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Membrane Bioreactors for Wastewater

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Welcome to the AECOM Water Webinar Series

Membrane Bioreactors for Wastewater Treatment will be delivered by

Nick Cooper

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Membranes in Your Future?

Membrane Bioreactors:
Process and Design
Nick Cooper
Vice President, AECOM Water

February 2014

Presentation
1. Terminology
2. Membrane Concepts
3. Membrane Process Configurations
4. Satellite Treatment
5. Membrane Suppliers
6. How Large MBRs?
7. MBR Plant Layouts
8. Immersed Membrane Technologies
9. Design Considerations
10. Design and Operational issues
11. Design Parameters
12. Future Trends

Nick Cooper nick.cooper@aecom.com

Vice President, Wastewater Technical Practice Leader
Project Manager Wastewater Treatment, Biosolids,
Water Reuse
35 years - Treatment Plant Planning and Design
Experience USA, Canada, Middle East, UK,
Southeast Asia, South America
Contributing Author and Editor:
Metcalf & Eddy - Water Reuse
MOP 32 Energy Conservation
MOP 34 Membrane Bioreactors
Metcalf & Eddy - Wastewater
Engineering, 5th Edition

Reference Projects Nick Cooper

Forsyth County WRF, Atlanta, Georgia 10 MLD (Hollow Fiber)
Johns Creek Environmental Campus, Roswell, GA 60 MLD (Hollow
Fiber)
Al Ansab STP, Muscat, Oman Phase 1 55 MLD (Flat sheet)
Al Ansab STP, Muscat, Oman Phase 2 125 MLD (Flat sheet)
Advisor:
Evan Thomas STP, Calgary, Alberta 10 MLD (Hollow Fiber)
Davie STP, Broward County, FL 15 MLD (Flat sheet)
Woodward Avenue, Hamilton, ON 500 MLD (Hollow Fiber)
Shek Wu Hui STP, Hong Kong 190 MLD
8

References

On-line Resource:
The MBR Site www.thembrsite.com Simon Judd, Cranfield University
9

Terminology

Terminology
Cross-Flow Membranes

Maintenance Cleaning

Ultrafiltration

Recovery Cleaning

Microfiltration

Fine Screening

Hollow Fiber Membranes

Peak Daily Flow (PDF)

Flat Plate Membranes

Average Daily Flow (ADF)

Flux Rate

Peak Hour Flow (PHF)

Permeability

Submerged Membrane Unit

(SMU)

Clean-in-Place
Cassette
Scour Air
11

Membrane Concepts

Membrane Bioreactors
A membrane bioreactor is not a biological process. It is a
process configuration that allows conventional processes
to work more efficiently and in a smaller footprint.
A MBR membrane is a high class filter
Microfiltration and ultrafiltration membranes restrict the
movement of solids and bacteria across the membrane.
MF and UF do not remove soluble material.

13

Filtration Spectrum

0.001

0.1

0.01

1.0

10

100

Aqueous Salt

Bacteria

Virus

Metal Ion

Colloidal Silica

REVERSE OSMOSIS

PARTICLE FILTRATION

ULTRAFILTRATION

NANOFILTRATION

MICROFILTRATION

14

1000

Membrane Bioreactor Immersed Membranes

15

Immersed Membranes

Membrane

TSS = 15,000 mg/L TSS = 0 mg/L

Air

Solids

Treated effluent
Air

Virus

TN = 15 mg/L

Air

TP = 5 Air
mg/L

Air

Bacteria
BOD5 = 10 mg/L

Air

16

Cross-flow Membranes

Extracts Reuse quality water

Thickens Sludge to 5+ percent
Reduced air requirements
Package Systems

Cross-Flow
Membranes

Reactor

Permeate

Cross-flow Membranes
Permeate
Mixed Liquor from
Reactor Basin

Concentrated Mixed
Liquor Return to
Reactor
Permeate

Ultrafiltration Membranes
Hollow Tubes
Low Pressure
Self-scouring
Robust and Long lasting

Membrane Bioreactor

Compact System

No Clarifiers or Filters

High Mixed Liquor

Concentrations Possible

No TSS or bacteria in effluent

Limits passage of viruses

Small Footprint (0.3 ha/10 MLD)

Highly automated

Requires close monitoring

19

Membrane Bioreactor - Benefits

When do you consider MBR:

