PSPD

MBBR TECHNOLOGY

ITC Ltd - PSPD, Unit : Bhadrachalam

PSPD Presentation in brief….

Organisation Profile

Introduction

Need for effluent Treatment

Treatment Methods

MBBR Technology

Activated Sludge Process with MBBR Technology in

ITC Ltd-PSPD, Unit : Bhadrachalam – A Case Study
PSPD COMPANY PROFILE
 PSPD, a Division of ITC Ltd, is India’s largest and most technology advanced
Pulp & Paper business

 Capital Investment of US 44 million with a turnover of

Unit Bhadrachalam is India’s largest single location integrated paperboard
company of capacity 4.0 lac TPA Paper and Paper Board & 2.35 lakh TPA
Bleached pulp

 98% self sufficiency in power requirement through co-generation.

 ISO 9001 , ISO 14001 and ISO 18001 are a proof of Quality, Environment,
Health and Safety Systems.

PSPD COMPANY PROFILE

 Leadership in Value added paper & board segments having presence in

Graphics writing printing , Food , Liquid packaging , Pharma and personal care.

 30% Market share – growing to 45% by 2009-10 in paperboards segment

 95% market share in value added paperboards

 90% share of paperboards usage of top 10 FMCG companies in India

 Usage of 90,000 TPA Recycled fiber.

 INTRODUCTION
PSPD NEED FOR EFFLUENT TREATMENT
Forest Industry Effluents Contain:

•Organic matter (BOD, COD, TOC)

• Color

• Toxicity (acute, chronic)

• Suspended material :

The suspended solids contain a large part of the lipophilic, potentially bio
accumulative material and also phosphorus.

INTRODUCTION
PSPD NEED FOR EFFLUENT TREATMENT
Forest Industry Effluents Contain:

•Nutrients (N and P)

Measured as total N and total P

Needed for biological treatment

• Heavy metals

Heavy metals mainly originate from the wooden raw material and are
present in low concentrations in the wastewater
May be accumulated in the bio sludge
PSPD METHODS FOR EFFLUENT TREATMENT

1.Mechanical Treatment - Separation of particles

•Usually treats suspended, rather

than dissolved pollutants by
allowing suspended pollutants to
settle out or float to the top
naturally– depending on
whether they are more or less
dense than water.

PSPD METHODS FOR EFFLUENT TREATMENT

1.Mechanical Treatment - Separation of particles

• Bygently stirring the water to

cause more small particles to
bump into each other and stick
together, forming larger particles
which will settle or rise faster

To aid flotation processes,

dissolved air under pressure may
be added to cause the formation
of tiny bubbles which will attach
to particles.
PSPD 2.Chemical Treatment

•Removal of COD, Metals and Suspended

Solids can effectively be done by chemical
treatment procedures.

• Chemical processes are also used to remove

Ammonia, and other Toxic Pollutants
e.g. cyanides. Organics, pesticides & herbicides

Examples:
• Flocculation of particles, precipitation of
phosphorus and some dissolved material with
alum or other chemicals.

PSPD 3. Biological Treatment

H2O

CO2

Biological treatment processes are based on the activity of microorganisms !!

Transformation of organic material in to carbon dioxide, water and biomass
PSPD AEROBIC BIOLOGICAL TREATMENT

Three basic processes in Biological treatment are

• Aerated lagoons
• Activated sludge
• Biofilm systems
Biofilm Systems or Moving Bed Bio Reactor (MBBR) Systems
What is a Biofilm?
A Biofilm is a community of different microorganisms, and
their extra-cellular products, attached to an “inert” surface.

PSPD

Biofilms can be found on many different surfaces….

•Boat hulls
• Pipes
• Heat exchangers
• Electrodes
• Teeth
• Whitewater system
Often causing problems

Sometimes we want Biofilm…

•Biotechnical processes
• Wastewater treatment processes
PSPD GROWTH ZONE

Anaerobic zone Slow growing microorganisms

Growth zone

H 2S

H 2SO 4

THE MBBR PROCESS

PSPD
Moving Bed Biofilm Reactor

MBBR Technology :
Treatment of effluents with micro organisms developed as
biofilms on biochips in a aeration tank, so as to reduce the
pollutant load (COD/BOD) in a Secondary Treatment process
is called as Moving Bed Biofilm Technology
 THE MBBR PROCESS
PSPD
Moving Bed Biofilm Reactor
Advantages of MBBR
•Robust towards variations and disturbances

•Can be operated at high organic loading rates

•Simple to operate, minimal need for control

•The Process is based on the biofilm principle, and the core

of the process is the biofilm carrier elements made from
polyethylene with a density slightly below that of water

• These are designed to provide a large protected surface for the

Bacteria culture.

PSPD MBBR PRINCIPLE

Due to Providing Large surface area via biochip the micro organisms
will not easily come out from the system and they develop biofilms
on the carrier element/biochip to easily degrade the organic material
and to reduce the pollutants (COD/BOD) load.

