About us

• We are Levapor Biofilm Technologies and Bio Consulting , GmbH.

• A specialized company providing innovative solutions for the treatment of wastewater and polluted air

• A team with more than 40 years of experience in research and development of fixed film based technologies for industrial and difficult to treat wastewater and polluted air

What We do • Problem analysis for the treatment of high strength

industrial and municipal wastewater treatment • Define treatment goals and conceptual process

design • Development of optimal process and parameters • Manufacturing of high performance tailor made bio

carriers for the application • Process Start up

Our Specialization • Anaerobic pre treatment of complex, persistent

industrial wastewater • Nitrification – De nitrification of effluents containing

inhibitory substances• Biological waste gas treatment using BTF(Bio

Trickling Filters) • Biofilm Reactor IFAS/MBBR for industrial and

municipal wastewater • Production and delivery of High Performance Bio

Carriers

Our Achievements • First full scale nitrification/denitrification plant for

ammonia rich effluents (1978) • Development of high performance bio carriers (1983) • Degradation of toxic effluents by anaerobic bio film

technologies (1985) • Design of full scale process for the anaerobic-aerobic

degradation of toxic effluents (1998) • Indoor bio treatment of polluted air for a ware house

of waste plastic (2002)

Industries We serve

• Chemicals and Pharmaceuticals• Petrochemicals and Refineries • Pulp and Paper • Coal Conversion : coke plant, coal gasification,

pyrolysis• Textile finishing and Leather manufacturers • Municipal Wastewater Treatment • Special effluents like land fill leachate and sludge

processing unit

Our Clientele• SAPPI , Germany : 20 MLD anaerobic-aerobic treatment

plant for treatment of high strength pulp and paper mill effluent

• City of Ningan, China : 22 MLD Municipal wastewater treatment plant for COD removal and nitrification

• City of Helsinki : Upgradation of existing municipal wastewater treatment plant

• Ludan Engineering, Middle East : Bio treatment of fine chemicals wastewater

• KERRY Intra, India : Bio treatment of container wash water

Our Technology

• LEVAPOR Bio Carrier • First synthesized Bio Carrier • Porous, Flexible, Durable PU foam

impregnated with surface active pigments with high surface area

• Due to variability of foam and pigment type and their ratios, tailor made carriers can be produced with varying properties

Our Technology

Unique Properties

PROPERTIES • High Adsorbing Surface

• High Porosity

• Fast wetting and water binding

• High surface Area • Higher fluidization ability

ATTRIBUTES• Adsorption of inhibitory

substances and fast colonization • Protection of biomass against

shear, anoxic zone formation • Homogenization of media and

maintenance of bio activity • Lower Degree of Filling (12-

15%)• Less Power consumption

Advantages • Reversible adsorption of inhibitory substances and slowly

bio degradable pollutants • Short process start up and higher performance compared

to suspended mass based systems (100 to 300%)• Colonization of carrier by more active bio mass and

simultaneous nitrification-de nitrification • Higher process stability and lower sludge yield • Lower degree of filling (12 to 15% compared to 40-65%

for plastic based media) • Remarkable lower power consumption compared to

conventional MBBRs

Applications• Up gradation/expansion of existing plants • Anaerobic-Aerobic treatment of high strength , slowly

bio degradable pollutants • Nitrification- de nitrification of effluents containing high

ammonia concentrations• Biological Treatment of Polluted air/gas (BTF)• Biofilm reactor MBBR/IFAS for the treatment of

industrial and municipal wastewater • Treatment of hyper saline effluents containing solvents • Treatment of land fill leachate and groundwater

containing PAHs.

Case Studies

• City of NINGAN Wastewater treatment Plant • Heilongjiang Province , China• 4,40,000 Population • Very Cold climate during winter • Difficulty in maintaining nitrification during

winter • Stricter Legal discharge limits

NINGAN,WWTP

• Solution :• 3200 m3 of aeration tank

volume • 480m3 of Levapor Bio

carrier• 15% Filling • 20 X 20 X 7 mm size

NINGAN, WWTP

• Legend Dimension Value

Volume of Reactor M3 3200 (4 X 800)

Volume of Levapor M3 480m3

HRT Hours 3.5-3.8

2012 October Nov. Dec.

COD in Mg/lit 294 295 302

COD out Mg/lit 33.7 35.8 37.7

BOD out Mg/lit 11.9 11.9 12.9

TKN in Mg/lit 28.8 35.5 23.2

NH4.N out Mg/lit 2.0 3.3 3.34

NO3.N out Mg/lit 12.5 14.8 11

Temperature Degree C 15.6 13.3 9.6

NINGAN ,WWTP

NINGAN,WWTP

NINGAN,WWTP

• Benefits:• 88-90 % COD and 91-93% NH4.N reduction despite

decreasing temperature and shorter HRTs• Remarkable process stability against temp, COD, TKN

variations • Lower level of nitrate confirming denitrification • Lower capital and operational cost

SAPPI,GERMANY• SAPPI EFFLUENT TREATMENT PLANT:• South Africa Pulp and Paper Industry, Ehingen, Germany • Sulfite based pulp and paper industry• Application of Chlorine for bleaching • High Concentration of toxic, weakly bio degradable

chloro-organic compounds • Strong Stream : COD 45 t/d @ 10 MLD • Weak Stream : COD 2.45 t/d @ 3.5 MLD

SAPPI,GERMANY

Lab scale testing Anaerobic or Aerobic?• Aerobic treatment with

suspended bio mass • Only 40-45 % COD

elimination • Anaerobic-Aerobic

Treatment ? • Anaerobic reactors using

different bio carriers

SAPPI,GERMANY

• 1 :Levapor • 2: Activated Carbon • 3: Unmodified PU foam • 4: Suspended Bio mass

SAPPI,GERMANY• Solution :• Anaerobic Treatment Using Levapor Carriers • Reactor Size only 15000 m3 instead of 65000m3 with

suspended bio mass • 1500 m3 of Levapor media • 66-70% COD removal • Further 50% of COD removal in Aerobic Treatment • 50,000 m3 less volume

SAPPI,GERMANY

Startup: 1990, only 2 of 3 ANA-reactors were started with LEVAPOR in order to compare the effect of immobilisation. After few weeks a toxic shock has stopped the reactor without LEVAPOR Nowadays: ~ 85 % COD- removal , 4 – 6 t/d sludge, 14.000 m³/d biogas

SAPPI,GERMANY

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0,5

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1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41

susp.biomass

May 90 June 90

immob. biomasskgCOD/m³ x day

Thank You!!!!