Levapor Bio Film Technologies and Bio Consulting GmbH


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

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Levapor Bio Film Technologies and Bio Consulting GmbH

  1. 1. About us• We are Levapor Biofilm Technologies and BioConsulting , GmbH.• A specialized company providing innovativesolutions for the treatment of wastewater andpolluted air• A team with more than 40 years of experiencein research and development of fixed filmbased technologies for industrial and difficultto treat wastewater and polluted air
  2. 2. What We do• Problem analysis for the treatment of high strengthindustrial and municipal wastewater treatment• Define treatment goals and conceptual processdesign• Development of optimal process and parameters• Manufacturing of high performance tailor made biocarriers for the application• Process Start up
  3. 3. Our Specialization• Anaerobic pre treatment of complex, persistentindustrial wastewater• Nitrification – De nitrification of effluents containinginhibitory substances• Biological waste gas treatment using BTF(BioTrickling Filters)• Biofilm Reactor IFAS/MBBR for industrial andmunicipal wastewater• Production and delivery of High Performance BioCarriers
  4. 4. Our Achievements• First full scale nitrification/denitrification plant forammonia rich effluents (1978)• Development of high performance bio carriers (1983)• Degradation of toxic effluents by anaerobic bio filmtechnologies (1985)• Design of full scale process for the anaerobic-aerobicdegradation of toxic effluents (1998)• Indoor bio treatment of polluted air for a ware houseof waste plastic (2002)
  5. 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 sludgeprocessing unit
  6. 6. Our Clientele• SAPPI , Germany : 20 MLD anaerobic-aerobic treatmentplant for treatment of high strength pulp and paper milleffluent• City of Ningan, China : 22 MLD Municipal wastewatertreatment plant for COD removal and nitrification• City of Helsinki : Upgradation of existing municipalwastewater treatment plant• Ludan Engineering, Middle East : Bio treatment of finechemicals wastewater• KERRY Intra, India : Bio treatment of container washwater
  7. 7. Our Technology• LEVAPOR Bio Carrier• First synthesized Bio Carrier• Porous, Flexible, Durable PU foamimpregnated with surface active pigmentswith high surface area• Due to variability of foam and pigment typeand their ratios, tailor made carriers can beproduced with varying properties
  8. 8. Our Technology
  9. 9. Unique PropertiesPROPERTIES• High Adsorbing Surface• High Porosity• Fast wetting and waterbinding• High surface Area• Higher fluidization abilityATTRIBUTES• Adsorption of inhibitorysubstances and fast colonization• Protection of biomass againstshear, anoxic zone formation• Homogenization of media andmaintenance of bio activity• Lower Degree of Filling (12-15%)• Less Power consumption
  10. 10. Advantages• Reversible adsorption of inhibitory substances andslowly bio degradable pollutants• Short process start up and higher performancecompared to suspended mass based systems (100 to300%)• Colonization of carrier by more active bio mass andsimultaneous 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 toconventional MBBRs
  11. 11. Applications• Up gradation/expansion of existing plants• Anaerobic-Aerobic treatment of high strength , slowlybio degradable pollutants• Nitrification- de nitrification of effluents containing highammonia concentrations• Biological Treatment of Polluted air/gas (BTF)• Biofilm reactor MBBR/IFAS for the treatment ofindustrial and municipal wastewater• Treatment of hyper saline effluents containing solvents• Treatment of land fill leachate and groundwatercontaining PAHs.
  12. 12. Case Studies• City of NINGAN Wastewater treatment Plant• Heilongjiang Province , China• 4,40,000 Population• Very Cold climate during winter• Difficulty in maintaining nitrification duringwinter• Stricter Legal discharge limits
  13. 13. NINGAN,WWTP• Solution :• 3200 m3 of aeration tankvolume• 480m3 of Levapor Biocarrier• 15% Filling• 20 X 20 X 7 mm size
  14. 14. NINGAN, WWTP• Legend Dimension ValueVolume of Reactor M3 3200 (4 X 800)Volume of Levapor M3 480m3HRT Hours 3.5-3.82012 October Nov. Dec.COD in Mg/lit 294 295 302COD out Mg/lit 33.7 35.8 37.7BOD out Mg/lit 11.9 11.9 12.9TKN in Mg/lit 28.8 35.5 23.2NH4.N out Mg/lit 2.0 3.3 3.34NO3.N out Mg/lit 12.5 14.8 11Temperature Degree C 15.6 13.3 9.6
  15. 15. NINGAN ,WWTP
  16. 16. NINGAN,WWTP
  17. 17. NINGAN,WWTP• Benefits:• 88-90 % COD and 91-93% NH4.N reduction despitedecreasing temperature and shorter HRTs• Remarkable process stability against temp, COD, TKNvariations• Lower level of nitrate confirming denitrification• Lower capital and operational cost
  18. 18. 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 degradablechloro-organic compounds• Strong Stream : COD 45 t/d @ 10 MLD• Weak Stream : COD 2.45 t/d @ 3.5 MLD
  19. 19. SAPPI,GERMANYLab scale testing Anaerobic or Aerobic?• Aerobic treatment withsuspended bio mass• Only 40-45 % CODelimination• Anaerobic-AerobicTreatment ?• Anaerobic reactors usingdifferent bio carriers
  20. 20. SAPPI,GERMANY• 1 :Levapor• 2: Activated Carbon• 3: Unmodified PU foam• 4: Suspended Bio mass
  21. 21. SAPPI,GERMANY• Solution :• Anaerobic Treatment Using Levapor Carriers• Reactor Size only 15000 m3 instead of 65000m3 withsuspended bio mass• 1500 m3 of Levapor media• 66-70% COD removal• Further 50% of COD removal in Aerobic Treatment• 50,000 m3 less volume
  22. 22. SAPPI,GERMANYStartup: 1990, only 2 of 3 ANA-reactors were started with LEVAPORin order to compare the effect of immobilisation.After few weeks a toxic shock has stopped the reactor withoutLEVAPORNowadays: ~ 85 % COD- removal , 4 – 6 t/d sludge, 14.000 m³/d biogas
  23. 23. SAPPI,GERMANY00,511,522,533,51 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41susp.biomassMay 90 June 90immob. biomasskgCOD/m³ x day
  24. 24. Thank You!!!!