Design, Operation and Maintenance Manual For Membrane Bioreactors !!!!

Design, Operation and Maintenance Manual for Membrane
Bioreactors applying MaxFlow-module Technology
Abstract of Version 1.13 – August 2014
Translation from the German manual mmf Rev.2.03

Manual for design & operation of membrane bioreactors
with MaxFlow-module technology
Preface
This manual, published by MaxFlow Membran Filtration GmbH, introduces design
and operational procedures for membrane bioreactors (MBRs) applying MaxFlow
module technology to its potential clients. Besides detailed safety regulations and
procedures for MaxFlow module technology, basic design concepts regarding
membrane bioreactors are described. The details are in general form, there is no
requirement of completeness and could be different from the actual achievement.
Non-observance of the instructions regarding the use, operation and handling of
MaxFlow membrane modules can lead to expiration of warranty.
!!!This manual does not substitute a personal instruction

by specialists and operational staff !!!
In this manual the following security symbol will be used:
This symbol highlights that, in case of non-observance of the safety

instructions, risks arise which may severely endanger/injure service staff,
damage or destruct the membrane module or lead to environmental pollution.
If due to operational reasons, the usage of hazardous material is necessary,

please respect the requests of the national / local directives.
Page 2 of 72
In case of questions or problems concerning the technology provided by MaxFlow

Membran Filtration GmbH, please contact:
MaxFlow Membran Filtration GmbH
Magdeburger Str. 16a
D-45881 Gelsenkirchen, Germany
Phone: +49 (0) 209-9 80 99-860
Fax: +49 (0) 209-9 80 99-865
Email: info@maxflow-gmbh.com
Page 3 of 72
Table of contents
1 MaxFlow Membran Filtration GmbH................................................................. 7
1.1 Company profiles ............................................................................................. 7
1.1.1 A3 Water Solutions GmbH .............. Fehler! Textmarke nicht definiert.
1.1.2 MaxFlow Membran Filtration GmbH ...................................................... 7
1.2 Filtration modules of the MaxFlow Membran Filtration GmbH ......................... 8
1.2.1 MaxFlow-Membrane modules microfiltration ......................................... 8
1.2.2 MaxFlow-Membrane modules ultrafiltration ........................................... 9
1.2.3 MaxFlow-Multi modules with high density - Ultrafiltration .................... 10
1.2.4 MaxFlow-Multi modules microfiltration ................................................. 11
1.2.5 MaxFlow-Multi modules ultrafiltration .................................................. 13
2 Safety instructions .......................................................................................... 15
3 Basics of the membrane technology .............................................................. 17
3.1 Definitions ...................................................................................................... 17
3.2 Membrane filtration ........................................................................................ 20
3.3 Operating parameters of a membrane unit .................................................... 23
3.4 Formation of a cake layer ............................................................................... 24
3.5 Limitation of cake-layer-formation .................................................................. 24
4 Basics of membrane bioreactors .................................................................... 26
4.1 Basics of the biological wastewater treatment – applications and limits......... 26
4.2 Parameters for characterisation of the wastewater ........................................ 27
4.3 The MBR-technology ..................................................................................... 29
4.3.1 Pre-treatment....................................................................................... 32
4.3.1.1 Screen / sieve ................................................................................. 32
4.3.1.2 Grit chamber and grease separator................................................ 33
4.3.2 Bioreactor ............................................................................................ 33

Page 4 of 72
4.3.2.1 Excess sludge ................................................................................ 34
5 Design parameters for membranes resp. membrane bioreactors .................. 35
5.1 Basics for the design of the activated sludge tank ......................................... 35
5.2 Basics to design the membrane stage ........................................................... 36
6 Arrangement and construction of the modules in a filtrationreaktor ............... 37
6.1 Arrangement and construction of the modules............................................... 37
6.2 Design of a MBR ............................................................................................ 40
6.2.1 Hints for module arrangement ............................................................. 40
6.2.2 Pumping technology of the filtration unit .............................................. 41
6.2.3 Aeration ............................................................................................... 41
6.2.4 Process measuring and control technology ......................................... 42
7 Membrane modules ....................................................................................... 43
7.1 Installation of the membrane modules ........................................................... 43
7.1.1 Installation in an empty tank ................................................................ 44
7.1.2 Installation in a filled tank .................................................................... 45
7.2 Commissioning .............................................................................................. 46
7.3 Shutdown ....................................................................................................... 47
7.3.1 Disassembly of the modules ................................................................ 47
7.3.2 Cleaning of the dismounted modules .................................................. 49
7.3.3 Conservation of the modules ............................................................... 49
7.4 Transport and storage of the modules ........................................................... 50
7.4.1 New modules ....................................................................................... 50
7.4.2 Used modules...................................................................................... 51
7.5 The disposal of old modules .......................................................................... 51
8 Intended Operation ........................................................................................ 51
8.1 Normal operation............................................................................................ 52
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8.1.1 Tests .................................................................................................... 53
8.2 Service and cleaning procedures ................................................................... 53
8.2.1 Service ................................................................................................ 53
8.2.1.1 Service notes.................................................................................. 54
8.2.1.2 Maintenance-cleaning .................................................................... 54
8.2.1.3 Recovery-Cleaning / cleaning in place (CIP) .................................. 55
8.2.1.4 External cleaning ............................................................................ 57
8.2.1.5 Resistance to cleaning chemicals .................................................. 59
8.3 Monitoring ...................................................................................................... 60
9 Approved chemicals ....................................................................................... 63
9.1 Glycerine ........................................................................................................ 63
9.2 Ultrasil 73 ....................................................................................................... 63
9.3 A3 MembranPlus............................................................................................ 64
9.4 A3 Activator A 101 ......................................................................................... 65
9.5 A3 Activator S 101 ......................................................................................... 66
10 Manufacturer´s declaration ............................................................................ 68
11 Annex ............................................................................................................. 70
11.1List of substances damaging the membrane.................................................. 70
11.2Example of P&ID ............................................................................................ 72
Page 6 of 72
1 MaxFlow Membran Filtration GmbH
1.1 Company profiles
1.1.1 MaxFlow Membran Filtration GmbH
MaxFlow Membran Filtration GmbH is focused on the production of microfiltration

and ultrafiltration membrane modules in the water and wastewater area. The
MaxFlow membrane modules are used as immersed low-pressure filtration modules
in wastewater treatment plants of every size as well as for filtration of surface water in
the drinking water production and in the production and process integrated filtration
process for recycling of recyclable material.
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1.2 Filtration modules of the MaxFlow Membran Filtration GmbH
1.2.1 MaxFlow-Membrane modules microfiltration
Module type M06-001 M20-002 M70-002 M70-003

Channel --- B20-002 B70-002 ---
Operating pressure [mbar] 20 – 250
Temperature range [°C] 5 - 50
Operation continuous / cyclic / pumped & gravity flow
Cleaning chemicals bases, oxidant , tenside, acid
Module data
Membrane material PVDF
Membrane surface [m²] 6.3 21.5 68.0 66.7
Material module PUR, PVC,
Pore size [µm] 0.2
Permeability, water [l/m²*h*bar] > 1000
Flux rate, activated sludge [l/m²*h] 15 - 35 15 - 35 15 - 35 15 - 35
Concentration, activated
[g/l] 8 - 15
sludge MLSS
Back wash pressure [mbar] < 50
pH, normal operation 5-9
pH, cleaning 2 – 11 (max. 30° C)
Demand of cleaning
solution per unit (CIP- [l] 28 81 249 245
Cleaning)
Design of filter bags sandwich
Grouting plastics
Module housing Protective plates PVC
Dimensions
Width [mm] 185 385 736 736
Height [mm] 1090 1058 1070 1070
Height with aeration
[mm] -- 1498 1510 --
channel
Depth [mm] 316 466 716 716
Depth with filtration pipe [mm] 395 562 825 825
Weight, dry [kg] 36 66 140 160
Weight, filled/wet [kg] 70 170 470 490
# connections 2 2 2 2
Filtration pipe diameter [DN] 16 25 50 50
Aeration
Design tube diffuser
# tubes 1 3 5 5
Material PVC, PE, stainless steel
Aeration bubble size medium-sized bubbles
Air demand per module [Nm³/h] 4.8 16 48 48
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1.2.2 MaxFlow-Membrane modules ultrafiltration
Module type U06-001 U20-002 U70-002 U70-003

Channel --- B20-002 B70-002 ---
Module data
Membrane material Polyethersulfon (PES)
Molecular Weight Cut-Off kDa 150
[g/l] 8 - 15
sludge MLSS
Demand of cleaning
Cleaning)
Grouting plastics
Dimensions
Width [mm] 185 385 736 736
Height [mm] 1090 1058 1070 1070
[mm] -- 1498 1510 --
channel
Depth [mm] 316 466 716 716
Weight, dry [kg] 36 66 140 160
Aeration
# tubes 1 3 5 5
Air demand per module [Nm³/h] 4.8 16 48 48
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1.2.3 MaxFlow-Multi modules with high density - Ultrafiltration
Module type U20-H-003 U20-HS-004 U70-H-004 U70-HS-005

Channel B20-002 B20-002 B70-002 B70-002
Module data
Membrane material Polyethersulfon (PES)
Membrane plates distance [mm] 7.0 5.5 7.0 5.5
[g/l] 8 - 15
sludge MLSS
Demand of cleaning
Cleaning)
Grouting plastics
Dimensions
Width [mm] 385 385 736 736
Height [mm] 1058 1058 1070 1070
[mm] 1498 1498 1510 1510
channel
Depth [mm] 466 466 716 716
Weight, dry [kg] 65 69 170 180
Aeration
# tubes 3 3 5 5
Air demand per module [Nm³/h] 16 16 48 48
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M06-001 M20-002 M70-002

Module type Or or or
U06-001 U20-002 U70-002
Channel --- B20-002 B70-002
Picture
1.2.4 MaxFlow-Multi modules microfiltration
Module type M70-002 double stock M70-003-MM-3-1-z-001 M70-003-MM-5-2-z
Channel B70-002 B70-002 B70-002
Operation continuous / cyclic; pumped & gravity flow
Cleaning chemicals bases , oxidant , tenside, acid
Module data
Membrane material PVDF
Membrane surface Z=1 Z=2 Z=3 Z=1 Z=2

[m²] 140
(approx. data) 210 420 630 700 1400
Material module PUR, PVC, PP
Pore size [µm] 0.2
Flux rate, activated sludge [l/m²*h] 15 - 35
[g/l] 8 - 15
sludge MLSS
pH, normal operation 5–9
Demand of cleaning solution Z=1 Z=2 Z=3 Z=1 Z=2

