MBR Course

Fundamental of MBR Processes &

Introduction to Process Design Tools
October 16 & 17, 2012
Hamid Rabie

Function of a WWTP
Removal of particulate materials
sand
hairs, fibrous materials
other solids
Biodegradation of undesired components

carbon
nitrogen
sulphur
phosphorus

CO2 + biomass
N2 + biomass
biomass
biomass

Solid liquid separation

Waste
water

WWTP

Effluent

biomass rejection
Microbial rejection
standard sedimentation: 10,000 CFU/ml
(colony forming unit: cfu)

Surplus sludge (biomass)

Fundamentals of Bio-Reactor Processes

Wastewater

Effluent

Solid - Liquid
Separation
Settling
Filter media
Membrane
Biological Process

Engineered systems to:

Accumulate microorganisms for oxidation of electron donor pollutants.
Convert soluble pollutants to large particles (biomass) for separation.

Sludge

Fundamentals of Bio-Reactor Processes

Pollutant
Measurement Biological Reaction
Process Name
O2
Carbonaceous BOD, COD
Organic
CO2 + cells BOD Removal
O2
Ammonia
N - NH3
Nitrification
NH
NO + cells
3

Condition
Aerobic
Aerobic

Nitrate

TN

NO3
N 2 + cells

Denitrification

Phosphorous

TP

P
cells

Bio-P Removal Anaerobic

BOD / Nit

Aerobic

BOD / Nit / Denit

Anoxic

Aerobic

BOD / Nit / Denit

Bio-P

Anaerobic

Anoxic

Anoxic

Aerobic

First Use of Membranes in Biological WWT

Effluent treatment with membrane technology tertiary treatment

GF

PC

Raw
wastewater

S
GF
PC
BS

BS

ST

DC

MT

Permeate

Effluent

=
=
=
=

Step screen
Grid and fat removal
Primary clarifier
Biological step

ST = Sedimentation tank
DC = Third cleaning step (e.g. filtration)
MT = Membrane technology

Membranes at the End of WWT Process

Tertiary treatment
Always end of the processes

additional costs to conventional technology;

additional footprint required

Low solid concentration

tolerance in membrane stage

no hair and fibrous material allowed

requires easy sludge management

Mostly dead end filtration mode

Pressurized membrane systems or

Submerged membrane systems

Sensitive against fouling

components

fouling components come in direct contact

with membrane surfaces;
often additional flocculation required;
operation difficult to optimize

Interesting for existing WWTP that need disinfection or reuse

Almost similar to surface water treatment (need for coagulant)

Changes in the MBR System

Membrane bioreactor (MBR)

GF

FS

PC

BS

Raw
wastewater

S
GF
FS
BS

BS

MT

ST

TC
Combination
of
biological step
and solid liquid
separation

Permeate

=
=
=
=

Step screen
Grid and fat removal
Fine screen
Biological step

MT = Membrane technology

Effluent

MBR vs. Conventional Activated Sludge

Conventional Activated Sludge System

Incoming
Wastewater

PreTreatment

Anoxic
Zone

Aerobic
Zone

Settling
Tank
Effluent
In case of Tertiary
More processes;
e.g. sand filter

RAS

Membrane Bioreactor (MBR)

Incoming
Wastewater

PreTreatment

Anoxic
Zone

Aerobic
Zone

MF/UF

RAS

Effluent

MBR Reduces the Footprint

Eliminate all clarifiers

Replace with
membrane systems
Membranes

Major Differentiations of MBR Technology

Stable
Biological
Treatment
Process

Activated
Sludge
Process

MBR

Membrane
Filtration

Absolute
Solids
Separation

Replaces conventional clarification; requires less footprint

Combines physical barrier of a membrane with biological treatment
Produces high quality effluent at all times
Comparable to tertiary treatment; then LCC is conventional technologies

membrane

key component to this market

Advantages of MBR over Conventional

Better effluent quality

Increased Efficiency

> 95%, 98% and 99.9% for COD,

BOD, SS removal

All bacteria retained, cold weather

nitrification

Effluent TSS independent of

bioreactor efficiency

Insoluble P retained reducing

chemical addition for P removal

High MW organics are retained and

bio-degraded

High MLSS (1-2%), greater organic

loads and less sludge production

Improved biological reactions (due

to longer SRT, shear, etc.)

Compact systems, less footprint

Sludge digestion within bioreactor

Process Control
Complete separation between HRT
and SRT
Accurate control over sludge age,
development of slow-growing
microorganisms (nitrifiers)

Modular expansion
Absorbs variation and fluctuations in
incoming flow and organic loads

Market Areas for MBR Technology

Space limitation
reuse; high quality
High & variable
salt content

pulp &
paper

municipal
wastewater

textile
industry

tank
cleaning

pharmacy
industry

beverage
industry

industrial
laundries

Membrane
Bioreactors

dairy
industry

High &
variable salt
content

High COD
content

petrochem
industry

vegetable
industry

leachate
fruit
industry

High COD
content

Slaughter
-house /
rendering

chemical
industry

High ammonia
content

Drivers of MBR Market & Technology

Increasing regulatory standards
especially regarding disinfectant byproducts and waterborne pathogens

Limited supply
tap into alternative supplies
such as water re-use

Growth in
Membrane
Technology
Growing demand
due to population growth, new
infrastructure in developed
countries, and aging infrastructure
in industrialized countries

Technological innovation
development of low cost,
high quality water treatment
solutions

Main Configurations for MBR Technology

Tubular modules

Hollow fiber modules

Plate modules

Inside/Out Filtration
(Pressurized Vessel)

Outside/In Filtration
Immersed (Vacuum)

Outside/In Filtration
Immersed (Vacuum)

