flow of approx. 4 m3/h

is attained. About 30 % of the permeate volume flow of
With this multi-stage waste water treatment process, the
the ultrafiltration plant is reused as recycling water 1.
total recycling efficiency of the waste water volume flow
The quality required for the recycling water 1 is COD <
is approx. 70 %.
1,000 mg/l and a residual mineral oil content of < 20 mg/L.
Figure 3-21
Figure 3-22
Ultrafiltration plant at Textile Service Mewa
Nanofiltration plant at Textile Service Mewa
[photo: ENVIRO CHEMIE 2004]
[photo: ENVIRO CHEMIE 2004]
202
Table 3-4
Quality of the recycling water 2 [Enviro Chemie 2004]
Parameter
Unit
Concentration
COD
mg/L
100
Conductivity
s/cm
500
colony-forming units/mL
100
Bacteria
3.5.8
In the metal processing industry, metal surfaces and also
Lowering the costs for discharge and raw material is the
non-metal surfaces (as far as they become metallized) are
primary motive of an enterprise to buy an internal pro-
treated by aqueous solution, emulsions, slimes, and also
cess- or waste water treatment plant which at the same
fused salts (mechanically, chemically, electrochemically
time contributes to protect the environment. A possible
and thermally). The various waste waters resulting from
solution to reduce the waste water quantity to be dis-
these processes are mainly loaded with inorganic pollu-
charged and, with this, the discharge costs is the treat-
tants and characterized by their high metal content. In
ment, i. e. concentration of the liquid waste by membrane
addition, they contain organic substances such as mine-
filtration and vacuum evaporation [SPECHT 1997]. The
ral oils (especially found in cutting fluids), varnish com-
resulting permeate may be recycled and used again in the
ponents, mineral greases, chlorinated hydrocarbons and
process. If permeate and concentrate are completely re-
other solvents.
used, the process is waste-water-free. However, it is not

possible to achieve waste-water-free operation off the
For the discharge of waste water from the metal industry,
peg, because treatment techniques as well as auxiliary
Appendix 40 of the Waste Water Ordinance [ABWV 2002]
material used in production, e. g. cleaning agents, have
as well as the requirements of the municipal statutes and
to be coordinated and adapted to the production facili-
the Ordinance on Indirect Discharges are valid. Compli-
ties [SPECHT 1997]. Comprehensive preliminary tests
ance with the limit values is only possible after internal
help to avoid mistakes and to save costs.
treatment of the process waste waters, otherwise they

have to be discharged as hazardous waste, which is rather
expensive.
203
3.5.8.1
UF

Rasselstein Hoesch GmbH
Membrane process
Ultrafiltration
Start-up
1999
Objectives
Reduction of the palm oil load in the waste water, i. e. the number of cleanings of the degreasing
facility and of new preparations of the degreasing baths are reduced
4.56 m2
Modules
Feed volume flow
1 m3/h (approx. 90 % of the feed are yielded as filtrate)
Pretreatment
none
Benefit
Saving of freshwater and chemicals, reduction of the waste water quantity and of the discharge costs
The Rasselstein Hoesch GmbH with its headquarters at
The filtrate (about 90 % of the feed) is recycled as clean
Andernach and production works at Andernach and Dort-
degreasing solution directly into the bath, while the con-
mund holds a top position among the European tinplate
centrate is fed to rolling grease treatment and afterwards
producers. Tinplate is cold-rolled blackplate with a thick-
discharged thermally.
ness between 0.12 mm and max. 0.49 mm, which is mainly used as packaging material.
After some initial operating problems, the advantages of

the installation became evident: With constant process
In the cold-rolling process, palm oil is used which has to
bath quality, the waste water quantity is reduced thanks
be removed before further processing by a degreasing
to recirculation of 9 m3 per hour. In addition, drinking
process. The waste water from this process is organically
water and chemicals are conserved. Also, the COD load is
loaded due to the palm oil. This waste and the waste
reduced by 24 % and with this the discharge costs. Accord-
water from the cleaning of the degreasing facility, which
ing to calculations, the total investment of 358,000 Euro
is necessary in regular intervals, and the new preparation
will be amortized after 1.5 years.
of the degreasing bath require considerable quantities of

degreasing agents.
Figure 3-23
These were the reasons for commissioning in 1999 an
Ultrafiltration installation at the company
ultrafiltration installation (Figure 3-23), in cooperation
Rasselstein Hoesch [photo: MFT GMBH]
with the company Membran-Filtrations-Technik-GmbH

(MFT). Ceramic tube modules working at an operating
pressure between 6 and 8 bar remove the palm oil from
the degreasing baths. The ultrafiltration membrane with
a surface area of 4.56 m2 processes a feed flow of 1 m3 per
hour. It is cleaned automatically after 120 hours (using at
first alkaline, then acid products, followed by backwashing with water). The installation has been operating now
for 1.5 years (as of June 2001); the service life of the
membranes is expected to be five years.
204
3.5.8.2
UF

Faurecia, Bertrand Faure Sitztechnik GmbH & Co. KG
Membrane process
Ultrafiltration
Start-up
October 2000
Objectives
Saving of costs by extension of the service life of the degreasing baths and ensuring of a constant product
quality
1.1 m2
Modules
Flat membranes wound on support structures made from high-grade steel
0.3 m3/h
Pretreatment
Grease and oil separation
Benefit
Saving of freshwater, waste water and degreasing chemicals as well as reduction of waste water levies
The company Faurecia Autositze GmbH & Co. KG has de-
The flat plastic membranes with a molecular separation
veloped into an international business group which sup-
size of 30.000 Dalton are wound on supporting structures
plies the car industry. Today the Faurecia group has about
made from high-grade steel. The total filter surface area is
100 works in 25 countries. In the works Stadthagen, about
1.1 m2 and processes a filtrate flow of 0.3 m3 per hour, at
800 employees produce metal fittings and seat components
an operating pressure of 2 bar. The membranes are cleaned
(seat- and seat back frameworks) for the car industry.
twice a week and replaced after approx. 12 months. Since

the filtrate is recycled into the production process, only
Cathodic dip coating of the frameworks requires upstream
the concentrate has to be discharged. With this operating
degreasing by special chemicals. The impurities removed
mode, the service life of the degreasing baths was extended
from the metal surfaces enter the degreasing bath and con-
from two weeks to six months.
tinuously reduce the cleaning efficiency, until the cleaning effect is no longer sufficient. At this stage, the degreasing bath has to be replaced.
Figure 3-24
Ultrafiltration installation at the company Faure-
In order to save costs by prolongation of the service life
cia, Bertrand Faure Sitztechnik GmbH & Co. KG
of the degreasing baths and to ensure a constant product
[KASTEN 2001]
quality, the company Faurecia decided to use a process

combination with membrane technology. The waste water
from the degreasing of the seat frameworks is pretreated
in a tank in which fats and oils float, and heavy pollutants as well as metal sludges are collected and separated
weekly via a special discharger. After a retention time of
three hours, the oil content in the oil-water mixture drops
to 0.2 %. The mixture is then fed to the ultrafiltration installation built by the company Atec Automatisierungstechnik GmbH (Figure 3-24).
Since October 2000, the ultrafiltration installation separates more oil quantities by means of a patent-protected
cross-flow process using agitators (Atec-Overflow-System).
205
Besides its ecological advantages, the ultrafiltration in-
90 %, and the discharge costs were reduced by 90 %, so
stallation provides also economic benefit by saving de-
that the installation will be amortized after less than two
greasing chemicals, water and waste water. The demand
years, according to the calculation of the person respon-
for chemicals was reduced by 85 %, the water demand by
sible for surface- and environmental technology.
3.5.8.3
Electroplating Enterprise Rudolf Jatzke
Membrane process
Membrane electrolysis
Start-up
1993
Objectives
Extension of the service life of the electrolytic solution and reduction of the demand for chemicals
1)
approx. 0.25 m2
Modules
2 cells per dialysator (standard)
no information
Pretreatment
none
Benefit
Saving of freshwater, reduction of the demand for chemicals, reduction of the heavy-metal sludge quantity
1)
The output of the chromium dialysator is not a function of the membrane surface area, but of the current quantity (the current density being the limiting
factor). If the current becomes too great, the membrane is destroyed.
In the electroplating enterprise Rudolf Jatzke at Bielefeld-
water-free, as it serves to recover iron and to oxidize chro-
Sennestadt, managed since 1979 by the owner Klaus
mium. Thanks to this installation by the company Ato-
Wickbold, 14 employees work in the field of hard chro-
tech, the service life of the chromium baths is theoreti-
mium plating. The work pieces, partly special models for
cally unlimited.
customers from all branches, are protected by chromiumplating against wear and corrosion. During this process,
In membrane electrolysis, a transport of charged parti-
metal cations, especially iron and chromium(III), are
cles through ion-selective membranes as well as electrode
removed by etching from the surface of the workpiece
reactions such as reduction or oxidation take place (see
and get into the electrolyte. This has negative effects on
Figure 3-25).
the quality and requires continuous cleaning or regular

discharge and new preparation of the highly toxic solu-
The ion-selective membrane separates the anolyte (chro-
tions.
mic acid) from the catholyte (polycarboxylic acid). Only

the cations, e. g. metallic impurities, are able to pass the
Up to now, a cation exchanger had been used to treat the
membrane. Due to the potential applied, the cations are
solutions, resulting in large quantities of waste water with
transported through the membrane to the cathode where
a heavy-metal load whose discharge required again large
they are reduced and separated as metal. At the same time
quantities of chemicals. For this reason a membrane elec-
the chromium (Cr 3+) reduced during the chromizing pro-
trolysis installation (called chromium dialysator) has been
cess is oxidized at the anode (Cr 6+) and recycled. Since
developed in cooperation with the University of Bielefeld
this oxidation process goes faster than the ion transport
and later with the University and Polytechnic of Pader-
to the cathode, only a very small part of the chromium
born, promoted by Deutsche Bundesstiftung Umwelt, Os-
passes the membrane.
nabrck. This plant has been operating since 1993 waste-
206
Figure 3-25
Mode of operation of the electrolysis membrane
[SCHMIDT 2002]
cathode
anode
Fe3+
Cr 6+
Cr 3+
Zn2+
Ni2+
(Cr3+)
chromium bath (anolyt)
metallic pollutions
Cu2+
membrane
Compared to the cation exchange installation used before, the yearly water de-mand is reduced by 28,000 m3
and the demand for chemicals by 25,000 kg. Only 750 kg
of harmless citric acid are used instead of 10,000 L of sulphuric acid. Also, 7.5 t of heavy-metal sludge are avoided.
Besides these environmentally relevant advantages, a reduction of the annual power consumption by 10 % results
from the conversion to continuous coating processes,
which also results in improved product quality.
In 1997, a European patent was issued for the membrane
electrolysis process. Membrane electrolysis is not only
applicable for chromium baths, but also for a large number of other processes (chromatizing, pickling).
In addition to the membrane electrolysis installation, the
company Jatzke is equipped with a computer-controlled
water cycle and vacuum evaporation system for the rinsing water. In 2000, the company Jatzke received the first
price of the Effizienz-Agentur NRW (EFA) for productionintegrated environmental protection.
207
3.5.8.4
UF
RO
Metal Processing Industry, Wieland Werke AG
Membrane process
Ultrafiltration
Start-up
1998
Objectives
Water saving
44 m2
Modules
Capillary modules
up to 6 m3/h
Pretreatment
Paper belt-, cartridge filter
Benefit
Saving of freshwater and reduction of the waste water quantity
Membrane process
Reverse osmosis
Start-up
2001
Objectives
Water savings
Modules
Cushion modules
approx. 24 m3/d
Pretreatment
Ultrafiltration
Benefit
Savings of completely demineralized water and reduction of the waste water quantity
The works Langenberg of the Wieland-Werke AG is a cold-
technik (CMU), Neuss, and der RWW Wassertechnologie
rolling mill where 361 employees are occupied with the
GmbH, Nettetal, and with a financial subsidy from the
processing of rough-rolled belts from copper and copper
Land Nord-Rhine Westphalia4). According to this concept,
alloys to finished high-grade products (including for the
the waste water from the brushing machines is treated by
electronics industry).
ultrafiltration in dead-end mode, after having passed a

paper belt- and a cartridge filter. Each of the four brushing
After each rolling process, the belts are given the neces-
machines integrated into this concept forms an internal
sary characteristics in annealing installations and acid-
local water cycle with an ultrafiltration installation
treatment plants. Afterwards the surface of the belts is
(Figure 3-26). The capillary modules from X-Flow have a
cleaned mechanically by brushing machines. In the past,
total filter surface area of 44 m2 and produce up to 6 m2
the waste water from these brushing machines (about
of filtrate per hour, at a transmembrane pressure of up to
80 m /h) was treated jointly with other process waste
max. 1 bar. The filtrate is reused in the brushing machines.
waters by neutralisation, precipitation/flocculation and

gravel filtration. A partial flow was recycled into the pro-
The particle-containing water (0.5 m3/h per installation)
cess. In this configuration, 46 m3/h of waste water still
from backwashing of the ultrafiltration is fed into the
have to be discharged into the public sewer system and
internal water cycle. With this, the water quantity in this
have to be replaced by freshwater from a river.
cycle as well as the freshwater demand and the consumption of neutralization and precipitation agents is reduced
In 1998, a concept for water saving was realized in the
by 60 %. The resulting sludge, which contains copper, is
works Langenberg which had been tested before in detail.
used in the iron and steel industry.
This was done in cooperation with the company Dr.-Ing.

Peters Consulting fr Membrantechnologie und Umwelt4)
Development program (1997-1999) Action group for ecological and sustainable water management NRW
208
Figure 3-26
The enterprise described above is the first cold-rolling
Ultrafiltration installation at the works Werk
mill for non-ferrous metals which uses ultrafiltration in
Langenberg of Wieland Werke AG [MUNLV 2001]
dead-end operation and low-pressure reverse osmosis.

The use of these methods represents an improvement in
the state of the art for this field.
The environmentally relevant investments (229,800 Euro,
with a subsidy of the Land NRW of 100,000 Euro) are
profitable: Besides the waste water quantity which now is
only approx. 4 m3 per hour, the water consumption, too,
was clearly reduced (by up to 90 %) by internal recirculation. Moreover, by ultrafiltration as well as low-pressure
reverse osmosis the particular and dissolved substances
are removed as far as possible from the individual water
cycles, so that the surfaces of the final products are of
constant high purity.
After successful conclusion of a pilot test for the demineralization of the filtrate from these ultrafiltration installations by low-pressure reverse osmosis, which was assisted
by ROCHEM UF-Systeme GmbH, Hamburg, and CMU,
Neuss, the water cycles at the brushing machines were
expanded in 2001 by corresponding RO installations.
These are equipped with the FM (flat membrane) module
(cushion module). The permeate is deionized as far as
possible so that completely deionized water, which is
very expensive, for the rewashing process can be saved.
209
3.5.9
Treatment of Waste Water from Car Painting
3.5.9.1
UF
Treatment of Waste Water from Car Painting, DaimlerChrysler AG
Membrane process
Ultrafiltration
Start-up
1998
Objectives
Reduction of the discharge costs for paint sludges
30 m2
Modules
Plate modules
1.0 1.4 m3/h
Pretreatment
Prefiltration, chemical conditioning
Benefit
Saving of paint, reduction of hauls because paint sludge is no longer produced
In the DaimlerChrysler AG plant in Dsseldorf, 5,400
the car body and had to be discharged at high costs as
employees are occupied with the production of goods
flocculated and dewatered paint sludge.
vehicles. The car bodies are painted by applying three

layers, each applied in a separate process. The second
By conversion of the painting process, the percentage of
paint layer, the so-called filler, absorbs rockfalls and
overspray was clearly reduced. At the same time, a water-
equalizes small anomalies in the bodywork.
soluble paint was used which is applied in a closed cycle

and a paint recycling process.
In former times, the filler was sprayed on the car body

using a pressure-driven manual system. With this proce-
The recycling installation from the company Eisenmann
dure, half of the paint ended up as overspray beside
Lacktechnik KG for water-soluble paint has been in operation since 1998. The ultrafiltration installation is an
important component of the process along with prefiltra-
Figure 3-27
tion and chemical conditioning (Figure 3-27). Plate mod-
Ultrafiltration installation in the DaimlerChrysler
ules made of polymer membranes (company Rhodia)
works at Dsseldorf [HARMEL 2001]
separate the paint particles from the water phase at an

operating pressure of between 3.5 and 4.5 bar.
Depending on the solid matter content, the membrane
surface area of 30 m2 processes a permeate flow of 1,060
to 1,400 L/h. The membranes are backwashed after one
or two weeks and cleaned chemically once a year. 10 % of
the membrane surface area is replaced per year. The filtrate is used to improve the quality of the circulating
water in the system, while the concentrate is reused as
recycled paint for the painting of car bodies.
The use of membrane technology for paint recycling
shows that ecological advantages may also be of economic benefit. Thanks to reprocessing, about 30 tons of
210
paint are saved per year. Moreover, the discharge of the
vant aspects, these savings are so great that the invest-
50 tons of paint sludge (70 % of this paint line) produced
ment of nearly 358,000 Euro will be amortized probably
up to now is no longer necessary, which means that dis-
after 3.5 years.
posal costs are saved. Besides the environmentally rele-
NF
3.5.9.2
Treatment of Paint Waste Water from the Production of Spare Parts in the Ford Works, Cologne
Membrane process
Nanofiltration
Start-up
2001
Objectives
Recycling of valuable substances, Reuse of the permeate and the concentrate in the production process
No information
Modules
No information
~ 2 m3/h
Pretreatment
Fine screen
Benefit
Reduced fresh-water consumption, lower waste water loads, reduced chemicals cost, lower total costs
Figure 3-28
Flow sheet of paint-spraying [IMB + FRINGS WATERSYSTEMS GMBH 2004]
1st step: degreasing
2nd step: phospating
3rd step: painting
car components to be painted
degreasing
rinsing baths
UF
phospating
rinsing baths
cathodic
dipcoat
rinsing baths
NF
RO
UF
concentrate for discharge
211
Figure 3-29
After degreasing, the car components are phosphated and
Nanofiltration plant at the Ford works Cologne
then flushed. The process waste water from flushing have
[photo: IMB + FRINGS WATERSYSTEMS GMBH 2004]
been treated since 2001 by a nanofiltration plant. One

objective is the recycling of heavy metals and phosphates.
Thus, the concentrate is used as replenisher for phosphating. The permeate is used with additives to flush the car
components after degreasing. Approximately 2 m3/h of
process waste water is treated by the nanofiltration plant
(Figure 3-29). The service life of the membranes is approx.
3 years.
Thanks to the operation of the nanofiltration plant, freshwater and chemical consumption were lowered and the
waste water load was reduced. The total costs of the process were lowered by 15 %.
The process concept presented above comprises as a final
step the recirculation of the anolyte in paint-spraying
(cathodic dipcoat) by single- or multistage reverse osmo-
Especially in the car industry it is useful to treat and to
sis and the prolongation of the service life of the dipcoat
recycle single process water flows because small volume
bathes by treatment of the liquid by means of an ultrafil-
flows can be treated effectively and valuable substances
tration plant. The realization of these measures for further
can be recovered. These valuable substances are found,
reduction of the fresh-water and chemical demand is in
among other places, in the process water flows resulting
the planning stage.
from the paint-spraying of car components.

The company imb+frings watersystems gmbH has developed in cooperation with Henkel Surface Technologies a
process concept for the recycling of water and valuable
substances from paint-spraying for the Ford works in
Cologne. The concept provides separate treatment for
each of the process water flows from degreasing, phosphating and paint-spraying (Figure 3-28). The treatment
of waste water from phosphating by nanofiltration
has been already implemented.
The process waste water from the degreasing bath for
cleaning of the car parts are treated by an ultrafiltration
plant. The permeate is used for flushing. Thus the freshwater and chemicals consumption can be reduced. The
concentrate is discharged as waste water.
212
3.5.10
UF
Pharmaceutical Industry, Schering
Membrane process
Ultrafiltration
Start-up
2003
Objectives
Optimized waste water treatment according to the state of the art
15,840 m2
Modules
Cassettes/capillary membranes
~ 150 m3/h
Pretreatment
Primary settling
Benefit
Reduction of waste water disposal costs
The foundations for the company Schering were laid in
To ensure waste water treatment according to the state of
1851 by Ernst Schering who opened the Green Pharma-
the art and satisfying the quality requirements of the re-
cy in the north of Berlin. Today Schering AG employs
ceiving water body, Schering AG tested the possibility of
approx. 26,000 people in 140 subsidiaries in the develop-
an industrial waste water pretreatment plant with mem-
ment and production of drugs as a main field of activity.
brane bioreactor technology. This process turned out to

be economically end ecologically efficient. The membrane
At the Bergkamen site, active agents are made as a basis
installation, which is nationwide the largest for the treat-
of drug production. Due to changing batch production,
ment of industrial waste water, has been in operation since
the composition of the waste water varies depending on
2003 (see Figure 3-30). Since 1st July 2004, the treated
the production process. Until 2003, the waste water was
waste water has been discharged directly.
temporarily stored after pretreatment in a mixing and

equalizing tank and then discharged into the nearby
The membrane bioreactor at the Bergkamen site treats on
municipal waste water treatment plant.
average 3,500 m3 of waste water per day. Its composition

is presented in Table 3-5.
Figure 3-30
Aerial photograph of the waste water treatment plant at Schering AG [photos: SCHERING AG 2004],
left: general view, right: side view of the membrane installation
213
Table 3-5
Inflow values, effluent requirements and operating values of the plant [SCHERING AG 2004]
Parameter
Unit
COD
mg/l
Inflow (mean values)

3,500
Effluent requirements*
Operating values
> 90 % reduction
compliance with the requirements
BOD5
mg/l
1,500
Ntot
mg/l
95
< 50 mg/l
Ptot
mg/l
< 2 mg/l
below detection limit
* according to Annex 22 of the Waste Water Ordinance
Figure 3-31
Flow sheet of the waste water treatment plant [according to SCHERING AG 2004]
membrane stage
denitrification
waste water
neutralisation
and primary
treatment stage
nitrification
waste water
buffer tank
receiving
water
emergency
catch
basin
recirculation
excess sludge
sludge
storage
Figure 3-31 shows the flow sheet of the waste water treat-
The three-line activated sludge stage with a total volume
ment. The first stage consists of to primary settling tanks
of 9,000 m3 is realized with upstream denitrification and
connected in series with a volume of 1,000 m3 each. They
nitrification, followed by the membrane installation with
serve to neutralize the waste water, to dose precipitants
four lines. The membrane installation consists of 36 mem-
and flocculants and to separate solids and precipitation
brane cassettes of the type ZW 500c from the company
products.
ZENON (Figure 3-32). It has a total membrane surface

area of 15,840 m2. After membrane filtration, the treated
waste water is discharged into the receiving water.
214
Two aerated sludge storage tanks with a total volume of

3
Figure 3-32
1,700 m have been built to manage the excess sludge.
Optical inspection of a membrane module
Three tanks with a total volume of 20,500 m3 are available
[photo: SCHERING AG 2004]
as emergency catch basins.

The investments for the new construction of the plant,
which mainly comprised the activated sludge tanks and
the membrane installation, were approx. 10 million Euro,
1.6 million Euro of which had been granted as funds by
the state North-Rhine Westphalia.
3.5.11
Miscellaneous
3.5.11.1
Landfill Leachate
Besides gas and odour, landfill leachate is one of the main

emissions from landfills for municipal waste. During the
the combination of a biological stage and oxidation or

activated carbon (Figure 3-33) and
amendment of the Federal Water Act in 1986, it has been

defined for the first time as waste water which has to be
the combination of reverse osmosis, high-pressure re-
treated [HENSS, OPITZER 1995]. In general it is highly
verse osmosis; if necessary nanofiltration and discharge
polluted by organic and inorganic matter, and the load
of the residues.
may vary considerably over the life of the landfill.

Besides these process variations, others are also used, e. g.
Various processes and process combinations exist for the
the extension of the biological pretreatment stage (from
treatment of landfill leachate [ATV 1993, VDMA 1994] to
the first bullet) by an integrated membrane stage.
produce a permeate which can be discharged without

restriction (Waste Water Ordinance, Appendix 51 [ABWV
The reverse osmosis process belongs to the state of the
2002]). Often a single process is not sufficient to achieve
art in leachate treatment [ATV 1993]. Many years of con-
the desired result.
tinuous operation of numerous large-scale installations

prove that the organic and inorganic constituents present
During the last years, two process combinations for the
in dissolved form in the leachate can be separated by 98
treatment and processing of landfill leachate have domi-
99 % with the help of reverse osmosis, at relatively low
nated [PETERS 1996]:
expense, if modules and installation systems are adapted
215
Figure 3-33
Process combination according to the state of the art for the treatment of landfill leachate
without using membrane processes [ROSENWINKEL, BAUMGARTEN 1998]
energy
excess sludge
oxidation (ozon)
raw leachate
biological pretreatment
treated leachate
activated carbon
regeneration
carbon source
Figure 3-34
Process combination according to the state of the art for the treatment of landfill leachate
using membrane processes with and without biological pretreatment
[completed according to ROSENWINKEL, BAUMGARTEN 1998]
controlled infiltration into the landfill body,

for a certain time and locally limited
concentrate
incineration
evaporation
drying
integration
oxidation
activated carbon
recycling
raw leachate
elimination
membrane process
biological pretreatment
residue
treated leachate
(reverse osmosis/nanofiltration)
controlled infiltration into the landfill body,

for a certain time and locally limited
residue
nitrogen
compound
nitrogen
removal
concentrate
evaporation
incineration
activated carbon
integration
recycling
raw leachate
216
gravel filter
residue
elimination
membrane process
(reverse osmosis)
treated leachate
to the specific problem [PETERS 1998, PETERS 2000].
Using membrane technology, there are three alternative
Operating results obtained with semi-industrial and large-
strategies for managing the leachate concentrates
scale membrane installations for leachate treatment have
[PETERS 2000]:
been documented and analyzed by BAUMGARTEN [1998].

Studies realized by THEILEN [2000] have shown that a
incineration of the concentrate in installations which
combination of conventional filtration (bag or cartridge
are especially equipped and certified for the discharge
filter) and one or two membrane stages is very well suited
of high-loaded liquids,
for the treatment of raw leachate. By means of a first membrane stage (e. g. cushion or tube modules) and a second
integration of the concentrate into various materials,
stage which is possibly required (cushion or spiral-wound
followed by deposition of the dry residues on the land-
modules), a permeate is produced from the high-loaded
fill,
leachate which has nearly surface water quality. Figure

3-34 presents process combinations for the treatment of
controlled infiltration of the concentrate into the land-
landfill leachate using membrane processes (reverse osmo-
fill body (for a certain period and locally limited) in
sis, nanofiltration) with and without biological pretreat-
order to improve the biochemical degradation process
ment according to the state of art.
of the organic waste and to accelerate the immobilisation of the organic material.
However, in leachate treatment, too, membrane processes

meet with their limits due to the development of irrevers-
The third alternative leads to an increase of the gas pro-
ible covering layers. Since the leachate matrix is very
duction and, with this, to accelerated reduction of the
complex, these process limitations cannot be determined
organic material in a landfill. Comprehensive studies as
on the basis of analytical results, but have to be deter-
well as knowledge acquired from many years of experi-
mined onsite for each individual leachate [ROSENWINKEL,
ence confirm that over the long term no noticeable
BAUMGARTEN 1998].
changes in the leachate quality are observed [PETERS

2000].
217
3.5.11.1.1
RO
Alsdorf-Warden Landfill
Membrane process
Two-stage: reverse osmosis, high-pressure reverse osmosis
Start-up
1999
Objectives
Treatment of the leachate, and thus protection of the landfill
Membrane surfacee area
approx. 460 m2
Modules
Disc tube modules
approx. 4.8 m3/h
Pretreatment
Gravel filter for separation of coarse matter and gravel filter
Benefit
Ensuring of the leachate treatment
The company Abfallwirtschaft Kreis und Stadt Aachen
The two-stage reverse osmosis installation (Figure 3-35)
GmbH (AWA) (Waste Management for the District and
for leachate treatment is owned and operated since 1995
the City of Aachen) operates the central landfill Alsdorf-
by the company Pall.
Warden (commissioned in 1976), where only inorganic

waste is deposited. Within the scope of its capacity, the
Both stages are equipped with so-called DT modules (disc
central landfill also accepts inert material from external
tube modules) from the company Pall. To protect the
corporations.
installation, a gravel filter for the separation of coarse

matter and a cartridge filter are arranged upstream. The
For leachate treatment, two installations are used. One of
installation comprises 60 modules in total, 44 of which
them is a two-stage reverse osmosis installation which is
are used in the leachate stage, 13 in the first concentrate
described in the following.
stage (120 bar) and 3 in the second concentrate stage

(150 bar). Each module has a membrane surface area of
approx. 7.6 m2, so that a total membrane surface area of
Figure 3-35
about 460 m2 is available. At present, 5 m3 of leachate are
Reverse osmosis installation at the landfill Alsdorf-
treated per hour, 92 95 % of which is yielded as per-
Warden [MAURER 2001]
meate. The permeate is fed to the waste water treatment

plant, and the brine is discharged externally.
The membranes used are composite membranes with an
active layer from polyamide (Figure 3-36). Cleaning of
the membranes is required once or twice a week. Replacement of the membrane has not yet been necessary since
starting up the installation.
Landfill leachate is treated exclusively for ecological reasons. Thus the benefit of the two-stage reverse osmosis
system is ensuring environmentally oriented operation
and possible aftercare of the landfill.
218
Figure 3-36
Structure of the composite membrane [MAURER 2001]
ultra-thin active layer

from modified polyamide
microporous intermediate layer

from polysulfone
0,2 m
40 m
supporting
fabric from
polyester
120 m
In North-Rhine Westphalia there are many other sites