[l] 498
per unit (CIP-Cleaning) 735 1470 2205 2450 4900
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Module type M70-002 double stock M70-003-MM-3-1-z-001 M70-003-MM-5-2-z
Channel B70-002 B70-002 B70-002
Module data
Grouting plastics
Dimensions
Width [mm] 742 2425 3710
Z=1 Z=2 Z=3 Z=1 Z=2

Height [mm] 2140
1070 2140 3210 1070 2140
Height with aeration channel [mm] 2880 2350 3420 4490 2350 3420
Depth [mm] 716 716 1432
Depth with filtration pipe [mm] 825 825 1650
Z=1 Z=2 Z=3 Z=1 Z=2

Weight, dry1) [kg] 280
480 960 1480 1600 3200
Weight, filled/wet1) [kg] 1000 1500 3000 4500 5000 10000
# connections 4 6 12 18 20 40
Filtration pipe diameter [DN] 50 50 50
Aeration
# tubes 5 15 50
Air demand per module [Nm³] 48 144 480
Page 12 of 72
Picture
M70-5-2-z=1
1)
Weight without aeration unit
1.2.5 MaxFlow-Multi modules ultrafiltration
Module type U70-002 double stock U70-003-MM-3-1-z-001 U70-003-MM-5-2-z
Channel B70-002 B70-002 B70-002
Operation continuous / cyclic; pumped & gravity flow
Cleaning chemicals bases, oxidant, tenside, acid
Module data
Membrane material PES
Membrane surface Z=1 Z=2 Z=3 Z=1 Z=2

[m²] 140
(approx. data) 210 420 630 700 1400
Material module PUR, PVC, PP
Flux rate, activated sludge [l/m²*h] 15 - 35
[g/l] 8 - 15
sludge MLSS
pH, cleaning 2 – 11
Demand of cleaning solution Z=1 Z=2 Z=3 Z=1 Z=2

[l] 498
per unit (CIP-Cleaning) 735 1470 2205 2450 4900
Page 13 of 72
Module type U70-002 double stock U70-003-MM-3-1-z-001 U70-003-MM-5-2-z
Channel B70-002 B70-002 B70-002
Module data
Grouting plastics
Dimensions
Width [mm] 736 2448 3960
Z=1 Z=2 Z=3 Z=1 Z=2

Height [mm] 2140
1070 2140 3210 1070 2140
Height with aeration channel [mm] 2880 2350 3420 4490 2350 3420
Depth [mm] 716 716 1432
Depth with filtration pipe [mm] 825 825 1650
Z=1 Z=2 Z=3 Z=1 Z=2

Weight, dry1) [kg] 280
480 960 1480 1600 3200
Weight, filled/wet1) [kg] 1000 1500 3000 4500 5000 10000
# connections 4 6 12 18 20 40
Filtration pipe diameter [DN] 50 50 50
Aeration
# tubes 5 15 50
Air demand per module [Nm³] 49 144 480
Page 14 of 72
Picture
1)
Weight without aeration unit
2 Safety instructions
Please always consider:
Safety first!
Page 15 of 72
The security installations, which were installed at the machine by the

manufacturer, are just the base of the industrial safety. The main
responsibility to guarantee an accident-free operation has to be taken on
by the operator and its trained staff.
Only appropriate and intended handling and the compliance with the
requested maintenance procedures can guarantee the functionality and a
long life-cycle of the membrane modules and of all the parts of the
installation. Moreover, appropriate and intended handling will help to
avoid any industrial accident.
The staff performing the operation and the maintenance of the filtration
plant has to have read and understood this manual. All the instructions
mentioned in this manual should be followed in detail. In order to
guarantee a high system security and to avoid any industrial accidents,
only authorized and well trained staff should be instructed in handling the
installation. A technical briefing regarding potential risks which may occur
during the operation of the installation should have been given to the
staff.
The manufacturer will not be liable for personal injuries resp. material
damage caused by improper handling or by non-observance of the
mentioned security advices. This risk will only be covered by the owner
resp. the operator of the installation.
An operation of the membrane modules, varying of the hints

mentioned in this manual, will cause the loss of any warranty right.
Page 16 of 72
3 Basics of the membrane technology
3.1 Definitions
Listed below is a short overview of critical definitions concerning membrane

bioreactors and membrane technology.
Biofouling
Biofouling is a biological contamination of the membrane due to microorganisms
and their excrements. These particles will create a “biofilm”, while first “pasting up”
and then, with increasing operation period, growing up at the membrane surface.
CIP treatment
Cleaning procedure where the module is cleaned without being removed. (Clean
in Place)
Concentrate
Portion of the flowrate which will be retained by the membrane (e.g. activated
sludge)
Covering layer
Deposit on the membrane caused by the filtration process comprising retained
organic and inorganic substances.
Cross-flux
The Cross-flux is the flowrate during the filtration process related to the membrane
surface ; unit: L/(m²*h).
Cross-flow
In this process type the feed flow constantly overflows the membranes parallel (the
membrane surface is installed parallel to the main flow direction) and the permeate
flow will be evacuated vertically to the main flow (cross-flow filtration). As this
overflow of the membranes will create shear forces at the membrane surface, a
balance between layer formation and layer removal is achieved. Considering
MBR-technologies with submerged membrane modules the cross-flow effect is
obtained by the aeration system in the bioreactor. In this way it is possible to limit
the layer formation.
Page 17 of 72
Dead-end-operation
Regarding the Dead-end-operation the membrane will be loaded vertically by the
main flow direction, compare „coffee filter“. The removal of detained particles is
achieved by a periodic back-flow of the membranes.
Feed
Flowrate charging the membrane, e.g. activated sludge.
Filtrate
Water separated from the feed by pore filtration (mixture of substances).
Flux
Specific filtrate per square and time ; unit: L/m²*h.
Fouling
Accumulation of particles at the membrane surface, at or in pores of the
membrane structure. Depending on the materials provoking the fouling it is
differentiated between colloidal fouling, inorganic fouling (scaling) and biofouling.
Fouling is provoking a reduction of the filtration capacity and the permeability.
In-place-cleaning
In-place-cleaning is a cleaning procedure adapted to the membrane bioreactor
technology (additional information in chapter 8.2.1.3 – Recovery-Cleaning (CIP)).
Maintenance cleaning
Regular cleaning during normal operation.
MBR
MBR = membrane bioreactor
Membrane
Barrier, which is provoking the retaining of particles (for further information see
chapter 3.2).
Membrane area
Membrane surface which is available for the filtration process.
Module
Component, which is ready for connection (functional) and which consists of the
membrane or the membrane element, collecting line and fittings.
Page 18 of 72
Net flux
Performance of the installation in a long term period (considering filtration breaks,
back-flow periods and the volume of filtrate needed for the backflow process).
Operational pressure
The operational pressure is the driving force for the physical separation process
with membranes. This operational pressure is necessary in order to guarantee a
filtration process. The operational pressure is consisting of the transmembrane
pressure and several pressure losses occurring in the connected periphery of the
system.
Performance (filtration performance)

The performance is appointing how much permeate is produced in certain period ;
unit e.g. L/h.
Performance test with drinking water

Performance test of the membrane during a filtration process of drinking water at
20°C.
Permeability
Porosity of a membrane under defined conditions (e.g. temperature).
Permeate
Portion of the flow-rate which is passing the membrane.
Pore size
Average pore size of a porous membrane, relevant for the retaining performance
of a membrane. The pores of a membrane will usually not be homogenous – they
will be characterized by a particle size distribution ; unit: µm.
Porous membrane
In case of porous membranes (MF, UF) the selective separation is obtained by a

screen effect.
Cyclic operation
Standard operation: filtration phase with subsequent back-flow phase resp.
standstill phase.
Page 19 of 72
Retentate
Portion of the flow-rate which will be retained by the membrane (e.g. activated
sludge)
Scaling
Accumulation of inorganic ingredients at the membrane surface, if limits of
solubility of dissolved salts will fall below as a result of concentration increase
Solution-diffusion (or “nonporous“ or “dense“) membrane

In case of solution-diffusion-membranes (NF, RO) the selective separation is
obtained by different solubility and different character of diffusion.
Transmembrane pressure
Pressure difference between the filtrate side and the feed side.
Drinking water
Water, which is suitable for human usage: the pH-value of drinking water is
determined to be between 6.5 and 9.5; the water hardness should be between 0.9
and 4.4 mmol/l.
3.2 Membrane filtration
The membrane filtration is a physical process which can remove, depending on the
membrane type, a wide range of substances (from fine particles up to dissolved
ingredients) out of water or wastewater.
The classification of the membrane processes is depending on the cut-off size. The
transition between the different membrane processes is smooth.
The following processes are existing:
Microfiltration (MF)
Ultrafiltration (UF)
Nanofiltration (NF)
Reverse osmosis (RO)
Page 20 of 72
Umkehrosmose
Reverse Osmosis Ultrafiltration
Membrane
process
Nanofiltration Mikrofiltration
Microfiltration
Size of the
100 200 10.000 20.000 100.000 500.000 molecular weight
retaining
substances [dalton]
0,00 0,01 0,1 1,0 approx. size

[µm]
reactive
Examples Pigmentfarbstoffe
pigment dye
dye
Enzyme
enzyme activated sludge
Belebtschlamm
flocken
flocs
Viren
viruses Bakterien
bacteria
Salze
salts
Tenside
tenside fat– and
Fett- undoil-
Öl-
Emulsionen
emulsions
Zucker
sugar Gelatine
gelatin Hefe
yeast
metal
Metall- colloidal
kolloidale
ionen
ion Silikate
silicate
Antibiotika
antibiotics
endocrinalwirksame
Endokrin effective
substances
Substanzen
Figure 1: Classification of membrane processes depending of their separating

1
mechanism [RAUTENBACH, 1997]
The membranes are fine permeable layers (thickness approx. 0.1 µm – 0.5 µm),
which are superimposed on a support frame for stability reasons.
Concerning the separating mechanism it is differentiated between porous

membranes (MF, UF) and solution-diffusion-membranes (NF, RO).
Regarding the membranes of micro- and ultrafiltration applications the separation

process is based on microporous layers with defined pore sizes. Particles - or also
molecules -, which are bigger than the max. pore size of the membrane are retained
completely. The membranes of the nanofiltration and reverse osmosis applications
1 RAUTENBACH (1997): Membranverfahren – Grundlagen der Modul- und Anlagenauslegung.

