Application of Levapor Carriers for the treatment of Contract Agro Chemicals manufacturer producing a wide Range of Pesticides and Herbicides. The effluent contained very high amount of active pesticides and herbicides with high salinity and TKN. A combination of Advanced Oxidation Process -- Anaerobic Treatment --- Levapor carriers based MBBR/IFAS Reactor provided stable nitrification of toxic effluent generating from Agro Chemicals Industry
1. LEVAPOR â porous, adsorbing carrier for
bioprocess improvement
Dr. Imre Pascik LEVAPOR GmbH
www. levapor.com Leverkusen, Germany
2. 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
3. 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 using
Anaerobic-Aerobic Processes
4. 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 design
parameters with pilot tests
⢠Manufacturing of high performance tailor made bio
carriers for the application
⢠Process Start up
5. 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
6. Bio Film Technology
⢠Biodegradation of pollutants occurs
via teamwork of microorganisms
united
in sludge flocs
⢠Important result of research :
⢠Some important, non-flocculating
organisms will be washed out from
bioreactor, resulting reduced plant
efficiency
⢠Solution: Biofilm technology
⢠via immobilisation, cell growth on
⢠solid surfaces, âcarriersâ made of
⢠plastics, sand, glass, etc.
⢠Target: Synthesis of biocarrier
7. 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
8. Our Technology
⢠LEVAPOR Bio Carrier
⢠First synthesized Bio Carrier
⢠Porous, Flexible, Durable PU foam
impregnated with surface active pigments like
activated carbon
⢠Due to variability of foam and pigment type
and their ratios, tailor made carriers can be
produced with varying properties
10. Properties
High Adsorbing Surface
⢠10 to 12 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 biodegradation
and thus regeneration of
surface
11. 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 and
fluctuations in reactor conditions
⢠Lower Degree of Filling (12 to 15%)
⢠Smaller foot print
⢠Lower energy consumption for fluidization
⢠Lower sludge production
⢠Simpler process control
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. Agro Chemicals, Middle East
⢠Pesticides Manufacturing Agrochemicals industries
⢠A Wide variety of agro chemicals manufactured at site due
to hectic crop cycle
⢠Effluents Containing :
⢠Biologically active biocides and often inhibiting raw
chemicals , active ingredients and their by products
⢠Solvents like methanol, aromates, dicholoromethane,
methyl-isobutyl-ketone(MIBK) from the formulations
⢠Higher Salinity
14. A typical Effluent Characteristics
⢠Up to 12,000 mg/lit COD comprising solvents in it
⢠Up to 600 mg/lit inhibitory , active ingredients and their by
products
⢠500 to 800 mg/lit Total Kjehldahl Nitrogen (TKN) containing
mostly Organic-N associated with slowly hydrolysable s-
triazine.
⢠Up to 1500 mg/lit Sulfates (SO4-)
⢠10,000 to 25,000 mg/lit Salt Concentration as NaCl
15. The Problem
⢠Adversely affect the environment
⢠Presence of high amount of biodegradable solvents make wet
oxidation processes costly and thus biological degradation
would be cost effective alternative
⢠Higher concentrations of inhibitory substances lower the COD
removal efficiency of suspended growth only reactors
⢠COD removal also affected due to high fluctuations of load
⢠Severe nitrification inhibition due to fluctuating COD removal
efficiency
⢠Aerobic only treatment increases aeration costs and also
handling of high amount of toxic sludge
16. The solution
⢠MicroAerobic-Anaerobic-Aerobic
⢠Provides most diverse microbial consortia responsible for
the biodegradation of complex molecular structures.
⢠During Anaerobic Step the complex molecules are
hydrolysed
⢠Much of the COD removed , thus reduce aeration demand
⢠Lower sludge production and thus solids handling costs.
⢠Presence of inhibitory substances, pH changes, salinity
fluctuations cause deflocculation and wash out of microbes
⢠Thus, immobilization of microbes on carriers
17. Pilot Testing
⢠Proposed Micro Aerobic-Anaerobic-Aerobic
Scheme with denitrification
⢠Tested for two years at site
â˘
24. LEVAPOR: IFAS
⢠Single Basin Construction
⢠12 to 15 % Filling
⢠Loading Rates 2.5 to 4
Kg.COD/m3.day
⢠6 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
25. 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