(e. g. Essen, Cologne, Mnchengladbach) where landfill
leachate is treated by membrane technology and biological treatment or other processes (e. g. adsorption on activated carbon).
219
3.5.11.2
MF
Fish Hatchery
Membrane process
Microfiltration
Start-up
2004, pilot plant
Objectives
Reuse of the waste water / closure of water circuits
21 m2
Modules
One-decker plate modules
~ max. 8 m3/h
Pretreatment
Not necessary
Benefit
Savings of costs for fresh water and waste water discharge
Since the middle of the seventies, considerable efforts
module consisting of 35 filter plates with a total filter
have been made in the field of fresh-water aquaculture to
surface area of 21 m2. The pore size of the membranes is
develop innovative, non-polluting and resource-conserv-
0.4 m. Below the filter module, air exhaust devices are
ing technologies for economic and environmentally
arranged which serve to clean the filter surface area and
compatible intensive fish hatchery The development of
to supply the sludge with oxygen. A second module exists
so-called closed-circuit plants was of special importance.
which can be used to double the filter surface area.
Since the middle of the nineties, the membrane bioreactor technology has been available as an innovative pro-
To ensure an internal sludge circuit between nitrification
cess for the realization of closed-circuit plants. The suita-
and denitrification, the circulation pump feeds sludge
bility of this process for the treatment of waste water from
from the filter tank into the denitrification stage.
fish hatcheries was confirmed by studies with a pilot plant

membrane bioreactor (see Figure 3-37) that was installed
The permeate pump sucks the treated water through the
on the test facility of the Umweltbundesamt at Berlin-
membranes and recycles it into the fish hatchery tank.
Marienfelde.
The pump operates constantly, apart from regular pauses

serving for better cleaning of the filter surface areas. The
The pilot plant consists of a tank for fish hatchery, which
water exchange rate for the fish hatchery tank is deter-
is approx. 4 m high and made from fibreglass-reinforced
mined by the turn-on and pause times of the pump and
plastic, and the treatment plant. A pump feeds the water
on the volume flow which can be chosen between 1 and
together with the settled sediment (throughput: 1.7 L/s)
8 m3/d.
in intervals from the tank into the denitrification stage,

which consists of three PE tanks equipped with agitators.
The excess sludge and the waste water flow from the fish
The volume of the denitrification stage can be adjusted
hatchery tank which is not recycled are discharged into
to satisfy the requirements of the test operation by a ver-
the waste water treatment plant.
tically adjustable overflow. Thus, the volume in the denitrification stage can be varied between 0.4 and 1.4 m3.
The work up to market maturity is continued in a project
Nitrification takes place in the membrane stage with a
of Deutsche Bundesstiftung Umwelt (DBU) (German Fede-
volume of approx. 1 m3. This tank contains the membrane
ral Foundation Environment).
220
Figure 3-37
Flow sheet of a circuit installation for the treatment of waste water from fish hatchery
[UMWELTBUNDESAMT 2004]
fresh water
recycling flow
tank
membrane stage
nitrification stage
denitrification stage
waste water to
treatment plant
DN 1
DN 2
excess sludge
DN 3
blower
installation
recirculation
3.5.11.3
UF
Power Stations, Dresden Gas and Steam Turbine Heating Power Station (GuD)
Membrane process
Ultrafiltration
Start-up
1996
Objectives
Cleaning of oil-contaminated cooling water or heating circuits by separation of emulsified oil from the
circuit water by means of ultrafiltration
15.2 m2
Modules
Ceramic multichannel elements
Filtrate volume flow
Up to 2.5 m3/h
Pretreatment
Cartridge filter < 1 m
Benefit
Rehabilitation of the cooling or heating capacity of oil-contaminated cooling or heating circuits

without downtimes of the power station
The Dresden gas and steam turbine heating power station,
branched intermediate cooling water system of the power
Nossener Brcke, was built in 1995. It has an electric out-
station. This free oil has deposited at different heat-ex-
put of 270 MW, a thermal output of 455 MW of heating
changing surfaces which resulted in deterioration of the
water and 25 MW of steam. Since 1997 the power station
heat transfer and thus of the cooling performance of in-
belongs to the DREWAG. In the middle of the operating
dividual pieces of equipment.
year 1996, turbine oil got into the long-winded and
221
Exchange of the cooling water quantity of approx. 90 m3
A RKU plant is conceived as a mobile unit and can be
and flushing of the cooling water system would not have
adapted with high flexibility to the local condition. It
been sufficient to clean the cooling system because it con-
consists of the main components prefiltration, raw water
sists of pipes of various diameters and different aggregates
storage tank, ultrafiltration unit (Figure 3-39) with four
with hydraulic dead zones. Alternatively, it would have
modules connected in series with 3.8 m3 of membrane
been necessary to change out all components of the pro-
surface area each, circulation tank, filtrate tank, and a
cess equipment separately and to flush them. Besides the
CIP device for cleaning of the membranes.
expenditure for cleaning of the individual aggregates,

temporary shut-down of the power station would have
In the case of the Dresden gas and steam turbine power
been required.
station, the oil sticking to the surfaces of the cooling water circuit was emulsified with the help of a specifically
In order to solve the problem, a process was developed
chosen emulsifier which was added to the cooling water.
jointly by the THERM-SERVICE fr Kraftwerke und Indus-
This emulsion was treated by the ultrafiltration unit con-
trie GmbH and the DPC, Dr.-Ing. Peters Consulting fr
nected in bypass. It is equipped with ceramic membranes
Membrantechnologie und Umwelttechnik, using the
and operated in cross-flow mode. The treatment took
module technology of atech innovations GmbH. This
place in batches. The permeate, which still contained
patented process was introduced under the designation
part of the emulsifier, was recycled into the circuit. The
RKU (Reinigung lkontaminierter Khlwasserkreislu-
concentrate, in which the oil micro-droplets separated
fe mit Ultrafiltration und Emulgierung bei laufendem
from the emulsion, was discharged. In this way, about
Blockbetrieb Cleaning of oil-contaminated cooling
1,600 L of oil were removed from the intermediate cool-
water circuits by ultrafiltration and emulsification at
ing water circuit of the Dresden gas and steam turbine
running block operation). Compared to the conventional
heating power station. After having attained the desired
procedure, the costs are lower and cost-intensive down-
residual oil content, the emulsifier is removed from the
times are avoided. Figure 3-38 shows the flow sheet of
circuit water, which is accordingly conditioned.
the RKU process.
Figure 3-38
Flow sheet of the RKU process [according to DPC 1997]
permeate
tank
cooling water without oil
ultrafiltration
concentrate
cooling water
circulation
emulsifier
222
cartridge filter
oil-loaded cooling water
raw water
storage
circulation
tank
oil discharge
Other examples for the use of this ultrafiltration-based
Figure 3-39
process were the rehabilitation in the heating power sta-
Ultrafiltration unit for the RKU process
tion Zolling of Isar-Amper Works in 1997 (separation of
[photo: THERM-SERVICE]
approx. 1,000 L of lubricating oil from the intermediate

cooling water circuit with a content of 300 m3) and in
1998 the cleaning of an intermediate cooling water circuit with a content of 130 m3 and 400 heating elements
in a hospital at Rottweil (removal of 2,600 L of lubricating oil).
3.5.11.4
UF
De-oiling of Bilge Water
Membrane process
Ultrafiltration
Start-up
1989
Objectives
Discharge of bilge water
23.6 m2
Modules
Tube modules
3 m3/h
Pretreatment
Oil separation
Benefit
Saving of volume on the ship, contribution to environmental protection
Various types of oily residues result from navigation (in-
as well as river or sea water in unknown concentrations
land or other navigation), which accumulate in the bilge,
[FURTMANN ET AL. 2001]. Therefore, the bilge water has
the deepest place in the machine room of a ship. This
to be pumped out periodically, i. e. the oil-water mixture
oily waste water, called bilge water, is a mixture of oil,
from the bilge has to be eliminated. In the past, the bilge
lubricating grease, fuel residues, cooling water, condensed
water was pumped out into a water body, but this has
water, antifreeze and anticorrosive agents, cleaning agents,
been prohibited since 1963.
223
Figure 3-40
Flow sheet of bilge de-oiling [according to DEUTSCH 2001]
sucking-off
from the bilge
oil phase
delivery
ashore
separator
collecting tank for
used oil
water phase
concentrate
recirculation after closing
the influent
ultrafiltration
permeate
In order to ensure the discharge of the bilge waters, the
lected in a tank and, according to the water content,
riparian Federal States of river Rhine have established in
reprocessed or submitted to thermal treatment. The ther-
1965 the Bilgenentwsserungsverband (bilge drainage as-
mal treatment is performed by other companies.
sociation). This is a corporation under public law, which

is under legal supervision of the Land North-Rhine West-
The water phase is fed to an ultrafiltration system (from
phalia. To fulfil its duties, the association makes use ot
the company Berghof) operated in cross-flow mode. Tube
the Bilgenentlungsgesellschaft mbH (bilge de-oiling
modules with polymer membranes and a molecular sepa-
company), which accepts and treats the bilge water free
ration size of 100,000 Dalton separate more oil from the
of charge from all ships (independent of their country of
water phase at an operating pressure of 7 bar. The total
origin).
membrane surface area (23.6 m2) produces 3.0 m3 of filtrate per hour, which according to the permission of the
The Bilgenentlungsgesellschaft mbH was established in
responsible water authority complies with the limit
1961 and employs 25 people. It is responsible for bilge
values and is discharged directly into a water body.
de-oiling of all inland navigation ships in the Federal

Republic of Germany south of Mnster. (For Hamburg,
The concentrate is fed again to the ultrafiltration system
Bremen and Berlin, other institutions have taken over
and is further concentrated. After several passes, only a
this task.) The company operates several bilge de-oiling
few litres of oil-containing concentrate are left which are
boats which separate the oil from the water phase by
also collected in the oil tank and either reused or dis-
gravity separators and, in addition, since 1989, by ultra-
charged. Depending on their operation, the membranes
filtration.
are backwashed once or twice a week. Practice has shown

that the service life of the membranes is about 15,000
The bilge water is sucked off and preseparated by a cascade oil separator (see Figure 3-40). The oil phase is col-
224
operating hours.
3.5.11.5
Swimming Pools
In swimming-pool water, in addition to small pollutants,
From time to time the filter has to be cleaned by back-
also water-soluble and emulsifiable substances (e. g. sweat,
washing (mostly with splash water). The sludge water
residues of skin cream and suntan lotions) accumulate
from backwashing is collected and discharged into the
and must not exceed certain concentrations. In usual
swimming-pool operation, this is managed by dilution

with drinking water which is pumped into the filled pool.
Between 30 L [DIN 19643] and 120 L of water per guest
Due to this pumping and water displacement by bathing
are consumed by discharge of water into the sewer sys-
people, water splash water flows off via the overflow
tem and addition of fresh drinking water.
launder into a splash-water tank. After having passed a

conditioning facility, the filtered water is fed back into
Due to water evaporation and refilling, the water hard-
the swimming-pool.
ness, consisting of lime and magnesium salts, increases.

From chlorination and correction of the pH, other salts
develop. Moreover, big swimming-pool companies with
brine pools face the problem that brine is carried over to
the normal swimming-pool water.
3.5.11.5.1
UF
RO
Swimming Pool, Aquana Freizeitbad GmbH & Co. KG
Membrane processes
Ultrafiltration (UF), Reverse osmosis (RO)
Start-up
1998
Objectives
Reduction of the freshwater quantities needed
42 m2 (UF), 140 m2 (RO)
Modules
Capillary modules (UF), spiral-wound modules (RO)
In total (UF and RO) 5 m3/h
Pretreatment
Prefiltration
Benefit
Saving of freshwater and energy for heating
Established in 1998, the city of Wrselen is 100 % respon-
For this purpose, two membrane filtration stages operate
sible for this leisure facility with 30 employees.
in series to treat sludge water (from filter backwashing),

shower water, water from washbasins and rainwater. In
In order to reduce the large freshwater quantities which
addition they remove substances such as organic chlorine
are necessary in conventional filtration, an ultrafiltration-
compounds, washing and cleaning agents and urine com-
and reverse osmosis installation (degebran GmbH Anla-
ponents (Figure 3-41). The membrane systems operate in
genbau) was planned and commissioned in 1998 in the
cross-flow mode. After prefiltration, back-washable capil-
course of the new construction of Aquana Freizeitbad.
lary membranes with a total filter surface area of 72 m2

separate in the first ultrafiltration stage solid pollutants
The plant is not integrated into the pool-water cycle, but
and suspended substances. From this filter cycle, 10 % of
serves to recover about 70 % of the large water quantity
concentrate is continuously withdrawn and discharged as
which is necessary for backwashing of the sand filters.
waste water. The filtrate is fed to the second stage, the
225
Figure 3-41
Water recirculation and treatment at the Aquana Freizeitbad [according to DEGEBRAN ]
overflow
channel
swimming-pool
splash water tank

normal operation
filter backwashing
shower
waste
clean water
activated carbon
adsorber
rain
waste
sludge water
permeate
reverse osmosis
brine as process
water
filtrate
ultrafiltration
prefilter
raw water
concentrate
reverse osmosis installation, where spiral-wound

2
Thanks to this process, up to 80 % of the freshwater
modules (140 m filter surface area) also reject dissolved
quantity used before, needed as filling water, is saved.
substances. The permeate of this second stage is recycled
In addition the energy demand is reduced because it is
via activated-carbon adsorption into the swimming-pool
possible to recycle the permeate in warm state into the
water cycle, while the brine, which contains more salts,
pool cycle without additional heating. The amortization
is used as process water. The total capacity of the system
period of the investment of 383,000 Euro is calculated at
is 5 m3 per hour.
three years.
226
3.5.11.5.2
UF
Swimming Pool, Freizeitbad Copa Ca Backum
Membrane process
Ultrafiltration
Start-up
August 1998
Objectives
Reduction of the freshwater quantity needed and ensuring disinfected water
300 m2
Modules
Hollow-fibre membranes
10 m3/h
Pretreatment
Sedimentation, particle separation by screening
Aftertreatment
Oxidation, adsorption, disinfection
Benefit
Saving of freshwater and energy
The Freizeitbad Copa Ca Backum (leisure facility) is oper-
To remove the developing covering layer from the mem-
ated by the Hertener Stadtwerken GmbH (municipal ser-
brane, backwashing every half hour (by reversing the flow),
vices). With the objective to reduce the freshwater de-
combined with air cleaning (hourly), is necessary. Che-
mand and to ensure a hygienic water quality, the Herte-
mical (alkaline) cleaning of the membranes is performed
5)
ner Stadtwerke GmbH and the L.V.H.T.-Institut , Essen
every four weeks. With this operating mode, the service
(scientific assistance) developed a process for the treat-
life of the membranes is expected to be five years.
ment of waste waters from public swimming-pools and

commercial plants. Since August 1998, this process com-
After additional treatment stages (oxidation as well as
bination, which includes membrane technology, has been
adsorption on activated carbon and final disinfection
used in the Freizeitbad Copa Ca Backum for the treatment
with chlorine), the filtrate has drinking water quality. It
of pool water, sludge water and shower water.
is collected in a storage tank and used as pure water for

filling of the swimming pool or for filter backwashing.
The used water from bathing and part of the shower water
are collected in a raw-water tank, where particulate sub-
The sludge water from filter backwashing is discharged
stances settle and are separated by a screen (Figure 3-42).
into the raw-water tank and flows together with the used
The downstream ultrafiltration installation serves for
pool water and the shower water through the treatment
pre-liminary treatment of the combined process water.
cycle described above. Water losses resulting from the
Polymeric hollow-fibre membranes (Pall system) separate
treatment and through evaporation or carry over in the
in dead-end mode undissolved particles and turbidity as
bath are compensated for by feeding freshwater.
well as oils, fats and ointments, so that only dissolved

substances are fed to the following process stages. In
Although freshwater is regularly fed, the salt content in
total, the six modules with a filter surface area of 50 m2
the swimming-pool water may increase by up to 10 15 %
each process a permeate volume of 10 m per hour.
in a year, due to recirculation of the backwashing water

and evaporation losses. But this is not relevant since according to DIN 19643 the complete pool volume must be
exchanged once a year.
5)
L.V.H.T.- Lehr- und Versuchsgesellschaft fr innovative Hygiene-Technik mbH, Institut fr angewandte Bau- und Bderhygiene GmbH, Essen
227
Figure 3-42
Water treatment at the Freizeitbad Copa Ca Backum [according to L. V. H. T. 2001]
shower water
swimming-pool
sludge water
raw water
ultrafiltration
sludge water from

backwashing
filtrate
oxidation
backwashing water
In the process combination presented above, the membrane technology is only employed as an upstream treatment stage. The economic advantages, such as savings of
freshwater and energy, are therefore related to the whole
system. With adherence to freshwater savings of 60 %
and the forecasted energy savings of 50 %, the plant will
be amortized after approx. 3 5 years.
228
filling water
storage tank
adsorption
final disinfection
3.6
Sample Applications of Plants Outside of Germany
The use of different membrane processes in Germany is
in chapter 3.5 according to the branches of industry in
described in the subsections of chapter 3.5. The subsec-
which the installations are used. All examples described
tions of this chapter deal with examples from internatio-
in the following are listed in Table 3-6.
nal practice. The examples are sorted in the same way as
Table 3-6
Sample applications for the use of membrane technology in industrial waste water treatment outside of
Germany
Branch of
Company
Location
Start-up
industry
Food industry
Membrane
Modules
Kellogg
Manchester
Membrane sur-
Chapter
face area m2
process
2004
UF
Tube modules
2004
UF
Immersed
5 216
3.6.1.1
1,188
3.6.1.2
(Great Britain)
Chemical
Raisio Chemicals
industry
Veurne
(Belgium)
rotating plate
modules
Food industry
Dairygold
Food industry
Dairy Crest
Mitchelstown
2000
UF
Tube modules
648
3.6.1.3
2003
UF
Tube modules
486
3.6.1.4
2004
UF
Immersed capil-
8,000
3.6.1.5
(Ireland)
Davidstow Camelford Creamery
(Great Britain)
Malthouses
Sobelgra n. v.
Antwerpen
(Belgium)
Laundries
Laundry Massop
Kerkrade
lary modules
1998
RO
(The Netherlands)
Pharmaceutical
Sandoz/
Barcelona
industry
BIOCHEMIE
(Spain)
Animal carcass
SARIA
Bayet
disposal
Mechanical-biological waste
Mallorca
250
3.6.2
1,440
3.6.3
1,800
3.6.4.1
100
3.6.4.3
modules
2003
MF
Immersed plate
modules
2000
UF
(France)
Tirme
Spiral-wound
Immersed capillary modules
2004
UF
Tube modules
(Spain)
treatment
229
3.6.1
Food Industry
3.6.1.1
UF
Muesli Production at the Kellogg Company,

Great Britain
Membrane process
Ultrafiltration
Start-up
2004
Objectives
Compliance with the requirements for indirect discharge and reduction of the costs for waste water treatment
5 x 216 m2
Modules
Tube modules
60 80 m3/h
Pretreatment
Rotary screen and decanting centrifuge
Benefit
Reduction of the effluent charge, expandable waste water treatment plant with low space requirement
Today the Kellogg Company has 25,000 employees in
Depending on the production batch, the waste water
19 countries who make more than 50 different cereal
may contain solids which are removed by a rotary screen.
products in 19 countries.
However, cocoa powder cannot be separated by sieving.

In this case, the waste water containing cocoa powder is
At the Manchester site, considerable quantities of flush-
detected by turbidimetry and is subsequently fed into a
ing water and waste water with different constituents
decanting centrifuge for the separation of solid matter.
(corn components, cocoa, sugar etc.) result from the pro-
The liquid phase is fed to the biological treatment stage
duction of muesli. Up to 2003, the waste water was only
where the dissolved organic constituents are degraded.
treated by a curved screen to separate the solid matter.
The biological treatment stage is realized according to the

activated sludge process, combined with externally arrang-
The main reason for the planning of an efficient waste
ed ultrafiltration for biomass separation according to the
water treatment plant in 2003 construction was the con-
BIOMEMBRAT process from Wehrle Umwelt GmbH.
tinuously increasing waste water fees. It was put into
The five-line ultrafiltration installation (Figure 3-44) is
operation in 2004.
operated in cross-flow mode. It produces 60 80 m3 of

permeate per hour. Depending on the waste water quantity,
For expansion of the waste water treatment plant, a pro-
the individual UF lines can be connected or disconnected.
cess was to be chosen which had a low demand for space
The resulting excess sludge is mixed with the cocoa-
and was able to cope with highly variable pollution loads
containing waste water in the aerated storage tank of the
and water quantities. Moreover, it should be expandable
decanting centrifuge. The solids are subsequently separated
with the ability to recycle the treated waste water. Figure
in the decanting centrifuge and discharged.
3-43 shows the flow sheet of the waste water treatment

plant.
230
Figure 3-43
Flow sheet of the waste water treatment plant at the Kellogg Company in Manchester
ultrafiltration
buffer tank
feed
activated sludge
tank
liquid phase
rotary screen
solids
receiving
water
turbidimetry
storage tank
decanter
decanter
solids
recirculation
Figure 3-44
and the energy costs for activated sludge separation by
Cross-flow ultrafiltration at the Kellog Company in
the cross-flow ultrafiltration membranes. On top of that
Manchester [photo: WEHRLE UMWELT GMBH 2004]
there are the costs for membrane replacement (membrane

exchange every four years is prognosticated) and the costs
for the application of membrane cleaning agents (chemical cleaning every 6 8 weeks, according to empirical
values from other installations).
The energy consumption of the biological stage depends
on the incoming COD load. The energy uptake of the external cross-flow ultrafiltration is a function of the
specific filtrate capacity. The possibility to connect individual ultrafiltration lines depending on the waste water
quantity and an automatic control of the aeration devices
allows for an energy-saving operation mode of the waste
water treatment plant.
The investment for the membrane installation was
930,000 Euro. The operating costs for the external cross-
The costs for waste water treatment mainly consist of the
flow ultrafiltration system amount to 0.36 s/m3 of perme-
energy costs for aeration of the biological treatment stage
ate, for the biological stage they are 0.38 s/m3.
231
UF
3.6.1.2
Primary Starch Production at Raisio Chemicals, Belgium
Membrane process
Ultrafiltration
Start-up
2004
Objectives
Efficient and compact waste water treatment
1,188 m2
Modules
Immersed rotating plate membranes
Max. 12 m3/h
Pretreatment
No mechanical pretreatment
Benefit
Reduction of the fresh-water demand and of the waste water, reduction of costs
Figure 3-45
Flow sheet of the membrane bioreactor at Raisio Chemicals [according to HUBER AG 2004]
membrane system
permeate
tank
waste water
collector
waste water
blower
installation
production
At the site Veurne/Belgium, the Finnish company Raisio
Figure 3-46
Chemicals, which was taken over in March 2004 by Ciba
Huber VRM process (rotating modules)
Spezialittenchemie, makes primary starch products from
[photos: HUBER AG 2004]
starch for the food industry, photographic industry and

the pharmaceutical industry.
The processing of the primary starch products requires
large amounts of fresh-water, so that a closed water circuit
would be useful for both economic and ecological reasons.
A waste water treatment plant suited for the site Veurne
had to be not only efficient but also compact due to restricted space. Figure 3-45 shows the flow sheet of the
membrane bioreactor.
232
The process technology for the installation, which was
process is the rotating plate membranes immersed in the
commissioned in 2004, consists of a mixing and com-
waste water. By the rotating membrane plates, combined
pensating tank, the membrane bioreactor and a permeate
with air input, optimized covering layer removal can be
storage tank. The waste water from the production is
attained. The membrane installation can be expanded
homogenized and fed into the activated sludge stage
with up to two additional plate membrane modules of
(V = 1,800 m ) in which two plate membrane modules of
the type VRM 20/252.The treated waste water is fed into
the type VRM 20/198 from the company Huber are
the production process via a permeate storage tank.
immersed (Figure 3-46). A special feature of the VRM
3.6.1.3
UF
Dairygold Food Products, Ireland
Membrane process
Ultrafiltration
Start-up
2000
Objectives
Compliance with the demands on the effluent quality during the milk season
648 m2
Modules
Tube modules
80 - 90 m3/h
Benefit
Relief of the existing activated sludge plant, compliance with the effluent standards
Dairygold Food Products is one of the biggest and lead-
ment of the waste water from whey treatment (approx.
ing dairies in Europe, with its headquarters in Michels-
2,000 m3/d) by a membrane bioreactor. In 2000, a new
town, Ireland. Dairygold Food Products produces milk
installation according to the BIOMEMBRAT process
powder, cheese and butter and runs a meat and sausage
from the company Wehrle Umwelt GmbH was built.
factory. At the site in Michelstwon, 5,000 m3 of waste

water are produced per day which is treated by a conven-
The concept provides the operation of the membrane
tional activated sludge plant. During the milk season
installation during the summer months with higher
from March to November the waste water volume increa-
loads and its shutting-down in winter. During winter
ses to 7,000 m3/d, due to whey processing. The increase
time, the membrane modules are preserved and stored.
of the waste water volume and of the COD load exceeded
The required short start-up phase in the beginning of the
the treatment capacity of the existing activated sludge
season is of special importance. Especially in times with
plant so that in the milk season the biological treatment
peak loads, the membrane installation contributes to a
stage was overloaded, which resulted in an exceedance of
considerable improvement in the effluent concentrations
the effluent limits. This situation was the reason to study
of the whole waste water treatment plant. Figure 3-47
the technical and economic efficiency of separate treat-
shows the flow sheet of the waste water treatment plant.
233
Figure 3-47
Flow sheet of the waste water treatment plant at Dairygold Food Products, Ireland
denitrification and
nitrification tank
clarifier
recirculation
sludge
membrane stage
feed
receiving
water
seasonal
activity
denitrification and
nitrification tank
recirculation
recirculation
Figure 3-48
The membrane bioreactor consists of an upstream deni-
Complete plant at Dairygold Food Products with
trification tank (V = 400 m3), a nitrification tank (V =
the membrane installation in the foreground
2,000 m3) and four lines of ultrafiltration, which are oper-
[WEHRLE UMWELT GMBH 2004]
ated in cross-flow mode and serve to separate the biomass.

Each of the four ultrafiltration lines has a membrane
surface area of 162 m2. They can be connected or disconnected individually depending on the waste water quantity. The membranes are tube modules with an inner diameter of the tubes of 8 mm. The mean transmembrane
pressure difference in operation is 0.8 bar. The individual
ultrafiltration lines have to be cleaned chemically in intervals of approx. 4 6 weeks to ensure a constant filtration
capacity. During the last four years the membranes have
not been replaced. A service life of 5 6 years is expected.
The COD inflow concentration of up to 3,600 mg/L
(2,600 mg/L on average) is reduced to 50 mg/L in the
effluent. The effluent requirements of BOD5 < 12 mg/L,
TKN < 15 mg/L and Ptot < 10 mg/l are reliably fulfilled.
234
From 2000 to 2003, the specific energy consumption was

3
total operating costs. The specific operating costs of the
approx. 5 kWh/m on average, approx. 2.8 kWh/m of which
overall membrane bioreactor are approx. 0.90 Euro per m3
was used for ventilation and recirculation and 2.2 kWh/m3
of permeate. However, it must be taken into account that
for membrane filtration. The energy consumption of the
the membrane installation only works about 7 months
biological treatment stage mainly depends on the COD
per year. The investment for the membrane installation
and notrogen loads.
was approx. 700,000 Euro.
The energy demand of the ultrafiltration and the membrane replacement costs make up approx. 23 % of the
3.6.1.4
UF
Dairy Crest Limited, Great Britain
Membrane process
Ultrafiltration
Start-up
2003
Objectives
Expansion of the capacity of the waste water treatment plant
486 m2
Modules
Tube modules
~ 50 m3/h
Pretreatment
Flotation
Benefit
Increase of the production capacity at the same site
The company Dairy Crest, one of the leading dairies in
After flotation, the waste water flow is divided. The daily
England, has increased its production capacity in the
waste water flow is approx. 2,000 m3/d, 1,200 m3/d of
Davidstow Creamery at the site Camelford. This resulted
which are fed into the new membrane stage and 800 m3/d
in an increase in the waste water volume and load. Since
into the existing conventional plant. The effluents of
the Dairy Crest waste water treatment plant had no cor-
both installations, operated in parallel, are then com-
responding reserve capacities, it had to be expanded. The
bined and discharged into the receiving water. The three-
waste water treatment process concept used at Dairygold,
line membrane installation is equipped with tube mod-
Ireland, has also been implemented at the site of the
ules with a membrane surface area of 162 m2 per line. It
company Dairy Crest.
is possible to expand the installation by a fourth line.
The existing conventional activated sludge plant had two
The BIOMEMBRAT installation in the Davidstow Cream-
lines. During expansion, one of these lines was replaced
ery at the site Camelford is able to reduce the influent
with a BIOMEMBRAT installation (Figure 3-49). In addi-
COD load by approx. 98 %, and the Ntot and Ptot loads by
tion, a flotation process was arranged upstream of the
approx. 90 % each. The demands on the effluent of BOD5
biological stage to separate grease and suspended matter
< 10 mg/L and NH4-N < 6 mg/l are met with reliability.
and thus relieve the downstream treatment stages.

The investment for the membrane installation was
550,000 Euro.
235
Figure 3-49
Flow sheet of the waste water treatment at Dairy Crest, Great Britain
denitrification and nitrification tank

clarifier
recirculation
sludge
feed
flotation
process
buffer
receiving
water
membrane stage
denitrification and nitrification tank
recirculation
3.6.1.5
UF
Malthouse Sobelgra n. v., Belgium
Membrane process
Microfiltration
Start-up
2004
Objectives
Compact, space-saving and efficient waste water treatment plant, pretreatment upstream of a planned
reverse osmosis installation
8,000 m2
Modules
Immersed capillary membrane modules
80 100 m3/h
Pretreatment
Curved screen
Benefit
Expansion of the waste water treatment capacity without extensive site construction. In future,
part of the treated waste water will be reused.
236
Figure 3-50
The company-owned waste water treatment plant treats
Aerial photograph of the malthouse Sobelgra in
the waste water from barley processing by a combination
the Antwerpen harbour [photo: PURON AG]
of mechanical presieving, biological stage and membrane

filtration (Figure 3-51).
After removal of coarse impurities by two curved screens
(mesh size: 1.0 mm), the waste water flows into the activated sludge stage, which consists of two tanks for denitrification and nitrification connected in series. The
membrane stage serving for separation of the biomass is
arranged downstream of the activated sludge stage. The
16 membrane modules from the company PURON AG
(Figure 3-52) have been installed in two separate chambers. A third chamber is available for future expansion of
the plant (represented as dotted line in Figure 3-51). The
chambers are fed from below so that the waste water flows
upward through the membranes modules. The permeate
is withdrawn from the membrane modules by means of
The Belgian malthouse Sobelgra is situated in the Antwer-
negative pressure. The concentrated activated sludge is
pen harbour and belongs to the multinational Boortmalt
recycled into the activated sludge tanks. The membrane
group. Sobelgra produces malt for breweries and is at pre-
surface area in the immersed modules is 8,000 m3, it is
sent increasing its production capacity from 110,000 to
able to treat the entire waste water of the company. With
250,000 t/a. This means that the works will become the
this, the installation has a capacity of more than 2,000 m3/d.
biggest independent malthouse in Belgium.
To maintain the filtration capacity of the membrane modules, backwashing with filtrate takes place in regular
Within the scope of production increase, the capacity of
intervals, combined with air rinsing of the membrane
the existing company-owned waste water treatment plant
modules. The chambers can be emptied independently of
had also to be doubled. Due to limited space at the facto-
each other for cleaning and maintenance purposes.
ry site (Figure 3-50), it was impossible to expand the plant

according to the conventional activated sludge process.
About 80 % of the treated waste water will be reused in
The reasons to install the membrane bioreactor process
the production process after installation of the planned
were its compact size and the high volume-specific degra-
reverse osmosis installation.
dation capacity.
237
Figure 3-51
Flow sheet of the company-owned waste water treatment plant of the company Sobelgra
[according to PURON AG]
membrane stage
blower
installation
sieve bend 1.0 mm

biological reactor
feed
sieve bend 1.0 mm
recirculation
recycling
Figure 3-52
Schematic representation of the membrane bioreactor (left) and membrane modules (right)
[photo: PURON AG]
238
3.6.2
RO
Laundry Massop, The Netherlands
Membrane process
Reverse osmosis
Start-up
1998
Objectives
Conservation of water and energy
approx. 250 m2
Modules
8 m3/h
Pretreatment
Integrated two-stage filter (fluff screen)
Benefit
Saving of freshwater, energy and chemicals
The following example illustrates the employment of
The waste water passes an (integrated) two-stage filter
membrane technology for the treatment of waste water
(fluff screen), before it flows into the reverse osmosis in-
from laundries. The installation described is used in a
stallation, which is equipped with spiral-wound modules
laundry in The Netherlands and is similar to two installa-
from polyethylene membranes. With a membrane surface
tions which will be commissioned in the near future in a
area of 250 m2 and at an operating pressure of 10 bar, the
laundry at Lemgo and another one at Olsberg. The reali-
permeate flow is approx. 8 m3 per hour. The permeate is
zation of these projects is supported by funds from a
reused as washing water. The brine is discharged into the
6)
development program of the Ministry for Environment
and Nature Conservation, Agriculture and Consumer Protection (MUNLV) of the Land North-Rhine Westphalia.
The membranes are backwashed once a day and cleaned

with commercial chemicals every third month. Practical
The company Massop at Kerkrade cleans laundry from
operation has shown that under these circumstances the
hospitals and hotels. The waste water from washing is
service life of the membranes is two years.
loaded with contaminants, surfactants, bacteria and salts,

so that it has to treated.
Figure 3-53
The reason for the employment of a membrane installa-
Reverse osmosis installation at the laundry Massop,
tion was the possibility to save water and energy. When
Kerkrade [ROTH 2001]
planning the installation, it was especially important to

consider the close interaction between the membrane
and the detergent applied. For parallel development of
the reverse osmosis (Figure 3-53) and the suitable detergent, the company Henkel-Ecolab GmbH & Co. OHG
(production of detergents and washing agents) cooperated with the company Wientjens, NL. The installation
has operated successfully since 1998 and treats the water
to a sufficient quality for reuse in the washing process.
6)
Development program for production-integrated environmental protection: Action group for ecological and sustainable water management NRW
239
The employment of reverse osmosis for waste water treat-
The development and employment of membrane proces-
ment and the reutilization of the treated water as process
ses for the treatment of laundry waste water is currently
water offer ecological and economic advantages. Besides
being pursued intensely. Besides the described process,
reduced detergent consumption, water (80 %), energy (50 %)
there are other membrane solutions for the treatment of
and softening chemicals (80 %) are also saved. The instal-
laundry waste water that are being developed. In plann-
lation at Kerkrade is leased, which is profitable for the
ing, it is critical to consider the interaction between the
operator. The amortization period of such an installation
membrane and the detergent applied, so that cooperation
may vary depending on the location and the general con-
between installation- or membrane manufacturer and the
ditions, thus it has to be determined for each single case.
detergent producer is imperative.
3.6.3
MF
Pharmaceutical Industry,
Penicillin Production at the Company Sandoz/Biochemistry, Spain
Membrane process
Microfiltration
Start-up
2003
Objectives
Expansion of the waste water treatment capacity at the site of the company-owned WWTP
1,440 m2
Modules
Immersed plate membranes
~ 400 m3/d
Pretreatment
Benefit
Protection of the site when increasing the production volume
With approx. 13,000 employees all over the world, the
Within the scope of pilot tests at the site Kundl of the
company Sandoz (formerly company Biochemie) works
company Sandoz, the membrane bioreactor process using
in the fields of development and production of pharma-
immersed plate membranes from the company Kubota
ceutical, biopharmaceutical and industrial products. In
was compared to other membrane systems at the site of
Barcelona, the company Sandoz makes penicillin for the
the company Sandoz (formerly company Biochemie) and
production of medicine.
implemented as a large-scale installation already in 1999.

The waste water treatment plant at Kundl was expanded
Up to now, the waste water generated from the produc-
in 2002 to a membrane surface area of 1,440 m2.
tion process at the site in Barcelona was treated by conventional processes. The quality of the treated waste
Based on the experience acquired at Kundl and on account
water strongly varied. Moreover, an increase in the pro-
of the comparable boundary conditions, the membrane
duction volume at Barcelona was planned which requir-
bioreactor at Barcelona was equipped with a membrane
ed an expansion of the company-owned waste water
surface area of 1,440 m2 without further pilot tests. Figure
treatment plant. Since an expansion with conventional
3-54 shows the flow sheet of the membrane bioreactor at
process engineering was impossible because of limited
the site Barcelona.
space, it was decided to build a membrane bioreactor.