Springer Verlag, Berlin.
Page 21 of 72
are nonporous solution-diffusion-membranes. The solvent – usually water – can

diffuse through the membrane.
The driving force of the separating mechanism is a pressure difference

(transmembrane pressure) between the feed side and the permeate side.
The microfiltration (MF), which is prevalent used for the concentration of colloidal
suspensions, is usually operated in a pressure-difference-zone of 0.1 bar up to
0.3 bar.
The ultrafiltration (UF) is characterized by a higher separation capacity compared to

the microfiltration (due to the smaller membrane pore sizes). The ultrafiltration is
used for the concentration of macromolecular and colloidal solutions. Dissolved
matters will pass the membrane. A transmembrane pressure of 0.5 bar up to 10 bar
is usually required.
Nanofiltration membranes (NF) are solution-diffusion-membranes. The cut-off of this

process is characterized by a molecular weight of 200 up to 500 Dalton. As
nanofiltration membranes allow the separation of dissolved organic molecules and
polyvalent inorganic ions, they are predominantly installed for industrial applications.
A nanofiltration membrane is usually operated at transmembrane pressures between
2 bar and 40 bar.
The reverse osmosis (RO) is allowing a concentration of solids of a low molecular

weight. Also dissolved substances - salts and macromolecules – can be isolated out
of a liquid. The fields of application for the reverse osmosis include the desalination
of brack- and salt-water as well as the treatment of landfill leachate.
For the reverse osmosis processes solution-diffusion-membranes are used. Reverse

osmosis membranes will usually be operated at transmembrane pressures of 5 bar
up to 70 bar.
Page 22 of 72
3.3 Operating parameters of a membrane unit
The driving force of the separation process is the pressure difference between
feed- and permeate-side, the transmembrane pressure. In case of the submerged
low-pressure-filtration the transmembrane pressure is created by a vacuum on the
filtrate side.
Specific flux
The flow rate of a membrane is an indicator of the capacity under certain
circumstances. If the flow rate is related to the membrane surface, the result is the
specific flux L/(m²*h) of the membrane. The temporary specific flux during the
operation process is defined as gross flux. The net flux is describing the
performance of a system in a long term period (considering filtration breaks, back-
wash periods and the volume of filtrate needed for the back-wash process); unit:
e.g. m³/d related to the membrane surface.
Permeability
The permeability is describing the permeably character of a membrane. It is
defined as the ratio of specific gross flux and transmembrane pressure, unit:
L/(m²*h*bar).
The permeability is directly depending on the condition of the membrane and the
filtration attributes of the fluid which should be permeated.
Critical flux
According to FIELD et al. (1995)2 there is no decrease of the membrane
performance observed, while operating the membrane below a certain flux
(„subcritical“). However while exceeding this critical flux („overcritical“), there
occurs a reinforced membrane fouling and a performance decrease of the
membrane is noticed.
2 FIELD et al. (1995): Critical flux concept for microfiltration fouling. Journal of Membrane Science.
Page 23 of 72
3.4 Formation of a cake layer
With proceeding period of operation a formation of a cake layer on the membrane

surface is to be observed caused by organic and inorganic solids retained by the
selective separation of the membrane. This layer will provoke a reduced filtrate flux
(at constant pressure) combined with an unwanted reduction of the performance of
the membrane. In order to guarantee the operation security and the cost-
effectiveness of membrane systems, a control-method for this layer-formation has to
be developed. A layer-control-mechanism results from the following constructive and
procedural steps:
pre-treatment of the wastewater,
process configuration
elaboration of a cleaning strategy
These steps should be considered in the design phase.
3.5 Limitation of cake-layer-formation
A pre-treatment stage must eliminate particles and matters that can negatively
influence and/or damage the filtration process, such as abrasive solids, fats, oils and
fibres. Suitable methods have to be chosen according to the specific attributes of the
wastewater, as e.g.
screen unit,
lightweight material separator
precipitation/ flocculation…
Please find a detailed description concerning this subject in chapter 4.3.1.
In order to guarantee the performance of the membranes, methods for removing the
cake layer at the membrane surface must be considered. Two types of substances
are differentiated:
- substances which can be released mechanically
- substances which can just be released by use of chemicals
Page 24 of 72
Easily removable cake layers will usually be eliminated by the aeration device that is
installed below the membrane modules. As a result of the ascending air, a flow
parallel to the membrane surface generating shear forces is established. All deposits,
which cannot resist the shear forces, will be removed from the membrane surface.
Membrane layers, which cannot be removed in this manner, must be dissolved by

cleaning chemicals. A cleaning solution is pumped in the opposite direction to the
usual filtration direction into the membrane. The cleaning solution stays for a defined
time within the membrane while soaking it. The time span depends on chemical
concentration, temperature, type of fouling, etc. Afterwards, the substances „pre-
dissolved“ in this way will be removed completely from the membrane either by the
shear forces caused by the ascending air or by a short back-flow of the permeate.
For a detailed description of the methods to maintain the filtration performance,

please refer to chapter 8.2.
Page 25 of 72
4 Basics of membrane bioreactors
4.1 Basics of the biological wastewater treatment – applications and limits
The common attribute of all types of biological wastewater treatments (activated

sludge method, fixed bed reactor,…) is that the elimination of the solids is caused
exclusively by the metabolism activity of the micro-organism. Due to the
concentration of the micro-organisms (e.g. activated sludge) combined with the air-
entry the natural self-cleaning-effect of the water is accelerated – so the water will be
cleaned.
During the biological reduction process the micro-organisms oxidise the solids.
Besides the biomass production (cell growth) by the metabolism of the biomass
gases (e.g. elementary nitrogen) which will exit to the atmosphere will be produced.
The biological wastewater treatment processes were originally developed for the
elimination of carbon. Since the 90s there were appointed limiting values for
discharge of nutrients (nitrogen and phosphorus) in Germany depending on the size
of wastewater treatment plants (compare Abwasserverordnung, AbwV (2004)3).
Therefore in wastewater treatment plants there are operated aerated and non-
aerated reactors which will eliminate the nitrogen (nitrification and denitrification) and
carbon. As a biological phosphorus elimination based on the technology of anaerobic
reactors is not a standard solution, more often the chemical phosphorus elimination is
applied. In waste water treatment plants the microorganisms are supplied with
sufficient oxygen so that they remove as much solid matter as possible as quickly as
possible. But when this occurs bacteria increase and new biomass is formed from a
part of the organic substance.
3 AbwV (2004): Verordnung über Anforderungen an das Einleiten von Abwasser in Gewässer. BGBl. I
Nr. 28 vom 22.6.2004
Page 26 of 72
4.2 Parameters for characterisation of the wastewater
Biochemical Oxygen Demand (BOD)

The biochemical oxygen demand is a sum parameter for determining the organic
pollution rate of the wastewater. The necessary oxygen demand for bio-chemical
metabolism processes of easily degradable solids is appointed on standardized
basic conditions. E.g. the BOD5 is determining the volume of the oxygen
necessary for the biological degradation of the solids comprised in the wastewater
at a temperature of 20°C during 5 days. The higher the BOD-value, the higher is
the biodegradable portion of the raw water.
Chemical Oxygen Demand (COD)

The chemical oxygen demand test is commonly used to indirectly measure the
amount of organic compounds in water. Contrary to the BOD-parameter the COD
is detecting the biotic degradable as well as the non-biotic degradable substances.
Volatile compounds which easily evaporate can not be registered.
The higher the COD-value, the higher is the portion of the organic and the
inorganic compounds in the raw water.
Total Organic Carbon (TOC)

The TOC is the amount of total carbon bound in an organic compound. The
dissolved organic and the individual organic bound carbon are registered.
Compared to the COD-parameter the bond rate, the oxidation rate and the
physical condition are not considered. The procedure of the TOC-determination is
a burning process in which all the carbon compound, part of the assay, will be
oxidized to CO2.
pH-value
The pH-value is considering the concentration of hydrogen-ions and is so an
indicator of acidity in aqueous solution. The pH-value is the negative common
logarithm of the hydrogen-ion-concentration which is calculated as mol H+/L. The
smaller the pH-value, the higher is the acidity of the solution. The pH-value of the
activated-sludge-water-mix has to be between 6.5 and 8.5, otherwise the
metabolisms of the biomass will be interrupted.
Page 27 of 72
For a detailed analysis of the available acid-/ base volume in addition the acid
capacity resp. the base capacity has to be determined.
Acid capacity / base capacity
The result of the acid capacity is an indicator for the buffer capacity of the water
compared to acid and is so guaranteeing the pH-value-stability. The acid capacity
of the water indicates the volume of acid – in practice 0.1 mol/L hydrochloric acid -
which is dissipated until achieving a pH value of 4.3. Caustic soda is used for the
base capacity in order to reach a pH value of 8.2 for a defined amount of water.
Temperature
While operating of a biological wastewater treatment installation it has to be paid
attention to the temperature as it strongly affects the metabolism of the micro-
organisms. Extreme (too low or too high) temperatures may negatively harm the
biological degradation process and may even destroy the biomass in the reactor.
The optimized temperature for a biological wastewater treatment is set between
10°C and 30°C.
Conductivity
In wastewater is the conductivity a sum parameter for the concentration of ions
and the salt compounds. The results are stated based on a reference temperature
(usually 25°C); 0.1 mS/m at 25°C corresponds to 0.425 mg/L salt content (mg/L
TDS = total dissolved solids). The higher the electrical conductivity, the higher is
the rate of the dissolved salts. The measurement of the conductivity serves
amongst others for monitoring the salt-concentration of the influent. The
conductivity is measured in S/cm.
Nutrient rate
In order to guarantee a successful biological degradation the rate of BSB5 to
nitrogen to phosphorus should be approx. 100:5:1 (DWA, 19974). A lack of one of
these nutrients may harm the biological degradation process.
4 DWA (1997): Biologische und weitergehende Abwasserreinigung. Ernst & Sohn Verlag, 4. Auflage
Page 28 of 72
4.3 The MBR-technology
The membrane bioreactor (MBR) is a combination of the activated sludge process

and the membrane technology.
After the biological cleaning process the biomass (activated sludge) is not isolated by
the conventional sedimentation process in the clarifier, but by the membrane (micro-
or ultrafiltration). Due to the small pore size, the membrane is not only a barrier for
the activated sludge, but also for suspended substances, bacteria and viruses. The
high quality of the effluent, allows the use of the permeate as service water.
Optionally a subsequent membrane level may be considered, like nanofiltration or
reverse osmosis.
Regarding the MBR-technology 2 types of system arrangement (MUNLV, 2006)5 are