X-Flow / Pentair

GE-Zenon

Kubota

Berghof

Mitsubishi

Toray

Koch Membrane

Siemens-Memcor

Huber

Koch Membrane-Puron

A3 Gmbh

Micronet PF

MBR with Tubular Modules Cross Flow Membrane Filtration

Pressure
Pump

External cross flow MBR

DN

MF

N
RC

RL

Pressure

modules cross flow operation

Feed side
Permeate side

Module Length

RC
RL
MF
N
DN

recirculation
return line
membrane filter
Nitrification
De-nitrification

Cross Flow Membrane Filtration for MBR

Tubular Membrane (Inside/Out Filtration)

Concentrated
Waste

Feed

Membrane
Support Material

Permeate
(Clean Water)

Cross Flow Membrane Filtration for MBR

Tubular Membrane
Original work-horse in MBR applications; used horizontal configuration
Large diameter membrane tube and high recirculation flow rate and high
TMP served to eliminate potential for plugging with biomass
Membrane designed to operate at MLVSS levels > 50,000 mg/l
Energy intensive on large flow rates (> 300,000 gpd)
Low packing density (requires large footprint for large flow rates)
New tubular systems from X-Flow uses air plugs in vertical tubes
operating at lower pressures

Tubular MBR Configurations

X-Flow Airlift

MLSS: 12-50 g/L

MLSS: 8.0-12 g/L

Flux: 50-150 lmh

Flux: 30-50 lmh

High energy consumption:

Lower energy consumption:

(1.5-4.0 kWh/m3)

(0.3-1.0 kWh/m3)

Continuous

Discontinuous

TMP: 1.0-5.0 bar

TMP: 0.2-0.6 bar

More valves & complexity

MBR with Submerged (Immersed) membranes

submerged
membranes

Vacuum Pump
Waste water
Permeate

Biological sludge
Air

Basic of Immersed MBR Train

1.Biological reactor
2.Membranes
3.Permeate pump & blower
4. Control panel
5. Permeate & air piping

5
1

Immersed Membrane Filtration (hollow fiber)

Membrane

Permeate to Top Header

(Puron has no top header)
Support Material
(e.g. Zenon, MPF, Puron)

Aeration
Bubbles (for
fluid agitation)

Suction

Outside/In Filtration

Coarse Bubble
Diffuser

Bulk Fluid
(Concentrate)

Coarse Bubble
Diffuser
Permeate to Bottom Header
(Siemens has no bottom header)

Immersed Hollow Fibers in Operation

Module Installation
with crane

Submerged module in operation

air injection phase

Immersed Membrane Filtration (flat sheet)

To suction
Suction

Panel

Air bubbles between

membrane panels

Air diffusers

MBR with submerged modules different tank configurations

Internal submerged MBR

DN

RC
RL
MF
N
DN

MF

RC

External submerged MBR (Preferred)

DN

MF
RC

RL

recirculation
return line
membrane filter
Nitrification
dnitrification

Key Aspects of MBR Products

For superior technological and economical performance, should consider:

Membrane structure and characteristics

Module design and features
Aeration system & sludge management
Membrane tank hydraulics
Membrane filtration process and system design

Classification of membrane processes

Pressure difference in [bar]

Saline solutions
Viruses

Bacteria

100
RO

10

Nanofiltration

Ultrafiltration
1

Microfiltration

0,1
0,0001

0,001

0,01

0,1

1,0

Particle size in [m]

Membrane pore size range from
different suppliers for MBR

10,0

Sand
filtration

100

Comparison of microorganisms vs
membrane pore size

E. Coli ~ 0,5 - 1,5 m

B. Subtilis
~ 0,3 m

MS2-Virus (Coliphage)
~ 0,025 m
poresize ~ 0,01 m

ultrafiltration

poresize ~ 0,2 m

microfiltration

MBR provides better effluent quality

Parameter

MBR

convent.
plant

Solids

mg/l

10 15

COD

mg/l

< 30

40 50

Ptotal with
precipitation

mg/l

< 0,3

0,8 1,0

g/l

< 20

<5

MLSS content in
aeration tank

Key Requirements for Membrane Properties

Material requirements
hydrophilicity - good wetability with water
low fouling tendency
chemical and thermal stability
mechanical stability
Morphological requirements
narrow pore distribution
minimized number of defects
high porosity
low hydraulic resistance
high bonding of membrane to support material
Economic requirements
cost-effective materials
cost-effective production

Different Types of Membranes & Structures

(SEM of Membrane Surfaces)
Zenon

Toray

Kubota

Mitsubishi

2 m

2 m

2 m

3 m

Avg. Pore: 0.1 m

Avg. Pore: 0.03 m

Avg. Pore: 0.4 m

Avg. Pore: 0.2 m

PVDF high MW

PVDF low MW

Chlorinated PE

PVDF low MW

Asymmetric

Asymmetric

Symmetric

Asymmetric

Coated on fabric

Coated on a support

Coated on fabric

Double coating

Coated on support

10 m

Asymmetric Structure

Membrane Skin/Surface

Introduction to Design
Tools

Key Elements of MBR Process Design

Full step by step biological reaction analysis and mass balances such as:
Carbon, Phosphorous, Nitrogen, etc
Sludge production
Aeration and nutrient requirements

Step by step process mass balances and all necessary sizing such as:
Pumping and coarse screen
Sand and fat removal
Fine screen
Equalization
All dosing systems
Different biological steps
Sludge treatment
Membrane systems: filtration tank, configuration, RAS, sludge g=feed,
aeration capacity, blower sizes, pump sizes, chemical dosing, etc

System Configuration

Step by Step Process Calculations

Step by Step Process Calculations

Process Trends for Different Key Parameters