The installation was commissioned in February 2003.
240
Figure 3-54
Flow sheet of the membrane bioreactor in Barcelona [according to AGGERWASSER GMBH 2004]
biological reactor
membrane stage
1
blower
installation
receiving
water
2
feed
blower
installation
recirculation
After treatment in the existing high-load biological stage

3
approximately doubled. The two-line membrane instal-
with 3 reactors of 500 m each, the waste water volume
lation consists of 6 plate membrane packages from the
of approx. 400 m3/d flows into the membrane separation
company Kubota of the type EK 300. Filtering takes place
stage. For operation of the membrane installation, the TS
at a constant transmembrane pressure of 0.05 0.15 bar.
content in the activated sludge tanks was increased from
Chemical in-situ cleaning is done automatically twice a
approx. 6 g/L to 12 16 g/L. With this, the biological de-
year. The permeate is discharged into a municipal waste
gradation capacity of the waste water treatment plant is
water treatment plant for further treatment.
Figure 3-55
Membrane bioreactor and membrane modules under construction at the company Sandoz in Spain
[photos: AGGERWASSER GMBH 2004]
241
3.6.4
Miscellaneous
3.6.4.1
UF
Animal Carcass Disposal Plant of SARIA

Bio-Industries, France
Membrane process
Ultrafiltration
Start-up
2000, expansion in 2002
Objectives
Compliance with increasing effluent standards and adaptation to capacity enlargement
1,800 m2
Modules
Immersed capillary membrane modules
~ 40 - 50 m3/h
Pretreatment
Fine screen
Benefit
Economic expansion and adaptation of the waste water treatment plant to the state of the art
The company SARIA Bio-Industries operates in Bayet, in
The individual waste water flows from the animal carcass
Central France, an aminal carcass disposal plant. Up to
plant are pretreated in part by flotation, treated mechani-
240,000 t of slaughterhouse waste and perished animals
cally by a fine screen and homogenized in a mixing and
are processed per year at this site. About 1,100 m of pro-
storage tank. The pretreated waste water is pumped into
duction waste water with a mean COD concentration of
an activated sludge tank (V = 4,000 m3) where the orga-
16,000 mg/L are produced per day. Due to increasing de-
nic substances are degraded (Figure 3-56). The activated
mands on the effluent quality and increasing operational
sludge flows through a curved screen with a mesh size of
capacity, the waste water treatment plant at the site of
750 m to protect the membranes from coarse matter
the animal carcass disposal plant at the site Bayet had to
before it is fed in free overflow into the membrane stage.
be adapted to the state of the art.
The membrane stage is realized with four lines (Figure

3-57). Each line is integrated in a filtration container and
The decision-maker of the animal carcass disposal plant
contains capillary membrane modules from the company
chose in 2000 to convert the existing waste water treat-
ZENON (Figure 3-58). At present approx. 1,800 m3 of mem-
ment plant to a membrane bioreactor. After successful
brane surface area are installed. The first membrane line
two-year operation, the installation was expanded already
consists of four immersed modules of the type 500a, the
in 2002.
second line has two immersed modules of the type 500c.

By treatment of the waste water in the membrane bioreactor it is possible to attain COD effluent concentrations
of < 300 mg/L. Thus, the COD load in the installation is
reduced by 98 %.
242
Figure 3-56
Flow sheet of the membrane bioreactor at SARIA Bio-Industries in Bayet
membrane stage
blower
installation
biological reactor
4.000 m3
receiving
water
fine sieve
750 m
feed
blower
installation
recirculation
Figure 3-57
Figure 3-58
General view of the membrane bioreactor of the
Container with fitted modules at SARIA Bio-Indus-
animal carcass disposal plant in Bayet
tries in Bayet [photo: ZENON GMBH 2004]
membrane containers
243
3.6.4.2
Mechanical-Biological Waste Treatment Plant
Mechanical-biological waste treatment has become es-
Depending on the treatment process, approximately half
tablished in Europe as a concept for the treatment of
of the treated solid waste results as waste water which
municipal waste. Biological conversion can take place in
needs treatment. The composition of the waste water
composting plants (aerobically) or in fermentation plants
mainly depends on the raw solid waste (water content,
(anaerobically). Biological conversion in mechanical-bio-
organic part) and on the fermentation process (wet, dry).
logical waste treatment plants aims at biodegradation of
The concentrations of the individual parameters may
the organic constituents to reduce the waste volume and
strongly vary. In principle, intensive conversion during
to get a stabilized final product. From biodegradation
fermentation means higher pollutant concentrations in
and dewatering results complex, high-loaded waste water.
the process waste water.
3.6.4.2.1
UF
Waste Disposal at the Company TIRME, Spain
Membrane process
Ultrafiltration
Start-up
2004
Objectives
Closed production water circuit
100 m2
Modules
Tube modules
5 6 m3/h
Pretreatment
Fine screen
Benefit
Savings of freshwater and waste water
Besides a waste incineration plant, the company TIRME
treats the waste water to such an extent that part of it can
also runs a plant for material separation and mechanical-
be used after treatment for this purpose. The installation
biological waste treatment at Mallorca. At this site, approx.
consists of a mechanical pretreatment stage, an activated
45,000 m of high-strength waste water are produced an-
sludge stage and an ultrafiltration installation (Figure 3-59).
nually which mainly comes from the mechanical-biological waste treatment plant. Additional waste water result
The plant is designed for a throughput of approx.
from the cleaning of yards and vehicles and from the treat-
45,000 m3/a or 140 m3/d of waste water with a COD con-
ment of waste air. The complex waste water composition
centration of 7,300 mg/L and a NH4-N concentration of
requires a combination of treatment processes. At first
2,500 mg/L. The effluent COD concentration has to be
the solids have to be removed from the waste water.
below 1,500 mg/L, which corresponds to a reduction of

approx. 80 %. Ammonium is completely degraded in
For mechanical-biological waste treatment, nitrogen-free
order to reuse the treated waste water as process water in
process water is required. The new waste water treatment
the mechanical-biological waste treatment plant.
plant installed by the company Wehrle Umwelt GmbH
244
Figure 3-59
Flow sheet of the waste water treatment plant at the company TIRME, Spain
fine screen
200 m
denitrification
nitrification
ultrafiltration
to mechanicalbiological waste water

treatment
feed
recirculation
receiving
water
excess
sludge
ultrafiltration
Figure 3-60
Waste water treatment plant at the company TIRME [photos: WEHRLE UMWELT GMBH 2004],
left: membrane installation, right: bioreactors
Mechanical pretreatment of the waste water takes place
modules each which can be operated and cleaned inde-
by settling with subsequent filtration by a fine sieve with
pendently of each other. The membranes are operated in
a separation size of 200 m. After mechanical treatment,
cross-flow mode with a mean transmembrane pressure of
the waste water flows into the activated sludge stage
approx. 4 bar and a flow velocity of 5 m/s. The total mem-
which consists of upstream denitrification with following
brane surface area is approx. 100 m2. The excess sludge is
nitrification (Figure 3-60). The activated sludge is separat-
discharged via the biological stage of the mechanical-bio-
ed in the downstream two-line ultrafiltration stage
logical waste treatment plant.
(Figure 3-60). The filtration lines consist of four tube
245
246
Instructions and Standards

in Membrane Technology
As shown in the preceding chapters, the fields of applica-
activated sludge tank compared to the conventional acti-
tion of membrane technology for waste water treatment
vated sludge process. The change results from the possibly
and the objectives pursued are manifold (see chapter 3.2).
higher dry matter content. It mainly consists of another
The utilisation of a membrane installation has to be exa-
calculation approach for the excess sludge production
mined for each single case and must be adapted to the
and the oxygen consumption as well as in the definition
specific task. This explains the lack of DIN standards and
of a minimum sludge age and a minimum excess sludge
the small number of existing instructions. There are no
production.
standard solutions for the use of membrane technology

and for the design of a membrane installation. However,
The DWA Working Group IG 5.5 Membrane technology
for some applications it is possible to fall back on the
has elaborated a work report with the title Treatment of
experience acquired to-date.
industrial waste water and process water by the membrane

bioreactor process [ATV-DVWK 2002]. This work report
The demands on the construction of membrane installa-
consists of two parts. Part 1 deals with the membrane
tions are defined in the instructions for plant construc-
process for the separation of undissolved, colloidal or dis-
tion. The design of installations with a certain capacity
solved substances. Part 2 addresses the membrane bioreac-
and the demands on the membrane depend on the defi-
tor process. It indicates in particular the differences which
ned aim and on the boundary conditions.
result from the application of the membrane bioreactor

process for the treatment of industrial waste water com-
The primary aim in waste water treatment consists of the
pared to municipal waste water. Due to the great variety
compliance with limit values which are defined in the
of application cases and the differences between the
conditions for discharge into water bodies [ABWV 2002]
waste waters, these work reports cannot contain design
and into the public sewer system (Ordinances on Indirect
instructions. But they give information on suitable or
Discharge of the federal states and stipulations in the
unsuitable applications and list examples.
articles of associations). They are based on 7a of the

Federal Water Act [WHG 1996]. To be able to comply
Additional instructions dealing with the utilization of
with these limit values, advisory leaflets give recommen-
membrane technology in water and waste water treat-
dations for the treatment of the characteristic emissions
ment are described briefly described in the following.
of single industrial branches. In some advisory leaflets,

the utilization of membrane processes is also mentioned,
The Verband Deutscher Maschinen- und Anlagenbau e. V.
e. g. for the treatment of emissions from the metal-wor-
(Association of the German Mechanical Engineering and
king industry [ATV-DVWK 2000b]. However, they con-
Plant Construction) has published a standard sheet con-
tain no design instructions.
cerning the application of membrane technology in the

treatment of landfill leachate [VDMA 1994]. This standard
DWA has established two expert committees concerning
sheet is to be seen as a provisional instruction which can
the subject membrane technology in waste water treat-
be used during consultations on the standardization or
ment: the Expert Committee KA-7 Membrane biore-
preciseness of European standards. It contains qualitative
actor process and the Working Group IG-5.5 Membrane
information on the design of membrane installations.
technology.
Not only the parameters to be determined are mentioned

(necessary membrane surface area, quantitative evaluation
The expert committee mentioned first has already pub-
of the volume flows for permeate and brine/concentrate),
lished two work reports Membrane bioreactor process
but also the necessary planning steps (laboratory tests,
[ATV-DVWK 2000a; DWA 2005]. The reports deal with
pilot installation and on-site tests in technical scale, see
the basics of the membrane bioreactor process, design
also chapter 3.3). It is emphasized in particular that values
approaches and necessary pretreatment measures. The
known from practice or determined by tests should be
design approaches are not related to the design of the
used to determine the operating parameters (e. g. operating
membrane used, but to the change in dimensioning the
pressure, overflow velocity, process temperature, specific
248
permeate flow), examining thoroughly the boundary conditions under which these values have been determined
[VDMA 1994]. This procedure for the planning of membrane installations can be transferred to all other fields of
application.
In addition, the working group Membrane technology
of the Bundesvereinigung der Firmen im Gas und Wasserfach e. V. (FIGAWA) (Federal Association of the Companies
of the Gas and Water Branch) has published some advisory leaflets and Technical Information on membrane
technology in water and waste water treatment. In different releases, electrochemical desalination [FIGAWA 1999],
reverse osmosis [FIGAWA 1996a; FIGAWA 1996b; FIGAWA
1985], cross-flow microfiltration [FIGAWA 1992], electrodialysis and diffusion dialysis [FIGAWA 1991] and membrane processes (RO, UF, elektrodialysis) in freshwater and
waste water treatment [MARQUARDT 1988] are explained.
Besides the mode of functioning of the respective process,
the Technical Information and advisory leaflets also mention the fields of application. However, concrete design
instructions are not given.
1)
FIGAWA: independent technical-scientific expert association, established in 1926. Its main task is the promotion of technology and science in the field
of gas and water. The working group Membrane technology was founded in 1975 within the specialist group Water treatment. It accompanies the
development of rules and standards in this field as well as the technical development of the corresponding plants and equipment [FIGAWA 1999].
249
250
Summary and Outlook
Summary and Outlook
Membrane technology currently represents a proven alter-
quantity may be reduced significantly by skillful multiple
native to classical processes for many applications in
use of the water.
municipal and industrial waste water treatment and may

contribute to reduce the costs for water supply and waste
Besides the examples presented in this publication, there
water disposal, production costs and environmental pol-
are other fields of application for membrane technology.
lution. This publication gives an introduction to mem-
Thanks to the availability of different membranes and
brane technology and its application in municipal and
modules, it is possible to find for nearly each task a tech-
industrial waste water treatment in Germany according to
nically suited system, which then has to be examined
the state of the art. Applicability and capacity of membrane
under economical and ecological aspects. An exact inven-
installations are illustrated with examples of large-scale
tory of the existing boundary conditions and an econo-
installation realized on a municipal and industrial level.
mic analysis in comparison to alternative processes

should precede the choice, independent of the field of
The share of membrane installations used on a municipal
application of a membrane process. However, it must be
level worldwide is still small due to economic aspects,
emphasized that in most cases no standard solution
concerning especially membrane replacement and energy
exists, so that in each case detailed planning and pilot
demand. Under some boundary conditions, the use of
tests by experts, considering the existing boundary condi-
membrane processes in municipal waste water treatment
tions, are necessary for successful operation of a membrane
may turn out to be economical, e. g. in the case of more
installation. Tests in laboratory and semi-technical scale
stringent or additional demands on the effluent quality,
contribute to plan a safe and practical system. Special
limitations in space for new construction or expansion of
attention should be paid to the demand for energy and
plants and possible reuse of the treated waste water.
cleaning chemicals as well as to the service life of the

membranes. Increasing water and waste water costs and
The utilisation of low-pressure processes has shown that
decreasing membrane prices lead to continuous improve-
waste water treatment by membrane technology with high
ment of the economic situation of membrane processes
biomass concentration in the activated sludge tank may
compared to other waste water treatment processes.
be technically feasible and profitable. The investment for

a modern conventional plant and the investment for a
The development of membrane technology in the field of
membrane bioreactor currently are of the same order of
water and waste water treatment has not yet ended. In
magnitude. However, the operating costs of a membrane
future, a still broader range of applications can be expect-
installation are a little higher. To reduce these costs,
ed. By continuous development of membrane materials
which also make a membrane bioreactor compete with a
and module constructions as well as process design and
conventional plant under economic aspects, research and
process engineering, it will be possible to solve problems
development have to focus on the increase of the permea-
for which, in the past, membrane processes were not suit-
te flow, the reduction of the specific energy consumption
ed due to the characteristic of the liquid to be treated.
and the prolongation of the service life of membranes.
Therefore it is important to always observe and examine

new developments, besides the assessment of working
In contrast to the municipal field of application, the use
plants. There is still need for research in the field of plant
of membrane technology in industry is common and pro-
design, operating parameters and in the control of fouling
ven by a large number of references. In industrial waste
effects.
water treatment, the use of membrane technology is often

associated with production-integrated environmental protection (PIUS). Since water is the solvent used most, PIUS
aims at avoiding the partly dissolved substances or, if this
is impossible, to separate them from the water and thus
to make a closed water circuit possible. Even if the water
circuit cannot be completely closed, the waste water
252
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Stein, S.; Walther, H.; Zastrow, P. (2001): Klranlage

Markranstdt Betriebsergebnisse einer Membranbele-
Schirm (2001): personal information, Eltmann.
bungsanlage. In: Melin, T.; Dohmann, M. (Hrsg.): Begleitband zur 4. Aachener Tagung Membrantechnik, IVT
Schilling, S. (2001): Einsatz eines Membranverfahrens
und ISA RWTH Aachen.
zur Aufbereitung des Klranlagenablaufs zu Brauchwasser.

In: Melin, T.; Dohmann, M. (Hrsg.): Begleitband zur
Stroh, N.; Walitza, E.; Brunner, H. (1997): Polymer-
membranen versus Keramikmembranen. In: Membran
RWTH Aachen.
HIT 97, 6. Hannoversche Industrieabwasser Tagung, Membrantrennverfahren in der Industrieabwasserreinigung,
Schlegel, H.-G. (1976): Allgemeine Mikrobiologie.
Verffentlichungen des Instituts fr Siedlungswasserwirt-
Georg Thieme Verlag, Stuttgart.
schaft und Abfalltechnik der Universitt Hannover, Nr. 103.
Schmidt, R. (2002): personal information, documents
Theilen, U. (2000): Einsatz von Membranverfahren bei
of a lecture on the chromium dialyzer for the company
der Industrieabwasserbehandlung. In: ATV-DVWK Schrif-
Atotech, Feucht.
tenreihe 20 zur ATV-Bundestagung 2000, S. 273 304.
Seyfried, A. (2002): Bemessung von Membranbio-
Van Houtte, E.; Verbauwhede, J.; Bach, S.; Brock-
reaktoren kommunaler Klranlagen. In: GWA, Bd. 188
mann, M. (2004): Aufbereitung von gereinigtem Ab-
zur 35. Essener Tagung fr Wasser- und Abfallwirtschaft.
wasser zu Rohwasser fr die Trinkwasserversorgung in

Flandern (Belgien), Korrespondenz Abwasser, Jg. 51, Nr. 7,
Specht, H. (1997): Wirtschaftlich weil abfallarm, Mem-
S. 754 759.
branfiltration und Vakuumverdampfung, mo metalloberflche, Jg. 51, Nr. 6, S. 410 415.
VA TECH WABAG (2002): personal information and

photos of the installation on the Transeuropa; Fotograf:
Stadt Dormagen (2004): personal information from
Ulrich Metelmann.
Mr. Wedowski, City of Dormagen.
261
References
VDMA (Verband Deutscher Maschinen- und
Wozniak, T.; Baumgarten, S. (2001): Zweijhrige
Anlagebau e. V.) (1994): Anlagen zur Reinigung von
Betriebserfahrungen mit der Membrantechnik auf der
Deponiesickerwasser, VDMA-Einheitsblatt 24439,
Klranlage Bchel. In: Melin, T.; Dohmann, M. (Hrsg.):
October 1994.
Begleitband zur 4. Aachener Tagung Membrantechnik,

IVT und ISA RWTH Aachen.
VDP (Verband Deutscher Papierfabriken e. V.)

(2004): Statistics of the paper industry, figures from the
Wozniak, T. (2002): personal information, among
year 2000. URL: www.vdp-online.de.
others on the failure at the Swanage waste water treatment plant, June 2002.
Verbandsgemeinde Bondorf (2004): personal information from Mr. Vogel, Regierungsprsidium Tbingen.
WVER (2004): personal information from Mr. Rolfs,

Wasserverband Eifel-Rur, Dren.
Voenkaul, K.; Melin, T.; Rautenbach, R. (2000):

Perspektiven der Membrantechnik im Wasserkreislauf
ZENON (2002): several information from the company
Schwimmbad. In: Melin, T.; Rautenbach, R.; Dohmann,
ZENON, Hilden.
M. (Hrsg.): Begleitband zur 3. Aachener Tagung Membrantechnik, IVT und ISA RWTH Aachen.
ZENON GmbH (2004): several information from the

company ZENON GmbH, Hilden.
Voenkaul, K.; Melin, T. (2001): Perspektiven fr die

Membrantechnik in der Abwasserbehandlung, UP Umwelt
ZKR Zentralkommission fr die Rheinschiff-
Praxis, Nr. 10, S. 36 40.
fahrt (2000): bereinkommen ber die Sammlung,

Abgabe und Annahme von Abfllen in der Rhein- und
Waizenegger, K.; Marzinkowski, J. M.; Fiedler, P.;
Binnenschifffahrt vom 9. September 1996; Straburg
Brille, F.; Saier, H.- D.; Pahl, S.; Peters, T. A.;
2000.
Baum, G. (2000): Recycling von Mischabwasser einer

Textilfrberei, Korrespondenz Abwasser, Jg. 47, Nr. 9,
S. 1296 1305.
Walther, H. (2001): Bercksichtigung der Membrantechnik im regionalen Abwasserentsorgungskonzept,
Korrespondenz Abwasser, Jg. 48, Nr. 8, S. 1092 1097.
Wehrle Umwelt GmbH (2004): personal information
from Mr. Wienands and photos from the company Wehrle
Umwelt GmbH, Emmendingen.
WHG (1996): Gesetz zur Ordnung des Wasserhaushalts
Wasserhaushaltsgesetz, Fassung vom 12. November 1996,
BGBl I, S. 1690.
Weise Water Systems GmbH (2004): personal information from Mr. Weise and photos from the company
Weise Water Systems GmbH, Langgns-Oberkleen.
262
Annex
Annex
A.1
Addresses (mentioned in the concrete examples)
A.1.1
Locations of the membrane systems in Germany

WWTP Bchel
Aggerverband
WWTP Schramberg-
Stadtwerke Schramberg
WWTP Seelscheid
Postfach 340240
Waldmssingen
GmbH & Co. KG
51624 Gummersbach
Am Hammergraben 8
Mr. Dr. Scheuer
78713 Schramberg
www.aggerverband.de
Mr. Rosenbohm
www.stadtwerke-schramberg.de
WWTP Kaarst
Erftverband
WWTP Rdingen
Paffendorfer Weg 42
WWTP Glessen
50126 Bergheim
rungs-Genossenschaft (LINEG)
Mr. N. Engelhardt
Friedrich-Heinrich-Allee 64
Ms. K. Drensla
47475 Kamp-Lintfort
www.erftverband.de
Mr. Dr. Khn
WWTP Xanten-Vynen
Linksniederrheinische Entwsse-
www.lineg.de
WWTP Knautnaundorf
KW Leipzig GmbH
WWTP Markranstdt
Johannisgasse 7
WWTP Eitorf
Gemeindewerke Eitorf
04103 Leipzig
Ver- und Entsorgungsbetriebe
Ms. S. Stein
Auf dem Erlenberg 3
www.wasser-leipzig.de
53783 Eitorf
Mr. Neulen
WWTP Simmerath
Wasserverband Eifel Rur
WWTP Konzen
Eisenbahnstrae 5
WWTP Rurberg-Woffelsbach
52325 Dren
www.eitorf.de
WWTP Kohlfurth
Wupperverband
Mr. T. Rolfs
Untere Lichtenplatz Strae 100
www.wver.de
42289 Wuppertal
Mr. Dr. Erbe
WWTP Geiselbullach
Amperverband
www.wupperverband.de
Verwaltung Eichenau
Bahnhofstrae 7
WWTP Merklingen
Gemeinde Merklingen
82223 Eichenau
Hauptstrae 31
Mr. T. Kopmann
89188 Merklingen
www.amperverband.de
WWTP Richtheim
WWTP Monheim
Stadt Monheim
Rathausstrae 1
Marktplatz 23
92289 Ursensollen
86653 Monheim
www.ursensollen.de
Mr. Wild
www.monheim.de
264
Gemeinde Ursensollen
Annex
Municipal waste water treatment (Continuation)

WWTP Hailfingen
WWTP Dormagen
WWTP Piene
Abwasserzweckverband
WWTP Golf Course St. Wendel
Stadt St. Wendel
Bondorf-Hailfingen
Rathaus IV, Abwasserwerk
Rathaus
Marienstrae 1
Marktplatz 18
66606 St. Wendel
72108 Rottenburg am Neckar
Mr. Schmidt
Stadt Dormagen
German Armed Forces
Bundesamt fr Wehrtechnik
Stadtentwsserung
und Beschaffung
Tiefbauamt
Ferdinand-Sauerbruch-Strae 1
Mathias-Giesen-Strae 11
56073 Koblenz
41540 Dormagen
www.bwb.org
Stadtwerke Gummersbach
Rathausplatz 1
51643 Gummersbach
Mr. Bock

Branch
Company
Branch
Company
Food industry
Potato starch production
Printing industry
Grafische Handelsvertretung
Emsland Strke GmbH
Peter Leis
Emslandstr. 58, 49824 Emlichheim
Mhlweg 32
Mr. Dr. M. Lotz
35606 Solms
www.emsland-staerke.de
Mr. P. Leis
Deutsche See GmbH & Co. KG
Paper mills
Papierfabrik Palm
BEECK Feinkost GmbH & Co. KG
Werk Eltmann
Albert-Schweitzer-Ring 35
Industriestrae 23
22045 Hamburg
97483 Eltmann
Mr. L. Diederichs
Mr. R. Schirm
www.beeck-feinkost.de
www.wellenwunder.de/
palm-gruppe/main.htm
Malthouse
Mlzerei Heinrich Durst

Malzfabriken GmbH & Co. KG,
Fibre industry
Vulkanfiber Ernst Krger
Betrieb Gernsheim
GmbH & Co. KG
Mainzer Stae 15 16
Postfach 1262, 47592 Geldern
64579 Gernsheim
Nordwall 39, 47608 Geldern
Mr. M. Filip
Mr. Dr. M. Joseph
www.durst-malz.de
www.hornex.de
265
Annex
Industrial waste water treatment (Continuation)

Branch
Company
Branch
Company
Textile industry
Gerhard van Clewe
Laundry (Continuation)
Textilservice MEWA GmbH
GmbH & Co. KG
Hermann-Gebauer-Strae 1
Loikumer Strae 10
15831 Gro Kienitz
46499 Hamminkeln-Dingden
Mr. Lehmann
Mr. A. van Clewe
www.mewa.de
www.van-clewe.de/vanclewe.html
Metal-working industry
Rasselstein GmbH
Drews Meerane GmbH
Koblenzer Strae 141
uere Crimmitschauer Strae 80,
56626 Andernach
08393 Meerane
Ms. Dr. S. Arnold
Mr. Ellmer
www.rasselstein-hoesch.de/
www.drews-meerane.de
deutsch/index.htm
Pongs Textil GmbH
Faurecia Autositze
Boschstrae 2
GmbH & Co. KG
48703 Stadtlohn
Werk Stadthagen
Mr. Wening
Industriestrae 3
www.pongs.de
31655 Stadthagen Ort

Mr. K. Kasten
Plastics industry
HT Troplast AG
www.faurecia.com
TROSIFOL
Mlheimer Strae 26
Wieland Werke AG
53840 Troisdorf
Werk Langenberg
Mr. U. Offermann
Ziegeleiweg 20
www.ht-troplast.de
42555 Velbert
Mr. H.- U. Kobcken
Laundry
Rentex Fortex B. V.
www.wieland.de
Locatie Massop
Grisenstraat 5
Galvanik Rudolf Jatzke
NL-6465 CE Kerkrade
Edisonstrae 7
Mr. P. Massop
33689 Bielefeld
www.fortex.nl
Mr. K. Wickbold
ALSCO Berufskleidungs-Service
DaimlerChrysler AG
GmbH
Werk Dsseldorf
Niederlassung Kaiserslautern
Ratherstrae 51
Otto-Hahn-Strae 1
40467 Dsseldorf
67661 Kaiserslautern
Mr. T. Bergmann
Mr. Winter
www.daimlerchrysler.com
www.alsco.de
266
Paint processing
Annex
Industrial waste water treatment (Continuation)

Branch
Company
Branch
Company
Paint processing (Continuation)
Ford-Werke GmbH
Swimming pools
Aquana Freizeitbad
Henry-Ford-Strae 1
GmbH & Co. KG
50725 Kln
Willy-Brandt- Ring 100
Mr. S. Baumeister
52146 Wrselen
www.ford.de
Mr. M. Dovermann
www.aquana.de
Pharmaceutical industry
Schering AG
Ernst-Schering-Strae 14
Hertener Stadtwerke GmbH
59192 Bergkamen
Schwimmbad COPA CA BACKUM
Mr. Dr. Neuhaus
Herner Strae 21
45699 Herten
Power stations
DREWAG
Mr. H. Kuhlmann
Gas- und Dampfturbinen
www.freizeitbad.de/deutschland/
Heizkraftwerk Dresden
copacabackum.html
Rosenstrae 32
01065 Dresden
Freizeitbad Bergische Sonne
www.drewag.de
GmbH & Co.

Lichtscheider Strae 90
Landfill leachate
Abfallwirtschaft Kreis und Stadt
42285 Wuppertal
Aachen (AWA) GmbH
Mr. G. Geier
Deponie Alsdorf-Warden
www.bergische-sonne.de
Postfach 1459
52243 Eschweiler
Fish hatchery
Umweltbundesamt
Mr. R. Koch
Fachgebiet III 3.5
www.awa-gmbh.de
Postfach 33 00 22
14191 Berlin
Deoiling of bilge water
Bilgenentlungsgesellschaft mbH
Mr. Dr. Pluta
August-Hirsch-Strae 3
www.umweltbundesamt.de
47119 Duisburg
Mr. R. Deutsch
www.bilgenentoelung.de
267
Annex
A.1.2
fore, in the following only the addresses of those com-
Planners and manufacturers of installations,
panies and offices are listed which have been specially
membrane manufacturers, Consulting Engineers
mentioned in the previous chapters and have contributed

information, e. g. for the concrete examples. Thus, this
A large number of planners and manufacturers of installa-
selection does not claim to be complete. Additional
tions, membrane manufacturers and consulting engineers
sources of information and important institutions in
are working in the field of membrane technology. Even for
connection with the subject membrane technology are
Germany, it is hardly impossible to draw up a complete
compiled subsequently.
list, partly due to high fluctuations in this branch. There-
A3-Abfall-Abwasser-
Magdeburger Strae 16 b
Anlagentechnik GmbH
45881 Gelsenkirchen
ATEMIS GmbH
Dennewartstrae 25 27
52068 Aachen
Mr. U. Brss
www.atemis.net
www.3a-gmbh.de
Atotech Deutschland GmbH
Aggerwasser GmbH
Industriestrae 69, 90537 Feucht
AV Aggerwasser GmbH
Postfach 12 40, 90532 Feucht
Sonnenstrae 40
Mr. Dr. R. Schmidt
51645 Gummersbach
www.atotech.com
www.aggerwasser.de
ACO Passavant GmbH
Altenburger Elektronic GmbH
Ulsterstrae 3
Berghof Filtrations- und
Harretstrae 1
Anlagentechnik GmbH & Co. KG
72800 Eningen
D- 36269 Phillipsthal
Mr. H.- U. Roth
www.aco-passavant.de
www.berghof.com
Schlossweg 2 5
BKT Burggrf GmbH
Zum alten Zollhaus 20 22
77960 Seelbach
42281 Wuppertal
Mr. Dr. S. Siegfried
Mr. H. Burggrf
www.altenburger.de/index.html
BUSSE GmbH
amafilter Deutschland GmbH
Zaucheweg 6
Am Pferdemarkt 11
047316 Leipzig
30853 Langenhagen
Mr. R.-P. Busse, Mr. C. Belz
Mr. Dr. G. Baumgarten
www.busse-gmbh.de
www.amafilter.com
CSM Filtrationssysteme
Gewerbestrae 32
GmbH & Co. KG
75015 Bretten-Glshausen
ATEC Automatisierungstechnik
Emmi-Noether-Strae 6
GmbH
89231 Neu-Ulm
Mr. R. Verschaeve
Mr. G. Enderle
www.guthgroup.de
www.atec-nu.de
degebran GmbH Anlagenbau
atech innovations GmbH
44653 Herne
45966 Gladbeck
Mr. K. Paulus, Mr. H.- J. Krein
Mr. P. Bolduan
www.degebran.de
www.atech.daw.com
268
Resser Strae 65
Am Wiesenbusch 26
Annex
DHV Water BV
Postbus 484
Hans Huber AG
Maschinen- und Anlagenbau
3800 AL Amersfort
Maria-Hilf-Strae 3 5
Mr. H. F. van der Roest
92334 Berching
www.dhv.nl
Mr. Dr. O. Christ

www.huber.de
Dr. Dahlem
Bonsiepen 7
Beratende Ingenieure
45136 Essen
Hydro-Ingenieure GmbH
Stockkampstrae 10
40477 Dsseldorf
www.drdahlem.de
www.hydro-ingenieure.de
Earth-Tech GmbH
Forumstrae 24
41468 Neuss
HST-Systemtechnik
Sophienweg 3
59872 Meschede
www.axeljohnson.de
www.systemtechnik.net
Eisenmann Lacktechnik KG
Heinrich-Hertz-Strae 8
74351 Besigheim-Ottmarsheim
Mr. E. Neubauer
iat-Ingenieurberatung fr
Taubenheimstrae 69
Abwassertechnik GmbH
70372 Stuttgart
www.iat-stuttgart.de
www.eisenmann.de
inge AG
EnviCare
Wittekeweg 9
86926 Greifenberg
A - 8010 Graz
Mr. M. Hank
www.envicare.at
ENVIRO-CHEMIE
In den Leppsteinswiesen 9
Abwassertechnik GmbH
64380 Rodorf
Flurstrae 17
www.inge-ag.de
Ingenieurbro Dr. Resch
Lehenwiesenweg 31
91781 Weienburg
Mr. J. Quaiser
Mr. Dr. H. Resch
www.enviro-chemie.de
imb + frings water systems gmbh
Erftverband
Fraunhofer IGB
Horbeller Strae 15
Paffendorfer Weg 42
50858 Kln
50126 Bergheim
Mr. Dr. J. Lindemann
www.erftverband.de
www.imbfrings.de
Nobelstrae 12
I-T-G GmbH, Ingenieurgemein-
Buchenstrae 24
70569 Stuttgart
schaft fr Umwelttechnologie
72810 Gomaringen
Ms. J. Kndler
Henkel-Ecolab GmbH & Co. OHG
Henkel-Ecolab Deutschland
www.itg-gmbh.de
Reisholzer Werftstrae 38 42
40554 Dsseldorf
Hese Umwelt GmbH/A3 GmbH
ItN Nanovation
Untertrkheimer Strae 25
Mr. R. Krack
66117 Saarbrcken
www.ecolab.de
www.itn-nanovation.de
Magdeburger Strae 16 a
Keppel Seghers Belgium NV
Hoofd 1
45881 Gelsenkirchen
B -2830 Willebroek
www.hese-umwelt.de
www.segherskeppel.com
269
Annex
Klapp-Mller GmbH,
Rehwinkel 15
Memcor Australia
40 Blackman Crescent
Ingenieurbro fr Umwelt-
51580 Reichshof
(see Siemens AG)
South Windsor, NSW 2576
und Bautechnik
Mr. Dr. S. Schilling
Memtec
Mergenthalerallee 45 47
www.klapp-mueller.de
65760 Eschborn
Mr. Baur
KOCH-GLITSCH GmbH
Membrane Systems Divisions