to be differentiated: wet installation and dry installation.
The “wet installation” is based on membranes which are directly submerged in the
activated sludge tank. Concerning the “dry installation” the membranes are installed
outside the aeration tank. The transport process will be provided by a pump, creating
the transmembrane pressure and the minimum flow-velocity. Apart from the
additional energy costs with this method of operation the mud flakes are under a
great deal of mechanical stress so that modules set up dry are not used in municipal
waste water treatment plants.
Regarding submerged modules the aeration device guaranteeing the necessary air
supply for the biomass degradation are installed under the membrane modules and
in the aeration tank. This upstream air flow will permanently pass the membrane
module and will relieve the cake layer from the membrane surface.
5 MUNLV (2006): Membrantechnik für die Abwasserreinigung. Ministerium für Umwelt, Naturschutz,
Landwirtschaft und Verbraucherschutz des Landes Nordrhein Westfalen, FIW-Verlag.
Page 29 of 72
Raw wastewater
Permeate
Aeration
Figure 2: Arrangement of membrane bioreactor
The MBR-technology provides the following main advantages compared to

conventional activated sludge systems:
Clarifier can be economised, as the membrane stage retains the solids totally
(cp. phosphate reduction by adsorption)
By installing further membrane modules, easy capacity upgrade of the MBR
installation possible
Smaller bioreactor volume due to higher TS compounds at constant sludge
loading
Obtaining a complete sludge generation interval of the biomass, due to a
higher sludge age
Flexible installation place due to low weight and small dimensions
Possible to influence the rate of the excess sludge by changing the sludge
loading
Flexible and modular construction possible, as no additional external piping
necessary and as all existing installation components can easily be used.
An automatic operation process is guaranteed by an independent control
system and a easy procedural principle
The installation can easily monitored by checking the transmembrane
pressure development
Page 30 of 72
Good acceptance in high populated areas due to smaller property and easy
enclosure
Reduction of residual organic contamination as well as hygienisation of the
plant’s outlet to the greatest possible extent whereby measures for
hygienisation or more extensive secondary treatment can be omitted.
A MBR-installation is less sensitive regarding the biological balance by
impulsive influent-charges, e.g. during heavy rain events
Even in case of floating sludge a solid-free outlet quality can be guaranteed
Safe separation process of all the particular solids even on mobile equipment
(e.g. on ships)
inlet outlet
screen activated sludge tank clarification grit filter
Inlet
inlet outlet
screen Membrane bioreactor

membrane
Figure 3 Schematic of a conventional WWTP (above) and of a membrane

bioreactor
Systems with membrane technology are considered to be in the industrial wastewater

treatment and in the landfill leachate treatment as state-of-the-art technologies. In the
last years by developing the low-pressure-membrane system (submerged
membranes) a cost-effective application field was established in the sector of
domestic wastewater treatment. The combination of the activated sludge method and
the membrane technology is guaranteeing the elimination of carbon, phosphorus and
Page 31 of 72
nitrogen, but is also effecting persistent, toxic (carcinogenic, mutagenous and

hormonal active) and bio-accumulative micro-contaminants.
Furthermore the system will comply with the hygienic quality standards requested
e.g. in the „European council directive concerning the quality of bathing water“
(limiting value for faecal and total coliform-bacteria germs).
As membrane bioreactors can be operated with higher biomass concentration, the

activated sludge tank size can be reduced keeping the sludge loading constant –
cost-effectiveness.
Pollutants, which can not be eliminated by a membrane bioreactor, can be retained

by a direct after-treatment, as a nanofiltration or a reverse osmosis. The total solid
retention of the selective separation of a membrane bioreactor is increasing the
performance and the economic efficiency of optionally downstream treatment stages
(compared to after-treatments of conventional WWTP).
4.3.1 Pre-treatment
When pre-treating untreated water, all particles and waste water components that
may damage the membrane, modules or other parts of the plant must be removed
from the untreated water. Especially hairs, fibre tissues and fats in high
concentrations will provoke clogging on the membranes. Other materials may
damage the membrane by high mechanical stress or by sharp angles.
Compared with the plate modules used here, the risk of clogging is considerably
higher when hollow fibre modules are used. Nevertheless, good pre-cleaning should
be carried out in order to ensure fault-free operation. It must particularly be ensured
that the pre-cleaning process cannot be bypassed in the case of an error in the
sieving procedure and that thus no sewage, which has not undergone pre-cleaning,
can enter the membrane tank.
4.3.1.1 Screen / sieve
For eliminating bigger and fibered pollutants out of the inlet-flow, the installation of
screens or sieves is urgently requested.
A classification of screens or sieves according to their mesh size is listed in Table 1.
Page 32 of 72
Table 1: Classification of screens or sieves
Type of screen Mesh size

coarse rack > 50 mm
strainer rack 10 mm – 20 mm
sieve < 10mm – 1 mm
fine sieve < 1 mm
4.3.1.2 Grit chamber and grease separator
In the grit chamber (and/or the grease separator) the flow-velocity of the wastewater
will be reduced in order to allow the sedimentation of mineral solids. A roll-flow is
obtained by aerating the grit chamber/ grease separator. A scum baffle is installed in
the tank in order to accumulate the grease components of the wastewater in a flow-
depressed area of the tank. The installation of a grit chamber/ grease separator is
necessary in order to protect the membranes and pumps as the cleaning effect of grit
chambers and grease separators is reducing the wearing of membrane and pumps.
4.3.2 Bioreactor
The elimination of the solids in the bioreactor is achieved by the concentrated micro-
organisms. Due to the selective separation of the membranes, standard average
TSS-concentrations in the activated sludge tank of MBRs are between 8 g/L und
15 g/L. which is significantly higher compared to conventional WWTPs (factor 3 - 5).
The type and the arrangement of the aeration system (intermittent aeration, upstream
denitrification) is chosen depending on the necessary elimination processes
(nitrification, denitrification, carbon elimination).
The necessary volume of the activated sludge tank is mainly influenced by the sludge
loading and sludge age. Most of the municipal membrane bioreactors are operated
with a sludge age of 25 days, so they are called installations with aerobic sludge
stabilisation (DWA, 1997)6. Basically it can be assumed that the biological processes
of MBRs do not vary from those of conventional activated sludge systems.
6 DWA (1997): Biologische und weitergehende Abwasserreinigung. Ernst & Sohn Verlag, 4. Auflage
Page 33 of 72
Usually the sludge of MBR-systems possesses a smaller floc size. Although this is
combined to a bigger specific floc surfaces, the capability of drainage of the sludge is
usually not negatively effected.
By adding A3 MembranPlus the quality of the activated sludge is improved so that

the flakes are denser and more compact and the sludge can be filtered better.
4.3.2.1 Excess sludge
As the growth of the micro-organisms is concentrating the activated sludge, this

additional sludge (excess sludge) has to be removed out of the system in order to
operate the system on a constant sludge loading.
The guideline A 131 of the German association for water, wastewater and waste
(DWA, 20007) is providing hints for estimating the volume of the excess sludge
production.
The treatment of the excess sludge is mainly achieved by the sludge dewatering (e.g.
centrifugal or chamber filter press) and/or by the sludge decomposition.
7 DWA (2000): Arbeitsblatt ATV-DVWK-A 131 – Bemessung von einstufigen Belebungsanlagen.

Gesellschaft zur Förderung der Abwassertechnik e.V., Hennef.
Page 34 of 72
5 Design parameters for membranes resp. membrane

bioreactors
5.1 Basics for the design of the activated sludge tank
The design procedure for membrane bioreactors is based in Germany on guidelines

for designing conventional WWTP with the activated sludge process. Beside the
guideline ATV-DVWK-A 131 of the DWA (2000)8 it is possible to design systems
based on the “Hochschulgruppenansatzes (HSG-Ansatz)”, (BÖHNKE et al. (1989)9,
DOHMANN et al. (1991)10), an approach established by a network of different
German universities. Moreover the Ministry of the Environment and Conservation,
Agriculture and Consumer Protection of the German State of North Rhine-Westphalia
(MUNLV) published a manual including notes and hints for the design of a membrane
bioreactor (MUNLV, 2006)11. This manual combines the characteristics of a MBR
with the design-guidelines which are based on the know-how of conventional
WWTPs.
Important parameters influencing the activated-sludge-tank-volume are: the inlet

concentrations, the design temperature, the relevant MLSS-concentration, the sludge
age resp. sludge loading and the requested monitoring parameters.
8 DWA (2000): Arbeitsblatt ATV-DVWK-A 131 – Bemessung von einstufigen Belebungsanlagen.

Gesellschaft zur Förderung der Abwassertechnik e.V., Hennef.
9 BÖHNKE et al. (1989): Bemessung der Stickstoffelimination in der Abwasserreinigung – Ergebnisse

eines Erfahrungsaustausches der Hochschulen. Korrespondenz Abwasser, Nr. 9, Jg. 36.
10 Dohmann et al. (1991): Bemessung der Belebungsbecken nach dem Ansatz der Hochschulgruppe
(HSG-Ansatz). Korrespondenz Abwasser, Nr. 8, Jg. 38.
11 MUNLV (2006): Membrantechnik für die Abwasserreinigung. Ministerium für Umwelt, Naturschutz,
Landwirtschaft und Verbraucherschutz des Landes Nordrhein Westfalen, FIW-Verlag.
Page 35 of 72
5.2 Basics to design the membrane stage
The necessary membrane surface is achieved by the ratio of the maximum inlet flow
to the max. permeate flow.
Amembrane = Qinlet / Fu
Amembrane = Membrane area
Qinlet = maximum inlet flow
Fu = Flux
Using MaxFlow-modules in a MBR with municipal wastewater a continuous flux of

10...25 L/(m²*h) and a maximum flux of 40 – 50 L/(m²*h) for a period of max. 2 hours
is often assumed. In average, the permeate flux is equal to the inlet flow (considering
the cyclic operation). As a result of the pulse/pause operation, during the pause less
waste water is filtered than flows in and during the filtration operation the filtration
volume stream exceeds the influent flow. Overall the mean value of the filtrate
volume stream is the same as that of the inflow volume stream.
Considering the water volume displaced by the membranes and the necessary
nitrification-volume, it should be controlled if the nitrification volume for the installation
of the membranes is sufficient or if additional volume has to be provided.
Moreover for the calculation of the minimum height of the tank, the minimum charging
level and a safety factor for intense rain events (resp. mixing pond and equalizing
reservoir) has to be considered.
Page 36 of 72
6 Arrangement and construction of the modules in a

filtrationreaktor
6.1 Arrangement and construction of the modules
The MaxFlow-membrane modules (Figure 4) of the MaxFlow Membran Filtration