Small sites
Near residential areas
High quality treatment (low phosphorus, virus control)
Satellite Plants

Benefits of MBR:

Can be totally enclosed

Simple Common Wall Construction
Excellent for fast-track implementation
Modular system
Fully automated
Low operator attention to physical systems
Creates its own hydraulics fits any site
Waste sludge has high concentration, reducing sludge storage

Membrane Bioreactors - Caution

Caution in considering MBR

High level pre-treatment needed

Can be impacted by industrial wastewater

High energy requirements

High chemical requirements

Maintenance Cleaning weekly or monthly

Recovery cleaning 2 6 times annually

Membrane replacement costs every 7 to 10 years

Need for relief pond or tank

Supplemental screening is desired and probably needed

Oil and grease must be limited to 150 mg/L or less

Membrane Process Configurations

Process Flow Diagram Conventional Activated Sludge

with Tertiary Treatment
Grit/Grease
Removal

Screening

Screenings

Primary
Settling

Biological
Treatment

Secondary
Settling

Grease

Grit
Primary Sludge

Influent
Pumping

Return Activated
Sludge

Secondary Sludge

23

Filtration

Disinfection

Process Flow Diagram Hollow Fiber MBR

Grit/Grease
Removal

Screening

Screening
s

Aeration Tank

Ultraviolet
Disinfection

Grease

TSE

Grit

Influent
Pumping

Hollow Fiber
Membrane
Bioreactor

Return
Sludge

24

Process Flow Diagram Flat Sheet MBR

Screening

Grit/Grease
Removal

Aeration Tank

Grease

Screenings

Flat Plate
Membrane
Bioreactor

Ultraviolet
Disinfection

TSE

Grit
Return
Sludge

Influent
Pumping

25

Process Flow Diagram External Cross-Flow MBR

Grit/Grease
Removal

Screening

Screenings

Aeration Tank

Grease

Cross-Flow
Membranes

Ultraviolet
Disinfection

TSE

Grit
Return
Sludge

Influent
Pumping

26

Example MBR Treatment Plants

Treatment in small spaces

20 MLD Membrane Bioreactor STP

60 MLD Membrane Bioreactor STP

10 MLD Membrane Bioreactor STP

28

Crescent STP
(FilmTec CrossFlow Membranes)

Palm Water STP

(Kubota Flat
Sheet)

Palm Jumeirah

21 MLD
Palm Jumeirah
WRF

Below-ground MBR

Palm Water STP - 18 MLD

(Kubota Flat Sheet Membranes)

Palm Water STP (Kubota Flat Sheet)

Anoxic Tanks

EQTanks

Anoxic Tanks

32

Cassette Tanks

Palm Water STP (Kubota Flat Sheet)

Aeration Tanks

Aeration Tanks

Aeration Tanks

33

Aeration and Anoxic Tanks

Permeate Room

34

Crescent STP - 15 MLD

(FilmTec Cross-Flow Membranes)

Crescent STP (Cross-Flow Membranes)

Piping Gallery

Mixed Liquor Feed Pumps

Mixed Liquor Feed Pumps

36

Piping Gallery

Crescent STP (Cross-Flow Membranes)

CIP Booster Pumps

Permeate Pumps

CIP Piping

FilmTec Cross Flow Membranes

Crescent STP (Cross-Flow Membranes)

30 Membranes per skid

20 skids at 750 m3/d

Permeate Pipe
(75 mm)

Return
Pipe
(200 mm)

39

Satellite Treatment:
Sewer mining, Scalping plants

Satellite Treatment for Reuse

Package Treatment
Building

Existing Park
Maintenance Building

Extraction Pump
Station

Reclaimed Water
Distribution

Return Flow to
Sewer

System used for the treatment and

reclamation of wastewater located close
to the point of reuse
Solids discharged back to a centralized
collection system

