SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

SBR/MBR Comparison

Project Ref: Client :

****** ******

ITT Project No. xxxxxxxx Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

Table of Contents

1 2

Introduction to the ICEAS SBR process.................................................................. 1 The ICEAS process................................................................................................. 2 2.1 History of ABJ and ICEAS process................................................................. 2 2.2 The ICEAS Process........................................................................................... 2 2.3 ICEAS Benefits................................................................................................. 7 ICEAS Comparison with MBR................................................................................ 10 3.1 History of MBR............................................................................................... 10 3.2 What is an MBR ............................................................................................. 10 3.3 Performance .................................................................................................. 10 3.4 Footprint ........................................................................................................ 11 3.5 Operability ..................................................................................................... 11 3.6 Cost ................................................................................................................ 12 3.7 MBR Application ............................................................................................ 13 3.8 ICEAS SBR suitability .................................................................................... 13

ITT Project No. xxxxxxxx Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

Introduction to the ICEAS SBR process

The unit processes of the Sequence Batch Reactor (SBR) and conventional activated sludge systems are the same. In a conventional activated sludge system, equalization, biological treatment, and secondary clarification would be accomplished by using separate tanks. The difference between the two technologies is that the SBR performs these unit processes in single tank using a time control sequence, meaning the overall footprint of the plant is significantly smaller thereby reducing construction costs. The ICEAS (Intermittent Cycle Extended Aeration Cycle) process is a variant of an SBR (sequential batch reactor) system that allows the process to take place in a single basin, whilst constantly filling. This process is a fully automatic system that responds to flow and load variations, is easily expanded and produces a high quality effluent. Notably ICEAS requires less land area and equipment than a conventional Activated Sludge plant and therefore lower operating and construction costs. In sensitive locations, the ICEAS tanks can be designed to be covered, thereby reducing the environmental impact and minimising noise and odour pollution. The ICEAS is more cost effective and can produce an equal or better quality of effluent than conventional activated sludge systems used for treating municipal wastewater (dependant on the incoming effluent parameters the process can also be used on industrial wastewater). In this compact system, flow equalisation, biological oxidation, secondary sedimentation, and biological nutrient removal occur in a single basin, significantly reducing capital costs. Inherently low energy requirements and O & M costs make the ICEAS economical to operate. Normal operation provides nitrification/denitrification without costly chemicals and additional equipment. Similarly, efficient phosphorus removal is consistently achieved with the ICEAS process option. The ITT W&WW ICEAS system are as of today (2008) successfully treating wastewater in over 350 operating plants worldwide, with loads ranging from a few hundred population equivalent over 1,000,000 population equivalent including projects such as Doha South in Qatar and the newly won ASeeb project in Oman.

ITT Project No. *******

1
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

2 2.1

The ICEAS process History of ABJ and ICEAS process

Since the end of the 19th Century, considerable research and development in the wastewater treatment industry has occurred worldwide. During this period, many activated sludge processes were developed and marketed in a variety of configurations. In the 1970s considerable activity was generated in Australia related to sequencing batch reactor (SBR) processes. Most of the work was completed in small plants and with relative anonymity outside of Australia. The patented Intermittent Cycle Extended Aeration System (ICEAS) was developed in Australia during the 1970s. Since Australia had traditionally been short of local capital, any innovative wastewater treatment system had to be economical as well as effective. In addition, since many plants would go unattended for extended periods of time, the system had to be selfcontrolled, especially in responding to load variations. Since smaller towns would eventually expand, the wastewater treatment system had to be flexible to grow with the city. ABJ, then known as Austgen-Biojet, rose to these unique challenges by developing the ICEAS process. It was fully automatic, operationally simple system that responded to load variations, could be expanded easily and provided a high quality effluent through the processes of biological oxidation, nitrification-denitrification, phosphorous uptake, and liquid-solids separation. 2.2 The ICEAS Process

The ICEAS is a hybrid of the fill and draw activated sludge vessels. Each cycle consists of three basic periodic processes: an aeration period, a settling period and an effluent drawing (decanting) period. The operation of the process is time controlled automatically through a microprocessor. Raw wastewater is continuously fed into the reactor regardless of which periodic process is in operation - aeration, settling, or decanting. Wastewater continuously flows into the prereact chamber where most of the soluble BOD5 is absorbed in the biomass. The prereact chamber acts as an organic selector, increasing the efficiency of the system, helping prevent the development of filamentous organisms. The partially treated waste then flows under the prereact baffle to the main react chamber. The prereact baffle wall also prevents short-circuiting from occurring during the decant phase. The tank serves as an equalisation basin during the fill period and therefore can tolerate greater peak flows and/or shock loads of Biological Oxygen Demand without degradation of the effluent quality.
ITT Project No. *******

