Biological Wastewater Treatment for Industry and Municipalities

TFR industrial for for industrial wastewater treatment
TFR industrial for for industrial wastewater treatment

Many different industries have various requirements for wastewater treatment, but all have one thing in common: The need for an optimised solution for wastewater treatment.

Whether we install a single treatment step, a complete wastewater treatment plant or equip an entire factory with systems for wastewater treatment – DAS Environmental Expert solutions are always tailor-made.

Process of biological wastewater treatment
Process of biological wastewater treatment

No matter if you need to limit discharge values to reduce wastewater charges or you need to increase process efficiency by recycling usage water, our specifically developed process for biological wastewater treatment was designed to fulfill all individual needs.

Customers of DAS Environmental Expert have been successfully using our technology for wastewater treatment in the chemical and pharmaceutical industries; the semiconductor manufacturing sector and energy industry; the cleaning and textile industries; the brewery and beverage industries; the meat and fish processing industries, and also in agriculture and municipal wastewater treatment as well as in rendering services. In all of these areas, DAS technology cleans and recycles accrued wastewaters in a safe, environmentally friendly and efficient way.

MBBR Treatment Plant
MBBR Treatment Plant

Wastewater Treatment With the MBBR Process

The MBBR (Moving Bed Bioreactor) or fluidised bed process is based on the biological process with sessile biomass (biofilm process). This allows microorganisms to grow inside the biofilms, which consist of immobilised biomass and become established on the surfaces of the filling material (substrate biology). 

Advantages of the MBBR Process Over the Activated Sludge Process

Activated sludge with suspended biomass can only reach a relatively young age due to the drainage of excess sludge. In contrast, the immobilised microorganisms on the substrates in the MBBR process can reach a significantly higher age. The colonising microorganisms exhibit very long generation times. The purification process is more stable than in activated sludge plants, and loading shocks are better absorbed. The substrate material used by DAS EE features an extremely high specific surface area of 3,000 m²/m³, therefore allowing exceptionally compact MBBR bioreactors. The particular shape reliably prevents blockage of the substrate and ensures consistently high degradation efficiency.

Reduced Excess Sludge Quantity for Biofilm Processes

Excess sludge builds up, as is typical in every aerobic biological process for the decomposition of organic carbon compounds. For biological reasons, the quantity is significantly lower than in activated sludge processes of a similar capacity. The purified wastewater must typically be separated from the sludge after MBBR treatment. This can be achieved through sedimentation in a secondary settling tank, for example. It may be possible to consider forgoing sludge separation in the case of indirect discharge into a downstream municipal wastewater treatment plant if the capacity and design of the plant permits and if undesirable sedimentation processes along the transport route can be suppressed.

The MBBR plants may be designed as compact plants or modular bioreactors. The modular reactors require less space and no excavation works. The MBBR may even be designed and operated as a denitrification reactor if the corresponding process configuration permits.

Carrier material for biological wastewater treatment
Carrier material for biological wastewater treatment

Biological Wastewater Treatment with TFR Technology

TFR stands for Trickle-Flow-Reactor, also called the trickle-flow principle. The system uses a very light, small-grain carrier material that, within days, is covered by a highly active mixed population of bacteria that is adapted to their respective conditions. Unlike commonly implemented wastewater systems, the carrier material bed is not located within a closed body of water and thus can be easily supplied with sufficient amounts of oxygen. The constant inflow of wastewater that trickles down over the bed is aerated by ambient air that is supplied by a ventilator at a minimum pressure flowing in the opposite direction.

Biological Wastewater Treatment with the TFR Bioreactor
Biological Wastewater Treatment with the TFR Bioreactor
Carrier Material with Microorganisms
Carrier Material with Microorganisms

Wastewater Technology with Lightweight Carrier Material

The carrier material is biologically, chemically and mechanically stable. An automatic operating rinse technology regularly flushes re-growing biomass from the system. The high density of microorganisms as well as the optimum conditions for the transition between biomass, water contaminants and excess oxygen are the basis for the system’s high performance and stable bio-degradation values.

No Activated Sludge Process or Trickling Filter System

In the early 1990s Germany tightened its policies for the wastewater sector. Just degrading carbon was no longer sufficient. Eliminating nitrogen and partially phosphorous were the new challenges for the classic trickling filter systems that was commonly used at the time. The new requirements, however, overexerted the old systems, which is why the wastewater sector transitioned into using the complex activated sludge process. Sludge pumps, inlet and outlet sludge handling and SPS-regulated aeration phases to control nitrification and de-nitrification replaced the trickling filter system.