Neusser Strae 33
Membrain
Contact: ZENON GmbH
MDS Prozesstechnik GmbH
Bahnhofstrae 315
40219 Dsseldorf
Mr. J. Hadler
www.kochmembrane.com
47447 Moers
Mr. Dr. D. Bttger
KOCH Membrane Systems
Krantzstrae 7, Eingang D
GmbH
52070 Aachen
Mr. Dr. S. Schfer
www.mds-prozesstechnik.com
MFT
www.puron.de
Membran-Filtrations-Technik GmbH
Eupener Strae 150
50933 Kln
Krger-Wabag
Baumeisterallee 13 15
Mr. H.- U. Hbbel
(see Veolia Water)
04442 Zwenkau
www.mft-koeln.de
Standort Ratingen
Lise-Meitner-Strae 4a
MICRODYN-NADIR
Kalle Albert Industriepark
40878 Ratingen
Filtration GmbH
Rheingaustrae 190
www.wabag.com
65174 Wiesbaden
Mr. W. Ruppricht
Kubota
Under licence Aggerwasser GmbH
L. V. H. T.
Lehr- und Versuchsgesellschaft fr
www.microdyn-nadir.de
NERAtec AG
Max-Planck-Strae 7b
innovative Hygiene-Technik mbH
52249 Eschweiler
Am Zehnthof 191a
Mr. U. Kolbe
45307 Essen
www.neratec.de
Mr. Dr. D. Pacik

www.lvht.de
NORIT N. V.
P. O. Box 89
7620 AB Borne
Mall GmbH
Hfingerstrae 39 45
The Netherlands
78166 Donaueschingen
www.norit.com
Mr. S. Klemens
www.mallbeton.de
OSMONICS
230, rue Robert Schumann

Z. A. des Uselles
Martin Systems AG
270
Ackerstae 40
B. P. 85
96515 Sonnenberg
F-77350 Le Mee sur Seine
Mr. M. Grigo
France
www.martin-systems.de
www.osmonics.com
Annex
Pall GmbH
Pall GmbH
Toray Deutschland GmbH
Philipp-Reis-Strae 6,
Hugenottenallee 175
63263 Neu-Isenburg
63303 Dreieich
Mr. Dr. H. Eipper, Mr. C. Maurer
Tuttahs & Meyer
Bismarckstrasse 2 8
www.pall.com
Ingenieurgesellschaft
52066 Aachen
www.tuttahs-meyer.de
PURON AG
refer to KOCH Membrane Systems

GmbH
US-FilterMEMCOR Products
441 Main Streel
www.puron.de
(see Siemens AG)
Sturbridge, MA 01566
www.usfilter.com
Dr.-Ing. Peters Consulting
Dr.-Ing. Peters Consulting fr
(CMU)
Membrantechnologie und
VA TECH WABAG AG
VA TECH WABAG
Umwelttechnik
Siemensstrae 89
Broichstrae 91
1210 Vienna
41462 Neuss
www.vatechwabag.com
Mr. Dr. T. A. Peters

Veolia Water Deutschland GmbH
ROCHEM UF-Systeme GmbH
Unter den Linden 21
Stadthausbrcke 1 3
10117 Berlin
Fleethof
www.veoliawater.de
20355 Hamburg
www.rochemuf.com
WEHRLE-WERK AG
Bismarckstrae 1 11
79312 Emmendingen
Rhodia
Stadelstrae 10
Mr. G. Streif
60595 Frankfurt
www.wehrle-werk.de
Mr. Hoffmann, Mr. Linz

www.rhodia.com
RWW Wassertechnologie GmbH
Weise Water Systems
Steinbruchstrae 6b
GmbH & Co. KG
35428 Langgns
Heinrich-Haanenstrae 6
www.weise-water-systems.com
41334 Nettetal-Lobberich
Mr. B. Lang
Wientjens b. v.
www.rww-wt.de
Im Sprokkelveld 9
NL-6596 DH Milsbeek
www.wientjens.com
Schwander GmbH
Theodor-Heuss-Strae 38
61118 Bad Vilbel
X-Flow B. V.
Bedrijvenpark Twente 289
Mr. Dr. T. Jger
(see NORIT N. V.)
NL-7602 KK Almelo
www.schwander.de
Mr. B. Brocades Zaalberg

www.xflow.nl
Siemens AG Water Technologies
Nonnendammallee 101
13569 Berlin
www.siemens.com/water
ZENON GmbH
Nikolaus-Otto-Strae 4
40721 Hilden
Mr. H. Mslang
TAMI Deutschland GmbH
Heinrich-Hertz-Strasse 2/4
www.zenonenv.com
07629 Hermsdorf
Mr. B. Ruschel
www.tami-industries.com
271
Annex
A.1.3
Scientific assistance for the realization of this publication
MUNLV
Ministerium fr Umwelt und
Institut fr Siedlungswasserwirt-
(Ministry for Environment and
Naturschutz, Landwirtschaft und
schaft der RWTH Aachen (ISA)
52056 Aachen
Nature Conservation, Agriculture
Verbraucherschutz des Landes
(Institute of Environmental
Mr. S. Baumgarten
and Consumer Protection of the
Nordrhein-Westfalen
Engineering of the RWTH
Mr. Dr. S. Kster
state North-Rhine Westphalia)
40190 Dsseldorf
Aachen University)
Univ. Prof. Dr.-Ing. J. Pinnekamp
www.munlv.nrw.de
www.isa.rwth-aachen.de
LUA NRW
Landesumweltamt
(Environmental Office of the
Nordrhein-Westfalen
Experts, consultants
Prof. Dr.- Ing. P. Cornel

(Head of the work group IG-5.5
state North-Rhine Westphalia)
Wallneyer Stae 6
Membrane technology of ATV-
45133 Essen
DVWK or DWA respectively)
www.lua.nrw.de
Technische Universitt Darmstadt

Institut WAR
EFA NRW
Effizienz- Agentur NRW
Petersenstrae 13
(Efficiency Agency North-Rhine
Mlheimer Strae 100
64287 Darmstadt
Westphalia)
47057 Duisburg
www.iwar.bauing.tu-darmstadt.de
www.efanrw.de
Mr. Prof. Dr.-Ing. F.-B. Frechen
BEW
Bildungszentrum fr die
(in place of the Committee of Ex-
(Training centre for waste water
Entsorgungs- und Wasser-
perts KA-7 Membrane bioreactor
and waste disposal and water
wirtschaft GmbH
process of ATV-DVWK or DWA
management)
Bildungssttte Essen
respectively)
Wimberstrae 1
Universitt Kassel
45239 Essen
FG Siedlungswasserwirtschaft
www.bew.de
Kurt-Wolters-Strae 3
34125 Kassel
DGMT
Deutsche Gesellschaft fr
www.uni-kassel.de
(German Association for
Membrantechnik e. V.
Membrane Technology)
Eupener Strae 150
Mr. Dr. Firk
50933 Kln
www.dgmt.org
Eisenbahnstrae 5
52353 Dren
Forschungsinstitut fr Wasser-
www.wver.de
und Abfallwirtschaft an der
52056 Aachen
RWTH Aachen (FiW) e. V.
Ms. M. Lange
Mr. Dr. J. Oles
(Research Institute for Water
Mr. Dr. F.-W. Bolle
Mr U. Voss
and Waste Management at the
Mr. J. Schunicht
Oswald Schulze GmbH & Co. KG
RWTH Aachen University)
www.fiw.rwth-aachen.de
Krusenkamp 22 24
45964 Gladbeck
www.oswald-schulze.de
272
Annex
Mr. Dr. T. A. Peters
Prof. Dr. rer. nat. W. Schmidt
Dr.-Ing. Peters Consulting fr
Fachbereich Versorgungs- und Ent-
Membrantechnologie und
sorgungstechnik (Department of
Umwelttechnik
Water Supply, Waste and Waste
Broichstrae 91
Water Disposal Engineering)
41462 Neuss
Fachhochschule Gelsenkirchen
(Gelsenkirchen University of
Members of the work group
Mr. Dr. V. Mertsch
Applied Sciences)
Membrane Book
Ministerium fr Umwelt,
45877 Gelsenkirchen
Naturschutz, Landwirtschaft und
www.fh-gelsenkirchen.de/
Verbraucherschutz des Landes
fb03/ent/enthf.html
Nordrhein-Westfalen (MUNLV)
40190 Dsseldorf
Ms. Dr. J. R. Tschesche
www.munlv.nrw.de
Ms. I. Dierschke
Effizienz-Agentur NRW (EFA NRW)
Ms. K. Drensla
Mlheimer Strae 100
Erftverband
47057 Duisburg
Abteilung Abwassertechnik
www.efanrw.de
(Division waste water engineering)

Forschung und Entwicklung
Mr. T. Wozniak
(Research and development)
Aggerverband
Paffendorfer Weg 42
Sonnenstrae 40
50126 Bergheim
51645 Gummersbach
www.erftverband.de
www.aggerverband.de
Ms. A. Kaste
Mr. S. Tenkamp
Ms. C. Wiedenhft
Staatliches Umweltamt Krefeld
Ms. Dr. K. Dreher
(StUA Krefeld)
Landesumweltamt
(State Environmental Office)
Nordrhein-Westfalen (LUA)
St. Tniser Strae 60
Wallneyer Strae 6
47803 Krefeld
45133 Essen
www.stua-kr.nrw.de
www.lua.nrw.de
Mr. RBD A. Schmidt

Bezirksregierung Kln
(District Government Cologne)
Zeughausstrae 2 10
50667 Kln
www.bezreg-koeln.nrw.de
273
Annex
A.1.4
Other institutions and persons having contributed to the contents
BMU
Bundesministerium fr Umwelt,
Prof. Dr. rer. nat. J. Marzinkowski
Bergische Universitt,
(Federal Ministry of the Environ-
Naturschutz und Reaktorsicherheit
Gesamthochschule Wuppertal
ment, Nature Conservation and
Alexanderplatz 6
(comprehensive university)
Nuclear Safety)
10178 Berlin
Fachbereich 14, Sicherheitstechnik
www.bmu.de
(Department of safety engineering)

Gaustrae 20
DBU
Deutsche Bundesstiftung Umwelt
42097 Wuppertal
(German Federal Foundation
Postfach 1705
Prof. Dr. rer. nat. J. Marzinkowski
Environment)
49007 Osnabrck
www.uni-wuppertal.de/FB14
www.dbu.de
Prof. Dr.-Ing. habil. N. Rbiger
Universitt Bremen
DECHEMA e. V.
Gesellschaft fr Chemische
Institut fr Umweltverfahrens-
(Society for Chemical
Technik und Biotechnologie e. V.
technik (Institute for Environ-
Engineering and Biotechnology)
Theodor-Heuss-Allee 25
mental Process Engineering)
60486 Frankfurt am Main
Postfach 330440
Mr. Dr. L. Nick
28334 Bremen
www.dechema.de
www.fb4.uni-bremen.de
FIGAWA
FIGAWA Bundesvereinigung
Tuttahs & Meyer
Tuttahs & Meyer Ingenieur-
(Federal Association of
der Firmen im Gas- und
gesellschaft mbH
Companies in the Field of Gas
Wasserfach e. V.
Bismarckstrae 2 8
and Water)
Marienburger Strae 15
52066 Aachen
50968 Kln
www.tuttahs-meyer.de
www.figawa.de
Universitt Wuppertal
Fachgebiet Sicherheitstechnik/
PIA e. V.
Prf- und Entwicklungsinstitut
Umweltschutz der Bergischen
(Testing and Development
fr Abwassertechnik an der
Universitt Wuppertal (Department
Institute for Waste Water
RWTH Aachen (PIA) e. V.
of Safety Engineering/Pollution
Engineering at the RWTH
Mies-van-der-Rohe Strae 1
Control)
Aachen University)
52074 Aachen
Campus Freudenberg, Gebude FF
www.pia.rwth-aachen.de
Rainer-Gruenter-Strae 21
42097 Wuppertal
Ms. E. Brands
Frau D. Kunz
Eisenbahnstrae 5
www.uws.uni-wuppertal.de
52352 Dren
www.wver.de
274
Annex
A.1.5
Other information sources in the field of membrane technology
DWA-Branchenfhrer Wasserwirtschaft Abwasser-Abfall 2005
Bremer Colloquium Produktionsintegrierte Wasser-/Abwassertechnik
(Trade directory water economy waste water solid waste)
(IUV Institut fr Umweltverfahrenstechnik, Universitt Bremen und
Edited by
GVC VDI-Gesellschaft Verfahrenstechnik, Dsseldorf)
Gesellschaft zur Frderung der Abwassertechnik e. V.
(Bremen Colloquium Production-integrated Water and Waste Water
Theodor-Heuss-Allee 17
Technology, organized by the Institute for Environmental Process
53773 Hennef
Engineering of the Bremen University and GVC-VDI Society Process
www.gfa-ka.de
Engineering, Dsseldorf)
ENVITEC- Internationale Fachmesse
Information on the Internet
fr Ver- und Entsorgung mit Fachkongress (International special fair for
The Internet portal www.pius-info.de is a cooperation project of the
water supply, waste water and solid waste disposal with specialist
federal states North-Rhine Westphalia, Rhineland-Palatinate and
conference)
Schleswig-Holstein. It offers, among other things, information on the
www.envitec.de
projects realized, literature, software and possibilities for promotion. It is

continuously updated, extended and supported with contents from other
IFAT
partners.
Internationale Fachmesse fr Wasser Abwasser Abfall Recycling
In January 2002 it received the Umwelt-Online-Award (Environment-On-
(International special fair for water waste water waste recycling)
line Award) in silver, the seal of quality for modern environmental com-
www.ifat.de
munication.
Conferences on membrane technology:
Office of the PIUS-Internet-Portal:
AMK Aachener Membran Kolloquium
c/o Die Effizienz-Agentur NRW
(Institut fr Verfahrenstechnik (IVT) an der RWTH Aachen)
Mlheimer Strae 100
(Aachen Membrane Colloquium, organized by the Institute for Process
47057 Duisburg
Engineering of the RWTH Aachen University)
Mr. H. H. Sittel, Ms. A. Schmitt

www.pius-info.de
ATSV Aachener Tagung Siedlungswasserwirtschaft und Verfahrenstechnik (Institut fr Verfahrenstechnik (IVT) und Institut fr Siedlungswasserwirtschaft (ISA) an der RWTH Aachen)
(Aachen Conference on Environmental Engineering and Process Engineering, organized by the Institute for Process Engineering and Institute
of Environmental Engineering of RWTH Aachen University)
275
Annex
A.2
port for innovations and investments, e. g. in the form of
cost sharing, loans, grants. In order to find the adequate

development program and to make the decision easier,
Planning and implementation of measures contributing
some development programs in the field of waste water
to pollution control, such as the utilization of a membrane
avoidance, closed process water circuit are compiled in
system for waste water treatment, may be promoted and
the following. The institutions and contact persons men-
funded in different ways. Comprehensive development
tioned give additional information and advice (for the
programs of the federal states, the Federal Government
most part free of charge) concerning the choice of an
and the EU promote consultancy and give financial sup-
adequate development program for each individual case.
A.2.1
Development programs and advisory service of the Federal Government
Development programs of the Federal Government
Contact
KfW-Umweltprogramm (environmental program)
Kreditanstalt fr Wiederaufbau
Palmengartenstrae 5 9
60325 Frankfurt am Main
Information centre:
0 18 01/33 55 77 (at local rates)
www.kfw.de
ERP Umwelt- und Energiesparprogramm
Deutsche Ausgleichsbank
(environmental and energy-savings program)
Ludwig-Erhard-Platz 1 3
DtA Umweltprogramm (environmental program)
53179 Bonn
BMU Programm zur Frderung von Demonstrationsvorhaben
Information line:
(program for the promotion of demonstration projects)
0 18 01/24 24 00 (at local rates)

www.dta.de
Different fields of promotion of DBU
DBU Deutsche Bundesstiftung Umwelt
(German Federal Foundation Environment)
Postfach 1705
49007 Osnabrck
An der Bornau 2
49090 Osnabrck
Tel.: 05 41/96 33 - 0
Fax: 05 41/96 33 - 190
276
Annex
Advisory service of the Federal Ministry of
Promotion data base of the
Economics and Labour (BMWA)
Federal Ministry of Economics and Labour

www.bmwa.bund.de
In the information office, founders of businesses and small

and medium-sized businesses seeking advice get quickly
and unbureaucratically information on the development
programs of the Federal Government, the federal states
The use of the promotion data base is only the first step.
and the EU, including information on the procedures to be
The various advisory services of the Chambers of Industry
followed for receiving development funds, on contact in-
and Commerce, associations, of management consultancy,
stitutions and conditions of the development programs.
tax advisers and banks help to clarify all questions con-
Founders of businesses and investors may also fix a date
cerning concepts, taxes or legislation.
for a personal conversation in order to get free-of-charge

A.2.2
information about promotion possibilities.
Development programs of the federal states

Advisory service of BMWA
The institutions to be contacted for the development
Tel.: +49 (0)30/20 14 -800
programs of the federal states are the environmental
Fax: +49 (0)30/20 14 -70 33
ministries or environmental offices of the respective
E-Mail: foerderberatung@bmwa.bund.de
federal state. Their addresses are compiled in Table A-1.

In addition, a selection of well-known development programs concerning the subject waste water avoidance,
closed process water circuit is listed together with the
Promotion data base of the Federal Ministry of
institutions and persons to be contacted.
Economics and Labour

For the state North-Rhine Westphalia, the EffizienzThe promotion data base of the Federal Ministry of Eco-
Agentur NRW (EFA) (Efficiency Agency) must be men-
nomics and Labour is available as central information
tioned in particular. It is an action group of the Ministry
source to private individuals, founders of businesses, enter-
for Environment and Nature Conservation, Agriculture
prises and consultants. It addresses users without previ-
and Consumer Protection. Since the end of 1998, it has
ous knowledge as well as experts in economic promotion
been the first institution to contact for all questions con-
and allows the search for development funds and ade-
cerning production-integrated environmental protection
quate promotion programs.
(PIUS).
The promotion data base of the Federal Government pro-
The EFA gives advice and supports small and medium-
vides a complete and topical overview of the development
sized businesses with the introduction of integrated pol-
programs of the Federal Government, the federal states
lution control measures. It establishes contacts to experts
and the European Union. The promotion activities are
and shows new ways and possibilities for future-oriented
summarized according to uniform criteria, independent
economic structures. The first analysis of the production
of the promotion level or the funding institution, and
by engineers of EFA shows potentials; the following con-
represented consistently. The connections between the
sultation in cooperation with external experts helps the
individual programs are also explained, this is important
enterprises to use them (PIUS -Check) . The aim is reduc-
for the efficient use of government promotion.
ing both the production costs and environmental pollution by increasing the efficiency of the raw material used.
The comprehensive cross-linkage on the Internet allows

to get more detailed information on the different providers of promotion information.
1)
PIUS is a registered trademark of the Effizienz-Agentur NRW
277
Annex
In addition, the EFA informs about topical possibilities for
EFA Die Effizienz-Agentur NRW: Frderprogramme fr den Produk-
the promotion of small and medium-sized businesses and
tionsintegrierten Umweltschutz. Zielgerichtet planen. Effizient
helps in searching the adequate development program for
umsetzen. Umfassend profitieren. (Development programs for pro-
financing of projects in the field of production-integrated
duction-integrated environmental protection. Calculated planning.
environmental protection. The headquarters of the EFA is
Efficient implementation. Comprehensive profit.) As of 06/2000.
the House of Economic Promotion in Duisburg. Since the

beginning of the year, four regional offices at Aachen, Bielefeld, Mnster and Siegen have ensured direct contact in
possibilities. Besides much additional information on
the different economic regions of North-Rhine Westphalia.
production-integrated environmental protection, the

Internet portal www.pius-info.de offers information on
In addition, the publication Frderprogramme fr den
promotion possibilities. The Internet portal is a joint pro-
Produktionsintegrierten Umweltschutz (Development
ject of the federal states North-Rhine Westphalia, Rhine-
programs for production-integrated environmental pro-
land-Palatinate and Schleswig-Holstein, it is continuously
tection) gives an overview of the different promotion
updated and extended.
Table A-1
Contacts for development programs of the federal states and selected development programs concerning
waste water avoidance, closed process water circuits
Federal state
Contact
Development programs
Baden-Wrttemberg
Landesanstalt fr Umweltschutz (LfU)
Development program for pollution control and
Baden-Wrttemberg
energy saving measures
Griesbachstrae 1
Contact:
76185 Karlsruhe
L-Bank; Wirtschaftsfrderung II
Postfach 21 07 52
Friedrichstrae 24
76157 Karlsruhe
70174 Stuttgart
Tel.: +49 (0)7 21/9 83-0
Telephone hotline: +49 (0)7 11/1 22-23 45
Fax: +49 (0)7 21/9 83-14 56
Fax call for information on the conditions:
www.lfu.baden-wuerttemberg.de
+49 (0)7 11/1 22-26 74

www.l-bank.de
Bavaria
Berlin
Bayerisches Staatsministerium fr
Additional program of LfA-Umweltschutz
Landesentwicklung und Umweltfragen
Contact:
Rosenkavalierplatz 2
LfA Frderbank Bayern
81925 Mnchen
Kniginstrae 17
Tel.: +49 (0)89 / 92 14-00
80539 Mnchen
Fax: +49 (0)89 / 92 14-22 66
Tel.: +49 (0)1 8 01/21 24 24 (at local rates)
www.umweltministerium.bayern.de
www.lfa.de
Senatsverwaltung fr Stadtentwicklung
Das Umweltentlastungsprogramm UEP
Brckenstrae 6
(program for pollution reduction)
10179 Berlin
Contact: Beratungs- und Servicegesellschaft

Umwelt mbH (B & SU)
Tel.: +49 (0)30/90 25-0
Hohenzollerndamm 44
Fax: +49 (0)30/90 25-29 20
10713 Berlin
www.stadtentwicklung.berlin.de/umwelt
Tel: +49 (0)30/3 90 42-84

www.uep-berlin.de
278
Annex
Table A-1 (Continuation)

Federal state
Contact
Brandenburg
Ministerium fr Landwirtschaft, Umweltschutz
und Raumordnung des Landes Brandenburg

Heinrich-Mann-Allee 103
14473 Potsdam
Tel.: +49 (0)3 31/8 66-0
Fax: +49 (0)3 31/8 66-70 68, -70 69, -70 71
www.brandenburg.de/land/mlur
Bremen
Der Senator fr Bau und Umwelt

Hanseatenhof 5
28195 Bremen
Tel.: +49 (0)4 21/3 61-21 36
Fax: +49 (0)4 21/3 61-60 13
www.umwelt.bremen.de
Hamburg
Freie und Hansestadt Hamburg
Development program for environmental technology
Behrde fr Umwelt und Gesundheit
Contact:
Fachamt fr Energie und Immissionsschutz (I1)
see left
Billstae 84
Freie und Hansestadt Hamburg
20539 Hamburg
Behrde fr Umwelt und Gesundheit
Tel.: +49 (0)40/4 28 45-0

www.hamburg.de/Behoerden/Umweltbehoerde
Innovation Foundation Hamburg

Alter Steinweg 4
20459 Hamburg
Tel.: +49 (0)40/4 28 41-17 59
www.hamburg.de/Behoerden/Umweltbehoerde
Hesse
Hessisches Ministerium fr Umwelt,

Landwirtschaft und Forsten
Bereich Umwelt und Energie
Mainzer Strae 80
65189 Wiesbaden
Tel.: +49 (0)6 11/8 15-0
Fax: +49 (0)6 11/8 15-19 41
www.mulf.hessen.de
Mecklenburg-Vorpommern
Umweltministerium Mecklenburg-Vorpommern
Allgemeine Information und Koordinierung
der Frderprogramme
Schlossstrae 6 8
19053 Schwerin
Tel.: +49 (0)3 85/5 88-0, -8 20
Fax: +49 (0)3 85/5 88-87 17
www.um.mv-regierung.de
279
Annex

Federal state
Contact
Lower Saxony
Niederschsisches Umweltministerium
Postfach 4107
30041 Hannover
Tel.: +49 (0)5 11/1 20-0
Fax: +49 (0)5 11/1 20-33 99
www.mu.niedersachsen.de
North-Rhine Westphalia
Ministerium fr Umwelt und Naturschutz,
Action group Ecological and Sustainable Water
Landwirtschaft und Verbraucherschutz des
Management in North-Rhine Westphalia NRW
Landes Nordrhein-Westfalen
Development area 1: Innovative or proved
Schwannstrae 3
production-integrated environmental protection
40 476 Dsseldorf
Contact:
Tel.: +49 (0)2 11/45 66-0
see left, and in addition:
Fax: +49 (0)2 11/45 66-3 88

www.munlv.nrw.de
INVESTITIONS-BANK NRW
Zentralbereich der WestLB
Landesumweltamt NRW
Friedrichstrae 56
Wallneyer Strae 6
40217 Dsseldorf
45133 Essen
Tel.: +49 (0)2 11/8 26-09
Tel.: +49 (0)2 01/79 95-0
Fax: +49 (0)2 11/8 26-84 59
Fax: +49 (0)2 01/79 95-14 48

www.lua.nrw.de
Effizienz-Agentur NRW
Mlheimer Strae 100
47057 Duisburg
Tel.: +49 (0)2 03/3 78 79-58
Fax: +49 (0)2 03/3 78 79-44
www.efanrw.de
Rhineland-Palatinate
Ministerium fr Umwelt und Forsten
IISB loans for small and medium-sized businesses
Kaiser-Friedrich-Strae 1
within the scope of pollution control
55116 Mainz
Contact:
Tel.: +49 (0)61 31/16-0
Investitions- und Strukturbank Rheinland-Pfalz
Fax: +49 (0)61 31/16 46 46
(ISB) GmbH
www.muf.rlp.de
Holzhofstrae 4
55116 Mainz
Tel.: +49 (0)61 31/9 85-3 50
www.isb.rlp.de
280
Annex

Federal state
Contact
Saarland
Ministerium fr Umwelt
Keplerstrae 18
66117 Saarbrcken
Tel.: 06 81/5 01-00
Fax: 06 81/5 01-45 21
www.umwelt.saarland.de
Saxony
Schsisches Staatsministerium fr Umwelt und

Landwirtschaft
Archivstrae 1
01097 Dresden
Tel.: 03 51/5 64-0
Fax: 03 51/5 64-22 09
www.smul.sachsen.de
Saxony-Anhalt
Ministerium fr Landwirtschaft
und Umwelt des Landes Sachsen-Anhalt
Olvenstedter Strae 4
39108 Magdeburg
Tel.: 03 91/5 67-01
Fax: 03 91/5 67-17 27
www.mrlu.sachsen-anhalt.de
Schleswig-Holstein
Landesamt fr Natur und Umwelt des Landes
Compilation of topical development programs in
Schleswig-Holstein (LANU)
the field of energy and pollution control
Hamburger Chaussee 25
Contact:
24220 Flintbek
Investitionsbank Schleswig-Holstein
Tel.: 0 43 47/7 04-0
Fleethrn 29-31
Tel.: 0 43 47/7 04-12
24103 Kiel
www.umwelt.schleswig-holstein.de
Tel.: 0431 / 900 3651

www.lanu.landsh.de
Thuringia
Thringer Ministerium fr Landwirtschaft,

Naturschutz und Umwelt
Beethovenplatz 3
99096 Erfurt
Tel.: 03 61/37-9 00
Fax: 03 61/37-9 99 50
www.thueringen.de/de/tmlnu
281
Annex
A.2.3
Industrial areas
Development programs of the EU in the field of
Rural areas
pollution control and water management
Urban areas
Areas depending on fishery
Structural and regional promotion

The measures within the scope of the Objectives 1 and 2
Structural and regional promotion by the European
are co-financed. The maximal part of the EU for Germany
Union is based on the four European Structural Funds:
and Objective 1 is 75 %, for Objective 2 maximally 50.
European Regional Development Funds (ERDF), European

Social Funds (ESF), The European Agricultural Guidance
Development programs in the field of environmental
and Guarantee Fund (EAGGF) and the Financial Instru-
protection
ment for Fisheries Guidance (FIFG). Concerning measures

in the field of pollution control, the ERDF is the most
The main objectives of the development programs descri-
important Structural Funds of the EU.
bed in the following are the protection of the environment

and the development of the environmental policy of the
Structural Funds
Community.
The aim of European Regional Development Funds
LIFE III Program
(ERDF) is to promote economic and social cohesion by
The general objective of LIFE is to contribute to the im-
correcting the main regional imbalances and partici-
plementation, updating and development of Community
pating in the development and conversion of the various
policy and legislation relating to the environment, in
regions. The ERDF funds are provided for certain less-
particular, with regard to the integration of the environ-
favoured regions and mainly used to finance improvement
ment into other policies, as well as to sustainable devel-
of the infrastructure, productive investments, local
opment in the Community.
development and protection of the environment.

LIFE offers financial support for environmental measures
For promotion, it is distinguished between Objective 1
in the Community and certain third countries (Mediter-
and Objective 2 regions.
ranean countries or littoral states of the Baltic Sea,

countries of Central and East Europe which have signed
Objective 1 supports the development and structural
association agreements with the European Union).
adaptation of underdeveloped regions. Among them are

those regions with a per capita gross domestic product
The following areas are promoted by LIFE:
(GDP) lower than 75% of the Community average.

Five main actions are provided:
European Community, Central and East European

countries: nature conservation, promotion of
Promotion of the competitiveness of the industry and

small and medium-sized businesses
sustainable development in industrial activities, integration of environmental aspects in regional planning
Development of the infrastructure
policy, waste management, atmospheric pollution and
Protection of the environment
water management;
Development of the manpower potential

Development of rural areas
other Third Countries: technical assistance in the

establishment of administrative structures, maintenance
Objective 2 supports the economic and social conversion
and rehabilitation of habitats of endangered species,
of areas experiencing structural difficulties. During the
promotion of sustainable development.
period 2000-2006, it is distinguished between four types

of areas with structural difficulties:
282
Annex
The eligibility for promotion mainly depends on the
quantifiable way and which can be reproducible at other
following points:
locations of the European Union.
The measures in the European Community have to be
In Germany, eight projects are being promoted by LIFE-
of Community interest, they must be innovative,
Environment in 2004, one of it in the field of waste
reliable and feasible.
water with the subject Nutrient removal by membrane

bioreactors. This project called ENREM will run until
The measures outside the Community must be technically and financially feasible and contribute to sustain-
December 2006. It is realized by Kompetenzzentrum

Wasser Berlin GmbH.
able development and cooperation.

EU contact:
Die Aktion wird in den betreffenden fnf Jahren (2000
General Direction Environment
2004) auf drei wichtige Bereiche konzentriert:
LIFE-Program
Bruno Julien
Over the respective five years (2000 2004), the action
General Direction Environment D. 1
will focus on three important fields:
BU 2/01
Rue de la Loi 200
Nature conservation (LIFE-Nature): actions aimed at

conservation of natural habitats and the wild fauna
B-1049 Brssel
bruno.julien@cec.eu.int
and flora of European Union interest They support

implementation of the nature conservation policy and
Instrument for structural policies for pre-accession
the Natura 2000 Network of the European Union.
(ISPA)
Environment (LIFE-Environment): actions which aim
This development program aims at preparing the countries
to implement the Community policy and legislation
Estonia, Latvia, Lithuania, Poland, The Czech Republic,
on the environment in the European Union and candi-
Slovakia, Hungary, Slovenia, Romania, Bulgaria) for acces-
date countries. This approach enables demonstration
sion. Investment projects in the field of national trans-
and development of new methods for the protection
port and environment are funded.
and the enhancement of the environment.

