MBBR (Moving Bed Biofilm Reactor)
Efficient MBBR (Moving Bed Biofilm Reactor) Solutions for Industrial Wastewater Treatment
The MBBR process is a highly adaptable aerobic treatment method, well-suited to the variability in industrial wastewater. It typically offers a small footprint and can be designed to focus on the removal of lower percentages of organics and nutrients rather than achieving full conversion like other systems. This makes it an ideal biological treatment solution for discharging to the sewer when primary treatment alone is insufficient.
Features and Benefits
Some of the main benefits of MBBR technology are:
Compact Design & Reduced Footprint – The high concentration of biomass attached to the media within the aeration zone allows for far smaller tank sizes than other aerobic treatment systems, making it ideal for space-constrained applications.
Flexible Organic Removal – MBBR systems are adaptable for both partial and full organic removal. The partial removal is especially beneficial in trade waste or sewer discharge scenarios, where primary treatment alone may not meet discharge limits.
Efficient Nutrient Removal – MBBR technology enables effective nitrogen removal through the integration of pre-anoxic zones and mixed liquor return (MLR), whilst the dosing of a coagulant prior to the clarification stage can easily achieve very low levels of phosphorous.
Upgrading Capability – Conventional activated sludge plants can be efficiently upgraded to the MBBR process. This upgrade increases the treatment capacity for larger flows and higher organic loads without the need for expanding the physical footprint of the wastewater treatment plant.
How the MBBR Works
An MBBR is one of several types of aerobic biological wastewater treatment processes that uses bacteria to consume organic matter in the presence of oxygen. The main difference between the MBBR and other conventional processes is that it uses small plastic carrier elements in the biological aeration vessel to provide a high surface area for biomass to attach to and grow. These carrier elements allow a very high concentration of biomass to be present in the bioreactor, which effectively increases its biological treatment capacity and allows greater volumes of wastewater to be treated in considerably smaller vessels.
The Stages of the MBBR Process
- Wastewater is introduced into the aeration tank containing the carrier elements at a constant flow rate where oxygen is introduced.
- Biologically treated wastewater flows out of the aeration tank directly into a HyDAF Dissolved Air Flotation system.
- The HyDAF dissolved air flotation system removes the biomass in the wastewater via flotation, and the treated water flows to the point of discharge.
- The removed biomass is either dewatered and further processed or removed from the site as waste-activated sludge (WAS). Some biomass is returned to the aeration tank as return-activated sludge (RAS).
Nutrient Removal
Nitrogen removal can be incorporated into the MBBR process by the inclusion of an anoxic zone upstream of the aeration tank with a mixed liquor return loop that recirculates water between the aeration and anoxic tanks. Some phosphorous will be taken up in the biological process however, if very low concentrations are required, the simple addition of coagulant to the DAF inlet will precipitate phosphorous from the clarified water stream to very low levels if necessary.
Sustainable Carriers and Exceptional Process Knowledge
The design of the carrier is critical to the performance of the MBBR process, and not all carriers are the same. The carriers used in the Hydroflux MBBR are designed based on many years of experience, having a specific engineered shape and openings to increase the surface area. It is this openness and shape that has been instrumental in maximising biofilm mass transfer and preventing clogging, which otherwise leads to excessive maintenance. All of our carriers are sustainably manufactured primarily from recycled PE and injection molded to provide a hard and durable biofilm carrier that are resistant to cracking and distortion.
Process oxygenation and mixing are performed by an advanced aeration system installed in the base of the MBBR aeration basin. The aeration system covers the entire base area, allowing the most efficient use of the capacity and surface area. Our aeration system is non-clogging and practically service-free. The high degree of prefabrication ensures excellent quality and reduces the onsite installation time.
Hydroflux offers proven, expertly designed cages that retain the MBBR media within the aeration tank. These cages are designed to ensure that the media remains securely contained, avoiding the risk of media clogging or fouling within the system whilst allowing for optimal flow dynamics within the tank and ensuring that the biofilm has maximum exposure to the wastewater for effective treatment.
MBBR FAQs
Yes, MBBR technology is highly effective for treating high-strength wastewater. The system’s moving carrier media provides a large surface area that supports a high concentration of biomass, allowing it to degrade organic pollutants efficiently even in wastewater with elevated and varying levels. This capability makes MBBR ideal for industries such as food processing, pharmaceuticals, and chemical manufacturing, where wastewater often contains high concentrations of organic materials, oils, or chemicals.
MBBR systems are highly versatile and can often be integrated into existing wastewater treatment plants with minimal disruption, offering a cost-effective way to improve treatment performance without the need for a complete system replacement. For example simply converting an aeration tank in an activated sludge process to a MBBR reactor can significantly increase the throughput of the plant.
A Dissolved Air Flotation (DAF) unit is often a better choice than a secondary clarifier for MBBR clarification, especially when dealing with poorly settling sludge. Unlike clarifiers that rely on gravity to settle solids, DAF uses fine air bubbles to float suspended biomass to the surface, making it highly effective for separating detached biofilm and suspended solids. This ensures a more consistent effluent quality, particularly in cases where MBBR sludge is light and does not settle well.
DAF also produces a thicker sludge compared to clarifiers, which reduces sludge handling requirements and dewatering costs.
One of the potential challenges with Moving Bed Biofilm Reactor (MBBR) systems is biofilm sloughing and uneven growth. Over time, biofilm can thicken on the carrier media, and if growth becomes excessive, large chunks can slough off, leading to fluctuations in treatment performance and increased suspended solids in the effluent. Proper aeration, organic loading balance, and occasional seeding of new biomass help maintain stable biofilm development.
Similarly, carrier clogging and fouling due to fats, oils, grease (FOG), can occur. The carriers used by Hydroflux are designed for self-cleaning through continuous movement and optimised aeration patterns however pre-treatment steps, such as dissolved air flotation (DAF) units, are recommended where in high FOG applications.
Why Industry Chooses to Work with Hydroflux
Hydroflux can deliver complete design and construct projects that cover all stages of treatment, including primary, secondary biological, sludge handling and tertiary processes. Our systems are designed to enable high-quality discharge or water reuse, with flexible delivery models available from equipment supply to integration of full turnkey solutions.
Our team comprises qualified civil, mechanical, chemical, and electrical engineers, along with experienced project managers, site supervisors, commissioning specialists, and service technicians. To maintain long-term performance and reliability, Hydroflux also offers comprehensive servicing and maintenance contracts.
Contact us for technical discussion about how we can assist you with your wastewater treatment facility.
Sustainable Solutions
As Australia’s first certified carbon-neutral water and wastewater chemical supply and service business, we focus on sustainability. Developing and delivering sustainable solutions for treatment plant operation and maintenance is at the core of what we do. Our equipment is the most sustainable in the Australian and New Zealand markets and is not just effective but also carbon-neutral. Click here to find out what this means for you.