The biofilm carrier elements are being kept suspended in the

water by air from the diffusers in the aerobic reactors, and by
means of a Mixer in the reactors.
PSPD TYPES OF BIOMEDIA

BIOMEDIA WITH BIOFILM

PSPD
MBBR TANK
PSPD HELPFUL MICRO ORGANISMS AS BIOFILMS
The most important microorganisms in effluent treatment:
• Bacteria , Archaea , Micro animals & Fungi
BACTERIA
Free living bacteria (dispersed bacteria)
Bacterial flocs

PSPD MICRO ANIMALS

•Necessary for clarification

• Filtrate the water from dispersed bacteria

• More sensitive than bacteria

Eg :

•Protozoa = unicellular animals

• Metazoa = multi-cellular animals

PSPD MICRO ANIMALS

Micro animals - Unicellular Multi-cellular

• Flagellates •Rotifers (Most Important)

• Amoebas • Nematodes
• Ciliates (Most Important) ~10 – 300 µm
 Free-swimming • Water Bears
 Crawling • Worms
 Stalked
 Suctoria

PSPD MICRO ANIMALS - UNICELLULAR

PSPD MICRO ANIMALS - MULTI-CELLULAR

RISK OF UNWANTED ORGANISMS

PSPD FILAMENTANIOUS BACTERIA.
PSPD

How Do We Keep Our Little Friends Happy?

PSPD ENVIRONMENTAL FACTORS AFFECTING TREATMENT

Temperature Oxygen

pH Nutrients

Toxicity Organic Material

PSPD TEMPERATURE

PSPD

Temperature
Bacteria
• Mesophilic optimum 35 – 40 ºC
• Mesophilic range 10 – 45 ºC
Micro animals
< 40 ºC (will die above this temp)

Biological treatment pH

5 < pH > 10
PSPD

Dissolved Oxygen

•≥ 2 mg/l in activated sludge

• 2.5 – 3 mg/l in MBBR

Nutrients
Nitrogen& phosphorus
must be added.
•Urea for N
• Phosphoric Acid for P
• DAP can also be used

PSPD

Nitrogen

•Bacteria can use different types of nitrogen, but ammonia-N is the

simplest.
• Urea must first be hydrolyzed to ammonia before it can be taken
up by the bacteria
• Bacteria contain about 10% N
• Keep the residual available soluble nitrogen in the MBBR tank at 1 – 2 mg/l
PSPD

Phosphorus

• Bacteria prefer phosphate- phosphorus

• Bacteria contain about 1 – 2 % P
• Keep the soluble phosphate- P content in the MBBR tank at 0.5 mg/l

PSPD

Organic Material (COD, BOD) Toxicity

FOOD!

Commonly caused by chemicals

• Surfactants
• Biocides
• Lubricants
Not too much, not too little. • Coloring agents
F/M • other
PSPD

Optimal Growth Conditions

• Organic load ≤ design data, F/M for AS
• Oxygen ≥ 2 – 3 ppm (MBBR)
• NH4-N ≥ 1 ppm
• PO4-P ≥ 0.5 ppm
• pH 6.5 – 8.5
• Temperature ≤ 38 ºC

PSPD CASE STUDY - MBBR Technology at ITC BCM

Treatment Facilities at ITC :

•Mechanical pretreatment – Bar screen and primary clarifier
• Biological treatment – Activated sludge , MBBR
• Post treatment – Clarifier (mechanical)

PROCESS

The Overflow from Primary Clarifier(Colored effluents) is led to

Moving Bed Bio-Reactor to reduce Soluble COD to 60%. The outlet of
MBBR enters into Aeration tank for further reduction of organic matter
and then to Secondary Clarifier for reduction of suspended solids and
other pollutant load.
 Effluent Treatment Plant flow sheet
PSPD
MBBR tank

I/L Sludge Sludge

dewatering
Machine
To Primary Clarifier-I

Treated effluent
B/W

Primary Aeration Tank-II Secondary

Clarifier- I (25 HP Aerators: 12 No’s) Clarifier- II
Pulp
Stream

Sump
U/F U/F
Return Sludge

Back water to
Process

Primary Secondary
Clarifier- II Aeration Tank-I
Clarifier- I
Paper (25 HP Aerators: 12 No’s)
Stream
U/F
Return Sludge

PSPD Process Design at ITC Bhadrachalam

• Number of reactors : 2
• Reactor dimensions: 21.3 m x 21.2 m x 8 m (WxLxH)
• Water depth : 7m
• Reactor volume : 3200 m3 each
• Media type : Biofilm-Chip P
• Amount of media : 320 m3 in each reactor
• Protected area : 900 m2/m3
• Void volume : 80%
MBBR Inlet Conditions
Parameter Unit Design
Flow m3/d 44,000
pH s.u 6-8
Temperature °C Max 40
TSSGF/A mg/l <120
COD mg/l 720
PSPD ACTIVATED SLUDGE PROCESS AT ITC BCM

PSPD MBBR TECHNOLOGY AT ITC BCM

PSPD Soluble COD reduction Trends

PSPD RESULTS

MBBR Final Effluent Discharge

Parameter Unit Inlet Outlet Before MBBR After MBBR

COD mg/lit 1120 672 250 190

% Reduction 40.0 25.0

Achieved COD Reduction by 40% in MBBR Outlet

PSPD

Thank you