Community assistance under the ISPA is granted for the
Third countries (LIFE-Third Countries): actions con-
period 2000-06. The total budget is 7 billion s. The rate
cerning technical assistance activities for establishing
of assistance may be up to 75 % of the total costs in the
administrative structures in the field of environmental
form of non-repayable subsidies for public administra-
protection, actions for nature conservation and
tions and public enterprises.
demonstration measures for promoting sustainable

development in some Mediterranean countries and
Further information:
littoral states of the Baltic Sea.
http://www.europa.eu.int/comm/regional_policy/
index_en.htm
For actions financed by the LIFE program, a subsidy of

50 % of the total costs is given. Within the scope of LIFE-
EU contact:
Environment, demonstration projects are funded which,
General Direction Regional Policy
however, must not be research, studies or investments in
Rue de la Loi
infrastructure. The proposals must have for subject pilot
B-1049 Bruxelles
actions or actions concerning technical assistance which
E-Mail: luis.riera-figueras@cec.eu.in
are suited to improve the environmental conditions in a
283
Annex
A.3
Reason and objective

Definition of the objective
Expansion/Upgrade of activated sludge stages
New construction
Upgrade in order to comply with more stringent demands
...
Analysis of the current situation

Technical boundary conditions
Demands on the effluent (minimum requirements/more far-reaching requirements)
Capacity of an existing waste water treatment plant
Drainage system
Inflow features
Conversion/possible addition of membranes into existing tanks
...
Economic conditions
Investments, in particular specific membrane costs
Subsidies for investments
Operating costs (membrane replacement costs, cleaning, energy consumption)
Waste water charge
...
Study of variations
Utilization of existing tanks
New construction of tanks and membrane stage
Selection and arrangement of the membrane modules
Necessary pretreatment measures
Design and realization of membrane cleaning
Planning, design and construction

Design
Sludge age, sludge loading, excess sludge production
Solid matter content in the activated sludge tank
Minimum retention time, mixing and compensating tank
Distribution of denitrification, nitrification and variable zone
Oxygen carry-over by recirculation
Necessary membrane surface area for constantly stable flow rates
Influence of the temperature on the permeability
Membrane surface area available in the case of cleanings
Module ventilation according to the manufacturers specification
Oxygen input depending on the solid matter content
Phosphorus removal
Sludge treatment: dewatering and digestibility
284
Annex
Design of the construction (continuation)

Design of the construction
Pretreatment quality (screen, separator for light-density material)
Buffer tank in the inflow or the installation
Realization of two or more lines
Hydraulic decoupling of several lines
Short membrane replacement and delivery times
Devices for membrane cleaning
Power supply

Operating stability
Training/instruction of the staff
Guarantee of the filtration capacity
Control of the membrane state (sticking of fibrous material etc.) and permeability
Regular membrane cleaning (intermediate, intensive cleanings)
Operating costs
Energy consumption of tank and module aeration
Service life of the membranes
Costs of cleaning agents
Regular membrane cleaning (intermediate, intensive cleanings)
Safety at work
Handling of cleaning agents
285
Annex
A.4
Reason and objective

Compliance with the demands
Cost reduction
Saving of water
Saving of chemicals
Saving of energy
Recovery of valuable substances
Reduction of discharge costs
Reduction of the transport costs
Reduction of waste water charges
Analysis of the current situation

Data recording
Production process
Input and output of resource flows
Determination of the material flows and place of their production
Waste water flows
Waste water volume, chemical and physical quality
Valuable and undesired substances in the flow to be treated
Processes limiting the process, and other restrictions
Costs for the current situation, i. e. without recovery and recycling under monetary and environmental-engineering aspects
Suggestions for improvements / potentials

Possibilities for avoidance in the production process
Treatment of residual matter
Is it possible to recover valuable resources from the material flow?
Utilization / whereabouts of the valuable material recovered
Selection of the process

Definition of the objective
Possible separation processes
Is it necessary or possible to modify the production process?
Effectiveness of the processes?
Is it possible to attain the required objectives by this process?
Comparison of the economic efficiency
Laboratory tests, pilot tests
286
Annex
Selection of the process (Continuation)

Comparison of the economic efficiency
Existing process, no change
Costs of water supply
Energy costs
Costs of chemicals
Costs of raw material
Discharge costs for liquid waste
Disposal costs for solid waste
Laboratory costs
Membrane process installed

Investments for new installation
Membrane replacement costs
Investments for peripheral installations, pumps, equalization tank
Separated valuable material
Planning and pilot phase

Tests on different levels
Preliminary tests
Laboratory tests
Choice of membranes
Pilot tests

Operator model or owner-operated
e. g. BOO Build-Own-Operate
Contract regulation
Duration of the contract
Guarantee period, service life of the membranes
Price regulation
287
Annex
A.5
With the cooperation of:
Work report of the ATV-DVWK working group

IG-5.5 Membrane Technology: Treatment of indus-
Dipl.-Biol. Annette Achtabowski, Bergkamen
trial waste water and process water by membrane
Dipl.-Ing. Stefan Krause, Darmstadt
processes and membrane bioreactor processes
Prof. Dr. Winfried Schmidt, Gelsenkirchen

Dipl.-Ing. Jens Wagner, Hannover
This work report has been established by the ATV-DVWK

working group IG-5.5 Membrane Technology of the
Part I
ATV-DVWK Committee of Experts IG-5 Industrial Waste
Membrane processes
Water Treatment. The report consists of several parts.

A.5.1
Part 1 deals with the membrane treatment process itself,
Introduction
i. e. with its use for the separation of undissolved, colloidal

or dissolved substances.
Membrane processes are pure physical processes for

material separation, by which the waste water or the pro-
Part 2 looks into the membrane bioreactor process. It
cess water to be treated is separated into purified water
focuses on the process unit consisting of biological de-
(filtrate or permeate) and a concentrated phase (concen-
gradation in the aeration tank and separation of the bio-
trate) (Figure A-1). The driving force for these separation
mass by membranes. It deals in particular with the requi-
processes is the transmembrane pressure difference. These
rements and specific features of the membrane bioreactor
pressure-driven processes differ in the extent of the pres-
process compared to the conventional activated sludge
sure difference. Membrane processes based on other
process. A third part is planned in which concrete exam-
driving forces, such as an electrical field or a concentra-
ples, operating experience and design instructions will be
tion difference, will not be discussed here because of
summarized.
their insignificant practical importance in waste water

treatment. In contrast to conventional filtration techno-
The ATV-DVWK working group included the following
logies, pressure-driven membrane processes allow for
members:
separation up to the molecular range.
Dr.-Ing. Goetz Baumgarten, Langenhagen
Two features are of special importance for the success of
Dr.-Ing. Martin Brockmann, Hilden
a membrane process:
Dipl.-Biol. Ulrich Br, Herten

Prof. Dr.-Ing. Peter Cornel, Darmstadt (speaker)
the selectivity of the membranes, i. e. their capacity to
Dr.-Ing. Oliver Debus, Hamburg
distinguish between the components of a mixture (e. g.
Dipl.-Ing. Michael Kiefer, Stuttgart
between oil and water or between ions and water). The
Dr.-Ing. Angelika Kraft, Essen
membrane hinders the transport of various components
Prof. Dr. Peter M. Kunz, Mannheim
in different ways.
Dr.-Ing. Otto Neuhaus, Bergkamen

Dr.-Ing. Thomas Peters, Neuss
the performance of the membrane (often called mem-
Prof. Dr.-Ing. Karl-Heinz Rosenwinkel, Hannover
brane flux), i. e. the permeate or filtrate (usually given
(deputy speaker)
in L/(m2 h) to be obtained under certain operating
Prof. Dr.-Ing. em. Carl Seyfried, Hannover (chairman)
conditions.
Dr.-Ing. Jianming Shang, Hamm

Prof. Dr.-Ing. Ulf Theilen, Gieen
Dr.-Ing. Frieder Wagner, Heuweiler
288
Annex
Figure A-1
Schematic representation of the basic principle of a membrane process
membrane process
waste water
(feed)
100 %
treated waste water

(permeate/filtrate)
e. g. 90 %
concentrated waste water

or reusable matter
(concentrate)
e. g. 10 %
Figure A-2
Classification of membrane and filtration processes
common salts
virus
bacteria
metal salts
coloured pigments
200
pressure difference [bar]
100
reverse osmosis
nanofiltration
10
ultrafiltration
microfiltration
filtration
0,1
0,0001
0,001
0,01
0,1
10
100
particle or molecular size [m]
Figure A-2 shows the classification of the membrane pro-
With membrane processes it is possible to separate waste
cesses as function of the particle or molecular size and
water constituents, such as:
the pressure difference.

solids
dissolved matter
colloids and
liquids of a second phase
289
Annex
Independent of the process or the separation goal, various
The pore membranes have a porous structure with
treatment objectives can be pursued which are of economic
channels. The selectivity is based on a screening effect
interest, for example:
which is determined by the pore size distribution of

the membranes. Material transport takes place in a
1.water purification e. g. for
pure convective way according to the principles of the
compliance with the discharge standards
laminar capillary tube flow (Hagen-Poisseulle principle)
reuse
as a result of the pressure difference between both sides

of the membrane. This model describes theoretically
2.concentration of water constituents, e. g. for
the separation effect of micro- and ultrafiltration mem
branes. In practice, however, these processes are as a
reduction of discharge costs
rule controlled by a covering layer. This covering layer

(secondary membrane) develops from the substances
To understand the selectivity of membranes, models have
concentrated on the membrane surface.
been developed which can be condensed, for a coarse

overview, into two borderline cases. One distinguishes
Due to the concentration of the water constituents taking
the so-called solution-diffusion membranes (reverse
place at the raw-water side of the membrane, the follo-
osmosis, nanofiltration) and the pore membranes (micro-
wing effects may occur on the membrane surface as well
and ultrafiltration).
as on components of the membrane elements or the

membrane modules which have negative effects on the
The solution-diffusion membranes have a homogeneous
performance of a membrane installation:
interlayer, comparable to a gel. To pass the membrane,

the substance must dilute in the membrane material.
scaling
Consequently, the selectivity is based on the varying
deposition of inorganic water constituents after precipi-
solubility and the varying passage velocity of the sub-
tation by supersaturation, crystal formation
stances to be separated through the membrane material.

Material transport through the membrane takes place
fouling
according to the principles of diffusion (Fick principle).
formation of a covering layer by organic water constituents
The driving force for the dissolved substances in all

diffusion-controlled membrane processes is the dif-
biofouling
ference in the chemical or electrochemical potential
formation of a biofilm by microorganisms
at both sides of the membrane, while the driving force

for the solvent, i. e. the water, is the pressure difference.
These effects can be avoided or at least minimized by cor-
This model describes the separation effect of reverse
responding measures. It is for example possible to avoid
osmosis membranes. To describe the separation features
the precipitation of inorganic components such as CaSO4
of nanofiltration membranes, electrochemical inter
or CaCO3 by shifting the pH value (and, with this, the
actions with the membrane surface, which as a rule is
solubility limit) and/or dosing of anti-scaling agents
negatively charged, must also be considered.
(complexing agents, e. g. phosphonic acid, polycarboxylic

acid). The formation of a biofilm can be avoided or minimized by corresponding pretreatment of the raw water
as well as backwashing and cleaning of the membranes
adapted to the special case.
290
Annex
Table A-2
Membrane processes and their fields of application
Abtrennbare
Trenngrenze
Verfahren
Betriebsdruck
Wasserinhaltsstoffe
(Porengre)
[Membran-Typ]
kPa (bar)
Partikel > 0.1 m
0.1 1 m
emulgierte Stoffe
Microfiltration (MF)
50 300 kPa
(pore membranes)
(0.5 3 bar)
Kolloide, Makromolekle
2,000 200,000 g/mol
Ultrafiltration (UF)
50 1,000 kPa
Molmasse > 2,000 g/mol
(0.004 0.1 m)
(pore membranes)
(0.5 10 bar)
> 200 g/mol Rckhaltung
Nanofiltration (NF)
500 4,000 kPa

(5 40 bar)
emulgierte Stoffe
Organische Molekle
mehrwertige, anorganische Ionen
MgSO4 > 90 %
(solution-diffusion
(0.001 0.005 m)
membranes with integrated
< 200 g/mol Rckhaltung
Reverse osmosis (RO)
500 7,000 kPa
fr NaCl > 95 %
High-pressure reverse osmosis
(5 70 bar)
(solution-diffusion membranes)
up to 12,000 kPa
ionogenic groups)
Organische Molekle und alle Ionen
(up to 120 bar)
A.5.2
unit (g/mol) for the molecular weight corresponds to the
Choice of a membrane process
unit Dalton which is used in other publications.
When choosing a membrane process, at first four impor-
A.5.2.2
tant decisions have to be made:
Determination of the membrane material
determination of the necessary molecular separation

size of the membrane to be chosen
Today nearly the whole membrane technology in the field

of water and waste water treatment is based on synthetic
determination of the membrane material
polymer membranes, briefly described in the following.
decision on the module type
In spite of high investment costs, ceramic membranes
decision of the process
recently have become established in special fields of ap-
The criteria for this choice are described in the following.
plication (high temperatures, aggressive media, solvents).
A.5.2.1
From the general material transport principles (convection,
Determination of the necessary molecular
diffusion) it is known that the permeate flow [L/(m2 h)]
separation size
is inversely proportional to the length of the transport way.

For this reason, the membrane manufacturers have tried
The type of the components to be separated from a waste
to make available rather thin separating layers. Yet the
water or a process water, i. e. the necessary selectivity,
mechanical strength of the membrane has to be ensured.
determines the type of the membrane to be used. Some

examples in Table A-2 illustrate the classification of the
While in microfiltration, as a rule, symmetric membranes
separation of water constituents with the membrane
are used, asymmetric membranes have gained acceptance
types. For the pore membranes, the pore size, utilized by
in ultra- and nanofiltration as well as in reverse osmosis.
majority in practice, is indicated. The units and separa-
In this case, one distinguishes between phase-inversion
tion sizes used in the Table correspond to the terms ap-
and composite membranes, depending on the production
plied normally by the membrane manufacturers. The
process. Active layer and substructure of the phase inver-
291
Annex
sion membrane are made from the same material, while
Figure A-3
composite membranes have a thin, homogeneous poly-
Cross-section of a phase-inversion membrane,
meric layer cast on a support back-up structure which
example: UF hollow-fibre membrane
enables separate optimization of the layers. The Figures

A-3 and A-4 show the general structure of phase-inversion and composite membranes.
The membranes produced from cellulose derivates often
applied in the past have been replaced to a great extent
by membranes from completely synthetic polymers (polysulphone, polyether sulphone, polyamide, polypropylene,
polyacrylonitrile etc.). These membranes offer the particular
advantage of being more resistant to the various media.
Table A-3 gives an overview of the most current membrane
materials used for the different membrane processes.
Figure A-4
Composite membrane, left: general structure of a composite membrane, right: cross-section of a composite
membrane
microporous backing material

up to a thickness of 50 m
porous polyester network
up to a thickness of 125 m
active layer up to 2500
= 1/4000 mm thickness
barrier layer
2500
292
Annex
Table A-3
Overview of the most current membrane materials for the different membrane processes
Process
Active layer
Microfiltration
polypropylene (PP)
polyvinylidene fluoride (PVDF)
polysulphone (PSU)
-aluminium oxide
high-grade steel, titanium dioxide
zirconium oxide
Ultrafiltration
polysulphone (PSU)
reg. cellulose
polyacrylonitrile (PAN)
polyether sulphone (PES)
titanium oxide, zirconium oxide
polyvinylidene fluoride (PVDF)
Nanofiltration
polyamide (PA)
(zirconium oxide), PES
cellulose acetate (CA)
Reverse osmosis
polyamide (95 %)
cellulose acetate (5 %)
A.5.2.3
specific applications. Disregarding constructive details,
Determination of the membrane module
the modules can be subdivided into two groups:
The main element of each membrane installation is the
modules with tubular membranes
module in which the membrane surface area is arranged
tube module
as an engineered system. The ideal module ensures the
capillary module
following aspects:
hollow-fibre module
good and constant flow over the membranes without
modules with flat membranes
dead-water zones
plate module
low pressure losses
spiral-wound module
high packing density
cushion module
low-cost production
rotating module
easy cleaning
easy replacement of the membranes
low disposition for clogging
Since no module is capable of meeting all these contradictory requirements in an optimal way, various module
types have been developed, including some designs for
293
Annex
Table A-4
Features and fields of application of different module types
Type (examples)
Packing density [m2/m3]
Specific costs per m2
Covering layer control
Fields of application
Rotating module
10 50
+++
MF and UF
Tube module
20 90
++
MF, UF, NF, RO
Plate and cushion module
100 250
++
MF, UF, NF, RO
Capillary module
600 1,200
MF, UF, NF
Spiral-wound module
700 1,000
RO, NF, UF
Hollow-fibre module
> 1,000
++
RO, UF
negative 0 average + positive
The size and investment and operating costs of a mem-
In waste water engineering, this means that the type and
brane installation are closely related to the specific per-
concentration of the solid matter fed to a membrane
meate performance and the membrane surface area to be
installation and the solid matter formed in the course of
installed. It has to be arranged as favourably, i. e. as com-
the process decisively influence the module system to be
pact as possible, without endangering the operational
chosen. Table A-4 gives an overview of the features and
safety.
fields of application of the different module types.

The structure of the different modules is represented in
Figures A-5 A-7.
Figure A-5
Figure A-6
Front view of a tube module with 5.5 mm tubular
View of a cushion module (type ROCHEM FM)
membranes [photo: X-FLOW]
294
Annex
Figure A-7
Principle of a spiral-wound module
wrap
permeate collecting tube

(central tube)
permeate spacer
feed
feed spacer
permeate
membrane
permeate
spacer
permeate outlet after

passage through the
membrane concentrate
membrane
tube water
A.5.2.4
Determination of the operating mode of
membrane installations
Like the choice of the module, the operating mode of a
The dead-end operation stands in contrast to the cross-
membrane process is determined by the load or the con-
flow mode. Like in classical cake-forming, static filtration,
centration of the dissolved and/or the undissolved
the filtration capacity decreases with increasing thickness
constituents of the respective waste water or process
of the covering layer. Combined with an effective back-
water. The specific energy demand of the operating mode
washing technique, this operating mode is used success-
influences the economic efficiency and, with this, the
fully in microfiltration and ultrafiltration applications.
feasibility of the individual applications.
The combination of both operating modes is called semicrossflow mode.
As a rule, membrane processes are operated in cross-flow

mode, also called tangential flow. Tangential flow to the
Both operating modes, dead- end and cross-flow, differ
brine or concentrate side of the membrane attempts to
considerably in their energy demand. Pure cross-flow
limit the development of a covering layer on the mem-
processes need between 2 kWh/m3 and 10 kWh/m3 (for
brane and to maintain a constant permeate flow at the
MF and UF) or between 0.5 and 5 kWh/m3 (for NF and
highest possible level.
RO), while pure dead-end processes operate with an energy consumption of between 0.1 and 0.3 kWh/m3.
295
Annex
A.5.3
Examples for the use of membrane processes
retention of sludge in membrane bioreactors

(MF, UF), see Part 2 of the work report
Pressure-driven membrane processes have proved their
A.5.4
suitability in many fields. The following list does not
Planning of membrane installations
claim to be complete.
A.5.4.1
filtration of pickling acids (MF, UF)
Acquisition of basic data
treatment of waste water from a CP plant in

electroplating (RO)
As a basis for the planning of a membrane installation,
treatment of landfill leachate (NF, RO)
all relevant data on the waste water or process water to
extension of the service life of degreasing baths
be treated has to be collected for the longest possible
(MF, RO)
recovery of reusable material from dyeing waste
water (UF)
treatment of waste water from flexographic
printing (MF)
period and documented in an adequate way. This data concerns volume flow or batch quantity, chemical/physical
parameters and other process-specific dissolved and undissolved water constituents (see chapter A.5.6 Questionnaire
for the acquisition of process data).
treatment of waste water from spark erosion (MF)

treatment of waste water from slide grinding (MF)
Besides the waste water situation of the present-day oper-
treatment of grey water on ships (RO)
ating state, the water balance of the whole enterprise
water recycling from solid matter-containing waste
also has to be determined in order to get the basis for the
water from the production of semiconductor
specification of the objective and a rough assessment of
elements (CMP, grinding, sawing) (UF)
the effects of a new process concept on the operation.
reutilization in the semiconductor industry (RO)
The assessment of the potential for savings and the results
oil separation from compressor condensates (MF)
expected should be completed by examinations of partial
concentration of cutting oils (UF)
flows and of changes concerning upstream process steps.
treatment of lyes (MF, UF, NF)

reutilization in the food industry (RO)
A.5.4.2
treatment of rinsing water from degreasing in the
Planning and design
metal-processing industry (RO)

treatment of recirculation water in non-metal
processing (UF)
separation of biologically hardly degradable organic
components (NF)
treatment of waste water from flue gas cleaning (MF)
When the acquisition of basic data has shown that a certain

membrane process can be used, the procedure described
below should be followed because it has proved successful
in planning such installations. As a rule, successful operation can only be ensured by the procedure described.
treatment of acids (NF)

treatment of sludge water (filter backwash water) (UF)
A.5.4.2.1
treatment of sludge water in swimming-pools (RO)
Preliminary laboratory tests
concentration before thermal treatment (RO)

pretreatment of waste water for further treatment by
reverse osmosis (MF, UF)
The preliminary tests serve for first orientation and are

usually carried out with reference to the following aspects:
closing of water cycles (UF, NF, RO)

recovery of reusable material from water-based paint
(UF)
reduction of germs in the effluents of waste water
treatment plants (MF, UF), see Part 2 of the work report
296
selection of membranes and modules with determination of the general suitability of a medium to be
treated by the membrane process chosen
Annex
preselection of potentially necessary pretreatment

measures, assessing at the same time the scaling,
membrane contamination by biofouling: cleaning by

oxidizing agents or by lyes, e. g. caustic-soda solution
fouling and biofouling potential, and preliminary tests

on membrane cleaning
approximate determination of the most important
process parameters such as pressure, temperature,
Between the individual cleaning steps, the installation

has to be rinsed with water to avoid interactions between
the chemicals used.
overflow velocity and attainable output

The following cleaning strategy is described by way of
A.5.4.2.2
example:
On-site pilot tests

1. displacement of the process water from the installation
The pilot tests to be outlined on the basis of the laboratory
tests serve to establish the specific design basis, the purification strategies and other process-engineering and installation-specific conditions. The pilot installation has to be
planned in such a way that the hydraulic conditions (overflow conditions of the membrane, module connection)
2. cleaning by citric acid/hydrochloric acid at pH 3 to

detach inorganic layers, duration about 1 4 hours at
slightly increased temperature
3. intermediate rinsing with water, i. e. displacement of
the cleaning solution used in step 2
4. treatment by NaOCl/NaOH at pH 11 to oxidize
of the membrane elements, i. e. of the modules, can be
bacterial depositions, duration about 5 8 hours at
transferred to the large-scale installation. Only in this way
slightly increased temperature
will up-scaling be possible without problems. The pilot tests

should be carried out with the following considerations:
5. final rinsing with water for complete displacement of

all chemicals from the system
6. the installation is again put into operation with
on-site operation of a semi-technical pilot plant in con-
process water
tinuous operation under practical conditions, taking

down all data relevant for calculation including pre-
The duration of the individual steps may vary depending
treatment
on the degree of contamination. It may also be necessary
determination of the permeate efficiency as function of
to repeat one of these steps several time.
the process section and the time

of the membranes: determination of the cleaning
intervals, optimization of the cleaning processes, deter-
A.5.4.2.3
mination of the demand for chemicals

The installation is now planned based on the results of
Optimal chemical cleaning of the membranes is impor-
the pilot phase. The working steps are as follows:
tant for their continuous functioning. Depending on the

type of contamination, different chemicals have to be
analysis of the test data, determination of the perme-
used. A cleaning strategy has to be developed for each
ability [in L/(m2 hbar)] at the end of the expected
single case, but in principle the following chemicals are
membrane service life at each point in the membrane
used for the different types of contamination:
process, as the most important design parameter

design of the installation considering the real operating
membrane contamination by scaling: cleaning by

acids, e. g. citric acid, hydrochloric acid; if necessary,
complexing agents
conditions of the membranes and modules used

integration of the membrane process into the complete
process
membrane contamination by fouling: cleaning by

oxidizing agents, e. g. hydrogen peroxide, peracetic acid,
sodium hypochlorite
297
Annex
Figure A-8
chemicals for operating

chemicals for chemical cleaning
resources (electric power, compressed air)
other consumables (filter substitute etc.)
treated water (permeate or filtrate)
waste water inflow

membrane installation
concentrate
waste water from backwashing

waste water from chemical cleaning
A.5.5
A.5.5.1.2
Assessment criteria for the choice of a membrane
Material and mass fluxes during operation
installation
of a membrane installation
After having followed the working steps described above,

the selection procedures carried out should be assessed
again before the installation is realized. The following
sections will serve the future operator as check list for his
own work and for the assessment of offers.
Are the mass fluxes logical, i. e. is the total balance

exact? (sum influents = sum effluents! Figure A-8)
Are the measuring devices available which are necessary
for balancing the operation of the installation?
Is it possible to bridge periods of chemical cleanings by
internal measures or buffering tanks?
A.5.5.1
Is the installation sized in such a way that it can cope
Technical assessment of a membrane process
in adequate time with the additional amount of waste
concerning employment and completeness
water resulting from these cleanings?

Are there problems with waste disposal (replaced
A.5.5.1.1
Definition of the terms of reference
Have the waste water constituents been sufficiently
specified and documented?
Have the variations in quality and quantity of the
waste water been defined?
Have rare or cyclically appearing conditions in the
production process been considered in the specification
of the waste water data?
298
membranes, prefilters?)
If yes, how high is the expense?
Annex
A.5.5.1.3
Utilization or discharge of the resulting products
Does the treated water (permeate or filtrate) comply
with the standards for discharge into the sewer system
Are the considered redundancies sufficient in light of

the costs arising from a breakdown of the installation?
A.5.5.1.7
References/similar applications
or the receiving water, or the standards for reuse?

Is the quality concerning this aspect continuously
controlled?
Can the concentrate stream be used internally, or does
Have examples already been realized which are similar

to this case?
Does the offering company have references for the
it comply with the standards for discharge into the
membrane technology chosen, perhaps for similar
sewer system or a receiving water?
applications?
Does the recycling of waste water have effects on the

existing waste water discharge or on the existing waste
A.5.5.2
water installation (increase of the concentration)?
Operating costs
Which method is used for the discharge of the waste

water from chemical cleaning of the installation?
A.5.5.2.1
Equipment
A.5.5.1.4
Pretreatment
How high is the input power/the power consumption?

How high is the consumption/the cost of compressed
Do the membrane modules/the membranes need a

pretreatment?
Does this pretreatment consider the required
technology and costs?
What happens if pretreatment breaks down
(emergency measures to protect the membranes)?
Have precautions (measuring methods, safety filters)
been taken in case of insufficient pretreatment?
air?
How high is the consumption of additional water
(e. g. for chemical cleaning, backwashing)?
Is the water available for these measures sufficient in
quantity and quality?
Which chemicals are necessary for normal operation?
Are these chemicals available in the company?
Is the amount of chemical consumption known?
How high are the annual costs for analyses?
A.5.5.1.5
Technical realization
A.5.5.2.2
Auxiliaries
How high is the degree of automation of the installation?

Is it sufficient for operation?
Is the installation offered capable of reacting to varying
Service life/annual costs for possible prefilters (offer for

wearing parts available)
quantities and compositions of the waste water to be

expected?
A.5.5.2.4
Service life and replacement of membranes
A.5.5.1.6
Redundancies
How long is the service life of the membranes used?

Expected/guaranteed service life (guaranteed value at least
What are the consequences to the operation of a break-
two thirds of the expected value?)
down of the complete installation for some hours/some
Is a longterm offer for spare membranes available?
days? (discharge costs/discharge safety/production los-
Does it include the costs for the amount of work involved
ses/follow-up costs)
in the replacement of the membranes?
299
Annex
A.5.5.3
A.5.5.4
Change of the conditions during operation of the
Other items
installation
A.5.5.4.1
A membrane process has not only to be assessed concern-
Failures
ing completeness, costs and process safety, but some

boundary parameters have also to be considered during
operation. Neglecting them may partly give rise to problems or damages. With existing installations, the following observations have been made:
corrosion of some components due to the change of
cleaning chemicals
Are spare membranes or modules available at short

notice in the required quantity, if necessary?
Is this time acceptable for operation (possible breakdown of the installation for this period)?
A.5.5.4.2
Preliminary tests
change of the composition of cleaning chemicals, e. g.

by change of the supply source
change of the succession of cleaning steps
change of the temperature during the cleaning process
hydraulic changes in the inflow or inside the
Have preliminary tests been carried out for this case or

application?
If yes, are the indications of the offer in accordance
with the data from the preliminary tests?
installation, e. g. by decreasing pumping performance

change of the inflow quality, e. g. by change of the load
or by additional constituents (use of process chemicals
A.5.6
Questionnaire for the acquisition of process data
from other suppliers or change of the production

process)
change of the membranes (change of the membrane
supplier)
A.5.6.1
Description of the separation problem to be
solved with the help of a membrane process
insufficient maintenance of the measuring or analytical

instrumentation (e. g. pH electrodes)
What type of waste water will be treated? Origin?

Composition? Results from physical and chemical
This list of operating problems observed in the past
analysis (among others temperature, pH value, electric
clearly shows that maintenance of a membrane installa-
conductivity, disposition for fouling, solid matter
tion is of high importance. Of course, changes to the
content, type of solid matter)
inflow quality cannot always be avoided because changes

in the production process are always possible. Slight
Which components have to be removed from the

medium?
changes normally will not influence the treatment instal-
What requirements are there for permeate quality?
lation. Nevertheless, it is recommended to keep close con-
Does the medium contain substances which may
tact with the manufacturer of the membrane installation,
damage the membrane? (see list in the annex) If yes,
since important changes to the water inflow can often be
which substances?
managed by slight modifications to the installation. Prerequisite is that the operator is informed immediately
about these changes by internal measures.
The pages 315 316 contain the bibliography of Annex A.5.
300
Is the medium microbiologically conspicuous?
Annex
A.5.6.2
Annex
Concerning the assessment or the integration

of a membrane process into an overall treatment
Depending on concentration and operating mode, the
concept
following substances may have negative effects on the

performance of the system and have to be examined in
Is there a possibility to reuse the permeate/filtrate and
a more detailed way:
the concentrate (e. g. reuse in operation, recovery of

reusable material)
oxidizing agents [e. g. chlorine, peroxide, chromium(VI)],
Which possibilities exist for the treatment of the con-
cationic detergents, flocculants, defoamers, polymers,
centrate, if necessary? Assessment of discharge paths
silicones, organic solvents, silicates, calcium, barium,
and costs?
strontium, iron/manganese, tin, acids/lyes (pH value),
How important are the cost savings which possibly
gypsum, lime, abrasives.
result from the use of a membrane process? (chemicals,

water and waste water levies etc.)
Which processes competing with the membrane
Part II
Aerobic membrane bioreactor processes
process have to be considered?

A.5.7
A.5.6.3
General information
Sizing of the installation

This work report addresses operators, planners and plant
What waste water quantity is to be expected? How is it
manufacturers who deal with industrial waste water treat-
produced? Are there mixing and equalizing possibilities,
ment. It is the second part of the work report Treatment
if necessary? Future development? (graphs of quantities
of industrial waste water and process water by membrane
and concentrations of the constituents, given in
processes and membrane bioreactor processes, based on
m2/h, m2/d and m2/a)
the work report Membrane bioreactor processes for
What is the minimum permeate output (= % related to

the treated water quantity) that should be obtained?
municipal plants which presents the most important

basics and definitions.
Are there possibilities to influence the process

temperature?
In membrane bioreactor installations, the final clarification stage is replaced by microfiltration or ultrafiltration.
A.5.6.4
From this result two important advantages:
Requirements for the construction of the

membrane installation
the effluent is free of solid matter,

the biomass concentration is independent of the
What demands are made of the material to be used?
sedimentation behaviour.
Are there materials which cannot or must not be used?

What other demands are made of the membrane
Therefore, membrane bioreactors are capable of reaching
installation? (e. g. flame protection, sanitary execution,
much higher TS concentrations than conventional acti-
operation under food conditions, CIP capacity)
vated sludge plants. Tank volume can be saved to the
Are there instructions for the degree of automation of
same extent, if the same design principles are applied.
the installation or for the type of control device?