Membrane Suppliers

Membrane Suppliers 1
Membrane

Type

Membrane

Type

GE ZeeWeed D500

Hollow Fiber

Econity CF Series

Hollow Fiber

Leap MBR GE Water

Hollow Fiber

Econity - Ecologix

Flat Sheet

Pentair X-Flow

Multi-tube

Evac MBR

Flat Sheet

Kubota RW-400

Flat Sheet

Tianjin Motimo

Flat Sheet

Kubota MicroBlox

Flat Sheet - blocks

Shanghai MegaVision

Flat Sheet

Xylem A-Series

Tubular

Gemini Hainan Litree

Hollow Fiber

MicroDyn-NADIR

Flat Sheet

LG Green MBR

Flat Sheet

Huber BioMem

Flat Sheet

Hina MBR

Hollow Fiber

Alfa Laval

Flat Sheet

Berghof HyperFlux

Multi-tube

Likuid CBR

Multi-tube Ceramic

Hangzhou H Filtration

Hollow Fiber

Beijing Origin MBRU

Hollow Fiber

Toray - Membray

Flat Sheet

FLI Water - Membright

Flat Sheet

Memos MEMCROSS

Multitube

Siemens Mempulse

Hollow Fiber

Microclear newterra

Flat Sheet

1 The MBR Site, S. Judd 2014

43

Membrane Suppliers 1
Membrane

Type

Membrane

Type

Micronet

Hollow Fiber

MMM MaxFlow

Flat Sheet

Asahi Kasei Microsa

Hollow Fiber

Zena Membranes

Hollow Fiber

China Lantian PEIER

Flat Sheet

Econity PF 90M

Hollow Fiber

Hyflux PetFlex

Flat Sheet

Koch Puron

Hollow Fiber

Philosep Philos

Hollow Fiber

Canpure - Saveyor

Hollow Fiber

Sumitomo Poreflon

Hollow Fiber

Senuo Senufil

Hollow Fiber

HyFlux PoroCep

Hollow Fiber

Liqtech SIC Ceramic

Ceramic Flat Sheet

Anua PuraM

Flat Sheet

Shanghai SINAP

Flat Sheet

Huber SmartMBR

Flat Sheet

Mitsubushi Rayon Sterapore

Hollow Fiber

Colloid SubSnake

Flat Sheet

ENE SuperMAK

Hollow Fiber

Superstring SuperUF

Hollow Fiber

Suzhou VINAP

Flat Sheet

Huber VRM

Flat Sheet

Dynatec

Multitube

1 The MBR Site, S. Judd 2014

44

How Large Can you go with MBRs?

Largest MBR Facilities Worldwide1

Installation

Location

Technology
Provider

Commissioned

PDF (MLD)

ADF
(MLD)

Seine Aval

Acheres, France

GEWPT

2016

357

224

Canton WWTP

Ohio, USA

Ovivo USA

Likely 2015-2017

333

159

Shek Wu Hui

Hong Kong

2016

250+

190

Macau

China

GEWPT

2014

189

137

Riverside

California, USA

GEWPT

2014

186

124

Al Ansab

Muscat, Oman

Kubota

2016

175

125

Brightwater

Washington, USA

GEWPT

2011

175

122

Visalia

California, USA

GEWPT

2014

171

85

Qinghe

China

OW/MRC

2011

150

150

North Las Vegas

Nevada, USA

GEWPT

2011

136

97

Ballenger McKinney WWTP

Maryland, USA

GEWPT

2013

135

58

Cox Creek WRF

Maryland, USA

GEWPT

2015

116

58

Yellow River

Georgia, USA

GEWPT

2011

114

71

Shiyan Shendinghe

China

OW/MRC

2009

110

110

Aquaviva

Cannes, France

GEWPT

2013

108

60

Busan City

Korea

GEWPT

2012

102

102

Guangzhou

China

Memstar

2010

100

Wenyuhe

Beijing, China

OW/Asahi Kasei

2007

100

1 The MBR Site, S. Judd 2014

PDF: Peak daily flow

ADF: Average daily flow, Megalitres per day
GEWPT: GE Water and Process Technologies
OW: (Beijing) Origin Water
MRC: Mitsubishi Rayon Corporation

100

Largest MBR Facilities Worldwide (Contd)

Installation

Location

Technology Provider

Commissioned

PDF
(MLD)

ADF (MLD)

