levapor carriers presentation
DESCRIPTION
High Performance, flexible, durable Levapor Carriers made of PU foam impregnated with activated carbon for wastewater treatmentTRANSCRIPT
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LEVAPOR – porous, adsorbing carrier for bioprocess improvement
Dr. Imre Pascik LEVAPOR GmbHwww. levapor.com Leverkusen, Germany
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Wastewater treat.plant„Bayer Tower Biology“ Start: 1980 Reactors: 4x16.000 m³
LEVAPOR biocarrier and several other wastewater treatment technologies Dr.Pascik has developed and applied in the Environmental Biotechnology Center of BAYER AG in Leverkusen, Germany.
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Nitrosomonas europaea
Important result of research work :Some important, non-flocculating organisms will be washed out from bioreactor, resulting reduced plant efficiencySolution: Biofilm technologyvia immobilisation, cell growth onsolid surfaces, “carriers“ made ofplastics, sand, glass, etc.
Target: Synthesis of biocarrier
Biodegradation of pollutants occurs via teamwork of microorganisms unitedin sludge flocs
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Our REQUESTS on OPTIMAL CARRIER
PROPERTY EFFECT 1. Adsorbing capacity - binding toxic pollutants
- fast colonisation+biofilm - fast startup at high level
2. Porosity, high inner surface - protection of the biofilm (high biomass content) - high space-time-yields
3. Fast wetting - homogene fluidisation
4. Water binding - mass transport, bioactivity
5. Proper fluidisation - lower energy consumption
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LEVAPOR, adsorbing, porous biocarrier have been designed on basis of above mentioned requirements
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Specialty: high content of powdered activated carbon resulting other effects than simple cell adhesion : Adsorption of inhibitorslower toxicity in bioreactor fast bioprocess start stable process
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Fast colonisation fast biofilm generation fast and stable bioprocess
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Confirmation test – 1 (next diagram) :
Biodegradation of toxic 2-Chloroaniline (2-CA)
in two parallel discontinuously operated aerobic lab plants
shows excellent the mechanisms of processes:
1. In the first 2 hours 2-CA became ca. 65% adsorbed, on LEVAPOR , while toxicity in the medium dropped .
2. Biodegradation of 2-CA in LEVAPOR-reactor started and became completed after 240 hours.
3. Quantity of released Cl– ions confirmed a quantitative degradation.4. 2-CA in the reactor without LEVAPOR has not been
degraded.
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Biodegradation of 2-CA with immobilised vs. suspended bacteria ( Univ. of VIENNA)
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Confirmation test -2
Degradation of 2-Chlorobenzoic acid under anaerobic conditions
in parallel discontinuously operated anaerobic lab plants confirmed the same mechanisms .
1. In the LEVAPOR-plant 2-CBA became adsorbed, biofilm generation and degradation started fast (CH4-production)
2. Biodegradation of 2-CA in LEVAPOR-reactor started and became completed after 240 hours.
3. Quantity of released Cl– ions confirmed a quantitative degradation.
4. 2-CA in the reactor without LEVAPOR has not been degraded.
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Anaerobic test for carrier screening (Prof. H.SAHM, DUS.)
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Application: 12 to 15 vol.% of 20*20*7 mm „cubes“ in a fluidised bed reactor
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LEVAPOR in a fluidised bed biofilm reactor: „ MBBR“ a) screen for carrier retention b) adequate aeration
Primary settler Aerated basin + carrier Clarifyer
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The first application in the practice was in a pulp mill withtoxic effluents from pulp bleaching:
Q = 10.000 m³/d COD = 3.500-4.000 mg/L AOX~ 90 mg/L
Lab tests :Aerobic degradation achieved 35 to 40% COD-removal.
Anaerobic tests with LEVAPOR = 65 - 75 % COD-removal + Aerobic post treatment removed 50 % of residual COD.
ANA/AER-pilot tests:using LEVAPOR,size of ANA-reactors was reduced by 75 %! 15.000 m³ instead of 65.000 m³ ! Startup: 1990, only 2 of 3 ANA-reactors were with LEVAPOR
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Effect of carrier types on COD-elimination under anaerobic biotreatment of toxic pulp mill effluents in lab scale plants
LEVAPOR
gran.activ. carbon
unmodified PUR-foam
suspended anaerobic sludge
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Plant for anaerobic-aerobic treatment of toxic pulp mill effluents by LEVAPOR-supported microorganisms
EQUALISATION
ANAEROB. REACTORS
AEROBICREACTORS
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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
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0
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susp.biomass
May 90 June 90
immob. biomasskgCOD/m³ x day
Comparison of biofilm reactors versus suspended biomass
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LEVAPOR- case history No. 2
Upgrading of an existing municipal plant for
nitrification in Espoo + Helsinki Problem: Nitrification in existing plants, designed for BOD-removal is not efficient in winter months. Standard proposal: doubling of reactor
volume.
Our idea: upgrading of the existing plant by fixing nitrifying biomass on LEVAPOR carrier !
Field-test: 12 vol.% LEVAPOR carrier cubes were added into the aerated basin !
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N (mg/L) TKNZul
NO3NAbl
NH4NAbl
07.11 02.0502.02
N-concentrations after addition of LEVAPOR at 10 to17°C After 3-4 weeks a stable nitrification has been establihed !
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N (mg/L)
TKNZul.
NH4NAbl.
days
NO3NAbl.
Pre-denitrification resulted in lower outlet-NO3N concentrations
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A usual aeration intensity achieves a nearby quantitative fluidisation
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Addition of 12 vol.% LEVAPOR carrier into aerated basin of existing municipal plant in
resulted in
efficient nitrification within 3 weeks, remaining stable over years !
Benefits for customers :
• 75,- 105 €/m³ costs instead of ~ 250- 350,- €/m³ for new reactor volume (savings: 175 - 275,- €/m³ !).
• ca. 15- 25 % less excess sludge.
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Legend Dimension NINGAN WWTP
Values (Aug. 2011)Water flow m³/day 22.000
Volume of reactors m³ 3200 (4 x 800)
Volume LEVAPOR m³ 500 (15,6 %)
Hydraulic ret. time h 3,5
Lv, COD kg/m³xday 2,2
Results 2011 in out % removal
COD mg/L 320 20-25 92 – 94
BOD5 mg/L 158 5 97
NH4N mg/L 24 2 - 3 88 - 92