How much space is available for a possible membrane
installation?
Figure A-9 shows the flow sheet of a membrane bioreactor

compared to a conventional activated sludge plant.
301
Annex
Figure A-9
Schematic comparison of the conventional activated sludge process with the membrane bioreactor process
BB = activated
sludge tank
inflow
BB
NK = secondary
settling tank
inflow
effluent
NK
BB
effluent
SS
SS = excess sludge
This work report is divided into the description of the
passes through the membrane and is withdrawn as filtrate.
construction of membrane bioreactors (chapter A.5.8),
The development of a covering layer can be influenced by
and the quality requirements for the effluent (chapter
varying the overflow conditions. Compared to membrane
A.5.9). In chapter A.5.10, instructions for design are given,
modules in a dry arrangement, immersed systems have a
and chapter A.5.11 deals with some special features of
lower specific energy demand for the generation of the
membrane bioreactors compared to conventional activated
cross-flow, but larger membrane surfaces are necessary
sludge processes. Chapter A.5.12 contains information on
because the flow rate [L/(m2 h)] is also lower.
the economic efficiency of membrane bioreactors. A list

of exemplary installations in the field of industrial waste
A.5.8.1.1
water treatment in Europe completes the report.
Immersed membrane modules
A.5.8
Immersed membrane modules are installed in the aerobic
Construction
part of the aeration tank or in a separate filtration tank

(Figures A-10 and A-11). The necessary cross-flow is gene-
Membrane bioreactors consist of an aeration tank in
rated by coarse-bubble aeration arranged below the mem-
which the waste water is biologically treated with the
branes and/or mechanical movement. The filtrate is with-
help of activated sludge and a filtration unit which serves
drawn by means of a vacuum of approx. 0.05 - 0.6 bar (as
to retain the activated sludge by means of membranes
low as possible).
integrated into modules, so that the effluent is free of

solid matter.
A.5.8.1.2
Dry-arranged membrane modules
A.5.8.1
Arrangement
In dry arrangement of the membrane modules, the mixed

liquor is taken from the aeration tank and pumped
The membranes and membrane modules available on the
through the module. The cross-flow is generated by a
market differ with regard to the module construction, the
pump. Due to high pressure loss in the common modules,
molecular separation size (micro- or ultrafiltration mem-
the energy demand is higher than that of immersed sys-
brane), the membrane structure (flat, tubular and capillary
tems. However, the covering layer control is very effective
membranes), the filtering sense (inside-out or reverse),
so that a higher specific flow is obtained. Figure A-12
the place of installation (dry-arranged or immersed
shows a diagram of this arrangement.
systems) and the operating mode. Because of the high

solid matter content of the activated sludge process, the
filtration unit of a membrane bioreactor is generally operated in cross-flow mode, i. e. the mixed liquor is fed
tangentially across the membrane surface; a partial flow
302
Annex
Figure A-10
Figure A-11
Arrangement of the immersed membrane modules
Arrangement of the immersed membrane modules
in the aerobic section of the activated sludge tank
in an external filtration tank
Figure A-12
Membrane modules in dry arrangement
A.5.8.2
Concerning flat membranes, it is possible to generate a
Control of the covering layer
forced air flow along the membrane by means of a fitting

(the membrane is cased in a box) or a mechanical move-
A.5.8.2.1
ment. With some systems, e. g. plate membranes, the re-
Control of the covering layer in immersed systems
sulting air lift pumps the activated sludge in an effective

way only if a free up-flow channel is arranged below the
Immersed systems are installed directly in the aeration
membrane to accelerate the air-sludge mixture.
tank or in an external filtration tank (cf. Figure A-10 and

Figure A-11). The covering layer is controlled by coarse
A.5.8.2.2
bubble aeration at the bottom of the modules. The rising
Covering layer control in dry-arranged systems
air bubbles generate innumerable small turbulences. By

pressure differences in these turbulences, particles attached
In dry-arranged systems, filtration by the membrane
to the membrane surface are detached.
bioreactor process is carried out in cross-flow mode. By

tangential flow across the membrane surface on the side
In hollow-fibre membranes, extensive movements of the
of the solid matter, the development of a covering layer
hollow fibres are generated by the large number of turbu-
is limited by deposition of filtered particles to obtain a
lences. These movements can be supported by intermittent
constant, high-level filtrate flow. The more permeable,
aeration; the resulting pumping effect induces a cross-flow
i. e. the thinner the filtering cover layer of the membrane,
inside the fibre bundle. This improved covering layer con-
the higher is the flow rate. To control the covering layer
trol has the additional advantage of minimizing the energy
as effectively as possible, several times the flow (feed) is
consumption for air intake.
recycled. The typical velocity in cross-flow filtration is

approx. 1 4 m/s, depending on the module construction.
303
Annex
Figure A-13
deposition of (colloidal) organic and inorganic particles
Qualitative relationship between necessary mem-
deposition and precipitation of salts (see scaling)
brane surface area, energy demand and flow
deposition of organic macromolecules

biofouling, i. e. penetration and growth of micro-organisms and/or their excretions such as enzymes, EPS
specific membrane surface [m2/(m3h)]
(extracellular polymer substances) in and at the

membrane
flow
flow [l /(m2h)]
surface
energy demand (kWh/m3)

immersed
membrane modules
dry-arranged
membrane modules
According to the diversity of causes, the cleaning strategies have to be adapted to the waste water composition,
to the operating mode of the activated sludge stage and
to the membranes and membrane modules used.
One distinguishes between process-controlled integrated
backwashing, periodic in-situ maintenance cleanings, e. g.
by backwashing using chemicals, and irregular, discontinuous main cleanings with chemicals for which the filtration unit has to be shut down.
A.5.8.2.3
All cleaning processes proceed more quickly at higher
General facts
temperatures. Moreover, the same effect is obtained with

a lower chemical concentration, i. e. the cleaning process
The generation of the cross-flow is the main contributor
is more gentle. Experience from large-scale testing of orga-
to the specific energy demand of membrane filtration.
nic membranes has been acquired at cleaning temperatures
The objective of a large number of process developments
of 35 40 C.
is the reduction of energy consumption by minimizing

the cross-flow, while maintaining the same high flow
Since cleaning processes strongly depend on the type of
rate. Therefore, the membrane surfaces required, and
membrane and module and new cleaning processes are
thus the investments and costs for membrane replace-
continuously being developed, it is only possible to pro-
ment, are reduced.
vide general information on membrane cleaning practices.
Figure A-13 presents the theoretical relationship between
Rinsing/backwashing
membrane surface area, energy demand and flow for the

membrane bioreactor processes.
Backwashing refers to a periodic reversal of flow in the

membranes to detach the particles adsorbed during the
filtration process (covering layer). In principle, the filtrate
A.5.8.3
is used for backwashing.
Cleaning strategies
A typical operating regime for a commercially available
Cleaning of the membranes is necessary to take precau-
hollow-fibre module is a filtering duration of 5 8 minutes,
tions against a reduction of the flow [more exactly: of the
followed by a backwashing interval of approx. 30 40 sec.
permeability, expressed in L/(m hbar) or to increase
[Remark: With this operating mode, one has to distinguish
the permeability in case of reduced throughput.
between cross flow (flow during the filtration phase) and
Permeability losses may have the following causes:
net flow (i. e. the flow obtained from a complete sequence
of filtration and backwashing, taking into account the

backwashing volume)].
304
Annex
Rinsing refers to shortterm operation with clear water

without flow reversal in order to wash away and to discharge the covering layer. This procedure is used for dryarranged membrane modules.
lisation heat), if the following cleaning step takes place

at alkaline pH values
cleaning by oxidizing chemicals to oxidize organic and
bacterial depositions, e. g. by a solution of 0.05 %
(weight percent) (= 500 ppm (500 mg/L) related to active
Maintenance cleaning (chemical enhanced backwash)
chlorine), i. e. a NaOCl solution of approx. 0.4 %

(= 4,000 ppm NaOCl) at pH 11 for an exposure time of
For this (intermediate) cleaning, chemicals such as citric

acid or oxidizing chemicals (e. g. hypochlorite) are added
5 20 h; if necessary, at high temperature.

final rinsing with water to wash out the caustic soda
to the rinsing or backwash water. Cleaning is done in situ,
solution (NaOH). This reduces the scaling potential and
i. e. the membrane remains in contact with the mixed
the risk of saponification (reaction of NaOH with grease
liquor (the mixed liquor can also be drained off). The inter-
and oil to glycerol and Na salts of the fatty acids, which
val between two rinsing cycles and the type of chemicals
might lead to undesired foam development).
and their concentration depends on the respective application.
In general, the cleaning solution should be purged from

the system, depending on the degree of contamination of
Typical intervals for maintenance cleanings, e. g. with
the membranes.
sodium hypochlorite (NaOCl) or acid, are from a few days

up to several weeks.
Cleaning instructions and experiences
Rinsing is done with a very low backwash flow rate (often
Given the large number of membrane applications and the
in a cycle of short rinsing leaving on rinsing, which is
variety of membranes and membrane modules, it must be
repeated several times) to minimize the introduction of
stated that cleaning concepts and experiences cannot be
chemicals and undesired formation of pollutants (AOX).
transferred from one case to another. However, the following general instructions should be considered:
Intensive cleaning
Cleaning chemicals, especially when concentrated, may
Depending on the application, an intensive cleaning may
affect membranes, back-up tissue of the membranes,
be necessary from between once a month up to twice a
components of the membrane modules, and tank walls
year. For an intensive cleaning the membrane modules are
and instruments.
put into a separate cleaning tank or the mixed liquor is
This is especially true for low and high pH values. It
withdrawn and substituted by cleaning solutions.
has to be considered that due to chemical reactions,

higher pH values may locally occur than measured/
The type of cleaning chemicals used depends on the appli-
calculated in the reactor (example: increase of the
cation. The cleanings should be carried with hot water. A
pH due to the oxidation of organic matter by sodium
typical cleaning sequence may comprise the following

steps:
hypochlorite).
Oxidizing chemicals attack organic membranes and
lead to accelerated aging. The more aggressive the che-
rinsing of the membranes with water
micals, the higher the concentration, and the longer
treatment by acids, e. g. citric acid (250 2,000 ppm)
the expo-sure time, the more acute is the damage to
with addition of hydrochloric acid or sulphuric acid to
the membrane. Some membrane manufacturers give
adjust the pH value to 2 3, in order to detach/remove
chemical-specific maximum values for the product of
inorganic depositions
chemical concentra-tion and exposure time. Example:
intermediate rinsing (neutralisation) to avoid salt depositions and heat development in the membrane (neutra-
250,000 ppmh of free chlorine mean 500 h with a solution concentration of 500 ppm, or 100 h with a solution concentration of 2,500 ppm.
305
Annex
Due to chemical reactions, cleaning chemicals themselves

may give rise to disturbances or may form harmful
A.5.9
Requirements for the influent
substances. Examples:
saponification, by reaction of NaOH with greases and
oils " intense foam development. Measure: sufficient
A.5.9.1
General information
rinsing with water

salt deposition in the membrane by neutralisation
Before feeding waste water to a membrane bioreactor, it
reactions. Measure: sufficient intermediate rinsing
is necessary to remove undesired material such as long
with water
fibres and filamentous or strongly abrasive, sharp-edged
AOX formation by reaction of OCl with organic

constituents. Measures: utilization of drinking water
substances because they may clog the modules or mechanically destroy the membranes.
(instead of filtrate) to prepare the cleaning solution;

utilization of halogen-free oxidants such as H2O2,
In addition, it must be considered that dissolved waste
peracetic acid (the cleaning effect has to be examined!)
water constituents may also damage the membranes. If
Cleaning solutions have to be duly stored; if necessary,
necessary, membrane-typical specifications (limit values)
they can be processed and reused several times. All safety
have to be taken into account. This concerns not only
regulations concerning the handling of chemicals have
the organic (non-degradable) solvents contained in the
to be observed.
waste water, but also substances which are added in waste
The cleaning solutions have to be duly discharged.
water treatment, e. g. defoaming agents (have to be free
(In principle, they can be fed into the activated sludge
of silicone!) and organic polymers. For the specific appli-
stage to be examined!)
cation, the experiences of manufacturers and suppliers
During planning it has to be assessed whether the
should be used.
necessary intensive cleanings shall take place in situ or

in an external tank. This has consequences for the costs,
A.5.9.2
for the material choice (e. g. tank coatings, fittings) as
well as for the logistics of removal and transport of the

membrane, feasibility of cleaning at higher temperature,
Screens
flexibility in the choice of chemicals, etc.

The concentrations of cleaning solutions should be
Fibrous, sharp-edged and agglomerating material has to
indicated as exactly as possible. Especially when using
be prevented from entering from membrane bioreactors.
hypochlorite, it must be indicated whether the concen-
The composition of the waste water from different indus-
tration value is related to NaOCl, HOCl, OCl , the
trial branches may vary considerably as to the content of
calculated Cl content or the free (active) chlorine. For
those substances. Large quantities of fibres, as present in
the conversion from litres into kg, weight percent or
municipal waste water, only occur in the waste water of
ppm, it is necessary to consider the density of the
few branches. Screens with an aperture size of 0.5 2 mm
commercial NaOCl solution (chlorine bleaching lye)
or slot sieves with a slot size of 0.5 1 mm are normally
of = 1.2 kg/L. The solution contains maximally
sufficient. If a pretreatment stage is arranged upstream, a
12 13 % of effective (free, active) chlorine.
screen mainly has a protecting task.
It is useful to coordinate the details of the cleaning

processes with the membrane supplier (manufacturer)
Separator for grease and light-density material
and to record the results of each cleaning. Membrane

guarantees should include agreement about cleaning
Undissolved, hardly degradable greases and oils have to
concepts, intervals and parameters to be recorded.
be removed from the waste water before it is fed into the

membrane bioreactor because they may have a negative
effect on the filtrate performance. Well degradable greases
and oils do not give rise to problems.
306
Annex
Primary treatment
A.5.9.5
Iron and aluminium content
Primary treatment should be planned in the case of high

solid matter contents in order to maintain a sufficient frac-
Partial flows of various industrial branches may contain
tion of active biomass in the activated sludge, so that the
iron and aluminium salts. They are frequently used as
biological treatment capacity is not negatively influenced.
precipitants to support primary treatment, and they may

also be present in the process waste water flow itself.
A.5.9.3
Oxidized forms and particular compounds have no in-
Mixing and equalizing tank
fluence on the membrane and the filtration characteristics. Dissolved compounds, which under aerobic condi-
With membrane bioreactors, hydraulic compensation is
tions are oxidized in an activated sludge stage, may give
of importance. The membrane surface area has to be de-
rise to depositions. Oxidation partly takes place directly
signed, proportionately to the secondary treatment, for
on the membrane so that the undissolved precipitation
the maximum water quantity. Since large membrane sur-
product sticks to the surface. The resulting visible colora-
faces are very expensive and an increase in the through-
tion can be removed, if necessary, by acid cleaning.
put rate in the case of larger waste water volumes is possible only to a rather limited extent, it is useful to equal-
A.5.10
ize the waste water flow. For this purpose, volume-equal-
Instructions for the design of membrane bioreactors
izing tanks are suited, independent of considerations

concerning the equalization of concentrations.
A.5.10.1
General information
If the waste water volume varies only slightly, the necessary

storage volume can be made available in the tank itself,
The biological degradation of organic matter in membrane
since impoundment is also possible in the aeration tank
bioreactors does not differ fundamentally from the pro-
to a limited extent.
cess in conventional installations, i. e. these substances

oxidize to CO2 and are used for cell growth. The biomass
A.5.9.4
developed accumulates as excess sludge together with the
Calcium concentration
input of non-degradable and insoluble particulate substances (chapter A.5.11.1.3).
2+
Increased Ca concentrations (> 200 mg/L), either from

the use of calcium in the production process, from up-
However, membrane bioreactors differ from conventional
stream precipitation processes, or from neutralisation of
installations in particular by the high TS content in the
acid waste water by lime milk, may be problematic for the
aeration tank (usually 10 20 g/L, conventional instal-
membranes. Due to the high air intake which provides
lations: 3 5 g/L) and the resulting change in the sludge
turbulent flow for immersed membranes, a large part of
characteristics. While aeration tank volumes are calculated
the CO2 formed in the aeration tank is stripped out. As a
according to the load to be degraded, the membrane sur-
result, the pH value rises (keyword: lime-carbon dioxide
face area is determined, correspondingly to the secondary
balance, solubility product), which may lead to a reduc-
settlement tank, according to the hydraulic throughput.
tion in the filtration capacity. Consequently, the mem-
Because of higher expense for the filtration unit, hydrau-
branes have to be cleaned more frequently.
lic design has to be performed with the utmost care

(cf. chapter A.5.12).
307
Annex
Comparisons of operating results of membrane bioreac-
sludge production. This is because in this operating mode,
tors by theoretical models have shown that the sludge
the organic matter has to be oxidized to CO2 to a greater
yield can be assessed rather well, especially by detailed
extent [CORNEL 2000].
models such as the Activated Sludge Model of the International Water Association, but also with simpler ap-
The increased operating TS concentration in a membrane
proaches, provided that the specific boundary conditions
bioreactor results in one of two design scenarios relative
of the respective industrial waste water are sufficiently
to conventional activated sludge treatment:
considered. With high sludge ages, it is recommended to

perform the calculation on the basis of the maintenance
metabolism [WICHERN AND ROSENWINKEL 2002].
smaller aeration tank volumes with equal sludge

loading and equal excess sludge production, or
equal aeration tank volumes and lower sludge loading
The references available show that the current engineering
with less excess sludge, but higher energy costs.
design based on semi-technical preliminary tests is the

basis for a large number of well-functioning installations.
It is not possible to realize all positive features low

energy demand, reduced excess sludge production and
A.5.10.2
smaller aeration tank volumes in the same installation,
Space requirements
because these features, in part, are mutually exclusive.
In industrial waste water treatment, the space requirement
The impact of an operating mode with low excess sludge
of an installation is often a decisive criterion. For new
production, i. e. low sludge loading rate, on the effluent
industrial settlements, space requirement for waste water
quality (refractory substances) has to be determined for
treatment can often be alloted. However, for industrial
each case. The extent of removal of refractory compounds
enterprises which have grown for decades it is often im-
depends on the waste water constituents and the operating
possible to integrate waste water treatment on their fac-
conditions (sludge age). Ultra- and microfiltration mem-
tory sites.
branes do not reject low-molecular weight substances.

However, increased degradation of slowly degradable sub-
Compared to a conventional activated sludge plant, the
stances is possible at high sludge ages along with possible
required aeration tank volume can be reduced to approx.
retention of macromolecules by the covering layer. Con-
one half or even one quarter; moreover, secondary treat-
stituents attached to particles, e. g. adsorbed AOX com-
ment is no longer necessary. Therefore, the space require-
pounds, are rejected by the membrane installation.
ment for the waste water treatment plant is significantly

reduced. This is often a decisive advantage for industrial
Compared to conventional activated sludge plants, load-
enterprises and enables them to treat their waste water
peaks have a stronger effect on the effluent quality. This
on their facilities.
is due to reduced dilution because of the smaller aeration

tank volume. In general, it is true that loadpeaks are
A.5.10.3
more difficultly to manage at very low sludge loading
Elimination rates
rates [F/M < 0.03 kg BOD5 /(kg TS d)], due to the lower
biomass activity.
An operating mode with low excess sludge production

requires attention to the considerably higher oxygen re-
Inhibited degradation due to the accumulation of heavy
quirement, the effluent quality, and the possible accumu-
metals in the activated sludge is observed in some indus-
lation of harmful and inhibitory substances in the acti-
trial branches. In cases where there exists increased heavy
vated sludge.
metal concentrations in the waste water, the sludge age

in membrane bioreactors has to be carefully controlled
The specific oxygen requirement increases with decreasing sludge loading, i. e. with decreasing specific excess
308
especially.
Annex
Phosphorus elimination in membrane bioreactors can be
may enrich during aeration with pure oxygen and conse-
realized very easily by simultaneous precipitation with
quently resulting in reduced CO2 discharge.
iron salts. Since ultrafiltration is able to absolutely reject

very small particles, better effluent quality can be obtained.
When transferring the results of oxygen transfer measure-
In this case, the molar ratio can be set more favourably.
ments in semi-technical or laboratory scale to large-scale
By adaptation of the cleaning strategies and the cleaning
installations, it has to be considered that the fluid-dynamic
agents, it is possible to counteract the adsorption of pre-
parameters can be represented and transferred only to a
cipitant residues on the membrane surface. Membrane
limited extent. Oxygen transfer measurements should be
filtration itself is not normally influenced by regular pre-
carried out at test installations with the waste water to be
cipitant dosing. If the installation is correspondingly de-
treated, the design sludge concentration, and the design
signed, biological phosphorus removal is also possible
liquid depth.
when the sludge age is designed in the appropriate range.

Membrane filtration produces solidsfree water which is
A.5.10.5
disinfected to a great extent. With conventional mecha-
Hydraulics
nical-biological processes it is not possible to reach

comparable effluent quality, even if a conventional filtra-
A.5.10.5.1
tion process, e. g. sand filter, is arranged downstream.
Flexibility
A.5.10.4
The modular construction of membrane installations allows
Aeration
adaptation to flow variations by switching on or off single

modules. In low flow events, it is more energy-efficient
The mass transfer of oxygen from the gas phase into the
to switch off single modules than treating the entire flow
liquid phase is influenced by, among others, the parameters
through the complete membrane system. If the waste water
salt concentration, viscosity of the medium, surface-active
volume is consistently higher than designed, the modular
substances, surface tension, solid matter content, aeration
construction facilitates easy upgrading and adaptation to
system, turbulence, and pressure (water depth). A general
the new requirements. In planning as well as during oper-
guide value of oxygen input and -values cannot be
ation, great importance has to be attached to distribute
given for industrial (membrane) bioreactors. In industrial
the flow as uniformly as possible to both modules.
waste water treatment plants with conventional biological

processes, -values of > 1 may also occur due to various
A.5.10.5.2
waste water constituents, and, above all, because of high
Recirculation
salt concentrations (> 5 g/l). These have positive effects

on the oxygen transfer due to their coalescence-reducing
The activated sludge concentrates on the membrane due
effect. However, the oxygen input also depends on the
to filtrate withdrawal. If immersed membranes are
dynamic viscosity which itself is strongly dependent on
directly installed in the aeration tank, concentration distri-
the sludge concentration. Therefore, lower -values than
bution by a mixing device is a sufficient compensating
in conventional activated sludge plants have to be expected
measure.
with high TS concentrations. Relatively high -values

compared to municipal applications can be expected
If the membranes are installed in separated tanks or
with higher salt concentrations.
arranged dry, sufficient recirculation has to be ensured.

In general the recirculation rate should be four or five
The transfer of air or pure oxygen is also possible by
times the filtrate quantity which is being discharged. In
means of injector systems. In the case of waste water
filtration tanks with immersed modules, the mixed liquor
which tends to deposits, it should be taken into account
feed and recirculation discharge should be at opposite
that the pH value will increase in intensely aerated zones.
ends of the tank in order to avoid short-circuit flows.
This is due to stripping of CO2, which on the contrary,
309
Annex
In the case of immersed membranes, the recirculation flow

is oxygenated. This has to be taken into account if this flow
is to be recycled directly into the denitrification reactor.
with immersed modules:

10 15 g TS/L and
with dry-arranged modules:
up to 30 g TS/L
A.5.10.6
Influence of the temperature
The dry matter content cannot be correlated directly

with the viscosity and the filterability. However, within
As a result of biological degradation in waste water treat-
an installation it can be used as indicator.
ment, the bulk liquid temperature rises by approx. 2 3 C

per gram of COD degraded per litre. This rise in tempera-
A.5.11.1.2
ture has to be taken into account, if necessary, in the
Rheological properties
treatment of high-strength industrial waste water. However, with low organic loads this does not give rise to
Activated sludge shows a more or less distinct shear thin-
problems. For dry-arranged systems, a rise in temperature
ning, i. e. the viscosity decreases with increasing shear
in the aeration stage may also be expected due to the
load. The viscosity of the activated sludge which devel-
energy input of the mechanical equipment, e. g. the
ops in the membrane bioreactor depends on many fac-
pumps for cross-flow generation.
tors, including the size and structure of the sludge flocs,

composition of the waste water, the TS concentration as
Concerning the flow characteristics, higher temperatures
well as the organic part of the TS concentration, and the
are quite favourable for the use of membranes. For acti-
physiological properties of the biology [e. g. formation of
vated sludge plants the temperature has to be limited to
extracellular polymeric substances (EPS) under certain
37 39 C.
operating conditions], e. g. floc stress due to forced circulation. Therefore, simple correlation between viscosity
A.5.11
and TS concentration of activated sludges from different
Specific features of membrane bioreactors
installations is not possible.
A.5.11.1
If the relationship between the viscosity and the TS con-
Sludge features
centration of the biology shall be used as an auxiliary

parameter for the description of mass transfer (i. e. of the
A.5.11.1.1
oxygen intake), it has to be determined individually for
Characterization of the sludge
each installation/each waste water and, if necessary, also

for each sludge loading. Moreover, due to the more or
Due to an increased solid matter content, the sludge fea-
less distinct shear thinning properties of the activated
tures differ considerably from those of activated sludge
sludge, the viscosity in the settling tank is not homoge-
from conventional plants. The strong shear forces occur-
neous, but appears dependent on the local shear stress
ring in cross-flow installations are responsible for an in-
condition. Thus, each statement on the viscosity of an
crease in the abundance of single bacteria in microscopic
activated sludge is useful only if the respective shear load
analysis. According to the biotic community, which de-
(shear rate D in s-1) is defined.
pends on the waste water quality, the sludge can be viscous or thick, but may also have the consistency of a gel.
Consistency, number of free bacteria, floc structure, inert
With high solid matter content, inclusion of oxygen bub-
fraction etc. have a great influence on the filterability of
bles may occur. As a rule, the viscosity is higher com-
the activated sludge. Although the filterability within one
pared to conventional activated sludge. The solid matter
installation may possibly correlate with the TS concentra-
contents are
tion, this parameter is too inexact for the design of the

required membrane surface area. For this purpose tests
have to be carried out.
310
Annex
The survey of rheological properties by continuous
threshold concentrations. For this reason regular excess
measurement of the viscosity at a certain shear load or
sludge withdrawal should be integrated into the design.
the measurement of flow curves, may represent for membrane bioreactors combined with TS determination and
A.5.11.1.4
the regular assessment of the biocenosis by microscopic
Sludge treatment
analyses a useful completion of the process parameters

for the control of the installation (cf. GNDER 1999;
In principle, all systems available on the market can be
KRAUSE ET AL. 2001).
used for sludge dewatering. Optimal mixing of the polymers, due to the increased viscosity of the excess sludge
at high TS concentrations, has to be considered in the
A.5.11.1.3
design.

According to the waste water situation, it may be useful
Sludge production results from the growth of heterotrophic
not to treat the excess sludge separately, but to dewater it
and autotrophic biomass as well as from the biologically
in a mixture together with the primary sludge. In this
inert fraction of the solid matter inflow and the inert
manner the consumption of conditioning agents may be
material resulting from the death of the biomass. While
reduced. It could be observed that the addition of e. g.
the organic part at infinitely high sludge age may be nearly
used activated carbon, which has to be discharged any-
completely biodegraded (at least in theory), the insoluble,
how, may have positive effects on the dewatering beha-
particulate, mineral part remains in the aeration tank and
viour. This is possibly also true for other structure-for-
has to be withdrawn as excess sludge. Since with usual
ming additive substances.
system settings the growth rates are higher than the death
rates, the excess sludge contains an organic part.
In each case, attention should be paid to using membranecompatible polymers for sludge dewatering. They should
The same principles as for all activated sludge processes
be tested on laboratory and technical scale.
are valid, i. e. the sludge output decreases with

A.5.11.1.5
decreasing sludge load, i. e. increased sludge age
Foam development
decreasing solid matter input and

rising temperature
The pressure differences necessary for dry-arranged membranes as well as the flow conditions may lead to consid-
Industrial waste water often has high temperatures and
erable stress on the biocenose and, with this, to increased
low solid matter contents. For this reason the excess
EPS development. In combination with intensive aeration,
sludge production rate, related to the treated load, is
this may result in considerable foam development.
often lower in the treatment of industrial waste waters
Construction measures to control foam are, for example,
than in municipal applications. This tendency is reinforced
flat tanks with a large surface area (more advantageous
by the use of a low-loaded membrane bioreactor design.
compared to slim tanks), and mechanical or physical

destruction of the foam. When using defoaming agents,
For the activated sludge process, the excess sludge with-
their membrane compatibility has to be ensured.
drawn represents an accumulation medium for nondegradable, but sorbable substances. If this withdrawal
does not take place, the substances are either found in
the filtrate or they accumulate as far as they cannot
pass through the membrane in the system. Several nondegradable substances have a biologically inhibiting
effect or are toxic for bacteria when they exceed certain
311
Annex
A.5.12
A.5.12.2
Economic efficiency
Investment/capital costs
A.5.12.1
The working life and the depreciation time of the indivi-
Definition of economic efficiency
dual components have an important impact on the capital

costs of membrane bioreactor processes. The planner has
Although the term economic efficiency is always used
to elaborate suggestions according to the information from
in technology and economy, there is no general definition
the membrane manufacturer; the client has to make the
that can be applied. It is necessary to define economic
decisions.
efficiency for each single case. However, membrane bioreactors will be applied in all probability in the case of
The greatest influence on the capital costs include the
corresponding demands on the effluent quality. Therefore,
tank volumes, and the membrane surface area. The mem-
a reference value related to other waste water treatment
brane surface area required (and the surface area kept in
processes can be defined: The membrane bioreactor pro-
reserve) is determined by the choice of the process. In
cess is more profitable than a conventional process if the
general, the choice of a smaller separating surface area
cash value (or capital value) of the discounted expense
leads to higher energy and cleaning costs (see also Figure
after X years is similar to or higher than the cash value of
A-13). With immersed modules, larger membrane surface
the alternative processes at comparable treatment results.
area is necessary than with dry-arranged ones, since the
ATV-DVWK recommends calculating the cash value; in
specific flow rate [L/(m2 h)] is lower.
industrial practice, calculation of the capital value is more

frequent. However, both methods only differ in the fact that
While the specific costs of aeration and final sedimentation
in the first case one considers the time of commencement
tanks rise only in a degressive way with increasing plant
and in the other case the end of the respective period.
size, the costs for the filtration unit of the membrane

process increase nearly in a linear way (costs per module).
Calculation of the cash value requires knowledge of the

expense for financing the investment (interest and amor-
The space requirement is often a decisive criterion for the
tization) as well as the operating costs for one year and the
use of a membrane installation. Reduction of the necessary
following years. The type of financing of the acquisition
aeration tank volume to approx. half or a quarter compared
and the expected service life (of installations, machines and
to a conventional activated sludge plant, and due to the
spare parts) have an effect on the part of fixed costs. The
fact that final sedimentation becomes unnecessary, the
operating costs mainly comprise energy and cleaning costs,
space requirement, and thus the capital costs, are consider-
costs for membrane replacement as well as for manpower,
ably minimized. In spite of space reduction for activation,
auxiliaries, etc. The costs avoided may possibly be included
one must not neglect that in some cases space is required
into the assessment (e. g. for saved space, further treatment
for mixing and compensation tanks, and possibly also for
steps, improved effluent quality, etc.). The process engi-
cleaning tanks.
neering determines not only the amount of fixed costs,

since type and size of the installation determine the investment volume and thus the size of annual charges, but also
the variable costs. The membrane surface area chosen, the
number of modules (and the reserve supply), and the resulting reactor volume required determine the amount of
investments. The operating mode determines the energy
consumption, personnel and cleaning costs. The following aspects have an effect on the costs:
312
Annex
A.5.12.3
Operating costs
Energy costs
The generation of a flow across the membrane is the main
contributor to the specific energy demand of membrane
filtration plants. The objective of numerous process developments is the minimization of the energy consumption
by reducing the amount of energy necessary for control
of the covering layer (flow across the membrane), while
maintaining high specific flow rates to minimize the necessary membrane surface area (examples: rotating modules, oscillating modules etc.).
Compared to dry-arranged membrane modules, the generation of a cross-flow with immersed systems requires less
energy; about 0.5 1.5 kWh/m3 are required for covering
layer control of immersed modules and 1 4 kWh/m3 are
needed for dry-arranged systems.
Cleaning costs
The type of cleaning and the cleaning intervals strongly
depend on the waste water quality, but also on the type
of membranes and modules. Therefore, no generalized
specific costs can be given. Besides the chemicals required,
inclusive of their storage, the personnel costs, the energy
costs for heating of the cleaning solutions and, if necessary, the discharge costs have to be taken into account.
According to the type of cleaning, additional investments
for separate cleaning tanks, including the necessary lifting
and transport facilities, or special chemical-resistant coatings of the filtration tanks may become necessary.
Membrane replacement and membrane disposal
costs
The service life of membranes depends on different factors,
such as:
type of the waste water
type and frequency of cleaning
General service lives or disposal costs cannot be indicated.
However, membrane replacement and membrane disposal costs have to be taken into account.
313
Annex
Table A-5
Membrane installations in West European industry
Branch/application
Total number
Number of
Number of dry-
immersed installations
arranged installations
Flow rate m3/d
Solid waste treatment
140
Car industry
230
Chemistry
15
Landfill for municipal waste
48
39
Print shops
25
Groundwater rehabilitation
20
50 - 1,400
10 - 900
Cosmetics industry
Laboratory water
120 - 700
10
Food industry
100 - 480
Leather production/tanneries
30 - 820
Malthouse
100
Pharmaceutical industry
15
14
50 - 1,500
Ships waste water
15
10
Tank cleaning
Textile industry
100 - 1,500
Animal waste processing
427 - 960
Laundries
30 - 820
4 - 740
200
A.5.12.4
Compared to conventional activated sludge plants, mem-
Comparison of cost-relevant factors
brane bioreactors may be more cost-effective if the influent

concentration is high, and the volume flow is small and,
The following factors improve the economic efficiency
in particular, very constant.
compared to conventional plants:

A membrane bioreactor process will always be considered
high influent concentrations
if the demands on the effluent are high or if the water

shall be reused, e. g. as process water.
low concentration of substances causing scaling

and/or fouling
If the filtrate can be reused, saved waste water charges

for indirect dischargers: saved effluent charges
high costs for the building site
according to the waste water statutes and saved freshwater

costs have to be included in the economic analysis.
constant hydraulic load

high demands on the effluent quality
reutilization of the treated waste water
314
Annex
A.5.13
A.5.14
Examples in the field of industrial waste water
Literature
(Europe)
Baumgarten, G. (1998): Behandlung von DeponiesickerWithout claiming to be complete, Table A-5 summarizes
wasser mit Membranverfahren Umkehrosmose, Nano-
exemplary applications of membrane bioreactors in
filtration Verffentlichungen des Institutes fr Sied-
Western Europe. The examples come from the reference
lungswasserwirtschaft und Abfalltechnik der Universitt
lists of the manufacturers and plant contractors, complet-
Hannover, Heft 99.
ed by the knowledge of the work group members. Test

installations have been or are being operated in a large
Brockmann, M. (1998): Beitrag zur membranuntersttzten
number of other branches.
biologischen Abwasserreinigung. Verffentlichungen des

Institutes fr Siedlungswasserwirtschaft und Abfalltechnik,
Pages 315 316 contain the bibliography of Annex A.5.
Universitt Hannover, Heft 98.