GmbH are plate modules, which are constructed by many parallel-arranged filter
bags with defined distances between these bags. The bags are fixed by collateral
grouting elements, in which the filtrate of the individual bags is collected and
discharged.
Figure 4: MaxFlow-membrane module
The individual bags are hollow inside and covered with a membrane on both sides.
The module is totally submerged in the liquid which has to be filtrated. All substances
smaller than the stated cut-off, will pass the membrane and will be extracted by the
filtration pipe.
Basically filtration modules will be arranged in MBR installations as follows (Figure 5):
The aeration unit is placed under the filtration module and will be fixed with retaining
plates on the filtration module. Above the filtration module the connection for the
lifting modules is screwed on. For flexibility reasons the collector line should be a
tube line.
A filtration unit may be a one-storied membrane construction or a multi-storied

membrane construction, in which 2 or 3 modules are installed on top of each other.
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buoyancy security permeate outlet
guide tube air inlet
lifting module
filtration module
brackets
aeration unit
Figure 5: Construction of a membrane module incl. aeration unit, filtration module and
lifting module – one-storied module (left) and 2-storied module (right)
Another possible arrangement is the multi-module (Figure 6): the aeration unit is
integrated in the module frame where max. 9 membrane modules can be installed in
total. As all the membrane modules can be dismounted completely, the installation/
disassembly effort is minimized. The main advantage of this arrangement is based on
the compact construction, minimized space requirements and the centralized air
supply.
The membrane modules will be installed in guide tubes. This must be done in such a
way as to prevent a lateral movement (slip) of the membrane modules (e.g. because
the tank or the water moves). Furthermore, the guide tubes must have lateral
reinforcements in order to prevent bulging of the module wall when back flushing the
module (counter bearings). The distance to the basement has to sufficient in order to
allow the formation of a roll-flow. To do this there must also be an open space next to
the module that is just as big as the area of the module (double area). The guide rod
ensures that the modules stay fixed in their place.
Page 38 of 72
Figure 6: Design of a Multi-module-system with three modules arranged next to one another
and three modules arranged one above the other.
Furthermore, a buoyancy security fixes the module unit in the tank and prevents that
the modules float. In order to remove the modules out of the tank, this buoyancy
security has to be arranged above the water surface.
The placement resp. disassembly of the modules has to be completed by a crane, as

the modules will be inserted from above in the activated sludge tank.
Different module fixings, distances from the floor or the walls and
aeration equipment must be cleared with
MaxFlow Membran Filtration GmbH.
Page 39 of 72
6.2 Design of a MBR
6.2.1 Hints for module arrangement
• It is required that the modules are totally submerged in the

activated sludge liquid guaranteeing always a minimum sludge-
coverage of the modules.
• In order to allow the formation of the necessary aeration roll-flow,

the footprint of the membrane tank should be double the size of
the assembly-area of the membrane modules (see below).
Furthermore the aeration modules need to keep a minimum
distance of 30 cm to the basin floor and the module footprint of the
side-by-side arranged modules must be equal to the face between
tank floor and aeration unit.
• The frames guide the modules sufficiently and sufficiently support

the side walls against bulging during back flushing.
Examples of membrane arrangements:
• Arrangement of the membrane bags parallel to the horizontal roll-flow direction
• Arrangement of maximum 2 module series parallel to the horizontal roll-flow

direction
Page 40 of 72
Varying module arrangements have to be confirmed by

MaxFlow Membran Filtration GmbH!
6.2.2 Pumping technology of the filtration unit
For filtrate-pumps usually rotary piston pumps, eccentric screw pumps or self-priming
centrifugal pumps are used as these pumps are easily adjustable and operate at
constant flow-rates and varying operational pressures. Also, positive displacement
pumps are used as they are self-priming and allow pumping an air-liquid-mixture.
Positive displacement pumps are bi-directional and can minimize equipment
installation for small and average sized systems (e.g.: no pump exchange necessary
during CIP cleaning of the membranes).
The resistance of the selected pumps to the chosen cleaning chemicals must be
confirmed.
A de-venting device can also be integrated in the filtration line. This is always of
benefit when any build-up of air or gas is expected in the filtration line that cannot be
eliminated by the pump alone. The de-venting device is to be produced so that it
ensures complete de-venting at the highest point of the line e.g. during the pause
phase in filtration.
6.2.3 Aeration
For the aeration of the MaxFlow-membrane modules a suitable aeration-aggregate is

offered by A3 Water Solutions GmbH. Self-designed aeration systems have to be
approved beforehand by MaxFlow Membran Filtration GmbH, in order to guarantee
the functional efficiency of the modules.
The necessary aeration rate for each type of MaxFlow-membrane module is noted in
the specifications in chapter 1.2.1. The aeration rate is related to footprint of the
module, viz. if 2 or 3 modules are installed on top of each other, the aeration rate will
remain constant as the footprint is constant too.
To ensure proper aeration, the aerator cartridges in the aerator module must be
checked regularly for proper functioning (homogeneous distribution of bubbles over
Page 41 of 72
the whole length of the cartridge). It is also recommended to do an optical inspection

of the aerator cartridges periodically by pulling out the aerators. The lifetimes of the
aerator cartridges can be very different depending on the waste water.
They should be replaced regularly:
Communal sewage water: every 2-5 years (depending on the condition)
Industrial waste water: every 1-3 years (depending on the condition)
The aeration units is installed below the membrane modules by retaining plates and
they are serving for the air supply of the nitrification process as well as for the control
of the cake layer thickness – formation of the flow parallel to the membrane surface
(compare chapter 3.5).
Different module assembly or self-developed aeration equipment must

be cleared with MaxFlow Membran Filtration GmbH.
Damaged aerators will lead to blocked membrane modules and can

destroy the membrane modules! Aeration must work proper during
filtration process.
Page 42 of 72
6.2.4 Process measuring and control technology
The process measuring and control technology are important equipments while
operating and controlling a MBR. For a higher operational safety the following
parameters should be measured online:
Permeate rate
MLSS-concentration of the sludge (recommended)
Dissolved oxygen in the activated sludge tank (recommended)
air flow rate for the aeration of the membrane
7 Membrane modules
7.1 Installation of the membrane modules
Figure 7: MaxFlow-Membrane module
The membranes must be installed in frost-free conditions! Moreover the modules

should be protected against intensive solar irradiation, dust and temperatures
> 50°C!
Page 43 of 72
Prior to commissioning, remove any impurities caused by the installation process,

substances used during treatment and contaminants from pipes and tanks.
7.1.1 Installation in an empty tank
1. Above the membrane module (1) a lifting module is installed and fixed. The
module can be lifted by a crane.
2. In case of a multi-storied arrangement the membrane modules will be installed

on top of each other and will be screwed on by retaining plates. The filtration
pipes will be interconnected by hose adapters and hose clamps.
3. The membrane module or the multi-storied modules will be installed on the

aeration unit and will be fixed by 2 retaining plates.
4. The lifting device is equipped with the buoyancy security.
5. The tube adapter will be connected at the top of the filtration pipe (2) of the
module. The other end of the tube adapter is remaining unbolted in order to
make it possible that the air can escape from the module when the module is
emerged. Otherwise the module can be damaged! The ball valve must be
closed and the screwed connection must be tightened.
6. The aeration unit is connected with the compressor by a tube line (pay
attention to the temperature and sewage resistance of the tube).
7. The interconnected modules will be SMOOTHLY inserted, lifted by the

buoyancy security, along the guide tubes in the tank.
8. The buoyancy security will be fixed at the tank edge in order to avoid a buoying
upwards-effect of the modules in operation.
9. Checking/ controlling the connected tubes and the circumference.
10. The filtration pipe has to be unbolted to the atmospheric pressure in order to
allow air exhausting the module.
11. Control the tidiness of the tank. All impurities caused by the installation
process have to be cleaned.
12. Steady filling of the tank (directly after the installation of the modules), in order
to allowed trapped air to exhaust out of the membrane. The minimum distance
Page 44 of 72
between the top of the module and the water surface must not be less than
30 cm after the filling process.
13. Close the filtration pipe.
7.1.2 Installation in a filled tank
1. Above the membrane module (1) a lifting module is installed and fixed. The
module can be lifted by a crane.
2. In case of a multi-storied arrangement the membrane modules will be installed

on top of each other and will be screwed on by retaining plates. The filtration
pipes will be interconnected by hose adapters and hose clamps.
3. The membrane module or the multi-storied modules will be installed on the

aeration unit and will be fixed by 2 retaining plates.
4. The lifting device is equipped with the buoyancy security.
5. The tube adapter will be connected at the top of the filtration pipe (2) of the
module. The other end of the tube adapter is remaining in order to make it
possible that the air can escape from the module when the module is emerged.
Otherwise the module can be damaged! The ball valve (4) must be closed and
the screwed connection must be tightened.
6. The aeration unit is connected with the compressor via hose (pay attention to
the temperature and sewage resistance of the tube).
7. The interconnected modules will be SMOOTHLY inserted, lifted at the

buoyancy security, along the guide rails in the tank. The filtration pipe has to
be unbolted to the atmospheric pressure in order to allow air exhausting the
module.
8. The buoyancy security will be fixed at the tank edge in order to avoid a buoying
upwards-effect of the modules in operation.
Page 45 of 72
The activated sludge tank should contain NO contaminants or

sharp-edged items, like cable slips, swarf or wires.
Move the module only by using the lifting module. NEVER use
the filtration pipe as a carrying handle!
The module must not be installed by use of force! Avoid any kind
of blows impacting the module, e.g. hammer blows!
The module must be protected against unintended fall during the

installation process! Multimodules must be protected against
toppling.
When moving a multimodule, a cross beam is to be used. The

fastening using chains and belts is expressly prohibited!
The dipping and immersion of the modules must be carried out
with open collector line with direct connection to the atmospheric
pressure in order to guarantee the captured air to be exhausted!
The modules must be fixed in the tank against buoyancy!
The minimum distance between the top of the module and the
water surface must not be less than 0.3 m after the filling
process!
7.2 Commissioning
The procedure of the commissioning is as follows:
1. Module installation according to chapter 7.1.
2. Switching-on of the aeration unit. Never operate the modules with out aeration!
3. Closing the filtration pipe against the atmosphere
4. Starting the installation according to the manual of the operator
Page 46 of 72
The minimum distance between the top of the module and the
water surface must not be less than 30 cm after the filling
process!
A fall-dry of the modules has to be avoided!
Filtration must never be carried out without sufficient scavenging

air (according to the module’s data sheet) being introduced below
the modules.
The following parameters have to be considered for modules with

microfiltration membrane:
Filtration capacity: 5 - 15 l/(m²h)
Transmembrane pressure: ≤ 40 mbar
Pulse/ Pause: 4 - 12 minutes filtration, 2 - 6 minutes pause
Modules should be retracted slowly. To do this the filtration

