High Performance Bio Carrier For the Treatment of High Strength Industrial And Municipal Effluents

2. About us
• We are Levapor Biofilm Technologies and Bio
Consulting , GmbH.
• A specialized company providing innovative
solutions for the treatment of wastewater and
polluted air
• A team with more than 40 years of experience
in research and development of fixed film
based technologies for industrial and difficult
to treat wastewater and polluted air

3. What We do
• 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

4. Our Specialization
• Anaerobic pre treatment of complex, persistent
industrial wastewater
• Nitrification – De nitrification of effluents containing
inhibitory substances
• Biological waste gas treatment using BTF(Bio
Trickling Filters)
• Biofilm Reactor IFAS/MBBR for industrial and
municipal wastewater
• Production and delivery of High Performance Bio
Carriers

5. Our Achievements
• First full scale nitrification/denitrification plant for
ammonia rich effluents (1978)
• Development of high performance bio carriers (1983)
• Degradation of toxic effluents by anaerobic bio film
technologies (1985)
• Design of full scale process for the anaerobic-aerobic
degradation of toxic effluents (1998)
• Indoor bio treatment of polluted air for a ware house
of waste plastic (2002)

6. Industries We serve
• Chemicals and Pharmaceuticals
• Petrochemicals and Refineries
• Pulp and Paper
• Coal Conversion : coke plant, coal gasification,
pyrolysis
• Textile finishing and Leather manufacturers
• Municipal Wastewater Treatment
• Special effluents like land fill leachate and sludge
processing unit

7. Our Clientele
• SAPPI , Germany : 20 MLD anaerobic-aerobic treatment
plant for treatment of high strength pulp and paper mill
effluent
• City of Ningan, China : 22 MLD Municipal wastewater
treatment plant for COD removal and nitrification
• City of Helsinki : Upgradation of existing municipal
wastewater treatment plant
• Ludan Engineering, Middle East : Bio treatment of fine
chemicals wastewater
• KERRY Intra, India : Bio treatment of container wash
water

8. Our Technology
• LEVAPOR Bio Carrier
• First synthesized Bio Carrier
• Porous, Flexible, Durable PU foam
impregnated with surface active pigments
with high surface area
• Due to variability of foam and pigment type
and their ratios, tailor made carriers can be
produced with varying properties

9. Our Technology

10. Unique Properties
PROPERTIES
• High Adsorbing Surface
• High Porosity
• Fast wetting and water
binding
• High surface Area
• Higher fluidization ability
ATTRIBUTES
• Adsorption of inhibitory
substances and fast colonization
• Protection of biomass against
shear, anoxic zone formation
• Homogenization of media and
maintenance of bio activity
• Lower Degree of Filling (12-
15%)
• Less Power consumption

11. Advantages
• Reversible adsorption of inhibitory substances and
slowly bio degradable pollutants
• Short process start up and higher performance
compared to suspended mass based systems (100 to
300%)
• Colonization of carrier by more active bio mass and
simultaneous nitrification-de nitrification
• Higher process stability and lower sludge yield
• Lower degree of filling (12 to 15% compared to 40-65%
for plastic based media)
• Remarkable lower power consumption compared to
conventional MBBRs

12. Applications
• Up gradation/expansion of existing plants
• Anaerobic-Aerobic treatment of high strength , slowly
bio degradable pollutants
• Nitrification- de nitrification of effluents containing high
ammonia concentrations
• Biological Treatment of Polluted air/gas (BTF)
• Biofilm reactor MBBR/IFAS for the treatment of
industrial and municipal wastewater
• Treatment of hyper saline effluents containing solvents
• Treatment of land fill leachate and groundwater
containing PAHs.

13. 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

14. NINGAN,WWTP
• Solution :
• 3200 m3 of aeration tank
volume
• 480m3 of Levapor Bio
carrier
• 15% Filling
• 20 X 20 X 7 mm size

15. NINGAN, WWTP
• Legend Dimension Value
Volume of Reactor M3 3200 (4 X 800)
Volume of Levapor M3 480m3
HRT Hours 3.5-3.8
2012 October Nov. Dec.
COD in Mg/lit 294 295 302
COD out Mg/lit 33.7 35.8 37.7
BOD out Mg/lit 11.9 11.9 12.9
TKN in Mg/lit 28.8 35.5 23.2
NH4.N out Mg/lit 2.0 3.3 3.34
NO3.N out Mg/lit 12.5 14.8 11
Temperature Degree C 15.6 13.3 9.6

16. NINGAN ,WWTP

17. NINGAN,WWTP

18. NINGAN,WWTP
• Benefits:
• 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

19. 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
• Strong Stream : COD 45 t/d @ 10 MLD
• Weak Stream : COD 2.45 t/d @ 3.5 MLD

20. SAPPI,GERMANY
Lab scale testing Anaerobic or Aerobic?
• Aerobic treatment with
suspended bio mass
• Only 40-45 % COD
elimination
• Anaerobic-Aerobic
Treatment ?
• Anaerobic reactors using
different bio carriers

21. SAPPI,GERMANY
• 1 :Levapor
• 2: Activated Carbon
• 3: Unmodified PU foam
• 4: Suspended Bio mass

22. 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

23. SAPPI,GERMANY
Startup: 1990, only 2 of 3 ANA-reactors were started with LEVAPOR
in order to compare the effect of immobilisation.
After few weeks a toxic shock has stopped the reactor without
LEVAPOR
Nowadays: ~ 85 % COD- removal , 4 – 6 t/d sludge, 14.000 m³/d biogas

24. 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/m³ x day

25. Thank You!!!!