Cornel, P. (2000): Membranbelebung: biologische Abwasserreinigung ohne Anfall von berschussschlamm?
61. Darmstdter Seminar Abwassertechnik, Schriftenreihe
WAR, Bd. 128.
Diverse Autoren (1997, 1998, 2000, 2001): Membrantechnik in der Wasseraufbereitung und Abwasserbehandlung Begleitbcher zur 1. bis 4. Aachener Tagung Siedlungswasserwirtschaft und Verfahrenstechnik, IVT der
RWTH Aachen.
Diverse Autoren: Preprints zum 1. bis 8. Aachener Membran Kolloquium, GVT, VDI-GVC Dsseldorf und IVT,
Aachen.
Flemming, H.- C. (1995): Biofouling bei Membranprozessen, Springer-Verlag Berlin, Heidelberg.
Grschel, A. (1991): Umkehrosmose organisch/wssriger
Systeme Stofftransport in Membranen und Verfahrensentwicklung; Dissertation RWTH Aachen.
Gnder, B. (1999): Das Membranbelebungsverfahren in
der kommunalen Abwasserreinigung, Stuttgarter Berichte
zur Siedlungswasserwirtschaft, Band 153.
Henze et al. (1987): Activated Sludge Model No. 1,
Scientific and technical report No. 1, IAWPRC (jetzt IWA),
London.
315
Annex
Irmler, H. W. (2001): Dynamische Filtration mit kerami-
Rautenbach, R.; Melin, T.; Dohmann, M. (1997): Mg-
schen Membranen, Vulkan-Verlag Essen.
lichkeiten und Perspektiven der Membrantechnik bei der

kommunalen Abwasserbehandlung und Trinkwasserauf-
Kiefer, M. (1995): Prozessnahe Aufbereitung von Abwasser
bereitung, Begleitbuch zur 1. Aachener Tagung Siedlungs-
aus der Chemie und Halbleiterindustrie und Rckgewin-
wasserwirtschaft und Verfahrenstechnik.
nung von Einsatzchemikalien mit Ionenaustausch und

Membrantechnik. Handbuch Fachveranstaltung Aufbe-
Rautenbach, R.; Melin, T.; Dohmann, M. (1998): Mem-
reitung und Entsorgung von Industrieabwssern und Pro-
brantechnik in der ffentlichen Wasseraufbereitung und
zesswssern mit Kombinationsverfahren, VDI Bildungs-
Abwasserbehandlung Bemessung, Umsetzung, Kosten,
werk, 25./26.10.1995, Dsseldorf.
Begleitbuch zur 2. Aachener Tagung Siedlungswasserwirtschaft und Verfahrenstechnik.
Kraft, A. (2000): Abwasserbehandlungskonzepte in der

chemischen und pharmazeutischen Industrie unter Einbe-
Rautenbach, R.; Melin, T.; Dohmann, M. (2000): Mem-
ziehung der Membranbioreaktoren Technik Beispiele,
brantechnik in der Wasseraufbereitung und Abwasserbe-
6. VDMA-Abwassertagung in der chemischen und phar-
handlung, Begleitbuch zur 3. Aachener Tagung Siedlungs-
mazeutischen Industrie.
wasserwirtschaft und Verfahrenstechnik.
Krause, S.; Cornel, P.; Wagner, M. (2001): Grundstzliche
Rautenbach, R. (1997): Membranverfahren Grundlagen
berlegungen zur Messung des Sauerstoffeintrags in
der Modul- und Anlagenauslegung, Springer-Verlag Berlin,
Membranbelebungsanlagen; 64. Darmstdter Seminar
Heidelberg.
Abwassertechnik, Schriftenreihe WAR, Bd. 134.

Wagner, J.; Rosenwinkel, K.-H. (1999): Sludge production
Lonsdale, H. K. (1972): Theory and practice of reverse
in membrane bioreactors under different conditions, In-
osmosis and ultrafiltration; in: R. E. Lacey, S. Lacey (Hrsg.):
ternational Specialized Conference on Membrane Techno-
Industrial processing with membranes, Wiley-Interscience,
logy in Environment Management, Tokyo, 1. 4., Novem-
New York, S. 123-178.
ber 1999.
Melin, T.; Dohmann, M. (2001): Membrantechnik in
Wichern, M.; Rosenwinkel, K.-H. (2002): Bemessung
der Wasseraufbereitung und Abwasserbehandlung Pers-
von Sauerstoffbedarf und berschussschlammanfall fr
pektiven, Neuentwicklungen und Betriebserfahrungen im
die Membranbelebung auf Basis des ATV-DVWK-A 131
In- und Ausland, Begleitbuch zur 4. Aachener Tagung
(2000); KA (49) Nr. 5, Mai 2002.
Siedlungswasserwirtschaft und Verfahrenstechnik.

Peters, Th. (1998): Wasseraufbereitung mit Membranfiltrations-Verfahren. Umwelt Bd. 28, Nr. 4, S. 34 39.
Peters, Th. (2001): Mglichkeiten und Grenzen der Membranverfahren aufgezeigt an internationalen Beispielen.
Handbuch Fachveranstaltung Membranverfahren in der
industriellen und kommunalen Abwassertechnik, Haus
der Technik, 22. 23. November, Berlin.
316
Annex
A.6
A.6.1
Introduction
nd
Work report of the DWA Committee of
Experts KA-7 Membrane bioreactor process

from 19th January 2005
Since the publication of the 1st working report on the

membrane bioreactor process [ATV-DVWK 2000b], the
This second working report has been prepared by the
knowledge of this technology has increased due to further
DWA Committee of Experts KA-7 Membrane bioreactor
operating experience with large-scale installations and
process. The committee includes the following people:
research projects. This 2nd working report takes the contents of the first report, completes them and describes
Dipl.-Ing. Eberhard Back, Ulm
the findings from the operation of large-scale installations.
Dipl.-Biol. Evelyn Brands, Dren
It is now possible to specify design parameters such as
Dr.-Ing. Elmar Dorgeloh, Aachen
oxygen input with the help of data from large-scale ap-
Dipl.-Ing. Kinga Drensla, Bergheim
plications. The following subjects are covered:
Prof. Dr.-Ing. Franz-Bernd Frechen, Kassel (chairman)

Dr.-Ing. Werner Fuchs, Tulln
pretreatment of the raw waste water,
Dipl.-Ing. Regina Gnir, Berlin
chemical cleaning,
Dipl.-Ing. Karl-Heinz Greil, Kundl
sludge treatment,
Prof. Dr.-Ing. Karl-Heinz Rosenwinkel, Hannover
energy consumption,
Dr.-Ing. Wernfried Schier, Kassel
commissioning,
Prof. Dr. rer. nat. Dirk Schoenen, Bonn
membrane bioreactor process for the upgrading of
Dipl.-Chem. Simone Stein, Leipzig

Prof. Dr.-Ing. Ulf Theilen, Gieen
Dipl.-Ing. Helle van der Roest, Amersfort
waste water treatment plants and

reference information on the costs of membrane
bioreactors.
Dr.-Ing. Klaus Voenkaul, Aachen

Dipl.-Ing. Detlef Wedi, Braunschweig
It must be noted that at present membrane technology is
Dipl.-Ing. Thomas Wozniak, Gummersbach
developing at a high speed, in particular in the field of
Dipl.-Ing. Petra Zastrow, Merseburg
municipal waste water treatment. This is reflected not

least by the high frequency of meetings of the Committee
and guests.
of Experts. Therefore the content of this second work

report, too, will certainly soon be supplemented by new
findings.
The next document of the Committee of Experts will be
an advisory leaflet which will probably be published in
2006.
317
Annex
A.6.2
tions can be distinguished for the membrane bioreactor
Description of the membrane bioreactor process
process.
Membrane bioreactor process with dry-arranged
Principle
membrane filtration
The combination of an activated sludge tank and membrane filtration for the separation of the activated sludge
Membrane filtration takes place downstream of the acti-
is called the membrane bioreactor process. The membrane
vated sludge tank in an external, closed filtration unit.
filtration takes over the separation of the activated sludge
The modules (e. g. tube modules) are set up in a dry ar-
in place of the conventional final clarification. While in
rangement (see Figure A-14). The activated sludge is
secondary settling tanks only the part of the activated
pumped through the modules, which results in higher
sludge that is settleable is separated, i. e. forms setlleable
pressures (more than 1 bar) with this process.
flocs, during membrane filtration all parts of the activated

sludge are separated which are larger than the molecular
Up to now, this external membrane filtration is not found
separation size of the membrane. Thus, the separation of
at municipal plants and therefore not a subject of this
the activated sludge from the treated waste water becomes
work report. Information is available in the work report
independent of the settling characteristics of the activated
IG 5.5 Part 2 [ATV-DVWK 2002].
sludge and depends only on the membrane applied.

To separate the activated sludge with its micro-organisms
and particles from the treated waste water, microfiltration
membranes with a molecular separation size of maximally
0.4 m are used for the membrane bioreactor process.
Concerning the arrangement of the modules, two varia-
Figure A-14
Membrane filtration in dry arrangement

membrane filtration
in dry arrangement
feed
permeate
concentrate (return sludge)
318
excess
sludge
Annex
Figure A-15
Ways of configuring an immersed membrane filtration
A) immersed membrane filtration

in the activated sludge tank
B) immersed membrane filtration

in a separate filtration tank
feed
permeate
concentrate
(return sludge)
excess sludge
feed
permeate
excess
sludge
membrane filtration
cross-flow
aeration
Membrane bioreactor process with immersed

membrane filtration
filtration
tank
membrane filtration
cross-flow
aeration
With immersed arrangement, the overflow necessary for

covering layer control is typically generated by coarsebubble aeration. For this purpose, a blower with air inlets
In this variation, the membrane modules are placed in the
under the immersed membrane modules and a suited flow
mixed liquor. The membrane modules can be installed
control to generate the overflow are necessary. Separate
either in the activated sludge tank or in a separate filtra-
aeration in the activated sludge tank is required besides
tion tank. Figure A-15 shows both configurations.
module aeration.
For proper functioning of the membrane bioreactor pro-
The transmembrane pressure difference can be generated
cess, the following basic requirements have to be fulfilled:
by a permeate pump or hydrostatically. In principle, the

lowest possible transmembrane pressure is favourable in
Oxygen supply to the activated sludge,
operation.
circulation and thorough mixing of the activated sludge

tank,
transmembrane pressure difference as a driving force
for the filtration process,
control of the development of a covering layer.
319
Annex
Constructional forms and operating modes
The permeate is withdrawn from the inside of the plate

by a suction duct.
Up to now, the following membranes have been used in

large-scale applications of the membrane bioreactor
Hollow-fibre modules consist of membrane hollow fibres
process:
which may be reinforced by an in-side supporting tissue.

Filtration takes place from outside to inside. For module
plate membranes and
assembling, a larger number of fibres are combined to form
hollow-fibre membranes
a bundle, and are potted with resin at one or both ends.

A permeate collecting tube connects all of the individual
Membranes are used as modules in different construc-
fibres. Depending on the manufacturer, the hollow-fibre
tional forms.
membranes are installed horizontally or vertically into

the module.
Plate modules are assembled from membrane plates

which are arranged in parallel. They consist of a support-
The module aeration device is for the most part integrated
ing plate with a drainage device. The plate membrane is
into the module. Other module constructions are in dif-
fitted for the most part on each side of the membrane.
ferent testing stages.
The flat membranes are overflown by the mixed liquor

and filtration takes place from outside to inside.
Figure A-16
Schematic representation of different module constructions
A) Plate module
B) Hollow-fibre module
vertically arranged
permeate
permeate
upper fitting
with resin
(depends on
provider)
flexible hollow-fibre
membrane
flat membrane on
supporting plate
module aeration
320
lower fitting
with resin
module aeration
horizontally arranged
lateral fittings
with resin
permeate
Annex
Figure A-17
Typical operating modes of the membrane modules
cycle
Membrane modules are operated discontinuously. Depen-
backwashing
flu
gro
ss
ne
tf
lu
x
time
filtration
permeate volume
sf
lux
pause
os
gr
permeate volume
filtration
ne
tf
lu
x
cycle
time
The permeate flow of all modules is changed equally.
ding on the module construction, periodic filtration pauses or backwashing with permeate are performed to mini-
Certain modules are disconnected such that the remain-
mize the covering layer. Therefore, it is necessary to dis-
ing modules work with the flow permissible for conti-
tinguish gross and net permeate flow (see Figure A-17).
nuous operation. A constant operating time of the individual modules has to be respected. Moreover, this
Additional chemical cleaning is required for further re-
operating mode ensures that sufficient recovery phases
generation of the modules and to remove the membrane
(phases without operation) for the individual modules
fouling (see chapter A.6.5).
are kept. As a rule, this operating mode is more energyefficient than the first mentioned.
To adapt the filtration capacity to the volume of inflow,

two operating modes are possible:
321
Annex
Capacity of the membrane bioreactor process
exist and that membranes and connections are always

secure. This requirement seems to be trivial. In practice,
The advantages of the membrane bioreactor process result
however, appropriate controls are necessary.
from the possible higher MLSS contents in the activated

sludge tank and complete separation of all solid matter
The elimination of micro-pollutants, e. g. residues from
by the membranes. From this results an improved elimi-
drugs and substances with endocrine effect, requires bio-
nation of nutrients and micro-organisms. Therefore, nitro-
logical processes or adsorption on at the sludge because
gen, phosphorus and carbon in the effluent of membrane
the membranes used with the membrane bioreactor pro-
bioreactors are reduced by the fraction which in conven-
cess do not retain dissolved substances.
tional plants results from solid matter in the effluent.

A.6.3
Membrane filters are able to retain micro-organisms to
Instructions for planning and design
a very large extent. The permeate complies with the

hygienic requirements of the EU Directive on Bathing
Pretreatment of the raw waste water
Waters 76/160/EWG [COUNCIL OF EC 1976] concerning

the microbiological parameters total number of Bacteria
Sufficient pretreatment of the waste water is an essential
coli, faecal coliforms and streptococci. Studies at the Rdingen
prerequisite for the operation of membrane bioreactors.
and Markranstdt waste water treatment plants during the
Especially hair and grease may accumulate and stick to
first months of operation (in 2000) have shown that the
the modules and thus cause considerable operating pro-
concentrations of all micro-organisms mentioned in the
blems. In principle, a grit and grease trap is necessary.
EU Directive on Bathing Waters were reduced to values

close to the detection limit, independent of the weather
Coarse matter can be removed by single-stage or two-stage
conditions (dry weather, storm, continuous rain). The
devices. Screens with spacings used up to now are not
limit values and guide values of the EU Directive on
sufficient as the only measure for the removal of coarse
Bathing Waters were met in all cases. Studies at the Rdin-
matter. Therefore, screens have to be combined with sieves
gen waste water treatment plant carried out after several
or with primary treatment.
years of operation (in 2002 and 2003) have shown that

the germ reduction continues to be at a high level, but
Sieves should have a mesh size of 3 mm and should be
indicate that with increasing operating time, the removal
preferably configured with flow reversal. The mesh size
rate may possibly decrease. This aspect has to be studied
of sieves should be chosen considering the following
in more detail.
boundary conditions:
Even virus, the smallest pathogenic organisms which theo-
of drainage system (combined or separate system,
retically may pass through the membrane pores, are re-
emptying and cleaning of stormwater tanks, etc.),
tained by the membrane bioreactor process. The viruses
sensitivity of the membrane module construction
typically accumulate with particles and micro-organisms

so that they are removed from the waste water by the
elimination of larger particles. During the studies men-
concerning fibrous matter,

other pretreatment installations, especially the spacing
of the screen, if existing.
tioned above, it was possible to significantly reduce the

concentrations of intestinal viruses. However, safe com-
Therefore, sieve mesh sizes of 1 mm may be required.
pliance with the limit values of the EU Directive on Bathing
If primary treatment is used in place of a sieve, special
Waters cannot be ensured.
measures are necessary to avoid the passage of floating

matter into the activated sludge stage. Experience has
Prerequisite for the high removal of pathogenic micro-
shown that primary treatment realized as so-called coarse
organisms in the membrane bioreactor process is that no
desludging is not sufficient to effectively retain undesired
short-circuits between treated and non-treated waste water
substances.
322
Annex
To protect the membrane effectively against coarse matter,
To avoid that the activated sludge in separate filtration
it is strongly recommended to install redundant screens
tanks is overconcentrated, it is required to maintain a
and sieves and not to equip the mechanical treatment
sufficient return sludge flow from the filtration tank back
stages with an emergency circuit.
into the activated sludge tank. Depending on the system,

the maximum solid matter content at the membrane may
Design and construction
be up to 18 g/L. The necessary return sludge flow is calculated from the solid matter content in the activated
The design data for biological treatment in a membrane
sludge tank and in the completely mixed filtration tank.
bioreactor have to be determined according to the proce-
Attention must be paid to constant mixing of the filtration
dure for conventional waste water treatment plants laid
tank to avoid deposits and to ensure optimal membrane
down in the standard A 198 [ATV-DVWK 2003]. In general,
functioning.
the loads, the inflows and the waste water temperatures

have to be determined for the design load period.
The waste water flowing into the waste water treatment

plant has to be filterable at any time by the available
The size of the activated sludge tanks can be calculated
membrane surface area. Therefore, the design basis for
according to the ATV-DVWK standard A 131 [ATV-DVWK
the membrane surface area is the combined water flow
2000a]. For determination of the volumes, a higher solids
QM at the lowest temperature over the course of the year
content has to be considered which in current practice is
because the permeate flow depends on the temperature.
not chosen higher than 12 g/L. Possibly existing filtration
In contrast to the standard A 198 [ATV-DVWK 2003],
tanks can be added to the volume VBB minus the volume
mean daily values of the waste water temperature are
displaced by the built-in components. For the load cases
essential.
to be fully assessed, it is necessary to consider the downtimes of filtration tanks.
The net permeate flow of designed installations (design

flow in constant operation) as a quotient of the combined
Compared to conventional activated sludge plants (acti-
water flow QM and the membrane surface area AM in-
vated sludge tank, secondary settling tank), the total
stalled is between approx. 8 L/(m2 h) and 30 L/(m2 h)
volume of membrane bioreactors is significantly smaller
depending on the module type. The design has to con-
which in the case of peak loads, this results in increased
sider necessary shut-downs because of chemical cleaning,
peak concentrations in the effluent for hydraulic reasons.
failures, module replacement, etc. During such shutdowns, the remaining membrane surface has to be able
Experience acquired up to now with the operation of test
to filter the maximum waste water volume QM. Depen-
plants and large-scale installations suggests that non-de-
ding on the membrane system, it is possible to attain, for
graded waste water components give rise to fouling of
a limited period, significantly higher permeate flows.
the membranes and thus accelerate the reduction of the

permeability. Therefore it is recommended to bring the
To manage hydraulic peaks, a buffer volume in the form
waste water to the membrane only after a time which is
of upstream tanks, storage capacities or as variable level
sufficient for biodegradation of the waste water consti-
in the activated sludge tank may be useful instead of
tuents. This can be realized by adequate hydraulic design
keeping membrane surface area in reserve.
of the tank volumes (cascading, plug-flow). Short-circuit

flows of the waste water to the membrane modules have
to be avoided at any rate.
The separate installation of the membrane stage in a filtration tank is normally also advantageous for cleaning
and maintenance.
323
Annex
Table A-6
Characteristic data of designed membrane bioreactors [WEDI 2002a]
Nominal pore size
mm
Membrane material
< 0,1 0,4

PVDF, mod. PVC,
PES, PAN or PE 1)
pH resistance
2 - 11
2
Filter surface area per module
240 - max. 2,880
Net permeate flow (QM/AM)
L/(m2 h)
8 - 30
L/(m hbar)
100 - 400
mbar
300 - 400
Permeability
Maximal working pressure
Mean working pressure
Footprint (modules in fitted state)
mbar
20 - 200
m2/m2
70 - 165
m2/m3
40 - 100
1.5 - 5.5
(filter surface area per tank floor area)

Package density (modules in fitted state)
(Filter surface area per module volume)
Injection depth module aeration
Energy demand module
aeration 2)
Energy demand permeate pump
kWh/m
INFLOW
0.25 - 0.80
kWh/m3 INFLOW
0.06 - 0.07
1)
PVDF: polyvinylidene fluoride; PVC: polyvinylidene chloride; PES: polyethersulfone; PAN: polyacrylonitrile; PE: polyethylene
2)
depending on the operating mode of the modules
Reference data on membrane systems from information
Oxygen input
of manufacturers and operating results available up to now

are compiled in Table A-6 [WEDI 2002a]. Together with
With membrane bioreactors, we distinguish between the
the progress of knowledge and module development,
coarse-bubble aeration of the modules and the typical
these data are also subject to changes.
fine-bubble aeration in the activated sludge tanks necessary

for the biological processes. For the design of the activa-
Typical cycle times are in the range of minutes. But there
ted sludge tanks, it has to be considered that the -value
are also installations with continuous filtration during
to be assessed for the air input into the activated sludge
several hours.
tank must be significantly lower because of the higher TS

content of the sludge.
Information on the service life (years until the membranes

have to be replaced) cannot yet be given.
The tendency of the reduction of the -value as a result

of increased solids concentrations is consistent in all
studies.
324
Annex
Figure A-18
Influence of the solids concentrations on the -value for fine-bubble pressure aeration installations
1,00
alpha
0,75
0,50
0,25
0
5
10
15
20
25
TS in g/L
Rdingen/Cornel et al. (2001)
Markranstdt/Cornel et al. (2001)
Rdingen/Wagner, Krause (2003)
1st work report KA-7, only pilot plants (2000)
Beverwijk
The -value also depends on other variables. In addition
If the cross-flow aeration of the membranes is considered
to the aeration system, other factors include the measure-
in the design to cover the biological oxygen demand, the
ment method (measurements with or without waste water
designer has to prove this separately, taking into consid-
inflow), the salt content, the surfactant concentration, and
eration the specific situation and the load cases. According
the specific air flow or the flow in the tank. Measurements
to the arrangement of the membranes in the system, this
at the Rdingen waste water treatment plant suggest that
oxygen input can be assessed to reduce the operating costs.
the characteristics of the activated sludge or substances
For the installation of the membranes in the nitrification
of biogenic origin which are retained in the process have
tanks, KRAUSE/CORNEL [2003] quote mean energy savings
effects on the oxygen input in the membrane bioreactor
of 15 %. If the membranes are arranged in separate filtra-
process (e. g. EPS).
tion chambers, the energy savings are lower. However,

the instructions in section A.6.3 concerning the reactor
It is recommended to use a reduced -value of 0.5 for the
form and the retention time behaviour have to be ob-
design of fine-bubble aeration systems in membrane bio-
served in any case.
reactor applications. This -value is based on a typical

solids concentration of 10 12 g/L. If there are specific
findings about further -value reduction at lower TS concentrations, a reduction should be made.
325
Annex
Nitrogen removal
Up to now, increased biological phosphorus removal in the

membrane bioreactor process has been only used within
Nitrogen removal is designed according to the ATV-DVWK
the scope of research and development [GNIR 2003],
standard A 131 [ATV-DVWK 2000a].
[DICHTL ET AL. 2004].
As a result of module aeration, a considerable quantity of
oxygen is entrained with the mixed liquor recycled from

the separate filtration tank or from the filtration zone, in
The design of a membrane bioreactor typically considers
particular in the case of combined water flow. This has to
a sludge age in the range that for of simultaneous aerobic
be considered in the design of the process.
sludge stabilization. Therefore, in principle it must be assumed that the biological metabolic rates in membrane
Phosphorus removal
bioreactors do not differ significantly from those in conventional activated sludge plants [among others ROSEN-
With the membrane bioreactor process, phosphorus elimi-
WINKEL/WAGNER 2000]. Concerning the treatment of
nation can take place by pre-precipitation in the primary
municipal waste water, no significant reduction of the
treatment stage or by simultaneous precipitation in the
excess sludge production can be expected compared to
activated sludge stage.
conventional systems.
For pre-precipitation, all common precipitants can be used.
According to GNDER [1999], the excess sludge produc-
There is no difference compared to the conventional acti-
tion can be reduced by operating with an extremely high
vated sludge process. A disadvantage of pre-precipitation
sludge age. However, the BOD5 sludge loadings of less
is significantly higher sludge production in the primary
than 0.01 kg/(kg d) required to achieve this are, as a rule,
treatment stage which has to be considered in the design
are not economic.
of the sludge treatment facilities.

The excess sludge production can be determined followIn the activated sludge stage, phosphorus removal can take
ing the ATV-DVWK standard A 131 and the ASM models
place by means of simultaneous chemical precipitation
[HENZE ET AL. 1987; HENZE ET AL. 1999; GUJER ET AL.
or increased biological phosphorus removal, in principle
1999].
combined with simultaneous precipitation. With the membrane bioreactor process, lower total phosphorus concen-
A.6.4
trations in the effluent can be attained than with a con-
Sludge treatment
ventional activated sludge process because

General facts
the particulate phosphorus compounds can be
separated completely, and
orthophosphate cannot be redissolved in a secondary
settling tank.
The excess sludge from the large-scale membrane bioreactors at Rdingen, Markranstdt and Monheim are
stored in a stacking container. They are either transported
periodically to a collecting place at a central waste water
The cleaning agents used for membrane cleaning have to
treatment plant for joint treatment with sludge from
be adapted according to the use of precipitants. Up to now,
conventional plants or they are still used for agricultural
no signs of increased cleaning expenditure for the mem-
purposes. Therefore, in Germany there is up to now no
branes by the use of precipitants have been observed. A
experience with the operation of large-scale sludge treat-
spatial distance between the dosing point and the mem-
ment plants.
brane modules is recommended. Additives into the waste

water treatment plants, including precipitants, generally
have to be approved by the membrane manufacturers.
326
Annex
The sludge from the large-scale plants, particularly from
to conventional sludge has to be expected. Screening in
the Rdingen waste water treatment plant, have been sub-
mechanical pretreatment removes structural substances
ject to extensive studies which are described in the follow-
that may affect the dewaterability.
ing section.
A special solution was chosen for the waste water treatDewaterability
ment plant on the Sntigs peak (Switzerland) [MRGELI

2001]. The excess sludge is filled into special bags. The
As a rule, sludge from membrane bioreactors has a small
water drains off and the sludge compacts. Then the sludge
floc size (about 50 m, in part only 10 m). Despite the
is ready for dispatch by the cableway. By means of this
increased specific floc surface area of the small flocs, no
method, a dried solid content of approx. 20 % is attained.
deterioration of the dewaterability has been observed.
This system has also been installed also at the Schwgalp
Table A-7 shows characteristic values of large-scale studies.
waste water treatment plant.
In a large-scale test with a high-performance centrifuge, a
Digestibility
dried solid content of nearly 30 % was attained with the

sludge from the Rdingen waste water treatment plant.
Despite the typically low sludge loading rate, which is
Laboratory tests proved this dewaterability with results of
similar to or less than that of a simultaneous aerobic sta-
27 % on annual average and maximum values up to 31 %
bilization plant, the organic total solids content of the
at an organic content of the sludge (ignition loss) of
excess sludge from large-scale installations and from pilot
61 48 %. With lower organic content, the sludge showed
plants varies between 46 % and 69 %. This high organic
an improved dewaterability. The polymer demand of
content was the reason for an examination of the digesti-
2.9 gWS/kg dried solid content on average was signifi-
bility or the residual gas potential respectively according
cantly below the polymer demand of 5.9 gWS/kg dried
to DIN 38 414 S8 [N. N. 1999].
solid content from 15 different conventional activated

sludge plants with aerobic stabilization.
Another reason to examine the digestibility is that the

membrane bioreactor process is also a possible variation
The studies to-date show that the demand for flocculation
for the upgrading of existing plants with aerobic sludge
agents is comparable to that of conventional plants or even
stabilization.
lower.
In literature, 200 to 300 standard litres of gas produced
The experience acquired up to now indicates that no
per kg of organic dry solids (Nl/kg oTS) are given for the
additional expenditure for sludge dewatering compared
digestion of excess sludge [BAHRS ET AL. 1994]. During the
Table A-7
Studies on the dewaterability of excess sludge on a large-scale centrifuge
Device/method
Installation
Dried solid content of the excess sludge
centrifuge
Markranstdt
2.4 % dried solid content
Rdingen
Monheim
Dried solid content after dewatering
Ignition loss of the excess sludge
65 % ignition loss
46 % ignition loss
54 % ignition loss
24.5 %
29.9 %
28 %
327
Annex
study, the excess sludge from membrane bioreactors
of the cleaning solution passing into the activated
attained this value reported in literature.
sludge depends to a high degree on the concept of

the cleaning process.
The results show that the sludge from membrane bioreactors has a (residual) gas production comparable to sludge
from conventional plants.
in the cleaning solution

The activated sludge is pumped off from the tank.
The tank is then filled with cleaning chemicals until
A.6.5
the modules are submerged.
Chemical cleaning of the membrane modules

in the air
To maintain and increase the permeability and to disinfect
As a rule, the level of the activated sludge is lowered
the permeate tubes, chemical cleaning of the membranes
to the bottom edge of the modules. The membrane
is required from time to time. There is no uniform recom-
modules suspend freely in the air. The chemicals are
mendation for cleaning. Optimization takes place conti-
added from the permeate side. The contact time is
nuously based on experiences from large-scale operation.
5 10 minutes.
Oxidizing chemicals serve to remove organic deposits. To
external cleaning
avoid AOX formation, chlorine-free chemicals should be

used, if possible, e. g. hydrogen dioxide. However, the
The membrane modules are withdrawn from the
best cleaning results up to now have been attained with
membrane bioreactor tank and put into an external
sodium hypochlorite solution as oxidizing agent, inde-
cleaning cell.
pendent of the membrane.

