Levapor Carriers and their application for wastewater treatment

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LEVAPORporous, adsorbing carrier forbioprocess improvement

Dr. Imre Pascik LEVAPOR GmbHwww. levapor.com Leverkusen, Germany


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About us

Innovative Organization

Fixed Film Based Process Solutions

Complex Effluent, Municipal Wastewater,Polluted Gas

CEO Dr. Imre Pascik

40 years of experience with Bayer AG,Environmental Bio Technology Centre,

Leverkusen


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About us

Development of innovative processes

Two Step nitrification of high Ammonia

containing effluents

Landfill Leachate Treatment

Bayer Tower Biology (Otto Award)

Degradation of toxic effluents usingAnaerobic-Aerobic Processes


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About Us

Biodegradation of pollutants occursvia teamwork of microorganismsunited

in sludge flocs

Important result of research :

Some important, non-flocculatingorganisms will be washed out frombioreactor, resulting reduced plantefficiency

Solution: Biofilm technology

via immobilisation, cell growth on

solid surfaces, carriers made of plastics, sand, glass, etc.

Target: Synthesis of biocarrier


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Our REQUESTS on OPTIMAL CARRIER

PROPERTY EFFECT

1. Adsorbing capacity - binding toxic pollutants

- fast colonization + bio film

- fast start up at high level

2. Porosity, high inner surface - protection of the biofilm

(high biomass content) - high space-time-yields

3. Fast wetting - homogenous fluidisation

4. Water binding - mass transport, bioactivity

5. Proper fluidisation - lower energy consumption


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Our Technology

LEVAPOR Bio Carrier

First synthesized Bio Carrier

Porous, Flexible, Durable PU foamimpregnated with surface active pigments like

activated carbon

Due to variability of foam and pigment typeand their ratios, tailor made carriers can be

produced with varying properties


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Properties

High Adsorbing Surface

15 to 50 kg of activated

carbon per m3 of foam

matrix

PU foam surface area 2500

m2/m3

1000-2000 m2/g surface

area of activated carbon

Extremely high adsorbing

surface

Benefits:

Reversible Adsorption

Rapid microbial colonization

and biofilm formation Temporary adsorption of

toxic and inhibitory

substances

Subsequent biodegradationand thus regeneration of

surface


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Properties

High Internal Porosity Benefits

Discrete microbial colonies

and Biofilm growth inside

pores

Prevention of complete

wash out due to excessive

shear

Establishment of substrate

and DO gradients enabling

anoxic zones

Feast-Famine conditions


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Properties

Hydrophilic Surface

Polyether based hydrophilic

PU foam

Fast Wetting and Waterbinding

Lower colonized weight

100-120 kg/m3

Benefits

Higher microbial affinity and

thus faster colonization

Better mass transfer anddiffusion coefficients

Better fluidization and

lower energy consumption


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Advantages

Treatment of effluents containing toxic substances

Short process start up and higher performance compared to

suspended mass based systems (100 to 300%)

Higher process stability against toxic shock loads andfluctuations in reactor conditions

Lower Degree of Filling (12 to 15%)

Smaller foot print

Lower energy consumption for fluidization

Lower sludge production

Simpler process control


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Lab Trials

Biodegradation of toxic 2-

Chloroaniline (2-CA)

in two parallel discontinuously

operated aerobic lab plants

In the first 2 hours 2-CA became ca.

65% adsorbed, on LEVAPOR , whiletoxicity in the medium dropped .

Biodegradationof 2-CA in LEVAPOR-

reactor started and completed after

240 hours.

Quantity of released Cl

ionsconfirmed a quantitative

degradation.

2-CA in the reactor without LEVAPOR

has not been degraded.0

1

2

3

4

5

6

7

8

9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

conc.(mM)

2-CA-immobil.

0 hr. 240 hr

2-CA susp.org.