Johns Creek

Georgia, USA

GEWPT

2009

96

42

Changi

Singapore

GEWPT

2014

92

61

Awaza/Polimeks

Turkmenistan

GEWPT

2011

89

71

Songsan Green City

Korea

Econity

Planned 2015

84

Beixiaohe

China

Siemens

2008

78

Al Ansab

Muscat, Oman

Kubota

2010

77

55

Cleveland Bay

Australia

GEWPT

2007

77

29

Broad Run WRF

Virginia USA

GEWPT

2008

73

38

Gongchon

Korea

Econity

2012

65

65

Lusail STP

Doha, Qatar

GEWPT / Degrmont

2013

62

58

La Moree

France

GEWPT

2013

Gaoyang

China

United Envirotech

Expected 2014

60

Cairns North

Australia

GEWPT

2009

59

19

Cairns South

Australia

GEWPT

2009

59

19

Peoria

Arizona, USA

GEWPT

2008

58

38

Aquapolo

Sao Paulo, Brazil

Koch Membrane
Systems

June 2013

56

56

Sabadell

Spain

Kubota

2009

55

Jordan Basin WRF

Utah, USA

GEWPT

2010
47

61

54

Membrane Plant Layouts and

Configurations

Fowler Water Reclamation Facility 10 MLD

49

Fowler Water Reclamation Facility 10 MLD

55 m

10 MLD
Process
Train

57 m

Al Ansab STP, Muscat, Oman 55 MLD

Operations Building

Aeration Basin

51

Membranes Basin

Permeate Gallery

Al Ansab STP
Muscat, Oman

New Reuse
Storage Tanks
New Aerated
Grit/
Grease
Removal
New
Pre-aeration Tank

New Aeration Tanks

New Membrane Tanks

Expansion from
55 MLD to 125 MLD

Al Ansab STP, Muscat, Oman 55 MLD

25 m

50 m

155 m

Expansion to 125,000 m3/d)

Johns Creek Environmental Campus, Georgia USA

Johns Creek Environmental Campus (60 MLD)

55

Membrane Bioreactors:
Immersed Membrane Technologies

Hollow Fiber Technology

Hollow Fiber

Ultrafiltration membrane
0.04 0.07

Trans-membrane pressure range

0.14 0.55 bar (2 8 psi)

Suction permeate extraction

Backpulsing required

External cleaning/in-tank or separate

Return flows to process pumped from membrane tanks

57

Membrane Technology - Hollow Fiber

GE Zenon ZeeWeed 500- vertically strung
membrane fibers, water is filtered by applying
a slight vacuum to the end of each fiber which
draws the water vertically up through the
membranes.

LeapMBR

Koch Puron PSH-500- vertically

strung membrane fibers, Water
is filtered by applying a vacuum
through the fibers.

Flat Sheet Technology

Flat Sheet

Microfiltration membrane
0.4 0.7

Low trans-membrane pressure

0.02 0.04 bar (0.3 0.6 psi)

Higher flux rates

Gravity filtering no pumps

Internal chemical cleaning

Forward flow pumping, gravity return flow

59

Membrane Technology - Kubota

SP 400

RW 400

EK 400

400 panels with tube

permeate piping

400 panels with tube

permeate piping

Cartridges in stacked
configuration, no tubing

Single or double stack

Single or double stack

Multiple stacks of
cartridges or blocks

340 m2 area per SMU

580 m2 area per SMU

400 m2 area per SMU

60

Design Considerations

Energy Management In-Tank Equalization

EQ in Aerobic Tank Flat plate MBR

EQ in Aerobic Tank Hollow Fiber MBR

Energy Management In-Tank Equalization

Determining Flow Equalization

Use Stage Storage Formula

Calculate volume for each hour based on the

diurnal curve

Plot cumulative volume and then determine

optimum treatment rate

Volume is distance between the target

treatment rate and the highest cumulative
volume

Rough rule of thumb: Dampening peak flows

Target PF
through plant

EQ Volume, as % of plant
capacity

2.0

7 8%

1.5

12 13%

1.0

20 22%

Stage Storage Evaluation

Energy Management
Option 1 Recirculation Pumps in each tank

Flow Distribution Channel - Aerated

Membrane
Tanks

Aeration Basins

Recirculation Pumps
64

Energy Management
Option 2 Recirculation Channel
Flow Distribution Channel - Aerated

Advantages

Membrane
Tanks

Recirculation Channel

Creates a
deoxygenation and
Anoxic zone

Centralized
Recirculation, WAS
and Foam Wasting
Pumps

Reduced number of
pumps, piping

Aeration Basins

Recirculation and Foam

Wasting Pumps
65

Return Sludge Channel

Return Sludge Channel

Brescia STP (Italy)