But the new complexity created new problems. Bulking sludge caused a decrease in biomass or floating sludge leading to undesired sludge overflow negatively effecting discharge values. This was a major challenge. The new process for wastewater treatment also increased the energy demands of wastewater treatment plants, due to the more elaborate oxygen supply and oversized process systems.

Biological Wastewater Treatment with DAS Environmental Expert
Biological Wastewater Treatment – Great Performance with Low Energy Consumption

Biological Wastewater Treatment – Great Performance with Low Energy Consumption

The more complicated the technology becomes the higher its susceptibility to faults which leads to increased maintenance and operating costs. We say: “Why not just forgo the extras, and focus on what is truly necessary to make operation reliable?” We call it ‘tailor-made wastewater treatment’ and our TFR Technology is based on this principle.

As we forgo the heavy water column, we eliminate the need for the immense wall thickness and inefficient, energy-intensive aeration of the classic systems. To achieve this we employ a light carrier material, which, due to its form and size, not only offers a large population surface for bacteria with high sludge age, but also provides an ideal balance between volume and surface.

Advantages

  • High biological adaptation
  • Effective and energy-saving aeration
  • Small footprint
  • Easy construction and installation even on intermediate ceilings
  • High flexibility at fluctuating wastewater loads
  • Fast installation
  • Low maintenance
  • Fully automated process control
  • Compatible with all classic processes

Fields of Application

  • Reduction of organic loads (COD/BOD value degradation)
  • Nitrification (ammonium degradation)
  • De-nitrification (nitrate degradation)
  • Decentralised treatment of wastewater streams
  • Complete treatment for direct and indirect discharge
  • Water recycling and multiple use
  • Plant engineering, system extensions and renovations

Selected Application Examples for using TFR Technology

TaskWastewater CharacteristicsGoal
Indirect Discharge
Pre-treatment before discharge into sewage system

Industrial wastewater, easily to not easily biodegradable


< 600 mg/l COD
< 400 mg/l BOD5

Direct Discharge
Treatment before direct discharge into surface waters

Industrial and municipal wastewater, easily to not easily biodegradable


< 100 mg/l COD
< 25 mg/l BOD5

Water re-use
Irrigation (in arid areas, for instance)


Usage Water


Low concentration and municipal wastewater


Industrial wastewater


< 20 mg/l COD
< 10 mg/l BOD5

Nitrogen removal
Industrial wastewater heavily loaded with ammonium

< 2 mg/l NH4-N

Product Line for Biological Wastewater Treatment

TFR industrialTFR municipalTFR mobileTFR pilot
Characteristics/ Application
  • Our bestseller of the TFR family
  • Modular configuration in different sizes
  • Multi- configurable and flexibly expandable
  • Specifically designed for smaller municipal wastewater loads
  • Application in communities, hotels, clinics, high-rise buildings
  • Optimally tailored to small sedimentation and storage tanks
  • Flexible solutions for temporary applications
  • Completely pre-mounted and tested ex works
  • Mounted in standard container 20 or 40 inches (ISO 668)
  • On-site pilot-plant at customer location
  • For data assessment, demonstration or performance proof
  • Ready-to-use, pre-mounted on two euro-pallets
Reactor measurements (Ø x H)
  • Standard size: 3 x 8 m;
    2.5 x 6 m;
    2 x 6 m
  • Special sizes per request
  • As a single reactor from 1.4 x 3.5 m up to 3.0 x 8 m
  • In modular configuration 1.2 x 2.25m
  • 2.25 x 6 m (20”) up to 2.25 x 12 m (40”)
  • 0.6 x 2.8 m (Height for transport = 2.0 m)
Influent per reactor
  • 10 – 1,300 m³/d (depending on wastewater parameters)
  • 10 – 400 m³/d
  • 5 – 800 m³/d
  • 5 – 300 l/h
Organic load per reactor
  • 1.2 – 8 kg COD/m³/d
  • 50 – 2,000 PE
  • 1.2 – 8 kg/m³/d
  • Customer specific
Space requirements per reactor
  • ca. 4 x 4 m
  • ca. 4 x 4 m
  • 2.44 x 2.90 m
  • 2 x (0.8 x 1.2) m
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