2
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

Figure 1 ICEAS Tank Layout

Screened Influent Baffle Wall Decanter

Pre-react Chamber

Main Chamber

Diffusers

AERATION REACT Raw wastewater from screening and grit removal flows into the basin and mixes with the mixed liquor. The basin is aerated while filling and biological oxidation takes place simultaneously. The aeration system of choice for municipal projects is fine bubble diffused air due to its oxygen transfer and operational efficiency. Figure 2 ICEAS aeration phase

ITT Project No. *******

3
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

During the aeration period, sufficient oxygen is provided to obtain full nitrification when required. The aeration blowers are normally operated continuously in two tank ICEAS plants unless special nitrogen and phosphorous removal requirements are required. In each pairs of basins, the two basins operate completely out of phase with each other at all times. One basin is aerating while the other basin is in an anoxic settling phase. In a four basin operation the two pairs are staggered by one quarter of a cycle. In this operation effluent decanting periods will be near continuous with few non-decanting periods. In the storm operation, the cycles are reduced to increase the hydraulic through put of the ICEAS, while still maintaining the overall aeration period. ANOXIC REACT Denitrification of the effluent occurs naturally in the settling and decant phases. Since denitrification occurs on a regular basis the level of nitrate in the system is low and rising sludge is not a problem. However, the settle and decant modes may not provide sufficient anoxic periods to provide the required level of denitrification and nitrogen removal for tight consent requirements. In such cases, an anoxic period can be added to the react period as shown in Figure 3. If anoxic react periods are required, mixers must be added to the tank to provide contact between the nitrate and the bacteria. Figure 3 Anoxic operation

SETTLE At the end of the react phase, aeration is stopped and the solids settle to the bottom of the basin leaving clear water on top. The settling period allows solids separation to occur providing a clarified supernatant to be discharged as an effluent. The settling process may vary from twenty (20) to sixty (60) minutes so that the sludge blanket remains below the basin bottom water level during the draw or decant period.
ITT Project No. *******

4
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

Figure 4

Settlement phase

The basin continuously receives the influent, even during the settle phase, but the prereact zone filters the incoming sewage through the sludge blanket at the far end from the decanters. This improves biological take-up of the BOD and minimises disturbance to the sludge blanket. DECANT At the end of the settle phase, the decanter arm is driven through the treated effluent to the bottom water level. The clear water is discharged from the top of the basin, while the basin continuously receives the influent. Typically, sludge is wasted during this phase of the cycle. Figure 5 Decant Phase

ITT Project No. *******

5
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

Decant: Influent is received continuously during all phases of the cycle, including settle and decant. This allows the ICEAS process to be controlled on a time, rather than flow basis and ensures equal loading and flow to all basins. Use of a time-based control system in the ABJ ICEAS process facilitates simple changes to the process control program. The duration of each cycle and segment of each operating cycle are the same among all basins in a time-based system. Therefore, changes to the process are made simply by changing the duration of individual segments. Single basin operation is also possible in the ICEAS process. The process does not require automatic influent control valves or an additional basin to hold diverted flow. This eliminates the need for designated fill and idle phases resulting in smaller basins. Sludge wasting is determined by performance requirements. Sludge can be withdrawn at any time during a normal cycle to control the sludge volume and the sludge age. Return activated sludge pumping is not required as the mixed liquor is retained in the basin.

The decanter as shown in Figure 6 consists of a trough with multiple down comers connecting to a cross header. A float or baffle prevents surface scum from being entrained in the continuous discharge. The discharge rate is controlled as required. This decanter design probably is the most successful device currently in operation. Figure 6: Picture of a large Decanter

ITT Project No. *******

6
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

The decanting period may vary from 15 minutes to one hour. A surface-skimming decanter designed to prevent floating material from being entrained in the discharge removes effluent. STORM FLOWS Hydraulically stable, even a single tank ICEAS system is capable of accommodating flow variations of up to 7 times average dry weather flow (ADWF). To accommodate storm flow, a storm cycle sequence is activated when it is predicted that the liquid level will rise in excess of the top water level (TWL). A float switch triggers a sequence of abbreviated process times of aeration, settlement and effluent decanting during the storm flows. The system will then automatically revert to the original treatment sequence once flows have reduced. 2.3 ICEAS Benefits

