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.

PSPD NEED FOR EFFLUENT TREATMENT

•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

Forest Industry Effluents Contain:

PSPD NEED FOR EFFLUENT TREATMENT

•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

Forest Industry Effluents Contain:

INTRODUCTION

PSPD

1.Mechanical Treatment - Separation of particles

METHODS FOR EFFLUENT TREATMENT

•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

1.Mechanical Treatment - Separation of particles

METHODS FOR EFFLUENT TREATMENT

• By gently 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

Biological treatment processes are based on the activity of microorganisms !!Transformation of organic material in to carbon dioxide, water and biomass

H2O

CO2

PSPD AEROBIC BIOLOGICAL TREATMENT

Three basic processes in Biological treatment are

• Aerated lagoons

• Activated sludge

• Biofilm systems

What is a Biofilm?

A Biofilm is a community of different microorganisms, and

their extra-cellular products, attached to an “inert” surface.

Biofilm Systems or Moving Bed Bio Reactor (MBBR) Systems

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

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H SO 2 4

H S 2

Growth zone

Anaerobic zone Slow growing microorganisms

GROWTH ZONE

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THE MBBR PROCESS

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

PSPD

•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.

Advantages of MBBR

THE MBBR PROCESS

Moving Bed Biofilm Reactor

PSPD

� 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.

MBBR PRINCIPLE

PSPD TYPES OF BIOMEDIA

BIOMEDIA WITH BIOFILM

PSPDMBBR TANK

PSPD

The most important microorganisms in effluent treatment:

• Bacteria , Archaea , Micro animals & Fungi

Free living bacteria (dispersed bacteria) Bacterial flocs

BACTERIA

HELPFUL MICRO ORGANISMS AS BIOFILMS

PSPD

•Necessary for clarification

• Filtrate the water from dispersed bacteria

•More sensitive than bacteria

MICRO ANIMALS

Eg :

•Protozoa = unicellular animals

•Metazoa = multi-cellular animals

PSPD MICRO ANIMALS

• Flagellates• Amoebas

• Ciliates (Most Important) ~10 – 300 µm

� Free-swimming

� Crawling

� Stalked

� Suctoria

Micro animals - Unicellular Multi-cellular

•Rotifers (Most Important)

• Nematodes

• Water Bears

• Worms

PSPD MICRO ANIMALS - UNICELLULAR

PSPD MICRO ANIMALS - MULTI-CELLULAR

PSPD

RISK OF UNWANTED ORGANISMS

FILAMENTANIOUS BACTERIA.

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How Do We Keep Our Little Friends Happy?

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Temperature

pH

Toxicity

Oxygen

Nutrients

Organic Material

ENVIRONMENTAL FACTORS AFFECTING TREATMENT

PSPD TEMPERATURE

PSPD

Bacteria

• Mesophilic optimum 35 – 40 ºC

• Mesophilic range 10 – 45 ºC

Micro animals

< 40 ºC (will die above this temp)

Temperature

Biological treatment pH

5 < pH > 10

PSPD

•≥ 2 mg/l in activated sludge

• 2.5 – 3 mg/l in MBBR

Dissolved Oxygen

Nitrogen& phosphorus

must be added.

•Urea for N

• Phosphoric Acid for P

• DAP can also be used

Nutrients

PSPD

•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

Nitrogen

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• 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

Phosphorus

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Organic Material (COD, BOD)

FOOD!

Not too much, not too little.

F/M

Toxicity

Commonly caused by chemicals

• Surfactants

• Biocides

• Lubricants

• Coloring agents

• other

PSPD

• 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

Optimal Growth Conditions

•

PSPD

Treatment Facilities at ITC :

•Mechanical pretreatment – Bar screen and primary clarifier

• Biological treatment – Activated sludge , MBBR

• Post treatment – Clarifier (mechanical)

CASE STUDY - MBBR Technology at ITC BCM

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.

PROCESS

PSPD

Primary

Clarifier- I

Primary

Clarifier- II

Secondary

Clarifier- II

Secondary

Clarifier- I

Sludge

dewatering

Machine

Aeration Tank-II

(25 HP Aerators: 12 No’s)

Aeration Tank-I

(25 HP Aerators: 12 No’s)

Sump

Treat ed effl u

ent

Sludge

Return Sludge

Return Sludge

U/F U/F

U/F

Effluent Treatment Plant flow sheet

To Primary Clarifier-I

B/W

Back water to

Process

Paper

Stream

Pulp

Stream

MBBR tank

I/L

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 : 7 m

• 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%

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

MBBR Inlet Conditions

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