Levapor carriers agro_chemicals
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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
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Levapor carriers agro_chemicals
- 1. LEVAPOR – 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, “carriers“ 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 •
- 18. Pollutant Removal Pollutant influent concentrations removal % overall in different steps mg/L % microaerob- + anaerobic aerobic Aromatic solvents 1,5-3,0 100,0 90,0 10,0 Methanol 930 - 1980 100,0 95,0-100,0 0-5,0 Dichloromethane 4,0 - 42,0 100,0 100,0 0,0 MIBK 9,0 -330,0 100,0 76,0 24,0 Amines 56,2 - 64,8 100,0 90,0-100,0 0,0-10,0 Triazine derivatives 96,5 - 114,3 100,0 64,2 35,8 Carbamates 17,8 - 24,3 80,0 72,0 28,0 Herbicides total 154,0 - 337,0 91,5 75 25
- 19. Biodegradation of Herbicides Component 26.10.05 Influent degree of removal, overall % removal in single steps mg/L absol. S D % MAE ANA AER Atrazine 20,4 19,6 96,1 57,1 18,4 24,5 Simazine 1,9 1,9 100,0 57,9 10,5 31,6 Terb.Azine 14,1 13,3 94,3 51,9 34,6 13,5 Ametryn 1,7 1,7 100,0 52,9 11,8 35,3 Prometryn 1,9 1,9 100,0 47,4 31,6 21,0 Tris 12,6 11,9 90,0 52,1 31,9 16,0 Unknown 60,3 53,1 88,1 62,3 23,4 14,3 Terbutryn 1,4 1,4 100,0 42,9 28,6 28,5 Linuron 11,3 11,3 100,0 92,9 7,1 Bromacil 1,0 0,8 80,0 50,0 50,0 0,0 Dicuran 7,4 6,8 91,9 20,6 29,4 50,0 Diuron 3,2 3,2 100,0 43,8 6,3 49,9 SHerbicides 161,9 148,1 91,5 60,6 9,2 30,2
- 20. Full Scale Plant • 1.8 MLD • 8-12,000 mg/lit COD • 300-600 mg/lit TKN • 12-25,000 mg/lit Salinity
- 21. Full Scale Plant
- 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
- 26. Thank You !!!!