In-situ cleaning in a cleaning solution or in the air are
Depending on the requirement and particularly to remove
particularly suited for installations with separate filtra-
inorganic deposits, more cleaning steps are added. The
tion tanks.
following chemicals can be used: citric acid, organic peroxide compounds, oxalic acid, acetic acid, mineral acids,
Up to now, we distinguish between intensive cleaning
surfactants, detergents and manufacturer-specific combi-
and intermediate cleaning, depending on the chemical
nation products.
concentration and the cleaning interval.
As a rule, two-step cleaning by means of an oxidizing agent
As a rule, intensive cleaning is required at least once a year
and an organic acid is used.
to significantly increase the permeability. It can be realized, for example, with high concentrations of oxidizing
The load on membranes from cleaning should be as low
agents (e. g. NaOCl 1,000 mg/l Cl or H2O2 2,000 mg/l),
as possible. This has to be considered in the choice and
followed by acid cleaning (e. g. by citric acid). The clean-
dosage of the cleaning chemicals. The cleaning method
ing cycles should preferably be timed in such a way that
has to be approved by the manufacturer.
the maximum hydraulic performance is reached in the

beginning of the cold season.
At present, the following cleaning processes are used:

Intermediate cleaning, typically by means of low oxidant
in-situ cleaning (in fitted state)
concentration (e. g. NaOCl 150 mg/L Cl), serves to prolong the interval between intensive cleaning events. It is
in the activated sludge
328
carried out in intervals of 2 7 days. In order to realize
During chemical cleaning, the membrane modules
longterm successful intermediate cleaning, it is necessary
remain immersed in the activated sludge. The chemi-
to apply this cleaning method during the first operating
cals are added from the permeate side. The quantity
period with a relatively contaminant-free membrane.
Annex
Intermediate cleaning is not used for all module construc-
Ordinance on the Workplace (ArbStttV),
tion types.
plant identifications according to the Ordinance on

Hazardous Substances (GSV),
In-situ cleaning can be used for intensive cleaning or inter-
if necessary, Ordinance on Flammable Liquids (VbF),
mediate cleaning. External cleaning is used exclusively for
if necessary, VCI concept for joint storage of chemicals,
intensive cleaning.
predefinition of the dangerous groups for storage,

if necessary, Ordinance on the Retention of Fire-
The operational expenditure of external cleaning is very
fighting Water (LRRL),
high. Therefore, it has been replaced in some installations
if necessary, leak detection according to DVGW,
by the in-situ cleaning method described above.
if necessary, other ordinances specific to the individual

federal state.
If cleaning takes place directly in the cleaning solution,

the effect at the membrane surface is far better because
Planning and approval of the installations should be car-
the solution is not diluted by the activated sludge. More-
ried out in coordination with authorities and specialized
over, it is possible to increase the temperature of the clean-
institutions such as industrial inspection boards, TV or
ing water to 30 35 C. To improve the mixing of the
occupational health services.
chemicals applied in the cleaning tank, the membrane is

aerated during cleaning.
A.6.6
Energy demand
The operator of a membrane bioreactor process should

demand a detailed instruction for proper membrane clean-
The operating cost of a membrane bioreactor system is
ing and the necessary cleaning intervals from the plant
influenced significantly by the energy demand for cross-
manufacturer or the membrane manufacturer, respectively.
flow aeration in addition to the energy demand for oxygen input for biological waste water treatment.
In the planning of membrane bioreactors, adequate stockrooms, dosing devices, adequate materials for tanks and
The aeration energy depends on the specific aeration de-
tubes as well as safety have to be considered (Wedi, 2002b).
mand of the membrane used and the immersion depth

of the corresponding aeration devices. For the membrane
Since cleaning processes are being continuously developed
modules currently applied, these values vary in a wide
and may be optimized for an individual case, as many
range for the specific air demand from 0.2 Nm3/(m2 h)
options as possible should be kept open for the chemical
to 0.45 Nm3/(m2 h) and immersion depths of 2 metres
stock-room and the dosing devices in compliance with the
to 5 metres.
relevant safety requirements. In Germany, besides the instructions according to the Federal Water Act, also aspects
Current experience with large-scale operation shows a
of work safety, fire protection and emission control have
specific energy demand for cross-flow aeration of approx.
to be observed depending on the combination of chemi-
0,25 kWh/m3 INFLOW to 0.8 kWh/m3 INFLOW (mean annual
cals. The following instructions can or have to be applied
value).
in particular:
Thus, the potential energy savings are to be found main Technical Regulations for Hazardous Substances
(TRGS), in particular TRGS 515,
instructions and advisory leaflets of the Statutory
Accident Insurance Institutions,
ly in the reduction of the specific air demand and in the

increase of the filtration capacity of the membrane system
(e. g. connection or disconnection of individual modules
depending on the inflow).
329
Annex
If the permeate is withdrawn by pumps, a specific energy

3
filtration and radiation plants with approx. 0.15 kWh/m3
demand of 50 W/m to 70 W/m can be assumed. Depend-
to 0.25 kWh/m3 altogether, the energy demand of mem-
ing on the system configuration, recirculation of the
brane bioreactors is still high. For this comparison it has
concentrated activated sludge from separate filtration
to be taken into account that the capacity of the mem-
chambers has to be considered with approx. 15 W/m3 to
brane bioreactor is greater, in particular concerning the
20 W/m . As a result of the lower -value, also the energy
hygiene-relevant parameters.
consumption for fine-bubble aeration devices increases

by the factor konv./ Membran.
Concrete data on the energy demand and its distribution
exists for the membrane bioreactors at Markranstdt and
Monheim. Both installations are equipped with hollowfibre membranes. From the figures below it can be seen
that as the waste water throughput approaches maximum capacity, the specific energy demand decreases.
The specific energy demand normalized to the mean
inflow (approx. 43 % or 35 % of Q max ) is in the range of
0.8 kWh/m3 to 0.9 kWh/m3 for both installations. Compared to conventional activated sludge plants with an
average specific energy consumption of 0.3 kWh/m3 to
0.5 kWh/m3 and additional expansions for e. g. space
Figure A-19
Specific energy consumption of the Markranstdt WWTP [STEIN, KERKLIES 2003]
2.0
specific energy consumption [kWh/m3]
microfiltration 500 A
without air-cycling
(Jun Jul 2001)
1.5
microfiltration 500 A
without air-cycling
(Jan Nov 2002)
1.0
microfiltration 500 C
with air-cycling
(Jan Jun 2003)
0.5
0
1,000
2,000
3,000
inflow [m3/d]
330
4,000
5,000
Annex
Figure A-20
Specific energy consumption of the KA Monheim WWTP [WEDI 2003]
4.0
specific power consumption [kWh/m3]
start-up, non-optimized operation in July/August 2003

3.5
3.0
2.5
future median of the inflow, 35 % of Qmax
2.0
1.5
1.0
0.5
min. consumption filtration
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
inflow [m /d]
A.6.7
For the conversion of phase separation from settling to
Upgrading of existing municipal waste water
membrane filtration, the utilization of the existing secon-
treatment plants
dary settling tank volume as additional activated sludge

tank volume is possible. In this way it is not only unne-
In future, the main focus of necessary investments in
cessary to build new activated sludge tanks but a TS BB
waste water treatment will move from new constructions
concentration results which is below the TS BB concentra-
of waste water treatment plants to rehabilitation and up-
tion typical with membrane bioreactor processes. De-
grading measures combined with expansion projects. For
pending on the degree of undercapacity of the existing
these tasks, too, the membrane bioreactor process may be
plant, the guarantee of the aerobic sludge age has to be
a technically and financially viable solution [SCHIER 2003].
considered in the design of the TS BB concentration be-
Favourable conditions for MBR treatment arise when in
sides the available activation volume. TS BB concentrations
the course of plant upgrades large new tank volumes would
of 4 g/l 7 g/l usually result [FRECHEN, SCHIER, WETT
have to be built, where problems exist as a result of in-
2001 and 2003]. If it were possible to realize such a con-
sufficient capacity of the secondary settling tanks, but
cept, the usual disadvantages of membrane bioreactors
especially in those cases where both problems have to be
(sensitivity to peak loads, unfavourable -value) could be
addressed. Prerequisite is that the structural condition of
largely compensated.
the existing activated sludge tanks and secondary settling

tanks allows further utilization.
331
Annex
Besides the higher effluent quality of the permeate, more
Extensive performance tests of the individual components
process- and expansionspecific advantages of this upgrad-
and the complete process- and electric measurement and
ing concept have to mentioned:
control equipment are indispensable. The programs used

for the control of the membrane installation are sized to
significant biological reserve capacities in the case of
the specific system of the respective project.
future demand for expansion,

economical handling of space resources.
The functional capability of the membrane-specific process components such as mechanical pretreatment stage
Up to now this upgrading concept has not yet been im-
and chemical treatment is of special importance.
plemented on an industrial scale. In a first research project, different membrane systems have been examined for
Leak detection
operating and design parameters by semi-technical tests

[UNI KASSEL 2004]. Besides the general technical feasibility
To detect defects of the membranes and their installations
and technical suitability of the membrane bioreactor pro-
due to their production or which may result from the con-
cess for upgrading of the waste water treatment plants
struction of the plant, it is necessary to carry out a per-
studied, it was stated that concerning the hydraulic capa-
formance test to examine for leaks. The following measu-
city, the hollow-fibre systems studied attained flow rates
res are possible for this purpose:
which were in the range of or even slightly above the

operating or design flow rates of large-scale plants. Thus we
cannot start from a reduced hydraulic capacity for the
air pressure holding test on the filtrate side

(low pressure) with an empty tank,
operation of a membrane bioreactor with process-specific

low TS BB concentrations. If a higher capacity is desired, it
air pressure holding test on the filtrate side (over-
is recommended to carry out preliminary tests. The studies
pressure) with constant clean water level or with a
concerning this are still ongoing (Kassel University).
clean water level which rises during measurement.
A further process solution is to upgrade existing plants
The pressure applied for the leak test has to be adjusted
with partial flow treatment with the membrane bioreac-
to the respective membrane system (capacity for back-
tor process.
washing, e. g. with plate modules).
A.6.8
Start-up operation
Instructions for start-up

After successful performance and leak testing, the instalPrinciples
lation is filled with activated sludge. If no adapted sludge

from a municipal membrane bioreactor is available, it is
For the start-up of a membrane bioreactor, the principles
possible to use return sludge from a conventional plant.
concerning the biological characteristics and the treatment
It is necessary to remove fibrous material from this acti-
capacities are similar to those of conventional plants. In
vated sludge (e. g. by sieving).
the following section some specific aspects of the start-up

of a membrane bioreactor are discussed.
During start-up of the installation, the TS content increases

to the level of the design values (cf. chapter A.6.3). From
Performance test
this may result a change in the floc structure. At TS contents of approx. 8 g/l 10 g/l, strong foaming may occur
Membrane bioreactors are complex technical installations,
which can be treated for example by defoamers. When
for which functional capability and the concurrence of
this process is finished, the tendency for foaming decreases.
the individual components are particularly important in
Experience has shown that the development of a foam
order to ensure long-term processstable operation.
layer in the range of < 10 cm can be expected.
332
Annex
A.6.9
However, the effects of increased pollution loads flowing
Costs
into the activated sludge stage and of possibly no digester gas production have to be considered in the overall
General facts
energy balance.
Cost comparisons have to consider the annual costs re-
Investments
sulting from operation and capital costs. In general, cost

estimates and comparisons for a rather new process tech-
Additional expenses arise from the purchase of the mem-
nology have the disadvantage that they typically become
brane installation, including the necessary mechanical
inaccurate after a short time, because developments in
pretreatment (cf. chapter A.6.3), which has to be equip-
process optimization and free-market regularities influence
ped very carefully, high-performance aeration equipment,
the costs to such an extent that new processes increasingly
the chemical storage room and the dosing stations as
gain competitiveness. Such estimates and comparative
well as the electrical and control technology.
calculations indicate that membrane technology may

become economically interesting, depending on the respec-
In the case of a new construction, the additional invest-
tive boundary conditions [RAUTENBACH ET AL. 2000].
ments for a single-stage sieving or screening installation

are limited in spite of significantly increased requirements
For purposes of evaluating the costs of membrane biore-
concerning screenings removal, redundancy and process
actors, the increased capacity for germ reduction of waste
stability. They are in the range of 2 4 % related to the
water compared to conventional processes must be
construction costs of a new membrane bioreactor. A two-
considered. For this reason, too, a simple comparison of
stage screening/sieving installation including the enclosed
membrane bioreactors with activated sludge plants accord-
volume results in additional construction costs.
ing to ATV-DVWK-A 131 without germ reduction is useful only to a limited extent and should be left to special
Compared to a conventional plant, smaller activated sludge
cases. As a rule, membrane installations are at present
tank volume has to be kept in reserve. The reduced costs
still more expensive compared to conventional activated
are not as high as the pure volume comparison would
sludge plants.
lead one to believe, especially if filtration tanks are built.
Since membrane bioreactors only consist of a few struc-
Figure A-21 shows a distribution of the investments in
tures, they are advantageous under special boundary con-
the case of a new construction of a membrane bioreactor
ditions, e. g. sites with restricted space, complicated sub-
(Monheim WWTP) for a maximum flow of approx.
soil conditions or in the case of special architectural de-
300 m3/h. Concerning the mechanical equipment, the
mands. This is increased in particular for demands on
membrane installation is clearly dominant with approx.
germ reduction in waste water due to special conditions
34 %. The expenditure for sieving installations and acti-
of the receiving water.
vated sludge tanks are of less importance.
On account of the higher total solids content in the acti-
The orienting guide values represented in Figure A-22
vated sludge, it is useful to examine for the membrane bio-
take into account costs for plate and hollow-fibre module
reactor process the possibility of simultaneous aerobic
systems available on the market in Germany from 1999
sludge stabilization. From this result significant liberties
to 2002, which were designed for comparable flows for
in planning. The size of the activated sludge tanks is con-
typical conditions (municipal waste water, temperatures
siderably reduced, settling devices and possibly necessary
of 8 12 C) of approx. 22 L/(m2 h) to 30 L/(m2 h)
filtration units can be spared as well as downstream germ
[WEDI 2003].
reduction installations. Depending on the possibility, separate sludge stabilization processes and primary treatment
may be dropped.
333
Annex
Figure A-21
Example for the distribution of construction costs of a membrane bioreactor
for approximately 300 m3/h [WEDI 2003]
ventilation/sanitation
3%
others
1%
electric equipment
13 %
construction engineering
39 %
(filtration chamber: 4 %)
(activated sludge tank: 5 %)
mechanical equipment
44 %
(total membrane filtration installation incl. electric,
measure and control equipment: 34 %)
(2 compact installations sieving/grit chamber: 5 %)
all data related to the total building costs
If the costs of the ready-for-use membrane installation
In these specifications, the ready-for-use filtration unit
are normalized by the maximum inflow of the installa-
with pumps, blowers, connecting tubes, dosing installa-
tion, the inflow-specific system price of the membrane
tions for chemicals and the necessary controls are con-
installation only results. This normalized cost allows mem-
sidered. Costs for equipment engineering, start-up and,
brane systems with different specific filtration capacities
as a rule, a five-year guarantee on the membranes are
to be compared.
also included. With increasing size of the installation, the

relative fraction of these services decreases significantly.
Structural parts of a waste water treatment plant or equipment for mechanical pretreatment are not included.
334
Annex
Figure A-22
Orienting net cost guide values for the ready-for-use membrane filtration installation without structural
part [WEDI 2003]
10,000
as of 1999 2002
9,000
specific costs [o/(m3/h)]
8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
0
300
600
900
1,200
1,500
1,800
2,100
2,400
design inflow [m3/h]
The share for the membranes only is approx. 50% to 65%
or separate sludge stabilization facilities as well as the
and rises with increasing size of the installation or with
site-specific cost advantages. Since the tank construction
increasing maximum inflow. Currently the surface-speci-
costs are low at the moment, there are limited possibili-
fic prices for membranes used for large-scale applications
ties for cost savings concerning the activated sludge
in Germany vary between 60 euro/m and 100 euro/m
tanks, in particular in the case of systems with filtration
(initial investment). But membranes with lower specific
tanks. The additional expenses for special installations,
filtration capacities and correspondingly lower prices are
coatings or additional mechanical equipment are often
available on the market.
comparable with the cost for larger activated sludge tanks.
The investments resulting from Figure A-21 and those
Due to the worldwide demand for membrane installa-
for mechanical pretreatment have to be considered
tions, additional reduction in the specific costs is expect-
against the savings for plant components which may no
ed during the next years. Also, technical simplifications
longer be necessary, such as secondary settling tanks,
are expected in the field of mechanical equipment.
sand filtration, UV disinfection, possibly primary settling
335
Annex
A.6.10
Table A-8 underlines the influence of the membrane replace-
Annual costs
ment on the annual costs of membrane bioreactors. From

this, it is clear that internal measures aiming at extending
A.6.10.1
the service life of the membranes are of importance.
Loan servicing and membrane replacement

A.6.10.2
Operating costs
In principle, the cost structure for a waste water treatment
plant changes if a membrane bioreactor process is instal-
Compared to conventional activated sludge plants, mem-
led. While with new conventional activated sludge plants
brane bioreactors have higher operating costs due to the
the structural equipment clearly dominates the machinery
energy- and chemical demand. An essential cost factor is
in terms of investment cost (in a ratio of 2:1 approxima-
the energy demand for cross-flow aeration.
tely), this ratio at least reverses for membrane bioreactors,

due to the elimination of the secondary settling tank and
The demand for chemicals of the various membrane sys-
the smaller activated sludge tank as well as the increased
tems may differ significantly. Depending on the necessary
expense for machinery. This ratio may move further still
intervals of intermediate and main cleanings as well as
if it is not a matter of a new plant building, but of a plant
the chemicals to be applied, specific costs of approx.
upgrading for which existing tank volumes are used (see
0.2 euro/(m2 a) to 1.1 euro/(m2 a) have been deter-
chapter A.6.7).
mined. This wide range indicates that there is still need

for optimization in membrane cleaning.
The investments for the membrane stage have to be

divided into those parts which are subject to the usual
A.6.11
depreciation periods for machinery, and the membrane
Final remark
itself which is replaced after the end of its service life.

The membrane replacement costs have to be covered by
A comparison of cost-effectiveness has to be made exclu-
the loan service. For definition of a depreciation period,
sively on the basis of the annual costs (sum of loan service
the service life of the membrane has to be estimated, which
and operation costs). A comparison based only on the in-
is normally shorter than the depreciation period of the
vestment is not serious.
machinery.
Table A-8
Membrane-specific annual cost shares
Costs [Ct/m3]
Field1)
0.20 0.75 kWh/m3
2.0 7.5
Permeate/recirculation
0.08 0.10 kWh/m
0.8 1.0
Additional demand for aeration
0.08 0.10 kWh/m3
0.8 1.0
Cross-flow aeration
Chemicals
Membrane replacement
1)
0.20 1.10 euro/m a

10 5 a
0.3 1.8
13.3 26.6
B = operating costs; K = loan service

electric current: 10 Ct/kWh; waste water production 90 m3/(PE a), specific membrane surface area: 1.5 m2/PE,
current chemical costs for H2O2, acids and alkalis, membrane costs: 80 euro/m2
336
Annex
A.6.12
Risks and disadvantages
Advantages and risks of the membrane bioreactor

process
For each case, the risks and disadvantages that may be

relevant for the installation of a membrane bioreactor
A.6.12.1
must be assessed. In the following section, critical issues
General facts
that should be examined, depending on the existing boundary conditions, are summarized:
From the comments above it is clear that the membrane

bioreactor process has important advantages compared to
the conventional activated sludge process. However, this
increased sensitivity to peak loads as a result of

reduced tank volumes,
process also has several risks and disadvantages. For the

individual case, an assessment of advantages and disadvantages has to be carried out in order to make a con-
increased total energy demand, in particular for

module aeration,
scientious decision on the optimum process. Therefore,

the most important arguments are given again in the
following section.
membrane modules may silt up or clog in the filtration zone by fibrous material, too high biomass concentration or poor intermixing; for this reason correct
Advantages
The special advantages of the membrane bioreactor process
can be summarized as follows:
functioning of the module aeration is critical,

membrane damaging waste water constituents, which
may get into the waste water treatment plant e. g. as a
result of failures, may lead to considerable and irrever-
less space required because the higher TS content
sible reduction of the filtration capacity,
allows smaller activated sludge tank volumes and

secondary settling can be eliminated,
increased technical expense and additional demands

on the process control,
it is easier to enclose the waste water treatment plant,

thus higher acceptance in densely populated areas,
input/production of pollutants by cleaning chemicals

(e. g. AOX by chlorine-containing oxidizing agents),
the process produces hygienically perfect effluent

quality because no filterable solids are found in the
building of adequate chemical stock-rooms.
effluent, and therefore the number of germs is significantly reduced,
A.6.13
Glossary
improvement in the operational reliability by avoidance

of negative effects on the effluent quality by bulking or
The terms which are of special importance for the mem-
floating sludge or sludge carry-over,
brane bioreactor process are briefly defined in the following section.
reduction in the residual organic pollution.
337
Annex
Backwashing
Filtrate
Part of the material mixture which passes the membrane
Short-term reversal of the flow direction through the mem-
in micro- and ultrafiltration (see also permeate).
brane in intervals to remove the particles accumulated

during the filtration process (covering layer), usually with
Flow
permeate.
Volume per time unit
Biofouling
Flux (or permeate flux)

specific filtrate volume flow per unit surface area- and
Development of a biofilm on the membrane surface or in
time unit (per m2 of membrane surface area, per hour),
the membrane due to the growth of micro-organisms; bio-
unit [L/(m2 h)]
fouling causes a reduction of the performance or the permeability (see also fouling and scaling).
F
Concentrate
QF
AM
1
=
AM
VF
t
L
m2 h
Partial flow of the material mixture in which the activated

VF = permeate flux
(L/(m2 h)
usually recycled as return sludge into the activated sludge
QF = permeate volume flow
(L/h)
tank (see Figure A-15).
AM = membrane surface area
(m2)
sludge retained by the membrane is concentrated. It is
Covering layer
with:
With stationary conditions, the permeate flux is calculated

from the permeate volume flow (Q F) related to the mem-
Accumulation of the components retained by the mem-
brane surface area (A M). With variable conditions, only
brane surface.
a mean permeate flux can be given. It is determined by
Cross flow
nying permeate volume (VF).
The term cross flow comes from the configuration of the
Fouling
choosing a sufficient time interval ( t) and the accompa-
dry-arranged membrane systems operated in a pressure

vessel. During this process, the membranes are overflown
In general: deposition of material on the membrane, at
(transverse flow = cross-flow) in order to limit the devel-
or in the pores. According to the material which causes
opment of a covering layer on the membrane surface. In
fouling, we distinguish organic fouling, inorganic fouling
membrane bioreactors with submerged membrane filtra-
and biofouling. Fouling always results in a reduction of
tion, a transverse flow develops at the membrane surface
the performance or the permeability of the membrane
by the air injected (usually coarse bubbles), which is also
(see also biofouling and scaling).
called cross flow and serves to control the covering layer.

As a result of the two-phase flow, the effective mechanisms
Gross permeate flux
clearly differ from the principle of classical cross-flow
Current permeate flux during the filtration phase of a
operation of pressure tube systems with inside flow.
cycle (see Figure A-17 and net permeate flux).
Cycle
Membrane
Barrier which causes the retention of particles in mem-
Temporal sum of filtration phase and following backwashing phase or shut-down phase (see Figure A-17)
338
brane bioreactors.
Annex
Membrane surface area A M
Operating pressure
The membrane surface available for the filtration process:
The operating pressure is necessary to attain filtration.

The operating pressure consists of:
systems with internal flow: inner surface, for tubeshaped systems defined by the inner diameter
transmembrane pressure and

feeder losses.
systems with external flow: external surface, for tubeshaped systems defined by the external diameter
The operating pressure is usually described as the pressure

difference between the suction side of the pump/control
Module
instrument and the ambient pressure considering the

water level situation (see also transmembrane pressure).
Plant component ready for connection and operation,

consisting of
Permeability
membranes or membrane elements,
Parameter for the description of the hydraulic perfor-
internal piping,
mance of a membrane. Quotient from the gross permeate
module aeration,
flux and the transmembrane pressure; unit:
fittings and valves, joints,

[L/(m2 h bar)]. The permeability should be corrected to
other holding devices
a reference temperature in order to allow accurate comparison of values.
Net permeate flux

The specific permeate flux that is actually attainable in
Lp
continuous operation and which is achieved in one cycle

of the membrane installation [L/(m2 h]; the following
Vp
pTM
L
m 2 h bar
points have to be considered:

[L/(m2 h)]
with: VP = gross permeate flux
filtration pauses,
backwashing times, switching times and
p TM = transmembrane pressure
(bar)
the permeate volume required for backwshing.

Permeate
Operating pauses required for cleaning as well as permeate
volumes have to be considered in conceptual planning.
Part of the material mixture which passes the membrane

in nanofiltration and reverse osmosis (see also filtrate).
Net permeate flux =
Permeate volume during one cycle [ L ] backwashing losses [ L ]

time of the cycle [ h ] membrane surface area [ m 2]
L
m2 h
339
Annex
Remark: Although the membrane bioreactor process in

municipal waste water treatment is micro- or ultrafiltration, according to the membrane pore diameteres used,
the term permeate has become established contrary to
the formal definition in practice, in literature and in
the specialist discussions. This will not be changed in this
2nd work report.
Pore diameter
As a rule, the pores of pore membranes are not uniform,
i. e. they show a more or less strong pore size distribution.
The pore diameter with a maximum in pore size distribution is called nominal pore diameter (unit as a rule [m])
(according to RAUTENBACH, Membranverfahren,
Springer-Verlag). The maximum pore diameter can be
determined with the help of the bubble point method
according to DIN 58 355, part 2, which is used to determine what pressure is required to press the first air bubbles through the membrane. The maximum pore diameter
is then calculated by means of a formula.
Scaling
Accumulation of inorganic water constituents at the
membrane after precipitation (see also fouling and biofouling).
Transmembrane pressure p TM
Pressure difference or pressure loss by the membrane
(between outside and inside of the membrane); abbreviation: TMP (see also operating pressure)
340
Annex
A.6.14
Engelhardt, E., Rothe, J. (2001): Sind grotechnische
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Hegemann W.; Busch K.; Spengler P. und Metzger J. W.
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rung ausgewhlter Estrogene und Xenoestrogenen in
Membranbelebung auf Basis des ATV-DVWK-A 131
Klranlagen ein BMBF Verbundprojekt; GWF Wasser
(2000); Wasserwirtschaft Abwasser Abfall 05/2002,
Abwasser 143 Nr. 5
S. 640 647
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Abwasser- und Schlammuntersuchung; Herausgeber:
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342
2003 in Bonn
Annex
A.7
Large-scale membrane installations for drinking water treatment in Germany
Location
Neckarburg
Capacity m3/h
70
Raw water
Start-up
Manufacturer
Membrane process
Karst spring
91998
Aqua-source
UF
Hermeskeil
140
Spring and Prims dam
21999
X-Flow
UF
Sundern
250
Sorpe dam
32001
X-Flow
UF
Marmagen
45
Karst spring
32001
Zenon
UF
Denkingen
15
Karst spring
62001
X-Flow
UF
Neustadt, Saale
70
River
72001
X-Flow
UF
Olpe, Elspetal
80
Creek/spring
82001
X-Flow
UF
Calw, Hirsau
50
Spring
32001
X-Flow
UF
Jachenhausen
72
Karst spring
82002
Inge
UF
35
Karst spring
112002
Inge
UF
X-Flow
UF
Partenstein
Olef
750
Olef dam
12003
Regnitzlosau
27
Well
12003
Zenon
UF
Bad Herrenalb
36
Spring
22003
X-Flow
UF
Kandern
50
Spring
32003
X-Flow
UF
Lauterhofen
90
Well
52003
X-Flow
UF
80
Well
62003
Zenon
UF
Spring
62003
Zenon
UF
Miltenberg
Waldberg
Burglauer
210
30
Well
72003
Inge
UF
Bad Kissingen
120
Well
112003
Inge
UF
Heinrichsthal
13
Well
112003
Inge
UF
Sulzbach-Lauf.
36
Spring
122003
X-Flow
UF
Bad Ditzenbach
22
Spring
122003
X-Flow
UF
Gnterstal
60
Spring
12004
PALL
UF
Fellen
18
Spring
12004
Inge
UF
Gaggenau
15
Spring
42004
Inge
UF
18
Spring
Bad Herrenalb
Roetgen
6,000
Dam
42004
under construction
X-Flow
UF
X-Flow
UF
343
Annex
A.8
Glossary
Key word
Explanation
Backwashing
Short-term reversal of the flow direction in intervals to remove the particles accumulated during the filtration
process (covering layer), normally with filtrate.
Brine/concentrate
Partial flow of the substance mixture which is retained by the membrane.
Capacity
Surface-specific permeate flow rate of a membrane under defined operating conditions.
Concentrate
Partial flow of the substance mixture which is retained by the membrane, i. e. separated from the feed respectively.
Covering layer
Accumulation of the components retained by the membrane at the feed side of the membrane surface area.
Cross-flow filtration/
Operating mode: the feed flows in parallel of the membrane surface area.
dynamic filtration
Dalton [D]
Unit for the molecular weight.
Dead-end filtration/
Operating mode: the membrane surface area is supplied orthogonally with the feed.
static filtration
Dynamic filtration
See cross-flow filtration.
End-of-pipe measures
Measures for the reduction of emissions at the end of a process chain.
Feed
Material mixture to be treated in the influent (raw solution in the case of liquid substance mixtures).
Feed-and-bleed structure
Variation in the connection of modules:

The concentrate of the upstream module is used as feed of the downstream module.
Filtrate, permeate
Part of the substance mixture that passes the membrane.
Filtration controlled
Height and thickness of the covering layer can be influenced by the pressure applied and the overflow velocity so
by the covering layer
that the filtering characteristics of the covering layer can be used in a calculated way.
Fir-tree structure
Variation in module connection: The modules within the blocks connected in series are connected in parallel. The
concentrate volume flow is continuously concentrated from one block to the other, i. e. minimized, the permeate
yield is increased accordingly. The permeate is discharged from each block so that the volume flow to be treated is
reduced from one block to the other.
Flow (surface-specific) or flux
Filtrate or permeate volume flow related to the membrane surface area. Throughput through the membrane.
Unit [ L/(m2 h)].
Flushing
Short-term operation with clear water without reversal of the permeation direction.
Fouling
Development of a covering layer on the membrane by organic components which leads to a reduction of
the filtration capacity.
Intermediate cleaning
Chemicals such as citric acid or oxidizing chemicals (e. g. hypochlorite) are added to the backwashing or
flushing water.
Irreversible fouling
Fouling which can no longer be removed by backwashing or flushing and chemical cleanings.
Membrane
Selective barrier between two phases of different concentration [RAUTENBACH 1997].
Module
Connectable, operable plant component consisting of membrane or membrane elements, pressure reservoir and
module-specific apparatus parts [MARQUARDT 1998].
The separation size of a membrane is indicated by the so-called cut-off molecular weight. This is the specific mass
of a macromolecule which is retained by 95 % by the respective membrane.
Nominal pore diameter
Pore size which occurs as maximum in the pore size distribution (of a membrane).
Nutrient removal
Degradation or elimination of nitrogen and phosphorus compounds.
Parallel connection
Module connection: the feed is distributed to two or more modules.
Permeability
Parameter for the description of the permeability of a membrane.

Quotient of the surface-specific flow and the transmembrane pressure. Unit: [ L/(m2 h bar].
Permeate, filtrate
344
Part of the substance mixture that passes the membrane.
Annex
Key word
Explanation
Pore membranes
Separation of these membranes is based on a screening effect which can be improved by the development of a
covering layer, microfiltration and ultrafiltration membranes.
Recirculation
Recycling of the concentrate or part of it into the feed.
Scaling
Layer on the membrane formed by inorganic precipitations (crystallization).
Selectivity
Capability of a membrane to differentiate between the components of a substance mixture to be separated.
Semi-cross-flow or
Combination of dead-end and cross-flow process, e. g. by dead-end filtration with discontinuous flow in parallel
semi-dead-end process
tothe membrane.
Series connection,
Module connection: the concentrate of one module serves as feed of the following module. The permeate of the
cascade connection
individual modules is combined.
Solution-diffusion membranes
Membranes which use the different solubility and diffusivity of the substance components for separation, reverse
osmosis and nanofiltration membranes.
Stage (pressure stage)
Unit of a membrane installation functioning in itself, consisting of modules, pumps, valves etc.
Static filtration
See dead-end filtration.
Tertiary waste water treatment
Originally: treatment steps which go beyond the separation of settleable substances and carbon elimination.
Today this term often summarizes measures which go beyond nutrient removal, zusammengefasst (e. g. sand
filtration, disinfection, material separation and treatment by membrane technology).
Transmembrane
Pressure difference or pressure loss across the membrane (from the feed or concentrate side to the
pressure difference
permeateside).
Waste-water-free operation
Closure of the circuit so that means that no waste water emissions develop. This means in the case of membrane
processes that permeate as well as concentrate can be reused.
Yield, output
Ratio of permeate (filtrate) and raw water quantity fed.
345
Annex
A.9
List of abbrevations
Abbreviation
Sense
VBB
volume of the bioreactor
BOD5
biochemical oxygen demand within five days
COD
chemical oxygen demand
PE
population equivalent
MF
microfiltration
NF
nanofiltration
Ptot
totality of phosphorus compounds (unit: mg/L)
Qd
daily waste water inflow at dry weather
Qt
maximum waste water inflow as 2 h mean value at dry weather
RO
reverse osmosis
TS
Trockensubstanz: der TS-Gehalt entspricht der Biomassekonzentration (Einheit: g/L)
UF
ultrafiltration
WHG
Wasserhaushaltsgesetz
VN
volume of the nitrification tank
VDN
volume of the denitrification tank
Vvario
volume of the variable zone
MW
combined water flow
WWTP
346
ISBN 3-939377-01-5
ISBN 978-3-939377-01-6

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Municipal Water and Waste Management

Municipal Water and Waste Management

Dr. rer. nat. Harald Friedrich

Institute of Environmental Engineering

of the RWTH Aachen University

Waste Management, Soil Conservation,

Municipal Water and Waste Management

Dr. rer. nat. Harald Friedrich

Institute of Environmental Engineering

of the RWTH Aachen University

Waste Management, Soil Conservation,

In municipal waste water treatment, certain types of

waste water shows impressively how innovative, future-

membrane installations the biomembrane filtration

orientated, and economically meaningful environmental

plants (membrane bioreactor process) havent been

protection technology can be. In the past 100 years of

used often so far, both for historical and economical

modern water and waste water treatment for households

reasons. But the application of membrane processes in

and enterprises, no other new technology has been intro-

municipal waste water treatment may be proven to be

duced offering so many positive effects like the membrane

cost-effective, in particular if the following conditions

Numerous different problems in water treatment can be

the space for the new construction or the expansion

solved, simultaneously resulting in significantly better

for waste water treatment plants is limited,

cleaning of the waste water.

waste water are to be used,

reprocessing of solid and dissolved substances.

quality of the waste water are required,

modules, technically suitable systems for nearly every

toxic substances have to be removed,

A large number of scientific institutions, industrial enter-

hygienically excellent waste water quality is demanded.

In Germany, the biomembrane filtration process has

technology. The Federal Government as well as the

become competitive already today in the field of domestic

governments of the federal states support this technical

and small waste water treatment plants as well as in ship

In Germany, membrane technology today represents a

Membrane technology can be applied in diverse fields of

industrial waste water treatment. This pays off in terms

industry, which is proven by a large number of references.

of ecology and economy because the usage of membrane

In industrial waste water treatment, membrane technology

technology denotes fewer costs for water supply and

is used for production-integrated pollution control.

waste water disposal as well as industrial production, and

With the help of membrane technology, water the sol-

This publication presents the membrane technology and

vent most frequently used in industry can be cleaned

its application in municipal and industrial waste water

to such an extent that it may be reused. The substances

treatment in Germany according to the state of the art

filtered from the water may also be reused again for

and science. Examples of installations realized in an in-

industrial processes. Although its impossible to realize a

dustrial scale in municipalities and industrial enterprises

completely closed water circuit by membrane technology,

demonstrate the range of application and the efficiency

the waste water quantity may be significantly reduced by

of membrane installations including planning, con-