output has to be adapted to the dry substance content of the
biological system and increased slowly (between one and three
weeks after setting in work) to the nominal flux.
Should two membrane pouches stick to each other on delivery

they must under no circumstances be pulled apart as this would
lead to the membrane separating in its dry state. Adhesions
loosen in water on their own and without consequential damage.
7.3 Shutdown
7.3.1 Disassembly of the modules
The disassembly of the modules is carried out in the following steps:
1. Shut down the installation according to the manual of the operator.
2. Start filtration shortly to minimize the volume of filtrate in the module as far as
possible
3. Disconnect the aeration unit (depending on the type).
Page 47 of 72
4. Open the filtration pipe, connected to atmosphere.
5. Pull the complete module block (on the buoyancy security) SMOOTHLY out of
the tank until the ball valve sticks out of the liquid.
In case of multi-storied modules pull the block SMOOTHLY out of the tank until
the first module sticks out of the liquid. Remove the tube adapter in order to
empty the module. Then pull the next module out of the liquid and open the
next hose adapter. Repeat this procedure until the ball valve of the last module
can be opened.
If the modules have an opening device for the lower ball valve which can be
operated from the tank surface, then the lower ball valve is to be opened
during lifting to allow the filtrate in the filter bags to escape and not accumulate
in the filter bags of the lower module.
6. Open ball valve at the last membrane module and empty the module
completely.
7. Remove the entire module block out of the tank. Relieve the filtration pipe and
the aeration pipe. Pay attention that no person is located in the pivot range of
the crane.
8. When putting modules down ensure that they are put on a level, clean surface
that has no sharp objects on it. Always put the modules down on the full
surface and do not tilt.
9. After having removed the retaining plates, the modules can separated from
each other!
10. You must ensure that the module is not exposed to strong sunlight and / or too
high (> +50°C)/ or too low (< +5°C) temperatures or start to dry or dry out.
Page 48 of 72
When moving a multimodule, a cross beam is to be used. The

fastening using chains and belts is expressly prohibited!
The module must be SMOOTHLY lifted out of the water in order

to allow the modules to discharge during this lifting procedure.
Move the module only by using the lifting module. Never use the
filtration pipe as a carrying handle!
The module must be protected against unintended fall during the

disassembly process! Multimodules must be protected against
toppling.
The module must not be dismounted by use of force! Avoid any

kind of blows impacting the module, e.g. hammer blows!
The modules have to be stored in an appropriate way and drying

has to be avoided. Drying of the membrane surface can destroy
the module.
7.3.2 Cleaning of the dismounted modules
The dismounted modules can be cleaned from rest of sludge by means of a SOFT
water-jet. Do never use a hard water-jet for the cleaning procedure (e.g. pressure
washer) as the membrane surface would be damaged!
The modules should be cleaned until all the rest of the sludge is removed from the
membrane or module surface and from the space between the membrane bags.
Cleaning is done from top to bottom in the module area which is in contact with the
activated sludge.
Prior to, during and after the cleaning, the modules must permanently be kept wet.
They must never become dry!
7.3.3 Conservation of the modules
The membrane modules must be conserved if they are not used for a longer period in
order to avoid any formation of mould. For that purpose the membrane modules must
be cleaned (see chapter 8.2.1) and dismounted (see chapter 7.3.1).
Page 49 of 72
Modules with microfiltration membranes, which should be stored in wet conditions,

need to be protected against the formation of algae and mould by the usage of
antifreeze-solutions and biocides. The modules are dipped into a solution containing
20 - 40% glycerine and 2% Ultrasil 73. After that the modules will be drained and are
either shrink-wrapped in wet conditions in a plastic bag or will be dried first and then
shrink-wrapped in a plastic bag. Wet stored modules should NEVER be exposed to
frost circumstances.
Modules with ultrafiltration membranes must never become dry (membrane must
always be moistened with water). Should these modules be stored for more than
24 hours they must be protected from biological fouling by using a preservative.
Membranes can be soaked and then stored with:
a. a 20 % solution of fructose and a 2 % solution of Ultrasil 73
or
b. a 0.5 % solution of benzoic acid
or
c. an aqueous solution with 0.5 - 1.0 % sodium bisulphite.
Here the whole membrane must be saturated with the preserving solution that must
be done with a short filtration with the solution. For longer storage the concentration
must be checked or changed regularly. Modules with ultrafiltration membranes must
not be exposed to frost at any time.
In case of questions concerning these procedures please contact

7.4 Transport and storage of the modules
7.4.1 New modules
New filtration modules have to be stored in dry conditions. During the stocking the
modules should NOT be exposed to intensive solar irradiation, high temperatures or
frost. For storing the modules in dry conditions, the modules should be shrink-
wrapped in plastic bags by adding drying agent. The storage temperature should
never exceed 50 °C. Please note that the modules are shock-sensitive.
Page 50 of 72
7.4.2 Used modules
Already used modules should be cleaned chemically before storage (see Chapter
8.2.1.4). No cleaning chemicals should remain in the membrane.
Modules must preferably be stored in wet conditions. A 40 – 60 % glycerine solution

is used for this. Here the solution must also penetrate the whole membrane (short
filtration). The modules must then be sealed in plastic bags.
Used, cleaned modules can also be dried for storage. To do this they must be
preserved with a 20 – 40 % glycerine solution before drying. The solution must
penetrate the membrane which is guaranteed by a short filtration. After emptying, the
suction pipe must be sealed and the air drawn off from the filtrate outlet so that the
membranes lie flat during drying and the module also dries from the inside. The
modules must not contain any residual moisture for storage because otherwise
mildew or algae could build up. The dried modules must then be sealed in plastic
bags with drying agents added.
Modules, which are forwarded for reparation or regeneration to the manufacturer,

have to be cleaned and dried completely before shipment. The type of package and
the type of shipment have to avoid any damages of the membrane modules caused
by the transport procedure.
7.5 The disposal of old modules
For the waste disposal of old submerged modules it has to be considered that these
are completely cleaned of sludge.
The entire membrane module has to be disposed as industrial waste.
8 Intended Operation
MaxFlow-membrane modules should only be used for the intended application area
of wastewater treatment.
Every modification by the client regarding the membrane modules or the utilities and
cleaning chemicals must be communicated and confirmed by
Page 51 of 72
Every non-authorized procedure may result to the loss of warranty.
8.1 Normal operation
Membrane bioreactors with submerged membranes may be operated in a continuous

or in a cyclic form. There are permanent concentration- and filtrate volume flow. The
concentration from the dissolved matter would be nearly constant in case of a
consistent inflow ratio.
The MBR should be operated in a cyclic form.
The cyclic operation is characterized by a filtration time of 6 – 12 min., followed by an

interval time of 2 – 4 min (without filtration).
The cyclic operation is needed for a minimization of the cake layer. In the interval
time there is no vacuum on the membrane and so the particles attached at the
membrane surface can easily be removed by the cross-flow provoked by the aeration
device.
The interval time with aeration must not be longer than 30 minutes. With longer
intervals, the scavenging air below the membrane modules must also be turned off,
in order to prevent destruction of the membrane modules. When filtration is carried
out again, heed that at first the scavenging air is turned on and only then filtration, in
order to ensure sufficient flushing of the membrane surfaces.
Page 52 of 72
8.1.1 Tests
REGULAR TESTS
frequency Check-list
daily - Visual check of permeate regarding suspended matter
- Visual check regarding leakages
- Visual check of bubble’s arrangement on water surface
- Checking and recording the operational parameters
- permeability
- MLSS-concentration
- Flow-rate
- Transmembrane pressure
- amount of scavenging air
-…
monthly - Checking amount of stocked spare parts
every 6-months or - chemical regeneration
when required
8.2 Service and cleaning procedures
8.2.1 Service
Regular maintained MaxFlow-membranes will have longer life-cycles. Besides daily

visual checks the maintenance work is including replacements of wear and tear parts.
Please consider the service notes in chapter 8.2.1.1.
Page 53 of 72
8.2.1.1 Service notes
The check- and maintenance-intervals should be followed

according to the handbook.
In case of service teams with several persons, the responsibilities

should be clearly appointed.
Do not repair damaged/ broken pipes, but replace these. Do

exchange hoses directly if porosity or tear is visible.
Do retighten leaky screwing only in depressurized condition. Pass

hose connections between different installations parts and
engines break-free and protect these against damage.
Do only use acceptable and compatible tools. Damaged parts

should be exchanged in time.
8.2.1.2 Maintenance-cleaning
The maintenance-cleaning for municipal wastewater can be arranged every

7 - 14 days after commissioning. For other types of wastewater the interval has to be
adapted. During the maintenance-cleaning there will be pumped clear water or a
permeate-cleaning-chemical-mixture (low concentration of the chemical liquid) in the
membrane (in the opposite direction to the standard operation direction). During the
residence time a portion of the low-concentrated cleaning solution will diffuse through
the membrane. So the “pre-dissolved” layer will be removed from the membrane.
After a period of 30 min. the cleaning solution will be evacuated out of the membrane
by changing to the standard operation (change of flow-direction).
Page 54 of 72
Notes for municipal wastewater:
cleaning period: every 7-14 days after commissioning
back wash flow: module specific (see handbook)
back wash velocity: Back wash flow in 15 min
max. back wash pressure: +50 mbar
residence time: 30 min
chemicals: sodium hypochlorite with 0.02 % free

chlorine; diluted (200 ppm)
8.2.1.3 Recovery-Cleaning / cleaning in place (CIP)
During the so-called recovery cleaning method, the modules remain in the filtration
tank and they will be cleaned in 2 steps.
First an alkaline cleaning solution is transported from the permeate side into the
membranes. Before starting the cleaning process, the remaining water volume in the
modules should be as small as possible, what could be done with a short filtration.
The cleaning chemicals added remain within the membrane pouches for the duration
of the reaction time when the membrane module is aerated for a short time (to mix
the cleaning solution thoroughly). Then the used cleaning solution is drawn off again
(filtration operation) and fed back into the cleaning container.
The inserted cleaning solution remains for the residence time inside the filter bags
while the modules are aerated. Then the used cleaning solution is evacuated again
(filtration operation) in the reservoir for the cleaning solution.
In a second cleaning step the procedure can be repeated with an acid cleaning
solution.
The used cleaning solutions may be reused by new concentration (control by pH-
measurement). After the third cleaning procedure the solutions should be discarded
at the latest.
Page 55 of 72
Cleaning period: at a transmembrane pressure of 200 mbar

every ~3 to 6 months
Bach wash flow: module specific (see handbook)
For microfiltration membrane:
Back wash velocity: back wash flow in 15 – 30 min
alkaline residence time: usually 2 – 3 hours
acid residence time: usually 1 - 2 hours
Cleaning chemical - alkaline: sodium hypochlorite with 0.34 %