Return Sludge Channel

Jurong STP (Singapore)

Return Sludge Channel

66

Design and Operation Issues

MBR Design and Operation Issues Membrane Cleaning

Maintenance Cleaning
Hollow fiber

Weekly

Backpulse through membranes inside to out

Maintain Tank in Service

Flat Sheet

No Maintenance Cleaning

Recovery Cleaning
Hollow Fiber

Flat Sheet

In situ or in dip tank

In situ or in dip tank

Drain entire tank with multiple

membranes

Gravity feed chemicals through

membranes inside to out

Backpulse through membranes

inside to out

Fill tank with plant effluent and

chemical (1000 ppm chlorine or
500 ppm citric acid

Individual banks of SMUs can

be cleaned without draining the
tank

Feed dose 6,000 ppm chlorine

or 10,000 ppm citric acid

Air scour for cleaning

No air scour during cleaning

Soak for 6 8 hours

Dispose chemicals and return to

service

Maintain chemicals in SMU for 1

hours

Return to service and permeate

chemicals

MBR Design and Operation Issues - Screening

Fine Screening

All solids getting through the screening will eventually end up on the
filters

Maximum 2 mm Perforation Required. 1 mm much better.

Supplemental screening often needed. Side stream screening or

secondary fine screens at entrance to biological process tanks

Side Stream Screening

10 MLD
Process
Train

Side Stream
Screening

Side Stream Screening

Side Stream Screens

Aeration Basin 1

Aeration Basin 2

Aeration Basin 3
Mixed Liquor Return Channel
Aeration Basin 4

Side
Stream
Pumps
From Pretreatment

Fixed Screen

Fixed screen panel 0.5 2.0 mm

Mixed liquor
From biological
tanks

Reference: Cote, Brink, et Adnan. Pretreatment Requirements for Membrane Bioreactors WEFTEC 2006
73

MBR Design and Operation Issues

Oil and Grease

Limit or prevent Oil and Grease entry into plant that would increase
influent O&G above 150 mg/L

Aerated grit/grease tank with good skimming required. Target should

be 50 mg/L O&G at the biological process.

Cleaning with oxalic acid periodically to limit staining of membranes.

Foam Isolation and Removal

Foam launder

Benefits
Foam
Well

Foam Isolated for

removal from each tank
Dedicated Foam Wells

Foam
Well

Improved Plant
hydraulics

MBR Design and Operation Issues

Foam Accumulation

With no effluent weirs, need positive foam removal system

Full length launder on aeration tanks and other tanks that can trap
foam, direct it to a foam pump station

Foam launder, above

normal water level

Foam launder, raised

water level

12 minutes
minute
minutes
3169minutes
minutes

MBR Design and Operation Issues

Air Requirements and Energy Management

Air scour one of the largest power uses at an MBR plant

Need adequate scour to prevent sludging accumulation

of thickened mixed liquor against the membrane

Scour requirements greater with higher MLSS

Savings only marginal and only if MLSS is between 8,000

and 12,000 mg/L in cassette tank

MBR Design and Operation Issues

Mixed Liquor Maintenance

Minimum MLSS for membranes operation is 7,000 mg/L.

Optimum range for hollow fiber membranes is 8,000 9,000 mg/L

MLSS in aeration basins; Maintain MLSS below 11,000 mg/L in
cassette tanks

Optimum range for flat plate membranes is 9,000 12,000 mg/L MLSS
in aeration basins; maintain MLSS below 14,000 mg/L in cassette
tanks.

If MLSS exceeds these levels, system could be subject to sludging. If

membranes become filled with sludge, plant capacity will drop
dramatically.

After sludging, cassettes must be removed from the tank and manually
cleaned. Plant could be at reduced capacity for many days.

MBR Design and Operation Issues

Mixed Liquor Maintenance (Contd)

Increase recycle to maintain MLSS in optimum range. Supplement with

greater air scour at top end of that range.

Monitor MLSS daily in each cassette tank. Increase wasting if MLSS

increases by more than 1000 mg/L in 7 days.

Monitor trans-membrane pressure continuously. Increase sludge

wasting if TMP increases by more than 0.1 bar for hollow fiber; 0.25 bar
for flat plate.