Cl-immobil.adsorption onLEVAPOR


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Applications

Up gradation/expansion of existing plants

Anaerobic-Aerobic treatment of high strength , slowly biodegradable pollutants

Nitrification- de nitrification of effluents containing highammonia concentrations

Biological Treatment of Polluted air/gas (BTF)

Biofilm reactor MBBR/IFAS for the treatment of industrialand municipal wastewater

Treatment of hyper saline effluents containing solvents

Treatment of land fill leachate and groundwatercontaining PAHs.


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SAPPI,GERMANY

SAPPI EFFLUENT TREATMENT PLANT:

South Africa Pulp and Paper Industry, Ehingen, Germany

Sulfite based pulp and paper industry

Application of Chlorine for bleaching

High Concentration of toxic, weakly bio degradable

chloro-organic compounds (AOX-90 mg/lit)

Strong Stream : COD 45 t/d @ 10 MLD

Weak Stream : COD 2.45 t/d @ 3.5 MLD


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SAPPI,GERMANY

Lab scale testing Anaerobic or Aerobic?

Aerobic treatment with

suspended bio mass

Only 40-45 % CODelimination

Anaerobic-Aerobic

Treatment ?

Anaerobic reactors usingdifferent bio carriers


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SAPPI,GERMANY

1 :Levapor

2: Activated Carbon

3: Unmodified PU foam

4: Suspended Bio mass


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Impact of Carriers on Methane Production


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SAPPI,GERMANY

Solution :

Anaerobic Treatment Using Levapor Carriers

Reactor Size only 15000 m3 instead of 65000m3 with

suspended bio mass 1500 m3 of Levapor media

66-70% COD removal

Further 50% of COD removal in Aerobic Treatment

50,000 m3 less volume


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SAPPI,GERMANY

Startup: 1990, only 2 of 3 ANA-reactors were started with LEVAPORin order to compare the effect of immobilisation.

After few weeks a toxic shock has stopped the reactor without LEVAPOR

~ 85 % COD- removal , 46 t/d sludge, 14.000 m/d biogas


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SAPPI,GERMANY

0

0,5

1

1,5

2

2,5

3

3,5

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41

susp.biomass

May 90 June 90

immob. biomass

kgCOD/m x day


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Case Studies

City of NINGAN Wastewater treatment Plant

Heilongjiang Province , China

4,40,000 Population Very Cold climate during winter

Difficulty in maintaining nitrification during

winter Stricter Legal discharge limits


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NINGAN,WWTP

Solution :

3200 m3 of aeration tank

volume

480m3 of Levapor Biocarrier

15% Filling

20 X 20 X 7 mm size

20- 22 MLD flow

3.2 -3.8 hours HRT

Started in October 2010


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2013 Performance

Summary

Wider Fluctuations ininlet COD (96 - 670

ppm)

Lower Temperatures

(5.1 - 21 Degree C)Outlet COD (9 - 49.6

mg/lit)

86.3 % Mean COD

reduction( 61.9 -97.4%)285 days COD < 39

mg/lit


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NH4.N /TN Reduction

For 182 days NH4.N

reduction >=80%

Min. NH4.N outlet :0.1

mg/lit


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NINGAN, CHINA

88-90 % COD and 91-93% NH4.N reduction

despite decreasing temperature and shorter

HRTs

Remarkable process stability against temp,

COD, TKN variations

Lower level of nitrate confirming

denitrification

Lower capital and operational cost


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LEVAPOR: IFAS

Single Basin Construction

12 to 15 % Filling

Loading Rates 2.5 to 4

Kg.COD/m3.day

8-10 mm retention screens Lower mixing energy

requirement :

2-3 mg/lit Bulk DO

4-7 Nm3/m2.hr mixing air Up to 35% reactor volume

saving compared to plastic

media


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How Can We Associate

Problem analysis for the treatment of high strength

industrial and municipal wastewater treatment

Define treatment goals and conceptual process

design Development of optimal process and parameters

Manufacturing of high performance tailor made bio

carriers for the application

Process Start up


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Thank You !!!!

Levapor Carriers and their application for wastewater treatment

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