The USEPA undertook an analysis of the ICEAS system in 1999 1. Advantages of a SBR wastewater treatment system they found were as follows: Minimal footprint Equalization, primary clarification (in most cases), biological treatment, and secondary clarification can be achieved in a single reactor vessel Operating flexibility and control Potential capital cost saving by eliminating clarifiers and other equipment

ITT believe this difference in system configuration gives the SBR system several advantages over the conventional activated sludge process including: Lower Capital Cost: Requires smaller footprint No primary or secondary clarifiers and accompanying pumping systems are needed Simpler and faster installation Lower construction costs Enhanced Biological Performance: Low sludge volume Enhanced nutrient removal Quick response to changing influent conditions No washout of activated sludge during peak storm flows Lower Operating Cost: Reduced power
ITT Project No. *******

7
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

Design

Reduced maintenance Nutrient removal without costly chemicals Flexibility: Easily expandable Hydraulic peaks easily accommodated Handles shock loads without degradation of final effluent quality Control system provides high flexibility

Some of the principal features and significant benefits of ICEAS are:

2.3.1

Simplicity of Operation

ICEAS cycles are timed based, rather than level based. The operator can modify the control system simply by entering process event timings through the Display Screen Controls. Level controlled processes often require more complicated control program revisions to adapt to changing process conditions. Air output is easily adjusted through blower run timers in the PLC controls for optimum basin Dissolved Oxygen (D.O.) levels. 2.3.2 Simplified Installation

In the simplest installations the fixed floor grid, membrane disc fine bubble or coarse bubble aeration system eliminates the need for any mechanical mixers and hoists, jet aspirators and motive pumps or retrievable diffuser frames. The small sludge pumps in each basin discharge directly to a sludge tank without the need for sludge recirculation piping, dry pit pumps and associated galleries. 2.3.3 Sludge Stability

The ICEAS process dispenses with return sludge recirculation lines and controls. Research conducted at ABJs pilot plant, and previous experience at operational plants has confirmed that sludge recirculation to bio sorption and/or pre-react zones do little to enhance treatment. Published data gathered over the last eight years from large operational ABJ treatment plants without sludge return provide evidence of the efficacy of the ICEAS process, even when located in severe winter locations such as the mountains of the Northeast U.S.A or the northern plains of the Midwest U.S.A. The sludge generated by the ICEAS process is well stabilised, since the process operates in an extended aeration mode with a high solids retention time, normally over 12 days. The biomass experiences anoxic and anaerobic conditions during the settle and decant phases of each operating cycle, using the continuous influent as a carbon source for NO3 ITT Project No. *******

8
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

conversion. Sludge stability in the ABJ basins is also enhanced as a result of the repeated aerated/non-aerated condition of the sludge. 2.3.4 Nutrient Removal

The ICEAS process has been refined over the years to meet increasingly stringent effluent quality standards for nutrient removal. The alternating aerobic and anoxic conditions during aeration and settling/decanting periods of each operating cycle encourage nitrification and denitrification. A phosphate removal option called ICEAS DNP is available. Several papers regarding treatment obtained at operating plants have been published. 2.3.5 Expansion Potential

The ICEAS process design lends itself to simplified expansion since each basin forms a modular treatment unit. Continuous influent allows additional flows to be distributed to all basins simultaneously. No motorised influent valves or piping, level controls or modified process controls are required. The standard ABJ 4-hour process cycle is designed for operating up to four basins without overlapping aeration periods, while using two duty blowers to supply both pairs of basins. Doubling the system capacity would only require the addition of four basins with fixtures (decanters, air control valves, aeration system, and sludge pumps), additional blowers and an expanded control system.