free chlorine, diluted (3400 ppm), pH 10.5, T < 30°C
Cleaning chemical - acid: Citric acid on 0.5 %; alternative acetic

acid or formic acid, set pH 2 – 2.5, T < 30°C
For ultrafiltration membrane:
Back wash velocity: back wash flow in 15 - 30 min
alkaline residence time: usually 2 – 3 hours
acid residence time: usually 1 - 2 hours
Cleaning chemical - alkaline: sodium hypochlorite with 0.08 %

free chlorine, diluted (850 ppm), pH 10.5, T < 30°C
Cleaning chemical - acid: Citric acid on < 2 %; alternative acetic

acid or formic acid, set pH 2 – 2.5, T < 30°C
As a dilution effect is occurring inside the modules, the concentrations of the sodium
hypochlorite will be twice as high as mentioned in Annex 11.1.
Page 56 of 72
8.2.1.4 External cleaning
External cleaning containers are used for this. With materials that are used for wall
cladding (pipelines etc.) you must ensure that they are resistant to the cleaning
chemicals.
For an external cleaning the modules have to be dismounted and have to be cleaned
by fresh water or permeate. Do not damage the membrane by the water-jet.
The membrane modules should never be cleaned by use of a

pressure washer!
In the next step an alkaline cleaning is needed. The washed up module is inserted in
the cleaning reservoir filled up with the alkaline cleaning solution. Please make sure
that the filtration pipe is installed and has a direct contact to the atmosphere. A
recirculation should be created inside the reservoir provided by pump or by a cyclic
aeration. The overall duration of aeration must not exceed 30 minutes, otherwise it
may result in a damage of the membrane. After a residence time of about 2 –
3 hours, the module should be removed out of the reservoir.
In case of scaling deposits on the membrane surface it is necessary to continue by

an acidic cleaning procedure. This would be necessary if the transmembrane
pressure is still (after the alkaline cleaning) raised. The module has to be flushed
again. After that the module is inserted again in the cleaning reservoir (now filled up
with acidic solution). Should the same reservoir the used for alkaline cleaning, it is
imperative to pay attention that no liquid of the previous cleaning remains in the
reservoir. Otherwise, uncontrolled, dangerous chemical reactions can take place.
After a residence time of 1 – 2 hours the module is removed again out of the
reservoir, can be reinstalled in the filtration tank and will be operated again.
Page 57 of 72
Cleaning period:
At a transmembrane pressure of 200 mbar ~ every 3 to 6 months
For microfiltration membrane
The membranes must be rinsed with sufficient water before and

after chemical cleaning.
alkaline residence time: usually 2 - 3 hours
acid residence time: usually 1 – 2 hours
Sodium hypochlorite on 0.2 % free chlorine, diluted (2000 ppm);

pH 10.5, T < 30°C
Cleaning chemical acidic: Citric acid on 0.5 %; alternative acetic

acid or formic acid, pH 2 – 2.5, T < 30°C
For ultrafiltration membrane
The membranes must be rinsed with sufficient water before and

after chemical cleaning.
alkaline residence time: usually 2 - 3 hours
acid residence time: usually 1 – 2 hours
Sodium hypochlorite on 0.05 % free chlorine, diluted (500 ppm);

pH 10.5, T < 30°C
Cleaning chemical acidic: Citric acid on < 2 %; alternative acetic

acid or formic acid, pH 2 – 2.5, T < 30°C
Page 58 of 72
The membrane surface must not be cleaned by hand or with sharp

or abrasive active items! Do not use a hard water-jet for the
cleaning procedure (e.g. pressure washer) as the membrane
surface would be damaged!
8.2.1.5 Resistance to cleaning chemicals
The membranes are resistant to the following concentrations of cleaning chemicals:
Table 2: Resistance to cleaning chemicals (microfiltration)
Cleaning chemicals concentration
pH (for all cleaning solutions) 2 < pH < 11 at a temperature of

max. 30 °C
max. 40 °C
H2O2 0,5 %
HCl 0,2 - 0,5 %
H2SO4 0,2 - 0,5 %
Citric acid <2%
Acetic acid <2%
Oxalic acid 0,2 - 0,5 %
Aspartic acid 0,2 - 0,5 %
Sodium hypochlorite max. 0.2 % of active chlorine with
a temperature from < 20°C
for max. 3 h
The membrane has a service life of 350,000 ppmh of chlorine under the specified
conditions.
Page 59 of 72
Table 3: Resistance to cleaning chemicals (Ultrafiltration)
Cleaning chemicals concentration

max. 30 °C
max. 40 °C
H2O2 1%
Citric acid <2%
Acetic acid <2%
Sodium hypochlorite 100 – 500 ppm free chlorine
The membrane has a service life of 100,000 ppmh of chlorine under the specified
conditions.
For cleaning solutions which are not tested and confirmed by the
MaxFlow Membran Filtration GmbH there is given no warranty regarding the
consistency of the membranes and the cleaning success.
In order to achieve best cleaning results, the optimized cleaning solutions offered by
MaxFlow Membran Filtration GmbH can be used (see chapter 9).
8.3 Replacing the aeration elements
The tube diffusers located in the aeration module underneath the membrane
modules, are subject to wear and must be checked and replaced from time to time.
Filtration without proper and sufficient aeration may lead to irreversible damage to the
membrane modules.
The aeration cartridges in the aeration module are to be checked for performance
regularly (even bubble distribution over the entire length of the cartridge) and
replaced if necessary to ensure proper aeration. A visual check of the aeration at
regular intervals by lifting out the aeration unit is also recommended. The life of the
aeration cartridges may vary greatly depending on the waste water.
Replacement is to be performed regularly:
Municipal waste water: every 2-5 years (depending on condition)
Page 60 of 72
Industrial waste water: every 1-3 years (depending on condition)
Defective diffusers lead to blockage of the membrane modules and

may damage the modules! Always ensure that filtration only takes
place with functioning aeration.
The old aeration devices are first removed and the condition of the ¾”
connection is checked. If necessary, the connection must also be replaced.
The connections are cleaned and re-sealed with Teflon tape.
The perforation is particularly important when screwing in the aerator. The

perforation must be located at the left and right at the side of the tube diffuser seen
from above (not top and bottom) to allow formation of an even bubble carpet
underneath the module.
Ensure, when fitting the diffuser tubes, that the perforation is positioned
correctly to the module (left and right of diffuser tube).
8.4 Monitoring
During the monitoring process the following parameters should be controlled and
recorded in order to guarantee a reliable operation process and a high-class
permeate quality.
Page 61 of 72
Table 4: Form for monitoring procedure
Mon Tue Wed Thu Fri Sat Sun

Name
Date
Time
Operation hours [h]
Time since cleaning [h]
Time since back wash [h]
Operation rate [min]

Pause rate [min]
Pressure operat. rate [mbar]
Pressure pause rate [mbar]
Permeability [l/(m²hbar)]
Flux [l/(m²*h)]
max. Flux in 24h [l/(m²h)]
for x hours [h]
min. Flux in 24h [l/(m²h)]
for y hours [h]
Permeate flow rate [l/h, m³/h]

Permeate appearance
Ntotal of permeate [mg/l]
NH4-N of permeate [mg/l]
COD of permeate [mg/l]
BOD5 of permeate [mg/l]
Ptotal of permeate [mg/l]
Temperature [°C]
MLSS-concentration in
filtration tank [kg/m³]
pH-value in
filtration tank [-]
Conductivity in
filtration tank [µS/cm)
Sludge volume [ml/, %l]
Page 62 of 72
9 Approved chemicals
The MaxFlow Membran Filtration GmbH is recommending the following chemicals:
Application Chemicals
Conservation Glycerine
Conservation Ultrasil 73
Improvement of filtration A3 MembranPlus
Alkaline Cleaner A3 Activator A 101
Acidic cleaner A3 Activator S 101
Subsequent you will find notes concerning the chemicals. In case of questions please
contact the MaxFlow Membran Filtration GmbH and consider the relevant spec
sheets.
9.1 Glycerine
The modules must be preserved with a 20 – 40%- glycerine solution for dry storage.
To do this the membrane is soaked with the solution by means of a short filtration.
When storing damp a 40 – 60%- solution is necessary. After being treated with the
preserving solution the modules are emptied and sealed in foil in both cases.
Appearance: viscous, colourless liquid
Density: 1.26 g/cm³ (20°C)
pH value: 5 (100 g/l H2O. 20°C)
9.2 Ultrasil 73
Ultrasil 73 is used as a biocide to preserve the membranes against mildew and algae
formation.
Appearance: yellow-brown liquid

Density: 1.05 g/cm³ - 1.09 g/cm³
pH-value: 2.1 - 2.7
Ultrasi 73 is suited especially for the conservation of sensitive systems. In order to

use Ultrasil 73 for membrane modules, these modules have to be cleaned first. Then
Page 63 of 72
the modules are submerged for 20 – 30 minutes in a 2 %- Ultrasil 73 solution (with

20 - 40% Glycerine). Here a complete moistening of the membrane surfaces has to
be guaranteed during the entire application time. The conservation solution is to be
drawn into the membrane pores by brief filtration. After the residence time the
modules drip off above a collecting tray and then they will be dried at the air!
After the conservation the dried modules have to be packed airproof.
Direct contact of skin and eyes with Ultrasil 73 has to be avoided!

