Dr. Imre Pascik

LEVAPOR GmbH

www. levapor.com
Germany

Leverkusen,

LEVAPOR – porous, adsorbing carrier
for bioprocess i...
Wastewater treat.plant
„Bayer Tower Biology“
Start: 1980
Reactors: 4x16.000 m³

LEVAPOR biocarrier and several other waste...
somonas europaea

Biodegradation of pollutants
occurs via teamwork of
microorganisms united
in sludge flocs
Important resu...
Our REQUESTS on OPTIMAL CARRIER
PROPERTY
1. Adsorbing capacity

EFFECT
- binding toxic pollutants
- fast colonisation+biof...
LEVAPOR, adsorbing, porous biocarrier have been
designed on basis of above mentioned requirements
Specialty: high content of powdered activated
carbon
resulting other effects than simple cell adhesion :
Adsorption of inh...
Fast colonisation  fast biofilm generation 
fast and stable bioprocess
Confirmation test – 1 (next diagram) :
Biodegradation of toxic 2-Chloroaniline (2-CA)
in two parallel discontinuously oper...
Biodegradation of 2-CA with immobilised vs. suspended bacteria
( Univ. of
Confirmation test -2
Degradation of 2-Chlorobenzoic acid under anaerobic
conditions
in parallel discontinuously operated a...
Anaerobic test for carrier screening

(Prof. H.SAHM, DUS.)
Application:
„cubes“

12 to 15 vol.% of 20*20*7 mm
Primary settler

Aerated basin + carrier

Clarifyer

LEVAPOR in a fluidised bed biofilm reactor:
„ MBBR“
The first application in the practice was in a pulp mill with
toxic effluents from pulp bleaching:
Q = 10.000 m³/d COD = 3...
LEVAPOR

gran.activ. carbon
unmodified PURfoam
suspended
anaerobic sludge

Effect of carrier types on COD-elimination unde...
EQUALISATIO
N

AEROBIC
REACTOR
S

ANAEROB
.
REACTOR
S

Plant for anaerobic-aerobic treatment of toxic pulp mill effluents ...
Startup: 1990, only 2 of 3 ANA-reactors were started with LEVAPOR
in order to compare the effect of immobilisation.
After ...
3,5

kgCOD/m³ x day
immob. biomass

3
2,5
2
1,5
susp.biomass

1
0,5
0

May 90
1

3

5

June 90
7

9 11 13 15 17 19 21 23 2...
LEVAPOR- case history No. 2
Upgrading of an existing municipal
plant for
nitrification in Espoo + Helsinki
Problem:
Nitrif...
50,0

N (mg/L)

TKNZul

45,0
40,0
35,0
30,0
25,0
20,0

NO3NAbl

15,0
10,0
5,0

NH4NAbl
07.11

02.02

02.05

0,0
1

3

5

7...
60,0
N (mg/L)
50,0

TKNZul.

40,0

30,0

20,0

NH4NAbl.
NO3NAbl.

10,0

days

0,0
1

3

5

7

9 11 13 15 17 19 21 23 25 27...
A usual aeration intensity achieves a nearby quantitative fluidisation
Addition of 12 vol.% LEVAPOR carrier into
aerated basin of existing municipal plant in
resulted in
efficient nitrification...
Dimension

NINGAN WWTP

m³/day

Values (Aug. 2011)
22.000

Volume of reactors

m³

3200 (4 x 800)

Volume LEVAPOR

m³

500...
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Levapor carriers presentation

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High Performance, flexible, durable Levapor Carriers made of PU foam impregnated with activated carbon for wastewater treatment

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Levapor carriers presentation

  1. 1. Dr. Imre Pascik LEVAPOR GmbH www. levapor.com Germany Leverkusen, LEVAPOR – porous, adsorbing carrier for bioprocess improvement
  2. 2. 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.
  3. 3. somonas europaea Biodegradation of pollutants occurs via teamwork of microorganisms united in sludge flocs Important result of research work : 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, “carriers“ made of plastics, sand, glass, etc.
  4. 4. Our REQUESTS on OPTIMAL CARRIER PROPERTY 1. Adsorbing capacity EFFECT - 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
  5. 5. LEVAPOR, adsorbing, porous biocarrier have been designed on basis of above mentioned requirements
  6. 6. Specialty: high content of powdered activated carbon resulting other effects than simple cell adhesion : Adsorption of inhibitors lower toxicity in
  7. 7. Fast colonisation  fast biofilm generation  fast and stable bioprocess
  8. 8. 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.
  9. 9. Biodegradation of 2-CA with immobilised vs. suspended bacteria ( Univ. of
  10. 10. 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.
  11. 11. Anaerobic test for carrier screening (Prof. H.SAHM, DUS.)
  12. 12. Application: „cubes“ 12 to 15 vol.% of 20*20*7 mm
  13. 13. Primary settler Aerated basin + carrier Clarifyer LEVAPOR in a fluidised bed biofilm reactor: „ MBBR“
  14. 14. The first application in the practice was in a pulp mill with toxic 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
  15. 15. LEVAPOR gran.activ. carbon unmodified PURfoam suspended anaerobic sludge Effect of carrier types on COD-elimination under anaerobic
  16. 16. EQUALISATIO N AEROBIC REACTOR S ANAEROB . REACTOR S Plant for anaerobic-aerobic treatment of toxic pulp mill effluents by LEVAPOR-supported microorganisms
  17. 17. 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
  18. 18. 3,5 kgCOD/m³ x day immob. biomass 3 2,5 2 1,5 susp.biomass 1 0,5 0 May 90 1 3 5 June 90 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 Comparison of biofilm reactors versus suspended
  19. 19. 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
  20. 20. 50,0 N (mg/L) TKNZul 45,0 40,0 35,0 30,0 25,0 20,0 NO3NAbl 15,0 10,0 5,0 NH4NAbl 07.11 02.02 02.05 0,0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 N-concentrations after addition of LEVAPOR at 10 to17°C After 3-4 weeks a stable nitrification has been establihed !
  21. 21. 60,0 N (mg/L) 50,0 TKNZul. 40,0 30,0 20,0 NH4NAbl. NO3NAbl. 10,0 days 0,0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 Pre-denitrification resulted in lower outlet-NO3N concentrations
  22. 22. A usual aeration intensity achieves a nearby quantitative fluidisation
  23. 23. 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.
  24. 24. Dimension NINGAN WWTP m³/day Values (Aug. 2011) 22.000 Volume of reactors m³ 3200 (4 x 800) Volume LEVAPOR m³ 500 (15,6 %) Hydraulic ret. time h 3,5 kg/m³xday 2,2 Legend Water flow Lv, COD 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
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