ITT Project No. *******

9
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

3 3.1

ICEAS Comparison with MBR History of MBR

MBR, in comparison with SBR is a new technology and is still very much in the development and optimisation phase. ITT has constructed/is constructing a number of MBR wastewater treatment plants on municipal and industrial waste. MBR was developed initially in Japan where many small installations have been made over the last 20 years mainly using plate and frame module construction. During the last decade hollow fibre immersed membranes have become prevalent and larger installations have been built using this geometry. In recent years pressurised or side stream tubular MBR has been successful and is offering an external alternative to the immersed membrane technology. MBR is under constant development with new technologies and geometries are being developed and tested all the time. The main difference between MBR and SBR in the development cycle is that SBR is in the system optimisation phase, whereas MBR is in the much earlier membrane development phase. 3.2 What is an MBR An MBR is an activated sludge system that utilises suspended growth bacteria to remove pollutants from a waste stream. In this sense it is exactly the same as an ICEAS SBR. The difference is the means of separating the bacteria from the cleaned effluent. An ICEAS SBR uses gravity to separate the solids from the cleaned effluent but an MBR uses membrane filters to separate the solids. A comparison of the two technologies is detailed below 3.3 Performance MBR An MBR will produce exceptional quality. effluent of ICEAS SBR An ICEAS SBR will produce effluent of very good quality. The plant will usually produce an average effluent of 10:10:1 BOD:SS:NH4, suitable for discharge to a long sea outfall or irrigation without further treatment, though residual disinfection may be required. The low turbidity of the SBR effluent makes it ideal for disinfection by UV

The plant will usually produce an average effluent of 5:5:1 BOD:SS:NH4, suitable for discharge to a long sea outfall or irrigation without further treatment, though residual disinfection may be required.

ITT Project No. *******

10
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

3.4 Footprint MBR The MBR basin has an aeration zone and membrane zone. These combined have a very low foot print. The MBR will also need blower and administration buildings. The MBR will need inlet works with fine (6mm perforated) and very fine (13mm perforated) screens grit removal and fat oil and grease removal. The MBR will need sludge storage. The works will require storm tanks.

ICEAS SBR The ICEAS SBR basin combines the aeration zone and settlement zones. These combined have a low foot print The ICEAS SBR will also need blower and administration buildings, The ICEAS SBR will need inlet works with fine (6mm perforated) screens only and grit removal.

The ICEAS SBR will need sludge storage. The works will require storm tanks.

The footprints of the two plants will be similar once all the ancillary units and equipment is added to the site. 3.5 MBR The MBR is a highly sophisticated system with significant process monitoring and control systems. The MBR system requires regular maintenance of the fine screens and grit removal to ensure protection of the delicate membranes. Operability the membranes require lifting out and chemical cleaning. See Figure 7. ICEAS SBR The ICEAS SBR is a time controlled system and requires minimal monitoring and control systems. The 6mm screens are standard waste water industry equipment. The ICEAS SBR can cope with high levels of grit, screenings and fats without affecting the process in the short to medium term.

The MBR has pressure monitoring on all units and regular backwashing of the membrane modules. The MBR membranes will slowly block until normal backwashing no longer provides sufficient cleaning. At his point

ITT Project No. *******

11
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

Figure 7: Hollow Fibre Immersed MBR Membranes being removed for cleaning.

3.6 Cost MBR MBRs are a high tech solution sized on the flow restrictions membrane units. They are utilised in low flow applications the high cost of the membranes. that is of the usually due to

ICEAS SBR The ICEAS SBR has no high cost membranes.

The very high solids design of the MBR basin means aeration efficiency is inefficient and so expensive to operate. The high cost hollow fibre membranes require replacing approximately every 7 years.
ITT Project No. *******

The solids concentration is standard for activated sludge processes.

There are no high cost hollow fibre membrane replacement costs.

12
Issue No.1

SBR/MBR Comparison

ITT Water & Wastewater

Project name: Date: General 20/10/08

3.7

MBR Application

With higher capital and operating costs, more complex operation and the overriding risk of managing the membrane condition and operating life, one would only select MBR where there is a specific need that cannot be achieved by other technology. The greatest use of such MBR technology is where the effluent is required to be treated to a higher standard for reuse as water for further processing for potable consumption; or to satisfy the needs of a sensitive discharge point. 3.8 ICEAS SBR suitability

The MBR produces an extremely high quality effluent, far better than that usually required for discharge to a long sea outfall or irrigation needs. It is very low foot print, but this is achieved by a highly increased technological complexity, capital and operating cost. The SBR produces a good quality effluent suitable for discharge to a long sea outfall and used for irrigation system (though may require some disinfection). Primarily, it is a simple robust, proven technology with low footprint.

ITT Project No. *******

13
Issue No.1

Aerobic Digesters

ITT Water & Wastewater

Project name: Date: Sulaibiya WwTW June 6th 2008

References 1. USEPA Wastewater (1999) Technology Fact Sheet, Sequencing Batch Reactor, EPA 832-F-99-073

ITT Project No. *******

15
Issue No.1