Breathing in or swallowing of Ultrasil 73 has to be avoided! While
handling with Ultrasil 73 goggles and protective glove must be
worn! Do never restore an already extracted portion back to the
reservoir!
Please note the safety data sheet!
9.3 A3 MembranPlus
The A3 MembranPlus is a special flocculant for membrane bioreactors. A3

MembranPlus is based on the mechanism of coagulation and is improving the
capacity and the efficiency of the MBR system.
A3 MembranPlus
is allowing a higher flux at significantly reduced membrane fouling,

is enlarging periods between membrane cleanings,
is avoiding and removing the formation of skimmings on the surface,
is guaranteeing a higher MBR-capacity also in exceptional circumstances and
is compatible to the biomass.
A3 MembranPlus is totally water soluble and AOX-free.
Appearance: clear-yellow liquid

Density: ~ 1.02 - 1.05 g/cm³
pH-value: ~ 6.5
A3 MembranPlus can be dosed (as concentrate or with water diluted) at positions of

high turbulences into the MBR. In case of need a suitable dosing unit can be
Page 64 of 72
delivered. The MaxFlow Membran Filtration GmbH is providing the system specific
dosing program as the optimized dosing rate is depending on a lot of site-specific
factors.
A3 MembranPlus is delivered in a jerry-can or in a barrel and should be stored

enclosed and frost-free. In compliance with these requirements the total functionality
of the product is confirmed for 12 months (in the original package).
As A3 MembranPuls reacts slightly acidic, goggles and protective

glove have to be worn while handling with A3 MembranPlus.
Do never restore an already extracted portion back to the reservoir!
9.4 A3 Activator A 101
A3 Activator A 101 is an alkaline cleaner, which is used for a recovery-cleaning or an

external cleaning. The solution contains organic and inorganic complexing agent as
well as special active ingredients for removing organic deposits on the membranes.
Moreover the A3 Activator A 101 is free of phosphate.
Continuous cleaning cycles with A3 Activator A 101 will result in long membrane life
cycles with high flux rates.
Appearance: yellowish liquid

Density: ~ 1.35 - 1.37 g/cm³
pH-value: 12.4 - 13.0
Dosage unit with CIP- or tank-to-tank-procedure:
Concentration: 2.0 - 5.0 %

Temperature: 20 - 50° C
Residence time: 30 – 60 minutes in the free-flushing-cycle
After usage it has to be flushed efficiently with fresh water in order to remove
deposits.
Close the reservoir always with the original closing and store the reservoirs in cool
conditions and without solar irradiation.
Page 65 of 72
As A3 Activator A 101 reacts in alkaline form, goggles and protective

gloves must be worn while handling with A3 Activator A 101.
9.5 A3 Activator S 101
A3 Activator S 101 is an acidic cleaner, which is used for a recovery-cleaning or an

external cleaning. The solution is especially used for removing layers which results
from water attributes, as e.g. carbonate, and is used in the free-flushing-cycle of the
system.
Continuous cleaning cycles with A3 Activator S 101 will result in long membrane life
cycles with high flux rates.
A3 Activator S does not contain any organic bound halogens (AOX). But A3 Activator
S contains phosphates.
Appearance: uncoloured liquid

Density: ~ 1.180 - 1.200 g/cm³
pH-value: 1.2 - 1.8
Dosage with CIP- or tank-to-tank-procedure:
Concentration: 1.0 - 5.0 %

Temperature: 20 - 40° C
Residence time: 10 – 30 minutes in the free-flushing-cycle
After usage it has to be flushed efficiently with fresh water in order to remove
deposits.
Close the reservoir always with the original closing and store the reservoirs in cool
conditions and without solar irradiation.
Page 66 of 72
As A3 Activator A 101 reacts in acidic form, goggles and protective

gloves have to be worn while handling with A3 Activator A 101.
Page 67 of 72
10 Manufacturer´s declaration
Declaration for the installation of a incomplete machinery
in terms of the Machinery Directive 98/37/EG, Annex II B
Herewith we,
MaxFlow Membran Filtration GmbH
Magdeburger Str. 16a
45881 Gelsenkirchen, Germany,
declare that the commissioning of the subsequently named incomplete machinery is

prohibited until it was noted that the machinery in which the incomplete machinery
will be installed in, is corresponding to the EG-machinery directive.
We approve the conformity to the Low Voltage Directive 2006/95/EWG.
Product: Microfiltration-Membrane module Type MaxFlow M06-001
MaxFlow M20-002
MaxFlow M70-002
MaxFlow M70-003
MaxFlow M70-H-004
Ultrafiltration-Membrane module Type MaxFlow U06-001
MaxFlow U20-002
MaxFlow U70-002
MaxFlow U70-003
MaxFlow U70-H-004
Engineer standards: 98/37/EWG
EN 292-1
EN 292-2
Page 68 of 72
The special technical documents for incomplete machinery according to the

Machinery Directive 98/37/EG, Annex VI, are present.
Page 69 of 72
11 Annex
11.1 List of substances damaging the membrane
Substances Effect on membrane concen-tration

1,1,1-trichlorethane 1 g/l
1-Nitropropane 2 g/l
2 N NaOH
3 N KOH
5 % ClOH 50 g/l
Acetone solvent 2 g/l
Amyl-alcohol 20 g/l
Fuel solvent 2 g/l
Benzene solvent 1 g/l
Butadiene solvent 2 g/l
Butyl-alcohol/butanol 1 g/l
Cationic polymers
Cresol solvent 1 g/l
Cyclohexane solvent 1 g/l
Diacetone alcohol solvent 2 g/l
Dichlorethane solvent 1 g/l
Dimethyl formamide solvent 1 g/l
Diesel oil closing the pores 2 g/l
Dimethyl sulfoxide solvent 1 g/l
Iron - & manganese
closing the pores 2 g/l
sludge
Ethyl alcohol / ethanol solvent 200 g/l
Ethylene chloride solvent 1 g/l
Ethyl formate solvent 2 g/l
Formaldehyde 50 g/l
Soak wax irreversible closing of the pores 2 g/l
Isopropyl alcohol solvent 100 g/l
Cationic tenside 2 g/l
Cationic polymers
Base pH > 12 precipitations
Methyl alcohol /
solvent 50 g/l
methanol
Page 70 of 72
Substances Effect on membrane concen-tration

Methylene chloride solvent 1 g/l
Methyethylketone solvent 2 g/l
Methylisobutylketone solvent 2 g/l
Non emulsified
closing the pores 2 g/l
organic fats
Nitrobenzol solvent 1 g/l
Nitrobenzene solvent 1 g/l
Nitro dilution solvent 2 g/l
N-Methylpyrrolin solvent 1 g/l
n-methyl Pyrrolidon solvent 1 g/l
Phenol solvent 1 g/l
Piperidine solvent 1 g/l
Pyridine solvent 1 g/l
Acid pH < 2
Silicone oil irreversible closing of the pores 2 g/l
carbon tetrachloride solvent 1 g/l
Tetrahydrofuran solvent 1 g/l
Toluole solvent 1 g/l
Toluen solvent 1 g/l
Trichloroethylene solvent 1 g/l
Xylene solvent 1 g/l
Xylol solvent 1 g/l
Sharp-edged solids damage of the membrane
Degreaser soaking/power drop 1 g/l
Page 71 of 72
with MaxFlow module technology
11.2 Example of P&ID
LISA LISA
Level Level
Reservoir Reservoir
for cleaning for cleaning
solution solution
Drain valve for condensate
f1
f2
PISA FICA
pressure flow
Blower f1
f2
FICA PISA
flow pressure
Filtrate,
permeate
sampling Permeate pump
Reduction Rotary piston compressor

LISA
Level
Non return valve
Drive pneumatic
Spring -loaded
Non return valve
Valve flap Rotary piston pump
Gate valve (open )
Gate valve (closed ) Membrane pump
Cut off cock (open )
Cut off cock (closed )

Label of the relevant
parameter
Slide valve Return activated sludge
f1 Frequency changer
Label of the relevant
control -parameter
Removal of excess sludge
f2
Draining
Compensator Engine
Page 72 of 72

Design, Operation and Maintenance Manual For Membrane Bioreactors !!!!

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Design, Operation and Maintenance Manual For Membrane Bioreactors !!!!

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Design, Operation and Maintenance Manual for Membrane

Bioreactors applying MaxFlow-module Technology

Abstract of Version 1.13 – August 2014

Translation from the German manual mmf Rev.2.03

!!!This manual does not substitute a personal instruction

In this manual the following security symbol will be used:

This symbol highlights that, in case of non-observance of the safety

If due to operational reasons, the usage of hazardous material is necessary,

In case of questions or problems concerning the technology provided by MaxFlow

MaxFlow Membran Filtration GmbH

Magdeburger Str. 16a

D-45881 Gelsenkirchen, Germany

Phone: +49 (0) 209-9 80 99-860

Fax: +49 (0) 209-9 80 99-865

1.1 Company profiles ............................................................................................. 7

1.1.1 A3 Water Solutions GmbH .............. Fehler! Textmarke nicht definiert.

1.1.2 MaxFlow Membran Filtration GmbH ...................................................... 7

1.2 Filtration modules of the MaxFlow Membran Filtration GmbH ......................... 8

1.2.1 MaxFlow-Membrane modules microfiltration ......................................... 8

1.2.2 MaxFlow-Membrane modules ultrafiltration ........................................... 9

1.2.3 MaxFlow-Multi modules with high density - Ultrafiltration .................... 10

1.2.4 MaxFlow-Multi modules microfiltration ................................................. 11

1.2.5 MaxFlow-Multi modules ultrafiltration .................................................. 13

2 Safety instructions .......................................................................................... 15

3 Basics of the membrane technology .............................................................. 17

3.1 Definitions ...................................................................................................... 17

3.2 Membrane filtration ........................................................................................ 20

3.3 Operating parameters of a membrane unit .................................................... 23

3.4 Formation of a cake layer ............................................................................... 24

3.5 Limitation of cake-layer-formation .................................................................. 24

4 Basics of membrane bioreactors .................................................................... 26

4.1 Basics of the biological wastewater treatment – applications and limits......... 26

4.2 Parameters for characterisation of the wastewater ........................................ 27

4.3 The MBR-technology ..................................................................................... 29

4.3.1.1 Screen / sieve ................................................................................. 32

4.3.1.2 Grit chamber and grease separator................................................ 33

4.3.2 Bioreactor ............................................................................................ 33

4.3.2.1 Excess sludge ................................................................................ 34

5 Design parameters for membranes resp. membrane bioreactors .................. 35

5.2 Basics to design the membrane stage ........................................................... 36

6 Arrangement and construction of the modules in a filtrationreaktor ............... 37

6.1 Arrangement and construction of the modules............................................... 37

6.2 Design of a MBR ............................................................................................ 40

6.2.1 Hints for module arrangement ............................................................. 40

6.2.2 Pumping technology of the filtration unit .............................................. 41

6.2.3 Aeration ............................................................................................... 41

6.2.4 Process measuring and control technology ......................................... 42

7 Membrane modules ....................................................................................... 43

7.1 Installation of the membrane modules ........................................................... 43

7.1.1 Installation in an empty tank ................................................................ 44

7.1.2 Installation in a filled tank .................................................................... 45

7.2 Commissioning .............................................................................................. 46

7.3 Shutdown ....................................................................................................... 47

7.3.1 Disassembly of the modules ................................................................ 47

7.3.2 Cleaning of the dismounted modules .................................................. 49

7.3.3 Conservation of the modules ............................................................... 49

7.4 Transport and storage of the modules ........................................................... 50

7.4.1 New modules ....................................................................................... 50

7.4.2 Used modules...................................................................................... 51

7.5 The disposal of old modules .......................................................................... 51

8 Intended Operation ........................................................................................ 51

8.1 Normal operation............................................................................................ 52

Permeability, water [l/m²hbar] > 1000