MBR Design and Operation Issues

Sludge Management

Sludge management design for an MBR is different than for

conventional activated sludge process.

The danger of excessive MLSS in cassette basins requires rapid

response to high MLSS.

Minimum sludge management capacity (storage, thickening and

dewatering) is 7 days to reduce MLSS in cassette tanks by 1000
mg/L.

That may be 2 3 times the peak month sludge generation, and

excess capacity should be available at all times for this condition.

Digesters may have to be bypassed to manage higher sludge processing

volume.

MBR Design and Operation Issues

Membrane Cleaning

Membrane cleaning is vital to maintaining membrane value for as long as

possible.

Cleaning should follow frequency in manufacturers requirements, if Fats, Oil

and Grease concentration is below 150 mg/L.

For greater concentrations of FOG, membranes must be cleaned more

frequently, with oxalic acid.

Debris should be removed from membranes as soon as it is detected.

Membranes should be inspected annually.

With normal wear and wastewater conditions, membranes can last up to 10

years. The value of adequate cleaning is extending the life of a
membrane by one year or more.

Full replacement of membranes is the most expensive OPEX cost in a MBR

plant. can cost more than $1.5 million per 10 MLD capacity.

MBR Design and Operation Issues

Membrane Replacement

Membranes are the largest component of Opex, and must be treated

as delicate filters.

A replacement cost contract should be negotiated that provides a

warranty replacement at no cost for the first 3 years

A maintenance contract can lock in cassette replacement costs for 20year period at a lower cost than replacing all cassettes at a fixed time
period.

Membrane Bioreactor
Design Parameters

Typical Design Parameters and Features Immersed Membranes

Flow Equalization volume in-tank to reduce peak hour flows to match

peak filtration rate

Multiple membrane tanks Membranes must be capable of handling

peak flows with one tank out of service for maintenance or cleaning

Aeration requirements for organics and nitrification. Do not accept credit

for scour air. Scour air must be added to aeration requirements
Parameter

Hollow Fiber

Flat Sheet

Mixed Liquor Concentration in

aerobic reactors

8,000 10,000 mg/L

9,000 12,000 mg/L

Filtration Capacity, average

0.4 m3/m2/day

0.61 m3/m2/day

Filtration capacity, peak hour

0.9 m3/m2/day

1.3 m3/m2/day

Membrane scour requirements

75 100 cfm per cassette (2.1

2.8 m3/min)

100 cfm per cassette (2.8

m3/min)

Periodic Backpulse

Pumped through membranes

minimum every 10 minutes

Relax only, no backpulse

pumping

Storage

In glycerine filled bags or

submerged in-tank

Stored dry panels

Sizing a Membrane Bioreactor System

Determine the plant process configuration and biological process first

Note that mixed liquor recycling is critical to maintaining flow across the membrane
modules, to prevent sludging. That will define mixed liquor recycle rates, and works
well with denitrification schemes

Determine level of equalization required based on diurnal flow ranges

Determine the optimum range of flux rates

Determine the numbers of cassettes (SMUs) required to handle peak future equalized
flow

Set maximum allowable mixed liquor concentrations and tank volumes

Determine the number of membrane tanks required, considering one tank out of service
for recovery cleaning or maintenance.

Coordinate with vendors and require guarantees on flux rates, chemical consumption
and air requirements.

Performance guarantees for process performance should be limited to the membrane

performance and control systems only. Effluent water quality is defined by the reactors,
not the membranes.
86

Future Trends

Future Trends in Membrane Bioreactor Systems

Submersible Ceramic Membranes

High permeability (3.0 m3/m2/hr at 0.04 pores)

Rugged membrane material silicon carbide

Less pretreatment required

High solids tolerance

Reduced potential for fouling

Chemically Inert

Cleaning by backwashing

Limitations

High cost of membranes

High pressure requirements

Ref: LiqTech International

88

Future Trends in Membrane Bioreactor Systems

Anaerobic Membrane Bioreactor

Anaerobic conditions treat high strength

wastewater

No air for scouring

Extracts water from septic waste or other

anaerobic wastes

Limitations
Daniel Yeh, University of South Florida

Small scale currently

Anaerobic Cross-Flow MBR

89

Thank you

Nick Cooper
nick.cooper@aecom.com